LS500 Auto Learn Line Leak Detection

Transcription

1 LS500 Auto Learn Line Leak Detection Installation & User s Guide Manual # Revision date Changes from Previous Revision H September 2014 Added TS-ALNIP / TS-AFALNIP notice to page 16 Franklin Fueling Systems 3760 Marsh Rd. Madison, WI USA Tel: Fax:

2 Notice Franklin Fueling Systems (FFS) strives to produce the finest manual possible and to ensure that the information that it contains is complete and accurate. However, FFS reserves the rights to change this document and specifications at any time without notice. FFS makes no expressed or implied warranty with regard to the contents of this manual. FFS assumes no liability for errors, omissions or for any damages, direct or consequential, that may result from the use of this document or the equipment that it describes. Applicable Models Console Model Installation Manual Programming Manual TS-550, TS TS-550 evo, TS-5000 evo Trademarks INCON, Tank Sentinel, System Sentinel, System Sentinel AnyWare and Tank Sentinel AnyWare are registered trademarks of Intelligent Controls. All brand and product names are trademarks or registered trademarks of their respective companies. Inspection of Materials Visually inspect all components for defects or damage prior to installation. If any defect or damage is found, do not use the product and contact Franklin Fueling Systems for further assistance. Warranty Information Please refer to the FFS Fuel Management Systems & Product Warranty Policy for all warranty information. Contacting Franklin Fueling Systems (FFS) Please feel free to contact us by mail at: Franklin Fueling Systems 3760 Marsh Rd. Madison, WI USA Or contact us by phone, fax or Tel: sales@franklinfueling.com Fax: techserve@franklinfueling.com Office and Sales Hours: 8 a.m. to 5 p.m. CST - Monday through Friday Technical Support Hours: 7 a.m. to 7 p.m. CST - Monday through Friday Please visit our website at 2 Copyright 2008 by Franklin Fueling Systems (FFS). No part of this publication may be reproduced in any form without the prior written consent of FFS. All rights reserved.

3 Contents Notice...2 Applicable Models...2 Important Safety Messages...4 Overview...5 Site Requirements...5 Intrinsically Safe LS500 Installation...7 Explosion Proof LS500E Installation...8 LS-500 Setup (Console Programming) mA Input Module Relay Module Turbine Pump Interface (TPI) Applications Fuel Management Systems (FMS) Line Application Set-Up Line Status and Control Screens Control Section Learn Section Pre-Operational LS500 Testing Required Equipment Line Stability Test Learn Process When to Learn / Re-Learn Procedure Learn Messages LS-500 Reports LS-500 Line Leak Reports Alarms LS-500 Alarms and Warnings...20 Clearing Alarms...22 LS-500 Functional Testing...23 Enabling/Disabling Lines...23 Enabling Lines...23 Disabling Line Channels

4 Important Safety Messages INCON equipment is designed to be installed in association with volatile hydrocarbon liquids such as gasoline and diesel fuel. Installing or working on this equipment means working in an environment in which these highly flammable liquids may be present. Working in such a hazardous environment presents a risk of severe injury or death if these instructions and standard industry practices are not followed. Read and follow all instructions thoroughly before installing or working on this, or any other related, equipment. As you read this guide, please be aware of the following symbols and their meanings: Warning Caution Danger This symbol identifies a warning. A warning sign will appear in the text of this document when a potentially hazardous situation may arise if the instructions that follow are not adhered to closely. A potentially hazardous situation may involve the possibility of severe bodily harm or even death. This is a caution symbol. A caution sign will appear in the text of this document when a potentially hazardous environmental situation may arise if the instructions that follow are not adhered to closely. A potentially hazardous environmental situation may involve the leakage of fuel from equipment that could severely harm the environment. This symbol identifies an electrical danger. An electrical danger sign will appear in the text of this document when a potentially hazardous situation involving large amounts of electricity may arise if the instructions that follow are not adhered to closely. A potentially hazardous situation may involve the possibility of electrocution, severe bodily harm, or even death. Warning Warning Warning Warning Warning Warning Warning Follow all applicable codes governing the installation and servicing of this product and the entire system. Always lock out and tag electrical circuit breakers while installing or servicing this equipment and any related equipment. A potentially lethal electrical shock hazard and the possibility of an explosion or fire from a spark can result if the electrical circuit breakers are accidentally turned on during installation or servicing. Please refer to the Installation and Owner s Manual for this equipment, and the appropriate documentation for any other related equipment, for complete installation and safety information. Follow all federal, state and local laws governing the installation of this product and its associated systems. When no other regulations apply, follow NFPA codes 30, 30A and 70 from the National Fire Protection Association. Failure to follow these codes could result in severe injury, death, serious property damage and/or environmental contamination. Always secure the work area from moving vehicles. The equipment in this manual is usually mounted underground, so reduced visibility puts service personnel working on this equipment in danger from moving vehicles entering the work area. To help eliminate these unsafe conditions, secure the area by using a service truck to block access to the work environment, or by using any other reasonable means available to ensure the safety of service personnel. When the Tank Sentinel system is used to monitor tanks containing gasoline or other flammable substances, you may create an explosion hazard if you do not follow the requirements in this manual carefully. All wiring must enter the Tank Sentinel console s enclosure through the designated knockouts. An explosion hazard may result if other openings are used. All wiring from probes or sensors to the Tank Sentinel console must be run in conduit separate from all other wiring. Failure to do so will create an explosion hazard. Substituting components could impair intrinsic safety. The Tank Sentinel 5 (T5) series consoles are intrinsically safe for sensors installed in Class I, Division 1, Group D hazardous locations. Substitution of components could make the energy limiting circuitry in the system ineffective and could cause an explosion hazard. Repairs to a T5 Series console or attached components should only be performed by a qualified, factory-trained technician. 4

