Cable-Tight Wire Management System Installation Guide Franklin Fueling Systems 3760 Marsh Rd. Madison, WI 53718 USA Tel: +1 608 838 8786 800 225 9787 Fax: +1 608 838 6433 www.franklinfueling.com
Safety Important! UPP Systems must only be installed by fully trained and certified installers. Failure to follow installation instructions will invalidate warranty and installer certification! Piping Installation Safety UPP Welding Units must never be operated in Zone 1 or Zone 0 areas (Hazardous area definitions are from European Directive 1999/92/EC and guidelines can be found in the APEA Blue Book 3rd Edition). Ensure Welding Units are connected to a power supply that meets the requirements detailed in the user manual and are within the requirements of any local authority or regional legislation. Important to any type of piping system is to safely connect all metallic components to ground. Metallic components, and more general conductive materials, due to their high capacitance, can have the potential to store high amount of electrostatic energy (sparks discharge can only be observed over conductive elements). All exposed metal parts used in UPP System installations should be adequately grounded to a dedicated earth electrode and brought to a potential equal to that of other metal parts in the close proximity. Chemical Safety Where using chemicals (such as acetone) during the installation of UPP systems products, follow all safety guidelines given on the chemical containers themselves or on any accompanying literature. Confined Space Some installation of UPP products may occur in confined spaces where a lack of oxygen and a concentration of toxic vapors is likely to be experienced. Such working conditions are dangerous and all local health and safety guidelines for working in such environments should be followed. Protective Equipment Ensure the correct personal protective equipment (PPE) is used at all times in line with local health and safety requirements. Material Safety Data Ensure all safety data is accessed and used while installing UPP Systems Transport & Storage UPP products should be transported and stored in accordance with guidelines contained in this manual. Heavy items Heavy items should be handled using suitable lifting equipment operated by authorised personnel. Visually inspect all components before use to confirm there is no sign of damage. Installation of ducting should be installed following UPP Systems Pipework Installation Instructions. Reference List of associated Installation Instructions. 408001007 Electro Fusion Process Manual (Conduits / Ducts) 408001016 UPP Piping Install Guidelines 408001017 UPP Electro Fusion Entry Seal 408047001 UPP System Integrity Testing Kit 2
Cable-Tight Wire Management System General Information The Cable-Tight Wire Management System provides a means of securely routing electrical conduit to and between sumps / chambers and sealing the entries against vapor and water intrusion. Removable Panel Creates Two Compartments Installation Installation of the electrical containment coincides with the pipework and follows installation of the sumps/ chambers. Install the Transition Chamber Position the transition chambers in accordance with local regulations. Ensure correct burial depth to provide drainage away from the chamber. Transition Chamber Preparation Prepare the area for the installation of the chamber taking into account the burial depth for the desired finished surface level. Anchor the electrical transition chamber with wood or angle iron or most commonly set into concrete to position it correctly. Allow for crowning of the surface around access cover frame to promote drainage away from Access Cover. Feet on chamber allow secure mounting in concrete Pre-marked drill centres Top View of Transition Sump Figure 2: Removable Panel The transition chamber connects ducting from the kiosk / control console to the conduit from the sumps / chambers. Ensure that the vapour seal to the kiosk is leak-tight by Tightness Testing in accordance with Local regulations. Where required by local regulations, ensure the duct termination at the kiosk is terminated more than 1 meter above ground level. The duct leading back to the kiosk should be sealed with suitable compound such as Rise duct seal, using Fiwa sealant or similar material, resistant to petroleum products or other VOC s in liquid or vapour form. Limit of concrete, front and back Figure 1: Transition Sump Pre-marked drill centres allow optimized placement of UPP entry seals in the side walls. Entry seals can be mounted before installing the transition sump. (Follow electrofusion fitting installation instructions, document 408001017). Recommended burial depth of UPP Duct & Conduit is a minimum of 300 mm (12"). Removable Separation The chamber can be fitted with an optional removable metal segregation panel that separates the sensor wiring from the high voltage wiring by creating two compartments (Figure 2). Ensure no cables cross from one side of the panel to the other when installed. Part number for the Segregation Panel is 408109001. From Kiosk / Console To Sumps / Chambers Figure 3: Transition Sump Connections Frame Bolt Gasket Draw Pit Backing Plate Connection detail Figure 4: Sump Installation Detail 3
Installing Entry Seal Fittings Incorrect selection or installation of seal or seal plugs can lead to loss of containment and may lead to transfer of flammable vapours. Measure the diameter of each cable and ensure they are fitted into the correct holes of the Entry Seal. 1. The entry seal (303-075-EC) is first installed with the compression nut removed following electrofusion guidelines (Document 408001017 for Electro fusion entry seals and document 408001007 for conduits duct.) 2. Lightly attach the compression nut on the threads of the entry seals. 3. Pull all wires / cables though to their final location. 4. Unscrew the compression nuts and let the nut rest on the cables. 5. Follow instructions on Figures 5 through 9. Figure 8: Push Entry Seal into the Entry Fitting Figure 9: Tighten Compression Nut Figure 5: Spread Cables and Insert Compression Disk (See Table 1) Tighten the compression nut hand-tight plus an additional ½ turn using a strap wrench, chain wrench or one as shown in Figure 10. Approved cable lubricant or liquid soap may be used on the vapor gland to assist positioning the cables and tightening the lock nut. Below are show two styles of wrenches that can be used to tighten the compression nuts. Figure 6: Using correct hole size in compression disk for cable diameter, push cable through opening in back of disk spreading material until cable is laying axially in hole. Figure 10: Compression Nut Wrenches Caution: Do NOT over-tighten the compression nut. Over-tightening of the compression nut will cause it to break. Unused channels must be fitted with cable plugs. Cable plugs are available to insert into unused channels in the vapor seal. Refer to Figure 7 and table 3 4 Figure 7: Insert Plugs If required, insert plugs into unused channels prior to tightening the compression nut. Plugs must be pushed fully home until Plug Flange is in contact with front face of the compression disk Figure 11: The 32 mm Conduit Entry Seal fittings are installed similarly to above. Select the required Vapour Seal from Table 2.
