STP-SCIIIC - Installation and Owners Manual

STP-SCIIIC - Installation and Owners Manual
3 PHASE SMART CONTROLLER
STP-SCIIIC
STP-SCIIIC 380-415 VAC, 50Hz, 240 Volt Coil
Installation
and
Owner’s Manual
Franklin Fueling • 3760 Marsh Rd. • Madison WI 53718 USA
Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
Important Safety Messages
FE Petro equipment is designed to be used to pump 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 are
present. This presents a risk of severe injury or death if these instructions and standard industry practices are
not followed. Read and follow this entire instruction booklet before installing or working on this equipment.
As you read these instructions, watch for the following safety symbols:
Warning
This symbol identifies a potentially hazardous situation which, if the instructions that follow it are not
adhered to, could result in death or serious bodily injury.
Caution
This symbol identifies a potentially hazardous situation which, if the instructions that follow it are not
adhered to, could result in serious property damage, including possible environmental contamination as a
result of the leakage of fuel from the equipment.
Warning
Warning
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 disconnect both power supplies (240V Hook and the 415 input) before installing or
servicing. Be sure to use proper lock and tag out techniques to ensure no power is applied
accidentally. Failure to do so could result in severe injury or death.
Installer: This instruction booklet MUST be left with the owner of the service station at which the equipment is being
installed.
Station Owner: Retain these instructions for future use and provide them to persons servicing or removing this
equipment.
2
STP-SCIIIC: For 240 Volt hook signal; 380-415 Volt, 3 phase, 50Hz ¾ , 1 ½ , 3 and 5 Horsepower pumps.
INSTALLATION INSTRUCTIONS
1. Install STP per applicable Installation and Owner’s Manual.
2. Remove cover of STP-SCIIIC and mount base to wall or other surface.
3. Connect input power of 380-415V for STP-SCIIIC to L1, L2, L3 and Ground wire to terminals (see Figure 2). On High
Capacity Pumps (3HP & 5HP) there is no need to connect the Thermal Overload wires (blue) coming from the pump
as long as an STP-SCIIIC is being used and is calibrated properly.
4. Connect dispenser hook signal or other equipment to terminals, 240V supply and return for STP-SCIIIC.
5. Using an ohmmeter, confirm M1, M2 & M3 have continuity to pump. Also, make sure M1 to Ground, M2 to Ground,
and M3 to Ground are not shorted.
6. Connect motor leads to M1, M2 and M3, and Ground wire to terminals.
7. Set SW1 Poles 4 and 5 for the motor Horsepower rating (see Table 3).
8. For Stand Alone installation, set (SW1) poles 1-3 per Table 2 (Factory Set). If installed as Master-Slave and/or
Alternating Circuit go to “Master-Slave/Alternating Circuit” section.
9. Attach cover of controller to base. Then go to “Calibration” section to complete installation.
Warning
Always replace the cover of the STP-SCIIIC before applying power. Failure to do so could result in
severe injury or death.
CALIBRATION
Note:
It is recommended to calibrate all manifolded Master and Slave controllers at the same time.
1. Turn on power supply to the STP-SCIIIC. The green light indicator will come on steady, the red light indicator will flash
8 times and an audible alarm will sound, thus indicating the controller is Uncalibrated.
Note:
The audible alarm will sound each time the red light indicator flashes. During the calibration process, do not
silence the alarm. Once the calibration process has been completed, an alarm can be silenced when an abnormal
condition is present by briefly depressing the push button. See “Troubleshooting Guide” for details.
2. Press and hold the push button on the bottom of the box until all three light indicators blink alternately. This will take
approximately 10 seconds. At this point the push-button should be released.
3. The handle on the dispenser should then be lifted to turn the pump on (for more than 16 seconds). After 16 seconds
the controller will take a “snapshot” of the voltage, current and power. The three lights will quit alternating and only the
green light should remain flashing. This will indicate the calibration has been completed and the dispenser handle can
then be turned off. If the controller(s) will not calibrate, see the “Troubleshooting Guide” section.