5 Overview The TS-LS500 is a continuous product line leak detection system that monitors the primary pipe. This product is an available option of Franklin Fueling Systems T5 Series Fuel Management System consoles. The TS-LS500 system includes the FMS application running on a T5 series console using a 4-20 ma input module and a transducer. One transducer, which monitors line pressure, is required per product line. Line Pressure is created by the pump and static seating pressure is metered by a pressure relief valve. Transducers (TS-LSU500) use the AutoLearn technology to continuously evaluate the line conditions. Note: The TS-LS500 requires pressure for leak tests and should only be installed in systems that are designed to obtain and hold this minimum static pressure (refer to Site Requirements table below). The system may report learned with errors if tests are run at less than optimum pressure. Applications The following diagram illustrates a typical installation of the LS500 equipment inside of a STP sump. FE Petro Submersible Pump TS-LSU500 Wire Splices Black Red White (capped) Shield (Not connected) Intrinsically safe wiring or explosion-proof conduit, depending upon application Figure 1: LS500 Install Overview To maintain optimal line pressure, Franklin Fueling makes the following recommendations for submersible pumps: For FE Petro Submersible Pumps, use a Standard Check Valve (part # ). For Red Jacket Submersible Pumps, use an adjustable functional element, adjusting the pump OFF pressure to be at least 2 psi below the pump ON pressure. Newer style Red Jacket Submersible Pumps do not have an adjustable functional element as an option. These submersible pumps have a check valve that meets the LS500 pressure requirements. Note: The TS-LSU500 is a pressure sensing device that can be installed anywhere in the product pipeline where accurate line pressure can be monitored. When installing in a location other than the mechanical leak detector port, consider the location of in-line check valves, solenoid valves, or any other equipment that can affect the line pressure being monitored. If an anti-siphon valve is installed at the discharge of the submersible pump, the TS-LSU500 transducer should be installed downstream of the valve to insure proper line pressure monitoring. Site Requirements Item Minimum Static Pressure Maximum line volume for rigid pipe Maximum line volume for flexible pipe Minimum volume for rigid or flexible pipe Table 1: Capacity Table Value 18 PSI for precision testing 15 PSI for gross leak testing 20 PSI for learning lines gallons 95.4 gallons 2.5 gallons Pipe Diameter I.D. 1" 1 ½" 1 ¾" 2" 2 ½" 3" 4" 5" Both Flex and Rigid Length 61' 27' 20' 15' 10' 7' 4' 2' Metric (18.6 m) (8.2 m) (6.0 m) (4.6 m) (3.0 m) (2.1 m) (1.2 m) (0.6 m) Table 2: Pipe Length Required for Holding Minimum Line Volume Pipe Diameter I.D. 1" 1 ½" 1 ¾" 2" 2 ½" 3" 4" 5" Flex Length 2339' (713 m) 1040' (317 m) 764' (233 m) 585' (178 m) 374' (114 m) 260' (79 m) 146' (45 m) 94' (29 m) Rigid Length 7656' (2334 m) 3403' (1037 m) 2500' (762 m) 1914' (583 m) 1225' (373 m) 851' (259 m) 479' (146 m) 306' (93 m) Table 3: Pipe Length Required for Holding Maximum Line Volume 5

