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Technical

Training
Seminar
Technical Support
608-838-8786
1-800-225-9787
techserve@fepetro.com
02/27/04

2004

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Thank you for your interest in FE Petro products! This Technical Manual has
an array of technical information for you, including Technical and Service
Bulletins, Installation and Owners manuals, and this Technical Training
Seminar handout. This Seminar handout is a printed version of the
presentation we give to teach people about the technical aspects of our
products. Please use the materials in this manual for your reference, but
always use the information that comes with our products for the most current,
complete installation and safety instructions. Feel free to contact the
Technical Support group at FE Petro with all of your questions (see contact
info above). Our office hours are 7:30 AM to 5:30 PM Central time Monday
through Friday. We take pride in answering all of your questions, quickly and
accurately whether by email or phone. You can also visit us at our website
www.fepetro.com where you will find links to technical documents and
drawings as well. You can find technical information about the whole family of
Franklin Fueling Systems (FFS) products at www.franklinfueling.com, EBW,
APT, INCON and FE Petro. Through our family of companies, Franklin
Fueling Systems is committed to providing the petroleum equipment industry
with the highest quality and most innovative products available. We strive to
serve our customers in a manner such that we always exceed their
expectations. Please contact us or visit one of our websites for details
regarding the products and services that we provide.
TechM001r3

02/27/04

FE Petro History
Purchased Gilbarco 4 XC pump and controls in 1988
Purchased Tokheim 6 550 3 & 5 Hp line & added to
product offering in 1993 as HCP

Corporate parent of FE Petro is Franklin Electric, world


leader in electric submersible motors

Franklin Electric acquired EBW / APT in 2000, INCON in


2001 and with FE Petro the four form Franklin Fueling
Systems
EBW supplies tank trim hardware
APT supplies piping and containment sumps
INCON supplies gauging and controls
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FE Petro was founded in 1988 when the Gilbarco 4" submersible pump line
was purchased. It is that submersible pump, that is the cornerstone of the FE
Petro product lines.
In 1993, FE Petro purchased the 6 550 sub pump line from Tokheim, and
added it to our product offering as the High Capacity Pump line.
Also with the 1993 purchase, FE Petro acquired the Tokheim 4 585/585A
sub pump line. FE Petro carries replacement parts for the Gilbarco and
Tokheim submersibles, although some parts are no longer available.
FE Petro is a wholly owned subsidiary of Franklin Electric. Franklin Electric is
the world leader in electric submersible motors. Franklin Electric also is the
supplier of Veeder Root/Red Jackets motors.
In 2000, Franklin Electric acquired EBW/APT and INCON in 2001. Now along
with FE Petro, the companies form Franklin Fueling Systems (FFS). EBW
supplies tank hardware and manholes, APT supplies piping and containment
sumps and INCON supplies gauging and control equipment. With the FFS
companies, Franklin Electric is devoted to being a key supplier of quality
products to the petroleum industry.

Todays Seminar Includes


4 Submersible Turbine Pumps
including Accessories and VLs

6 High Capacity Turbine Pumps


Mechanical Leak Detectors
including HCs

Pump Controllers
including SCIs, MagVFCs & DHIs
Please Ask Questions!
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Todays Seminar will be covering installation, operation, and troubleshooting


of the following product lines:
4 STPs including accessories and the variable length option.
6 High capacity STPs and options.
Mechanical leak detectors, standard and high capacity, including testing.
Pump controllers: Both models of the Smart Controller will be covered (single
and three phase) as well as the Variable frequency controller and Dispenser
Hook isolation box.
And please do not hesitate to ask questions! As we stated earlier, we are
always happy to answer any and all of your questions. Dont forget to also
reference these materials for help, but use the owners manuals that come
with the equipment for the most current, complete details on installation and
safety precautions.

Safe Working Practices


Follow all federal state and local laws governing
installation of all components in the system
Reference NEC, NFPA, PEI and API codes and practices

Refer to Installation and Owners manuals for

most current safety and installation information


Be cautious of the presence of highly flammable
vapors and liquids at all times
Ventilate and test for vapors in the work zone
Make every provision to remove any liquid present
Never enter a containment sump with hazardous vapors
or liquids present
Have assistant when working in containment sumps
Do not smoke or use sparking tools
Never open circuits at hazardous locations with power
applied

2004

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We want to take this opportunity to discuss safe working practices. We cant


cover everything, so in general, adhering to all federal, state and local laws is
of utmost importance when installing and servicing petroleum equipment. In
addition to federal and local regulatory agencies, the National Electrical
Code, National Fire Protection Association, Petroleum Equipment Institute
and American Petroleum Institute publish guidelines governing the safe
installation of petroleum equipment. FE Petro equipment is designed to be
used to pump volatile hydrocarbon liquids, such as gasoline and diesel fuel.
This presents a risk of severe injury or even death if installation instructions
and standard industry practices are not followed. Always refer to the
Installation and Owners manuals for the most current safety and installation
information. Installing or working on this equipment means working in an
environment in which these highly flammable vapors or liquids may be
present. Always test for the presence of vapors before begining work, as
inhaled vapors can lead to dizziness and fainting or, if ignited, could result in
an explosion causing serious personal injury or death. If vapor levels in the
work zone are deemed to be unsafe, ventilate the area with fresh air, then
recheck the work zone before entering, and periodically thereafter. Always
make sure any liquid that escapes is thoroughly removed before proceeding
with work. Always have a second person for assistance when working in or
around a containment sump. Also, do not smoke, always use non-sparking
tools, and never have circuits open in hazardous locations with power
applied.

Safe Working Practices


Always lockout and tagout circuit breakers
Minimizes the risk of breakers being accidentally turned
on while service is performed
Reduces electrical spark hazard which could lead to
explosion or fire

Always secure the entire work area


Bag off nozzles
Use safety cones
Park vehicle in work zone
YOU CAN NEVER BE TOO SAFE!!

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To reduce the risk of an electrical accident, circuit breakers should always be


locked out and tagged out. The practice of lockout/tagout reduces the risk of
power being accidentally applied, which can prevent both an electrical shock
and a spark being created in a hazardous location.
When working on service station equipment, the risk of an accident being
caused by a moving vehicle exists. Therefore, it is recommended to secure
the work area by any means possible. Some examples are bagging off
nozzles, the use of safety cones, and service vehicles parked in the work
zone.
Again, we cant cover everything, so follow all applicable policies regarding
installation and service safety, you can never be too safe.

Safe Working Practices


Do not modify STP in any way
Modifications may result in safety hazards, fuel in
conduit, leaks into the environment
Modifications will void safety agency approvals and
warranty.

Pay close attention to warnings, cautions, and


notes in Installation manuals
!

WARNING

CAUTION

NOTE

THINK SAFETY!
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Under no circumstances should an STP be modified in any way. Modifying an


STP can result in safety hazards, such as fuel getting into the electrical areas
or a leak into the environment. Modification, misuse, or alteration will void
safety approvals and product warranty.
The symbols shown are found in all of our Installation and Owners manuals.
When the WARNING symbol is seen, it identifies a potentially hazardous
situation which, if the instructions that follow are not adhered to, could result
in death or serious bodily injury.
The CAUTION 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.
The NOTE symbol identifies particular instructions which if not followed, could
cause serious damage to the equipment or lead to equipment failure.
FE Petro takes safety very seriously, and want all of you to as well. We
recommended that everyone read the PEI Safety Letter, which is published
monthly and describes accidents, and how they can be prevented. The PEI
also produces Safe Practices guidelines, Dos & Donts brochures, Think
Safety decals, and other safety items (purchase online at
www.pei.org/catalog/safe.htm).
Now, lets get started with the product presentation!

Where do FE Petro products fit in?


MLDs

Submersible
Pumps

Pump
Controls

PMAs

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The submersible pump is just one part of the entire system in a typical
fueling application. The fueling process begins when a handle is activated at
a dispenser. The POS system then authorizes the dispenser, while the
handle signal turns on the pump controller. We call this handle signal from
the dispenser the hook. The hook signals the controller that power is to flow
to the STP, allowing the pump to run and allowing product to flow. When
troubleshooting a problem, any or all of the components could be the cause
of the problem. Investigate the symptoms, and pursue all possible causes.
When the submersible equipment is involved, we recommend starting at the
controllers in the backroom, before working your way out to the hazardous
area of the tank. Since installing and servicing petroleum products can be
hazardous, always practice safe working practices as we discussed earlier.

FE Petro Product Identification


Nameplate located on top of STP
Serial Number
Date code (yymmxxxx)
Year of manufacture (yy)
Month of manufacture (mm)

Model information

4 STP
2004

6 STP

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To identify the product a nameplate is attached to each product. The


Submersible Turbine Pumps have the nameplate attached to the top of the
manifold.
Each STP nameplate will contain the model number of the STP, serial
number, Approvals, electrical and horsepower specifications.
The serial number is also a date code that indicates the year and month of
manufacture for the STP.
The serial number is 8 digits long and the first 4 digits are the year and month
of manufacture.
The model number also provides information about the pump and we will look
at it more closely on the next slide.*
*See Technical Bulletin TB012 Product Identification in the Reference
Document section of this manual for details on date codes

Identifying FE Petro Products


Model Designation XXXyyyzzz-www-qq
STP or IST (XXX)
Mechanical options (yyy)
AG, EXT, H, K, M, R

Horsepower (zzz)
75 = hp, 150 = 1 hp
VS2 = variable speed 2 hp

Model length in inches or VL (www)


VL is variable length

Riser length in inches (qq)


Stock sizes are 7, 10, 12, 13, 14, 15, 17, 19, 21, and 24
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The model designation has useful information on the submersible pump.


