LS500 Auto Learn
Line Leak Detection
Installation & User’s Guide
Manual #
000-2145
Revision
H
date
September 2014
Changes from Previous Revision
Added TS-ALNIP / TS-AFALNIP notice to page 16
Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA
Tel:  +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
Notice
Franklin Fueling Systems (FFS) strives to produce the finest manual possible and to ensure that the information that
it contains is complete and accurate. However, FFS reserves the rights to change this document and specifications at
any time without notice. FFS makes no expressed or implied warranty with regard to the contents of this manual. FFS
assumes no liability for errors, omissions or for any damages, direct or consequential, that may result from the use of this
document or the equipment that it describes.
Applicable Models
Console Model
Installation Manual
Programming Manual
TS-550, TS-5000
000-2150
000-2142
TS-550 evo, TS-5000 evo
000-2171
000-2173
Trademarks
INCON®, Tank Sentinel®, System Sentinel®, System Sentinel AnyWare® and Tank Sentinel AnyWare® are registered
trademarks of Intelligent Controls. All brand and product names are trademarks or registered trademarks of their
respective companies.
Inspection of Materials
Visually inspect all components for defects or damage prior to installation. If any defect or damage is found, do not use the
product and contact Franklin Fueling Systems for further assistance.
Warranty Information
Please refer to the FFS Fuel Management Systems & Product Warranty Policy for all warranty information.
Contacting Franklin Fueling Systems (FFS)
Please feel free to contact us by mail at:
Franklin Fueling Systems
3760 Marsh Rd.
Madison, WI 53718 USA
Or contact us by phone, fax or e-mail:
Tel: +1 800 225 9787
Fax: +1 608 838 6433
E-mail: [email protected]
[email protected]
Office and Sales Hours: 8 a.m. to 5 p.m. CST - Monday through Friday
Technical Support Hours: 7 a.m. to 7 p.m. CST - Monday through Friday
Please visit our website at www.franklinfueling.com
Copyright ©2008 by Franklin Fueling Systems (FFS). No part of this publication may be reproduced in any form without the prior written consent of FFS.
All rights reserved.
2
Contents
Notice............................................................................................................................................. 2
Applicable Models.................................................................................................................... 2
Important Safety Messages...................................................................................................... 4
Overview........................................................................................................................................ 5
Site Requirements................................................................................................................... 5
Intrinsically Safe LS500 Installation....................................................................................... 7
Explosion Proof LS500E Installation...................................................................................... 8
LS-500 Setup (Console Programming).................................................................................. 9
4-20mA Input Module............................................................................................................. 10
Relay Module......................................................................................................................... 11
Turbine Pump Interface (TPI) Applications............................................................................ 12
Fuel Management Systems (FMS) Line Application Set-Up.................................................. 13
Line Status and Control Screens.......................................................................................... 14
Control Section................................................................................................................ 15
Learn Section.................................................................................................................. 15
Pre-Operational LS500 Testing.............................................................................................. 16
Required Equipment.............................................................................................................. 16
Line Stability Test................................................................................................................... 16
Learn Process............................................................................................................................ 17
When to Learn / Re-Learn...................................................................................................... 17
Procedure.............................................................................................................................. 17
Learn Messages.................................................................................................................... 18
LS-500 Reports.......................................................................................................................... 19
LS-500 Line Leak Reports..................................................................................................... 19
Alarms.......................................................................................................................................... 19
LS-500 Alarms and Warnings................................................................................................ 20
Clearing Alarms..................................................................................................................... 22
LS-500 Functional Testing....................................................................................................... 23
Enabling/Disabling Lines........................................................................................................ 23
Enabling Lines....................................................................................................................... 23
Disabling Line Channels........................................................................................................ 23
3
Important Safety Messages
INCON equipment is designed to be installed in association with volatile hydrocarbon liquids such as gasoline and diesel
fuel. Installing or working on this equipment means working in an environment in which these highly flammable liquids
may be present. Working in such a hazardous environment presents a risk of severe injury or death if these instructions
and standard industry practices are not followed. Read and follow all instructions thoroughly before installing or working
on this, or any other related, equipment.
As you read this guide, please be aware of the following symbols and their meanings:
Warning
Caution
Danger
Warning
Warning
Warning
This is a caution symbol. A caution sign will appear in the text of this document when a potentially hazardous
environmental situation may arise if the instructions that follow are not adhered to closely. A potentially
hazardous environmental situation may involve the leakage of fuel from equipment that could severely harm
the environment.
This symbol identifies an electrical danger. An electrical danger sign will appear in the text of this document
when a potentially hazardous situation involving large amounts of electricity may arise if the instructions that
follow are not adhered to closely. A potentially hazardous situation may involve the possibility of electrocution,
severe bodily harm, or even death.
Follow all applicable codes governing the installation and servicing of this product and the
entire system. 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. Please refer to the Installation and Owner’s
Manual for this equipment, and the appropriate documentation for any other related equipment, for
complete installation and safety information.
Follow all federal, state and local laws governing the installation of this product and its associated
systems. When no other regulations apply, follow NFPA codes 30, 30A and 70 from the National Fire
Protection Association. Failure to follow these codes could result in severe injury, death, serious
property damage and/or environmental contamination.
