PLC-5000 FULL SHUT-DOWN SYSTEM INSTALLATION AND OPERATION MANUAL

Transcription

1 PLC-5000 FULL SHUT-DOWN SYSTEM INSTALLATION AND OPERATION MANUAL Central Control Node Software Version 6.3 Revision Date August 5, 2003 Vaporless Manufacturing 8700 East Long Mesa Road Prescott Valley, Arizona

2 ii PLC-5000 Full Shut-down System Installation and Operation Manual

3 TABLE OF CONTENTS SECTION I - INTRODUCTION System Concept Power Line Communication GPH Leak Detection Precision Leak Detection Line Pressure Regulation Certifications SECTION II LEAK DETECTOR NODE Introduction General Function Packaging Pressure Sensing and Shunt Valve Override Function LDN Labeling Installation Procedure for Single Phase Power Systems Installation Procedure for Three Phase Power Systems Remote Sensor Inputs SECTION III CENTRAL CONTROL NODE Introduction General Function Packaging Input and Output Signals Installation SECTION IV SPECIAL APPLICATIONS Introduction Variable Speed Turbines Solenoid Actuated Shut-off Valve Multi-Turbine Manifolds with Staged Turbine Starting Option B Mater Slave Select PLC-5000 Full Shut-down System Installation and Operation Manual iii

4 SECTION V SET-UP PROCEDURE Introduction LonWorks Installation Philosophy Installation Procedure Resilience Constant Measurement GPH Leak Detection Test SECTION VI SYSTEM OPERATION Introduction System Hardware Display Push-Button Keypad Printer Changing Printer Paper Changing Printer Ribbon Turbine Sequence Control Basic Operating Sequence Variations of Turbine Sequence Control Control Valve (CV) Sequence Staged Turbine (ST) Sequence Variable Speed (VS) Sequence Option B Master-Slave Select CCN State List CCN Alarm List Command Codes Leak Test Protocols Printout Formats iv PLC-5000 Full Shut-down System Installation and Operation Manual

5 TABLE OF ILLUSTRATIONS Figure 1.1 Distribution Network Illustration Figure 2.1 Power Connection Schematic, 1-phase Figure 2.2 Power Connection Schematic, 3-phase Figure 2.3 LDN Physical Layout Figure 2.4 LDN Dimensions Figure 2.5 LDN Installation, 1-phase Figure 2.6 LDN Installation, Exploded View, 1-phase Figure 2.7 LDN wiring with starting capacitor mounted in turbine head Figure 2.8 LDN wiring with starting capacitor mounted in electrical panel Figure 2.9 TMS System Modification Figure 2.10 Control Box Modification Figure 2.11 LDN Installation, 3-phase Figure 2.12 LDN Installation, Exploded View, 3-phase Figure 2.13 Sump Sensor Circuits Figure 2.14 Cable Connector Installation Figure 2.15 Model PLC-5021 Label Figure 2.16 Model PLC-5031 Label Figure 2.17 Model PLC-5041 Label Figure 3.1 CCN Dimensional Information Figure 3.2 CCN Connector Location Diagram Figure 3.3 Power Mains and Authorization Signal Connections Figure 4.1 Variable Speed Turbine System Figure 4.2 Solenoid Activated Shut-off Valve Figure 4.3 Manifolded Two-turbine System Figure 4.4 Manifolded Three-turbine System Figure 6.1 Changing Paper Roll and Ribbon Cartridge Figure 6.2 Configuration / Status Report Format Figure 6.3 Alarm Log Report Format Figure 6.4 Precision Test Log Report Format PLC-5000 Full Shut-down System Installation and Operation Manual v

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7 SECTION I - INTRODUCTION SYSTEM CONCEPT The PLC-5000 Full Shut-down System monitors and detects leaks in closed piping systems. Specifically, it is designed to meet Environmental Protection Agency (EPA) guidelines for gasoline station monitoring. The system is configured as a distributed control network composed of elements referred to as nodes. Each electronic node is capable of performing a specific task. The central control node functions as the master node in the network. The communication media in this network is the power mains. To restate this concept, all communication between central and remote nodes is carried on the same wires that provide power to the nodes of the network. Figure 1.1 illustrates the arrangement of nodes in a typical detection network. The basic function of the Central Control Node (CCN) is to monitor for product dispensing requests, monitor the activity of each of the remote Leak Detector Nodes, and determine the operation of the submersible pumps or turbines. Also, in the event of a detected leak or other error condition, the CCN will issue appropriate alarms. The basic function of the Leak Detector Node (LDN) is to monitor pressure in the distribution line and communicate the status of the line to the CCN. The LDN also directly controls its associated pump or turbine under instruction from the CCN. In addition, the LDN is capable of monitoring an optional sump sensor for the presence of liquids. This sensor may be of the type which discriminates between water and hydrocarbons (fuels). As shown in Figure 1.1, mechanical leak detectors are also included in the monitoring system. A leak detector is connected to an LDN so that both line pressure and the status of the leak detector can be monitored. Also, there are additional benefits provided by the leak detector which are discussed in other sections of this manual. The following statements outline the basic operation of the shut-down control system: 1. With power applied, the system is active and monitors for dispensing requests and alarm conditions. 2. Upon receiving an authorization signal for fuel dispensing, the CCN will issue a command to the appropriate LDN to energize its turbine. 3. Using the mechanical leak detector, the system will perform a 3 gph leak test. If the LDN determines that proper line pressure has been achieved, it will communicate this status to the CCN. The CCN will then allow the dispensing of fuel. 4. If proper line pressure is not achieved, a 3 gph leak failure exists. Under this condition the CCN will signal the LDN to deenergize its turbine contactor and an appropriate alarm will be issued. This action represents one of the full shut-down modes of the system. 5. In addition, the CCN will also conduct a 3 gph leak test following completion of any dispensing sequence. 6. When requested, the CCN node will also conduct precision leak testing at levels of 0.1 gph and 0.2 gph. POWER LINE COMMUNICATION This shut-down system uses the site s power lines as the communication pathway. The LonWorks protocol designed by Echelon Corporation has been selected for network communication. This standard is also used by the International Forecourt Standards Forum (IFSF), a group of oil companies backing the development of standards for the motor fuels retail sector. LonWorks is a general purpose control network technology that can be used to monitor sensors and control outputs in a wide variety of applications. Using LonWorks power line transceivers, control networks can be implemented through the same AC mains that power the equipment under supervision. Power line signaling eliminates the need for additional communications cabling both reducing the cost and simplifying the task of retrofitting control networks in existing installations. Designed for worldwide application, the transceivers used by Vaporless meet the regulations for AC mains signaling of the FCC (Federal Communication Commission), Industry Canada (formerly DOC), and CENELEC (European Committee for Electrotechnical Standardization). PLC-5000 Full Shut-down System Installation and Operation Manual 1-1