The major designation is STP (Submersible Turbine Pump) or IST (Intelligent
Submersible Turbine).
IST implies variable speed, variable length, and Alcohol/Gas compatible.
Factory installed Options are listed next as a letter or series of letters. Here
are a few of the options available, AG (pump can be used in up to 100%
ethanol or methanol), EXT (replacement extractable portion of the pump is in
use), H (high pressure on 1.5 or 2 hp fixed speed pumps), K (intake filter
screen factory installed), M (MagShell PMA supplied with this pump), R (R
model check valve factory installed in this pump)
Next the horsepower rating of the pump is listed (zzz).
33 = 1/3 hp, 75 = hp, 150 = 1 hp, 200 = 2 hp, VS2 = variable speed 2 hp
and VS4 = variable speed 4 hp.
www is the Model length listed in inches for fixed length pumps or VL
followed by 1, 2 or 3 for one of the three variable length models.
The last number (qq) is the riser length included with the pump. Stock sizes
are 7, 10, 12, 13, 14, 15, 17, 19, 21, and 24 inches.*
*See Technical Bulletin TB011Pump Model Designation Listing in the
Reference Document section of this manual for more details on the model
designations.

4 Submersible Turbine Pumps


(STP)

2004

Manifold

Extractable

Pump Motor Assembly (PMA)

TechM001r3

A submersible turbine pump consists of three major parts: the manifold, the
extractable, and the pump motor assembly (PMA). The PMA picks up fuel
from the fuel storage tank, sends it up through the extractable into the
manifold, and into the pipeline. Power from the controller passes through the
manifold, into the extractable to the PMA. Lets first look at the electrical path
of the STP.

Female Wire Connector


(not a power disconnect)

Junction Box
(capacitor compartment)
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Field Wiring Entry

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The junction box is the connection point for the field wiring from the pump
controller. Field wiring enters vertically from the bottom and connects to the
pump wiring inside the junction box. The wire connector assembly, also
referred to as the bridge or yoke, disconnects the wiring connection between
the junction box and the extractable wiring. The wire connector should never
be disconnected with power applied or damage could occur. Make sure the
STP circuit breaker is locked out and tagged out before disconnecting the
wire connector. When working with the wire connector, never force removal
or insertion. In fixed speed pumps, the junction box is also where the
capacitor will be found.

Wire Connector
(disconnected)

3-Pin Male Connector


(always 3 wire)

3/4
Connector
Bolt

TIP

2004

J-Box Bolts
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When servicing the PMA or extractable, it is necessary to disconnect the


Wire Connector. This is done by loosening the 3/4 connector bolt. If the
wire connector binds as it is being disconnected loosen the Junction Box
bolts to alleviate the binding and allow the wire connector to disconnect
freely.
With the wire connector disconnected, it lifts up and swings out of the way.
Once it is out of the way, the male connector is exposed. In all FE Petro
pumps, the wire connector and male connector are always 3 wire.
Prior to a start up of a STP, we recommend leaving the wire connector
connected to avoid potential corrosion build-up, which could become a
problem.
If the wire connector assembly needs replacement we recommend the male
and female connectors be replaced as a pair. A replacement kit is shipped
with both connectors and the o-rings.
After servicing loosen the junction box bolts to help align the wire connector.
Start threading the 3/4 bolt. Again do not force the wire connector assembly.
If using grease to lubricate the brass sleeves of the wire connector always
use a non conductive grease. Make sure the wire connector is tightened
down completely to the mating surface of the extractable to prevent moisture
and dirt from contaminating the connection. After the wire connector is in
place, tighten the junction box bolts.
See Service Bulletin SB002 in the Reference Section of the manual for
further details on wire connector assembly servicing.

Capacitor Info
O

Provides starting & running voltage for single-phase


pump motors
Internal Shunt Resistor
Two sizes available
15 F for 1/3 hp thru 1 hp
can be 17.5 F
25 F okay for 1 hp

40 F for fixed speed 2 hp


O

2004

can be 50 F (check height)

No capacitor required for 3 phase


models IST, ISTVS4, PMAVS2 or PMAVS4
TechM001r3

A capacitor is required for all single phase pumps. The purpose of the
capacitor is to provide starting and running voltage for single phase pumps.
The capacitor that FE Petro uses has an internal shunt resistor which
provides a discharge path so the capacitor will not remain charged with the
power turned off.
We use two different values of capacitor in our single phase pumps:
15uF for 1/3 Hp through 1 1/2 Hp
A Red Jacket 17.5uF can be used in place of the 15uF
A Red Jacket 25uF is ok for use with FE Petro 1 1/2 Hp PMAs
FE Petro supplies a 40uF for fixed speed 2 Hp PMAs only.
A Red Jacket 50uF may be used with the 2Hp PMAs, however check its
height to make sure it will fit within the Junction Box properly. Never run a
sub pump without all of the covers and plugs in place.
No capacitor is required for IST, ISTVS4, PMAVS2 or PMAVS4 variable
speed submersible turbine pumps and PMAs.
See Service Bulletin SB003 in the Reference Documents section of the
manual for further details on wiring the capacitor.
* uF is the abbreviation for microFarad, which is the electrical unit of
capacitance.

Capacitor Wiring Details


To wire connector
and PMA
Orange Black Red
Junction
Box
Capacitor

Correct wiring shown


Verify correct Capacitor
size
Symptoms of incorrect
wiring
PMA does not run
PMA thermal overloads
PMA runs backwards
Low pressure
Slow product flow

Power Supply

GND

From Control Box

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From the control box, 2 power wires and one ground wire will be pulled to the
STP junction box. Inside the junction box the wires from the controller will be
connected as shown. One power wire will connect directly to the orange wire
from the wire connector. The other power wire will connect to the same
capacitor terminal as the black wire from the wire connector. The red wire
will be the only connection on the other capacitor terminal. The Ground wire
will attach to the grounding lug inside the junction box.
Before starting the pump, verify that the capacitor is sized properly for the
horsepower of the PMA; 15 microFarad for 1/3 to 1 hp and 40 microFarad
for the fixed speed 2 hp. The Variable speed PMAs do not use a capacitor.
If wired incorrectly the pump will not run, it could thermally overload, or run
backwards. If it is running backwards the operating pressure will be lower
than the expected, 12 to 20 psi depending on the PMA horsepower, and the
flow rate will be low.*
*See Service Bulletin SB003 Wiring Capacitor in the Reference Document
section of this manual for more details.

Wiring
Compartment
Contractor
Plug

Lead
Assembly

Conduit
(VL shown)
2004

4 NPT Riser
(.188 WT)
TechM001r3

After the pump wiring passes through the wire connectors, the male
connector wires are connected to the lead assembly wires in a second wiring
compartment. The lead assembly passes through the extractable portion to
the PMA inside the conduit. The lead assembly is an interchangeable part
with Red Jacket pumps, FE Petro lead assemblies can be used in Red Jacket
submersible turbine pumps.
Wiring in this compartment is made in the factory on fixed length pumps.
Although, on VL units this connection must be made in the field, which may
be overlooked and should be checked at startup. The Contractors plug is not
a primary seal, its purpose is to hold lead assembly wires taut when
removing a PMA.
The 4 Riser, sometimes referred to as the stand-pipe, is thin wall tubing.
Using a Schedule 40 pipe(.25 Wall Thickness) can cause problems with
removing the PMA.

3/8 NPT
Access
Plug

Water
O-Ring

Syphon
Jet

Vacuum
O-Ring

Syphon
Port

Pressure
O-Ring
Tank
O-Ring

Tank
Port

Column
Pipe

Vapor
Tube

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Product is delivered from the PMA, through the extractable, and into this area
of the manifold. In the extractable area of the manifold, we have a number of
things happening. The extractable manifold is sealed into the stationary
manifold by means of four o-rings. The very top o-ring seals the mating
surfaces to prevent corrosion which may result in difficult extraction. The
middle two o-rings protect the syphon port from internal pressure and
external air degrading the vacuum capabilities of the pump. The lowest oring prevents product from being discharged back into the tank*. This area is
also the high point of the pump, thus any air in the product migrates to this
high point. The air is pushed out of the manifold through the syphon jet and
down the vapor tube. Lets take a closer look at the syphon area.

* See Service Bulletin SB008 in the Reference Documents section of the


manual for further details on positive tank increase issues.

Syphon Action

3/8 Access Plug

Skip Syphons

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When the pump turns on, the syphon action begins as product passes
through the top of the syphon jet, causing the check valve (shown in yellow)
to open. As product and air from the high point pass through the jet, the flow
creates turbulence at the exit of the jet, and this turbulence creates a vacuum
at the port. When the STP shuts off, the check valve closes, thereby
preventing air from the tank, to travel up the vapor tube, get into the manifold,
and drop the product out of the extractable. If the check valve in the jet
should start to fail, product in the extractable could slowly return to the tank,
and as a result, cause a positive rate increase warning on tank gauging
equipment.* The check valve is integral to the jet assembly, replace as a
unit, which is accessed through the 3/8 pipe plug at the top of the
extractable. CAUTION! This 3/8 pipe plug is a pressure port, full pump
pressure is present when the submersible turbine pump is on.

*See Service Bulletin SB008 in the Reference Documents section of the


manual for further details on positive tank increase issues.

MLD Vent Line


(into Tank Port)
Syphon Check Valve
(into Syphon Port)
Copper Tubing
(to bar high point)

Cut away view of


syphon check valve

checking the vacuum directly at the


Syphon Port should read 16- 28 Hg

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The vacuum created within the manifold is seen at the syphon port. A
vacuum gauge installed at the syphon port should read between 16 - 28
inches of Mercury. In a typical application where two or more tanks are
manifolded, a syphon check valve is utilized to maintain prime in the bar
when the pump is off. From the syphon check valve, a copper tube is utilized
to connect to the high point of the manifold bar, where air is pulled off to
establish and maintain the prime, and cause the transfer of product.*
The new design for the syphon check valve was introduced in July 2003.
This new design is interchangeable with Red Jacket submersible turbine
pumps. One difference from our original design is the new design no longer
has any serviceable repair parts.
FE Petro offers a Secondary Syphon Assembly as an accessory. The
secondary syphon replicates the design of the internal syphon area of the
manifold, with the exact same jet and flow paths. This unit is intended for
applications where a secondary vacuum source is required. A typical
application would be where a vacuum source is required for evacuating a
Stage II vapor pot.
The secondary syphon connects from the 3/8 pipe plug over the syphon jet
and terminates at the tank port. If a mechanical leak detector is used along
with the secondary syphon, the vent line of the MLD can be connected in a
tee fitting. Make sure the MLD vent line slopes upward from the tee for proper
draining of the MLD chamber.
*See Service Bulletin SB005 in the Reference Documents section of the
manual for further details on syphon system issues and testing

Product Flows
From Extractable
to Check Valve
Compartment

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While product flows through the syphon path and eliminates air, the majority
of the flow from the extractable is into the stationary manifold (see arrows),
and into the check valve compartment. This is a good time to note that this
area is all prior to the check valve and line pressures.