Always secure the work area from moving vehicles. The equipment in this manual is usually
mounted underground, so reduced visibility puts service personnel working on this equipment in
danger from moving vehicles entering the work area. To help eliminate these unsafe conditions,
secure the area by using a service truck to block access to the work environment, or by using any
other reasonable means available to ensure the safety of service personnel.
Warning
When the Tank Sentinel system is used to monitor tanks containing gasoline or other flammable
substances, you may create an explosion hazard if you do not follow the requirements in this
manual carefully.
Warning
All wiring must enter the Tank Sentinel console’s enclosure through the designated knockouts. An
explosion hazard may result if other openings are used.
Warning
All wiring from probes or sensors to the Tank Sentinel console must be run in conduit separate
from all other wiring. Failure to do so will create an explosion hazard.
Warning
4
This symbol identifies a warning. A warning sign will appear in the text of this document when a potentially
hazardous situation may arise if the instructions that follow are not adhered to closely. A potentially hazardous
situation may involve the possibility of severe bodily harm or even death.
Substituting components could impair intrinsic safety. The Tank Sentinel 5 (T5) series consoles
are intrinsically safe for sensors installed in – Class I, Division 1, Group D – hazardous locations.
Substitution of components could make the energy limiting circuitry in the system ineffective and
could cause an explosion hazard. Repairs to a T5 Series console or attached components should
only be performed by a qualified, factory-trained technician.
Overview
The TS-LS500 is a continuous product line leak detection system that monitors the primary pipe. This product is an
available option of Franklin Fueling Systems’ T5 Series Fuel Management System consoles.
The TS-LS500 system includes the FMS application running on a T5 series console using a 4-20 mA input module and a
transducer. One transducer, which monitors line pressure, is required per product line. Line Pressure is created by the pump
and static seating pressure is metered by a pressure relief valve. Transducers (TS-LSU500) use the AutoLearn technology to
continuously evaluate the line conditions.
Note: The TS-LS500 requires pressure for leak tests and should only be installed in systems that are designed to obtain
and hold this minimum static pressure (refer to Site Requirements table below). The system may report “learned with
errors” if tests are run at less than optimum pressure.
Applications
The following diagram illustrates a typical installation of the LS500 equipment inside of a STP sump.
Wire Splices
FE Petro
Submersible
Pump
TS-LSU500
Black
Red
White (capped)
Shield (Not connected)
Intrinsically safe wiring or explosion-proof
conduit, depending upon application
Figure 1: LS500 Install Overview
To maintain optimal line pressure, Franklin Fueling makes the following recommendations for submersible pumps:
• For FE Petro Submersible Pumps, use a Standard Check Valve (part # 400988931).
• For Red Jacket Submersible Pumps, use an adjustable functional element, adjusting the pump OFF pressure to be at
least 2 psi below the pump ON pressure.
Newer style Red Jacket Submersible Pumps do not have an adjustable functional element as an option. These
submersible pumps have a check valve that meets the LS500 pressure requirements.
Note: The TS-LSU500 is a pressure sensing device that can be installed anywhere in the product pipeline where accurate
line pressure can be monitored. When installing in a location other than the mechanical leak detector port, consider the
location of in-line check valves, solenoid valves, or any other equipment that can affect the line pressure being monitored.
If an anti-siphon valve is installed at the discharge of the submersible pump, the TS-LSU500 transducer should be
installed downstream of the valve to insure proper line pressure monitoring.
Site Requirements
Item
Minimum Static Pressure
Value
18 PSI for precision testing
15 PSI for gross leak testing
20 PSI for learning lines
312.2 gallons
95.4 gallons
2.5 gallons
Maximum line volume for rigid pipe
Maximum line volume for flexible pipe
Minimum volume for rigid or flexible pipe
Table 1: Capacity Table
Pipe Diameter I.D.
Both Flex and Rigid Length
Metric
1"
61'
(18.6 m)
1 ½"
27'
(8.2 m)
1 ¾"
20'
(6.0 m)
2"
15'
(4.6 m)
2 ½"
10'
(3.0 m)
3"
7'
(2.1 m)
4"
4'
(1.2 m)
5"
2'
(0.6 m)
Table 2: Pipe Length Required for Holding Minimum Line Volume
1"
1 ½"
1 ¾"
2"
2 ½"
3"
4"
5"
Pipe Diameter I.D.
2339' (713 m) 1040' (317 m) 764' (233 m) 585' (178 m) 374' (114 m) 260' (79 m) 146' (45 m) 94' (29 m)
Flex Length
7656' (2334 m) 3403' (1037 m) 2500' (762 m) 1914' (583 m) 1225' (373 m) 851' (259 m) 479' (146 m) 306' (93 m)
Rigid Length
Table 3: Pipe Length Required for Holding Maximum Line Volume
5
3/4" NPT
2-3/8" (70mm)
across flats
6.25"
(159 mm)
5.13"
(130 mm)
2" NPT
Figure 2: TS-LS500 Dimensions
Transducer Installation
1. Apply UL Classified Gasoline / Oil resistant pipe thread sealant to the threads of the transducer and use a 2 3/8”
open-end wrench to install it in the Leak Detector Port of the STP housing (see Figure 1).
