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

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4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual
GREEN MACHINE ™ - North America
(Patents Pending)
Model # VST-GM-CS2-101
Installation, Operation, Maintenance, & Troubleshooting Manual
Rev. 4.5 – Published April 2019
Manual #9600-003
Vapor Systems Technologies, Inc.
650 Pleasant Valley Drive
Springboro, Ohio 45066
(937) 704-9333 PH
(937) 704-9443 FX
www.vsthose.com
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  • Page 1 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual GREEN MACHINE ™ - North America (Patents Pending) Model # VST-GM-CS2-101 Installation, Operation, Maintenance, & Troubleshooting Manual Rev. 4.5 – Published April 2019 Manual #9600-003 Vapor Systems Technologies, Inc.
  • Page 2 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual This page left intentionally blank Page 2...

  • Page 3: Table Of Contents

    Other Information to Document ......................35 1.15.1 Gasoline Stations..........................35 1.15.2 Dispensers ............................36 1.15.3 Vent Risers ............................36 1.15.4 VST GREEN MACHINE ........................36 1.15.5 Electrical ............................37 1.15.6 Additional Documentation ......................37 1.16 Sample Sketch ............................40 1.16.1 Your Sketch .............................
  • Page 4 Electrical Wiring Installation ........................53 3.5.1 INSTALLING THE VST CONTROL PANEL: ....................53 3.5.2 OPTION 1: POWER TO THE VST CONTROL PANEL FROM THE MAIN ELECTRICAL DISTRIBUTION PANEL. 54 3.5.3 OPTION 2: POWER THE VST CONTROL PANEL FROM THE STATION EMERGENCY SHUT-OFF (ESO) RELAY.
  • Page 5 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Programming the Fuel Management System Overfill Alarm Relay for the GREEN MACHINE ....87 Testing the Overfill Alarm on the GREEN MACHINE VST Control Panel ........... 88 6.7.1 TLS-350 Overfill Alarm Test ........................
  • Page 6 Chapter 9: Replacement Procedures ......................... 151 Replacement Parts Procedures ........................151 List of Replacement Parts ........................151 9.1.1 North America VST Control Panel Replacement Parts ............... 152 9.1.2 Replacement Procedures by Part ...................... 155 PLC (Controller) Replacement ........................ 155 9.2.1 Removing the PLC ..........................
  • Page 7 About VST ..............................199 11.1 GREEN MACHINE Theory of Operations .................... 199 11.2 VST Control Panel ..........................201 11.2.1 VST Control Panel Overview ......................201 11.2.2 Main Screen ..........................202 11.2.3 Maintenance Screen ........................203 11.2.4 Alarm Screen ..........................205 11.3...
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  • Page 9: Table Of Figures

    Figure 2-2: GREEN MACHINE Connections ......................45 Figure 2-3: Pressure Sensor w/ 3-Way Isolation Valve Open ................48 Figure 3-1: VST Control Panel - GM Disabled - Enter CODE Main Screen ............. 57 Figure 3-2: GREEN MACHINE Installation Overview Option 1 ................58 Figure 3-3: The Control Panel Power and ESO Connections Option 1 ..............
  • Page 10 Figure 8-2: VST GREEN MACHINE Control Panel Main Screen with an Alarm Active .......... 119 Figure 8-3: VST Control Panel Alarms and Faults Screen Example ..............120 Figure 8-4: Power to the North America VST Control Panel or Controller is OFF ..........121 Figure 8-5: Electrical Field Wiring Diagram ......................128 Figure 8-6: Incoming Power Connections ......................
  • Page 11 Figure 10-5: Inserting and Removing the SD Card from the PLC ................ 197 Figure 11-1: GREEN MACHINE Gasoline Station Overview ................200 Figure 11-2: VST Control Panel .......................... 201 Figure 11-3: Main Screen ..........................202 Figure 11-4: Maintenance Screen ........................203 Figure 11-5: Overfill Alarm shown on the Faults &...
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  • Page 13: About Vst

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

  • Page 14: Safety

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Safety ELECTRICITY TURN POWER OFF A potential shock hazard Turn power OFF to the device and exists. High voltage is its accessories when installing supplied to and exists in and servicing the unit.

  • Page 15: Table Of Terms & Abbreviations

    Read and understand all materials related to installing, testing, and operating the GREEN MACHINE prior to installation. CAUTION: ALL SERVICEABLE / REPLACEMENT PARTS MUST BE OBTAINED FROM VST TO MAINTAIN SUITABILITY FOR A DIVISION 2 LOCATION. Table of Terms & Abbreviations...

  • Page 16: Regulations & Jurisdiction

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Regulations & Jurisdiction • Under vapor recovery regulations, local and national authorities have primary authority for regulating gasoline stations. • Before modifying the facility, gasoline station operators should contact the national and local authorities for specific information and requirements on local vapor-recovery requirements.

  • Page 17: Green Machine Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual GREEN MACHINE Overview Ref# Part Name Part Description Vapor Filtration Cartridge Captures and cleans VOC’s from the vapor emissions Vapor Piping Piping for the transfer of vapor Liquidtite Flexible Conduit Used for installing wires to the junction box 1”...

  • Page 18: Green Machine Theory Of Operation

    GREEN MACHINE, and manages the GREEN MACHINE operation. • The pressure data is provided to the VST Control Panel for system monitoring functions. • The closed loop vapor piping solution continuously operates the system to control UST pressure below 0.2 IWC.

  • Page 19: Green Machine Dimensions & Weight

    L-14” x W-12” x H-8” 22 lbs. How the GREEN MACHINE is Shipped • Verify that all the items are in the shipping crate: • GREEN MACHINE - VST-GM-CS2-101. • Aluminum Cover • VST Control Panel • (4) 24” Steel Legs •...
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  • Page 21: Chapter 1: General Contractor Installation

    MACHINE prior to installation. 1.2 Preparing the GREEN MACHINE for Installation Follow these steps to prepare the GREEN MACHINE for installation: Verify that all the items are in the shipping crate: • GREEN MACHINE - VST-GM-CS2-101. • Aluminum Cover • VST Control Panel •...

  • Page 22: Installing The Legs On The Green Machine

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 1.3 Installing the Legs on the GREEN MACHINE Support the GREEN MACHINE with a forklift or a set of saw horses so the legs can be installed.

  • Page 23: Green Machine Dimensions & Weight

    • NOTE: Minimum vapor-piping slope must always be maintained for all GREEN MACHINE mounting options. • VST requires a minimum slope of ¼” per foot on all vapor piping away from the GREEN MACHINE to the vent risers. • Select a location for the concrete pad as close as possible to the vent risers to minimize piping and pressure drop.

  • Page 24: Setting The Concrete Pad

    NOTE: VST CANNOT BE HELD RESPONSIBLE FOR DAMAGE CAUSED BY IMPROPER GREEN MACHINE FOUNDATION SUPPORT. • VST does not provide any hardware to install the GREEN MACHINE on the pad. • VST recommends using an 18” minimum clearances around the perimeter of the GREEN MACHINE for maintenance and service.