Check Valve Compartment


Line Test Port
Manifold Cover
Security Seal
Manifold Cover O-ring

Check Valve Spring


Check Valve Assembly
(w/Thermal Relief)
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Within an FE Petro sub pump, the check valve is the beginning of the
pipeline. The check valve compartment is made up of the following
components :
The manifold cover, with an o-ring seal and Line test port which is a 1/4 pipe
plug, creating access to the clamp valve and a line pressure testing port.
From the factory, the manifold cover has a Security seal, added as an
assurance that the check valve that was specified when the STP was
ordered, and noted on the nameplate, is what is in the STP.
Under the manifold cover is the Check valve spring and check valve
assembly. Lets take a closer look at the check valve assembly.

Check Valve Cross-Section

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The check valve assembly closes and seals into the manifold, holding
pressure in the line when the pump is off. Integral to our check valve
assembly is a thermal expansion relief valve. When line pressure exceeds
the threshold of the pressure relief valve, the poppet (shown in yellow) opens
and relieves pressure back to the tank until the line pressure is reduced
below seating threshold (spring tension), and then the poppet closes against
the quad ring and seals. We offer the check valve assembly in four seating
thresholds.

Check Valve Info


O

2004

Maintains line pressure when pump is not running,


built in thermal relief for pump off reset
Four models offered:
O STD model opens about 40 PSI and resets above
35 PSI, used with MLDs, INCON TS-LS300 and
Auto/Stik LS300
O R model opens about 24 PSI and resets about 22
PSI, typically used for Veeder-Root pressurized
line leak detection
O W model opens about 16 PSI and resets above
13 PSI, typically used on RJ PPM4000 electronic
line leak detection
O 65 PSI model opens about 70 PSI and resets
above 65 PSI, used in Slave pumps
TechM001r3

All of our check valves maintain line pressure when the STP is not running. The
only difference among the models is the built in pressure relief, and the threshold
of pressure the relief opens and resets at.
The 4 distinct models are: The Standard model opens at approximately 40psi
and resets above 35psi and is typically used when MLDs are used. It maintains
higher line pressure to keep the MLDs open (i.e. STPxx) **.
The R model which opens at approximately 24 psi and resets above 22psi is
typically used with Veeder Root PLLD to match the swift check performance (i.e.
STPRxx) **.
The W model opens at about 16psi and resets above 13psi. Typically used on
systems with Red Jacket PPM 4000 to match functional element performance
(this model is rarely sold now) (i.e. STPWxx)**.
The 65psi model is our newest, which opens at approximately 70psi and resets
above 65 psi (typically used in slave pumps in place of a non-vented check
valve). The 65psi will prevent normal master pump product pressures from
entering the slave tank when the slave pump is dormant. The 65psi model is only
available as a spare part.
See Technical Bulletin TB010 in the Reference Documents section of the manual
for further details on check valve models.
**

NOTE: For the examples in parentheses, the xx would indicate additional


mechanical options, if applicable, followed by the horsepower rating.

Check Valve Identification


ID Nut: Silver for Std or W models
ID Nut: Black for R model
O
Blue ID Plate for 65 psi model
Date
Code
R or W
(YYMM)
Stamp
R 0310
(No stamp,
Std
implied)
ID Nut
O
O

Top View of Std, R,


and W Check Valve
(R shown)
2004

Blue ID Plate

Top View of 65 PSI


Check Valve

TechM001r3

We have made it easy to distinguish the four check valve models from one
another.*
The Model R check valves are stamped on the top plate with an R and has
a black ID nut, the only model with a black nut.
The STD and W models have a silver nut, but the W models additionally are
stamped with a W in the top plate of the check valve.
If there is no stamp, it is implied that it is a STD model.
The 65psi check valve has Blue ID plate that makes it easy to identify.
There is also a 4 digit date code on the check valves the first 2 digits are the
year and the last 2 digits are the month of manufacture.
The groove on the surface of the check valve was removed in September
2002.

*Please refer to Technical Bulletin TB010 in the Reference Documents


section for information on identifying all of our check valve models.

Manual Pressure Relief


(MPR)
O

Relieves line pressure back to tank prior to servicing


filters, leak detectors, check valves, etc.
Up, for pressure
relief (to ring)
Down, for normal
operation
Replace cover
after use

2004

TechM001r3

The manual pressure relief is a feature included in all of our pumps to allow
for relieving line pressure without expelling product to the environment. To
utilize the MPR, remove the MPR cover (large brass, straight slotted cover
adjacent to the manifold cover), turn the MPR valve with a screwdriver up to
the retaining ring, and line pressure will drop to 0 psi. To return to normal
operation, turn the MPR fully down and replace the cover to prevent debris
from entering the cavity. Lets take a closer look at the MPR / Clamp Valve
area.*

*See Technical Bulletin TB005 in the Reference Documents section of the


manual for further details of the Manual Pressure Relief.

Clamp Valve / MPR


Normal Operation
MPR Plug
Assembly

Line Test Port


(Clamp Valve
Access)

Manifold Cover
Fluid Path
(pressure to port)

Retaining
Ring

Clamp Valve
(up for normal
operation)

MPR Screw
(down for normal
operation)

Check Valve Spring


removed for clarity

2004

TechM001r3

In normal STP operation, the manual pressure relief should be all the way
down, blocking the path from the line side of the check valve to the tank side.
Also in normal operation, the clamp valve should be all the way up, allowing
full motion of the check valve. Make sure the clamp valve is tightened
completely up against the manifold cover, or product flow and pump vibration
will allow the clamp valve to screw down into the check valve path. The line
test port is the access point for the clamp valve. Because of a fluid path in
the manifold cover, the line test port sees line pressure whether the pump is
on or off, making it an ideal point for line pressure tests. Make sure to
lockout/tagout before removing the plug from the line test port, as full
pump/line pressure is under it. After lockout/tagout, use the MPR to relieve
line pressure and then remove Line Test plug.

Clamp Valve
Tank / Line Test

Clamp Valve
Sealing Disc
(seals off relief)

Clamp Valve
(down for testing)

Check Valve
Sealing Disc
(seals to manifold)

Check Valve Spring


removed for clarity

2004

TechM001r3

When it is necessary to isolate the line from the tank, the clamp valve can be
used. Screwing the clamp valve down does 2 things: it seals off the pressure
relief portion of the check valve, and also forces the check valve onto its
sealing seat. With the clamp valve down against the check valve, the line is
isolated from the tank.

Clamp Valve / MPR Static Pressure Test


O

O
O

Raise MPR to relieve line


pressure to tank, leave open
Lower Clamp Valve onto Check
Valve & Relief to seal off
Insert pressure gauge into Line
Test Port instead of pipe plug
Turn Pump ON, leave ON
Lower MPR to stop pump
delivery to line
Turn OFF pump and monitor
pressure gauge for decay

Check Valve Spring removed for clarity


2004

TechM001r3

With the combination of the MPR & Clamp Valve, we can use the pump to
perform a simple static pressure test. After locking out power to the pump, do
the following:
Remove the MPR Plug and raise the MPR to relieve line pressure, leave the
MPR open for now.
Remove the line test pipe plug and lower the clamp valve onto the check
valve, thus creating our barrier to test against.
Insert a 0-60psi pressure gauge into the line test port (instead of the pipe
plug).
Return power and Turn pump on and leave on
Once the line is pressurized, lower the MPR to stop delivery to the line.
Turn pump off and monitor pressure gauge for decrease in line pressure.
If a pressure loss is seen, open the MPR and return line pressure to zero.
Close the MPR and turn the pump on again. If a pressure gain is seen,
inspect MPR o-rings and sealing disc of check valve. If no gain is seen,
pressure decay is elsewhere in the line.*
*See Service Bulletin SB007 in the Reference Section of the manual for
further details on using the MPR for doing a static pressure test.

4 Extractable Portion
(EXT)
O

Design allows for removing PMA without disturbing


leak detector, check valve, or syphon system

2004

TechM001r3

Earlier, we discussed the some of the elements of the extractable manifold,


i.e. product flow, vacuum creation, and the electrical path. The extractable is
the portion of the pump that is removed typically for servicing the motor. It
can be removed without disturbing the leak detector, check valve, or syphon
prime. Since the extractable is on the pump side of the check valve, removing
it has no effect on line pressure. Also, since you are just removing the
extractable portion, and not these other components, the weight is much less.

Fixed Length Extractable


O

Sold as a Replacement Part to lengthen or shorten


installed pumps (or repair damaged units)
Column Pipe

Motor Discharge Head

Extractable
Discharge Head

Lead Assembly
Plug
Vapor Tube

2004

TechM001r3

The Fixed Length Extractable is generally sold as a replacement part, to


change the length of an existing pump or replacing a damaged unit. As a
replacement part, the extractable consists of the extractable discharge head
(including all internal components and external o-rings), motor discharge
head (including lead assembly and o-ring), and piping in between (vapor
tube, conduit, and column pipe).