Note: When using TS-LS500 line leak detection in a manifolded line application, you only need to use one transducer
to monitor the entire line. This transducer should be located in the master STP. In-line check valves should NOT
be used as the line leak detection will not be able to test beyond them. Please see the STP manufacture about
appropriate check and / or relief valves.
2. Install Couplings, threaded Rigid Metal Conduit (RMC), and Explosion / Weather Proof Junction Boxes (J-Boxes)
in the STP sumps. For intrinsically safe wiring, run the transducer lead to the junction box. For explosion-proof
installations, run conduit to the top of the transducer.
3. Install threaded RMC and EYS fittings along with Transducer Cables (Belden #9365) from LS500 console to
the Explosion / Weather Proof J-Boxes. A licensed electrician should splice the cables together. If this wiring is
Intrinsically Safe it MUST NOT be run with any Explosion-Proof wiring or other non-Intrinsically safe wiring!
Alpha cable #58411 must be used if using nonmetallic (PVC) conduit as allowed by local code.
Definitions and Acronyms
AIM – 4-20mA Analog Input Module (Intrinsically Safe)
FMS – Fuel Management Systems
IS – Intrinsically Safe
ISD – In-Station Diagnostic
LCD – Liquid Crystal Display
LED – Light Emitting Diode
LLD – Line Leak Detection
6
PC – Personal Computer
PM – Probe Module (Intrinsically Safe)
RM – Relay Module
SCM– Secondary Containment Monitoring
STP – Submersible Turbine Pump
TPI – Turbine Pump Interface
T5 – T5 Series FMS Consoles
(TS-5 / 608, TS-550 EMS, TS-5000 / EXPC / TS-550evo)
TS-EMS – Environmental Monitoring System
TSA – TankSentinel Anywhere
Intrinsically Safe LS500 Installation
Note: The Intrinsically Safe 4-20mA Input Module has a BLUE face.
Warning
Lockout and tag circuit breakers, and disconnect console power wiring before installing or servicing
any system wiring.
Warning
DO NOT make transducer wiring connections with power connected to the console or any module.
Caution
Do not run intrinsically safe (IS) wiring and non-intrinsically safe (non-IS) wiring in the same conduit.
Caution
Do not use explosion-proof transducers (TS-LS500E) with intrinsically safe LS500.
Note: TS-LS500 must be installed in accordance with the national electrical code, ANSI / NFPA 70, CEC or other
applicable national or local codes.
1. Pull the wiring through the intrinsically safe conduits that will be used for the TS-LS500 transducers.
2. Mount the TS-LS500 in the Leak Detector Port of the STP housing. (As outlined in the Transducer Installation
Section above).
3. The TS-LS500 wiring must enter the console in IS conduit through a knockout on the IS side of the barrier. Secure
each pair of transducer wires to a single channel on the 4-20mA Input Module. Always start at the first available
channel and do not skip channels. For example, if channels one through three are already being used for another
application channel 4 must be used. Be sure to connect the wires to the correct polarity (+/-). If the transducer is
wired backwards it will not function.
4-20mA Input
Module
RUN
ERR
(Blue)
Non-Hazardous
Location
Hazardous Location
Class I, Division 1, Group
D, Group IIA, Zone 0
–
+
–
+
–
+
–
+
–
+
LS-500
–
+
- (BLK)
–
+
–
+
+ (RED)
- (BLK)
+ (RED)
Tank Pressure Sensor
Intrinsically Safe Conduit
Figure 3 – 4-20 mA Input Module Wiring
7
Explosion Proof LS500E Installation
Note: The Explosion Proof 4-20mA Input Module has a RED face.
Warning
Lockout and tag circuit breakers, and disconnect console power wiring before installing or servicing
any system wiring.
Warning
DO NOT make transducer wiring connections with power connected to the console or any module.
Caution
Do not run intrinsically safe (IS) wiring and non-intrinsically safe (non-IS) wiring in the same
conduit.
Note: LS500E must be installed in accordance with the national electrical code, ANSI / NFPA 70, CEC or other applicable
national or local codes.
Note: The explosion-proof transducer needs to have explosion-proof conduit to the head of the transducer.
1. Pull the wiring through the explosion proof conduit that will be used for the TS-LS500 transducers.
2. Mount the TS-LS500E in the pump manifold.
3. The TS-LS500E wiring must enter the console in Explosion Proof conduit through a knockout on the Hazardous
side of the barrier. Secure each pair of transducer wires to a single channel on the 4-20mA Input Module. Always
start at the first available channel and do not skip channels. For example, if channels one through three are
already being used for another application channel 4 must be used. Be sure to connect the wires to the correct
polarity (+/-). If the transducer is wired backwards it will not function.