  • Page 25: Installing The Green Machine On The Concrete Pad

    See Figures 1-2 and 1-3. • For applications that require expansion anchors that are especially suited to seismic and cracked concrete, VST recommends using the HILTI KWIK TZ (KB-TZ) BOLT, KB-TZ 3/8” X 5”, (item number 00304583) or approved equal.

  • Page 26: Figure 1-2: Concrete Mounting Pad Dimensions

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 1-2: Concrete mounting pad dimensions Chapter 1: GREEN MACHINE™ Installation Instructions Page 26...

  • Page 27: Figure 1-3: Green Machine Ground Mounting Pad

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 1-3: GREEN MACHINE Ground Mounting Pad Chapter 1: GREEN MACHINE™ Installation Instructions Page 27...

  • Page 28: Roof-Top Installation

    • VST requires a minimum slope of ¼” per foot on all vapor piping away from the GREEN MACHINE to the vent risers. • The GREEN MACHINE may be installed on a station’s roof provided the structure can support the weight of the GREEN MACHINE.

  • Page 29: Vent-Stack Mount Installation

    • VST requires a minimum slope of ¼” per foot on all vapor piping away from the GREEN MACHINE to the vent risers. • The GREEN MACHINE may be installed elevated on the existing vent risers provided there is an existing structure that can support the weight of the GREEN MACHINE, or a structure can be installed to support the weight of the GREEN MACHINE.

  • Page 30: Figure 1-4: Vent Stack Installation

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 1-4: Vent Stack Installation Chapter 1: GREEN MACHINE™ Installation Instructions Page 30...

  • Page 31: Pre-Installation Site Survey

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 1.11 Pre-Installation Site Survey • Vapor Systems Technologies, Inc. created a “Pre-Installation Site Survey” as a guide to help installers and troubleshooters in the planning of a GREEN MACHINE installation. •...

  • Page 32: Snapshot Of Site Requirements

    The GREEN MACHINE must be within 100 feet of the Vent Risers regardless of the installation location. • VST requires a minimum slope of ¼” per foot on all vapor-piping away from the GREEN MACHINE to the Vent Risers or to any other UST connection. •...
  • Page 33 VST recommends setting the GREEN MACHINE on a concrete pad with the following minimum dimensions: 42” long x 30” wide, 6” thick. • Follow the local jurisdiction’s building codes. • VST does not provide any hardware to install the GREEN MACHINE on the pad. Chapter 1: GREEN MACHINE™ Installation Instructions Page 33...
  • Page 34 GREEN MACHINE. • Due to a variety of roof construction designs, VST cannot recommend how the GREEN MACHINE should be mounted on the roof; however, the GREEN MACHINE must be installed at a height allowing the piping inlet and outlets to be above or through the building parapet.

  • Page 35: Other Information To Document

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

  • Page 36: Dispensers

    (OD of Vapor Pipe) 3. MPD or Unihose 4. Number of dispensers  Yes  No 5. Is the current hose a VST hose 6. Do the current hoses have a  Yes  No retractor 7. Curb hose length 8.

  • Page 37: Electrical

    1. Does the GDF have 1-Phase 115V available? 2. Are there any existing conduits at or near  Yes  No the proposed VST GREEN MACHINE location (for example: lights, signs, vacuum)?  Yes  No 3. Available breaker space for a 115V 1-phase circuit? ...

  • Page 38: Figure 1-5: Example Of A Gdf Layout

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 1-5: Example of a GDF Layout Chapter 1: GREEN MACHINE™ Installation Instructions Page 38...

  • Page 39: Figure 1-6: Example Of A Green Machine With Vapor Piping Layout

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 1-6: Example of a GREEN MACHINE with Vapor Piping Layout Chapter 1: GREEN MACHINE™ Installation Instructions Page 39...

  • Page 40: Sample Sketch

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 1.16 Sample Sketch Chapter 1: GREEN MACHINE™ Installation Instructions Page 40...

  • Page 41: Your Sketch

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 1.16.1 Your Sketch Chapter 1: GREEN MACHINE™ Installation Instructions Page 41...
  • Page 42 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual This page left intentionally blank Chapter 1: GREEN MACHINE™ Installation Instructions Page 42...

  • Page 43: Chapter 2: Vapor Piping Installation

    • Under normal operation, the valves must be locked in the OPEN position. • VST requires a minimum slope of 1/4” per foot on all vapor-piping away from the GREEN MACHINE to the vent risers or to any other UST piping connection.

  • Page 44: Figure 2-1: Vapor Piping Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 2-1: Vapor Piping Overview Chapter 2: Vapor Piping Installation Page 44...

  • Page 45: Flexible Piping

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 2-2: GREEN MACHINE Connections 2.2 Flexible Piping • If flexible piping is required by the local authority to meet seismic requirements, install the flexible piping between the GREEN MACHINE locking ball valve and the vent riser(s). •...

  • Page 46: Vapor Inlet And Vapor Return Piping Installation

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

  • Page 47: Air Outlet Piping Installation

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 2.4 Air Outlet Piping Installation • Install a new vent riser next to an existing vent riser (if possible). • The 1” piping must slope away from the GREEN MACHINE a minimum of ¼” per foot. See Figure 2-1.

  • Page 48: Figure 2-3: Pressure Sensor W/ 3-Way Isolation Valve Open

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 2-3: Pressure Sensor w/ 3-Way Isolation Valve Open Chapter 2: Vapor Piping Installation Page 48...

  • Page 49: Vapor Piping Bill Of Material

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 2.6 Vapor Piping Bill of Material Contractor Supplied 1” diameter straight tees with caps 1” diameter unions Straight tee (sized to match existing vent riser) Straight tee with cap (sized to match new vent riser) Rain cap (on the new air outlet vent riser) 1”...
  • Page 50 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual This page left intentionally blank Chapter 2: Vapor Piping Installation Page 50...

  • Page 51: Chapter 3: Electrical Installation

    Protected by GREEN MACHINE 24VDC 24VDC power Controller supply *Note 1: The 8.8 amp listed is only for the ½ HP, 115 VAC, 1-Phase, 60-Hz Leeson Motor. Table 1: VST Control Panel Power Requirements Chapter 3: Electrical Page 51...

  • Page 52: Electrical Installation

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 3.2 Electrical Installation • The VST Control Panel and the GREEN MACHINE Internal Junction Box arrive from the factory pre-wired and completely tested. • The Electrical Contractor is responsible for supplying all additional wires, conduits, fittings, seal-offs, outlets, and the Safety Disconnect Switch required to install the GREEN MACHINE and meet regulation requirements and standards.