Variable Length (VL)

Model Length

Variable Length pumps telescope to desired length


during installation - VL2 fits 94% of applications
(STP150-VL2 model length range is 91 to 152)
VL length is set easily at the site without affecting UL
listing or Warranty, no more cutting pumps down

2004

TechM001r3

Our Variable length pumps incorporate a telescopic extractable section,


which allows for the length to be set at the job site. There are three models of
variable length pumps, VL1, VL2 and VL3. The VL2 is the most common and
is used in 94% of applications. As an example the VL2 with a 1.5Hp PMA
attached goes from 91 fully retracted to 152 fully extended.
The length is set at the job site without affecting the UL listing or warranty.
The variable length option also eliminates the practice of cutting pumps down
to fit an installation, which voids warranty.

VL Info
O

Inspect lead assembly for shipping damage prior to


setting length
When setting length, make sure that lead feeds
smoothly through Extractable to prevent damage
When setting the length, do not turn the motor more
than one turn either direction or lead may be damaged

2004

TechM001r3

Prior to extending a variable length pump, it is a good practice to inspect the


lead assembly for damage. Any nicks in the wire insulation may result in
problems, replace the lead assembly as needed.
While one person is extending the column, another person should apply
tension to the lead. This practice ensures that the lead will feed smoothly in
and out of the extractable portion, as the pump is extended and retracted to
set the proper model length.
When setting the length, do not rotate the motor more than one turn (360
degrees) in either direction. Rotating the motor more than one full turn can
result in the lead assembly becoming tangled and/or damaged.*

*See Service Bulletin SB001 in the Reference Documents of this manual for
further details on the replacement of a lead assembly.

VL Locking
O

When locking the length, hold the top half of the


eccentric coupling, and turn the lower coupling 180
degrees until thru hole lines up with drill point
When locked, install supplied set-screw and tighten

SET-SCREW
SET SCREW

2004

TechM001r3

Once the VL extractable is at the desired length, lock the length by holding
the top half of the eccentric coupler with a pipe wrench, to prevent the pipe
above the coupler from rotating, and turn the lower half of the coupler 180
degrees. The coupler will lock with a half turn in either direction. The coupler
is locked when the set screw hole in the bottom half is aligned with the drill
point in the top half of the coupler. Once the through hole and drill point are
aligned, install the supplied set screw and tighten down completely.

Pump Motor Assembly


(PMA)
Serial Number
yymmxxxx

Model Number
Horsepower
Electrical information
Windings (w/ Thermal Overloads)

Internal Cooling Path (filtered)


Impeller / Diffuser Stages
Product Intake (End Bell)
2004

TechM001r3

The pump motor assembly consists of the electric explosion proof motor
which is supplied by our parent company, Franklin Electric. The motor has
thermal overloads incorporated into the windings which protect the motor
from excessive heat typically encountered from dry running. There is also an
internal cooling path, which is filtered and separate from the product flow,
which is provided to cool the motor and lubricate the bearings, from the inside
out. As power is fed to the windings, the rotor spins, turning the attached
impeller stages, pushing fuel up and around the outside of the motor.The
outer shell that holds the unit together,is made of either aluminum or stainless
steel. The aluminum shell is the standard shell, where the stainless steel shell
is used in our AG version pumps, ( when high concentrations of Ethanol or
Methanol are being pumped) and also in our MagShell pump motors.

End Bell Info / Shaft Access


End Cap
(shaft access)

O
O
O

End bell is plastic not intended to support weight


of entire STP
Damage may result in motor failure
End cap may be removed to allow access to rotor
Rotor can be manually spun to determine if motor
is damaged

2004

TechM001r3

Since the end bell is plastic, care should be taken to not support the entire
weight of the STP on the end bell and to avoid damaging the end bell, as
binding and premature motor failure may result. On the bottom of the PMA,
the end bell incorporates a black plastic cap that can be removed for access
to the motor shaft. With access to the shaft, you can spin the motor manually
to determine if the PMA is binding because of damage or debris. This shaft
access may also be used when corrosion has locked a PMA after tank
ballasting or the like.

PMA (Top View)


Motor
Alignment Pin

3-Pin
Electrical Connector

Keyed Lead
Housing

Product Discharge Ports


(match the gasket)
2004

Internal Cooling
Discharge

TechM001r3

Looking at the top of the PMA, there is an alignment pin to ensure the proper
mating of the motor pins to the lead assembly sockets. The lead assembly is
keyed to ensure proper electrical connection to the PMA.
There are also 4 discharge ports and the internal cooling discharge. Care
must be taken when replacing a PMA that the motor gasket is placed on
properly to avoid restricting flow.
The 3-pin electrical connector opening of the motor is also keyed, matching
the keying of the lead assembly within the extractable. The three pins can be
a good point to measure the winding resistance of the motor. The resistance
values for all of our motors can be found in the Reference Document section
of this manual.*

*See Technical Bulletin TB004 in the Reference Document section of this


manual for all of our motor details.

Introducing

MagShell
Patent Pending

Available as
PMAM200
PMAHM200
PMAMVS2
PMAMVS4

2004

TechM001r3

Our patent pending concept of MagShell is available in 4 pump motor


assembly models, the PMAM200 and PMAHM200 our fixed speed 2 hp pump
motor assemblies and also the PMAMVS2 and the PMAMVS4 our variable
speed pump motor assemblies. Lets take a closer look at MagShell.

Standard Shell
PMA

Max O.D.
Al=4.014
SS=3.922

MagShell
Patent Pending

Max O.D.
4.050
Riser Nom. I.D.
4.124
(sch.40=4.026)

MagShell creates
45% greater flow
area in the PMA
2004

TechM001r3

With MagShell, we have increased the outside diameter of the shell, through
the flow area around the motor, creating an increased flow area by 45%.
Whereas the maximum outside diameter of our standard PMAs was 4.014,
AG was max 3.922, the maximum outside diameter of the MagShell is now
4.050. The MagShell OD matches current sump adapter IDs, and will fit
easily through the ID of our standard, thin wall Riser pipe. Although,
schedule 40 riser pipe will not work with the MagShell, its not recommended
even with our standard PMAs.
The standard Aluminum shell PMA has an Outside diameter of 4.014. It can
be used in fuel mixtures of up to 15% ethanol or methanol.
The AG, alcohol gas, PMA has a stainless steel shell with an Outside
diameter of 3.922 it can be used in fuel mixtures up to 100% ethanol or
methanol.
All MagShell PMAs have a stainless steel shell, but must be labeled AG to
be compatible with fuels with 15% or greater ethanol or methanol.

PMA Info
O

PMA models are interchangeable with 4 Red Jacket, Tokheim,


and Gilbarco submersibles (approx. same length and pressure of
like competitive models, except for variable speed)

MODEL
PMA33
PMA75
PMA150
PMAH150

MAX FLOW
45 GPM
65 GPM
100 GPM
65 GPM

MAX PSI
27 PSI
30 PSI
32 PSI
45 PSI

PMAMVS2
PMAMVS4

115 GPM
140 GPM

24-42 PSI
24-42 PSI

PMAM200
120 GPM
PMAHM200 110 GPM

36 PSI
46 PSI

LENGTH
16
18.5
21.5
22
20
25

NEW

23.25
23.75

Adjustable pressure output with MagVFC controller


FE Petros are longer than Red Jacket versions (not X3)
2004

TechM001r3

Since the bolting pattern and connections are standard throughout the
industry, our PMAs are interchangeable with 4 Tokheim, Gilbarco and RJ
pumps (our PMAs are on an average about 3/4 longer than Red Jacket
models)
The table details the maximum flow rates, maximum pressures, and lengths
of our PMAs. The maximum flow is the rate that would be discharged directly
out of the STP. The maximum pressure is the dead head (no flow) pressure.
Notice the maximum pressure of the high pressure models, as the higher
pressure can cause problems for stations without the restrictions these
models were designed to overcome.
The PMAMVS2 and PMAMVS4 are only used in conjunction with our
MagVFC, and are not interchangeable with competitive models.The MagVFC
allows the motor operating pressure to be selectable from 24-42psi of the
PMAVS2 and PMAVS4, covering the entire range of the other model
offerings. We will discuss details of the MagVFC in a later portion of this
presentation.*

*See Technical Bulletin TB004 in the Reference Document section of this


manual for all of our motor details.

PMA Accessories

Intake Filter Screen (IFS)


adds 1 to PMA
two screws for mounting
one FE Petro, one RJ
2004

Floating Suction Adapter


Female 1 NPT
replaces end bell
formed over at factory
only

TechM001r3

These are two accessories that are available for 4 PMAs, the primary one
being the intake filter screen (IFS). The IFS is a filter element that can be
mounted directly to the PMA, adding approximately 1 to the length of the
PMA. The IFS comes with hardware to mount on an FE Petro or Red Jacket
PMA, make sure to use the proper hardware.
The Floating suction adapter (FSA) option allows the PMA to be connected to
a floating suction arm, popular in aviation fueling applications. The floating
suction arm allows for fuel to always be taken from the highest level of the
product in the tank. The FSA replaces our standard end bell when the shell
is formed over at the factory, therefore it is not a field installed option. The
FSA option only adds the 1-1/2 Female NPT connection point for the arm, no
other fittings or hardware for the arm are included.*

*See Technical Bulletin TB014 in the Reference Documents section of this


manual for further details on the floating suction adapter option.

6 STP High Capacity Pumps


(HCP)
O

Pump Motor
Assembly
(PMA)

Extractable

Manifold

2004

TechM001r3

In this section, we will be discussing the High Capacity pumps. The 6 STP
consists of the same three main parts the as the 4 sub pumps: Pump Motor
Assembly, Extractable, and Manifold. As we move through this section, you
will notice that most of the concepts of the 4 fixed speed turbines apply to
this pump, just in a slightly different design. This design is virtually the same
as when we purchased the Model 550 product line from Tokheim.