4 - 20mA EXP
INPUT MODULE
RUN
ERR
(Red)
Non-Intrinsically
Safe Side of
Console
Hazardous Location
Class I, Division 1, Group
D, Group IIA, Zone 0
–
+
–
+
–
+
–
+
–
+
LS-500E
–
+
–
+
–
+
- (BLK)
+ (RED)
Explosion-Proof Conduit
Figure 4 – 4-20 mA Input Module Wiring
8
LS-500 Setup (Console Programming)
The following instructions are a guide to programming the LS-500 only. The administrator password will be necessary to
save the programming changes. For instruction on FMS programming, or how to obtain the Administrator access level,
please refer to the T5 Series FMS Programming Guide (p/n 000-2142) or the TS-550 / 5000 evo FMS Programming Guide
(p/n 000-2173).
Access the T5 Series FMS console (via the LCD touch screen or by the web) and navigate to the Setup Menu, Go to each
of the following parameters, shown in the next tables, and set them accordingly per the site. You will be prompted to enter
the Administrator password when it is required.
Note: Site setups vary depending on the products used and other equipment installed. Setup information in the sections
of this chapter depicts a typical site and are meant as examples only.
AC Input Module
One of the functions of the AC input module is to accept incoming dispenser hook signals. The hook signal tells the
console which product the dispenser is requesting, then turns the appropriate Submersible Turbine Pump (STP) on using
either a relay (from the relay board or from the power supply board) or the turbine pump interface (TPI). The LS500 is
constantly monitoring the pressure on the line, and testing accordingly. To perform tests properly, the LS500 needs to
know when the pumps are being used by other applications.
Parameter
Number of Gasoline Hooks
per Dispenser
Parameter value
The number of product hook signal inputs to the console from each dispenser.
Channels
Select the number of inputs in use.
Name
Text box, name each channel to easily identify in the mapping.
Enabled
Select YES. This will allow the channel to be mapped to another module. Other modules
need this signal to trigger events.
Active State
Select HIGH. A high signal level will activate the channel and a low signal will deactivate
the channel. If set to LOW, then the channel is inverted and will only become active when
a signal is absent and inactive when a signal is present.
Action
Select NONE
Example: AC Input Module FMS Setup
Group Name
AC Input Modules
 
Module 1
 
Channel 1
Parameter Name
Parameter Value
Number Gasoline Hooks per Dispenser 2
Channels 3
Name Disp 1 Unleaded Hook Signal
Enabled Yes
Active State High
Action None
Channel 2
Name Disp 2 Unleaded Hook Signal
Enabled Yes
Active State High
Action None
Channel 3
Name Disp 3 Unleaded Hook Signal
Enabled Yes
Active State High
Action none
9
4-20mA Input Module
TS-LSU500 Transducers use a single 4-20mA channel per product line which allows the console to monitor the pressure
on each product line.
Parameter
Parameter Value
Channels
Select the number of channels used for LLD.
Name
Text box, name each channel to easily identify in the mapping.
Service Type
Select Line Leak Detection. This indicates that the type of device connected to the channel to indicate that the
device is a TS-LS500 transducer.
Example: 4-20mA Input Module LS-500 Setup
Group Name
4-20mA Input Modules
Module 1
 
10
 
Channel 1
Parameter Name
 
Parameter Value
 
Channels 1
Name Unleaded Transducer
Service Type Line Leak Detection
Relay Module
The 2A relay module contains 8 separate relays (relay channels). The 10A relay module contains 6 relay channels. Each
relay is used by the console to turn a specific STP on or off in applications where Turbine Pump Interface (TPI) is not used.
Parameter
Parameter Value
10 Amp
Select either yes or no depending upon which type of relay module is used
Channels
Select the number of channels that will be used
Name
Text box, name each channel to easily identify in the mapping
Enabled
Select Yes
Type
Submersible Pump
Polarity
Normal
Logic
OR logic
Physically Wired As
Normally Open
Number of Inputs*
1 for transducer plus number of AC inputs for this product, plus any other inputs to operate the submersible pump
Type
Module type that the input is on
Channel
Specific channel the input is wired to.
* Calculate the total number of inputs that need to turn on the STP:
1 transducer
+ Number of AC inputs for the specific line
+ Any other inputs to operate the STP
= Total number of inputs
Example: Relay Module Setup for STP Control
Group Name
Relay Modules
 
Module 1
 
Channel 1
Parameter Name
 
Parameter Value
 
Channels 1
Name Unleaded STP
Enabled Yes
Type Submersible Pump
Polarity Normal
Logic OR Logic
Physically Wired As Normally Open
Number of inputs 4
 
Input 1
Type 4-20mA Input Module
Channel Unleaded Transducer
 
Input 2
 
Input 3
Type AC Input Module
Channel Dispenser 1 Unleaded Hook Signal
Type AC Input Module
Channel Dispenser 2 Unleaded Hook Signal
Input 4
Type AC Input Module
Channel Dispenser 3 Unleaded Hook Signal
11
Turbine Pump Interface (TPI) Applications
In systems where TPI is used, the relays are not needed for line leak or STP operation. Communication with the FFS
smart controllers is done exclusively by the RS-485 connection. Refer to the Programming Manual for full TPI instructions.