6 3/4" NPT 2-3/8" (70mm) across flats 6.25" (159 mm) 5.13" (130 mm) 2" NPT Figure 2: TS-LS500 Dimensions Transducer Installation 1. Apply UL Classified Gasoline / Oil resistant pipe thread sealant to the threads of the transducer and use a 2 3 / 8 open-end wrench to install it in the Leak Detector Port of the STP housing (see Figure 1). Note: When using TS-LS500 line leak detection in a manifolded line application, you only need to use one transducer to monitor the entire line. This transducer should be located in the master STP. In-line check valves should NOT be used as the line leak detection will not be able to test beyond them. Please see the STP manufacture about appropriate check and / or relief valves. 2. Install Couplings, threaded Rigid Metal Conduit (RMC), and Explosion / Weather Proof Junction Boxes (J-Boxes) in the STP sumps. For intrinsically safe wiring, run the transducer lead to the junction box. For explosion-proof installations, run conduit to the top of the transducer. 3. Install threaded RMC and EYS fittings along with Transducer Cables (Belden #9365) from LS500 console to the Explosion / Weather Proof J-Boxes. A licensed electrician should splice the cables together. If this wiring is Intrinsically Safe it MUST NOT be run with any Explosion-Proof wiring or other non-intrinsically safe wiring! Alpha cable #58411 must be used if using nonmetallic (PVC) conduit as allowed by local code. Definitions and Acronyms AIM 4-20mA Analog Input Module (Intrinsically Safe) FMS Fuel Management Systems IS Intrinsically Safe ISD In-Station Diagnostic LCD Liquid Crystal Display LED Light Emitting Diode LLD Line Leak Detection PC Personal Computer PM Probe Module (Intrinsically Safe) RM Relay Module SCM Secondary Containment Monitoring STP Submersible Turbine Pump TPI Turbine Pump Interface T5 T5 Series FMS Consoles (TS-5/ 608, TS-550 EMS, TS-5000 / EXPC / TS-550evo) TS-EMS Environmental Monitoring System TSA TankSentinel Anywhere 6

7 Intrinsically Safe LS500 Installation Note: The Intrinsically Safe 4-20mA Input Module has a BLUE face. Warning Lockout and tag circuit breakers, and disconnect console power wiring before installing or servicing any system wiring. Warning DO NOT make transducer wiring connections with power connected to the console or any module. Caution Do not run intrinsically safe (IS) wiring and non-intrinsically safe (non-is) wiring in the same conduit. Caution Do not use explosion-proof transducers (TS-LS500E) with intrinsically safe LS500. Note: TS-LS500 must be installed in accordance with the national electrical code, ANSI / NFPA 70, CEC or other applicable national or local codes. 1. Pull the wiring through the intrinsically safe conduits that will be used for the TS-LS500 transducers. 2. Mount the TS-LS500 in the Leak Detector Port of the STP housing. (As outlined in the Transducer Installation Section above). 3. The TS-LS500 wiring must enter the console in IS conduit through a knockout on the IS side of the barrier. Secure each pair of transducer wires to a single channel on the 4-20mA Input Module. Always start at the first available channel and do not skip channels. For example, if channels one through three are already being used for another application channel 4 must be used. Be sure to connect the wires to the correct polarity (/-). If the transducer is wired backwards it will not function. 4-20mA Input Module (Blue) RUN ERR Non-Hazardous Location Hazardous Location Class I, Division 1, Group D, Group IIA, Zone 0 - (BLK) (RED) LS (BLK) (RED) Tank Pressure Sensor Intrinsically Safe Conduit Figure ma Input Module Wiring 7

8 Explosion Proof LS500E Installation Note: The Explosion Proof 4-20mA Input Module has a RED face. Warning Lockout and tag circuit breakers, and disconnect console power wiring before installing or servicing any system wiring. Warning DO NOT make transducer wiring connections with power connected to the console or any module. Caution Do not run intrinsically safe (IS) wiring and non-intrinsically safe (non-is) wiring in the same conduit. Note: LS500E must be installed in accordance with the national electrical code, ANSI / NFPA 70, CEC or other applicable national or local codes. Note: The explosion-proof transducer needs to have explosion-proof conduit to the head of the transducer. 1. Pull the wiring through the explosion proof conduit that will be used for the TS-LS500 transducers. 2. Mount the TS-LS500E in the pump manifold. 3. The TS-LS500E wiring must enter the console in Explosion Proof conduit through a knockout on the Hazardous side of the barrier. Secure each pair of transducer wires to a single channel on the 4-20mA Input Module. Always start at the first available channel and do not skip channels. For example, if channels one through three are already being used for another application channel 4 must be used. Be sure to connect the wires to the correct polarity (/-). If the transducer is wired backwards it will not function. 4-20mA EXP INPUT MODULE (Red) RUN ERR Non-Intrinsically Safe Side of Console Hazardous Location Class I, Division 1, Group D, Group IIA, Zone 0 - (BLK) (RED) LS-500E Explosion-Proof Conduit Figure ma Input Module Wiring 8

