Contents Introduction ............................1 Applicable documentation ......................1 Conventions used in this manual ....................2 Questions and concerns ........................2 Operating precautions ........................2 Installing the ATG ..........................5 Selecting a location ........................5 Mounting the ATG ..........................5 EVO™ 5000 ATG ..........................6 Size 6 Wiring the ATG and modules ......................6 Non-intrinsically safe module wiring ..................7 Controller module (CM) ......................7 Flexible cable connector ......................7...
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2-wire sensor module (2WSNS) ....................19 4-20 mA analog input module (420IB) ..................20 Relay Module (RM) ........................21 Communication ports ........................22 RS-232 communication connectors....................23 Setup checklist ..........................24 System Setup and Programming Parameters ...................27 System ID ............................27 System configuration ........................28 Probe module ..........................28 AC input module ...........................29 2-wire sensor modules ........................30 2-wire sensor modules (continued) ....................31...
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Learn process ..........................62 When to learn or re-learn ......................62 Procedure ...........................63 Learn messages ..........................64 Line status and control screens .....................64 LS500 status screen ........................64 LS500 control screen ........................65 Status section...........................65 Control section ........................66 Learn section ...........................66 Pre-operational LS500 testing .......................66 Required equipment ........................66 Line stability test .........................67 LS-500 reports ..........................67...
Introduction This guide is specifically for Kwik Trip for installing EVO 550 and EVO 5000 Automatic Tank Gauges (ATGs). Applicable documentation The following list includes documents that may be useful. They, and other applicable FFS documents, are available at: www.franklinfueling.com: Document Part number Fuel Management System Programming Guide T5 Series...
Conventions used in this manual This manual includes safety precautions and other important information presented in the following format: NOTE: This provides helpful supplementary information. IMPORTANT: This provides instructions to avoid damaging hardware or a potential hazard to the environment, for example: fuel leakage from equipment that could harm the environment. CAUTION: This indicates a potentially hazardous situation that could result in minor or moderate injury if not avoided.
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WARNING: Follow all codes that govern how you install and service this product and the entire system. Always lock out and tag electrical circuit breakers while installing or servicing this equipment and related equipment. A potentially lethal electrical shock hazard and the possibility of an explosion or fire from a spark can result if the electrical circuit breakers are accidentally turned on while you are installing or servicing this product.
Installing the ATG Selecting a location The location that you select to install the ATG must be indoors in an area classified as non- hazardous. (See the ATG specifications table at the beginning of "Wiring the ATG and Modules.") To get the maximum benefit from this system, install the ATG where personnel can easily make use of it;...
EVO™ 5000 ATG The EVO™ 5000 ATG is a modular, automatic and continuous monitoring system that is also a versatile and capable ATG. It retains all of the features of the smaller models, but, because of its large module capacity, it is ideal for larger market stations. The EVO™ 5000 ATG: •...
Controller Module (CM) Power Supply Module (PS) Non-IS IS Modules (blue) Modules (red) (TS-5000 evo front view with cover removed) Non-intrinsically safe module wiring WARNING: Always lock out and tag electrical circuit breakers while installing or servicing this equipment and any related equipment. A potentially lethal electrical shock hazard and the possibility of an explosion or fire from a spark can result if the electrical circuit breakers are accidentally turned on during installation or servicing.
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After the ribbon has been correctly inserted all of the way into the LCD connector so that the metals bands are no longer showing above the connection, it should hold itself firmly in place. Once the flexible cable connector is properly attached to the CM’s LCD connector, hook it up to the corresponding connector on the inside of your ATG’s door by making the same kind of metal- to-metal connection that you made while inserting it into the CM’s faceplate.
Power supply module (PS) The PS is a non-intrinsically safe module that provides power to the EVO™ 550 and EVO™ 5000 ATGs from line voltage rated 110 - 240 VAC. The PS is two inches wide, occupies two slots and is located immediately to the right of the CM. The PS consists of two AC/DC switching power supplies - one switching power supply is +5V and the other is +24V.
As illustrated in the diagram below, the power supply module’s two relay outputs can be used to activate an external alarm (TS-RA2) and the two inputs can be used to silence that alarm remotely (TS-RK). NOTE: The TS-RA2, TS-RA1 and TS-RK are not part of the UL certification of this system. MAIN Power Supply Module...
