Manual No: Revision: V PLLD. Site Prep and Installation Guide

Transcription

1 Manual No: Revision: V PLLD Site Prep and Installation Guide

2 Notice Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this publication. Veeder-Root reserves the right to change system options or features, or the information contained in this publication. This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication may be photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root. For complete warranty, technical support, and additional product information, refer to your console s Operator Manual. DAMAGE CLAIMS 1. Thoroughly examine all components and units as soon as they are received. If damaged, write a complete and detailed description of the damage on the face of the freight bill. The carrier's agent must verify the inspection and sign the description. 2. Immediately notify the delivering carrier of damage or loss. This notification may be given either in person or by telephone. Written confirmation must be mailed within 48 hours. Railroads and motor carriers are reluctant to make adjustments for damaged merchandise unless inspected and reported promptly. 3. Risk of loss, or damage to merchandise remains with the buyer. It is the buyer's responsibility to file a claim with the carrier involved. Immediately advise your Veeder-Root representative, distributor, or the factory so that we may assist you. RETURN SHIPPING For the parts return procedure, please follow the instruction in the Veeder-Root Warranty and Dispatch Program pages in the Policies, Literature, and Contact Section of the Veeder-Root Consoles - North America Price List. Veeder-Root All rights reserved.

3 Table of Contents 1 Introduction Contractor Certification Requirements Related Manuals Safety Symbols Before You Begin System Description Preparing the Site Manholes Stage II Vapor Recovery Piping Runs Existing Check Valves Manifolded Product Lines Submersible Pumps Running Conduit/Wiring for PLLD System Safety Warnings Field Wiring Requirements National Electrical Code Compliance PLLD Transducer-to-Console Wiring PLLD Interface Module PLLD Controller Module Pump Control Wiring Pump Power Wiring to PLLD Controller Module Installing the PLLD Transducer Safety Warnings Transducer Installation Installing the SwiftCheck Valve Installing the PLLD Transducer Transducer Installation Modifying Pumps to Disable Functional Elements and Relief Valves Red Jacket Pumps Tokheim Pumps (Models , , and ) Bennett Pumps Adjusting the Pressurstat Relief Pressure for 3 GPH Testing PLLD Installation in FE Petro Pumps PLLD Operation with an FE Petro Variable Speed Pump System PLLD Installation in Red Jacket Quantum Pumps with SpikeCheck Valve Manifolded Product Line PLLD Installation Dual Pumps in Single Tank Multiple Tanks PLLD Installation with Stage II Vapor Recovery Systems Warning Tags Connecting PLLD System Wiring Safety Warnings General Wiring Practices PLLD Interface Module Wiring Connections PLLD Transducer Field Wiring Connections PLLD Controller Module Wiring Wiring Connections i

4 Table of Contents 6 Checking the PLLD System PLLD System Checkout Procedure Vent The Line Determine PLLD Transducer Pressure Offset Purge Air from the Line Enable the Line for Dispensing Checking the Site s Emergency Stop Switch Figures Tables Appendix A: PLLD Safety Instructions... A-1 Figure 1-1. FE Petro R Style Precision Check Valve Figure 3-1. PLLD Interface Module Wiring Diagram Figure 3-2. PLLD Transducer-to-Controller Module Wiring Figure 4-1. Sealing surface for SwiftCheck Valve s external O-ring Figure 4-2. SwiftCheck Valve and PLLD Transducer Installation Figure 4-3. Example PLLD Installation in a Red Jacket Maxxum Big-Flo Figure 4-4. Modifying the Functional Element in Red Jacket Pumps Figure 4-5. Locating Relief Valve on Tokheim Pumps Figure 4-6. Check Valve Assembly for Bennett Pumps Figure 4-7. Red Jacket Pump Pressurstat Adjustable Valve Assembly Figure 4-8. Location of PLLD Transducer and Model R Precision Check Figure 4-9. Valve in FE Petro Pump Dip Switch SW2 and Rotary Switch locations in the FE-Petro IST-VFC unit Figure PLLD Installation in Red Jacket Quantum Pumps Figure Manifolded Product Lines PLLD Installation Example - Dual Red Jacket Pumps, Single Tank Figure Manifolded Product Lines PLLD Installation Example - Multiple Tanks with Red Jacket Pumps Figure PLLD Install. w/ Healy Mini-Jet Sys Figure WARNING Tag Figure 5-1. Epoxy Sealant Connections Figure 5-2. PLLD System and Pump Control Diagram for Red Jacket Relay Control Box Figure 5-3. STP Power Interlock Relay Installation Figure 5-4. Red Jacket Maxxum Big-Flo Single-Phase Wiring Figure 5-5. Red Jacket Maxxum Big-Flo 3-Phase Wiring Figure 5-6. PLLD System and Pump Control Diagram for Non-Red Jacket Relay Control Box Figure 5-7. Wiring Diagram - Manifolded Product Lines PLLD - Single Tank, Dual Pumps Figure 5-8. Wiring Diagram - Manifolded Product Lines PLLD - Multiple Tanks Figure 5-9. PLLD System and Pump Control Diagram for Gilbarco Dispenser Isolation Box Figure Manifolded product lines - dual FE Petro IST-VFC Controllers Figure Manifolded product lines - dual Red Jacket IQ Controllers Table 1-1. PLLD Required Kits Table 1-2. PLLD System Table 1-3. PLLD System Table 1-4. Non-Vented Valve Kit Table 4-1. Dip Switch (SW2) Settings Table 4-2. Rotary Switch Positions ii