9 LS-500 Setup (Console Programming) The following instructions are a guide to programming the LS-500 only. The administrator password will be necessary to save the programming changes. For instruction on FMS programming, or how to obtain the Administrator access level, please refer to the T5 Series FMS Programming Guide (p/n ) or the TS-550 / 5000 evo FMS Programming Guide (p/n ). Access the T5 Series FMS console (via the LCD touch screen or by the web) and navigate to the Setup Menu, Go to each of the following parameters, shown in the next tables, and set them accordingly per the site. You will be prompted to enter the Administrator password when it is required. Note: Site setups vary depending on the products used and other equipment installed. Setup information in the sections of this chapter depicts a typical site and are meant as examples only. AC Input Module One of the functions of the AC input module is to accept incoming dispenser hook signals. The hook signal tells the console which product the dispenser is requesting, then turns the appropriate Submersible Turbine Pump (STP) on using either a relay (from the relay board or from the power supply board) or the turbine pump interface (TPI). The LS500 is constantly monitoring the pressure on the line, and testing accordingly. To perform tests properly, the LS500 needs to know when the pumps are being used by other applications. Parameter Number of Gasoline Hooks per Dispenser Channels Name Enabled Active State Action Parameter value The number of product hook signal inputs to the console from each dispenser. Select the number of inputs in use. Text box, name each channel to easily identify in the mapping. Select YES. This will allow the channel to be mapped to another module. Other modules need this signal to trigger events. Select HIGH. A high signal level will activate the channel and a low signal will deactivate the channel. If set to LOW, then the channel is inverted and will only become active when a signal is absent and inactive when a signal is present. Select NONE Example: AC Input Module FMS Setup Group Name Parameter Name Parameter Value AC Input Modules Number Gasoline Hooks per Dispenser 2 Module 1 Channels 3 Channel 1 Name Disp 1 Unleaded Hook Signal Enabled Yes Active State High Action None Channel 2 Name Disp 2 Unleaded Hook Signal Enabled Yes Active State High Action None Channel 3 Name Disp 3 Unleaded Hook Signal Enabled Yes Active State High Action none 9

10 4-20mA Input Module TS-LSU500 Transducers use a single 4-20mA channel per product line which allows the console to monitor the pressure on each product line. Parameter Channels Name Service Type Parameter Value Select the number of channels used for LLD. Text box, name each channel to easily identify in the mapping. Select Line Leak Detection. This indicates that the type of device connected to the channel to indicate that the device is a TS-LS500 transducer. Example: 4-20mA Input Module LS-500 Setup Group Name Parameter Name Parameter Value 4-20mA Input Modules Module 1 Channels 1 Channel 1 Name Unleaded Transducer Service Type Line Leak Detection 10

11 Relay Module The 2A relay module contains 8 separate relays (relay channels). The 10A relay module contains 6 relay channels. Each relay is used by the console to turn a specific STP on or off in applications where Turbine Pump Interface (TPI) is not used. Parameter Parameter Value 10 Amp Select either yes or no depending upon which type of relay module is used Channels Name Enabled Type Polarity Logic Physically Wired As Number of Inputs* Type Channel Select the number of channels that will be used Text box, name each channel to easily identify in the mapping Select Yes Submersible Pump Normal OR logic Normally Open 1 for transducer plus number of AC inputs for this product, plus any other inputs to operate the submersible pump Module type that the input is on Specific channel the input is wired to. * Calculate the total number of inputs that need to turn on the STP: 1 transducer Number of AC inputs for the specific line Any other inputs to operate the STP = Total number of inputs Example: Relay Module Setup for STP Control Relay Modules Group Name Parameter Name Parameter Value Module 1 Channels 1 Channel 1 Name Unleaded STP Enabled Type Polarity Logic Physically Wired As Number of inputs 4 Yes Submersible Pump Normal OR Logic Normally Open Input 1 Type 4-20mA Input Module Channel Unleaded Transducer Input 2 Type AC Input Module Channel Input 3 Type AC Input Module Input 4 Channel Type Channel Dispenser 1 Unleaded Hook Signal Dispenser 2 Unleaded Hook Signal AC Input Module Dispenser 3 Unleaded Hook Signal 11

12 Turbine Pump Interface (TPI) Applications In systems where TPI is used, the relays are not needed for line leak or STP operation. Communication with the FFS smart controllers is done exclusively by the RS-485 connection. Refer to the Programming Manual for full TPI instructions. Example: TPI Setup Power Supply Group Name Parameter Name Parameter Value RS-485 Enable Interface Yes TS-TPI Enable Interface Yes Controllers A Number of Controllers 3 Controller 1 Name Unleaded Controller Enabled Type Address 1 Group 0 Tank 1 Height * Number of inputs 4 Yes Mag/Eco 5.00 in Input 1 Type 4-20 ma Input Module Channel Unleaded Transducer Input 2 Type AC Input Module Channel Input 3 Type AC Input Module Channel Input 4 Type AC Input Module Channel * Calculate the total number of inputs that need to turn on the STP: 1 transducer Number of AC inputs for the specific line Any other inputs to operate the STP = Total number of inputs Dispenser 1 Unleaded Hook Signal Dispenser 2 Unleaded Hook Signal Dispenser 3 Unleaded Hook Signal Note: Height is the estimated distance from PMA bottom to tank bottom. This distance is used for empty tank and high water conditions. 12