  • Page 53: Electrical Components

    • The contractor must drill holes in the VST Control Panel for all wiring connections. • Install the VST Control Panel only inside the GDF. The location may vary within the GDF given the allowable space. • When possible, place the VST Control Panel as close to the Fuel Management System as possible.

  • Page 54: Option 1: Power To The Vst Control Panel From The Main Electrical Distribution Panel

    1. When activated, the ESO will turn OFF and disconnect power, the neutral, and ground from the GREEN MACHINE. 2. Two wires MUST BE INSTALLED from the VST Control Panel to the ESO relay or control system. The technician making these connections MUST BE CERTIFIED to work on this system.

  • Page 55: Wiring The Electrical Components At The Green Machine Location

    UST reaches the Overfill Level volume during a fuel drop. 3. Install two wires from the VST Control Panel to the Fuel Management System Overfill Alarm (N.O.) output relay. (Refer to the Fuel Management System Installation Manual for connecting and configurating the correct relay.

  • Page 56: Wiring The Vst Control Panel To The Green Machine

    Wires from the VST Control Panel to the GREEN MACHINE Internal Junction Box Wiring Diagram. 1. This drawing is used for wiring from the VST Control Panel to the Internal Junction Box for the Vacuum Pump Motor, the 5-control valves, and the Pressure Sensor. For Reference.

  • Page 57: Figure 3-1: Vst Control Panel - Gm Disabled - Enter Code Main Screen

    PANEL AT THIS TIME. The power to the VST Control Panel will be turned ON AGAIN during the GREEN MACHINE Post Installation Start-Up. Figure 3-1: VST Control Panel - GM Disabled - Enter CODE Main Screen Chapter 3: Electrical Page 57...

  • Page 58: Figure 3-2: Green Machine Installation Overview Option 1

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 1 Figure 3-2: GREEN MACHINE Installation Overview Option 1 Chapter 3: Electrical Page 58...

  • Page 59: Figure 3-3: The Control Panel Power And Eso Connections Option 1

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 1 Figure 3-3: The Control Panel Power and ESO Connections Option 1 Chapter 3: Electrical Page 59...

  • Page 60: Figure 3-4: The Green Machine Installation Overview Option 2

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 2 Figure 3-4: The GREEN MACHINE Installation Overview Option 2 Chapter 3: Electrical Page 60...

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

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 2 Figure 3-5: The Control Panel Power Connection Option 2 Chapter 3: Electrical Page 61...

  • Page 62: Figure 3-6: The Vst Control Panel Field Wiring

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 3-6: The VST Control Panel Field Wiring Chapter 3: Electrical Page 62...

  • Page 63: Figure 3-7: Green Machine Internal Junction Box Field Wiring

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 3-7: GREEN MACHINE Internal Junction Box Field Wiring Chapter 3: Electrical Page 63...

  • Page 64: Figure 3-8: Pressure Sensor Wiring Diagram

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 3-8: Pressure Sensor Wiring Diagram Chapter 3: Electrical Page 64...

  • Page 65: Figure 3-9: Vacuum Pump Motor Wiring Diagram

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 3-9: Vacuum Pump Motor Wiring Diagram Chapter 3: Electrical Page 65...
  • Page 66 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual This page left intentionally blank. Chapter 3: Electrical Page 66...

  • Page 67: Chapter 4: Control Panel

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

  • Page 68: Main Screen Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 4.1 Main Screen Overview Figure 4-2: Main Screen • The Control Panel PLC will always power up in the Main Screen. See Figure 4-2. • The GREEN MACHINE will always be in the Normal Operating mode when the Main Screen is showing on the PLC, unless there is an Alarm Condition.

  • Page 69: Maintenance Screen Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual GREEN MACHINE Messages: GREEN MACHINE – Running: Due to the UST pressure being greater than 0.20 IWC (Blue Text Box). GREEN MACHINE – Idle: Due to the UST pressure being less than 0.20 IWC (Blue Text Box).
  • Page 70 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Maintenance Screen, continued… • When the Maintenance Screen is shown, the GREEN MACHINE will always be in the OFF mode (unless the Manual ON button is pushed or testing is being conducted). See Figure 4-3.

  • Page 71: Alarm Screen Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 4.3 Alarm Screen Overview Figure 4-4: Pressure Sensor Alarm shown on the Alarm Screen The Alarm Screen shows the following - See Figure 4-4: • GM Status •...
  • Page 72 Alarm Screen, continued… • Maintenance Switch Alarm: • The Maintenance Switch is used when we want power to the VST Control Panel, but do not want the GREEN MACHINE to operate. • The GREEN MACHINE will not operate during this alarm.

  • Page 73: Chapter 5: Open: No Content

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Chapter 5: OPEN: NO CONTENT 5 Left intentionally blank Chapter 5: Intentionally Blank Page 73...
  • Page 74 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Left intentionally blank Chapter 5: Intentionally Blank Page 74...

  • Page 75: Chapter 6: Testing & Start-Up

    6 Post-Installation GREEN MACHINE Testing & Start Up VST Control Panel Initial Start-Up Power: When the power is turned ON to the VST Control Panel, the Main Screen will show on the PLC with the label GM DISABLED – ENTER CODE.

  • Page 76: Before Beginning The Testing And Start-Up Procedures

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 6.2 Before beginning the Testing and Start-Up procedures Follow the steps below to prepare the GREEN MACHINE and VST Control Panel for Testing & Start-Up STEPS DESCRIPTION Unlock the hasps and remove the cover on the GREEN MACHINE.
  • Page 77 5. Click on “Appendix B – Start-Up Contractor Check Out Form.” 6. Fill out and submit Appendix B with the required photos. 7. Receive an email from VST with the Verification CODE and a copy of the filled out Appendix B These items are to be checked in Appendix B as they are completed.

  • Page 78: Figure 6-2: Vapor Piping Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 6-2: Vapor Piping Overview Chapter 6: Testing and Startup Page 78...

  • Page 79: Bump Test

    Screen button to access the Password Screen then enter the password to access the Maintenance Screen: Password is 878. One person needs to be at the VST Control Panel to begin the Bump Test. A second person needs to be at the GREEN MACHINE when the Motor Bump Test begins.

  • Page 80: Bump Test Procedure

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 6.4.3 Bump Test Procedure 1. At the Maintenance Screen, push the Vac Pump Bump button to go to the Bump Motor Confirmation Screen. See Figure 6-3. 2.

  • Page 81: Figure 6-5: Vacuum Pump Motor Wiring Diagram

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 6-5: Vacuum Pump Motor Wiring Diagram Chapter 6: Testing and Startup Page 81...

  • Page 82: Functionality Test

    6.5.2 Preparation for the Functionality Test At the VST Control Panel, make sure the Maintenance Screen is showing on the PLC. See Figure 6-6. (The GREEN MACHINE is now in the Manual OFF mode and will not operate.) If the PLC is not in the Maintenance Screen: At the Main Screen, push the Maintenance Screen button to access the Password Screen, then enter the password to access the Maintenance Screen: Password is 878.