Identifying FE Petro High Capacity Pumps


Model Designation STPyyyzzz-www-qq
Mechanical options (yyy)
AG (suitable up to 100% ethanol or methanol)
F (Floating suction adaptor)
R (Pressure relief valve set to 23 psi)

Horsepower (zzz)
3 or 5 hp

Model length in inches (www)


Riser length in inches (qq)
Stock sizes 6 to 30 in 3 increments except 27

Serial Number
Date code (yymmxxxx)
2004

TechM001r3

Like the 4 submersible turbine pump the model number of the High Capacity
pump provides useful information about the pump. The model designation is
the same form as the 4 pumps. After the STP label is a letter or letters
indicating the options installed in the pump (yyy). AG option is Alcohol/gas
compatible, meaning it is suitable for fuel blends up to 100% ethanol or
methanol. F is a floating suction adaptor factory installed on the pump, and R
is a pressure relief set at 23 psi. Following the letter/s is a number 3 or 5
(zzz) which indicates the PMA horsepower. For the example on this slide the
www is the model length measured in inches. The model length is
measured from the bottom of the discharge manifold down to the bottom of
the PMA. Finally the qq is the riser length supplied with the submersible
turbine pump. Stock riser sizes start at 6 and increase by 3 up to 30 except
for 27
Like the 4 pumps a serial number is engraved on the nameplate and
includes a date of manufacture code. The first 2 digits are the year of
manufacture and the 3rd and 4th digits are the month of manufacture.*
*For more details and a complete list of mechanical options see Technical
Bulletin TB011 in the Reference Documents section of this manual.

3 NPT
Discharge
(both
sides)

Pump-On
Pressure
Port

Pressure
Relief Valve

Tank Port
6 NPT
Riser
(.25 WT)

Check Valve
(both sides)
sides are
connected
internally

Column
Pipe
2004

NEW

TechM001r3

The 6 STPs incorporate a pressure port at the top of the manifold. This port
is accessed by removing a 1/4 pipe plug, but notice where this port is fed
from. This port is located in the product path prior to the check valves, thus
only giving us access to pump-on line pressure, line pressure with the pump
off cannot be measured at this port. Just below this is a tank port, used to
return the vent line of a mechanical leak detector or the product return line
from an external syphon system. The riser is 6 NPT threaded .25 wall
thickness pipe, like the 4 STPs this is a thinner wall tube and not a schedule
40.
The 6 STPs incorporate (2) 3 discharge ports, (2) check valves, and
pressure relief valve (redesigned for more precision and reliability). The
design allows discharge out either or both sides, as both sides are
connected. Since both sides are connected, make sure when
troubleshooting these turbines to take both check valves and relief valve into
consideration.

Connector
Compartment
Junction
Box
Lead
Assembly

Upper Seal
(atmosphere)

Conduit
Lower Seal
(tank)

2004

TechM001r3

The Extractable portion of the 6 turbine is sealed in by two face seals, an


upper, that seals the product path from atmosphere, and a lower seal that
seals the product path from the tank. In the extractable portion is a junction
box where the lead assembly from the motor passes up through the conduit
and over into the connector compartment.

Extractable Bolts
(eight total)
Field Wiring
(18 leader
supplied)

Male
Connector

Female
Connector

Field Wiring
Entry
2004

Connector
Compartment

TechM001r3

The lead assembly passes through the extractable into the connector
compartment. The leads terminate directly onto the male connector, which
plugs into the female connector in the stationary manifold, onto which the
factory supplied leader wiring is terminated. The leaders are supplied to
allow the field wiring to be connected to the pump wiring external to the field
wiring entry. The fittings and junction box for this external connection are not
supplied. If it should become necessary to service these connections or the
components of the extractable, including the PMA, there are 8 bolts to
remove around the head of the pump that allow the pulling of the extractable
portion. Always practice lockout/tagout and other safety precautions prior to
servicing the pump.

HCP Extractable Portion


Lifting
Eyebolts

Male/Female
Connectors
Alignment Pin
(two total)

2004

TechM001r3

Once the 8 bolts are removed around the head of the pump, two eyebolts are
provided for removing the extractable. When reinserting the extractable
portion, there are two alignment pins to ensure the extractable is properly
aligned into the stationary manifold, mating the female and male connector
without issue.

HCP PMA Info


O

*
*

PMA models are interchangeable with 6 Tokheim


Model 550s and Red Jacket (different shell)
MODEL PMA3 or PMARJ3
MAX FLOW : 195 GPM
MAX PSI :
33 PSI
LENGTH :
33
MODEL PMA5 or PMARJ5
MAX FLOW : 275 GPM
MAX PSI :
40 PSI
LENGTH :
39
PMARJ Models are approx. longer

* PMARJ3 is 2 shorter, PMARJ5 is 5 shorter than actual Red Jacket models

2004

TechM001r3

FE Petro 6 PMAs are interchangeable with Tokheim Model 550s and also
can be used on a Red Jacket pump. If ordering a 6 PMA for a Red Jacket
pump, make sure to specify the RJ model (i.e. PMA5-RJ), as the shell
engagement is longer for a RJ pump. As a result, a standard FE Petro model
PMA will not seal up properly on a RJ pump. The overall length of PMA3RJ is
2 shorter than RJ built 3hp, and the PMA5RJ is 5 shorter than a RJ built
5hp.
The PMA3 has a max flow rate (at the discharge) of 195gpm. The max
pressure (dead head) is 33psi (almost exactly the same performance as two
PMA150s manifolded together).
The PMA5 has a max flow rate of 275 gpm at the discharge, and a max
pressure of 40psi .
See TB004 STP Motor Data in the Reference Document section of this
manual for more PMA details

Pump-On
Pressure Port

HCP Syphon Install


Product Flow
(Pump ON)
Syphon Jet
Body
To Syphon Bar
(high point)
Syphon Check
Valve

Tank Port
2004

Tee (for MLD Venting)


TechM001r3

In the 6 STP design an external syphon assembly is available as an


accessory, for applications where manifolding tanks is required. When the
pump turns on, product flows from the pressure port through the syphon jet
body and returns to the tank, creating a vacuum at the syphon check body,
where the high point of the bar is connected. If using an MLD in conjunction
with the syphon, the coupler going into the tank port should be replaced with
a tee, for terminating the vent line from the MLD. For best results, the tee
connection to the MLD vent line should be pointed up.

Mechanical Leak Detectors (MLD)

STP-MLD-HC (w/Adapter)
approx. 260 GPM
2004

STP-MLD
approx. 100 GPM

TechM001r3

In this section, we will be discussing the Mechanical leak detectors (MLD) FE


Petro manufactures, both HCP and standard. The STP-MLD-HC is typically
used in 6 STP applications, with a maximum flow rate of about 260gpm. The
STP-MLD is typically placed directly into a 4 STP, and has a maximum flow
rate of about 100gpm.

MLD Product Info


O

Five Distinct models :


O STP-MLD (Blue) for gasoline, rigid & most flex piping
O STP-MLD-D (Tan) for diesel/kerosene (rigid & flex)
O STP-MLD-E (Gray) for expandable piping
O STP-MLD-HC (Blue) for gasoline, rigid & most flex
O STP-MLD-HCD (Tan) for diesel/kerosene (rigid & flex)

All MLDs are compatible in fuels with up to 100% ethanol or methanol


2004

TechM001r3

Within the MLD family there are 5 distinct models, 3 standard and 2 HC:
STP-MLD is blue in color and is designed for use with gasoline, rigid and
most flexible piping. This unit will work in diesel or kerosene, but will be more
sensitive to leaks, and thus slower to open.
STP-MLD-D is designed for use in diesel and kerosene only, and is used with
rigid and most flexible piping. If this unit were put in gasoline, it would not
detect acceptable leak rates.
STP-MLD-E version should only be used if a standard or diesel do not catch
a 3gph leak. This unit has been modified to detect leaks in very expandable
systems, and thus has a very long opening time (20-30 sec).
STP-MLD-HC is used in high capacity applications and is designed for use
with gasoline, rigid and most flexible piping. Again, it could be used in diesel
or kerosene, but would be slower to open.
The STP-MLD-HCD is used with diesel or kerosene and rigid or flex pipe.
All of FE Petros leak detectors are compatible to our Alcohol Gas model
levels, concentrations of ethanol or methanol up to 100%.*

*See Technical Bulletin TB002 in the Reference Documents section of this


manual for further details on the MLD offerings.

MLD Install Info


O

STP-MLDs installed in leak detector tee housing or MLD


port of submersible, including competitive pumps
STP-MLD-HCs require special Adapter Housing that uses
O-ring sealing for ease of installation

Venting to tank required for proper MLD operation


2004

TechM001r3

The standard STP-MLDs are typically installed directly into the MLD port on
STPs, including competitive make pumps, or can also be installed in a special
tee housing.
The high capacity MLDs require a special adapter housing, which can be
ordered with the MLD. The HCP versions seal into the adapter with O-rings,
as opposed to NPT threads, which makes installation easier.
All of our MLDs are a piston style leak detector, which require venting for
proper operation. Some older STPs do not have a tank port or and MLD port,
so in order to use an MLD in an older pump (Gilbarco models and Tokheim
model 550 4 for example), a provision must be made to ensure proper
venting is achieved and a special MLD tee housing is used. It is important to
note, mechanical leak detectors can only detect leaks in the pipeline back to
the point at which they are installed. Keep this in mind when using the tee
housing. Leaks prior to the leak detector can not be detected.

MLD Installation
O

2004

Ensure correct MLD is used for application


Install into MLD port or use special T-housing
O No sealant required for HC models
O Grease o-rings to ease install
O 2 NPT thread sealing tips
O Clean & Dry port / housing threads
O Use approved thread sealant
O Minimum torque of 138 lb-ft
Connect Vent tubing to Tank port
O Make sure to properly identify Tank Port
Check MLD for proper operation
TechM001r3

When installing a MLD, the following needs to be followed:


Make sure the correct leak detector is being used. For example, a diesel
version in gasoline will not catch an appropriate leak rate.
MLDs can only be installed into be installed in the MLD port of a 4 pump or a
special tee housing.
The High capacity models thread into the adapter and seal with o-rings, no
need for sealant (pipe dope) on the HC models (grease the O-rings to ease
installation).
When installing the standard 2 MLD the following tips will minimize sealing
problems: Clean and dry the MLD port or housing threads. Product in the
cavity should be down below the threads, so threading can be engaged
without sealant being washed away. Make sure to use an approved thread
sealant, soft-set, and torque to a minimum 138 lb-ft.*
When connecting the vent tube of the MLD, make sure the vent tubing is
connected to the tank port (the tank port is the lower one, on the side of our
manifold).
After installation, always test the MLD for proper operation
*See Technical Bulletin TB008 in the Reference Documents section of this
manual for further details on sealing the MLD threads.

