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GREEN MACHINE VST-GM-CS2-101
VST GREEN MACHINE VST-GM-CS2-101 Manuals
Manuals and User Guides for VST GREEN MACHINE VST-GM-CS2-101. We have
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VST GREEN MACHINE VST-GM-CS2-101 manual available for free PDF download: Installation, Operation, Maintenance, & Troubleshooting Manual
VST GREEN MACHINE VST-GM-CS2-101 Installation, Operation, Maintenance, & Troubleshooting Manual (219 pages)
Brand:
VST
| Category:
Other
| Size: 14 MB
Table of Contents
Table of Contents
3
Table of Figures
9
About VST
13
Notice
13
Warranty
13
Safety
14
Table of Terms & Abbreviations
15
Regulations & Jurisdiction
16
GREEN MACHINE Overview
17
GREEN MACHINE Theory of Operation
18
GREEN MACHINE Dimensions & Weight
19
How the GREEN MACHINE Is Shipped
19
Chapter 1: General Contractor Installation
21
Installation Instructions
21
Installation Safety for All Contractors
21
Preparing the GREEN MACHINE for Installation
21
Installing the Legs on the GREEN MACHINE
22
Figure 1-1: Bolting Sequence to Attach Legs to the GREEN MACHINE Base
22
GREEN MACHINE Dimensions & Weight
23
Ground Mount Locations
23
Setting the Concrete Pad
24
Installing the GREEN MACHINE on the Concrete Pad
25
Figure 1-2: Concrete Mounting Pad Dimensions
26
Figure 1-3: GREEN MACHINE Ground Mounting Pad
27
Figure 1-4: Vent Stack Installation
30
GDF Contact Information
31
Pre-Installation Site Survey
31
Snapshot of Site Requirements
32
Gasoline Stations
35
Other Information to Document
35
Dispensers
36
Vent Risers
36
Vst Green Machine
36
Additional Documentation
37
Electrical
37
Figure 1-5: Example of a GDF Layout
38
Figure 1-6: Example of a GREEN MACHINE with Vapor Piping Layout
39
Sample Sketch
40
Your Sketch
41
Canopy-Top Installation
28
Roof-Top Installation
28
Vent-Stack Mount Installation
29
Chapter 2: Vapor Piping Installation
43
Vapor Piping Installation Overview
43
General Notes
43
Figure 2-1: Vapor Piping Overview
44
Figure 2-2: GREEN MACHINE Connections
45
Figure 2-3: Pressure Sensor W/ 3-Way Isolation Valve Open
48
Vapor Piping Bill of Material
49
Vapor Inlet and Vapor Return Piping Installation
46
Air Outlet Piping Installation
47
Vapor Piping Post-Installation
47
Flexible Piping
45
Chapter 3: Electrical Installation
51
Electrical Safety
51
Electrical Requirements
51
Electrical Installation
52
Electrical Installation Code Requirements
52
Electrical Components
53
Electrical Wiring Installation
53
Installing the Vst Control Panel
53
Option 1: Power to the Vst Control Panel from the Main Electrical Distribution Panel
54
Option 2: Power the Vst Control Panel from the Station Emergency Shut-Off (Eso) Relay
54
Wiring the Electrical Components at the GREEN MACHINE Location
55
Wiring the Overfill Alarm Field Wiring
55
Wiring the VST Control Panel to the GREEN MACHINE
56
Wiring the Pressure Sensor
56
Vacuum Pump Motor Wiring Diagram
56
Applying Power to the VST Control Panel
56
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
59
Figure 3-4: the GREEN MACHINE Installation Overview Option 2
60
Figure 3-5: the Control Panel Power Connection Option 2
61
Figure 3-6: the VST Control Panel Field Wiring
62
Figure 3-7: GREEN MACHINE Internal Junction Box Field Wiring
63
Figure 3-8: Pressure Sensor Wiring Diagram
64
Figure 3-9: Vacuum Pump Motor Wiring Diagram
65
Figure 4-1: VST North America Control Panel, Front View
67