  • Page 83: Figure 6-7: Green Machine Vapor Piping Layout

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 6-7: GREEN MACHINE Vapor Piping Layout Chapter 6: Testing and Startup Page 83...

  • Page 84: Functionality Test Procedures

    Pushing the F4 button will return the system to the Maintenance Screen and the GREEN MACHINE will be in the OFF mode. When the test has ended, the VST Control Panel PLC will display GREEN MACHINE OFF. During the 60-second Run mode: See Figure 6-10.

  • Page 85: Figure 6-8: Functionality Test Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Functionality Test, continued… During the Purge cycle: No air blowing/suction at the Vapor Inlet: NORMAL No air blowing/suction at the Air Outlet: NORMAL Momentary blowing at the Vapor Return: NORMAL All other blowing or suction condition at each location: •...

  • Page 86: Figure 6-9: Functionality Test Confirmation Button

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 6-9: Functionality Test Confirmation Button Chapter 6: Testing and Startup Page 86...

  • Page 87: Programming The Fuel Management System Overfill Alarm Relay For The Green Machine

    GREEN MACHINE OVERFILL ALARM RELAY CIRCUIT • The Electrical Contractor has installed the Overfill Alarm signal wiring from the VST Control Panel to the “Fuel Management System Overfill Alarm” output module. • The VST Control Panel supplies 24 VDC to the Overfill Alarm relay.

  • Page 88: Testing The Overfill Alarm On The Green Machine Vst Control Panel

    Chapter 3: Electrical Installation. • When an Overfill occurs, the Overfill relay closes which completes a 24 VDC circuit to the VST Control Panel. The GREEN MACHINE will remain OFF two hours after the Overfill Alarm clears.

  • Page 89: Overfill Alarm Test

    The Overfill Relay and VST Control Panel Check is used to test the TLS-450 Overfill Relay as it is connected to the VST Control Panel. When the Overfill relay is active, the VST Control Panel will not allow the unit to operate.

  • Page 90: Tls 450 Plus Overfill Alarm Test

    Test Completion: Touch the selected Overfill Relay to deselect it or close the screen. After the test is complete, check the VST Control Panel PLC to make sure the Overfill Alarm is active. If the Overfill Alarm is active, the wiring of the Overfill Relay and the Overfill programming is correct.

  • Page 91: Changing The Date And Time Procedure

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual TLS 450 Plus Overfill Alarm Test, continued… □ Deselect the Relay # that is connected to the VST Control Panel. 10. Push the Home button to conclude the Overfill Alarm Test 6.8 Changing the Date and Time Procedure 6.8.1...

  • Page 92: Figure 6-13: Time & Date

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 6-13: Time & Date Chapter 6: Testing and Startup Page 92...

  • Page 93: Submitting Appendix B To Vst For The Verification Code

    Click on “Start-Up/Commissioning Contractor.” Click on “Appendix B – Start-Up Contractor Check Out Form.” Fill out and submit Appendix B with the required photos. Receive an email from VST with the Verification CODE and a copy of the filled-out Appendix B 6.9.2 Procedures Apply power to the VST Control Panel The PLC starts up in the Main Screen where the GREEN MACHINE is shown to be DISABLED.

  • Page 94: Figure 6-14: Verification Code Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 6-14: VERIFICATION CODE screen Figure 6-15: Enter the Verification CODE screen Chapter 6: Testing and Startup Page 94...

  • Page 95: Chapter 7: Maintenance Procedures

    Check the Air Outlet for Liquid Condensation Separator Check Procedure 7.1 Maintenance Procedures At the VST Control Panel Main Screen, check to make sure there are no alarms. See Figure 7-1. If there are alarms, repair the item causing the alarm (See Chapter 8: Troubleshooting) before proceeding.

  • Page 96: Figure 7-1: Vst Plc Main Screen W/No Alarms

    Check the Air Outlet for Liquid Condensate: See Section 7.7. Check annually for liquid condensate in the air outlet pipe. Check the Separator for debris: See Section 7.8. Figure 7-1: VST PLC Main Screen w/no alarms Chapter 7: Maintenance Procedures Page 96...

  • Page 97: Recommended Replacement Parts

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 7.2 Recommended Replacement Parts VST recommends the ASC bring the parts shown in the table below for replacement parts. The entire list of GREEN MACHINE replacement parts can be found in Chapter 9: Replacement Procedures.

  • Page 98: Functionality Test

    7.3.2 Preparation for the Functionality Test At the VST Control Panel, make sure the Maintenance Screen is showing on the PLC. See Figure 7-3. (The GREEN MACHINE is now in the Manual OFF mode and will not operate.) If the PLC is not in the Maintenance Screen: At the Main Screen, push the Maintenance Screen button to access the Password Screen, then enter the password to access the Maintenance Screen: Password is 878.

  • Page 99: Figure 7-4: Green Machine Vapor Piping Layout

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-4: GREEN MACHINE Vapor Piping Layout Chapter 7: Maintenance Procedures Page 99...

  • Page 100: Functionality Test Procedures

    Pushing the F4 button will return the system to the Maintenance Screen and the GREEN MACHINE will be in the OFF mode. When the test has ended, the VST Control Panel PLC will display GREEN MACHINE OFF. During the 60-second Run mode: See Figure 7-7.

  • Page 101: Figure 7-5: Functionality Test Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Functionality Test, continued… During the Purge cycle: No air blowing/suction at the Vapor Inlet: NORMAL No air blowing/suction at the Air Outlet: NORMAL Momentary blowing at the Vapor Return: NORMAL All other blowing or suction conditions at each location: •...

  • Page 102: Figure 7-6: Functionality Test Confirmation Button

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-6: Functionality Test Confirmation Button Figure 7-7: GREEN MACHINE Operation Diagram Chapter 7: Maintenance Procedures Page 102...

  • Page 103: Pressure Sensor Verification Test

    10. Put the cover on the GREEN MACHINE and lock the hasps. 11. Turn ON power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. The GREEN MACHINE is now operational and will operate if the UST pressure is greater than or equal to 0.20 IWC.

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

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-8:Pressure Sensor & 3-Way Valve, Normal Operation Chapter 7: Maintenance Procedures Page 104...

  • Page 105: Figure 7-9: Pressure Sensor & 3-Way Valve, Test Position

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-9: Pressure Sensor & 3-Way Valve, TEST Position Chapter 7: Maintenance Procedures Page 105...

  • Page 106: Figure 7-10: Main Screen W/Pressure Reading

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-10: Main Screen w/Pressure Reading Chapter 7: Maintenance Procedures Page 106...

  • Page 107: Rubber Flange Sleeve Replacement

    Removing the Rubber Flange Sleeve See Figure 7-11. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 108: Replacing The Rubber Flange Sleeve

    6. Put the cover on the GREEN MACHINE and lock the hasps. 7. Remove the lock(s) and tags from the lockout & tagout. 8. After the work is completed, turn ON power to the VST Control Panel. The GREEN MACHINE is now operational.