MLD Operation
Tripped or Bottom Position
O Pressure less than 1 psi
O

2004

Flow rate 2-3 GPM

TechM001r3

Now lets take a look at how a MLD works. Youll notice all of the pictures
show the standard MLD, but the operation of the HCs is the same, except
where noted. The MLD is a pressure sensor, and the spring is its pressure
reference. When the MLD is installed, or pressure in the line is below 1psi,
the spring has forced the MLD into its tripped or bottom position. In this
position, you can see the product path is completely sealed off, except for the
horizontal hole of the brass poppet, around the stainless steel pin, and in the
pipeline. When the pump comes on, product flow through this path is about
2-3 gpm. This initial flow into the pipeline moves the MLD into its sensing
position.

Leak Sensing Position


O

2004

Line pressure increases to 12 - 15


PSI (20 - 24 PSI with HC models)
Flow limited to equivalent of 3 GPH
@ 10 PSI (EPA Standard)
If a leak of 3 GPH @ 10 PSI or greater
is in the system, MLD will return to
the Tripped position

TechM001r3

In the sensing position, the pipeline pressure is now at about 12-15 psi (20-24
psi with HCs), and flow is restricted to the EPA standard (3gph @ 10psi). If
a leak greater than the 3gph @ 10psi is detected, the MLD will return to the
tripped position when a nozzle is opened, and again only 2-3 gpm will be
delivered into the pipeline, this is slow-flow. If a leak less than the threshold
of the MLD is present, the MLD opening time will be increased, but it will
eventually open. If no leak is detected, the MLD will move to the full flow
position within a few seconds.

Full Flow Position


O

2004

No leaks greater than 3 GPH have


been detected
If, while pumping, the line pressure
at MLD drops to about 1 PSI (6 PSI
with HC models), the MLD will
return to Tripped or Bottom
position
If, after pumping, the system
pressure drops to 3 - 5 PSI, a line
test will be performed the next time
the pump is turned on

TechM001r3

Once the MLD is in the full flow position, if pressure in the pipeline drops
below 1psi (6 psi with HCs), the spring will overcome the pipeline pressure
and return the MLD to the tripped position, and flow will be restricted to 2-3
gpm. The MLD will stay in the full flow position as long as there is no
pressure decay in the line, even if the pump is off. If pressure does decay in
the line, the spring will start to overcome the line pressure under the piston
and return the MLD to the tripped position. At about 3-5 psi line pressure, the
spring has returned the MLD to a point where the product flow is sealed off,
resulting in a test being performed the next time the pump comes on.

MLD Operational Testing


O

Min. Test Fixture Reqd


(drain hose with two
valves and a pressure
gauge)
Tools : watch with
seconds sweep and
graduated cylinder
Make sure MLD catches 3
GPH @ 10 PSI leak
Make sure MLD cycle
time is less than
dispenser solenoid delay
2004

0-60 PSI
GAUGE

LEAK VALVE

REGULATE VALVE
GRADUATED CYCLINDER

3/8 TUBING

SHEAR VALVE

TechM001r3

To verify a Mechanical Leak Detector is operating properly, a leak test must


be performed.The minimum test fixture that is required consists of tubing, two
valves and a 0-60 psi pressure gage. A watch with a second hand, or
stopwatch, and a graduated cylinder are also required.
Turn the pump off and install the test fixture into a shear valve of a dispenser.
Turn on the pump and watch the MLD open (0psi, jumps to 12-15psi, then full
pump pressure) and adjust the leak rate valve until a leak rate of 3gph or
less@10psi is achieved. Determine the leak rate achieved by adjusting the
regulate valve to 10 psi and then catching the product into the graduated
cylinder. The volume caught in 60 seconds should be equal to 188 milliliters
or less, to be equal to 3gph or less. Once the calibrated leak rate is
established, open the regulate valve fully, turn off the pump, and let the line
pressure drop completely to 0psi. Once the line is at 0psi, turn the pump
back on and watch the pressure gauge, it should never go over 20 psi. Once
ensured that the MLD detects leaks, it is also important to determine the test
cycle time. Turn the pump off, drain the line pressure again to 0psi, close the
leak valve, and turn the pump on. Ensure the dispenser solenoid delay times
are longer than the leak detector test time by holding a nozzle open, full flow
should be achieved.*
*For complete testing instructions, refer to the STP-MLD and STP-MLD-HC
Installation and Owners manuals in the Manuals section of this manual.

Manifolded Pumps with MLDs


To Dispensers

MLDs

Multiple pumps should never turned on simultaneously with


MLDs or 3 GPH @ 10 PSI leak detection will be multiplied
2004

TechM001r3

When manifolding STPs together, it is very important to take line leak


detection into consideration. In the example above, two STPs are
manifolded into one line with MLDs in each pump. If both STPs are turned
on simultaneously, both MLDs would try and detect the 3gph@10psi leak at
the same time, resulting in only 6gph@10psi system detection possible.
Through the use of Master/Slave controllers, available in Smart Controllers or
VFCs, only the Master pump would turn on, do the leak detection of
3gph@10psi on the system, and only ask for the Slave pump and leak
detector when flow significantly increases. The other solution here is placing
the MLD beyond the point that the lines manifold together, but remember,
everything in the pipeline prior to the MLD, will be unprotected by the MLD.
This configuration also results in significant flow restrictions, if desired flows
are greater than MLD capacities.

MLD Service Info


O

2004

Units color coded for proper application, when in


doubt, go with blue (standard)
Proper venting critical to proper operation
O Vent line to Tank (not Line or Syphon)
O No kinks in vent line (cant be plugged)
O Slope vent line for proper draining
Slow Flow Issues
O Line Pressure losses (leaks or thermals)
O Vapor/Air in line (repair or thermals)
O Dispenser issues (solenoid timing or leaks)
O STP issues (wrong check valve or bad power)
TechM001r3

Remember the FE Petro MLD color codes when selecting the proper unit for
the an application. When in doubt, use the standard, blue model, for the
application. Always test an MLD after install, this is the only way to ensure
the right unit is installed and working properly.
Proper venting is critical for proper operation of our piston style MLDs. Make
sure the vent line is in the tank port, not the syphon port or the line test port.
Again, the tank port is the lower on the side of our manifold. Make sure the
vent line is free of kinks, sloped down to the tank port, to allow proper venting
and draining of the MLD chamber.
When troubleshooting a slow-flow condition, inspect the following: Check for
line pressure losses, including visible leaks under dispensers and/or thermal
contraction. Another cause can be vapor or air in the lines, resulting from
repairs or thermal contraction. Ensure that dispenser solenoid delays are
longer than the opening time of the MLD installed, typical opening times are
2-4 seconds. Put a pressure gauge in the system, checking that line
pressure holds when the pump shuts off, and that the pump creates adequate
pressure immediately when requested to turn on.*

* See Technical Bulletin TB001 in the Reference Section of this manual for
further information on thermal contraction and testing for it.

Smart Controller, Single Phase


(STP-SCI)
O

Compatible with 1/3, 3/4, 1, &


2 hp single phase, fixed speed
pumps, including competitive
One Smart Controller per STP
Controls and protects with
internal diagnostics based on
calibration snapshot
Fault Indication by audible
alarm & flashing light code

2004

TechM001r3

Our second generation of the single phase Smart Controller (STP-SCI). It is


very similar in operation and design to the original STP-SC, with several
added functions.
It is compatible with 1/3, 3/4 1.5 and 2Hp fixed speed pumps, including
competitive motors, with one Smart Controller required per pump
The Smart Controller replaces the standard relay box. The Smart
Controllers internal diagnostics are based on a snapshot of the motors
power consumption, taken during a calibration process. The internal
diagnostics indicate abnormal conditions by both an audible alarm and a
flashing light error code on the front panel. The fault indications are listed on
the front panel for your reference.

STP-SCI Fault Indications


1. Underload (Dry run or calibrated with flow)
2. Low Incoming Voltage (bad input power)
3. Overload (short in wiring, locked motor)
4. Open Circuit (open in wiring, thermal overload)
8. Uncalibrated (new install, calibration incomplete)
9. Extended Run (60 min. run with no flow change)
10. Relay fault (pump run with no Hook)

2004

TechM001r3

The SCI is capable of detecting and indicating a number of fault conditions.