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The wiring or use of discrete inputs is optional — skip this section if you don’t plan to use this interface. Discrete inputs may be wired to a ATG with 18 AWG, type TFFN or THWN wire. You may also use THHN wire in sizes larger than 18 AWG. Emergency backup power generator run-relay(s) are wired to the discrete input interface terminals at the ATG.
AC input module (ACI) The ACI is a non-intrinsically safe module that has 12 identical optically isolated AC input channels that can be used for dispenser hook isolation, vapor processor input, or as generic AC inputs. The EVO™ 550 and EVO™ 5000 ATGs can handle a total of 36 AC inputs or up to three AC Input Modules in one system.
Standard installation materials Recommended standard materials should be selected and installed per all applicable local, state and federal codes governing the installation of this product and its associated systems. Please see the corresponding ATG/module wiring section or the associated devices section of this manual for complete installation details.
Weatherproof junction boxes Minimum 16 cubic inch (406.4 cubic mm) weatherproof junction box, cover, and cover gasket for the manholes of liquid level probes and leak detection sensors. See sales literature for part numbers for ½ and ¾ inch (12.7 mm and 19.05 mm) conduit junction boxes and recommended manufacturers.
Splice connector kits IMPORTANT: You must use splice connector kits. This is a warranty requirement. Use the FFS-approved, moisture-resistant, no-strip splice connectors for liquid level probe and leak detection sensor wires. You may order the TSP-KW30, which contains 30 of the FFS- approved, moisture-resistant connectors.
Manufacturer’s tank chart for each tank The manufacturer’s tank chart and other documentation will be used for installation and programming, and possibly for future reference. Do not discard this information. If you need to create a new tank chart, contact Kwik Trip Engineering or FFS Technical Support. One web resource for generating tank charts is the web site for Modern Welding Company: http://www.xerxes.com/library.html http://www.moderntankchart.com/...
Intrinsically safe module wiring WARNING: Always lock out and tag electrical circuit breakers while installing or servicing this equipment and any related equipment. A potentially lethal electrical shock hazard and the possibility of an explosion or fire from a spark can result if the electrical circuit breakers are accidentally turned on during installation or servicing.
Probe module (PRB) The Probe Module (PRB) gathers data from probes and presents that information to the Controller Module (CM) for use in inventory reconciliation and reports. Each PRB can accommodate 12 probes and the system as a whole can accept a total of 36 probes (3 modules with 12 inputs each) if space allows.
2-wire sensor module (2WSNS) The 2-Wire Sensor Module (2WSNS) is designed to accept 12 sensor inputs per module, and the system as a whole can accept a total of 36 sensors (3 modules with 12 inputs each). The 2WSNS only supports standard sensors, and does not accept inputs from BRITESENSORs .
4-20 mA analog input module (420IB) The Analog Input Module has 8 identical channels for loop powered IS sensors with a 4-20 mA interface. EVO 550 and EVO 5000 ATGs can support up to 24 inputs (3 modules with 8 inputs each) depending on available space in your ATG.
Relay Module (RM) The RLY is a non-intrinsically safe module that has 8 identical Form C output channels. Each channel has a fuse and three terminals. Each channel can be configured as NO or NC with the power off by wiring to the appropriate terminals. A T5 Series ATG can accommodate up to 24 outputs (8 outputs on up to 3 modules) as space allows.
Communication ports 550 and EVO 5000 ATGs have several communication ports that can be used to talk to various devices. The communication ports can be used for a wide variety of applications: to connect the ATG to a computer network, to print reports on an external printer or to fax reports via the optional internal fax/modem.
RS-232 communication connectors Two connectors for RS-232 interfaces are provided on the bottom of the EVO 550 and EVO 5000 (TS-EMS) or on the right side of the T5 (TS-608). The pin designations for the RS-232 connectors are as follows: ATG RS-232 Comm Port 1 ATG RS-232 Comm Port 2 DB9 Connector, Female, DCE...
Setup checklist □ Check for upgrade to latest software revision □ Put IP and ethernet address on box (label maker) • IP Address: 192.168.1.10 • Subnet Mask: 255.255.255.0 • Gateway: 192.168.1.1 FE Petro Controllers □ Switch Bank 2 • Pole 2 up •...