5 1 Introduction This manual tells you how to install the Pressurized Line Leak Detection (PLLD) System, for use with. PLLD transducers can be used only with the FE Petro, Tokheim, Red Jacket, and Bennett pumps discussed in this manual. Contractor Certification Requirements Veeder-Root requires the following minimum training certifications for contractors who will install and setup the equipment discussed in this manual: Level 1 Contractors holding valid Level 1 Certification are approved to perform wiring and conduit routing, equipment mounting, probe and sensor installation, tank and line preparation, and line leak detector installation. Level 2/3 Contractors holding valid Level 2 or 3 Certifications are approved to perform installation checkout, startup, programming and operations training, troubleshooting and servicing for all Veeder-Root Tank Monitoring Systems, including Line Leak Detection and associated accessories. Warranty Registrations may only be submitted by selected Distributors. Related Manuals Line Leak Application Guide TLS-3XX Series Site Prep and Installation Manual Pressurized Line Leak Interface Module - Installation Manual Pressurized Line Leak Controller Module - Installation Manual PLLD Alarm Quick Help Guide Safety Symbols The following safety symbols may be used throughout this manual to alert you to important safety hazards and precautions. Explosive Fuels and their vapors are extremely explosive if ignited. Flammable Fuels and their vapors are extremely flammable. Electricity High voltage exists in, and is supplied to, the device. A potential shock hazard exists. No Smoking Sparks and embers from burning cigarettes or pipes can ignite fuels and their vapors. OFF Turn Power Off Live power to a device creates a potential shock hazard. Turn Off power to the device and associated accessories when servicing the unit. No Open Flames Open flames from matches, lighters, welding torches, etc. can ignite fuels and their vapors. 1-1

6 Before You Begin No Power Tools Sparks from power tools (such as drills) can ignite fuels and their vapors. No People in the Area Unauthorized people in the area during service can create a potential for personal injury to you and them. Wear Eye Protection Fuel spray from residual pressure in the lines can cause serious eye injuries. Always wear eye protection. No Vehicles Moving vehicles in the area during service can create a potential for personal injury to you or others. Sparks from starting vehicles can ignite fuels and their vapors. Use Safety Barricades Unauthorized people or vehicles in the work area are dangerous. Always use safety cones or barricades, safety tape, and your vehicle to block the work area. Injury Careless or improper handling of materials can result in bodily injury. Gloves Wear gloves to protect hands from irritation or injury. Read All Related Manuals Knowledge of all related procedures before you begin work is important. Read and understand all manuals thoroughly. If you do not understand a procedure, ask someone who does. Before You Begin 1. Your console must have the PLLD Controller and PLLD Interface Modules installed. If these modules are not installed, the system will not be able to control the pumps or receive data from the PLLD transducers. If you need to install these modules, refer to manuals and. Also make sure that your console has additional slots to accommodate these modules. (If sufficient slots are not available, you will need an Module Expansion Board, part no ) 2. PLLD can only be installed in systems using approved pumps and piping types. Refer to the Line Leak Application Guide (part no ) for updates on approved pumps, piping lengths, and piping types which are supported. 3. Ensure that the submersible pump is properly grounded as per the manufacturer s instructions. 4. We recommend that your system have a shutoff valve installed between the PLLD transducer and the product pipeline. Although not required for the PLLD system to work, the valve can aid in troubleshooting the system and in reducing any product spillage while performing service work in the submerged pump sump. 5. To make installation easier for sites having FE Petro Pumps or Red Jacket Pumps with no valve, you can use a socket made by K. D. Tools (part no. 2431) to install the PLLD transducer. System Description The PLLD System performs 3.0 gph leak tests following each dispense. Depending on the software enhancement module installed, the PLLD System will also allow, with certain pump types, 0.2 and/or 0.1 gph line tests at full pump pressure. Since PLLD executes these tests automatically, there is no need for separate annual line leak testing. Table 1-1 shows required modules, kits, and check valves for PLLD operation, by pump type. Table 1-2 and Table 1-3 list the contents of the two PLLD system kits and Table 1-4 lists the contents of the Non-Vented Valve kit. 1-2

7 System Description Pump Type Red Jacket Quantum (All models) Red Jacket Standard (All models) Red Jacket Maxxum Big-Flo 3.0 GPH ONLY TESTING HARDWARE AND KIT REQUIREMENTS PLLD Kit Required FE Petro Tokheim & Bennett Check/Relief Valve Required Kits RJ SpikeCheck valve (factory installed) Red Jacket Pressurstat Assy. SwiftCheck (in PLLD kits) SwiftCheck (in PLLD kit) Red Jacket Pressurstat Assy. Table PLLD Required Kits 3.0, 0.2, & 0.1 GPH TESTING HARDWARE AND KIT REQUIREMENTS PLLD Kit Required Not Supported Not Supported Check/Relief Valve Required Kits RJ SpikeCheck valve (factory installed) Not Supported SwiftCheck (in PLLD kit) SwiftCheck (in PLLD kits) Not Supported ADDITIONAL PARTS REQUIRED FOR MANIFOLDED LINES Single Tank w/ 2 STPs Non-Vented SwiftCheck Valve for Slave Pump Kit* P/N And Interlock Relay 2 or More Tanks w/ STP in Each Non-Vented SwiftCheck Valve for each Slave pump Kit* P/N None Required Not Supported Not Supported Interlock Relay None Required FE Petro Model R P/N and replacement O-ring for the valve housing SwiftCheck (in PLLD kit) FE Petro Model R P/N , and replacement O-ring for the valve housing SwiftCheck (in PLLD kit) Non-Vented SwiftCheck Valve for Slave Pump Kit P/N OR FE Petro 65 psi Relief Check Valve (FE P/N ) And Interlock Relay Non-Vented SwiftCheck Valve for Slave Pump Kit P/N And Interlock Relay Non-Vented SwiftCheck Valve for each Slave pump Kit P/N OR FE Petro 65 psi Relief Check Valve (FE P/N ) Non-Vented SwiftCheck Valve for each Slave pump Kit P/N *Not required for systems performing 3 gph only testing. Black ID nut R "R" stamp plld\fervlv. eps Top View Bottom View Figure 1-1. FE Petro R Style Precision Check Valve 1-3

8 System Description Table PLLD System Quantity Description 1 PLLD transducer 1 sheet WARNING tags 1 Sealing pack 1 Cord grip 2 Wire connector 11 Tie wraps 1 Site Prep and Installation Guide Table PLLD System Quantity Description 1 PLLD transducer 1 Valve 1 sheet WARNING tag 1 Sealing pack 1 Cord grip 2 Wire connector 11 Tie wrap 1 Site Prep and Installation Guide Table Non-Vented Valve Kit Quantity Description 1 Non-Vented Valve Assembly 1 WARNING note 1-4