13 Fuel Management Systems (FMS) Line Application Set-Up Setting up the lines establishes which transducer and relay is used on the specific line and allows the user to change certain parameters in the operation of the line leak testing. Make sure the line is holding at or above the minimum required pressure (see page 5). If the pressure is too low, review the check-valve used, and adjust the pump / pump controller for proper pressure. Parameter Number of lines Name Submersible Pump Module Submersible Pump Channel Transducer Enable SLLD Product Enable Pressure Up Test Wait Time * Catch Pressure Wait Time * Dispenser Pressure Test Gross / Monthly / Annual Tests Enable Wait Period Between Tests Shutdown on Test Fail Parameter Value Number of product lines Text box, name each channel to easily identify in the mapping. Select either power supply module or relay module depending upon which relay is being used for pump control, or if TPI is being used. If Power Supply Board is selected and a relay from this power supply board was associated to a pump, an additional option will show up to indicate if TPI or relay will be used. Select the channel that the submersible controller is connected to. Select the transducer installed in the line. Select Yes Enter Product name (grade) Select yes Default is 4 Seconds. This is the time that the gauge waits for the line to pressure up above 12 PSI. Default is 2 seconds. This is the time the gauge waits after the pump turns off to make sure the pressure is at least 12 PSI. When selected, this gauge monitors the line pressure while dispensing. If the pressure decreases to 7.5 PSI, the line goes into alarm mode. The pump shuts off and is disabled. Select Yes. This allows the LS500 to run the tests. Default setting is 0 days. (This is the scheduling for line test after the test passed). If selected, this will shut down the submersible if that line fails that type of test * These settings typically will not need to be changed. Contact FFS tech support before changing these settings. Example: LS500 Application Setup Group Name Parameter Name Parameter Value Lines Number of lines 3 Line 1 Name Unleaded Line Submersible Pump Module Relay Module Submersible Pump Channel Unleaded STP Transducer Unleaded Transducer Enable SLLD Yes Product Unleaded Enabled Yes Pressure Up Test Wait Time 4 Sec Catch pressure Wait Time 2 Sec Dispenser Pressure Test Yes Gross Tests Enable Yes Monthly Tests Enable yes Wait Period Between Passed Tests 0 Days Shutdown on Failed Test Enable Yes Annual Tests Wait Period Between Passed Tests 0 Days Shutdown on Failed Test Note: Do not enable the line in set-up until the transducers have been properly connected to the 4-20 Input Module. 13

14 Line Status and Control Screens The status of each line channel can be viewed at any time by navigating to the Line Status or Control screens. To get to the Line Status or Control screens, go to FMS > Status > Lines or FMS > Control > Lines. LS500 Status Screen The status of each line can be viewed at any time by navigating to the line status or control screens. Status and alarm Indicators Status Line Pressure Enabled Not Learned Pump Shutdown Alarm Running Gross Leak Test Running Monthly Leak Test Running Annual Leak Test Between Test Waiting out Thermal Transducer Failure Pump On Pump Request Description Indicates the condition of the line Indicates the current line pressure Green, enabled. Red, disabled Red, if not learned. Gray, if learned Red, if pump is shutdown. Gray, if not shutdown Red, if in alarm. Gray, if not in alarm Green, if running test. Gray, if not running test Green, if running test. Gray, if not running test Green, if running test. Gray, if not running test Green, if running test. Gray, if not running test Green, if waiting out thermal, Gray, if not Red, if the LS-500 is not communicating with the transducer Green, if the STP is on The LS-500 is attempting to turn the STP on When viewing the Line Status Summary screen, remember to enable Auto Refresh. The Auto Refresh button will allow the on-screen results to be automatically updated. The Line Control screen will automatically update line information. Administrator privileges will be necessary to use the Line Control screen. For instructions on FMS programming or on how to obtain an Administrator access level, please refer to the T5 Series FMS Programming Guide (p / n ) or the TS-550 / 5000 evo FMS Programming Guide (p/n ). 14

15 LS500 Control Screen Status Section Indicator Line Pressure Enabled Not Learned Pump On Alarm Description Indicates the current line pressure Green, enabled. Red, disabled Red, if not learned. Gray, if learned Green, if the STP is on Red, if in alarm. Gray, if not in alarm Control Section Indicator Enable/Disable Reset Alarm Reset Line Force Gross Leak Test Force Monthly Leak Test Force an Annual Leak Test Learn Section Indicator Start/Stop Learn Message Learn Mode Active Learn Mode Error Description Manually enable or disable the line Manually reset an alarm on the line Manually reset line Manually start a gross leak test Manually start a monthly leak test Manually start an annual leak test Description Manually start or stop the learn cycle Indicates the status of the learn process Green: The line is being learned Red: An error has been detected in learning the line 15