Calibration Tips:
The “snapshot” values will be used as the nominal values. The calibration process will be aborted if not completed within
10 minutes or if the push button is depressed during calibration. The calibration must be done at zero flow. If an
electronic line leak detector is being used, it is important that the STP-SCIIIC be in the calibration mode (all three lights
flashing alternately) before the dispenser handle is turned on. Otherwise, the STP-SCIIIC will not turn on and the line leak
detector will likely detect a fault. If the line leak detector shows a fault, it will not provide a dispenser hook signal to the
STP-SCIIIC and it will not be possible to calibrate the STP-SCIIIC until the line leak detector is reset.
Note:
All STP-SCIIICs must be calibrated prior to operation.
Note:
All three indicator lights will flash alternately in calibration mode.
Note:
When calibrating system and dispensers that are blenders, both STP-SCIIICs must be calibrated simultaneously
by selecting the mid-grade at the dispenser.
Note:
The calibration data is retained in non-volatile memory (i.e. it is saved in the event of power loss to the controller).
3
MASTER-SLAVE/ALTERNATING CIRCUIT
Note:
RS 485 Connection is only required if Master-Slave or Alternating Circuit operation is desired.
Note:
Be sure L1, L2, L3; M1, M2, M3 and Grounds are installed at each STP-SCIIIC.
The Master-Slave feature allows the master to turn on additional STP’s when the first STP operating needs help due to
loading (flow rate) or an abnormal condition exists. The Alternating Circuit (AC) feature continuously alternates the lead
pump, thus turning on a different STP each time all dispensers are shut off and at least one dispenser is turned back on.
1. (Fig. 2) Connect RS 485 (+, G, & –) to terminals. Connect drain wire of shielded cable to Ground (G) at one end only.
Wire per NFPA 30A and NFPA 70. For the signal wires, use 18 AWG 3 conductor cable (300V min.), with conductors
twisted and within a common jacket. Cut wires to length so that there is no excess wire touching circuit board
components.
2. (Fig. 2) Connect hook between STP-SCIIIC’s.
3. Set Master-Slave and Alternating Circuit features on (SW1) poles 1-3 per Table 2.
4. Set (SW1) poles 6-8 per “Table 1”. The address must be set for each STP-SCIIIC.
5. Attach cover of controller to base. Then go to “Calibration” section to complete installation.
Warning
Note:
Always replace the cover of the STP-SCIIIC before applying power. Failure to do so could result in
severe injury or death.
There can only be one Master in a system and up to 7 slaves.
SW1-Pole 1 in the ON position = selected
Figure 1
4
Figure 2
Address Selection
Address
Master-0
Slave-1
Slave-2
Slave-3
Slave-4
Slave-5
Slave-6
Slave-7
Pos-7
Off
Off
On
On
Off
Off
On
On
Table 1
5
Pos-8
Off
On
Off
On
Off
On
Off
On
Pole
Stand
Alone
**Master-Slave
Only
1
On
2
Off
3
Off
4-5
See Table 3
See Table 3
See Table 3
See Table 3
6
See Table 4
See Table 4
See Table 4
See Table 4
Master
Off
Master
On
Master
Off
**Master-Slave/AC
Slave(s)
Off
Slave(s)
Off
Slave(s)
Off
Master
Off
Master
On
Master
On
Slave(s)
Off
Slave(s)
Off
Slave(s)
Off
**AC
Only
Master
Off
Master
Off
Master
On
Slave(s)
Off
Slave(s)
Off
Slave(s)
Off
7-8
N/A
See Table 1
See Table 1
See Table 1
**See “Master-Slave/Alternating Circuit” section for definition, AC= Alternating Circuit
Table 2
Motor Horsepower Rating Selection Table
Motor Horsepower Rating
¾ HP
1.5 HP
3 HP
5 HP
Pole 4
Off
Off
On
On
Pole 5
Off
On
Off
On
Table 3
Fault Readout Selection Table
Pole 6 Setting
Off
On
Description
Normal Operation
Displays the last 5 abnormal conditions the controller
encountered. With this mode selected, the controller
will display the last 5 abnormal conditions it
encountered. The controller will beep once and then
the red LED will flash the most recent abnormal
condition. It will then beep twice and the red LED will
flash the second to last abnormal condition. The
controller will follow this sequence through 5 beeps and
then repeat the sequence. It will continue to repeat the
sequence while in this mode. If there is less then 5
abnormal conditions the controller will continue the
beep sequence but the red LED will not flash after the
beep.