Chapter 4: Control Panel
67
VST Control Panel Overview
67
Figure 4-2: Main Screen
68
Figure 4-3: Maintenance Screen Overview
69
Maintenance Screen Overview
69
Alarm Screen Overview
71
Main Screen Overview
68
Figure 4-4: Pressure Sensor Alarm Shown on the Alarm Screen
71
Chapter 5: OPEN: no CONTENT
73
Left Intentionally Blank
73
Chapter 6: Testing & Start-Up
75
Figure 6-1: Main Screen with the GM DISABLED - ENTER CODE
75
Figure 6-2: Vapor Piping Overview
78
Figure 6-3: Maintenance Screen
79
Bump Test Procedure
80
Bump Test
79
Preparation for the Bump Test
79
Purpose of the Bump Test
79
Post-Installation GREEN MACHINE Testing & Start up
75
VST Control Panel Initial Start-Up Power
75
Before Beginning the Testing and Start-Up Procedures
76
Post Installation Start-Up Tests
76
Figure 6-4: Bump Confirmation Screen
80
Figure 6-6: Maintenance Screen
82
Figure 6-8: Functionality Test Screen
85
Figure 6-9: Functionality Test Confirmation Button
86
Figure 6-10: GREEN MACHINE Operation Diagram
87
Programming the Fuel Management System Overfill Alarm Relay for the GREEN MACHINE
87
Overfill Alarm Test
88
Testing the Overfill Alarm on the GREEN MACHINE VST Control Panel
88
Figure 6-11: Output Relay Setup
89
Overfill Alarm Test
89
TLS 450 Plus Overfill Alarm Test
90
Changing the Date and Time Procedure
91
Figure 6-12: Main Screen
91
Figure 6-13: Time & Date
92
Procedures
93
Start up of the GREEN MACHINE
93
Submitting Appendix B to VST for the Verification CODE
93
Figure 6-7: GREEN MACHINE Vapor Piping Layout
83
Functionality Test Procedures
84
Figure 6-5: Vacuum Pump Motor Wiring Diagram
81
Functionality Test
82
Preparation for the Functionality Test
82
The Purpose of the Functionality Test
82
Figure 6-14: VERIFICATION CODE Screen
94
Figure 6-15: Enter the Verification CODE Screen
94
Chapter 7: Maintenance Procedures
95
Maintenance Overview
95
Maintenance Procedures
95
Figure 7-1: VST PLC Main Screen W/No Alarms
96
Figure 7-2: Maintenance Replacement Parts
97
Functionality Test
98
Preparation for the Functionality Test
98
The Purpose of the Functionality Test
98
Recommended Replacement Parts
97
Figure 7-3: Maintenance Screen
98
Figure 7-5: Functionality Test Screen
101
Figure 7-7: GREEN MACHINE Operation Diagram
102
Pressure Sensor Verification Test
103
Procedure
103
Safety
103
Figure 7-4: GREEN MACHINE Vapor Piping Layout
99
Functionality Test Procedures
100
Figure 7-6: Functionality Test Confirmation Button
102
Figure 7-8:Pressure Sensor & 3-Way Valve, Normal Operation
104
Figure 7-9: Pressure Sensor & 3-Way Valve, TEST Position
105
Figure 7-10: Main Screen W/Pressure Reading
106
Figure 7-11: Vac Pump Rubber Flange Sleeve Replacement
107
Figure 7-12: Replacing the Rubber Flange Sleeve
108
Cleaning the Control Valves
109
Figure 7-13: GREEN MACHINE Control Valves Identification Tags
109
Figure 7-15: Solenoid Base Interior
110
Removing the Valve Solenoid and Core Assembly
110
Replacing the Valve Solenoid and Core Assembly
111
Replacing the Rubber Flange Sleeve
108
Figure 7-14: Vale Solenoid Assembly
110
Figure 7-16: Valve Core Assembly
111
Figure 7-17: Air Outlet, Drain Tee, and Plug
113
Figure 7-18: Separator Location
114
Removing and Inspecting the Separator
114
Safety
114
Separator Check Procedure
114
Installing a New Separator
115
Reinstalling the Existing Separator
115
Check the Air Outlet for Liquid Condensation
112
Removing the Drain Plug
112
Replacing the Drain Plug
112
Safety
112