The SCI fault indications are listed above by the number of flashes/beeps that
will be displayed under detection of an abnormal condition. The conditions
are defined as:*
1 Underload- Typically detected as dry run, this could be caused by an
obstruction on PMA intake, empty tank or calibration done with flow.
2 Low input voltage- This self resetting condition indicates a problem with
input power
3 Overload- This condition indicates high motor draw, as in a wiring short or
a locked motor
4 Open circuit- This condition indicates an open in the field wiring, which
could be the internal thermal overloads of the motor
8 Uncalibrated-Condition indicates calibration has not been done or was
unable to complete because of another detected abnormal condition
9 Extended run- SCI has 60 minutes of hook without a change in
flow/power
10 Relay fault- Condition indicates motor draw after the hook has been
removed indicating a faulty relay.
*See STP-SCI Installation and Owners manual for further details on fault
indications and troubleshooting the conditions found in the Manuals section
of this manual

STP-SCI Configuration Options


Stand Alone Operation (default)
O Master Slave Operation (up to 32 submersibles)
O Alternating Circuit (individual alternating pumps)
O Master Slave Alternating Circuit (both operations)
Fault Shutdown (M/S only, ON will cause all to stop)
O

default is OFF, fault shutdown of detection unit only

Extended Run Disable (ON will cancel detection)


O

default is OFF, extended run detection active

Fault Read Out (ON displays last five faults)


O

TIP

default is OFF, only current fault condition indicated

Bypass (ON causes dumb controller for 10 minutes)


O

default is OFF, full implementation of Smart Controller

Auto Restart (Dry Run restart attempt on next hook)


O

2004

default is OFF, must be manually reset on error detection


TechM001r3

The smart controller can be configured a number of ways. Its shipped from
the factory in stand alone operation.
The Master Slave (M/S) operation is used when 2 or more pumps are
connected to the same delivery line. The pump designated as the master will
turn on first, and as demand increases the master pump will signal the slave
pump(s) to turn on, all pumps run until the hook is deenergized.
The alternating circuit (AC) feature turns on only one pump, changing the
pump that runs at each hook sequence
The Master Slave Alternating Circuit feature combines both the Master Slave
and alternating circuit features. Not only does the lead pump alternate, but
the on demand feature is also present.
Fault shutdown (M/S and/or AC configurations only) When ON, all pumps
shut off if any one detects a fault condition
Extended run disable turns off the extended run fault so the pump will not
shut down with the extended run fault. Used in applications when a constant,
continuous run is normal, such as supplying a generator.
Fault readout will display the last 5 faults detected by the controller. Can be
used only when the pump not running.
Bypass will disable most of the diagnostics for 10 minutes.
Fault readout and the Bypass are valuable troubleshooting features that can
provide information in diagnosing a site.
Auto restart feature attempts to reset the controller on the next hook signal
after a dry run fault has been detected.

STP-SCI Stand Alone


Startup

SW2 (factory default,


extended run enabled)
Reset Switch
SW1 (factory default, no
auto restart)

2004

Ground
M1
M2

STP

L2
L1
Neutral
Ground

208-240
Volts

Dispenser

120V

TechM001r3

To startup a STP-SCI in stand alone operation, the factory defaults for SW1
and SW2 will normally be used. You will need to supply field wires from the
controller to the motor, including a ground wire, power wires, single phase,
from a power panel to the input lines, L1 and L2 of the controller, with a
ground wire and neutral wire(for the hook return), and a 120 volt dispenser
hook signal. See Installation and Owners Manual for complete details on
switch settings and wiring. (Note the reset button has moved to the side of
the unit)

STP-SCI Stand Alone Calibration Process


* All units come uncalibrated
Power ON to STP-SCI
O

Press and hold Reset Button


O

No pumping during calibration

Calibration snapshot taken


O

Hold until all three lights blink

Lift handle at dispenser to


energize hook circuit
O

Green light solid, 8 red flashes

RESET

Learning takes about 15 seconds

STP-SCI ready for service


O
O

2004

Pump running, green light flashing


Handle OFF, green light solid
TechM001r3

Before any SCI can be put into normal operation, the calibration process
must be completed as follows:
Apply input power to the Smart controller, check that the green light comes
on solid, the red light will be flashing/beeping 8 times (uncalibrated).
Press and hold the reset button until all three lights start flashing in sequence,
this signals that the unit is ready to be calibrated. Do not allow dispensing
during the calibration process, calibration must be done at no flow.
Go out to a dispenser and lift a handle to energize the hook. The pump will
run while the controller learns the motor/system it is connected to (this takes
about 15 seconds). If fault conditions are encountered, the process will be
halted and the condition will be indicated with the red light. Once the
calibration process is finished, the controller will go into normal running
condition, flashing green light (pump running), until the dispenser handle is
deactivated. With no dispenser handles active, the controller will go back to a
standard idle condition, green light solid, with no other lights illuminated.*

*See Installation and Owners manual in the Manuals section of this manual
for complete details on the calibration process.

STP-SCI Calibration Notes


O

Calibration process will abort if no hook within 10 minutes


Calibration must be done at deadhead, no flow. Closing
ball valve or clamp valve recommended (fuel in tank)
When STP-SCIs in blender system, recommended
calibration of both Smart Controllers at once
Once system is learned, calibration data is retained in
the event of power loss
Recalibrate on motor or wiring changes. Same process
as initial calibration process.
Use Bypass feature for purging air before Calibration
2004

TechM001r3

If the calibration process is not completed within 10 minutes of putting the


controller in calibration mode, the calibration process will abort, returning to
the 8 flashing/beeping red light, uncalibrated condition
Calibration must be done at no flow. We recommend closing the ball valve at
the STP discharge, or screwing down the clamp valve if no ball valve is
present. If there is product flow during the calibration process, false dry run
detection may occur at normal no flow, deadhead. Also, this may sound
obvious, but fuel needs to be in the tank at least to the level of the impellers
for proper calibration.
Once calibration is completed, calibration data is stored in non-volatile
memory, not affected by power loss.
We recommend recalibration if the motor or wiring is changed. Simply repeat
the calibration process as done at startup.
To purge air from the lines, the bypass feature of the SCI may be used, which
allows the Smart controller to run for 10 minutes without all diagnostics on.

STP-SCI Master/Slave and/or Alt. Circuit Startup


SW2 (set Master, Slave)
(set Alt. Circuit)

Master
Power
N, L2,
L1, Gnd

SW1 (set Addressing)

N
L2
L1
GND

L1
L2
GND

RS485
+, G, GND
M1
M2

M1

M2
GND

No Slave
Hook
To Master STP
M1, M2, Gnd

2004

Slave
Power
L1, L2,
Gnd

Hook
120V

To Slave STP
Gnd, M1, M2

TechM001r3

To startup a STP-SCI in Master/Slave, with or without Alternating Circuit,


operation, SW1 and SW2 will need to be set as detailed in the installation
manual for the application. On both the Master and Slave units you will also
need to connect single phase input line power, with a ground, and the field
wring for the motors, including a ground. A neutral and 120 volt dispenser
hook signal will be wired into the Master only, as the Slave unit SCI does not
require a hook. The Master will enable the slave or slaves via an RS-485
communication cable.
To verify that the Smart controllers are communicating, observe the yellow
lights on the front panel of the controller. The yellow light on the controllers
should be flashing. If the yellow lights are not flashing, there is a problem with
the communication.
See the Installation and Owners Manual for complete details on switch
settings and wiring.
NOTE: FE Petro is in the process of renaming the Master/Slave and
Alternating Circuit feature to Manifolded Pumps On Demand and Alternating
lead in all of its documentation. This document will change over to the new
terminology when all the other documents are changed.

STP-SCI Service Info


O

Reset Button Operation


O
O
O

Fault Readout Mode


O

Silence = push briefly (indicator light will continue flashing)


Reset = push about 3 seconds until all three lights dim
Calibrate = push about 10 seconds until all three lights sequence

When selected, Controller will display last five codes


TIP
O beep once, then flash indicator light code for last fault
O beep twice, then flash indicator light code for last previous fault
O continues up to last five faults indicated

Not compatible with old -SC for M/S or Alt. Circuit apps
Extended Run Disable Feature should not be used if system
requires pump OFF for line leak detection to function properly
2004

TechM001r3

The reset button of the SCI is a multifunction switch. Depressing the reset
button briefly will silence an alarm, but will not clear the fault. To clear a fault
and reset the controller, push and hold the reset switch in for about 3
seconds, at which time all three lights will dim. To force the SCI into
calibration mode, push and hold the reset button in until all three lights flash
in sequence (approximately15 seconds).
A feature in the SCI which can help with troubleshooting is the fault read out
mode. In this mode, the controller will display the last 5 faults detected.
When selected, the controller will beep once and then display the last
detected fault, it will then beep twice and then display the second to last
detected fault, and so on through the last five faults.
The SCI is not compatible with the previous version of the smart controller for
M/S or Alternating circuit configurations, due to enhanced communication
protocols.
Before using the extended run disable setting, make sure the line leak
detection equipment does not require pump off time to function properly.

Smart Controller, Three Phase


(STP-SCIII)
O

Compatible with 3/4, 1, 3, &


5 hp three phase, fixed speed
pumps, including competitive
One Smart Controller per STP
Controls and protects with
internal diagnostics based on
calibration snapshot
Fault Indication by audible
alarm & flashing light code

2004

TechM001r3

Like the SCI, FE Petro also offers a three phase smart controller (STP-SCIII)
The SCIII is compatible with , 1-1/2, 3 and 5Hp fixed speed three phase
pumps, including competitive makes, with one controller per STP required. In
the the domestic market, the SCIII can only be used with 3 and 5 Hp pumps.
The 3 phase model works just like the single phase version, controlling the
pump and displaying faults by both an audible alarm and flashing light error
codes on the front panel. The SCIIIs also incorporates internal diagnostics,
which base protection on a snapshot of the motors power consumption,
taken during the calibration process. The fault indications are listed on the
front panel for your reference.

STP-SCIII Fault Indications


1. Underload (Dry run or calibrated with flow)
2. Low Incoming Voltage (bad input power)
3. Overload (short in wiring, locked motor)
4. Open Circuit (open in wiring, thermal overload)
8. Uncalibrated (new install, calibration incomplete)
9. Extended Run (60 min. run with no change)
10. Relay fault (pump run with no Hook)
11. L2 Open (input leg L2 not connected)
12. Over Voltage (input voltage too high)
13. Voltage Unbalance (input unbalance, warning only)
14. Load Unbalance (faulty wiring, PMA, or voltage)
2004

TechM001r3

The SCIII is capable of detecting and indicating a number of fault conditions.