Table 4
6
WIRING DIAGRAM 1
7
TROUBLESHOOTING GUIDE
To aid field service personnel the STP-SCIIIC is equipped with a microprocessor control that makes it possible for the unit
to diagnose abnormal operating conditions, and communicate them via the LEDs and an audible alarm. The following is a
definition of all operation and abnormal operating codes.
RESETTING THE CONTROLLER
To reset the controller from an abnormal condition depress the push-button (reset button) on the bottom of the control box
and hold it in until the lights on the front panel go out (approximately 3 seconds).
DISABLING THE AUDIBLE ALARM
To disable the audible alarm, depress and release the push button. Note: This only stops the audible alarm and does not
clear the fault code.
Warning
1.
2.
Always disconnect all power sources to the STP-SCIIIC prior to removing the cover and replace
cover prior to applying power. Failure to do so could result is serious injury or death.
Green light on steady - Power (380-415V) is applied to the STP-SCIIIC.
Green light flashing - Pump Motor Assembly (PMA) is running.
Note: If the green light stays steady, even when a dispenser is energized, double check dispensers signal terminal on
STP-SCIIIC. Verify there is 240V for the STP-SCIIIC between the two terminals for the hook (See Wiring Diagram, p.7). If
the green light remains steady, power is supplied to the “HOOK” connector, and all switch settings are correct, call FE
Petro Technical Service for assistance.
Note: If the green light constantly flashes, even when all the dispensers are turned off, there may be some power still
applied to the STP-SCIIIC Hook Connector. If this condition exists call FE Petro Technical Service for assistance.
3.
4.
No lights illuminated – Verify L1 and L3 are properly connected to the L1 and L3 terminals on the STP-SCIIIC
Red light flashing/Audible alarm - Abnormal condition, see below:
Flashes/Beeps
1
2
Condition
Dry Run
(Under-load)
Potential Causes
Low fuel level in
the storage tank or
obstruction to
motor intake.
Under Voltage
Voltage
fluctuations or low
input voltage.
Proposed Action
1. Check fuel level in storage tank; schedule fuel
delivery, when delivery is complete and fuel level is
above PMA end bell, depress and hold in push
button until all lights go out (approximately 3
seconds).
2. If fuel levels are within an acceptable range, check
motor for an obstruction such as a rag.
3. If condition is still present, verify the switch settings
for motor horsepower rating are correct. If they are
not correct, change them and recalibrate the
controller.
1. Push reset button and hold in for three seconds.
2. If condition is corrected, check for proper operation
of system; if operating correctly do not continue to
next step. If condition is still present continue to
next step.
3. Disconnect Input Voltage at the load center.
Remove cover from enclosure. Re-apply input
power. Use AC voltmeter to verify incoming voltage
is within the 190-250VAC for STP-SCIII or 340-420
VAC for STP-SCIIIC acceptable range. If voltage is
not within this range, contact an electrician to
correct problem. If voltage is within acceptable
range and you still get “Under Voltage” condition
after reset, recalibrate controller per “Calibration”
section.
8
Flashes/Beeps
3
(Continued on
next page)
Condition
Locked
Rotor/Overload
Potential Causes
Foreign material in
PMA or rotor
within motor is
locked up.
