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Incon TS-LLD Installation Manual

Electronic line leak detector
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TS-LLD
Installation Guide
Electronic Line Leak Detector
Part Number: 000-1359, Rev. H
Copyright © March 2012
TS-LLD INSTALLATION GUIDE

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  • Page 1 TS-LLD Installation Guide Electronic Line Leak Detector Part Number: 000-1359, Rev. H Copyright © March 2012 TS-LLD INSTALLATION GUIDE...
  • Page 2 NOTICE INCON has strived to produce the finest possible manual for you, and to ensure that the information contained in it is complete and accurate. However, INCON makes no expressed or implied warranty with regard to its contents. INCON assumes no liability for errors or omissions, or for any damages, direct or consequential, that result from the use of this document or the equipment which it describes.

  • Page 3: Table Of Contents

    Before you Begin ....................P - ii NOTES ..................... P - ii 1 TS-LLD Electronic Line Leak Detector – Overview ......1 - 1 Overview and Theory of Operation ................1 - 1 Leak Test Requirements and Length ..............1 - 2 The LSU (Leak Sensing Unit) ................

  • Page 4: Chapter . Section

    Table of Contents Chapter . Section Page No. 2.4 Optional TS-LLD – Tank Sentinel Console Interface ....2.4 - 1 TS-1000 Tank Gauge Interface ................2.4 - 1 Example TS-1000 & TS-2000 ATG Reports: ............ 2.4 - 2 TS-2000 Tank Gauge Interface ................2.4 - 3 NOTE .....................
  • Page 5 When a 0.2 gph Leak Test Fails / Leak is Detected ? ........3 - 8 When a 0.1 gph Annual Precision Leak Test Fails / Leak is Detected ? ..3 - 8 4 TS-LLD Line Leak Detection .............. 4 - 1 When a Line Leak is Detected ................4 - 1 NOTE ......................
  • Page 6 Table of Contents Chapter . Section Page No. 5 TS-LLD Maintenance & Service ............5 - 1 NOTE ......................5 - 1 Cleaning the Control Unit ..................5 - 1 Control Unit Replacement Parts ................5 - 1 Pump Relay Control Box Replacement Parts ............5 - 1 Leak Sensing Unit (LSU) Adapters &...
  • Page 7 Figure 2.2-12 Tightening MI Cable Adapter Fitting – FE Petro ..2.2 - 11 Figure 2.2-13 Typical Installation TS-LLD Line Leak Detector ... 2.2 - 12 Figure 2.2-14 INCON TS-LLD Installation @ Ext. Leak Det. Port ..2.2 - 13 Figure 2.2-15 INCON TS-LLD Installation at BigFlo Diaphragm Valve ........
  • Page 8 Figure 2.3-1 CU Internal & Bottom Views, and Relay Box Top View .. 2.3 - 1 Figure 2.3-2 CU Component Location - Internal View ......2.3 - 2 Figure 2.3-3 TS-LLD CU Typical Mounting and Conduit Routing ..2.3 - 3 TABLE 2.3 -1 Typical Single Phase Wire Connection List ....2.3 - 4 Figure 2.3-4 Typical Single Phase 240 VAC...

  • Page 9: Ppreface

    PREFACE Contents: Graphic Symbol Conventions (used in this manual) Page Numbering and Layout Conventions Components Included with Each TS-LLD System Before You Begin Graphic Symbol Conventions NOTE Important information, tips, and hints are highlighted by the NOTE graphic. CAUTION or...

  • Page 10: Components Included With Each Ts-Lld System

    Heed all CAUTIONS and WARNINGS ! See Chapter 2.1 about Safety, before attempting any installation, maintenance, or service work. This manual is your reference guide for the INCON TS-LLD line leak detector. It includes typical installation details, which may vary depending on the actual equipment at the site.

  • Page 11: Overview And Theory Of Operation

    M I C A B L E A D A P T E R The TS-LLD detects leaks in the pipeline leading from the submersible pump to the dispenser. To comply with current EPA regulations, three types tests are provided.

  • Page 12: Leak Test Requirements And Length

    The LSU not only receives power from the existing pump power-lines, but it transmits data (communicates) over these lines. One of the power lines is routed through a communications pickup coil inside the Control Unit (CU). Page 1 - 2 TS-LLD INSTALLATION GUIDE...

