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Pneumercator LLP203 Instruction Manual

3 gph line leak sensor
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Peter Sinkiwskij
Date: 2021.09.02 17:58:46 -04'00'
DN: cn=Peter Sinkiwskij, o=Pneumercator Co., Inc., ou=Headquarters, email=peter@pneumercator.com, c=US
Digitally signed by Peter Sinkiwskij
PNEUMERCATOR
Liquid Level Control Systems
© COPYRIGHT 2021 PNEUMERCATOR CO., INC.
LLP203 Instruction Manual - 2021-09-02.docx
INSTRUCTION MANUAL
1785 EXPRESSWAY DRIVE NORTH
HAUPPAUGE, NY 11788
TEL: (631) 293-8450
FAX: (631) 293-8533
Product Support: (800) 209-7858
www.pneumercator.com
DRAWING NO. 20238 REV. N/C
LLP203
3 GPH
LINE LEAK
SENSOR
September 2, 2021

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Summary of Contents for Pneumercator LLP203

  • Page 1 Peter Sinkiwskij Digitally signed by Peter Sinkiwskij DN: cn=Peter Sinkiwskij, o=Pneumercator Co., Inc., ou=Headquarters, email=peter@pneumercator.com, c=US Date: 2021.09.02 17:58:46 -04'00' 3 GPH PNEUMERCATOR LINE LEAK Liquid Level Control Systems SENSOR INSTRUCTION MANUAL DRAWING NO. 20238 REV. N/C LLP203 © COPYRIGHT 2021 PNEUMERCATOR CO., INC.

  • Page 3: Table Of Contents

    Line Leak Mode, 3 GPH (Header Menu) ................20 Pump Status Contact Closure Input (CC Input Menu) ............21 LLP203 and Piping Settings, TMS2000/TMS3000 (Sensor Input Menu) ......22 LLP203 and Piping Settings, TMS4000 (Sensor Input Menu) ........... 24 4.4.1 MANUAL Discharge Time Capture Mode, TMS4000 ............24 4.4.2 CALCULATED Discharge Time Capture Mode, TMS4000 ..........

  • Page 5: Preface

    TMS for use with the LLP203 Sensor. Station Owner/Operator: The station owner or operator of the TMS console equipped with the LLP203 may only modify select TMS LLP203 settings. Performing the TMS AUTO CAPTURE procedure and servicing/removing the LLP203 is strictly prohibited.

  • Page 6: General Overview

    Important Notes: Each product line must be tested and verified free of leaks prior to installing LLP203 sensors, and all must be tested upon startup, and routinely thereafter (at least annually) under NFPA standards. These NFPA and other industry testing practices must be followed by the installer and the end user.

  • Page 7: Site Survey & Assessment

    CHANGE WITHIN THE PIPELINE AFTER 5 MINUTES OF Pump-OFF MUST BE LESS THAN 5 PSI. The TMS cannot be accurately calibrated unless the product is stable in pipeline.  A minimum static line pressure of 20 PSI is required for the LLP203 to perform a Gross (3 GPH) line leak test. ...

  • Page 8: Section 1 Safety

    (an environmental hazard associated with costly clean-ups), and fire or explosion hazard that may result in injury or death. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 8...
  • Page 9 WARNING off all pump power and relieve pipeline pressure (reference and follow the pump manufacturer’s directions). If the LLP203/plug (or any other part of the pump and fuel line) is removed without first relieving pressure, then a product leak will occur.
  • Page 10 The LLP203 is designed for use in specific applications and in compliance with CAUTION industry standards and practices. Using it in applications for which it was not designed or failure to follow industry standards and practices may cause the product to malfunction or fail.

  • Page 11: Section 2 Mechanical Installation

    SECTION 2 – MECHANICAL INSTALLATION 2.1 LLP203 INSTALLATION The LLP203 Line Leak Pressure Sensor is intended to be installed in the 2” Leak Detector Port of the Pump. Refer to Pump manufacturer’s instructions for port location. 1. At the electrical Service Panel: lock-out & Tag POWER OFF for the Pump, Pump Controller, and Dispensers.
  • Page 12 INSTRUCTION MANUAL LLP203 7. After all LLP203 Line Leak Pressure Sensors have been installed, check that the system is ready to be pressurized to check for the absence of leaks. 8. After the installation is checked and all personnel are clear, have the electrician turn on power at the Service Panel for the Pump (Submerged Turbine Pumps and Output Devices).
  • Page 13 CABLE 2 [51] REF. 5 [127] REF. LLP203 SUBMERSIBLE TURBINE PUMP (STP) (PUMP HEAD SIDE VIEW) DRAWING NO. 20239 REV. N/C Figure 2-1: LLP203 Mounting in a Submersible Turbine Pump LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 13...