Proposed Action
1. Push reset button and hold in for three seconds.
2. If condition is corrected, check for proper operation
of system; if operating correctly do not continue to
next step. If condition is still present continue to
next step.
PMA Replacement/Inspection for 3/4 & 1.5 hp
pumps
3. Disconnect input voltage at load center, lock and
tag circuit breakers.
4. (See PMA Replacement Instructions P/N
400289002) Disengage the 3/4” securing bolt of the
electrical connector and swing out of the way.
Remove two 9/16” bolts from extractable portion of
the manifold.
5. Pull extractable part of the pump.
Note: Pump Motor Assembly shell can be damaged
by blows from hard surfaces, use care in
removing.
6. Remove black end cap from PMA and attempt to
spin rotor with a ¼” Allen wrench to determine if
there’s any binding. If rotor does not spin freely
and/or there is physical damage (note this on a
warranty claim form for FE Petro use), proceed with
the next step. If no binding or physical damage to
PMA, and it is a new installation, reinstall
extractable.
Note: PMA can have a locked rotor during startups if
it has been exposed to a corrosive
environment, such as a ballasted tank.
Turn on power to the STP-SCIII unit and verify
correct system operation. If condition is corrected, do
not continue to next step. If condition is still present,
remove the extractable (repeat steps 3, 4, & 5) and
continue to next step.
7. Remove four 5/16” cap screws that connect the
PMA and remove the PMA from the motor
discharge head.
Note: Prior to mounting a new PMA, check lead
assembly (wires inside the extractable portion
to PMA) for shorted wires which may have
caused the condition.
8. Replace with new PMA.
Note: Pump motor shell can be damaged by blows
from hard surfaces, use care in replacing.
9. Re-install extractable and secure by following
reverse order of disassembly.
10. Turn on power to the STP-SCIII unit and verify
correct system operation.
PMA replacement/inspection for 3 & 5 hp pumps
1. Disconnect input voltage at load center. Lock and
tag circuit breakers.
2. Pull extractable portion of the pump.
3. Remove 4 socket head cap screws and 4 lock
washers securing PMA to STP.
4. Place 2 push rods and 2 headless set screws
(furnished with replacement PMA) in holes opposite
each other.
5. Turn set screws clockwise until pressure is felt,
then alternately turn each screw until PMA is free of
connector housing.
6. Install 2 new O rings and 4 rubber washers. Attach
9
Flashes/Beeps
Condition
Potential Causes
4
Open Circuit
Or
Locked Rotor
W/Thermal
Overload Open
Or
Relay Fault
Connection broken
from STP-SCIII to
PMA or Relay
Failure
8
Uncalibrated
New Installation
9
Extended Run
Continuous Hook
Signal applied for
more than 60 min.
without pumping
product
3
Continued
Proposed Action
new PMA with 4 socket head cap screws and 4
lock washers; draw the PMA tight to the connector
housing with screws.
Key on lead assembly plug
Caution
connector must line up into keyway
of connector housing for proper
mating of PMA receptacle.
1. Wait 5 minutes before depressing the push button.
This will allow the thermal overload to reset if a
locked rotor has occurred on the ¾ or 1.5 hp
pumps.
2. If condition is corrected, check for proper operation
of system; if operating correctly do not continue to
the next step.
3. Disconnect power at load center, lock and tag out
circuit breakers.
4. Remove cover from the STP-SCIII.
5. Remove the three motor control outputs (M1, M2 &
M3) from the STP-SCIII unit. Using an ohmmeter,
measure the winding resistance between all three
leads (M1 to M2, M1 to M3 and M2 to M3) and
compare the values with the values found in the
STP/IST Installation Manual, High Capacity
Installation Manual or TB004.
6. Troubleshoot the wiring to determine the cause of
the open circuit between the STP-SCIII and the
PMA.
Note: Always lockout and tagout power sources
before servicing.
7. If the problem has been corrected, put the cover
back on the enclosure, turn on power to the STPSCIII and verify system is operating correctly.