9 2 Preparing the Site As you prepare the site, you need to consider: Manholes Stage II Vapor Recovery system Piping runs Manifolded product lines Manholes When using a SwiftCheck Valve, the manhole must provide at least 8 inches of clearance above the pump head to install the PLLD components. Stage II Vapor Recovery If there is a Stage II Vapor Recovery system installed that includes a device in the pressurized piping, such as a Healy Mini-Jet, see PLLD Installation with Stage II Vapor Recovery Systems on page 4-12 for installation guidelines. Piping Runs Where piping runs have been installed for future use, but are connected to the active piping system, isolate the inactive lines from the active lines using a shutoff valve. Failure to do so may harm system performance. Existing Check Valves You must ensure that there are no existing check valves already installed in the pipeline. The presence of any check valve (other than the one used with the PLLD system) can prevent the PLLD system from detecting line leaks in the area of pipeline downstream from the check valve. Manifolded Product Lines If the PLLD system will be used on manifolded product lines, see Manifolded Product Line PLLD Installation on page 4-9 for installation instructions. Submersible Pumps The PLLD system is not qualified for use with Red Jacket X5 model submersible pumps or FE Petro S and S model pumps. Pump output pressure must be 23 psi minimum. 2-1

10 3 Running Conduit/Wiring for PLLD System Safety Warnings Circuitry within the sensor and console barrier form an intrinsically safe, energy limited system. This system makes the sensor intrinsically safe for use in a Class I, Group D hazardous location. The sensor wiring is intrinsically safe only when connected to TLS-350 Series Consoles. WARNING OFF This device is installed in equipment where potentially lethal voltages may exist. This device attaches to accessory components which operate in areas where flammable liquids and vapors may be present. Serious injury or death from shock, explosion, or fire may result if power is on during installation and the device is improperly installed. When installing this product: 1. Read and understand all instructions. 2. Turn off, tag, and lockout power to the console and submersible pumps while installing the PLLD system. 3. Do not allow PLLD pump control wires to share conduit with wires from intrinsically safe devices such as probes and sensors. 4. Insure that any assembled conduit only enters the console through the properly designated knockouts. 5. Wiring must comply with all applicable requirements of the National Electrical Code; federal, state, and local codes; and any other safety codes. 6. Substitution of components may impair intrinsic safety. Field Wiring Requirements NATIONAL ELECTRICAL CODE COMPLIANCE The following information is for general reference and is not intended to replace recommended National Electric Code (NEC) procedures. It is important for the installer to understand that electrical equipment and wiring located in Class I, Division 1 and 2 installations shall comply with the latest appropriate Articles found in the National Electric Code (NFPA 70) and the Automotive and Marine Service Station Code (NFPA 30A). PLLD TRANSDUCER-TO-CONSOLE WIRING Preferred Wiring Type #14 - #18 AWG stranded copper, shielded cable (REQUIRED) and manufactured with a material suitable for the environment, such as Carol C2534, Belden 88760, or Belden Wiring to be installed as a Class 1 circuit with the following provisions: Wire run must not exceed 1000 feet to meet intrinsic safety requirments, Capacitance does not exceed 100 pf/ft, Inductance does not exceed 0.2 µh/ft. 3-1

11 PLLD Interface Module Note: Throughout this manual, when mentioning any cable or wire being used for PLLD transducer-to- console wiring, it will be referring to shielded cable. Alternate Wiring Type - When Approved by the Local Authority Having Jurisdiction! #22 AWG stranded copper, shielded cable (REQUIRED) and manufactured with a material suitable for the environment, such as Belden Wiring to be installed as a Class 1 circuit with the following provisions: Wire run must not exceed 750 feet to meet intrinsic safety requirments, Capacitance does not exceed 100 pf/ft, Inductance does not exceed 0.2 µh/ft. Splices Veeder-Root recommends that no splices be made in the wire run between a PLLD transducer junction box and the console. Each splice degrades signal strength and could result in poor system performance. PLLD Interface Module 1. Run conduit from the Intrinsically Safe bay of the console to each STP manhole with a PLLD transducer installed. There are knockouts for ¾-inch, 1-inch or 1¼-inch conduit in the console s enclosure. When deciding on the size and number of conduits required, consider the number of wires entering the console. 2. Install a weatherproof electrical junction box with a gasketed cover for each PLLD transducer. IMPORTANT! The junction box in the STP manhole must be within 4-feet of the PLLD transducer. The junction box interior must be a minimum of 16 cubic inches with ½-inch NPT threads. 3. Pull shielded cable designed for use in the presence of gasoline and oil, from each PLLD transducer to the console (Figure 3-1). 4. Use gasketing or sealing compound at each entry to the junction box to keep it waterproof. Use a watertight cord grip at the PLLD transducer cable entry into the junction box. 5. IMPORTANT! Seal the conduit between the console and the PLLD transducer junction box within the submersible pump manhole and the boundary where they pass from a Class I, Division I area into a nonhazardous area in accordance with the National Electrical Code (NFPA 70) and the Automotive and Marine Service Station Code (NFPA 30A). 3-2

12 PLLD Controller Module Junction box 16 cubic inches minimum 1) Epoxy seal transducer wires 2) Do not ground shield to box Cord grip Intrinsically Safe Bay of Console Rigid conduit PRESSURE XMIT MAXIMUM SENSOR OUTPUT RATINGS: 15 VDC.15 AMP PRESSURE LINE LEAK INTERFACE MODULE Attach Cable Shields to Ground Lug Closest to Conduit Entry plld\plldwir.eps NOTES: 1. Connect with #12 awg (or larger) conductor the barrier ground to the earth ground bus at the power distribution panel. 2.Intrinsically safe wiring shall be installed in accordance with article of the NEC ANSI/NFPA 70. Rigid Conduit (enters Console through an Intrinsically Safe bay knockout) + PLLD Sensor #2 Up to 6 PLLD Sensors + PLLD Sensor #6 (Observe polarity when connecting PLLD Sensors.) + Shield Figure 3-1. PLLD Interface Module Wiring Diagram As you use the wiring diagrams, refer to Field Wiring Requirements on page 3-1 and Connecting PLLD System Wiring on page 5-1. PLLD Controller Module OFF PUMP CONTROL WIRING 1. Switch Off, tag, and lockout all AC power to the TLS Console, dispensers and submersible pumps. 2. Run conduit(s) from the console to the control box or boxes for the STPs that will have PLLD transducers installed. The conduit must be large enough to fit two #14 AWG wires for each pump control leg you are installing. There are knockouts for ¾-inch, 1-inch or 1¼-inch conduit in the console. When deciding on the size and number of conduits required, consider the number of wires entering the console. 3. Pull two #14 AWG color-coded or marked wires for each PLLD Controller Module between the power bay of the console and the submersible pump relay control box (Figure 3-2). Since wiring for multiple pump controls may be entering the console through the same conduit opening, be sure to color code or mark each wire to identify its source! IMPORTANT! Dispensers and console must be wired to the same leg of incoming power at the main electrical panel; otherwise damage may result to dispensers and console. 3-3