  • Page 14: Section 3 Electrical Installation & Wiring

    • Tank ID: The configured Tank ID Number corresponding to the LLP203 • Sensor Input Number: The hardware position number in the TMS where the LLP203 is connected. • CC Input Number: The Contact Closure (CC) Input Number where the signal representing pump activity is connected.
  • Page 15 INSTRUCTION MANUAL LLP203 Follow the instructions below to wire the LLP203 Line Leak Sensor to the TMS. A licensed electrician is recommended and may be required to perform the electrical installation. 1. All cabling from the LLP203 transducer to the TMS console must be separated from non-intrinsically safe wiring as per Article 504 of the National Electric Code.
  • Page 16 INTRINSICALLY WIRING - LLP203 TO TMS TMS CONSOLE WARNING Refer to TMS installation manual for NOTE: TERMINAL BLOCK ORIENTATION AND WARNINGS and CAUTIONS before proceeding. FAILURE TO COMPLY WIRE CONNECTION NAMES MAY BE MAY RESULT IN PERSONAL INJURY, DIFFERENT ON CIRCUIT BOARD OR LABEL.
  • Page 17 Refer to the following two pages for an illustrated example. Note that this connection is shown with a blue line. 8. As needed, connect Pump Shut Off Relay Output for each LLP203. Note that there are two methods available for support Pump Shut Off: •...

  • Page 20: Section 4 Tms Configuration

    The TMS supports two modes of operation that affect the frequency of the line leak test. Each mode is described below, including all TMS connection requirements: Note: The Line Leak Mode should be set prior to addressing any other LLP203 settings. •...

  • Page 21: Pump Status Contact Closure Input (Cc Input Menu)

    Normal State: The normal contact state of the incoming wiring, representing the pump not running, must be specified. Note that the CS-10 is a Normally Open device. Otherwise, refer to the pump documentation regarding the dry contact signal. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 21...

  • Page 22: Llp203 And Piping Settings, Tms2000/Tms3000 (Sensor Input Menu)

    INSTRUCTION MANUAL LLP203 4.3 TMS2000/TMS3000 LLP203 AND PIPING SETTINGS MAIN MENU MENU ACCESS CONFIG SENSOR INPUT ITEM ENTRY SENSOR ENABLE ALARM SENSOR TYPE LLP203 INPUT NAME PIPING YES or NO FAULT DETECT ENABLE TIME or Enter Volume PIPE VOLUME DISCHARGE TIME...
  • Page 23 Pump Control Relay: The Relay specified will activate the Pump, as needed, to recharge the line pressure prior to starting a test. This setting is only required for the Hourly Line Leak Mode. See Section 4.1 for details. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 23...

  • Page 24: Llp203 And Piping Settings, Tms4000 (Sensor Input Menu)

    INSTRUCTION MANUAL LLP203 4.4 TMS4000 LLP203 AND PIPING SETTINGS Discharge Time Capture Mode: Selects the method used to determine the Discharge Time. The Discharge Time represents the amount of time, in seconds, that it will take for a fully pressurized line to drop to 10 PSI with a known 3 GPH leak after the pump powers off.

  • Page 25: Calculated Discharge Time Capture Mode, Tms4000

    Failure to enter accurate information may result in creation of environmental CAUTION hazards in the event that a leak is undetected. Line Volume: Total volume of the piping being tested. • Range: o English: 10-1180 Gallons o Metric: 50-4450 Liters LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 25...

  • Page 26: Auto Capture Discharge Time Capture Mode, Tms4000

    Pump Control: The Relay specified will activate the Pump, as needed, to recharge the line pressure prior to starting a test. This setting is only required for the Hourly Line Leak Mode. See Section 4.1 for details. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 26...

  • Page 27: Positive Pump Shutdown

    Specify the Relay Output selected for Positive Pump Shutdown as wired in Section 3. TMS2000/TMS3000 Setting Location MAIN MENU MENU ACCESS CONFIG RELAY SENSOR ITEM ENTRY SENSOR TRIGGER TMS4000 Setting Location LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 27...

  • Page 28: Section 5 Discharge Time Measurement

    AUTO CAPTURE. A calibrated 3 GPH Leak Generating Device is required for this measurement. Pneumercator offers the LG203, a calibrated Leak Generating Device, as a separately purchased item. See Section 5.1 below for installation instructions for the Pneumercator LG203 or refer to the documentation supplied with the third-party device.
  • Page 29 5. Install the LG203 Leak Generating Device with associated hardware in the ¼” Line Test Port of the pump for the line being observed. This hardware will include a tee which will allow a pressure gauge to be connected when manually measuring the Discharge Time. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 29...
  • Page 30 Failure to meet these requirements may result in an inaccurate measurement, which could result in not properly detecting leaks in a monitored line. Call Technical Support at (800) 209-7858 for assistance. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 30...

  • Page 31: Manual Discharge Time Measurement

    Device still open. If the leak is not detected, confirm the amount of time has been configured in the TMS or call Technical Support at (800) 209-7858 for assistance. 5. Advance to Section 5.5 to remove the LG203 for use when calibrating an additional line. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 31...