8 Figure 1.1 Distribution Network Illustration 1-2 PLC-5000 Full Shut-down System Installation and Operation Manual

9 The LonTalk Protocol follows the reference model for open systems interconnection (OSI) developed by the International Standards Organization (ISO) and provides services at all seven layers of the OSI reference model. 3 GPH LEAK DETECTION The EPA s regulations require operators to test for leaks on a routine basis (40 CFR Part 280, Subpart D). The regulations require that underground piping must be equipped with an automatic line leak detector that will alert the operator to the presence of a leak by restricting or shutting off the flow of fuel through the pipe or by triggering an auditory or visual alarm. This test is designed to detect the presence of very large leaks which may occur between the more accurate regularly scheduled monthly monitoring tests or annual line tightness tests. The standard requires that a leak greater than 3 gph must be detected within one hour of its occurrence. The PLC-5000 System in combination with Vaporless family of mechanical leak detectors will meet and exceed these requirements. PRECISION LEAK DETECTION In addition to large leak detection requirements, the EPA regulations also require the periodic testing for much smaller leaks. The PLC-5000 Full Shut-down System provides for precision leak detection at levels of both 0.1 gph and 0.2 gph. Statistically based test regimes have been developed to monitor for and report leak rates referenced to the EPA standard of 0.1 gph at 45 psi. When a leak is detected, the quantified result of the test is presented to assist in the troubleshooting process. Fundamental to the operation of the precision leak detection system it is known that a specific volume of fuel must leave the distribution line for the pressure in the line to move from a specific higher pressure to a specific lower pressure. This volume is known as the resilience constant measured in milliliters. Since the volume is dependent on line characteristics such as length and flexibility, it must be measure for each line at a site. Measuring the resilience constant is only the beginning. Precision leak detection in a distribution system is a complicated affair. Since gasoline and diesel fuels are not ideal fluids, that is, they can significantly expand and contract with temperature, the protocols of leak detection must deal with many variables. These variables include the magnitude of the resilience constant; measurement error associated with the resilience constant; the size of the leak (if any is present); the thermal conditions encountered by the fuel transferring from the storage tank to the distribution line; the thermal transfer characteristics of the distribution line which is influenced by the type of line material, depth of burial, moisture content of the surrounding soil, type of soil and ambient temperature; and the EPA requirements of reporting results at better than a 95% probability of detecting the leak, and less than 5% probability of declaring a leak when the actual leak rate is less than the detection threshold. The protocols in the PLC-5000 deal with these issues. LINE PRESSURE REGULATION In a dispensing system provision must be made to limit the pressure in the line. This is necessary for two reasons. First, excessive pressure may create a leak by blowing out seals or rupturing fittings. Second, some types of dispensing nozzles will not open under high line pressure conditions. It is important to note that Vaporless mechanical leak detectors contain a check valve which prevents fuel from flowing from the line, through the turbine and back into the supply tank. This check valve allows pressure to be maintained and controlled in specific ways necessary for the proper functioning of the Shut-down System. Contained within the LDN is a solenoid operated valve which under system control can shunt fuel from the pressurized line back to the tank. Following a dispensing operation, the shunt valve is used to reduce line pressure to an acceptable level. This valve is also used to reduce excessive line pressure caused by thermal expansion of fuel in the line. It is also used to adjust line pressure during electronic line leak testing. THIRD PARTY EVALUATION Ken Wilcox Associates conducted tests to verify the performance of the PLC-5000 Full Shut-down System. Results of the tests are presented in their report titled Evaluation of PLC-5000 Site Controller with Automatic Electronic Line Leak Detection with the 98 LD-2000 and 98 LD-2000 PLC Mechanical Line Leak Detectors; Final Report, May 20, PLC-5000 Full Shut-down System Installation and Operation Manual 1-3