13 PLLD Controller Module OFF PUMP POWER WIRING TO PLLD CONTROLLER MODULE 1. Switch Off, tag, and lockout all AC power to the console, dispensers and submersible pumps. 2. Run conduit(s) from the Power bay of console to the main power panel (Figure 3-2). The conduit must be large enough to fit two #14 AWG wires for each pump which has an installed PLLD transducer. There are knockouts for ¾-inch, 1-inch or 1¼-inch conduit in the console. When deciding on the size and number of conduits required, consider the number of wires entering the console. 3. Mark and pull two #14 AWG wires (one black and one white) from the main power panel through this conduit(s) for each pump in which you will install a PLLD transducer. Power Bay Intrinsically Safe Bay RELAY NC NO C NC NO C NC NO C NC NO C RELAY RATINGS Form C Contacts 120 VAC, 2A Max; or 24 VDC, 2A Max. PROBE / THERMISTOR PROBE THERMISTOR MAXIMUM SENSOR OUTPUT RATINGS: 15 VDC.15 AMP PI 4-RELAY OUTPUT MODULE 1 PR LI PO PI 2 PR LI PO PI 3 PR LI PO PRESSURE LINE LEAK CONTROLLER MODULE RELAY RATINGS FORM A CONTACTS: 120 VAC 2A MAX. PRESSURE XMIT PROBE / THERMISTOR INTERFACE MODULE PRESSURE LINE LEAK INTERFACE MODULE MAXIMUM SENSOR OUTPUT RATINGS: 15 VDC.15 AMP plld\contolwir.eps Pull a marked pair of 14 AWG wires from the main power panel for each pump that has a PLLD transducer installed Pull a marked pair of 14 AWG wires from each pump control box for each pump which has a PLLD transducer installed TO PUMP CONTROLS See "Pump Control Wiring" for specific wiring connections Figure 3-2. PLLD Transducer-to-Controller Module Wiring 3-4

14 4 Installing the PLLD Transducer Safety Warnings OFF WARNING This device is installed in equipment where potentially lethal voltages may exist. This device attaches to accessory components which operate in areas where flammable liquids and vapors may be present. Serious injury or death from shock, explosion, or fire may result if power is on during installation and the device is improperly installed. When installing this product: 1. Read and understand all instructions. 2. Turn off, tag, and lockout power to the console and submersible pumps while installing the PLLD system. 3. Use only Veeder-Root supplied service parts to avoid compromising safety. 4. Do not allow PLLD pump control wires to share conduit with wires from intrinsically safe devices such as probes and sensors. 5. Insure that any assembled conduit only enters the console through the properly designated knockouts. 6. Wiring must comply with all applicable requirements of the National Electrical Code; federal, state, and local codes; and any other safety codes. 7. To protect yourself and others from being struck by vehicles, block off your work area during installation or service. IMPORTANT! If there is a Stage II Vapor Recovery System installed that includes a device in the pressurized piping, see PLLD Installation with Stage II Vapor Recovery Systems on page 4-12 for installation guidelines. Transducer Installation - 1 This installation procedure is to be used with Red Jacket (Excluding Quantum w/spikecheck Valve & CPT, and Maxxum Big-Flo), Tokheim, or Bennett Pumps. INSTALLING THE SWIFTCHECK VALVE The SwiftCheck valve mounts directly into the mechanical line leak detector pump port. It eliminates the need to break product lines for installation and service. It also provides a means of precision testing the discharge O-ring and threaded discharge. Since the SwiftCheck valve replaces the existing mechanical device, it is suitable in applications where there is no sump. Follow the steps below to install a SwiftCheck valve in a Red Jacket, Tokheim, or Bennett pump. For Bennett pumps, be sure that an LLD tee fitting is installed before you install the SwiftCheck valve. 1. Do one of the following: a. If the submersible turbine pump is equipped with a mechanical LLD, remove the mechanical unit and any related tubing and fittings, or b. If the submersible turbine pump is not equipped with a mechanical LLD, remove the 2-inch mechanical LLD port plug. 4-1

15 Transducer Installation Ensure that the sealing surface for the valve s external O-ring is smooth and free from corrosion, pitting, and any material build-up [Figure 4-1]. IMPORTANT! Failure to ensure a smooth seal surface can result in false line leak alarms. Sealing surface of pump port pumps\rdjkport.eps Figure 4-1. Sealing surface for SwiftCheck Valve s external O-ring 3. Lubricate the external O-ring on the valve using mineral oil or other suitable lubricant. IMPORTANT! Do not overtighten the SwiftCheck valve when installing it into the pump. Overtightening the valve can cause a flow restriction in the line! 4. Install the SwiftCheck valve [Figure 4-2] in the mechanical LLD pump port. IMPORTANT! Seal the NPT threads only with a UL-classified, nontoxic pipe sealant suitable for the fuel involved. PLLD Sensor SwiftCheck Valve pumps\rdjkswfv.eps INSTALLING THE PLLD TRANSDUCER Figure 4-2. SwiftCheck Valve and PLLD Transducer Installation 1. Thread the PLLD transducer into the SwiftCheck Valve [Figure 4-2]. IMPORTANT! Seal any pipe threads using a UL-classified, nontoxic pipe sealant suitable for the fuel involved. 2. Feed the PLLD transducer cable through the watertight cord grip on the PLLD transducer junction box. Tighten the nut on the cord grip to ensure a watertight seal. 4-2