  • Page 32: Auto Ca

    See LLP203 Troubleshooting Guide at end of this manual for information on verifying NOTE the operation of the LLP203. Call Technical Support at (800) 209-7858 for any other concerns or questions regarding installation or service of the TMS system. 5.3 AUTO CAPTURE DISCHARGE TIME MEASUREMENT (TMS4000 ONLY) Note: For MANUAL measurement of the Discharge Time, please refer to Section 5.2 for instructions.
  • Page 33 SETUP > SECURITY. Refer to TMS4000 Operations Manual for details. 2. Tap SETUP, then LLP AUTO CAPTURE 3. Select the Sensor Input number, using the plus or minus control, representing the LLP203 to be configured. Tap START AUTO CAPTURE to begin the process.
  • Page 34 INSTRUCTION MANUAL LLP203 A Pneumercator trained service technician must perform the AUTO CAPTURE CAUTION procedure. Failure to heed this Caution may result in an improperly configured TMS with its ability to detect a 3 GPH Leak impaired. Subsequently, this could result in serious property damage and/or environmental contamination.
  • Page 35 The pump will need to be left running for at least 30 seconds to ensure that the line has been fully pressurized. Pump Start LED stays active to indicate the Pump is running LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 35...
  • Page 36 6. Power off the pump. Wait for the line pressure to drop to 10 PSI as indicated by the below screen. Leak Detected LED is active indicating the Line Pressure has dropped to 10PSI. 7. Tap ACCEPT to save the Discharge Time. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 36...

  • Page 37: Verification Of 3 Gph Leak

    See LLP203 Troubleshooting Guide at end of this manual for information on verifying NOTE the operation of the LLP203. Call Technical Support at (800) 209-7858 for any other concerns or questions regarding installation or service of the TMS system. 5.4 VERIFICATION OF 3 GPH LEAK...

  • Page 38: Lg203 (Leak Generating Device) Removal

    Repeat this procedure with each dispenser, working your way back to the pump. Return to the beginning of Section 5 for each additional LLP203 configured for NOTE MANUAL or AUTO CAPTURE Discharge Time Measurement.

  • Page 39: Section 6 Operation

    Edit Enable button on the back of the TMS door. Go to Section 6.3 to address the failed Line Leak Test. 6.2 TMS4000 Tap BELL button to view current alarms or tap SENSORS button to view Sensor Status. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 39...
  • Page 40 The TMS4000 represents a Leak Alarm in both the Sensor Status and Alarm Acknowledgement screens. The Leak alarm is acknowledged from the Alarm Acknowledgement screen by tapping the Leak Bell button. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 40...

  • Page 41: Detected Line Leak

    If a leak was found in Step 2, skip Step 4, and perform Step 5. 4. Initiate a Line Leak Test by manually activating the pump for at least 30 seconds to verify the failure. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 41...
  • Page 42 Compliance determined local/State/Federal Laws and Regulations. Non-compliance may cause site shutdown, fines, or legal action. LLP203 Instruction Manual - 2021-09-02.docx September 2, 2021 PAGE 42...

  • Page 43: Section 7 Llp203 Maintenance And Troubleshooting Guide

    NOTE in Step 4. 5. Remove the ¼” plug from the Line Test Port on the pump for the line to have the LLP203 tested. Save the ¼” plug removed from the Line Test Port so that it may be reinstalled after NOTE the Pressure Gauge is removed later in this Section.
  • Page 44 6. Apply Petroleum resistant, non-hardening, UL Classified, FEP Pipe Dope/Thread Sealant (Hercules Megaloc, Gasoila, etc.) to the ¼” threads of the Pressure Gauge. 7. Install the Pressure Gauge in the ¼” Line Test Port of the pump for the LLP203 transducer being tested.

  • Page 45: Tms Troubleshooting

    LLP203 7.3 TMS TROUBLESHOOTING Many problems with the TMS supporting the LLP203 can be caused by an improperly configured TMS and/or wiring problems. Refer to Section 3 for complete wiring instructions and Section 4 for TMS Configuration details. Below is a list of symptoms with the recommended troubleshooting actions.

  • Page 46: Appendix A Specifications

    INSTRUCTION MANUAL LLP203 APPENDIX A - LLP203 LINE LEAK DETECTOR Technical Specifications • Electrical Connection: 3-Conductor Cable(two wires used), 3-Pin Quick Disconnect, 3/4” NPT Male Conduit Connection • Pressure Connection: 2” NPT Male • Weight: Aluminum Housing, 316SS Sensor Body 2.25 lbs (1 kg), All 316SS 3.75 lbs(1.7 kg)
  • Page 48 LIMITED WARRANTY TMS Series Pneumercator, here and after referred to as PCO, warrants its LLP203 to be free of defects in material and workmanship for a period of Twelve (12) months from date of installation or Fifteen (15) months from date of invoice, whichever comes first.

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