10 Quoting from the Conclusions: The Vaporless PLC-5000 Line Leak Detection System exceeds the EPA performance requirements for hourly testing and annual line tightness testing. In the monthly monitoring/annual line tightness test mode, the probability of detection of a 0.1 gph leak is 100% and the probability of false alarm on a tight line is 0%. Questions regarding this evaluation should be directed to Vaporless Manufacturing. APPLICATION APPROVALS The PLC-5000 Full Shut-down System has been approved by specific localities for application within their jurisdiction. Questions regarding regulation and application should be directed to Vaporless Manufacturing. SAFETY APPROVAL (PENDING) The PLC-5000 family of Leak Detector Nodes has been approved for operation in Class I, Division 1, Group D hazardous environments by Underwriters Laboratories. The product is listed under Process Control Equipment for Hazardous Locations, Control Number 47LL. 1-4 PLC-5000 Full Shut-down System Installation and Operation Manual

11 SECTION II LEAK DETECTOR NODE INTRODUCTION This section presents specific information regarding the function, physical characteristics and installation of the Leak Detector Node (LDN). The basic function of the LDN is to monitor pressure in the distribution line and communicate the status of the line to the Central Control Node (CCN). The LDN also directly controls a pump or turbine under direction from the CCN. In addition, the LDN is capable of monitoring an optional sump sensor for the presence of liquids. This sensor may be of the type which discriminates between water and hydrocarbons (fuels). Up to four Leak Detector Nodes may be present in the network controlled by a single Central Control Node. An LDN functions as a slave node in the network. GENERAL FUNCTION An LDN controls only the single turbine and monitors the pressure of only the single distribution line to which it is connected. Appropriate hardwired inputs and outputs are provided for connection to the power mains and turbine. Additional intrinsically safe inputs are provided for the optional sensor which may be connected to the node through the circular connector located on the LDN enclosure. The application software resides in the program memory section of the microcontroller which forms the central operating unit of the LDN. This custom software controls the sequence of operations performed by the LDN and is not available to the user for modification. Various members of the LDN family of nodes are designed to operate from single phase or three phase power mains depending upon the size of the turbine load. Figure 2.1 is a schematic illustrating power connections in a single phase system, while Figure 2.2 is illustrates power connections in a three phase system. Table 2.1 lists the various model numbers within the LDN family of products. The various models differ only in the size of the applicable motor load and the number of power phases. Note that all of the LDN models are powered from a nominal 230 VAC ( VAC). Table 2.1 LDN Model Numbers Model Number Turbine Size (Max Hp) Power (Phases) PLC PLC PLC PACKAGING The LDN is packaged in a custom explosion proof and water-tight enclosure designed to function in a Class I, Division 1, Group D hazardous environment. As indicated in Table 2.2, an installation kit is available which will maintain the integrity of the device. However, it is the responsibility of the installer to provide an appropriate configuration which meets National Electrical Code and local code requirements. Additional information regarding installation of the LDN is available in this section of the manual. Table 2.2 LDN Installation Kits LDN Model Number PLC-5021 PLC-5021 PLC-5031 PLC-5041 Installation Kit Part Number PLC-5025 (Red Jacket) PLC-5026 (FE Petro) PLC-5035 PLC-5045 Figure 2.3 illustrates the accessible parts of the unit. Figure 2.4 provides dimensional information for each model in the family of products. PRESSURE SENSING AND SHUNT VALVE Because the system performs its function by monitoring pressure, it is necessary to have a pressure connection from the line, or the line side of the mechanical leak detector, to the LDN. As illustrated in Figures 2.1 and 2.2, 1/4 copper tubing is installed between the LDN and the pressure source, and between the LDN and the vent port of the leak detector. PLC-5000 Full Shut-down System Installation and Operation Manual 2-1

12 Figure 2.1 Power Connection Schematic, 1-phase 2-2 PLC-5000 Full Shut-down System Installation and Operation Manual

13 Figure 2.2 Power Connection Schematic, 3-phase PLC-5000 Full Shut-down System Installation and Operation Manual 2-3

14 Figure 2.3 LDN Physical Layout 2-4 PLC-5000 Full Shut-down System Installation and Operation Manual

15 Figure 2.4 LDN Dimensions PLC-5000 Full Shut-down System Installation and Operation Manual 2-5

16 As described in Section I Line Presssure Regulation, the LDN contains a solenoid operated valve which under system control can shunt fuel from the pressurized line back to the tank. The copper lines illustrated in Figures 2.1 and 2.2 are also used for this purpose. When the valve is open, fuel is allowed to flow from the pressurized line back to the tank. OVERRIDE FUNCTION While good design practice has been employed in the development of the control circuits and the selection of components, failure of components may happen from time to time. With this in mind, provision has been made to override the turbine contactor output in order to ensure a method of continued operation of the facility. The override function is engaged using a toggle switch located on the side of the LDN enclosure. Figure 2.3 indicates the location of the 3/4 NPT hole plug used to protect and seal the switch. The LDN must not be operated with the plug removed. This will void both the explosion proof and water-tight features of the enclosure. The override function may be used to bypass the functions of the LDN when an electronic system failure has disabled the control system. The override function may also be used to provide a means of troubleshooting and system testing to prove the function of various sub-systems. With the switch toggle in the down position the LDN will operate in its normal mode. With the toggle in the up position the LDN will be in the override mode. While in the override mode the control circuits of the LDN will remain unpowered and the coil of the turbine contactor will be energized directly from the power mains. This means that the turbine will run whenever power is applied to the LDN. When an LDN is in the override mode, the system will be incapable of detecting certain alarm conditions. This is considered to be a temporary situation which will be corrected by the timely replacement or repair of the defective elements within the system. It is the responsibility of the operator and technician to ensure timely service. It should be noted that even when the override switch is in the engaged position, the mechanical leak detector still performs its normal function. The function of the mechanical leak detector cannot be overridden. Additional information regarding the override function may be found in the section discussing operation of the total system. LDN LABELING Figures 2.15, 2.16 and 2.17 illustrate the labels attached to the PLC-5020, PLC-5030, and PLC respectively. The following information is presented on each label: Model and serial numbers Voltage, current and load specifications Summary of connector and port locations Location and direction of the override switch Hazardous environment classification Warnings and cautions regarding operation Note regarding communication installation Reference to the installation control drawing Safety approval notation The installer should be familiar with the information presented on the label. 2-6 PLC-5000 Full Shut-down System Installation and Operation Manual