  • Page 13: The Control Unit (Cu)

    The CU (Control Unit) The CU monitors data that it receives from the pickup coil. The control unit automatically turns on the pump when no one is dispensing product and calculates accurate liquid flow rates to determine if a line leak exists or not. The dispense signal is also monitored to identify when a customer is about to dispense product.

  • Page 14: Your Notes

    — Your Notes — — — Page 1 - 4 TS-LLD INSTALLATION GUIDE...

  • Page 15: Ts-Lld Materials & Tools Required

    Pipe Dope — Non-hardening (Soft-Set), UL Classified, gas/oil resistant — to seal the Leak Sensing Unit, and the 1/4 inch Tank Test Port plug at the pump MI Cable Adapter — for installation on the TS-LLD Leak Sensing Unit (LSU). The TS-RJ 2" NPT Cable Adapter for Red Jacket ®...

  • Page 16: Tools Required

    (1) Completed Warranty Registration Card – (supplied with each TS-LLD) TS-LLD Quick Reference guide – INCON P/N 000-1447 (supplied with each TS-LLD). Leave all TS-LLD Quick Reference guide(s) on-site for use by the station owner, shift managers / personnel !

  • Page 17: Ts-Lld Safety

    NOTE INCON Danger stickers (see above left) are supplied with the TS-LLD line leak detector. Apply these stickers on the pump relay box cover, in locations near dispenser fuel-line filters, plugs, emergency safety-shut-off valves, on the TS-LLD Leak Sensing...

  • Page 18: Safety Notes And Warnings (Continued

    (motor control) box in the facility to comply with Codes. CAUTION Although the LSU is water resistant, INCON does not recommend operating the LSU while submerged for long periods of time (drain sump and manhole immediately).

  • Page 19: Ts-Lld Lsu Installation

    1) Install the appropriate size MI Cable Adapter on the LSU. Use an adjustable wrench and a 7/8 inch wrench to tighten the MI cable adapter onto the TS-LLD as shown in Figure 2.2-1. NOTE: The cable adapter that you install must match the size of the junction box plug at the submersible pump housing (two different cable adapters are shown in Figure 2.2-1).
  • Page 20 1/4 NPT hole plug, and install this plug into the tank test port. MEC HA NIC AL LINE LEAK 2" PLUG D ETEC TOR 2" PLUG 1/4" PLUG STATION C OND UIT PIPELINE PUMP HOUSING ® Figure 2.2-2 Plug Location – RedJacket Submersible Pump Housing Page 2.2 - 2 TS-LLD INSTALLATION GUIDE...
  • Page 21 4) Apply Pipe dope to the line leak detector threads per Figure 2.2-4. TS-LLD LINE LEAK DETECTOR LEAK SENSING UNIT Pipe dope (LSU) only the se Pipe thre ads Dope Figure 2.2-4 TS-LLD Leak Sensing Unit – Thread Doping LSU Installation Page 2.2 - 3...
  • Page 22 S T A T IO N C O N D U IT PIPE LIN E P U M P H O U S IN G ® Figure 2.2-5 Line Leak Detector Installation – RedJacket Pump Housing Page 2.2 - 4 TS-LLD INSTALLATION GUIDE...
  • Page 23 M I CABLE ADAPTER MI CABLE STATION CONDUIT LINE LEAK PORT DETECTOR PUMP HOUSING Figure 2.2-6 Line Leak Detector Installation – FE Petro Pump Housing LSU Installation Page 2.2 - 5...
  • Page 24 7) Carefully remove each wirenut, one at a time and check each for the absence of power (see Figure 2.2-7, or 2.2-8). M I CABLE LINE LEAK DETECTOR STATION PIPELINE CONDUIT PUMP HOUSING ® Figure 2.2-7 Line Leak Detector Wiring – RedJacket Pump Housing Page 2.2 - 6 TS-LLD INSTALLATION GUIDE...
  • Page 25 Again use a red wire nut, and twist the remaining lead from pump together with the remaining black wire lead from the LSU. c) For Canadian TS-LLD leak sensing units only: connect the green (ground) wire from the pump to the green LSU wire.
  • Page 26 2.2-9, or 2.2-10. M I CABLE LINE LEAK DETECTOR STATIO N P I P E L I N E CONDUIT PUMP HO USING ® Figure 2.2-9 MI Cable Adapter Installation – RedJacket Pump Housing Page 2.2 - 8 TS-LLD INSTALLATION GUIDE...
  • Page 27 M I CABLE M I CABLE ADAPTER LINE LEAK DETECTOR STATION CONDUIT PORT PUMP HOUSING PIPELINE Figure 2.2-10 MI Cable Adapter Installation – FE Petro Pump Housing LSU Installation Page 2.2 - 9...
  • Page 28 S T A T IO N P IP E L INE C O ND UIT P UM P HO US ING ® Figure 2.2-11 Tightening MI Cable Adapter Compression Fitting – RedJacket Pump Page 2.2 - 10 TS-LLD INSTALLATION GUIDE...
  • Page 29 DANGER Explosion Hazard — Flammable Vapor Area. After any installation or service of the submersible pump or its housing, inspect the MI Cable at the LSU (Leak Sensing Unit) for damage, twists, kinks, or breaks... 240 VAC power flows through this cable to the LSU.