Example: TPI Setup
Group Name
Parameter Name
Parameter Value
Power Supply
RS-485
Enable Interface Yes
TS-TPI
Enable Interface Yes
Controllers
A
Controller 1
Number of Controllers 3
Name Unleaded Controller
Enabled Yes
Type Mag/Eco
Address 1
Group 0
Tank 1
Height 5.00 in
* Number of inputs 4
Input 1
Type 4-20 mA Input Module
Channel Unleaded Transducer
Input 2
Type AC Input Module
Channel Dispenser 1 Unleaded Hook Signal
Input 3
Type AC Input Module
Channel Dispenser 2 Unleaded Hook Signal
Input 4
Type AC Input Module
Channel Dispenser 3 Unleaded Hook Signal
* Calculate the total number of inputs that need to turn on the STP:
1 transducer
+ Number of AC inputs for the specific line
+ Any other inputs to operate the STP
= Total number of inputs
Note: Height is the estimated distance from PMA bottom to tank bottom. This distance is used for empty tank and high
water conditions.
12
Fuel Management Systems (FMS) Line Application Set-Up
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 (see page 5). If the pressure is too low, review the check-valve used, and adjust the pump / pump controller for
proper pressure.
Parameter
Parameter Value
Number of lines
Number of product lines
Name
Text box, name each channel to easily identify in the mapping.
Submersible Pump Module
Select either power supply module or relay module depending upon which relay is being used for
pump control, or if TPI is being used. If Power Supply Board is selected and a relay from this power
supply board was associated to a pump, an additional option will show up to indicate if TPI or relay
will be used.
Submersible Pump Channel
Select the channel that the submersible controller is connected to.
Transducer
Select the transducer installed in the line.
Enable SLLD
Select Yes
Product
Enter Product name (grade)
Enable
Select yes
Pressure Up Test Wait Time *
Default is 4 Seconds. This is the time that the gauge waits for the line to pressure up above 12 PSI.
Catch Pressure Wait Time *
Default is 2 seconds. This is the time the gauge waits after the pump turns off to make sure the
pressure is at least 12 PSI.
Dispenser Pressure Test
When selected, this gauge monitors the line pressure while dispensing. If the pressure decreases to
7.5 PSI, the line goes into alarm mode. The pump shuts off and is disabled.
Gross / Monthly / Annual Tests
Enable
Select Yes. This allows the LS500 to run the tests.
Wait Period Between Tests
Default setting is 0 days. (This is the scheduling for line test after the test passed).
Shutdown on Test Fail
If selected, this will shut down the submersible if that line fails that type of test
* These settings typically will not need to be changed. Contact FFS tech support before changing these settings.
Example: LS500 Application Setup
Group Name
Lines
Line 1
Parameter Name
Parameter Value
Number of lines 3
Name Unleaded Line
Submersible Pump Module Relay Module
Submersible Pump Channel Unleaded STP
Transducer Unleaded Transducer
Enable SLLD Yes
Product Unleaded
Enabled Yes
Pressure Up Test Wait Time 4 Sec
Catch pressure Wait Time 2 Sec
Dispenser Pressure Test Yes
Gross Tests
Enable Yes
Monthly Tests
Enable yes
Wait Period Between Passed Tests 0 Days
Shutdown on Failed Test
Enable Yes
Annual Tests
 
Wait Period Between Passed Tests 0 Days
Shutdown on Failed Test
Note: Do not enable the line in set-up until the transducers have been properly connected to the 4-20 Input Module.
13
Line Status and Control Screens
The status of each line channel can be viewed at any time by navigating to the Line Status or Control screens. To get to
the Line Status or Control screens, go to FMS > Status > Lines or FMS > Control > Lines.
LS500 Status Screen
The status of each line can be viewed at any time by navigating to the line status or control screens.
Status and alarm Indicators
Description
Status
Indicates the condition of the line
Line Pressure
Indicates the current line pressure
Enabled
Green, enabled. Red, disabled
Not Learned
Red, if not learned. Gray, if learned
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. Gray, if not running test
Between Test
Green, if running test. Gray, if not running test
Waiting out Thermal
Green, if waiting out thermal, Gray, if not
Transducer Failure
Red, if the LS-500 is not communicating with the transducer
Pump On
Green, if the STP is on
Pump Request
The LS-500 is attempting to turn the STP on
When viewing the Line Status Summary screen, remember to enable Auto Refresh. The Auto Refresh button will allow the
on-screen results to be automatically updated.
The Line Control screen will automatically update line information. Administrator privileges will be necessary to use the Line
Control screen. For instructions on FMS programming or on how to obtain an Administrator access level, please refer to the
T5 Series FMS Programming Guide (p / n 000-2142) or the TS-550 / 5000 evo FMS Programming Guide (p/n 000-2173).
14
LS500 Control Screen
Status Section
Indicator
Description
Line Pressure
Indicates the current line pressure
Enabled
Green, enabled. Red, disabled
Not Learned
Red, if not learned. Gray, if learned
Pump On
Green, if the STP is on
Alarm
Red, if in alarm. Gray, if not in alarm
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 Section
Indicator
Description
Start/Stop
Manually start or stop the learn cycle
Learn Message
Indicates the status of the learn process
Learn Mode Active
Green: The line is being learned
Learn Mode Error
Red: An error has been detected in learning the line
15
Pre-Operational LS500 Testing
The line stability test procedure assumes that all STP’s, pump controllers, and AC inputs have been installed,
wired, calibrated and are operational and in accordance with their respective installation and operation
procedures. It also assumes that all T5 Series FMS console programming has been completed accurately.