17 INSTALLATION PROCEDURE FOR SINGLE PHASE POWER SYSTEMS The installation procedure for a single phase power system is slightly different than that for a three phase system. The following procedure applies to single phase systems only. As indicated in Table 2.2, an installation kit is available from Vaporless which will maintain the integrity of the LDN while operating in a hazardous environment. However, it is the responsibility of the installer to provide an appropriate configuration which meets National Electrical Code and local code requirements. Following is a list of materials supplied in the PLC-5025 and 5026 installation kits. TECHNICAL NOTE This procedure is designed to produce both an explosion proof and watertight installation. Application of sealing compound is required as noted. TECHNICAL NOTE The voltage for all nodes in the network must be derived from the same power phase. Figures 2.5 and 2.6 illustrate the basic arrangement of components in an installation using the PLC-5025 or 5026 kits. Some modification may be required to deal with specific problems presented by a particular installation. TECHNICAL NOTE DO NOT rotate the List of Supplied Materials elbow from which the wires exit the side of the LND. Doing so may permanently damage the Qty Description control unit. 1 1/2 NPT 90º pulling elbow 1 1/2 NPT 2-port conduit outlet box 1 1/2 NPT male union 1. Apply sealing compound to the 1-1/2 nipple 1 1/2 sched 40 galvanized nipple x 1-1/2 lg and assemble the bushing, nipple and half of 1 1/2 sched 40 galvanized nipple x 6 long the union. Do not forget to include the 1 1/2 sched 40 galvanized nipple x 8 long union s capture ring. 1 1/2 sched 40 galvanized nipple x 12 long 2. Remove the plug from the turbine s wiring 1 2 x 1/2 NPT bushing (PLC-5025 only) junction box /2 x 1/2 NPT bushing (PLC-5026 only) 1 Mounting bracket, short 3. If the motor starting capacitor is located in 2 Bolt, 1/4-20 x 1/2, hex the turbine head, two wires will enter the 2 Lockwasher, split-ring, 1/4 junction box. These wires are the power 1 Bolt, 1/2-13 x 2, hex mains and are connected to the motor wires 1 Lockwasher, split-ring, 1/2 which exit the box. Disconnect the wire 2 Tubing, 1/4 copper, 24 long pairs. It may be helpful to identify the wires 1 Fitting, 1/4 tube x 1/8 NPT male, straight for matching purposes. Figure 2.7 illustrates 1 Fitting, 1/4 tube run x 1/4 NPT male branch the wiring scheme with the capacitor in the tee turbine head. 1 Magnet (Used for communication installation) 4. If the motor starting capacitor is located in the Additional Required Materials electrical panel, three wires will enter the junction box. These wires are the power mains Heavy duty thread sealing compound with Teflon and one end of the starting capacitor and are Wire nuts or splices connected to the three motor wires which exit the box. Disconnect the wires from the power Installation Procedure mains. Do not disconnect the wire from the starting capacitor. It may be helpful to identify the wires for matching purposes. Figure 2.8 illustrates the wiring scheme with the capacitor located in the control panel. TECHNICAL NOTE Removing hole plugs from the turbine housing is the most difficult part of the installation procedure. Experience has shown that the use of proper tools for removing the plugs will significantly reduce installation time. A pipe wrench or adjustable wrench are not necessarily the proper tool. A socket and T-bar handle are recommended. 5. Extend each of the exposed wires about 12 inches. 14 gage wire is recommended; in this case bigger is not better. Use either wire nuts or splices to connect the wire ends. PLC-5000 Full Shut-down System Installation and Operation Manual 2-7

18 Figure 2.5 LDN Installation, 1-phase 2-8 PLC-5000 Full Shut-down System Installation and Operation Manual

19 Figure 2.6 LDN Installation, Exploded View, 1-phase PLC-5000 Full Shut-down System Installation and Operation Manual 2-9