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□ �ules • Overfill Alarm Rule set to High Level Alarm (90%) • 3 gph Fail Email Email address to use: incontankmonitor@kwiktrip.com □ �ules • 2 Wire Sensor Alarm email, 3 Wire Sensor Alarm email and Line Alarm email all use email address: helpme@kwiktrip.com □...
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□ Tanks • Disable SCALD on all tanks. • Disable monthl, annual compliance on all tanks. □ Lines • Disable annual testing on all lines. • Disable annual compliance on all lines. □ Sensors Should have the following labels: • Dispenser sump - Disp 1/2 sump •...
System Setup and Programming Parameters Use the following programming parameters to set up T5 Series ATGs at Kwik Trip retail fueling facilities. Refer to the T5 Series Fuel Management System Installation Guide (000-2150) for complete setup instructions. NOTE: System setup must be performed by a certified FFS service contractor. Set up the DNS Server and Protocol Settings with the site’s specific DNS sever addresses.
System configuration Group Name Parameter Name Parameter Value System Configuration Technical Support Key This function is not used Enable Log Files This function is not used Modules Expected AC Input Relay Probe 2-Wire Sensor 3-Wire Sensor 4-20mA Input Printer ATG DTU NOTE: The system configuration is pre-programmed into the ATGs when shipped, and should...
AC input module Group Name Parameter Name Parameter Value AC Input Modules Number Gasoline Hooks per Dispenser Module 1 Channels (10) Channel 1 Name Unlead North Hook Enabled (Yes) Active State High Action Setup None Channel 2 Name Unleaded South Hook Enabled (Yes)
2-wire sensor modules Group Name Parameter Name Parameter Value 2-Wire Sensor Modules Module 1 Channels Channel 1 Name Unlead North STP Sump Monthly Compliance Channel 2 Name Unlead South STP Sump Monthly Compliance Channel 3 Name Unlead Plus STP Sump Monthly Compliance Channel 4 Name...
4-20mA input modules Group Name Parameter Name Parameter Value 4-20mA Input Modules Module 1 Channels Channel 1 Name Unlead North ELLD Service Type Line Leak Detection Channel 2 Name Unlead North ELLD Service Type Line Leak Detection Channel 3 Name Plus ELLD Service Type Line Leak Detection...
Power supply NOTE: The two VFCs and SCI must be addressed properly before the TPI will recognize them. See "T5 to SCI programming diagram" later in this chapter for MagVFC and SCI wiring. Group Name Parameter Name Parameter Value Power Supply RS-485 AB (POS) Enable Interface RS-485...
Power supply (continued) Group Name Parameter Name Parameter Value Power Supply (continued) Controller 4 Name Premium Controller Enabled Type Smart 1 Address Group Tank Height 5.00 in Number of Inputs Input 1 Type AC Input Module Channel Premium Hook Input 2 Type 4-20A Input Module Channel...
Power supply (continued) Group Name Parameter Name Parameter Value Power Supply (continued) Controller 7 Name Prem DSL Auto Enabled Type MagVFC Address Group Tank Height 5.00 in Number of Inputs Input 1 Type AC Input Module Channel Prem DSL Auto Hook Input 2 Type 4-20mA Input Module...
103 - Administrator access level Personal Preferences Setup Confirmation: Update setup? Group Name Parameter Name Parameter Value Power supply (continued) System Preferences » ..System ID » ..Group Name Parameter Name Parameter Value System Configuration » ..Power Supply (continued) Communications »...
Fuel management system Group Name Parameter Name Parameter Value Fuel Management System Ullage Percent Delivery Delay 5 min Correction Temperature 60.00 °F High Product Limit Level Static Tank Testing Region United States Monthly Leak Test 0.20 gph Threshold Yearly Leak Test Threshold 0.10 gph Sentinel Mode Threshold 3.00 gph...
Fuel management system (continued) Group Name Parameter Name Parameter Value Tank 2 Name Unleaded Plus Type Special 2 Manifolded Product # Delivery Threshold 200.0 gal Theft Threshold 5.0 gal Monthly Compliance Annual Compliance Probe Module FMS Probe Module Channel Unlead Plus Type Standard 101 Ratio...
Fuel management system (continued) Group Name Parameter Name Parameter Value Tank 3 Name Premium No Lead Type Special 3 Manifolded Product # Delivery Threshold 200.0 gal Theft Threshold 5.0 gal Monthly Compliance Annual Compliance Probe Module FMS Probe Module Channel Premium Probe Type Standard 113...