Caution
DO NOT proceed to the Learn Process until each line successfully completes pre-operational
testing. Failure to perform this test or ignoring any failed tests may prevent the FMS application
from detecting a line leak.
Note: State and / or local laws may require a separate, more stringent manual line tightness test.
Before installing the LS500, ALWAYS verify and comply with local regulations.
Note: The STP connected to the line being tested will need to be activated by lifting the appropriate product dispenser
handle. Verify that all STP’s and pump controllers are installed, calibrated and operational.
Note: The lines must be able to reach 20 PSI. If the lines cannot reach 20 PSI, the issue needs to be resolved or the
LS500 will not work in that STP.
Required Equipment
• LS500 3.0 GPH Leak Generator Kit (TSP-ALCAL)
• Needle Valve Kit (TS-ALNIP)
• Pressure gauge
• Approved safety container
ATTENTION
.
The Needle Valve Kit (TS-ALNIP) included with this kit is NOT compatible with E85 and other fuels
containing high levels of Ethanol / Alcohol.
For E85 and other high Ethanol / Alcohol mixture applications the Alternative Fuels Needle Valve Kit
(TS-AFALNIP) should be ordered separately.
All other regularly wetted components are E85 compatible.
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. Pressurize the line by lifting
the dispenser handle without dispensing fuel.
2. Once the line is pressurized, turn the STP off and monitor the pressure on the pressure gauge. The pressure
should not change more than 5 PSI (34.5 Kpa) in 5 minutes.
3. If the pressure does change, pressurize the line again by lifting the dispenser handle (do not dispense), and check
again.
4. If it does not change more than 5 PSI in 5 minutes proceed to the learn process. If the pressure changes more
than 5 PSI pressurize the lines again, and re-test.
Purging the line
If air is in the system, the lines must be purged of the air. If needed, this procedure should be done before the Line
Stability Test or Learning the line.
Purge the line by dispensing from each fueling point starting with the dispenser furthest from the tank. The STP should be
running the full time that the line is purged.
16
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 (TSALCAL). 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.
Note: All console programming must be completed prior to the learn process. Refer to the Setup (Console Programming)
chapter in this manual for details. Administrator privileges are necessary to Learn Lines. Refer to T5 Series
FMS Programming Guide (p / n 000-2142) or the TS-550 / 5000 evo FMS Programming Guide (p/n 000-2173). for
information on gaining Administrator privileges.
Note: Complete the Pre-Operation Line Testing chapter prior to starting the Learn Process.
Note: No dispensing can take place during the Learn Process. If product is dispensed while Learning, stop the process
by pressing the Stop button.
Note: DO NOT submerse or block the TS-ALCAL orifice while learning the line. The orifice MUST be kept free of dirt and
debris.
When to Learn / Re-Learn
• Line installation and start-up
• After repairs or modifications that effect the operating or holding pressure of the line
• After 4-20mA Input Module replacement
• After certain 4-20mA Input Module firmware upgrades (consult FFS Technical Services Department)
• If moving the LS-500 to another 4-20mA channel
TS-ALCAL
TS-ALNIP
Place a container to
catch the product
Figure 4 – Leak Generator Kits
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. Let the line
pressure bleed down to 0. Make sure that the pressure reads 0 on the pressure gauge installed on the needle
valve kit.
3. Navigate to the line control screen on either the touch screen or by the web page. Locate the learn section and
press start.
4. If the learn process is performed correctly the screen will show the events in the following sequence,
• Learning zero offset
• The system turns on the STP to learn pump pressure
• Learn the pressure decay curve
17
5. When finished, the message Learn Completed – No Errors is displayed on-screen and the Not Learned indicator
will become inactive.
Note: Each line is different, but if the pump takes an excessively long time to bleed down to 0 PSI, then there may be air
in the system. Re-purge the line and if air remains, look for pathways that air could have been introduced.
Note: If any errors are encountered at any time during the Learn Process, the screen will display the applicable error
message and the Not Learned indicator will remain active. Refer to the Alarms chapter of this guide for information
on troubleshooting any errors that are displayed.
6. Once the line has been successfully learned, the line will automatically be enabled. Leave the leak generator
open. The console will automatically begin a gross leak test. If the line was learned properly it will detect the
leak and positive shutdown will occur after the 2nd failed 3 GPM test (Approximately 10 minutes). The console’s
screen updates will indicate if the line is failing a gross test.
7. Close the needle valve. To clear the alarm, navigate to the line control screen and choose reset alarm. The console
will ask: Do you also want to enable this line? Select OK. (If you select CANCEL the line will not be enabled) This
will automatically start another gross line test. A 3 gph pass will allow the FMS to continue to monitor the line. If this
test fails, isolate why the test failed, make necessary repairs, and then reset the alarm again.
8. Remove the leak generator and replace the leak generator plug. The needle valve kit should be left installed in the
manifold to easily allow functional testing, and re-learning lines if needed.