16 Pre-Operational LS500 Testing The line stability test procedure assumes that all STP s, pump controllers, and AC inputs have been installed, wired, calibrated and are operational and in accordance with their respective installation and operation procedures. It also assumes that all T5 Series FMS console programming has been completed accurately. Caution DO NOT proceed to the Learn Process until each line successfully completes pre-operational testing. Failure to perform this test or ignoring any failed tests may prevent the FMS application from detecting a line leak. Note: State and / or local laws may require a separate, more stringent manual line tightness test. Before installing the LS500, ALWAYS verify and comply with local regulations. Note: The STP connected to the line being tested will need to be activated by lifting the appropriate product dispenser handle. Verify that all STP s and pump controllers are installed, calibrated and operational. Note: The lines must be able to reach 20 PSI. If the lines cannot reach 20 PSI, the issue needs to be resolved or the LS500 will not work in that STP. Required Equipment LS GPH Leak Generator Kit (TSP-ALCAL) Needle Valve Kit (TS-ALNIP) Pressure gauge Approved safety container ATTENTION. The Needle Valve Kit (TS-ALNIP) included with this kit is NOT compatible with E85 and other fuels containing high levels of Ethanol / Alcohol. For E85 and other high Ethanol / Alcohol mixture applications the Alternative Fuels Needle Valve Kit (TS-AFALNIP) should be ordered separately. All other regularly wetted components are E85 compatible. Line Stability Test Perform the following steps for each line. 1. Install the needle valve kit, pressure gauge and leak generator into the STP manifold. Pressurize the line by lifting the dispenser handle without dispensing fuel. 2. Once the line is pressurized, turn the STP off and monitor the pressure on the pressure gauge. The pressure should not change more than 5 PSI (34.5 Kpa) in 5 minutes. 3. If the pressure does change, pressurize the line again by lifting the dispenser handle (do not dispense), and check again. 4. If it does not change more than 5 PSI in 5 minutes proceed to the learn process. If the pressure changes more than 5 PSI pressurize the lines again, and re-test. Purging the line If air is in the system, the lines must be purged of the air. If needed, this procedure should be done before the Line Stability Test or Learning the line. Purge the line by dispensing from each fueling point starting with the dispenser furthest from the tank. The STP should be running the full time that the line is purged. 16

17 Learn Process Each line must be learned before the FMS system can continuously monitor it. Learning involves bleeding the line pressure down to zero, with no air in the line, then introducing a calibrated leak, facilitated by the leak generating kit (TS- ALCAL). The system learns this pressure decay curve and uses it to compare test data during continuous operation to determine if there is a leak in the line. Note: All console programming must be completed prior to the learn process. Refer to the Setup (Console Programming) chapter in this manual for details. Administrator privileges are necessary to Learn Lines. Refer to T5 Series FMS Programming Guide (p / n ) or the TS-550 / 5000 evo FMS Programming Guide (p/n ). for information on gaining Administrator privileges. Note: Complete the Pre-Operation Line Testing chapter prior to starting the Learn Process. Note: No dispensing can take place during the Learn Process. If product is dispensed while Learning, stop the process by pressing the Stop button. Note: DO NOT submerse or block the TS-ALCAL orifice while learning the line. The orifice MUST be kept free of dirt and debris. When to Learn / Re-Learn Line installation and start-up After repairs or modifications that effect the operating or holding pressure of the line After 4-20mA Input Module replacement After certain 4-20mA Input Module firmware upgrades (consult FFS Technical Services Department) If moving the LS-500 to another 4-20mA channel TS-ALCAL TS-ALNIP Place a container to catch the product Figure 4 Leak Generator Kits Procedure 1. The needle valve kit (TS-ALNIP) and 3.0 GPH Leak Generator (TSP-ALCAL) should be installed in the STP manifold. The line must be purged of all air prior to learning the line. 2. Open the needle valve with the leak generator in an approved container to catch any product. Let the line pressure bleed down to 0. Make sure that the pressure reads 0 on the pressure gauge installed on the needle valve kit. 3. Navigate to the line control screen on either the touch screen or by the web page. Locate the learn section and press start. 4. If the learn process is performed correctly the screen will show the events in the following sequence, Learning zero offset The system turns on the STP to learn pump pressure Learn the pressure decay curve 17

18 5. When finished, the message Learn Completed No Errors is displayed on-screen and the Not Learned indicator will become inactive. Note: Each line is different, but if the pump takes an excessively long time to bleed down to 0 PSI, then there may be air in the system. Re-purge the line and if air remains, look for pathways that air could have been introduced. Note: If any errors are encountered at any time during the Learn Process, the screen will display the applicable error message and the Not Learned indicator will remain active. Refer to the Alarms chapter of this guide for information on troubleshooting any errors that are displayed. 6. Once the line has been successfully learned, the line will automatically be enabled. Leave the leak generator open. The console will automatically begin a gross leak test. If the line was learned properly it will detect the leak and positive shutdown will occur after the 2nd failed 3 GPM test (Approximately 10 minutes). The console s screen updates will indicate if the line is failing a gross test. 7. Close the needle valve. To clear the alarm, navigate to the line control screen and choose reset alarm. The console will ask: Do you also want to enable this line? Select OK. (If you select CANCEL the line will not be enabled) This will automatically start another gross line test. A 3 gph pass will allow the FMS to continue to monitor the line. If this test fails, isolate why the test failed, make necessary repairs, and then reset the alarm again. 8. Remove the leak generator and replace the leak generator plug. The needle valve kit should be left installed in the manifold to easily allow functional testing, and re-learning lines if needed. Learn Messages Learn Message Description Learning 0 offset Displayed when the console is calibrating 0 Excessive Offset or Unstable Pressure Learning pump pressure Insufficient pressure No pressure loss Insufficient volume (line too small) Learning pressure decay curve Modulus out of range Learned Pressure is unstable Displayed when the console is learning the operating pressure STP is not operating at a high enough pressure Console does not detect a leak Console detects a pressure drop that is too great Displayed during the learn process to indicate that the calibrated leak decay curve is being recorded Console detects a pressure drop that is too small The line has been learned 18