  • Page 109: Cleaning The Control Valves

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 7.6 Cleaning the Control Valves Safety Use lockout / tagout procedures prior to starting work. Figure 7-13: GREEN MACHINE Control Valves Identification Tags Chapter 7: Maintenance Procedures Page 109...

  • Page 110: Removing The Valve Solenoid And Core Assembly

    7.6.1 Removing the Valve Solenoid and Core Assembly See Figure 7-14. 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 111: Replacing The Valve Solenoid And Core Assembly

    Remove the lock(s) and tags from the lockout & tagout. After the work is completed, turn ON power to the VST Control Panel. The GREEN MACHINE is now Figure 7-16: Valve Core Assembly operational. Chapter 7: Maintenance Procedures Page 111...

  • Page 112: Check The Air Outlet For Liquid Condensation

    Removing the Drain Plug See Figure 7-17. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 113: Figure 7-17: Air Outlet, Drain Tee, And Plug

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-17: Air Outlet, Drain Tee, and Plug Chapter 7: Maintenance Procedures Page 113...

  • Page 114: Separator Check Procedure

    7.7.1 Removing and Inspecting the Separator See Figure 7-18. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 115: Reinstalling The Existing Separator

    ¼ turn for a metal-to-metal seal. Put the cover on the GREEN MACHINE and lock the hasps. Remove the lock(s) and tags from the lockout-tagout. After the work is completed, turn ON power to the VST Control Panel. The GREEN MACHINE is now operational. 7.8.4 Installing a New Separator See Figure 7-19.

  • Page 116: Figure 7-19: Separator Fitting Orientation

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 7-19: Separator Fitting Orientation Chapter 7: Maintenance Procedures Page 116...

  • Page 117: Chapter 8: Troubleshooting

    8 Troubleshooting Procedures 8.1 Troubleshooting Procedures Overview • The purpose of the Troubleshooting chapter is to explain what troubleshooting actions to take when the GREEN MACHINE or the VST Control Panel are not functioning properly. • In detail, this guide will cover: 8.2 Alarm Overview...

  • Page 118: Alarm Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 8.2 Alarm Overview • The VST Control Panel is continuously monitoring the VST GREEN MACHINE for alarm conditions. • During normal operation when the GREEN MACHINE is functioning properly and no alarm conditions exist, the “NORMAL”...

  • Page 119: Alarm List

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-2: VST GREEN MACHINE Control Panel Main Screen with an Alarm Active 8.2.1 Alarm List 1. Pressure Sensor 2. Vacuum Pump 3. Maintenance Switch 4. Overfill 5.

  • Page 120: Troubleshooting Procedures

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-3: VST Control Panel Alarms and Faults Screen Example 8.3 Troubleshooting Procedures • Each of the following Troubleshooting Procedures is preceded by a Decision Tree.

  • Page 121: Power To The Vst Control Panel Or Plc Controller Is Off

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 8.4 Power to the VST Control Panel or PLC Controller is OFF Figure 8-4: Power to the North America VST Control Panel or Controller is OFF Chapter 8: Troubleshooting...
  • Page 122 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Power to the Control Panel or the Controller is OFF, continued… Figure 8-4 continued… Power to the North America VST Control Panel or Controller is OFF Chapter 8: Troubleshooting...

  • Page 123: Control Panel General Information

    Check the wire terminals 02011 and 02032, then proceed to the appropriate procedures: Option 1: If there are two wires landed in these terminals, the VST Control Panel is powered directly from the distribution panel. See Section 8.4.2. Option 2: If there is a jumper connecting these terminals, the VST Control Panel is powered through an ESO breaker.

  • Page 124: Option 1: Control Panel Is Powered From Distribution Panel

    Steps Procedures 1. Verify that the Breaker for the VST Control Panel in the main power distribution panel is ON. If not, turn the breaker ON. See Figures 8-5 & 8-6 2. Check that the Power Switch on the front of the Control Panel is ON. If not, turn it ON.
  • Page 125 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 1: Control Panel is powered from Distribution Panel, continued… 5. Check that there is power at the VST Control Panel and the wiring is installed correctly and tight. See Figure 8-10.

  • Page 126: Option 2: Control Panel Is Powered From Eso Breaker

    See Figure 8-9. 3. The VST Control Panel must be supplied 115 VAC power through an Emergency Shut- Off (ESO) dry relay for the VST Control Panel to have power and for the GREEN MACHINE to operate. See Figures 8-7 & 8-8.
  • Page 127 ON the switch. If the switch has a Lockout/Tagout lock, do not remove the lock and leave the switch OFF. Someone is preforming maintenance. 5. Check that there is power at the VST Control Panel and the wiring is installed correctly and tight. See Figure 8-10.

  • Page 128: Figure 8-5: Electrical Field Wiring Diagram

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 1 Figure 8-5: Electrical Field Wiring Diagram Chapter 8: Troubleshooting Page 128...

  • Page 129: Figure 8-6: Incoming Power Connections

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 1 Figure 8-6: Incoming Power Connections Chapter 8: Troubleshooting Page 129...

  • Page 130: Figure 8-7: Vst Control Panel Powered From Eso Relay

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 2 Figure 8-7: VST Control Panel Powered from ESO Relay Chapter 8: Troubleshooting Page 130...

  • Page 131: Figure 8-8: Electrical Overview Installation Drawing

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Option 2 Figure 8-8: Electrical Overview Installation Drawing Chapter 8: Troubleshooting Page 131...

  • Page 132: Figure 8-9: Vst Control Panel Components - Front Cover

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-9: VST Control Panel Components – Front Cover Chapter 8: Troubleshooting Page 132...

  • Page 133: Figure 8-10: Vst Control Panel 115 Vac Power Circuit Diagram

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-10: VST Control Panel 115 VAC Power Circuit Diagram Chapter 8: Troubleshooting Page 133...

  • Page 134: Pressure Sensor Alarm

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 8.5 Pressure Sensor Alarm • A Pressure Sensor Alarm will occur if the PLC is not receiving a 4-20 mA input from the Pressure Sensor, or the mA reading is less than 2.5 mA or if there is not 24 VDC power to the Pressure Sensor.

  • Page 135: Pressure Sensor Alarm: Troubleshooting Steps

    Chapter 9: Replacement Procedure to replace the Pressure Sensor. • If the Pressure Sensor Alarm is still active after repairing Items 1-2, call a VST Service Technician. Chapter 8: Troubleshooting Page 135...

  • Page 136: Figure 8-12: Pressure Sensor Wiring Diagram (24Vdc Power And 4-20 Ma Signal)

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-12: Pressure Sensor Wiring Diagram (24VDC Power and 4-20 mA Signal) Chapter 8: Troubleshooting Page 136...