Learn Messages
Learn Message
Learning 0 offset
Description
Displayed when the console is calibrating 0
Excessive Offset or
Unstable Pressure
Pressure is unstable
Learning pump pressure
Displayed when the console is learning the operating pressure
Insufficient pressure
STP is not operating at a high enough pressure
No pressure loss
Console does not detect a leak
Insufficient volume (line too
small)
Console detects a pressure drop that is too great
Learning pressure decay
curve
Displayed during the learn process to indicate that the calibrated leak decay curve is
being recorded
Modulus out of range
Console detects a pressure drop that is too small
Learned
The line has been learned
18
LS-500 Reports
Line test reports are available on demand from the console or using the web page. The reports can also be generated by
using the rules engine.
Several report options are available to print or save generated reports. For more information on reports in general, please
refer to either the T5 Series Programming Manual (p / n 000-2142) or the T5 Series Operator’s Guide (p / n 000-2151) or
the TS-550 / 5000 evo FMS Programming Guide (p/n 000-2173).
LS-500 Line Leak Reports
LS-500 Line Leak Reports include any line tests completed within the date range chosen by the user. An example of an
LS-500 report can be found below.
Alarms
When a T5 FMS console is in alarm, the Alarm LED on the front of the console 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. If the condition still exists after reset, the alarm will return. A service
visit may be required to identify and correct the condition.
Warning
Always REMOVE POWER from the console prior to installing/removing a module or performing any
maintenance while the console door is open.
Note: Refer to the Important Safety Messages outlined in the beginning of this manual before performing any console
maintenance.
Note: If this guide is not able to help you correct a Warning or Alarm, please contact FFS Technical Services
(1-800-984-6266).
19
LS-500 Alarms and Warnings
Alarms During the Learn Process
Alarm
Symptom
Failed to pressure up STP is not turning on
Possible Cause
Resolution
Verify that the 4-20 transducer is
a relay / TPI input
Check the programming
Is the pump controller powered
on?
Check the controller
If controlled by a relay, is the
Test the voltage on the relay
common of the relay wired to 110 common
Volts?
Is another STP turning on?
Check the other STPs
Is the 4-20 transducer in alarm?
Check alarms
Is the wrong transducer
mapped?
Check programming
Is the clamp valve down?
Look at the pressure gauge on
the needle valve kit for operating
pressure
Line is not
configured
Program mapping error
Verify programming
Program error
detected
Console software error
Reboot console
Air in line
Console has sensed line
pressure variations
Investigate, then Purge Line Starting
at the Furthest Dispenser
Not learned
Learn Line (FMS > Control
> Lines > Learn) follow learn
procedures
Follow learn procedures
Insufficient volume
Line is too small
Leak generator not correct
Air in the line
Check line size
Review leak generator set-up
Purge air from the line
STP is turning on, but
the LS500 doesn’t see
the pressure change
Alarms During Operation
Alarm
Failed to pressure
up
Symptom
Resolution
Pressure was less
that 12 psi after
programmed delay
when STP turned on
Clogged STP intake
Investigate, force a manual test
and observe pressure
STP is not turning on
Verify that the transducer is
programmed as an input for the
relay / TPI.
Check the programming
Is the pump controller powered
on
Check the controller
If controlled by a relay, is the
common of the relay wired to
110 V
Test the voltage on the relay
common
Is another STP turning on?
Check the other STPs
Is the 4-20 transducer in alarm?
Check alarms
Is the wrong transducer mapped
Check programming
STP is turning on, but
the LS500 doesn’t see
the pressure change
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Possible Cause
Operating Alarms (Continued)
Test Result
Failed to catch
pressure
Sudden Pressure
Loss
Catastrophic leak
Investigate for leaks
Is the clamp valve down
Look at the pressure gauge on
the needle valve kit for operating
pressure
Condition
Pressure was less
that 12 psi after
programmed delay
when STP turned off
Pressure dropped to
less than 5 psi
Possible Cause
Resolution
Check valve damaged
Investigate, force a manual test
and observe pressure
Dispenser solenoid is still open
after hook signal is off
Dispense, release hook, keep
nozzle open
Catastrophic leak
Investigate for a catastrophic leak
such as a pipe breaking
Catastrophic leak
Monitor line pressure using a
pressure gauge, investigate for
leaks
Dispensing Pressure Pressure dropped to
Test Failed
less than 7.5 psi while
dispensing
Monitor line pressure using a
pressure gauge, investigate for
leaks
High Pump Pressure Pressure was above
50 psi during the catch
pressure test 3 times
consecutively
Monitor line pressure using a
pressure gauge, investigate for
faulty check valve
Extended Hook
Signal
Hook signal was applied Dispenser hook signal on steady Verify that all handles are down,
for more than 4 hours
test AC inputs to determine which
is giving a signal
Pressure Transducer Communication failure
Fail
to transducer
Wiring
Check wiring connections at the
console, junction box and quick
disconnect.
Transducer failure
Direct connect, if still in alarm,
replace.