16 Transducer Installation - 2 Transducer Installation - 2 This installation procedure is to be used with Red Jacket Maxxum Big-Flo Pumps. 1. Remove the cap from the 2-inch Transducer port next to the 3-inch discharge port. Thread the PLLD transducer into the Transducer port (see Figure 4-3). IMPORTANT! Seal any pipe threads using a UL-classified, nontoxic pipe sealant suitable for the fuel involved. 2. Verify that the console has Version x19 or later software. Junction box (customer supplied) Seal-off, epoxy seal per NFPA spec (customer supplied) PLLD transducer in 2" Transducer port conduit to console (customer supplied) plld\maxxum.eps Figure 4-3. Example PLLD Installation in a Red Jacket Maxxum Big-Flo Modifying Pumps to Disable Functional Elements and Relief Valves If you are using a FE Petro pump, a Red Jacket pump with a Pressurstat adjustable valve, or a Red Jacket Quantum pump with SpikeCheck valve skip this section. RED JACKET PUMPS (Excluding Quantum w/spikecheck Valve, and Maxxum Big-Flo) The PLLD SwiftCheck valve eliminates the need for the pump s functional element relief valve. You must modify the functional element as part of the PLLD system installation on Red Jacket pumps. 1. Remove the six 1/4-28 slot-head screws from the functional element [Figure 4-4]. 2. Remove the functional element s spring and piston and diaphragm. 3. Carefully reassemble the functional element using a new diaphragm suitable for the fuel involved. Be sure that all mating surfaces are free from debris when reinstalling. 4. Torque the six slot-head screws to in-lbs. 4-3

17 Modifying Pumps to Disable Functional Elements and Relief Valves WARNING Failure to properly reseal the functional element may result in product leakage, which could create serious environmental and safety hazards. Fire, explosion, or ground contamination could occur. Carefully reassemble and reseal the functional element, following the procedures described in this manual. Remove spring & piston Replace gasket Functional element orifice - drill out to 3/16" diameter pumps\rjrsp.eps TOKHEIM PUMPS (MODELS , , AND ) Figure 4-4. Modifying the Functional Element in Red Jacket Pumps The PLLD SwiftCheck valve eliminates the need for the pump s relief valve. You must remove it as part of the PLLD system installation on Tokheim pumps. 1. Remove the two bolts which secure the Syphon housing assembly to the pump [Figure 4-5]. 2. Turn the Syphon housing assembly over. Remove and discard the Relief Valve. 3. Replace the gasket and two O-rings as noted in the figure. 4. Replace Syphon housing assembly and tighten the retaining bolts securely. WARNING Failure to properly reseal the Siphon Housing assembly may result in product leakage, which could create serious environmental and safety hazards. Fire, explosion, or ground contamination could occur. Carefully reassemble and reseal the Siphon Housing assembly, following the procedures described in this manual. 4-4

18 Modifying Pumps to Disable Functional Elements and Relief Valves Syphon housing assembly Replace O-rings Replace gasket Remove relief valve Pump discharge head Bottom view of Syphon housing pumps\tokfele.eps BENNETT PUMPS Figure 4-5. Locating Relief Valve on Tokheim Pumps The PLLD SwiftCheck Valve eliminates the need for the pump s check valve. You must remove the pump check valve as part of the PLLD system installation on Bennett pumps. Bennett pumps may have a siphon valve assembly or suspension valve assembly. 1. Disconnect any tubing from the siphon valve assembly, if present. 2. Remove the siphon or suspension valve assembly from the pump discharge head. The assembly is located at the top of the pump on the side opposite the discharge ports. 3. Unscrew retainer plug from valve assembly. Remove spring, check valve, internal O-ring and discard [Figure 4-6]. (It may be necessary to tap the valve housing to dislodge the check valve.) 4. Replace external O-ring if necessary and install retainer plug back into valve assembly. 5. Reinstall siphon or suspension valve assembly in pump discharge head, being sure to apply a suitable sealing compound to the threads. WARNING Failure to properly reseal the Siphon or Suspension Valve assembly may result in product leakage, which could create serious environmental and safety hazards. Fire, explosion, or ground contamination could occur. Carefully reassemble and reseal the Siphon or Suspension Valve assembly, following the procedures described in this manual. 4-5

19 Adjusting the Pressurstat Relief Pressure for 3 GPH Testing External O-ring Housing Remove Check valve & O-ring Remove Spring plld\valvasm.eps Retainer plug Figure 4-6. Check Valve Assembly for Bennett Pumps (Suspension Valve Assembly Shown) Adjusting the Pressurstat Relief Pressure for 3 GPH Testing This procedure is for Red Jacket pumps (Excluding Quantum Pumps with SpikeCheck Valve and Red Jacket and Quantum pumps using SwiftCheck valve). Read this section if you have purchased, or your STP is equipped with, a Pressurstat adjustable valve to run 3.0 gph tests only. Refer to Before You Begin on page 1-2 for more information. To adjust the relief pressure: 1. Remove the brass cap [Figure 4-7] by unthreading it. 2. Turn down the adjustment screw [Figure 4-7]. Tightening the screw clockwise increases the pressure. When the adjustment screw is fully down, the relief pressure is approximately 40 psi. Set the relief pressure to psi; measure pressure by installing a pressure gauge on the line. Verify the relief pressure by using the console; refer to 4. Enable the Line for Dispensing on page 6-2 for the procedure to obtain pressure readings. 3. Check the sealing surface for the O-ring and the condition of the ring. Clean or replace as required. 4. Replace the brass cap and hand tighten (the O-ring completes the seal between the body and cap). Brass Cap Adjustment Screw O-ring pumps\rjfeadj.eps Figure 4-7. Red Jacket Pump Pressurstat Adjustable Valve Assembly 4-6