20 The following color code is used in single phase LDN installations: 14 Feed the four wires from the turbine through the upper union and into the junction box. Black AC L1 15. Rotate the junction box assembly, being careful not to damage the wires at the union tran- White AC L2 Red One side of motor (switched L1) sition, so that the two halves of the union Orange One side of motor (switched L2) mate and secure the union connection. 6. Apply sealing compound to the external threads of the bushing, feed the four extended wires through the bushing assembly and screw the bushing into the top of the turbine s wire junction box. 7. Mount the LDN to the turbine using the triangular mounting bracket. The bracket attaches to the LDN using the two 1/4-20 x 1/2 bolts and lockwashers. This assembly then mounts to the turbine housing using one of the turbine casing bolts. A 1/2-13 x 2 bolt and lockwasher are supplied to replace the existing bolt which may be too short to satisfactorily complete this installation. 8. Apply sealing compound to one end of the 12 nipple. Feed the four wires from the LDN through this section of pipe and screw the nipple into the conduit elbow on the side of the LDN. 9. Apply sealing compound to the exposed end of the just installed nipple. Feed the four wires through one side of the pulling elbow and screw the elbow onto the exposed end of the 12 nipple. 10. Apply sealing compound to the male threads of the remaining portion of the union and screw it into the bottom of the junction box. 11. Select one of the two remaining nipples which will correctly span the distance between the pulling elbow and the junction box which will eventually mount above the bushing assembly. Apply sealing compound to one end of the nipple and screw this section into the side of the junction box. 12. Apply sealing compound to the exposed end of the just installed nipple. Screw this assembly into the open end of the pulling elbow. At this point slight adjustments in the angle and fit of various components may need to be made to allow for the future connection of the two union pieces. 13. Feed the four LDN wires through the pulling elbow and into the junction box. 16. Using wire nuts, connect the wires in the junction box according to the color coded functions noted in step Install the caps on the pulling elbow and the junction box. The application of grease to the cap threads is recommended. 18. If not previously completed, install the LD Leak Detector. TECHNICAL NOTE DO NOT apply sealing compound or tape to the fittings for the copper tubing. To do so may introduce contamination which will foul the shunt valve. 19. If not previously completed, screw a 1/4 tube x 1/8 NPT male straight fitting into the vent port of the LDN. This port is marked with two dots and is the port closest to the back of the LDN. DO NOT apply sealing compound or tape to this fitting. 20. If not previously completed, screw a 1/4 tube x 1/8 NPT male straight fitting into the pressure port of the LDN. This port is marked with one dot and is the port closest to the cover of the LDN. DO NOT apply sealing compound or tape to this fitting. 21. Develop and implement a method of connecting a 1/4 tube x 1/8 NPT male fitting to the pressurized line down stream from the Leak Detector. Contact the factory for suggested solutions to this problem. 22. Screw the 1/4 tube x 1/4 NPT tee fitting into the top of the Leak Detector. Sealing compound may be carefully applied to the fitting s threads. 23. Install 1/4 copper tubing between the pressure takeoff and the LDN s pressure port. TECHNICAL NOTE It is recommended that a small pore, large surface area fuel filter be placed in the pressure line. Contact the factory for recommendations PLC-5000 Full Shut-down System Installation and Operation Manual

21 24. Install 1/4 copper tubing between the tee fitting on the Leak Detector and the vent port on the LDN. 25. Screw the straight tube fitting supplied with the Leak Detector into the tank test port on the turbine housing. Sealing compound should be carefully applied to the fitting s threads. Install 1/4 copper tubing between the remaining connection on the tee fitting and the tank test port fitting. TECHNICAL NOTE The turbine s tank test port is used as a none pressurized return to the tank for the LDN vent. If such a port is not available, a return to the tank must be developed. Tapping into the turbine riser pipe, the fill tube, a fuel monitor riser pipe, a vapor recovery riser pipe, the cap on any such pipes, or an unused bung might be options to consider. 26. To supply continuous power to the LDN, modifications must be made to the existing control circuits. If the turbine was controlled by a control relay, install wire jumpers across the contacts of the existing relay as illustrated in Figures 2.1, 7 and 8. If the turbine was controlled through a TMS system, move the turbine power lead as shown in Figure 2.9. If the turbine was controlled through a Red Jacket or FE Petro remote control box, jumpers may be applied across the relay contacts or on the terminal barrier strip as illustrated in Figure TECHNICAL NOTE Rather than installing jumpers, power could be supplied to the LDN by rearranging the power wiring. This approach is not recommended. While in the override mode the coil of the turbine contactor in the LDN will be energized directly from the power mains. To reestablish cycling control of the turbine, the power circuit wiring will need to be returned to its original configuration. The presence of jumpers makes the reestablishment of the original circuit obvious and easier to implement. TECHNICAL NOTE The circuit driving the coil of a control relay should not be disturbed. This circuit will be extended during the installation of the Central Control Node. 27. This completes the mechanical and electrical portions of the installation procedure for single phase systems. The magnet is used during the communication set-up procedure. PLC-5000 Full Shut-down System Installation and Operation Manual 2-11

22 Figure 2.7 LDN wiring with starting capacitor mounted in turbine head 2-12 PLC-5000 Full Shut-down System Installation and Operation Manual

23 Figure 2.8 LDN wiring with starting capacitor mounted in electrical panel PLC-5000 Full Shut-down System Installation and Operation Manual 2-13