  • Page 30: Note

    P u m p consoles, use the LLD / I interface ...see the OPTIONAL TS-LLD TANK SENTINEL ATG CONSOLE INTERFACE chapter in this manual. Tank - Pump # 1 Tank - Pump # 2 Figure 2.2-13 Typical Installation INCON TS-LLD Line Leak Detector...
  • Page 31 INTERFACE chapter in this manual. Tank - Pump # 1 Tank - Pump # 2 ("Standard" Single Phase Installation within an Installation) External Leak Detector Port ( not pump housing) Figure 2.2-14 INCON TS-LLD Installation at External Leak Detector Port...
  • Page 32 P u m p wires, and possibly an additional conduit run to the LSU, are required for 3 Phase Applications. Explosion- The INCON TS-LLD LSU MUST be installed Existing BigFlo Pump proof so the fasteners are aligned in a 12 & 6 o'clock...
  • Page 33 Containment / Storage Tank No te: Use tw o condu its w hen con duit fill exceeds 40% fu ll as specified by you r Nation al Electric Code. Use recommended components or equivalent Figure 2.2-15 INCON TS-LLD Installation at BigFlo Diaphragm Valve...
  • Page 34 Tank - Pump # 2 ( "Standard" STP Single Phase ( FE PETRO Three Phase: Installation ) IST pump or STP Installation ) Figure 2.2-16 INCON TS-LLD Installation at FE PETRO STP or IST pumps Single or Three Phase 240 VAC Applications...

  • Page 35: Ts-Lld Cu Installation & Wiring

    TS-LLD CU Installation & Wiring Contents: • Control Unit Installation Steps (Location, Product Configuration, TS-2000 Configuration, Mounting the Control Unit, Relay Box & Control Unit Wiring TABLE 2.3-1) • Wiring Diagrams & Schematics (Pump Control Relay Box, Single Phase 240 VAC, 3 Phase 240 VAC, 3 Phase RedJacket BigFlo, 3 Phase 240 VAC - FE Petro - STP &...
  • Page 36 3) INCON TS-2000 Configuration (Bottom Jumper Link) — this step is required only when the TS-LLD will be wired to or interfaced to an INCON model TS-2000 ATG console. Remove the plastic shield from the control unit cover. At J2, pull up and reposition the bottom jumper-link so that its installed over the left two pins.

  • Page 37: Note

    N O TE: G r o u n d e q u ip m e n t a s re q u ir e d b y yo u r lo c a l a n d N a tio n al Ele c tr ic C o d e s . Figure 2.3-3 TS-LLD CU Typical Mounting and Conduit Routing NOTE 4) Mount the CU to the pump relay box (see Figure 2.3-3 above for typical...