20 PLLD Installation in FE Petro Pumps PLLD Installation in FE Petro Pumps The PLLD transducer mounts directly into the mechanical line leak detector pump port. It eliminates the need to break product lines for installation and service. 1. Thread the PLLD transducer directly into the mechanical LLD port on the pump as shown in Figure 4-8. IMPORTANT! Seal any pipe threads using a UL-classified, nontoxic pipe sealant suitable for the fuel involved. 2. Feed the PLLD transducer cable through the watertight cord grip on the PLLD transducer junction box. Tighten the nut on the cord grip to ensure a watertight seal. 3. If necessary, install the FE Petro Model R precision check valve.. Manifold cover Pressure Test Port - remove plug to access valve clamp adjustment screw. Turn screw CCW until valve clamp is all the way up and snug against manifold cover. Valve clamp (should be snug up against cover) Check valve spring FE Petro O-ring Part No or PLLD transducer Model R Precision check valve pumps\feptp.eps Figure 4-8. Location of PLLD Transducer and Model R Precision Check Valve in FE Petro Pump PLLD OPERATION WITH AN FE PETRO VARIABLE SPEED PUMP SYSTEM The FE Petro Variable Speed Pump System contains a submersible pump and adjustable frequency drive. For satisfactory operation with the PLLD System, you need to change the following in the adjustable frequency drive as described below: Dip switch (SW2) settings Rotary switch positions IMPORTANT! The correct hardware and switch settings must be used for the system to detect leaks less than 3.0 gph. If the correct hardware and switch settings are not used, the system will always pass 0.1 gph tests, but the results will be invalid. IST-VFC Software Version 1.1 and 1.2 The settings and positions depend on the software version of the FE Petro IST-VFC (Intelligent Submersible Turbine- Variable Speed Controller). To determine the software version of the IST-VFC, remove its cover and check the label on the FE Petro chip, which is on the printed circuit board. The instructions below are for Version 1.1 and 1.2 of the IST- VFC. 4-7

21 PLLD Installation in FE Petro Pumps Dip Switch SW2 Pole 1 on dip switch SW2 (Figure 4-9) controls the pump start up time. Set this switch to OFF so that the submersible pump will run at 34 psi for 6 seconds each time it is started. Pole 2 does not affect PLLD operation; it sets the product type for the IST-VFC (Table 4-1). Table Dip Switch (SW2) Settings Pole 1 Pole 2 OFF ON-gasoline OFF-diesel Rotary Switch The rotary switch (Figure 4-9) controls the pump pressure of the submersible pump. As shown in Table 4-2, use positions 1, 2, 3, or 4 to run the pump at a pressure range compatible with PLLD operation. Do not use positions 0, 5, 6, 7, 8, or 9. Dip switch pumps\feptrvsp.eps SW2 Rotary switch Figure 4-9. Dip Switch SW2 and Rotary Switch locations in the FE-Petro IST-VFC unit Table Rotary Switch Positions Position Pressure (psi) IST-VFC Software Version 1.3 The settings for Software Version 1.3 are the same as Versions 1.1 and 1.2, except that the Rotary Switch can be set to any position from 1 to

22 PLLD Installation in Red Jacket Quantum Pumps with SpikeCheck Valve PLLD Installation in Red Jacket Quantum Pumps with SpikeCheck Valve The PLLD transducer mounts directly into the mechanical line leak detector pump port. It eliminates the need to break product lines for installation and service. Since the PLLD transducer replaces the existing mechanical device, it is suitable in applications where there is no sump. 1. Do one of the following: a. If the submersible turbine pump is equipped with a mechanical LLD, remove the mechanical unit and any related tubing and fittings, or b. If the submersible turbine pump is not equipped with a mechanical LLD, remove the 2-inch mechanical LLD port plug. 2. Thread the PLLD transducer directly into the mechanical LLD port on the pump (see Figure 4-10). IMPORTANT! Seal any pipe threads using a UL-classified, nontoxic pipe sealant suitable for the fuel involved. 3. Feed the PLLD transducer cable through the watertight cord grip on the PLLD transducer junction box. Tighten the nut on the cord grip to ensure a watertight seal. plld/quantumpvr.eps PLLD transducer Manifolded Product Line PLLD Installation Figure PLLD Installation in Red Jacket Quantum Pumps (w/ SpikeCheck Valve Assy) Version 9/109 or later software provides a feature that permits the use of PLLD on product lines supplied by: (1) two submersible pumps in a single tank or (2) two tanks with two submersible pumps, up to a combined maximum of eight tanks and pumps. Please refer to the System Setup Manual (Manual No ) for detailed instructions on selecting this option. For additional parts you need when installing a manifolded PLLD system, see Before You Begin on page 1-2. DUAL PUMPS IN SINGLE TANK SpikeCheck Valve Assy. Follow these guidelines as you install a manifolded PLLD system with dual pumps in a single tank: Dielectric unions and flexible piping elements should be used as required by federal, state, and local requirements for the specific piping application. Location of unions may vary with configuration. An interlock relay must be installed so that the slave pump is energized only when dispensing (but is switched Off when performing line tests). A Non-Vented SwiftCheck valve must be installed in the slave pump. 4-9

23 Manifolded Product Line PLLD Installation PLLD System Installation Procedure WARNING G A S Product spillage could create serious environmental and safety hazards. Fire, explosion, or ground contamination could occur. 1. If the SwiftCheck Valve is being installed at an existing site, drain the product pipeline using approved containers and procedures that will prevent product spillage. 2. Dispose of drained fuel properly. Use an approved container suitable for moving fuel. Dispose of fuel soaked materials properly and not into trash barrels that may be used by customers. OFF G A S 1. Turn off, tag, and lockout AC power to the submersible pumps and console before beginning the installation. 2. If the system is equipped with an in-line shutoff valve, close the valve to reduce the amount of drainage from the product lines. Collect drained fuel in an approved container. 3. Install the Non-Vented SwiftCheck valve 1 in the slave pump s mechanical LLD pump port. 4. Install the PLLD transducer and SwiftCheck valve 2 in the master pump [see Figure 4-11 on page 4-11]. IMPORTANT! Seal any NPT threads using a UL-classified, nontoxic pipe sealant suitable for the fuel involved. 5. Wire the system as shown in Figure 5-7, Figure 5-8, Figure 5-10, or Figure 5-11 as applicable. Follow the procedure described in PLLD Controller Module Wiring on page 5-3. MULTIPLE TANKS Follow these guidelines as you install a PLLD system into multiple manifolded tanks: Dielectric unions and flexible piping elements should be used as required by federal, state, and local requirements for the specific piping application. Location of unions may vary with configuration. A relay must be available on either a Four Relay Module or I/O Combination Module to control the pump on the higher-numbered tank. The PLLD Module will provide pump control output for the primary tank and the Pump In (Dispenser ON) signal for the set. A Non-Vented SwiftCheck valve must be installed in the slave pump(s) 1. Remove any other check valve or leak detect device in the line that is not shown. PLLD System Installation Procedure 1. Install the Non-Vented SwiftCheck valve 3 in the mechanical LLD port of the slave pump (higher numbered tank). IMPORTANT! Seal any NPT threads using a UL-classified, nontoxic pipe sealant suitable for the fuel involved. 2. Install the PLLD transducer and SwiftCheck valve 4 in the master pump (lower numbered tank) as shown in Figure 4-12 on page If you are installing more than two tanks and pumps, connect the additional tanks and pumps the same way that you installed the higher numbered tank and slave pump. 1. For Maxxum Big-Flo, set the Pressurstat on the the slave STP to psi. 2. Not required for FE Petro pumps (see Figure 4-8 on page 4-7), or Red Jacket Quantum or Maxxum Big-Flo pumps (see Figure 4-10 on page 4-9). 3. For Maxxum Big-Flo, and systems performing 3 gph only testing, set the Pressurstat on the the slave STP to psi. 4. Not required for FE Petro pumps (see Figure 4-8 on page 4-7), or Red Jacket Quantum or Maxxum Big-Flo pumps (see Figure 4-10 on page 4-9). 4-10