24 Figure 2.9 TMS System Modification 2-14 PLC-5000 Full Shut-down System Installation and Operation Manual

25 Figure 2.10 Control Box Modification PLC-5000 Full Shut-down System Installation and Operation Manual 2-15

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27 INSTALLATION PROCEDURE FOR THREE PHASE POWER SYSTEMS The installation procedure for a three phase power system is slightly different than that for a single phase system. The following procedure applies to three phase systems only. As indicated in Table 2.2, an installation kit is available from Vaporless which will maintain the integrity of the LDN while operating in a hazardous environment. However, it is the responsibility of the installer to provide an appropriate configuration which meets National Electrical Code and local code requirements. TECHNICAL NOTE DO NOT rotate the elbow from which the wires exit the side of the LND. Doing so may permanently damage the control unit. 1. Remove the cover from the conduit junction box. Three wire will enter the junction box. These are the three phase power mains and are connected to the three motor wires which exit the box. Disconnect the wire pairs. It may be helpful to identify the wires for matching purposes. Reconnecting the wires in the wrong order will cause the motor to run in the reverse direction and not deliver its specified volume. Following is a list of materials supplied in the PLC-5035 and 5045 installation kits. 2. Remove the existing junction box and List of Supplied Materials Qty Description replace it with a 3-port junction box (not supplied with kit). The new box has an additional conduit port which will allow for proper installation of the LDN. Alternatively, appropriate tapping of the existing box may produce the required additional port. 2 1/2 NPT 90º pulling elbow 1 1/2 NPT male union 1 1/2 x 3/4 NPT reducer 1 Mounting bracket, long 3. At this point, the installation includes the 2 Bolt, 1/4-20 x 1/2, hex 2 Lockwasher, split-ring, 1/4 1 Bolt, 1/2-13 x 2, hex 1 Lockwasher, split-ring, 1/2 2 Fitting, 1/4 tube x 1/8 NPT male, straight 1 Magnet (Used for communication installation) Additional Required Materials 3/4 NPT 3-port conduit outlet box 1/2 sched 40 galvanized nipples of various lengths 1/4 copper tubing Heavy duty thread sealing compound with Teflon Wire nuts or spices Installation Procedure TECHNICAL NOTE This procedure is designed to produce both an explosion proof and watertight installation. Application of sealing compound is required as noted. TECHNICAL NOTE The voltage for all nodes in the network must be derived from the same power phase. Figures 2.11 and 2.12 illustrate the basic arrangement of components in an installation using the PLC-5035 or 5045 kits. Some modification may be required to deal with specific problems presented by a particular installation. new junction box with the three power mains wires and the three motor wires entering the box. One port is still unused. 4. The following color code is used in three phase LDN installations: Black AC L1 Blue AC L2 White AC L3 Red One motor phase (switched L1) Yellow One motor phase (switched L2) Orange One motor phase (switched L3) 5. Mount the LDN to the turbine using the triangular mounting bracket. The bracket attaches to the LDN using the two 1/4-20 x 1/2 bolts and lockwashers. This assembly then mounts to the turbine housing using one of the turbine casing bolts. A 1/2-13 x 2 bolt and lockwasher are supplied to replace the existing bolt which may be too short to satisfactorily complete this installation. 6. Using the union and elbows supplied with the kit along with galvanized nipples of various lengths (not supplied with kit), construct a conduit system resembling that illustrated in Figure Some modification may be required to deal with the specifics of a particular installation. Apply sealing compound at all joints. The six wires exiting the LDN must be fed through the conduit during assembly. PLC-5000 Full Shut-down System Installation and Operation Manual 2-17

28 Figure 2.11 LDN Installation, 3-phase 2-18 PLC-5000 Full Shut-down System Installation and Operation Manual

29 Figure 2.12 LDN Installation, Exploded View, 3-phase PLC-5000 Full Shut-down System Installation and Operation Manual 2-19

30 7. Using wire nuts, connect the wires in the junction box according to the color coded functions noted in step Install the caps on the pulling elbow and the junction box. The application of grease to the cap threads is recommended. 9. If not previously completed, install the LD High Capacity Leak Detector. TECHNICAL NOTE DO NOT apply sealing compound or tape to the fittings for the copper tubing. To do so may introduce contamination which will foul the shunt valve. 10. If not previously completed, screw a 1/4 tube x 1/8 NPT male straight fitting into the vent port of the LDN. This port is marked with two dots and is the port closest to the back of the LDN. DO NOT apply sealing compound or tape to this fitting. 11. If not previously completed, screw a 1/4 tube x 1/8 NPT male straight fitting into the pressure port of the LDN. This port is marked with one dot and is the port closest to the cover of the LDN. DO NOT apply sealing compound or tape to this fitting. 12. Remove the 1/8 NPT plug for the line pressure port on the side of the main body of the Leak Detector. Install the 1/4 tube x 1/8 NPT male 90º fitting. Sealing compound should be carefully applied to the fitting s threads. 13. Screw the 1/4 tube x 1/4 NPT tee fitting into the vent port on the top of the Leak Detector s cap. Sealing compound should be carefully applied to the fitting s threads. 14. Install 1/4 copper tubing between the 90º fitting in the pressure port of the Leak Detector and the pressure port on the LDN. TECHNICAL NOTE It is recommended that a small pore, large surface area fuel filter be placed in the pressure line. Contact the factory for recommendations. 15. Install 1/4 copper tubing between the tee fitting on the Leak Detector s vent port and the vent port on the LDN. 16. Screw the straight tube fitting supplied with the Leak Detector into the tank test port on the turbine housing. Sealing compound should be carefully applied to the fitting s threads. Install 1/4 copper tubing between the remaining connection on the tee fitting and the tank test port fitting. TECHNICAL NOTE The turbine s tank test port is used as a none pressurized return to the tank for the Leak Detector and LDN vents. If such a port is not available, a return path to the tank must be developed. Tapping into the turbine riser pipe, the tank fill tube, a fuel level monitoring riser pipe, a vapor recovery riser pipe, the cap on any such pipes, or an unused bung might be options to also consider. 17. To supply continuous power to the LDN, modifications must be made to the existing control circuits. If the turbine was controlled by a control relay, install wire jumpers across the contacts as illustrated in Figures 2.2. If the system was controlled through some other means, apply jumpers as necessary to provide continuous power to the LDN. TECHNICAL NOTE Rather than installing jumpers, power could be supplied to the LDN by rearranging the power wiring. This approach is not recommended. While in the override mode the coil of the turbine contactor in the LDN will be energized directly from the power mains. To reestablish cycling control of the turbine, the power circuit wiring will need to be returned to its original configuration. The presence of jumpers makes the reestablishment of the original circuit obvious and easier to implement. TECHNICAL NOTE The circuit driving the coil of a control relay should not be disturbed. This circuit will be extended during the installation of the Central Control Node. 18. This completes the mechanical and electrical portions of the installation procedure for three phase systems. The magnet is used during the communication set-up procedure PLC-5000 Full Shut-down System Installation and Operation Manual