  • Page 38: Note

    Other pump relay boxes may have different terminations, and/or may be wired differently than what is shown in this manual. Typical Single Phase Wire Connection List TABLE 2.3 -1 PUMP RELAY BOX — to — TS-LLD CONTROL UNIT ( CU ) Wire From...
  • Page 39 TS-LLD Control Unit No te rm ination - wire runs through the do nut-shape d P ickup C o il 1 48 5A 2 485B 3 D S Y1 RLY N.O. CONTACT (ORG) 4 D S Y2 5 ALAR M...
  • Page 40 PN 020-0028) between input AC line terminals at Pump Motor the Relay Box. with Thermal 2) The TS-LLD is installed at the submersible pump Overload housing (see Chapter 2.2 for details). 3) Follow your local and National Electrical Codes for electrical grounding requirements.
  • Page 41 Figure 2.3-6 Single Phase 240 VAC Multiple Pump & Manifolded Line with Single LSU & CU Interface Schematic Control Unit Installation Page 2.3 - 7...

  • Page 42: Ts-Lld Line Leak Detector Mechanical Blender Interface

    (electric blenders can be wired normally). Wire both premium and regular TS-LLD Control Units at TB1-4 (P-IN). See the typical (partial) wiring diagram below. Because the mid-grades are blended mixtures of the premium and regular octanes, any product dispense will abort leak tests at the premium and regular Control Units.
  • Page 43 2) Install the 1uF Line Filter Capacitor (INCON PN 020-0028) Thermal between AC input line terminals at the Relay Box. Overload 3) The TS-LLD is installed at the submersible pump housing (see Chapter 2.2 for details). 4) Follow your local and National Electrical Codes for electrical grounding requirements.
  • Page 44 Reference Site Layout Figure 2.2 - 15 Figure 2.3-9 Three Phase 240 VAC Supply – Starter – Motor Control Box – and BigFlo Pump (3 wire) Interface Schematic to TS-LLD Page 2.3 - 10 TS-LLD INSTALLATION GUIDE...
  • Page 45 Reference Site Layout Figure 2.2 - 15 Figure 2.3-10 Three Phase 240 VAC Supply – Starter – Motor Control Box – and BigFlo Pump (5 wire) Interface Schematic to TS-LLD Control Unit Installation Page 2.3 - 11...
  • Page 46 Reference Site Layout Figure 2.2 - 16 Figure 2.3-11 Three Phase 240 VAC Supply – Starter – and Motor Control Box Standard Interface Schematic to TS-LLD Page 2.3 - 12 TS-LLD INSTALLATION GUIDE...
  • Page 47 Reference Site Layout Figure 2.2 - 16 Figure 2.3-12 Three Phase 240 VAC Supply – FE PETRO Variable Frequency Controller, Motor Control Box – and IST Pump Interface Schematic to TS-LLD Control Unit Installation Page 2.3 - 13...