24 Manifolded Product Line PLLD Installation 3. Wire the system as shown in Figure 5-8 on page 5-8. Follow the procedure described in PLLD Controller Module Wiring on page 5-3. To Dispensers Tank plld\mfdsing.eps Flexible Pipe with Swivel or Union Ball Valve Ball Valve Flexible Pipe with Swivel or Union SwiftCheck Valve PLLD Sensor Warning Tag Non-Vented SwiftCheck Valve Master Pump Slave Pump Figure Manifolded Product Lines PLLD Installation Example - Dual Red Jacket Pumps, Single Tank To Dispensers Flexible Pipe with Swivel or Union Ball Valve Ball Valve Flexible Pipe with Swivel or Union SwiftCheck Valve PLLD Sensor Warning Tag Non-Vented SwiftCheck Valve plld\mfdtanks.eps Master Pump Lower Numbered Tank Higher Numbered Tank Slave Pump Figure Manifolded Product Lines PLLD Installation Example - Multiple Tanks with Red Jacket Pumps 4-11

25 PLLD Installation with Stage II Vapor Recovery Systems PLLD Installation with Stage II Vapor Recovery Systems Systems that have a Stage II Vapor Recovery Device installed in the pressurized piping require special installation procedures. Because the PLLD transducer must be installed downstream from these devices, a monitored containment sump is required. Also, there must not be a check valve installed between the SwiftCheck valve 1 and the pump for PLLD to function properly. Refer to Figure 4-13 for PLLD installation with a Healy Mini-Jet system. Follow the applicable guidelines of Installing the SwiftCheck Valve on page and Installing the PLLD Transducer on page 4-2. Ensure that the Healy pump is wired according to the manufacturer s instructions and utilizes isolation relays. Submersible pump Healy TM Mini-Jet Containment sump PLLD sensor SwiftCheck valve Red Jacket leak detector fitting (Red Jacket Part# ) Product line to dispensers Sump sensor Note: remove inline check valve, if present plld\healy.eps Figure PLLD Install. w/ Healy Mini-Jet Sys. (Req d. Dielectric Union and Shutoff Valve Not Shown) Warning Tags WARNING tags [Figure 4-14] are provided with the PLLD System. For your safety and the safety of others who may service dispensers, submersible pumps, or PLLD Systems, you must attach a tag to each of the following devices where it can clearly be seen by a serviceman performing work on the system: Console Submersible pump Dispenser filter 1. Not required for FE Petro pumps (see Figure 4-8 on page 4-7), or Red Jacket Quantum or Big-Flo Maxxum pumps (see Figure 4-10 on page 4-9). 4-12

26 Warning Tags WARNING THE SUBMERGED PUMP SYSTEM SUPPLYING THE DISPENSERS MAY TURN ON UNEXPECTEDLY TO PERFORM A LINE LEAK TEST. THIS MAY RESULT IN FUEL SPRAYING DURING DISPENSER, PRODUCT LINE, LEAK DETECTOR OR STP SERVICE. PERFORM THE FOLLOWING BEFORE BEGINNING SERVICE: OFF G A S 1. CLOSE AFFECTED DISPENSER SHEAR VALVE AND TEST FOR PROPER SHUTOFF OF THE VALVE IF PERFORMING DISPENSER HYDRAULIC SERVICE. 2. REMOVE POWER TO THE SUBMERGED PUMP (STP) AND TO THE CONSOLE AND THE LINE LEAK DETECTOR SYSTEM. 3. WEAR EYE PROTECTION. 4. COLLECT FUEL IN APPROVED CONTAINERS. DO NOT CONTAMINATE ENVIRONMENT. TO ORDER TAGS - USE PART NO consoles\warntag.eps Figure WARNING Tag 4-13