19 LS-500 Reports Line test reports are available on demand from the console or using the web page. The reports can also be generated by using the rules engine. Several report options are available to print or save generated reports. For more information on reports in general, please refer to either the T5 Series Programming Manual (p / n ) or the T5 Series Operator s Guide (p / n ) or the TS-550 / 5000 evo FMS Programming Guide (p/n ). LS-500 Line Leak Reports LS-500 Line Leak Reports include any line tests completed within the date range chosen by the user. An example of an LS-500 report can be found below. Alarms When a T5 FMS console is in alarm, the Alarm LED on the front of the console will flash. If the line has been programmed to shut down the pump on failed test (in the FMS Setup), the pump will be unavailable for all system tests and dispensing until the line with the active alarm is manually reset. If the condition still exists after reset, the alarm will return. A service visit may be required to identify and correct the condition. Warning Always REMOVE POWER from the console prior to installing/removing a module or performing any maintenance while the console door is open. Note: Refer to the Important Safety Messages outlined in the beginning of this manual before performing any console maintenance. Note: If this guide is not able to help you correct a Warning or Alarm, please contact FFS Technical Services ( ). 19

20 LS-500 Alarms and Warnings Alarms During the Learn Process Alarm Symptom Possible Cause Resolution Failed to pressure up STP is not turning on Verify that the 4-20 transducer is a relay / TPI input Line is not configured Program error detected Air in line Not learned Insufficient volume STP is turning on, but the LS500 doesn t see the pressure change Is the pump controller powered on? If controlled by a relay, is the common of the relay wired to 110 Volts? Is another STP turning on? Is the 4-20 transducer in alarm? Is the wrong transducer mapped? Is the clamp valve down? Program mapping error Console software error Console has sensed line pressure variations Learn Line (FMS > Control > Lines > Learn) follow learn procedures Line is too small Leak generator not correct Air in the line Check the programming Check the controller Test the voltage on the relay common Check the other STPs Check alarms Check programming Look at the pressure gauge on the needle valve kit for operating pressure Verify programming Reboot console Investigate, then Purge Line Starting at the Furthest Dispenser Follow learn procedures Check line size Review leak generator set-up Purge air from the line Alarms During Operation Alarm Symptom Possible Cause Resolution Failed to pressure up Pressure was less that 12 psi after programmed delay when STP turned on STP is not turning on STP is turning on, but the LS500 doesn t see the pressure change Clogged STP intake Verify that the transducer is programmed as an input for the relay / TPI. Is the pump controller powered on If controlled by a relay, is the common of the relay wired to 110 V Is another STP turning on? Is the 4-20 transducer in alarm? Is the wrong transducer mapped Investigate, force a manual test and observe pressure Check the programming Check the controller Test the voltage on the relay common Check the other STPs Check alarms Check programming 20

21 Operating Alarms (Continued) Catastrophic leak Is the clamp valve down Investigate for leaks Look at the pressure gauge on the needle valve kit for operating pressure Test Result Condition Possible Cause Resolution Failed to catch pressure Sudden Pressure Loss Dispensing Pressure Test Failed High Pump Pressure Extended Hook Signal Pressure Transducer Fail Air in line Pressure was less that 12 psi after programmed delay when STP turned off Pressure dropped to less than 5 psi Pressure dropped to less than 7.5 psi while dispensing Pressure was above 50 psi during the catch pressure test 3 times consecutively Hook signal was applied for more than 4 hours Communication failure to transducer Console has Sensed Line Pressure Variations Check valve damaged Dispenser solenoid is still open after hook signal is off Catastrophic leak Catastrophic leak Dispenser hook signal on steady Wiring Transducer failure Line left open or air elimination loop failing Not Enabled Line disabled Either manually, or by another application shut the STP down Marginal Pass of Gross Leak Test Pump Request Ignored Passing result of gross test, but marginally STP did not turn on when requested Line is not thermally stable Controller not functioning System is busy TPI problem STP is disabled by another application Investigate, force a manual test and observe pressure Dispense, release hook, keep nozzle open Investigate for a catastrophic leak such as a pipe breaking Monitor line pressure using a pressure gauge, investigate for leaks Monitor line pressure using a pressure gauge, investigate for leaks Monitor line pressure using a pressure gauge, investigate for faulty check valve Verify that all handles are down, test AC inputs to determine which is giving a signal Check wiring connections at the console, junction box and quick disconnect. Direct connect, if still in alarm, replace. Investigate, then Purge Line Starting at the Furthest Dispenser Check other alarms, find source of interruption Force a gross leak test Check RS485 communication 4-20 ma Input error Contact Technical Support Module is Offline Communication failure between the control module and the module offline Look at module LEDs Red, replace module. Green solid or flashing, power down the console and re-seat the module 21