31 REMOTE SENSOR INPUTS The LDN incorporates inputs which monitor a remote sump sensor. A variety of sensor configurations are possible as described below. Single point sensors provide reliable monitoring of a containment sump for the intrusion of liquids. These sensors typically contain magnetic float and reed switch liquid level detectors. Single point sensors that incorporate a polymer element can also be accommodated by the LDN. Dual point sensors are used to detect two levels of liquid intrusion into a sump. These sensors typically contain magnetic float and reed switch liquid level detectors. Dual point sensors that incorporate polymer elements can also be accommodated. Discriminating sensors also provide reliable monitoring of containment sumps. Not only will these sensors detect liquid levels, but the sensors can discriminate water from hydrocarbons. These sensors typically combine magnetic float and reed switch liquid level detectors with a polymer strip that reacts to hydrocarbons. Any change in the status of the sensor will be reported to the CCN and recorded with a time and date stamp. As indicated in the following circuit diagrams, the LDN is also capable of detecting the presence or absence of a sensor attached to the sump inputs. Disconnect and reconnect of a sensor will also be reported to the CCN and recorded with a time and date stamp. In the following illustrations all switches are shown in their inactivated position, that is, without the presence of liquid. Note that some switches are shown as normal open while others are normal closed. Polymer elements are characterized by their resistance. In all cases, the voltage to power the sensor circuit is supplied from the node and meets UL intrinsic safety requirements. Sump Sensor The sump sensor input is generally used to monitor a turbine containment sump. Figure 2.13 illustrates sensor circuits which may be connected to the sump sensor input. The circuits include single, dual and discriminating sensor configurations. In all cases, activation of the low input will produce a caution alarm. This type of alarm serves as a warning to the presence of liquid. Activation of the high input will produce a service alarm. This type of alarm results in a turbine shut-down since sump capacity requirements have been violated or the presence of hydrocarbon (fuel) has been detected. The turbine will remain disabled until the fault condition is cleared. All alarms relating to this input are referred to as sump alarms when reported on the display or printout. Series and Parallel Combinations Various series and parallel combinations of sensors are possible. Please contact Vaporless to discuss your particular application. NOTE The mating cable connector for the sensor ports is available from Vaporless. Please contact us. We would be please to discuss your particular requirement. NOTE Figure 2.14 illustrates the procedure for attaching the connector to the cable. PLC-5000 Full Shut-down System Installation and Operation Manual 2-21