Air in line
Console has Sensed
Line left open or air elimination
Line Pressure Variations loop failing
Investigate, then Purge Line
Starting at the Furthest Dispenser
Not Enabled
Line disabled
Either manually, or by another
application shut the STP down
Check other alarms, find source of
interruption
Marginal Pass of
Gross Leak Test
Passing result of gross
test, but marginally
Line is not thermally stable
Force a gross leak test
Pump Request
Ignored
STP did not turn on
when requested
Controller not functioning
System is busy
TPI problem
Check RS485 communication
STP is disabled by another
application
4-20 mA Input error
Module is Offline
Contact Technical Support
Communication failure
between the control
module and the module
offline
Look at module LEDs
Red, replace module.
Green solid or flashing, power
down the console and re-seat the
module
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Test Result Alarms
Test Result
Condition
Possible Cause
Resolution
Pass
Line is tight
Fail
Actual Leak
Line pressure variations are outside
threshold
Check for leaks, force leak test
to verify
Temperature Instability
Temperature fluctuations cause
pressure variances
Check for leaks, force leak test
to verify
Inadequate learning
Line not properly bled to zero during Re-learn the line, follow
learning
procedures
Abort (no
indication)
STP Shutdown
Air was not bled out of the line prior
to learning
Purge the line, re-learn
Air in line
Line left open or air elimination loop
failing
Purge the line
Dispensing
A hook signal was detected, this
resets the testing
Allow test cycle to complete
before dispensing
Line disabled
Either manually, or by another
application shut the STP down
Check other alarms, find source
of interruption
Manual test started
User forced a line leak test
Cycle resets after manual test
completes
2 consecutive 3 GPH test
failures
Possible gross leak
Investigate, then Force a
Manual Gross Test
1-2 consecutive 0.2 GPH
test fails (depending on
programming)
Possible 0.2 GPH leak
Investigate, then Force a
Manual Monthly Test
1-3 consecutive 0.1 GPH
test fails (depending on
programming)
Possible 0.1 GPH leak
Investigate, then Force a
Manual Annual Test
3 consecutive catch pressure High line pressure
tests that over 50 psi
Investigate, adjust or replace
check valve or functional
element
Catch pressure test failure
Pressure was less that 12 psi after
programmed delay when STP
turned off
Investigate, force a manual test
and observe pressure
Pressure up test failure
Pressure was less that 12 psi after
programmed delay when STP
turned on
Investigate, force a manual test
and observe pressure
Clearing Alarms
Clearing a console of alarms is important because, depending on how the T5 Series FMS console has been set up,
alarms can: disable channels, start an annunciator, or stop a line test under way.
Administrator privileges will be necessary to clear line alarms on the T5 Series FMS console. For instructions on how to
obtain an Administrator access level, please refer to the T5 Series FMS Programming Guide (p/n 000-2142) or the
TS-550 / 5000 evo FMS Programming Guide (p/n 000-2173).
1. Identify the alarm on the FMS Alarms screen.
2. Diagnose the condition using information found in the Alarms chapter of this guide.
3. Follow the troubleshooting steps in the previous section of this chapter to correct the issues indicated by the alarms.
4. Navigate to the Line Control screen.
5.Select Reset Alarms on the Control screen.
6.Select Enable/Disable on the Control screen if you were not given the choice to enable the line when the alarms were
reset.
If the condition still exists, the alarm can take up to several hours to reappear after the line is enabled.
22
LS-500 Functional Testing
Perform a Functional Test annually. This test will verify that the LS-500 application will detect and alarm on a leak
condition. This test should be performed during times when there is no dispensing.
1. If the channel is Enabled, disable the channel. At the T5 Series FMS console (via LCD or by the web page), navigate
to the FMS > Lines Control screen. Press the Enable / Disable button to disable the line.
2. Remove the plug in the needle valve kit on the manifold. Connect the TS-ALCAL (Leak Generator Kit) to this port.
3. Open the needle valve.
4. Enable the line. This will initiate a gross line test.
5. Verify that the console displays a gross line test fail. This can take up to 10 minutes.
Note: The system must run two separate tests five minutes apart and fail them both before a hard alarm occurs.
6. The channel will be disabled by the FMS application. Remove the TS-ALCAL. Replace and tighten the plug.
7. At the T5 Series FMS console (via LCD or by the web page), navigate to the FMS Lines Control screen. Press the
Reset Alarm button to clear the alarm and enable the channel.
8. Select OK when prompted.
9. If the Annual Functional Test passed by properly detecting the leak, please skip this step. If the system did not catch
the leak and the test failed, disable the channel and run the pre-operational tests. Perform the functional test again. If
the system still fails to detect the leak, please contact FFS Technical Support (1-800-984-6266).
Enabling/Disabling Lines
After learning the line(s), each line will need to be enabled to allow monitoring. The Line Status reflects the current status.
Enabling Lines
At the T5 Series FMS console (LCD or by the web page), navigate to the FMS Control screen. Press the Enable / Disable
button to enable the line.
Only while the line is enabled will it continuously monitor and test pressure levels by activating the STP as necessary.
Disabling Line Channels
At the T5 Series FMS console (LCD or by the web page), navigate to the FMS>Lines Control screen. Press the
Enable / Disable button to disable the line.
Important: While the line is Disabled, FMS will neither maintain nor test line pressure levels.
If alarms or errors occur, please refer to the Alarms chapter of this guide.
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Control Drawing
24
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©2014 FFS 000-2145 Rev.H