  • Page 137: Vacuum Pump Alarm

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 8.6 Vacuum Pump Alarm Figure 8-13: Vacuum Pump Troubleshooting Procedures Chapter 8: Troubleshooting Page 137...

  • Page 138: Vacuum Pump Alarm: Troubleshooting Steps

    1. Check to see if the Vacuum Pump breaker (BKR2) in the Control Panel has tripped. See Figure 8-14. a) Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).
  • Page 139 2. Check to see if the Vacuum Pump Solid State Relay is damaged. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE.
  • Page 140 Physically check the Vacuum Pump to make sure the pump, motor, and drive couplings are functioning correctly. a) Remove the carabiner clip and turn the Power Switch on the front of the VST Control Panel OFF. b) At the GREEN MACHINE, turn OFF the Safety Disconnect Switch.
  • Page 141 4. Check the Vacuum Pump wiring circuit inside the VST Control Panel. See Figure 8-14. • Physically check the Vacuum Pump wiring connections at the vacuum pump junction box and at the VST Control Panel to make sure the connections are tight and wired correctly. 5. Check the Control Valves •...
  • Page 142 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Vacuum Pump Alarm: Troubleshooting Steps, continued… • Procedure 1. To start the test, push the F1 button on the Maintenance Screen. Press the Start Button to energize all the control valves. 2.

  • Page 143: Figure 8-14: Vacuum Pump Power And Control Circuit

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-14: Vacuum Pump Power and Control Circuit Chapter 8: Troubleshooting Page 143...

  • Page 144: Figure 8-15: Vst Control Panel Electrical Components

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-15: VST Control Panel Electrical Components Chapter 8: Troubleshooting Page 144...

  • Page 145: Figure 8-16: Green Machine Isometric With Control Valves Identification Labels

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-16: GREEN MACHINE isometric with Control Valves Identification Labels Chapter 8: Troubleshooting Page 145...

  • Page 146: Maintenance Switch Alarm

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 8.7 Maintenance Switch Alarm • The Maintenance Switch Alarm will activate when the Maintenance Switch has been turned OFF. The Maintenance Switch is used to stop the GREEN MACHINE from running, which will keep power ON to the Control Panel and to the PLC Controller.

  • Page 147: Overfill Alarm

    8.8 Overfill Alarm Figure 8-17: GREEN MACHINE Controller Alarm Screen • A VST Control Panel Controller Overfill Alarm is Active when the Fuel Management System Overfill Alarm is Active. See Figure 8-17. • An overfill condition exists when, during a fuel drop, the gasoline level in the UST exceeds the overfill alarm setting, which is 90% capacity of the UST.

  • Page 148: Overfill Alarm Troubleshooting Steps

    The Fuel Management System OVERFILL ALARM will not guarantee that the GREEN MACHINE is protected from gasoline entering it. 3. The table below lists the VST recommended alarm settings for the tank level. Position of Tank Alarm VST Recommended Alarm...

  • Page 149: Figure 8-18: Fuel Level Tank Alarms

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 8-18: Fuel Level Tank Alarms Overfill Report Date: Contractor Name: Contractor Company: GDF Name: Address: City: State: ZIP Code: GDF Contact Person Name: GDF Contact Person Title: GDF Contact Person Phone: GDF Contact Person E-mail: Overfill Details...

  • Page 150: Sd Card Alarm

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 8.9 SD Card Alarm • The GREEN MACHINE will operate when there is a SD Card Alarm, but the card will not or cannot record the data. •...

  • Page 151: Chapter 9: Replacement Procedures

    9.1 List of Replacement Parts • The North America GREEN MACHINE parts shown in the picture and table below must be supplied by VST. See Figure 9-1. Figure 9-1: North America GREEN MACHINE Replacement Parts VST North America GREEN MACHINE Replacement Parts Ref.

  • Page 152: North America Vst Control Panel Replacement Parts

    VST NORTH AMERICA GREEN MACHINE Replacement Parts Ref. # Description Part Number Manufacturer NA GREEN MACHINE™ Control Panel (Complete) GM-030 VST NORTH AMERICA GREEN MACHINE Control Panel (Sub-Component) Replacement Parts Ref. # Description Part Number Manufacturer NA GREEN MACHINE™ PLC Controller GM-016...

  • Page 153: Figure 9-2: Vst Control Panel, Front Cover Replacement Parts

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-2: VST Control Panel, Front Cover Replacement Parts Figure 9-3: VST Control Panel, Inside the Front Cover Replacement Parts Chapter 9: Replacement Procedures Page 153...

  • Page 154: Figure 9-4: Vst Control Panel, Inside Panel Replacement Parts

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-4: VST Control Panel, Inside Panel Replacement Parts Chapter 9: Replacement Procedures Page 154...

  • Page 155: Replacement Procedures By Part

    Use lockout / tagout procedures prior to starting work. 9.2.1 Removing the PLC 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 156: Installing The New Plc

    9.2.2 Installing the New PLC 1. Install the new PLC in the front door of the VST Control Panel in the same orientation the old PLC was removed. 2. Install the two hold-down clips on the side of the PLC and lightly tighten.

  • Page 157: Figure 9-6: The Plc With Connectors Removed

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-6: The PLC with Connectors Removed Figure 9-7: Removing the PLC Hold Down Clips Chapter 9: Replacement Procedures Page 157...

  • Page 158: Control Panel Small Components Replacement

    • See Figures 9-2, 9-4 & 9-8. 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 159: Vacuum Pump Motor Solid-State Relay Replacement

    • See Figure 9-2 & 9-9. 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 160: Figure 9-9: Vacuum Pump Solid State Relay

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-9: Vacuum Pump Solid State Relay Chapter 9: Replacement Procedures Page 160...

  • Page 161: Pressure Sensor Replacement

    Removing the Pressure Sensor • See Figure 9-10. 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 162: Installing The Pressure Sensor

    6. Install the Internal Junction Box cover. 7. Remove the lock(s) and tags from the lockout & tagout. 8. Turn the Maintenance Switch OFF at the VST Control Panel so the GREEN MACHINE cannot operate. 9. Turn power ON to the VST Control Panel.

  • Page 163: Figure 9-10: Pressure Sensor Replacement

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-10: Pressure Sensor Replacement Chapter 9: Replacement Procedures Page 163...

  • Page 164: Figure 9-11: Wiring The Pressure Sensor Inside The Internal Junction Box

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-11: Wiring the Pressure Sensor Inside the Internal Junction Box Chapter 9: Replacement Procedures Page 164...

  • Page 165: Rubber Flange Sleeve Replacement

    Removing the Rubber Flange Sleeve See Figure 9-12. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 166: Replacing The Rubber Flange Sleeve

    6. Put the cover on the GREEN MACHINE and lock the hasps. 7. Remove the lock(s) and tags from the lockout & tagout. 8. After the work is completed, turn ON power to the VST Control Panel. The GREEN MACHINE is now operational.