32 Figure 2.13 Sump Sensor Circuits 2-22 PLC-5000 Full Shut-down System Installation and Operation Manual

33 Figure 2.14 Cable Connector Installation PLC-5000 Full Shut-down System Installation and Operation Manual 2-23

34 Figure 2.15 Model PLC-5021 Label 2-24 PLC-5000 Full Shut-down System Installation and Operation Manual

35 Figure 2.16 Model PLC-5031 Label PLC-5000 Full Shut-down System Installation and Operation Manual 2-25

36 Figure 2.17 Model PLC-5041 Label 2-26 PLC-5000 Full Shut-down System Installation and Operation Manual

37 SECTION III CENTRAL CONTROL NODE INTRODUCTION This section presents specific information regarding the function, physical characteristics and installation of the Central Control Node (CCN). The basic function of the CCN is to monitor for product dispensing requests, monitor the activity of each of the remote Leak Detector Nodes, and determine the operation of the submersible pumps or turbines. Also, in the event of a detected leak or other error condition, the CCN will issue appropriate alarms. The Central Control Node can manage the operation of up to four Leak Detector Nodes. A CCN functions as the master node in the network. GENERAL FUNCTION The model PLC-5010 Central Control Node is capable of simultaneously monitoring and controlling up to four product channels. In its role as the master node in the network, the CCN receives requests for dispensing operations, directs the appropriate LDN to energize its turbine, monitors for proper line pressure conditions, controls precision test protocols, and issues alarms when error conditions exist. The CCN is the heart of the PLC-5000 Full Shut-down System. The application software which directs the actions of the controller resides in the nonvolatile memory coupled to the microcontroller. This custom software is not available to the user for modification. The CCN is capable of controlling all of the members of the Leak Detector Node family of products. Different models of LDNs may be present in the same network. The CCN is designed to operate from a single phase of a nominal 230 VAC power mains. The input voltage may range from 208 to 240 VAC. Figure 2.1 is a schematic illustrating power connections in a single phase power system, while Figure 2.2 is a schematic illustrating power connections in a three phase system. Note that in a three-phase system the voltage for the CCN is taken from the same phase that connects to the black and white leads of the LDNs. PACKAGING The CCN is packaged in a custom enclosure which meets NEMA1 standards. It is not designed to operate in a classified environment. The enclosure is provided with mounting holes which allow it to be secured to a wall or mounting board with screws. Also, four holes for conduit connections are provided on the bottom and both side panels. The control circuits are contained on a single printed circuit board (PCB) secured in the enclosure. Field termination to this PCB are made to connectors along the edges of the PCB. These connectors are of a plug-in type which allows for removal without disconnecting the wiring. This eases both initial installation and field service. Figure 3.1 provides dimensional information for the CCN, while Figure 3.2 indicates the location of the various connectors on the controller circuit board. INPUT AND OUTPUT SIGNALS Four classes of signals or devices are generally connected to the controller power mains, dispensing authorization requests, channel sequencing options and remote controlled devices such as line shut-off solenoid valves. Each of these signals or types of devices will be addressed in the following paragraphs. Regarding the mounting location of the CCN, the following general statement can be made the CCN should be located so that it is not only accessible by the operator, but is also in the vicinity of the signals that must be connected to the controller. As each of the signals and device types are discussed, a better understanding of the preceding statement will be developed. Power Mains The CCN operates from a single phase of nominal 230 VAC power mains. This single phase must be in common with that used to power the turbines. In a three phase power system the voltage for the CCN is taken from the same phase that connects to the black and white leads of the LDNs. The CCN draws approximately 0.12 A from the mains. PLC-5000 Full Shut-down System Installation and Operation Manual 3-1

38 Figure 3.1 CCN Dimensional Information 3-2 PLC-5000 Full Shut-down System Installation and Operation Manual

39 Figure 3.2 CCN Connector Location Diagram PLC-5000 Full Shut-down System Installation and Operation Manual 3-3

40 Figure 3.3 illustrates the connection of the power mains to the CCN controller. Note that there are a pair of L1 connections (formerly L) and a pair of L2 connections (formerly N). Each pair of terminals is internally connected on the PCB. The E terminal connects to the enclosure and may be connected to earth ground. Authorization Input Signals Authorization is the term for the signal that represents a dispensing request. When the signal is active the channel is authorized to dispense fuel. The authorization signal may be of any voltage from 60 to 230 volts AC or DC. The controller s authorization input is open ended, that is, it is without a reference, so that signals from a variety of sources may be connected to the inputs. Figure 3.3 illustrates several circuit configurations. In all cases, the switch in the figure represents any control element which can provide the necessary signal. In most cases, an appropriate authorization signal can be found on the coil of an existing motor contactor. If the turbine is powered through a TMS system, refer to Figure 2.8 for an illustration of how to create the authorization signal. Alarm Outputs Two levels of alarms may be generated by the PLC-5000 Full Shut-down Controller. These are termed caution and service. A caution alarm represents a warning that an error condition has been detected, but it is not of sufficient importance to shut-down the turbine. A service alarm represents an error condition of sufficient importance to warrant the shut-down of the turbine. These alarms are communicated in several ways. Active alarms are indicated on the display, while a record of past alarms may be presented on the display or printout. In addition, an audio alarm is initiated with the activation of any alarm. The audio alarm may be silenced using a push-button on the operator interface. The audio alarm will also be silenced by the clearing of the condition which triggered the alarm. Also, the audio alarm may be disabled through setup procedure. Refer to Section VI System Operation for directions on how to disable the audio alarm. Remote Controlled Devices In addition to directly controlling the dispensing turbine, several other devices may be controlled by the PLC These special applications will be discussed in detail in Section IV Special Applications, but are briefly presented as an overview of the system s capabilities. Variable speed turbines are designed to adjust their speed, and therefore the available volume of fuel, depending on the perceived demand. These devices are driven by a controller supplied with the turbine. Since the turbine is under the supervision and control of its own controller, the LDN cannot assume direct control of the turbine. The channel outputs on the CCN are used to drive the inputs of the variable speed controller, signaling it to start and stop the turbine. In some applications it is desirable to have a solenoid activated shut-off valve located in the distribution line. Even with the turbine running, this valve must be opened to allow the delivery of fuel. The channel output will control this solenoid valve. INSTALLATION The CCN is packaged in an enclosure meeting the NEMA1 standard. It is not designed to operate in a classified hazardous environment. As indicated in the preceding discussion, the unit should be located in a manner so that it is both accessible by the operator and in the vicinity of the signals that must be connected to the controller. Following is a general outline of the installation procedure for the CCN. Some modification may be required to deal with issues presented by a specific application or site. It is the responsibility of the installer to provide an appropriate installation which meets National Electrical Code and local code requirements. 1. Select a location for mounting the unit with attention to the availability of power mains and authorization signals. TECHNICAL NOTE In accordance with the NEC, the unit should be mounted at least three feet above the floor PLC-5000 Full Shut-down System Installation and Operation Manual