Parts Tables Image Part Number 408102001 408103001 408113001 408122001 Number of Holes x Cable Diameter Typical Location Corresponding Plug: Quantity x Part number 2 x 14-17 mm 1 x 11-14 mm 2 x 9-12 mm Dispenser Power and Data (Non Sensor) 2 x 408129001 1 x 408131001 2 x 408132001 12 x 5-8 mm 3 x 12-15 mm 6 x 7-10 mm Tanks (Sensor) Tank Power (Pressure Only) 4081340 01 3 x 408130001 6 x 408133001 Blank Line Testing and Future Expansion Pack Size 5 5 5 5 Table 1: Multi-Cable Compression Disks N/A Image Part Number 408107006 408107005 408107004 408107003 408107002 408107007 Grommet Size 6 mm, (3) 9 mm 11 mm 14 mm 16 mm Blank Cable diameter mm 5-6 7-9 9-11 12-14 14-16 N/A Pack Size 10 5 5 5 5 10 Table 2: Compression Grommets Image Plug Part Number 408128001 408129001 408130001 408131001 408132001 408133001 408134001 Grommet Size 25 mm 16 mm 14 mm 12 mm 11 mm 9 mm 6 mm Compression Disk Part Number N/A 408102001 408113001 408102001 408102001 408113001 408103001 Hole Size N/A 15 mm 13 mm 12 mm 10 mm 8 mm 6 mm Pack Size 10 10 10 10 10 10 10 Table 3: Plug Table Select the correct size of compression disk or compression grommet when replacing these items. Follow Installation Instructions. 5
Installation 303-2DBC Entry 2 x direct-buried cable Ensure that the cables are buried at depths as required by local regulations. Note: Grommets are sold separately 1. Determine the location of the entry seal and install it following electrofusion guidelines (Document 408001017). Installation 302-DBC Entry direct-buried cable Note: Ensure that the cables are buried at depths as required by local regulations. Grommets are sold separately 1. Determine the location of the entry seal and install it with the compression nuts removed, following electrofusion guidelines (Document 408001017). Figure 12: Entry Seal for the 303-2DBC Measure cable Ø and select the proper size of grommets for cable size (refer to table 2). Figure 14: 302-DBC Entry Seal Measure cable Ø and select the proper size of grommets for cable size (refer to table 2). Figure 13: 303-2DBC Assembly 2. Route the first cable through entry seal, housing grommet and compression nut. 3. Repeat with second cable. Tighten the compression nuts hand tight plus an additional ½ turn using a strap or chain wrench. Note: For a second seal on the cables, the backside of the housing can be potted inside the housing before electrofusion sealing in entry seal using ELAN-Tron MC-W363 or equivalent. 4. Position the housing into entry seal so that the threaded face is flush with entry seal. Weld housing into entry seal following electrofusion guidelines. Figure 15: 302-DBC Assembly 2. Route the cable first through the compression nut and grommet and then through the entry seal, 3. Pass cable through 2nd grommet and compression nut. Tighten the compression nuts hand tight plus an additional ½ turn using a strap or chain wrench. Figure 16: 302-DBC Assembled 6
Installation 305-3X27MM-CON Entry 27 mm Rigid Conduit 1. Determine the location of the entry seal and install it following electrofusion guidelines (Document 408001017). Outside Entry Seal Inside Figure 17: Entry Seal without Housing PE Wall 2. Position housing into entry seal so that threaded face is flush with entry seal. Weld housing into entry seal following electrofusion guidelines. Outside Inside Tightness Testing of Containment and Conduit The UPP Vacuum Test Unit VTU2 is recommended to prove tightness of installation including joints between electrical chamber and all entry seals. Recommended test setting: 1 ft: -30 mbar. Refer to the UPP System Integrity Testing Kit Instructions 408047001. To Vacuum Test Transition Chamber and conduits running to Tank chambers and dispenser sumps. Plug Entry seals at Tank Chamber and dispenser end with blank plugs shown on Table 1 & 2. Plug Duct running to kiosk with suitable duct plug. Use UPP Vacuum Test Unit VTU2 with Test lid VTL- 750X650 to test tightness. Tank Chambers, Dispenser sumps and Transition chamber should be vacuum tested individually following installation of cables with vapour seals, sealing plugs and duct sealant installed. Ensure duct to the kiosk is sealed with suitable compound such as Rise duct seal, using FIWA sealant or similar