  • Page 167: Vacuum Pump Motor (Only) Replacement

    • See Figures 9-14 & 9-15. 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 168: Replacing The Vacuum Pump Motor

    10. Remove the lock(s) and tags from the lockout & tagout. 11. Turn ON power to the VST Control Panel. At the VST Control Panel, put the PLC in the Maintenance Screen. At the Main Screen, push the Maintenance Screen button to access the Password Screen then enter the password to access the Maintenance Screen: Password is 878.

  • Page 169: Figure 9-15: Junction Box Motor Wiring Diagram

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-15: Junction Box Motor Wiring Diagram Chapter 9: Replacement Procedures Page 169...

  • Page 170: Control Valve Replacement

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 9.7 Control Valve Replacement Figure 9-16: GREEN MACHINE Control Valves Identification Tags Chapter 9: Replacement Procedures Page 170...

  • Page 171: Removing The Valve Solenoid And Core Assembly

    9.7.1 Removing the Valve Solenoid and Core Assembly See Figures 9-16 & 9-17. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 172: Replacing The Valve Solenoid And Core Assembly

    Figure 9-18: Valve Assembly Remove the lock(s) and tags from the lockout & tagout. After the work is completed, turn ON power to the VST Control Panel. The GREEN MACHINE is now operational. Chapter 9: Replacement Procedures Page 172...

  • Page 173: Vacuum Pump (Only) Replacement

    9.8.1 Preparation for Cleaning the Tubes and Manifold Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 174: Figure 9-20: Items Associated With Cleaning The Green Machine Tubing And Manifold

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-20: Items Associated with Cleaning the GREEN MACHINE Tubing and Manifold Figure 9-21: Tubes 1-6 removed Chapter 9: Replacement Procedures Page 174...

  • Page 175: Removing The Vacuum Pump

    Removing the Vacuum Pump For the Vacuum Pump Assembly and Components, See Figure 9-22. Make sure the power is OFF to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. NOTE: The Motor will not be affected during the replacement of the Vacuum Pump.

  • Page 176: Replacing The Vacuum Pump

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 9.8.3 Replacing the Vacuum Pump The new pump will come with a drive coupling and rubber flange sleeve. See Figure 9-22. Install the flange coupling on to the pump shaft. Then install the rubber flange sleeve into the pump flange coupling so that when the pump is installed, the rubber flange sleeve mates with the motor flange coupling.

  • Page 177: Preparation For Cleaning The Tubes And Manifold

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 9.8.4 Preparation for Cleaning the Tubes and Manifold On the manifold, remove the Solenoids A, B, C, and D from the 4 Control Valves located on the manifold. Do not remove Solenoid E. See Figure 9-23. GM Control Valve Assembly and Components.

  • Page 178: Figure 9-24: Gm Control Valve Assembly And Components

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-24: GM Control Valve Assembly and Components Figure 9-25: How to remove the Red Cap from the Solenoid Base Figure 9-26: Manifold with the Solenoids Removed, showing the Solenoid Bases Chapter 9: Replacement Procedures Page 178...

  • Page 179: Figure 9-27: Solenoid With Solenoid Base And Red Cap

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-27: Solenoid with Solenoid Base and Red Cap Figure 9-28: Solenoid with Solenoid Base and Red Cap installed Figure 9-29: Solenoids (with the Solenoid Bases Installed) Arranged Out of the Way Chapter 9: Replacement Procedures Page 179...

  • Page 180: Figure 9-30: Manifold Ready For Cleaning

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-30: Manifold Ready for Cleaning Figure 9-31: Vacuum Pump with the Blowout Tube Installed Chapter 9: Replacement Procedures Page 180...

  • Page 181: Cleaning The Tubes And Manifold

    The Cleaning of the tubes and manifold is complete. 10. At the VST Control Panel Maintenance Screen, push the Manual OFF button to turn OFF the Vacuum Pump. 11. At the VST Control Panel, turn the Maint. Switch to OFF.

  • Page 182: Reassemble The Tubes And Valve Components

    3. Put the cover on the GREEN MACHINE and lock the hasps. 4. Remove the lock(s) and tags from the lockout & tagout. 5. After the work is completed, turn ON power to the VST Control Panel. Make sure the Main Screen is showing on the PLC.

  • Page 183: Canister Housing Replacement

    9.9.1 Removing the Canister Housing, Tubing, and Fittings 1. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 184: Figure 9-33: Removing/Installing The Canister Housing

    5. Install the cover on the GREEN MACHINE and lock the hasps. 6. Remove the locks from lockout & tagout. 7. Turn ON power at the Power Switch on the front of the VST Control Panel. The GREEN MACHINE is now operational.

  • Page 185: Separator Replacement

    9.10.2 Removing and Inspecting the Separator See Figure 9-34. Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel. (The power, ground, and neutral will be completely disconnected from the GREEN MACHINE).

  • Page 186: Installing A New Separator

    Put the cover on the GREEN MACHINE and lock the hasps. Remove the lock(s) and tags from the lockout-tagout. After the work is completed, turn ON power to the VST Control Panel. The GREEN MACHINE is now operational. Figure 9-35: Separator Fitting Orientation...

  • Page 187: Leak Test

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 9.11 Leak Test 9.11.1 Purpose of the Leak Test • The purpose of the Leak Test is to ensure that all of the GREEN MACHINE tubing fittings and tubes located inside the GREEN MACHINE are leak free.

  • Page 188: Figure 9-36: Vapor Piping Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-36: Vapor Piping Overview Chapter 9: Replacement Procedures Page 188...

  • Page 189: Figure 9-37: Maintenance Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-37: Maintenance Screen Figure 9-38: Leak Test Screen Chapter 9: Replacement Procedures Page 189...

  • Page 190: Leak Test Procedure

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Leak Test Procedure, continued… 9.11.3 Leak Test Procedure Install the Leak Test Fixture in the empty 1” pipe tee on the GREEN MACHINE. See Figures 9-39, 9-40, and 9-41. The Leak Check is conducted with 1.0-PSI nitrogen.

  • Page 191: Figure 9-39: Green Machine Vapor Inlet, Return, And Air Outlet Connections

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Leak Test Procedure, continued… After the Leak Test 30-minute timer expires and the test is complete: The GREEN MACHINE Controller will show the Maintenance Screen where the GREEN MACHINE is in the Manual OFF mode and will not operate.

  • Page 192: Figure 9-40: Leak Check Fixture

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 9-40: Leak Check Fixture Figure 9-41: GREEN MACHINE with Vapor Inlet, Vapor Return, and Air Outlet Chapter 9: Replacement Procedures Page 192...

  • Page 193: Chapter 10: Operator Instruction Sheet

    • If it is active, power will be OFF to the Control Panel. • When the ESO is de-activated, power will be restored to the VST Control Panel. • If items 1-4 are true, and the Controller screen is still blank, call your GREEN MACHINE Authorized Service Contractor (ASC).