Fuel management system (continued) Group Name Parameter Name Parameter Value Tank 4 Name Diesel #2 Type Special 4 Manifolded Product # Delivery Threshold 200.0 gal Theft Threshold 5.0 gal Monthly Compliance Annual Compliance Probe Module FMS Probe Module Channel Diesel #2 Probe Type Standard 101 Ratio...
Fuel management system (continued) Group Name Parameter Name Parameter Value Tank 5 Name Prem Diesel Type Special 5 Manifolded Product # Delivery Threshold 200.0 gal Theft Threshold 5.0 gal Monthly Compliance Annual Compliance Probe Module FMS Probe Module Channel Prem Diesel Probe Type Standard 113 Ratio...
Fuel management system (continued) Group Name Parameter Name Parameter Value Tank 6 Name E-85 Type Special 1 Manifolded Product # Delivery Threshold 200.0 gal Theft Threshold 5.0 gal Monthly Compliance Annual Compliance Probe Module FMS Probe Module Channel E-85 Probe Type Standard 101 Ratio...
Fuel management system (continued) Group Name Parameter Name Parameter Value Tank 7 Name Type Special 1 Manifolded Product # Delivery Threshold 200.0 gal Theft Threshold 5.0 gal Monthly Compliance Annual Compliance Probe Module FMS Probe Module Channel DEF Probe Type Standard 101 Ratio 1 to 1 tip to head...
NOTE: For programming of special tanks, refer to the tank chart furnished for the tank. Other resources are: "Kwik Trip Engineering/Help Desk," "www.moderntankchart.com," and "www.xerxes.com/library.html." (These websites are not affiliated with Franklin Fueling Systems.) Typical Kwik Trip site setup 20K unleaded ......Tank 1 20K unleaded plus ....Tank 2...
Fuel management system (continued) Fuel Management System Special Products Special 1 Correction Type Table 6A API Gravity 63.500 Alpha 600.000 Density 500.0 Mole Weight 130.000 Vapor A 12.101 Vapor B 8,907.000 Group Name Parameter Name Parameter Value Lines Number of Lines Line 1 Name Unlead North Line...
Fuel management system (continued) Line 2 Name Unlead South Line Submersible Pump Module Power Supply Module Submersible Pump Channel Unlead South Controller Transducer Unlead South ELLD Enable SLLD Product Unleaded Enable Monthly Compliance Annual Compliance Pressure Up Test Wait Time 7 sec Catch Pressure Wait Time 3 sec...
E-Mail Group Name Parameter Name Parameter Value E-mail “From” Address NoReplyStore430@kwiktrip.com* SMTP Host KTSMTPMAIL.KWIKTRIP.COM SMTP Port Enable Authentication Maximum Queue Size Retry Timeout 3600 Watchdog Timeout Enable Debugging * The “From” address contains the store number and is specific to the installation site. System Sentinel AnyWare IP Address Port...
Rules Group Name Parameter Name Parameter Value Rules Rule: Power On Sound Name Power On Sound Enabled Event Type Application Event Category System Device None Code System power on Action Type Sound Frequency 2800 Hz On Length...
Rules (continued) Rule: New Alarm Sound & Counter Alarm Name New Alarm Sound & Counter Alarm Enabled Event Type Alarm Occurred Category Device Code Action Type Sound Frequency 2800 Hz On Length 250 ms Off Length 250 ms Number of cycles Action Type Relay...
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Rule: Line Alarm Name Line Alarm Enabled Event Type Alarm Occurred Category Device Line Device ID Code Not Enabled Event Type Alarm Occurred Category System Device Pump Device ID Code Pump Communication Fail Event Type Alarm Occurred Category Device Code Clogged Intake Event Type...
Rules (continued) Rule: Line Alarm (continued) Event Type Alarm Occurred Category Device Code High Water/Phase Sep Event Type Alarm Occurred Category Device Code Line Not Enabled Event Type Alarm Occurred Category Device Code Line Pump Request Ignored Event Type Alarm Occurred Category Device Code...
Fuel Management Systems Line Application Setup Setting up the lines establishes which transducer and relay is used on the specific line and allows the user to change certain parameters in the operation of the line leak testing. Make sure the line is holding at or above the minimum required pressure.