material, resistant to petroleum products or other VOC s in liquid or vapour form. Note: Make sure plugs and blanks (see tables 1&2) are positioned in entry seals and sealed. Outside Flush Figure 18: Entry Seal with Housing Installed Route rigid conduit at an axial alignment to Entry Seal of no greater than ± 5 degrees through the housing and then the grommet. Secure conduit in position by tightening the nut. Hand-tighten nuts plus an additional ½ turn using strap wrench Inside Housing Grommet Figure 19: Entry Seal with Conduit Installed Nut Note: If any opening are not used, seal with 25 mm plug 408128001 in the grommet. UPP System Integrity Testing Unit Figure 20: Vacuum Testing Electrical Transition Sump IMPORTANT: Inspect all Entry seals, vapour seals, Conduit & duct and ensure there is no physical damage prior to backfilling. Replace any damaged or incorrectly fitted items. Consult Franklin Fueling Systems for further details on replacement practices. Ensure all parts are correctly fitted, when cables have been installed ensure sealing plugs are installed in unused vapour seal holes and nuts have been tightened. Ensure that where a segregation panel is fitted in the Transition Chamber no cables cross from one side of the panel to the other. Ensure Access Cover lifting point plug is installed in cover whenever cover is replaced to prevent water ingress into transition sump. 7
Final Backfilling (Electrical Transition Chamber) Acceptable backfill materials Acceptable backfill materials are the following Class I and II materials, per ASTM d-2321: Class IA materials include angular, open-graded, clean, manufactured aggregate that contain little or no fines such as crushed stone or crushed cinders or shells. Class IB materials include angular, dense-graded, clean, processed aggregate such as Class IA materials mixed with sand and gravel to minimize migration. Class II materials include clean, coarse-grained soils that contain little or no fines such as gravel, gravel-sand mixtures, and well and poorly graded sands. Important: To help prevent the electrical transition chamber from deforming, do not over compact the backfill, and before you add backfill, make sure the access cover and segregation panel are in position. Important: Do not use mechanical compactors such as vibrating plates or road rollers. Shovel slicing (cutting the backfill with a shovel) is the recommended way to compact Class I and II materials. To improve compaction, slightly wet the backfill, but do not saturate the material or flood the trench. Important: Make sure the backfill material fully supports UPP pipes. Also, make sure the backfill material is free from contaminants (such as ice, silt, or peat) that can decay or dissolve and cause voids or ground movement. Preparing the forecourt surface To maximize the load capabilities of EN124 D400 access covers, make sure there is a minimum finished base thickness of 250 mm (10 inches) in C 30-35 concrete. If you use hot rolled asphalt (HRA), the access cover will work for installations up to a maximum HRA depth of 100 mm. Make sure the underside of the access cover frame is supported with enough concrete to withstand the load due to traffic. Crowning To improve the dispersion of water away from the cover, crown the cover slightly above the finished surface level. Make a crown of 5-10 mm over a distance of 300 mm (0.2 to 0.4 inches over 12 inches) around the perimeter of the cover. When you complete the installation, clean the cover and frame thoroughly to remove excess concrete. In particular, give special care to the area around the seal and the corresponding sealing face of the cover. Maintenance When you replace the composite access cover seal (which is a service spare), clean all of the old silicon mastic from the seal channel and apply a continuous bead of fresh silicone mastic in the channel before you place the new seal. A Franklin Fueling Systems Brand franklinfueling.com3760 Marsh Rd. Madison, WI 53718 USA Tel: +1 608 838 8786 800 225 9787 Fax: +1 608 838 6433 ELAN-Tron is a registered trademark of ELANTAS PDG, Inc. 408123001 r2 2016 Franklin Fueling Systems. All rights reserved. RISE and FIWA are registered trademarks of Beele Engineering/CSD Sealing Systems.