  • Page 48: Final Installation Steps

    P roduc t: 9) Reinstall the pump relay box cover. See N u m b e r Figures 2.3-1 & 2.3-3. 10) Nine INCON Danger stickers are supplied with each line leak detector (P/N 240-1175). Apply CU TOP VIEW one sticker:...
  • Page 49 • TS-1001 / TS-2001 LLDI Interface TS-1000 Tank Gauge Interface The TS-LLD can be interfaced to an INCON TS-1000 console with the addition of a TS-TGI module. The TGI module (Tank Gauge Interface module) can interface up to 4 TS-LLD systems with the TS-1000. NOTE – The devices and installation methods covered in this Section have not been evaluated by Underwriters Laboratories and are not considered part of this Listing.
  • Page 50 TS-1000 Internal View (CU) / LINE # N SIG RTN ( with door open ) with cover off Figure 2.4-2 TS-1000 – TS-TGI Module – TS-LLD Control Unit Wiring Diagram 4 line report header (standard) 4 line report header (standard) Example 6/20/1999...
  • Page 51 TS-2000 Tank Gauge Interface Remove the TS-LLD control unit cover & plastic shield, and reposition the blue jumper links as shown in the diagram below. Do this when wiring to the discrete input terminals of an INCON model TS-2000 ATG.
  • Page 52 240 AC POWER WIRING Trough Only Motor Control Panels ( Relay Boxes - or - Starters ) Figure 2.4-4 TS-1001 / TS-2001 LLDI Typical Connecting Hardware Layout Page 2.4 - 4 TS-LLD INSTALLATION GUIDE...
  • Page 53 TS-LLD Control Units. COMMUNICATIONS CABLE IN SAME CONDUIT AS LINE VOLTAGE WIRES. Up to four TS-LLD Control Units ( CUs ) can be interfaced to the TS-1001 console and up to eight CUs CU #2 last CU #N can be interfaced to the TS-2001 console.
  • Page 54 — Your Notes — — — Page 2.4 - 6 TS-LLD INSTALLATION GUIDE...
  • Page 55 After Installation – Steps & Testing Contents: • After Installation Steps / Testing • Important Warranty Information • Important Customer Documentation After Installation Steps & Testing (follow steps in order): 1) Make sure that all wiring is checked – completed – and correct, that all electrical box covers are reinstalled, and that all personnel are clear.
  • Page 56 Have the customer / owner / manager sign this card give a copy to him. Finally, fax a copy or mail the original card back to INCON. Please make certain that you fill out the CU & LSU serial numbers.
  • Page 57 What to do: When a Leak Test Fails ? (Leak is Detected) System Operation The TS-LLD system can perform three different pressurized line leak tests, two of which run automatically. The automatic line leak tests are: a gross 3.0 gph hourly test, and a standard 0.2 gph monthly-compliance test.
  • Page 58 Identifies the minimum leak rate detected (in gallons per hour) 0.1 gph line leak was detected (annual precision test failed) 0.2 gph line leak was detected (monthly compliance test failed) 3 gph line leak was detected (hourly gross leak test failed) Page 3 - 2 TS-LLD INSTALLATION GUIDE...
  • Page 59 4) The leak test fail / line leak alarm can be printed out or faxed i f the LLD has been optionally interfaced with an INCON ATG Monthly-Compliance Warning – Flashing Day Codes A 0.2 gph monthly-compliance test still hasn’t passed.
  • Page 60 Prevent dispensing / bag dispenser during this time. The manual test needs 4 hours of quiet-time BEFORE it is started, and takes about 13 minutes to finish. Definition: quiet-time is the inactive period –between– product dispensing Page 3 - 4 TS-LLD INSTALLATION GUIDE...
  • Page 61 A Flashing 80 Error code will be produced, and dispensing inhibited, if a dispense NOTE is attempted when an annual test is running. This error can be cleared by pushing the RESET-TEST touch button. How to Start a Manual Test Press and hold the RESET-TEST touch button down more than 5 seconds until the Line Leak Test light turns on.
  • Page 62 This test should finish in about 1 hour and reset the day count to 00 and turn the Line Leak Test light off. See the Troubleshooting Guide in Chapter 6.2 of this manual about flashing 84 alarm error codes if this test does not finish. Page 3 - 6 TS-LLD INSTALLATION GUIDE...
  • Page 63 RESET TEST button. Remember that the Line Leak Detected Light will continue to flash on and off until another test, of equal or greater precision finally does pass. Visually inspect the sump and dispenser areas whenever the TS-LLD reports a leak ! Continued next page... System Operation & Testing...
  • Page 64 When a 0.1 gph Annual Precision Leak Test Fails / Leak is Detected ? The display shows a flashing 1 Alarm code — follow the instructions in Chapter 4 Visually inspect the sump and dispenser areas whenever the TS-LLD reports a leak ! —...
  • Page 65 Need Help (with line test failures) ? When a Line Leak is Detected The TS-LLD line leak detection system: disables the Submerged Turbine Pump, flashes the Line Leak Detected light, and displays a flashing test-fail Alarm code when a line leak test fails.
  • Page 66 6) If a leak is found, or if the second line leak test also fails, then: a) Shut off all power to the affected pump and dispenser & contact INCON Technical service b) Take corrective action in accordance with local, State, and Federal regulations c) Contact the local inspection agency, and follow all procedures and instructions as required by State Laws and Regulations.