Removing the Rubber Flange Sleeve
107
Rubber Flange Sleeve Replacement
107
Figure 7-19: Separator Fitting Orientation
116
Chapter 8: Troubleshooting
117
Troubleshooting Procedures
117
Troubleshooting Procedures Overview
117
Troubleshooting the GREEN MACHINE and the VST Control Panel
117
Alarm Overview
118
Figure 8-1: VST GREEN MACHINE Control Panel Main Screen
118
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
Power to the VST Control Panel or PLC Controller Is off
121
Control Panel General Information
123
Option 1: Control Panel Is Powered from Distribution Panel
124
Option 2: Control Panel Is Powered from ESO Breaker
126
Troubleshooting Procedures
120
Alarm List
119
Figure 8-5: Electrical Field Wiring Diagram
128
Figure 8-6: Incoming Power Connections
129
Figure 8-7: VST Control Panel Powered from ESO Relay
130
Figure 8-8: Electrical Overview Installation Drawing
131
Figure 8-9: VST Control Panel Components - Front Cover
132
Figure 8-10: VST Control Panel 115 VAC Power Circuit Diagram
133
Figure 8-11: Pressure Sensor Alarm Troubleshooting Procedure
134
Figure 8-12: Pressure Sensor Wiring Diagram (24VDC Power and 4-20 Ma Signal)
136
Figure 8-13: Vacuum Pump Troubleshooting Procedures
137
Vacuum Pump Alarm
137
Vacuum Pump Alarm: Troubleshooting Steps
138
Pressure Sensor Alarm: Troubleshooting Steps
135
Figure 8-14: Vacuum Pump Power and Control Circuit
143
Figure 8-15: VST Control Panel Electrical Components
144
Figure 8-16: GREEN MACHINE Isometric with Control Valves Identification Labels
145
Figure 8-17: GREEN MACHINE Controller Alarm Screen
147
Overfill Alarm Troubleshooting Steps
148
Figure 8-18: Fuel Level Tank Alarms
149
SD Card Alarm
150
Figure 9-1: North America GREEN MACHINE Replacement Parts
151
North America VST Control Panel Replacement Parts
152
Maintenance Switch Alarm
146
Overfill Alarm
147
Pressure Sensor Alarm
134
Chapter 9: Replacement Procedures
151
Replacement Parts Procedures
151
List of Replacement Parts
151
Figure 9-3: VST Control Panel, Inside the Front Cover Replacement Parts
153
Figure 9-5: Removing the PLC Connectors
156
Figure 9-6: the PLC with Connectors Removed
157
Figure 9-8: Vacuum Pump BRK2
158
Vacuum Pump Motor Solid-State Relay Replacement
159
Figure 9-9: Vacuum Pump Solid State Relay
160
Pressure Sensor Replacement
161
Removing the Pressure Sensor
161
Installing the Pressure Sensor
162
Figure 9-10: Pressure Sensor Replacement
163
Figure 9-11: Wiring the Pressure Sensor Inside the Internal Junction Box
164
Figure 9-12: Vac Pump Rubber Flange Sleeve Replacement
165
Removing the Rubber Flange Sleeve
165
Rubber Flange Sleeve Replacement
165
Figure 9-13: Replacing the Rubber Flange Sleeve
166
Replacing the Rubber Flange Sleeve
166
Figure 9-14: Vacuum Pump Components
167
Removing the Vacuum Pump Motor
167
Vacuum Pump Motor (Only) Replacement
167
Replacing the Vacuum Pump Motor
168
Figure 9-15: Junction Box Motor Wiring Diagram
169
Control Valve Replacement
170
Figure 9-16: GREEN MACHINE Control Valves Identification Tags
170
Figure 9-17: Valve Solenoid Assembly
171
Removing the Valve Solenoid and Core Assembly
171
Figure 9-18: Valve Assembly
172
Replacing the Valve Solenoid and Core Assembly
172
Figure 9-19: Vacuum Pump Components
173
Preparation for Cleaning the Tubes and Manifold
173
Vacuum Pump (Only) Replacement
173
Figure 9-20: Items Associated with Cleaning the GREEN MACHINE Tubing and Manifold
174
Figure 9-21: Tubes 1-6 Removed