Learn process Each line must be learned before the FMS system can continuously monitor it. Learning involves bleeding the line pressure down to zero, with no air in the line, then introducing a calibrated leak, facilitated by the leak generating kit (TS-ALCAL). The system learns this pressure decay curve and uses it to compare test data during continuous operation to determine if there is a leak in the line.
Procedure 1. The needle valve kit (TS-ALNIP) and 3.0 GPH Leak Generator (TSP-ALCAL) should be installed in the STP manifold. The line must be purged of all air prior to learning the line. 2. Open the needle valve with the leak generator in an approved container to catch any product.
Learn messages Learn Message Description Learning 0 offset Displayed when the ATG is calibrating 0 Excessive offset/unstable Pressure is unstable Learning pump operating pressure Displayed when the ATG is learning the operating pressure Insufficient pressure STP is not operating at a high enough pressure No pressure loss ATG does not detect a leak Insufficient volume (line too small)
Pump Shutdown Red, if pump is shutdown. Gray, if not shutdown Alarm Red, if in alarm. Gray, if not in alarm Running Gross Leak Test Green, if running test. Gray, if not running test Running Monthly Leak Test Green, if running test. Gray, if not running test Running Annual Leak Test Green, if running test.
Control section Indicator Description Enable/Disable Manually enable or disable the line Reset Alarm Manually reset an alarm on the line Reset Line Manually reset line Force Gross Leak Test Manually start a gross leak test Force Monthly Leak Test Manually start a monthly leak test Force an Annual Leak Test Manually start an annual leak test Learn...
Line stability test Perform the following steps for each line: 1. Install the needle valve kit, pressure gauge and leak generator into the STP manifold. Purge the line by dispensing from each fueling point starting with the dispenser furthest from the tank.
Alarms When a T5 ATG is in alarm, the Alarm LED on the front of the ATG will flash. If the line has been programmed to shut down the pump on failed test (in the FMS Setup), the pump will be unavailable for all system tests and dispensing until the line with the active alarm is manually reset.
Air in line The ATG has sensed line Investigate, then Purge Line pressure variations Starting at the Furthest Dispenser Not learned Learn Line (FMS > Control > Follow learn procedures Lines > Learn) follow learn procedures Insufficient Line is too small Check line size volume Leak generator not correct...
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Test Result Condition Possible Cause Resolution Failed to catch Pressure was less Check valve damaged Investigate, force a pressure that 12 psi after manual test and observe programmed delay pressure when STP turned off Dispenser solenoid is still Dispense, release hook, open after hook signal is off keep nozzle open Catastrophic leak...
TPI problem Check RS485 communication STP is disabled by another application 4-20 mA Input Contact Technical error Support. Module is Communication Look at module LEDs Red, replace module. Offline failure between the Green solid or flashing, control module and power down the ATG and the module offline reseat the module.
STP Shutdown 2 consecutive 3 GPH Possible gross leak Investigate, then Force test failures a Manual Gross Test 1-2 consecutive 0.2 GPH Possible 0.2 GPH leak Investigate, then Force test fails (depending on a Manual Monthly Test programming) 1-3 consecutive 0.1 GPH Possible 0.1 GPH leak Investigate, then Force test fails (depending on...
LS-500 functional testing Perform a Functional Test annually. This test verifies that the LS-500 application will detect and alarm or a leak condition. Perform this test when there is no dispensing. 1. If the channel is enabled, disable it. At the T5 ATG (via LCD or TSA), navigate to the FMS > Lines Control screen.
DEF installation FMP-TEM wiring The FMP-TEM Temperature Sensor includes 2 electrical connectors for installation inside the junction box only. 1. Use the 2 moisture-resistant connectors provided for each sensor. For these splices, the wire insulation is NOT cut-back (NOT Stripped) 2.
5000 ATG Setup Module Wiring The Probe Module gathers data from the DEF Inventory level probe. The Relay Module connects to the motor controller. The 4-20mA Input Module takes a signal from the temperature sensor. LCD/PRINTER Hook Signal...
Troubleshooting Condition Solution • Check the pump circuit breakers and make sure they are • Verify the wiring conforms to that described in this manual. No flow at nozzle • If cold weather, check that DEF has not frozen in the lines.
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