22 22 Test Result Alarms Test Result Condition Possible Cause Resolution Pass Line is tight Fail Actual Leak Line pressure variations are outside threshold Abort (no indication) STP Shutdown Temperature Instability Inadequate learning Air in line Dispensing Line disabled Temperature fluctuations cause pressure variances Line not properly bled to zero during learning Air was not bled out of the line prior to learning Line left open or air elimination loop failing A hook signal was detected, this resets the testing Either manually, or by another application shut the STP down Check for leaks, force leak test to verify Check for leaks, force leak test to verify Re-learn the line, follow procedures Purge the line, re-learn Purge the line Allow test cycle to complete before dispensing Check other alarms, find source of interruption Manual test started User forced a line leak test Cycle resets after manual test completes 2 consecutive 3 GPH test failures 1-2 consecutive 0.2 GPH test fails (depending on programming) 1-3 consecutive 0.1 GPH test fails (depending on programming) 3 consecutive catch pressure tests that over 50 psi Catch pressure test failure Pressure up test failure Possible gross leak Possible 0.2 GPH leak Possible 0.1 GPH leak High line pressure Pressure was less that 12 psi after programmed delay when STP turned off Pressure was less that 12 psi after programmed delay when STP turned on Investigate, then Force a Manual Gross Test Investigate, then Force a Manual Monthly Test Investigate, then Force a Manual Annual Test Investigate, adjust or replace check valve or functional element Investigate, force a manual test and observe pressure Investigate, force a manual test and observe pressure Clearing Alarms Clearing a console of alarms is important because, depending on how the T5 Series FMS console has been set up, alarms can: disable channels, start an annunciator, or stop a line test under way. Administrator privileges will be necessary to clear line alarms on the T5 Series FMS console. For instructions on how to obtain an Administrator access level, please refer to the T5 Series FMS Programming Guide (p/n ) or the TS-550 / 5000 evo FMS Programming Guide (p/n ). 1. Identify the alarm on the FMS Alarms screen. 2. Diagnose the condition using information found in the Alarms chapter of this guide. 3. Follow the troubleshooting steps in the previous section of this chapter to correct the issues indicated by the alarms. 4. Navigate to the Line Control screen. 5. Select Reset Alarms on the Control screen. 6. Select Enable/Disable on the Control screen if you were not given the choice to enable the line when the alarms were reset. If the condition still exists, the alarm can take up to several hours to reappear after the line is enabled.

23 LS-500 Functional Testing Perform a Functional Test annually. This test will verify that the LS-500 application will detect and alarm on a leak condition. This test should be performed during times when there is no dispensing. 1. If the channel is Enabled, disable the channel. At the T5 Series FMS console (via LCD or by the web page), navigate to the FMS > Lines Control screen. Press the Enable / Disable button to disable the line. 2. Remove the plug in the needle valve kit on the manifold. Connect the TS-ALCAL (Leak Generator Kit) to this port. 3. Open the needle valve. 4. Enable the line. This will initiate a gross line test. 5. Verify that the console displays a gross line test fail. This can take up to 10 minutes. Note: The system must run two separate tests five minutes apart and fail them both before a hard alarm occurs. 6. The channel will be disabled by the FMS application. Remove the TS-ALCAL. Replace and tighten the plug. 7. At the T5 Series FMS console (via LCD or by the web page), navigate to the FMS Lines Control screen. Press the Reset Alarm button to clear the alarm and enable the channel. 8. Select OK when prompted. 9. If the Annual Functional Test passed by properly detecting the leak, please skip this step. If the system did not catch the leak and the test failed, disable the channel and run the pre-operational tests. Perform the functional test again. If the system still fails to detect the leak, please contact FFS Technical Support ( ). Enabling/Disabling Lines After learning the line(s), each line will need to be enabled to allow monitoring. The Line Status reflects the current status. Enabling Lines At the T5 Series FMS console (LCD or by the web page), navigate to the FMS Control screen. Press the Enable / Disable button to enable the line. Only while the line is enabled will it continuously monitor and test pressure levels by activating the STP as necessary. Disabling Line Channels At the T5 Series FMS console (LCD or by the web page), navigate to the FMS>Lines Control screen. Press the Enable / Disable button to disable the line. Important: While the line is Disabled, FMS will neither maintain nor test line pressure levels. If alarms or errors occur, please refer to the Alarms chapter of this guide. 23

24 24 Control Drawing

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26 2014 FFS Rev.H