8. Inspect the 3-phase relay. It may be stuck open or
damaged. Replace the relay.
1. Calibrate per “Calibration” section.
2. If condition is corrected, check for proper operation
of system; if operating correctly do not continue to
next step. If condition is still present continue to
next step.
3. Check the following:
• Calibration is done at no flow (dead head).
• Hook signal is applied within 10 min. when set in
calibration mode.
• No open circuits between controller and motor.
• Lines have been purged.
• Proper Motor Horsepower Rating has been
selected. (See Table 3).
• Push button has not been depressed to silence
the alarm during calibration process.
4. If the above conditions are correct, contact FE
Petro Technical Support for assistance.
1. Disconnect power at load centers, lock and tag
circuit breakers. Remove cover from enclosure.
2. Check voltage across hook terminal with all
dispenser handles off. There should be no voltage
applied. If voltage is present, contact an electrician
to correct the problem. If no voltage is present,
contact FE Petro Technical Support for assistance.
3. After the problem has been corrected, put cover
10
Flashes/Beeps
Condition
Potential Causes
10
Relay Fault
Relay contact
failure
11
L2 Open
L2 Input Leg not
connected
Proposed Action
back on enclosure, turn on power to the STP-SCIII
and verify system is operating correctly.
The STP will continue to run after
Caution
this fault indication is displayed.
1. Push reset button and hold in for three seconds on
the STP-SCIII.
2. If the condition is corrected, check for proper
operation of system; if operating correctly do not
continue to next step. If condition is still present
continue to next step.
3. Disconnect power at load centers, lock and tag
circuit breakers.
4. Replace Relay, see “Replacement Parts” section.
5. Turn on power to the STP-SCIII unit and verify
correct system operation.
1. Disconnect power at load center, lock and tag
circuit breakers. Remove cover from enclosure.
2. Verify that the L2 leg is connected to the terminal
labeled L2 on the STP-SCIII. Put cover back on
enclosure.
3. Re-apply input power. Press reset on the STP-SCIII
and verify correct system operation.
4. If the problem is not corrected, contact an
electrician to correct the problem.
12
Over Voltage
Voltage Too High
(Out of Spec)
1.
2.
3.
4.
13
Voltage
Unbalance
Warning Only
1.
2.
3.
14
Load Unbalance
Start Capacitor
Inadvertently
Connected Across
2 Phases/
Faulty PMA /
Large Voltage
Unbalance
1.
2.
3.
Warning Only
4.
5.
Press and hold push button for three seconds.
Verify proper system operation.
Re-calibrate (See Under Voltage 2 flashes section).
If system is not operating correctly, contact
FE Petro Technical Support for assistance.
Push reset button and hold in for three seconds.
If the fault clears, verify proper system operation.
If the fault does not clear, contact an electrician to
troubleshoot the incoming power.
Push reset button and hold in for three seconds.
If the fault clears, verify proper system operation.
If the fault does not clear, turn off power at the
load center, lock out and tag the circuit breaker.
Remove the cover at the pump junction box. If a
capacitor is present, remove the capacitor and
connect the junction box wiring per the wiring
diagram in this manual. If there is no capacitor
present, proceed to the next step.
With the power still off, measure the resistance of
the windings. (See TB004 for the proper values)
If the measurements are not within the acceptable
limits
replace
PMA.
See
“PMA
Replacement/Inspection” section in the three
flashes section of this manual.
Apply input power and depress the push button. If
the fault clears, verify proper system operation. If
the fault does not clear, contact FE Petro technical
support for assistance.
Contact FE Petro for additional troubleshooting information at 1-800-225-9787.
11
REPLACEMENT PARTS
Item #
1
2
3
Part #
223878102
223905901
223910902
Description
3-Phase Relay, 240 Volt Coil
Logic Board Assembly
380-415 Volt Power Board Assembly
STP-SCIIIC Right Side View
(Shown with cover off)
©2004 FE Petro
Form No. 223879102 Rev. 1
Qty
1
1
1
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