174
Figure 9-22: Vacuum Pump Assembly and Components
175
Removing the Vacuum Pump
175
Replacing the Vacuum Pump
176
Preparation for Cleaning the Tubes and Manifold
177
Figure 9-7: Removing the PLC Hold down Clips
157
Control Panel Small Components Replacement
158
Vacuum Pump Motor Breaker Replacement
158
Figure 9-2: VST Control Panel, Front Cover Replacement Parts
153
Figure 9-4: VST Control Panel, Inside Panel Replacement Parts
154
PLC (Controller) Replacement
155
Removing the PLC
155
Replacement Procedures by Part
155
Installing the New PLC
156
Figure 9-23: Manifold Valves
177
Figure 9-24: GM Control Valve Assembly and Components
178
Figure 9-25: How to Remove the Red Cap from the Solenoid Base
178
Figure 9-26: Manifold with the Solenoids Removed, Showing the Solenoid Bases
178
Figure 9-27: Solenoid with Solenoid Base and Red Cap
179
Figure 9-29: Solenoids (with the Solenoid Bases Installed) Arranged out of the Way
179
Figure 9-30: Manifold Ready for Cleaning
180
Figure 9-32: Maintenance Screen
181
Figure 9-33: Removing/Installing the Canister Housing
184
Figure 9-34: Separator Location
185
Removing and Inspecting the Separator
185
Safety
185
Separator Replacement
185
Figure 9-35: Separator Fitting Orientation
186
Installing a New Separator
186
Leak Test
187
Preparation for the Leak Test
187
Purpose of the Leak Test
187
Figure 9-36: Vapor Piping Overview
188
Figure 9-38: Leak Test Screen
189
Leak Test Procedure
190
Conduct a Functionality Test
182
Ending Stage
182
Reassemble the Tubes and Valve Components
182
Canister Housing Replacement
183
Installing the New 8" Canister Housing
183
Removing the Canister Housing, Tubing, and Fittings
183
Figure 9-28: Solenoid with Solenoid Base and Red Cap Installed
179
Figure 9-31: Vacuum Pump with the Blowout Tube Installed
180
Cleaning the Tubes and Manifold
181
Figure 9-37: Maintenance Screen
189
Figure 9-39: GREEN MACHINE Vapor Inlet, Return, and Air Outlet Connections
191
Figure 9-40: Leak Check Fixture
192
Figure 9-41: GREEN MACHINE with Vapor Inlet, Vapor Return, and Air Outlet
192
Chapter 10: Operator Instruction Sheet
193
Alarm Instructions
193
Controller Screen
193
Pressure Sensor Alarm
193
Vacuum Pump Alarm
193
Maintenance Switch Alarm
194
Overfill Alarm
194
SD Card Alarm
194
Figure 10-1: Main Screen
195
Figure 10-2: Maintenance Screen
195
Figure 10-4: Password Screen
196
How to Remove and Insert the SD Card into Unitronics PLC Slot
197
Figure 10-3: Faults & Alarm Screen
196
Figure 10-5: Inserting and Removing the SD Card from the PLC
197
Chapter 11: GM Operator Training Guide
199
About VST
199
GREEN MACHINE Theory of Operations
199
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
Maintenance Screen
203
Alarm Screen
205
Alarms Overview
205
Figure 11-5: Overfill Alarm Shown on the Faults & Alarms Screen
205
GM Status
205
Pressure Sensor Alarm
205
Maintenance Switch Alarm
206
Overfill Alarm
206
Vacuum Pump Alarm
206
SD Card Alarm
207
Figure 11-6: Inserting and Removing the SD Card from the PLC
208
Locks and Keys
209
Station UST Environmental Compliance Testing and Services
209
Main Screen
202
VST Control Panel
201
VST Control Panel Overview
201
Appendix A - General Contractor Check-Out Form
211
Appendix A - General Contractor Check-Out Form
212
Appendix B - Start-Up Contractor Check-Out Form
215
Appendix B - Start-Up Contractor Check-Out Form
216
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