  • Page 67 TS-LLD Maintenance & Service Contents: • Cleaning the Control Unit • Control Unit Replacement Parts • Rump Relay Control Box Replacement Parts • Leak Sensing Unit Replacement Parts LSU Removal for Service / Inspection and Cleaning • • After Maintenance or Service DO...
  • Page 68 O-Rings are made from a special material that are LSU O-Ring UL rated – use no substitutes. Install only genuine INCON LSU O-Rings. (Also see Appendix A about Applicable Liquid Products.) Bottom & Side Views 5) Reinstall / Install the Leak Sensing Unit per steps shown in Chapter 2.2...
  • Page 69 This log could be FAXed to you and would prove to be very useful diagnostic tool. Distributors and Installers: you may order more guides by contacting INCON and asking for part number 000-1447. Certain restrictions may apply.
  • Page 70 FAX in registration. Return Shipments If it should become necessary to return the LSU or CU to INCON please use the original packaging materials if possible. Return shipping damage due to inadequate or inappropriate packaging is your responsibility. Make sure the return- goods shipment is insured.
  • Page 71 POSTAGE WILL BE PAID BY THE ADDRESSEE ATTN: TECHNICAL SERVICE INTELLIGENT CONTROLS INC PO BOX 638 SACO ME 04072-9962 Warranty Registration Form: (copy, fill-in, & FAX Registration Form back to INCON) TS-LLD Warranty Registration Form 000-1480 REV. C ♦ ♦...
  • Page 72 — Your Notes — — — Page 6.0 - 4 TS-LLD INSTALLATION GUIDE...
  • Page 73 Test Fail Alarms, Warnings & Error Codes Contents: • Normal Display Codes (on steady – not flashing) • Flashing Alarm, Warning, and Error Display Codes • Diagnostic Display Codes Display Codes The following Normal, Alarms, Warnings, and Error Codes are displayed at the control unit at this publication date.
  • Page 74 0.2 gph leak test (00 - 99 solid ...solid 99 represents a number from 99 to 149 and flashing 99 represents a number from 150 and above). Record this number for assistance from INCON. Fourth press: Flashing number which represents the...
  • Page 75 TS-LLD Troubleshooting Guide Contents: • Problem • Description / Symptoms • Probable Cause (and Action to Take) Display Codes This chapter contains a current listing of Warnings, Alarms, and Error Codes that may be displayed at the control unit. Before attempting any service, maintenance or troubleshooting work on this system, be sure to review and follow all instructions, and heed all cautions and warnings in this manual...
  • Page 76 18 cycles... neither a pass or fail result can be determined. The monthly test will start again after another dispense. Call INCON when days count up and when this Diagnostic Error Code is consistently displayed.) Page 6.2 - 2...
  • Page 77 Please call our service department for tips and solutions to other problems not addressed at the time of this publication. Also, call INCON technical service when warnings, alarms, or error codes happen often or repeat often. Also, see Chapter 6.0 before calling INCON.
  • Page 78 — Your Notes — — — Page 6.2 - 4 TS-LLD INSTALLATION GUIDE...
  • Page 79 TS-LLD Warranty Registration Card (or facsimile thereof), or 18 months from the date of shipment, whichever occurs first. During this period INCON will, at its option, modify, repair or replace defective products at no charge. This is a materials only warranty, and does not include labor or service charges.
  • Page 80 This warranty gives you specific legal rights. You may also have other rights which vary from state to state. For further information, contact INCON Technical Service Department at: INCON...
  • Page 81 Appendix A TS-LLD Technical Specifications Abbreviations: LSU = Leak Sensing Unit, CU = Control Unit, STP = Submerged Turbine Pump Operating Specifications Electrical Specifications Application Power Supply (Frequency: 60 Hz) Leak detection monitoring of pressurized 120 VAC (CU) – from pump control relay box underground fuel lines 208 to 240 VAC (LSU) –...
  • Page 82 Appendix A TS-LLD Technical Specifications Abbreviations: LSU = Leak Sensing Unit, CU = Control Unit, STP = Submerged Turbine Pump Environmental Specifications Mechanical Specifications Operating Temperature Display — Type: 32° to 121° F (0° to 40° C) CU Alphanumeric LED (Light Emitting Diode) —...
  • Page 83 User Feedback Form Technical Publications Manager We’ll listen – we promise ! INTELLIGENT CONTROLS INC Please complete and return 74 INDUSTRIAL PARK ROAD this form ...Mail or F SACO ME 04072 USA FAX #: 207-286-8414 Your ideas and opinions are important to us ! Please help us improve our products, our service, and our organization...
  • Page 84 You were not kept on hold (for a long time) Service / Support Suggestions The INCON system or product: Please circle (1 = no / poor, 2 = fair, 3 = okay, 4 = good, 5 = yes / excellent, N = don’t know)
  • Page 85 TS-LLD INSTALLATION GUIDE...
  • Page 86 PO BOX 638 SACO ME 04072 TS-LLD Installation Guide...

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