  • Page 194: Maintenance Switch Alarm

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 10.4 Maintenance Switch Alarm • When a Maintenance Switch Alarm is active on the Controller: 1. Maintenance Switch on the front of the Control Panel cover is turned OFF. 2.

  • Page 195: Figure 10-1: Main Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 10-1: Main Screen Figure 10-2: Maintenance Screen Chapter 10: Operator Instruction Sheet Page 195...

  • Page 196: Figure 10-3: Faults & Alarm Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 10-3: Faults & Alarm Screen Figure 10-4: Password Screen Push ESC to return to the Main Screen when in the Maintenance, Faults & Alarms, or Password Screens. Chapter 10: Operator Instruction Sheet Page 196...

  • Page 197: How To Remove And Insert The Sd Card Into Unitronics Plc Slot

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 10.7 How to Remove and Insert the SD Card into Unitronics PLC Slot Figure 10-5: Inserting and Removing the SD Card from the PLC • See Figure 10-5 above shows how the SD Card is inserted into the PLC. Please note the orientation of the SD Card.
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  • Page 199: Chapter 11: Gm Operator Training Guide

    United States, but also the world. VST specializes in the development, engineering, and manufacturing of products that are sold into the GDF segment of the petroleum industry. The VST focus provides our customers and users with exceptional products, services, and innovative solutions for improving the fueling-station experience as well as the world’s air quality.

  • Page 200: Figure 11-1: Green Machine Gasoline Station Overview

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Figure 11-1: GREEN MACHINE Gasoline Station Overview Chapter 11: Operator Training Guide Page 200...

  • Page 201: Vst Control Panel

    11.2 VST Control Panel 11.2.1 VST Control Panel Overview • The VST Control Panel is designed to manage the operations of the GREEN MACHINE based on UST vapor pressure. Figure 11-2 shows the front of the Control Panel with the following items: •...

  • Page 202: Main Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 11.2.2 Main Screen Figure 11-3: Main Screen • The Control Panel PLC will always power up in the Main Screen. See Figure 11-3. • The GREEN MACHINE will always be in the Normal Operating mode when the Main Screen is showing on the PLC, unless there is an Alarm Condition.

  • Page 203: Maintenance Screen

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual GREEN MACHINE Messages, continued… • GREEN MACHINE Messages: • GREEN MACHINE – Running Due to the UST pressure being greater than 0.2 IWC (Blue Text Box) •...
  • Page 204 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Maintenance Screen, continued… • When the Maintenance Screen is shown, the GREEN MACHINE will always be in the OFF mode (unless the Manual ON button is pushed). See Figure 11-4. •...

  • Page 205: Alarm Screen

    Instruction Sheet for directions. 11.3.2 Pressure Sensor Alarm • The fault will occur if the Pressure Sensor is not connected to the VST Control Panel or is wired incorrectly at the VST Control Panel or the Pressure Sensor fails. •...

  • Page 206: Vacuum Pump Alarm

    An overfill condition exists when, during a fuel drop, the gasoline level in the UST exceeds the overfill alarm setting, which is 90% capacity of the UST. • The VST Control Panel is connected to the Tank Overfill Alarm output relay. • When an overfill occurs, the output (N.O.) relay closes and GREEN MACHINE will turn OFF.

  • Page 207: Sd Card Alarm

    Below are the precautionary measures taken to protect the GREEN MACHINE against an overfill situation: • The VST Control Panel will disable the GREEN MACHINE when the UST level reaches the OVERFILL Alarm setting (OVERFILL LIMIT: 90%) when the relay contacts close at the Fuel Management System.

  • Page 208: Figure 11-6: Inserting And Removing The Sd Card From The Plc

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual 11.3.6.1 How to Insert and Remove the SD Card into Unitronics PLC Slot Figure 11-6: Inserting and Removing the SD Card from the PLC • See Figure 11-6 shows how the SD Card is inserted into the PLC. Please note the orientation of the SD Card.

  • Page 209: Station Ust Environmental Compliance Testing And Services

    • Before Testing Begins: 1. At the front of the VST Control Panel, remove the carabiner clip and turn OFF the Power Switch. Reinstall the carabiner clip after power is turned OFF by pushing in the “handle slide” then installing the clip. This will turn OFF all power to the VST Control Panel and to the GREEN MACHINE.
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  • Page 211: Appendix A - General Contractor Check-Out Form

    6. Fill out and submit Appendix A with the required photos. 7. Receive an email from VST with a copy of the filled-out Appendix A. The following pages contain the contents of Appendix A and the questions you’ll be asked. You may find it helpful to review these pages, so you’re prepared for the online questions and requirements.

  • Page 212: Appendix A - General Contractor Check-Out Form

    GREEN MACHINE cover, and on the outside of the cover. Important!!! • VST highly recommends going through this check out form with the Piping and Electrical Contractors so that all the steps can be verified to be complete. Appendix A Page 212...
  • Page 213 Name Date POST-INSTALLATION GREEN MACHINE™ CHECK-OUT: • Upon completion, the General Contractor must submit this signed and dated form on-line to VST. • After the form is complete, Click the Submit button at the end of the form. Appendix A...
  • Page 214 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual This page left intentionally blank. Appendix A Page 214...

  • Page 215: Appendix B - Start-Up Contractor Check-Out Form

    5. Click on “Appendix B – Start-Up Contractor Check Out Form.” 6. Fill out and submit Appendix B with the required photos. 7. Receive an email from VST with the Verification CODE and a copy of the filled-out Appendix B The following pages contain the contents of Appendix B and the questions you’ll be asked.

  • Page 216: Appendix B - Start-Up Contractor Check-Out Form

    4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual Appendix B - Start-Up Contractor Check-Out Form To be filled out by the Start-Up Contractor SITE INFORMATION: Site: ________________________________________________________ Site ID: ________________________________________________________ Site Address: ________________________________________________________ Station Phone: ________________________________________________________ START-UP CONTRACTOR INFORMATION: Start-Up Contractor Company: ________________________________________________________...
  • Page 217 4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual The following readings must be filled out. This information is to make sure the VST Control Panel is reading the correct information and that the underground storage tanks are below the Overfill Alarm Level of 90%.
  • Page 218 Place the cover on the GREEN MACHINE and lock the hasp on INSTALL THE the cover. COVER Turn the Maintenance Switch on the front of the VST Control MAINT. Panel to ON. SWITCH IS ON At the Main Screen, push the Alarms Screen to make sure...
  • Page 219 Picture of the VST Control Panel PLC Main Screen. Pictures to Up-Load 11.5 Picture inside the VST Control Panel, inside the front door. 11.6 Picture inside the VST Control Panel, inside the panel. 11.7 Picture inside the VST Control Panel, showing the field wiring connections.

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