27 5 Connecting PLLD System Wiring Safety Warnings Circuitry within the PLLD transducer and console barrier form an intrinsically safe, energy-limited system. This system makes the transducer intrinsically safe for use in a Class I, Group D hazardous location. The transducer wiring is intrinsically safe only when connected to Series Consoles. WARNING OFF This equipment uses lethal voltages and attaches to accessory components which operate in areas where flammable liquids and vapors may be present. Serious injury or death from shock, explosion, or fire may result if power is on during installation and the device is improperly installed. When installing this product: 1. Read and understand all instructions. 2. Turn off, tag, and lockout power to the console, dispensers, and submersible pumps while installing the PLLD system. 3. Use only supplied service parts to avoid compromising safety. 4. Do not allow PLLD pump control wires to share conduit with wires from intrinsically safe devices such as probes and sensors. 5. Insure that any assembled conduit only enters the console through the properly designated knockouts. 6. Wiring must comply with all applicable requirements of the National Electrical Code; federal, state, and local codes; and any other safety codes. 7. To protect yourself and others from being struck by vehicles, block off your work area during installation or service. Refer to the following wiring diagrams as you connect the wiring: PLLD system--figure 3-2 on page 3-4 Manifolded PLLD system--figure 5-7 on page 5-7 or Figure 5-8 on page 5-8 Red Jacket pumps-- Figure 5-2 on page 5-4 through Figure 5-5 on page 5-5 Non-Red Jacket pumps--figure 5-6 on page 5-6 Gilbarco Dispenser Isolation Box--Figure 5-9 on page 5-9 Manifolded product lines - dual FE Petro IST-VFC Controllers--Figure 5-10 on page 5-10 Manifolded product lines - dual Red Jacket IQ Controllers--Figure 5-11 on page 5-11 General Wiring Practices Be sure all wires are color-coded or carefully marked to identify their source. The PLLD Interface Module in the console comes with a connector in place. Do not remove the connector from the module or remove the module from its slot in the console during wiring. Terminal identifications appear only on the module bracket. Removing the connector from the module increases the risk of wiring errors. Label all connectors, using the supplied self-adhesive labels, according to the slot in which the modules are installed. 5-1

28 PLLD Interface Module Wiring Connections IMPORTANT! Once a connector has been wired on a module and the console has been programmed, the connector and module cannot be moved to another slot without reprogramming the system. Record the location (i.e., Line #1 (regular), Line #2 (super), etc.) of each PLLD wired to a module on the circuit directory inside the console door. PLLD Interface Module Wiring Connections OFF 1. Turn Off, tag, and lock out all AC power to the console and submersible pumps. 2. Connect the color-coded or marked wires from each PLLD transducer to the proper terminals on the PLLD Interface Module connector starting with position 1 [Figure 3-1 on page 3-3]. Wire each position on the module(s) in order without skipping a position, e.g., 1, 2, 3, 4, etc., not 1,3,4. IMPORTANT! The console software will identify PLLD Controller Module positions 1-3 (one module) and 4-6 (optional second module, highest in I.S. bay) with PLLD Interface Module positions 1-6. Therefore you must wire the PLLD System so that the STP connected to position 1on the PLLD Controller Module has the PLLD transducer installed that is connected to the position 1 on the PLLD Interface Module. The same relationship holds for the remaining 5 positions. 3. Connect the bare wire (shield) to one of the ground screws in the console only. 4. Maintain correct circuit orientation between the color-coded or marked field wires and connector terminals during wiring. PLLD Transducer Field Wiring Connections OFF 1. Turn Off, tag and lock out all AC power to the console and STP. 2. Using wire nuts, connect the white and black wires from the PLLD transducer to field wires in the junction box. Be sure to maintain correct circuit orientation between the color-coded or marked field wires and PLLD transducer wires during wiring. Cut off the transducer shielded ground wire (if present) flush with the cable jacket. Do the same for the cable shield. IMPORTANT! Connect the shielded cable to the shielded ground wire lug (supplied) in the intrinsically safe area of the console [Figure 3-2 on page 3-4]; do not connect it to the transducer. 3. Seal wire nut connections using the epoxy sealant furnished with each PLLD. Use one packet for no more than two wire nut connections. Ensure the end of the cable jacket is covered by the epoxy. Refer to Figure 5-1 as you prepare epoxy and seal connections. CAUTION: Epoxy sealant is irritating to eyes, respiratory system, and skin. Can cause allergic skin reaction. Contains: epoxy resin and Cycloaliphatic epoxycarboxylate. Precautions: Wear suitable protective clothing, gloves, eye, and face protection. Use only in well ventilated areas. Wash thoroughly before eating, drinking, or smoking. 5-2

29 PLLD Controller Module Wiring A B C From probe, sensor, or transducer To console Make sure that the ends of cable sheathing are submerged in sealant Tie wrap Wire nuts Instructions: NOTE: When temperature is below 50 F (10 C), keep resin in a warm place prior to mixing (e.g., in an inside pocket next to body). 1. Open epoxy sealant package, and remove resin pak. 2. Holding resin pak as shown in A, bend pak along long length. 3. As shown in B, firmly squeeze the RED SIDE of the resin, forcing it through the center seal and into BLACK SIDE. 4. Mix thoroughly to a uniform color by squeezing contents back and forth times. 5. Squeeze mixed, warm resin into one end of bag and cutoff other end. 6. Slowly insert wiring connections into sealing pack until they fit snugly against the opposite end as shown in C. 7. Twist open end of bag and use tie wrap to close it off and position the tie wrapped end up until the resin jells. probes\epxy2w.eps Figure 5-1. Epoxy Sealant Connections IMPORTANT! Do not put more than two wire nut connections in one epoxy sealant bag or the connections will not be properly sealed. Improper sealing of the connections will result in inaccurate system readings and possibly false alarms. PLLD Controller Module Wiring PLLD pump control wiring varies depending on the pump manufacturer s relay control box. Refer to the appropriate wiring diagram (circuit diagrams are for switched hot dispensers): Red Jacket--Figure 5-2 on page 5-4 through Figure 5-5 on page 5-5 Non-Red Jacket--Figure 5-6 on page 5-6 Manifolded--Figure 5-7 on page 5-7 or Figure 5-8 on page 5-8 Gilbarco Dispenser Isolation Box--Figure 5-9 on page 5-9 IMPORTANT! Dispensers and console must be wired to the same leg of incoming power at the main electrical panel; otherwise damage may result to both. The console must be able to detect when dispensers are switched On or Off so it only initiates line leak tests when the dispenser is switched Off. The console must also be able to start the submersible pump to perform a line leak test, and shut off the pump if a leak is detected. IMPORTANT! The console, when wired correctly, will control the pump independent of the dispenser control circuits. It is imperative that when the Emergency Stop switch is wired and tested the console s pump control circuitry CANNOT switch On the pump. To ensure that the pumps are unable to be activated in an emergency situation, it is best to have the Emergency Stop switch interrupt pump power at the circuit breaker panel via shunt breakers. Note: (OPTIONAL) In order to prevent 3.0 gph tests from running when STP power is switched Off, an Interlock relay may be used on the PUMP IN signal (ref. Figure 5-3 and Figure 5-7). 5-3