The SCIII fault indications listed above by the number of flashes/beeps that
will be displayed under detection of an abnormal condition. Youll notice that
faults 1 through 8 match exactly those of the single phase unit. The
conditions added in the three phase model are defined as:
Fault 11, L2 Open, is detected when the L2 leg of input power is not
detected (the controller wont power up without L1 or L3).
Fault 12, Over Voltage, this condition protects the controller and motor when
the incoming voltage increases beyond the controllers threshold.
Fault 13, Voltage Unbalance, is a warning condition (no shutdown) indicating
that the three legs of input voltage are significantly out of balance.
Fault 14, Load Unbalance, is a warning condition (no shutdown) indicating
that the three output legs to the motor are significantly out of balance.*

*See STP-SCIII Installation and Owners manual for further details on fault
indications and troubleshooting the conditions

STP-SCIII Configuration Options


O

Stand Alone Operation


O

Master & Slave Operation


O

(individual alternating lead pump)

Master / Slave Alternating Circuit


O

(up to 7 slaves can be tied to a Master)

Alternating Circuit
O

(default)

(alternating lead Pump with Master & Slave operation)

Horsepower Rating
O
O

2004

(set calibration range as either 3 or 5 hp)


(beeps horsepower rating at startup)
TechM001r3

The smart controller can be configured a number of ways. The smart


controller is shipped from the factory in the stand alone configuration.
The master slave operation is a configuration that is used when 2 or more
pumps are pumping into the same delivery line. The pump designated as the
master will turn on first, and as demand increases, then the master will send
a signal to the slave pumps to turn on, both pumping until all hooks drop out.
The alternating circuit feature turns on only one pump at a time, alternating
which pump runs every hook sequence
The master slave alternating circuit feature combines both the master slave
and alternating circuit features. Not only does the lead pump alternate, but
the master slave feature is also present.
Prior to power up of the SCIII, select the proper switch setting to indicate the
horsepower of the attached motor. Once set, the controller will indicate the
horsepower rating at power-up and on reset with beeps, 3 times for 3hp and
5 times for 5 hp.

208-230
Volts

STP

Dispenser
120V Hook
2004

Not
Used

Ground
M3
M2
M1
Thermal
Thermal

L3
L2
L1
Neutral
Ground

STP-SCIII Stand Alone Startup

SW1
(set hp rating)
Reset Button
(underneath)
TechM001r3

To startup a STP-SCI in stand alone operation, the factory defaults for SW1
will normally be used except the horsepower setting needs to be made. You
will need to connect field wiring for the motor, including a ground, your three
phase input line power, with a ground and neutral (for the hook return), and
your 120 volt dispenser hook signal. See the Installation and Owners
Manual for complete details on switch settings and wiring. Note that the
Reset button for the three phase model is located under the front lip of the
enclosure.

STP-SCIII Calibration Notes


O

Calibration Process same as STP-SCIs


O
O
O
O

Power ON Smart Controller (all units come uncalibrated)


Push and hold reset button until all three lights sequence
Lift handle at dispenser to energize hook, no pumping
Snapshot taken, unit is ready for service

Calibration process will abort if no hook within 10 minutes


Calibration must be done at deadhead, no flow. Closing
ball valve recommended (fuel in tank)
Once system is learned, calibration data is retained in
the event of power loss
Recalibrate on motor or wiring changes. Same process
as initial calibration process.
2004

TechM001r3

The calibration process is the same as the calibration for the SCI, but lets
review. Power up the controller, the green light should be on solid, red light
flashing uncalibrated. Push and hold the reset button until all lights flash in
sequence. With no pumping on this product, lift a handle, the pump will run,
the controller will take a snapshot, calibration is complete and the product is
ready for service.
If the calibration process is not completed within 10 minutes of putting the
controller in calibration mode, the calibration process will abort, returning to
the 8 flashing/beeping red light, uncalibrated condition
Calibration must be done at no flow. We recommend closing the ball valve at
the STP discharge. If there is product flow during the calibration process, the
false detection of dry run may occur at normal no flow, deadhead.
Remember, calibration must be done with fuel in the tank, at least up to the
impellers.
Once calibration is completed, calibration data is stored in non-volatile
memory, not effected by power loss.
We recommend recalibration if the motor or wiring is changed. Simply repeat
the calibration process as done at startup.

STP-SCIII Master/Slave and/or Alt. Circuit Setup

120 V

+
G

N/U

GND

M2

M3

L3

Slave
STP
M1

L2

L1

GND

N/U

Slave
Power

GND

M2

M3

L3

M1

L1

L2

Master
STP

Dispenser

GND

Master
Power

Slaves
get
Hook

RS485
+, G, 2004

SW1 (set Master, Slave, Alt. Circuit)


(set addressing, hp rating)
TechM001r3

To startup a STP-SCIII in Master/Slave, with or without Alternating Circuit,


operation, SW1 will need to be set as detailed in the installation manual for
your operation. On both the Master and Slave units you will also need to
connect in your Three phase input line power, with a ground, and the field
wring for the motors, including a ground. A neutral and your 120 volt
dispenser hook signal will be pulled into the Master and the Slave, unlike the
SCI Slave units which do not get a hook. The SCIII slaves get the hook but
are enabled to run only when the Master communicates to the Slave across
the RS485 wiring.
To verify that the Smart controllers are communicating, observe the yellow
lights on the front panel of the controller. The yellow light on the master will
flash more rapidly than the yellow lights on the slaves. If the yellow lights are
not flashing, there is a problem with the communication. If alternating circuit
is in use, the fast flashing light will alternate with the master control.*
*See Installation and Owners Manual for complete details on switch settings
and wiring.
NOTE: FE Petro is in the process of renaming the Master/Slave and
Alternating Circuit feature to Manifolded Pumps On Demand and Alternating
lead in all of its documentation. This document will change over to the new
terminology when all the other documents are changed.

STP-SCIII Service Info


O

Reset Button Operation


O
O
O

Silence = push briefly (indicator light will continue flashing)


Reset = push about 3 seconds until all three lights dim
Calibrate = push about 10 seconds until all three lights sequence

Calibration Issues
O
O
O
O

check connections
check pressure
check input power
check SW1 settings
O

ON = towards board

SW1 pin 8
thru
SW1 pin 1
2004

TechM001r3

The reset button of the SCIII is a multifunction switch. Depressing the reset
button briefly will silence an alarm, but does not clear the fault. To clear a
fault and reset the controller, push and hold the reset switch in for about 3
seconds, at which time all three lights will dim and the reset button should be
released. To force the SCIII into calibration mode, push and hold the reset
button in until all three lights flash in sequence.
If you have issues calibrating the SCIII units, here are some common things
to check. First, double check all of the connections throughout the system
(loose connections can cause the snapshot to go out of calibration range).
Put a pressure gauge in the system and watch deadhead pressure when the
pump turns on for calibration. You correlate deadhead pressure to the
horsepower of the motor for proper rotation and horsepower selection on
SW1 (reverse rotation will produce about half the normal deadhead pressure,
swap two motor leads to correct rotation). Check the input power, making
sure all three legs are in range. Check the SW1 setting to make sure they
make your application and motor horsepower, also making sure pins 1
through 8 have been identified properly.*
*See Installation and Owners Manual for further details on troubleshooting
and switch settings and see Technical Bulletin TB004 in the Reference
Documents section of this manual for further details on deadhead pressures.

MagVFC
O

2004

NEW

Compatible with FE Petro


PMAMVS2, 2 horsepower, and
PMAMVS4, 4 horsepower three
phase, variable speed
submersible turbine pumps
One MagVFC per variable speed
submersible turbine pump
Controls and protects with
internal diagnostics
Fault Indication by 2 seven
segment displays plus an audible
alarm
TechM001r3

The next controller we will be discussing is the new MagVFC. The MagVFC
was introduced and has been shipping 100% since June 2003. The
MagVFC is for use with our 2 Hp variable speed motor (PMAVS2) and 4 hp
variable speed motors (PMAVS4) only. The MagVFC accepts either single or
three phase power input, and creates the three phase variable frequency
output for the PMAVS2. As with all of our controllers, one MagVFC is
required per pump, IST, ISTVS4, STPVS2 or STPVS4 (the IST is an Alcohol
gas compatible pump, the non-AG version is STPVS2 or VS4). Like the smart
controllers, the MagVFC controls and protects the motor with internal
diagnostics, indicating faults on the front panel with a display code. Also like
the smart controllers the MagVFC can work together in a Master/Slave
operation with or without the Alternating feature.

MagVFC Front Panel


Two 7 segment Indicator
Displays
Fault Readout /
Silence Alarm
Button
Indicator
Display Codes
Reset Button
Power Indication
(7 segment displays Id = power applied)
(Flashing Pr or PL = PMA running)
2004

TechM001r3

Unlike the smart controller, which uses a green light for power status, the
MagVFC has two 7 segment displays for power status, displaying Id (idle)
indicates input power is applied, and flashing Pr or PL when the PMA is
running. This display on the front panel is also the fault indicator, flashing an
abbreviated code that indicates a fault is present (these codes are defined on
the label). There is a reset button on the front panel, when depressed it will
attempt to clear the fault. If an error is still present, the error code will return
to its flashing state (maybe only after a hook request is made). When a fault
is indicated on the MagVFC an audible alarm signal is present. This alarm
signal can be silenced without resetting the controller by pressing the silence
alarm button on the front panel. This silence alarm button can also access
the last 3 fault conditions of the controller to aid in troubleshooting. To view
the last three fault conditions push and hold in the silence alarm button until
the display shows F0. Release the button and push it again and the most
recent fault will display. Follow this same press and release sequence to
display the second and third fault. The second fault will be proceeded by F1
and the third fault proceeded by F2.

MagVFC Fault Indications


UL - Underload (Dry run or blocked PMA intake)
LI - Low Incoming Voltage (bad input power)
LU or Lr - Overload (locked motor, short into water)
OC - Open Circuit (open in wiring, thermal overload)
rl - Capacitor Bank (failing VFC capacitor bank)
SC or SU - Short Circuit (short in wiring, VFC to PMA)
HO - High Temperature (excessive VFC temp)
Er - Extended Run (Continuous hook signal for greater than 60
minutes)

OS - Over Speed (the MagVFC is outside of frequency range)


2004

TechM001r3

The MagVFC is capable of indicating a number of abnormal conditions. The


conditions are displayed on the 7 segment displays and are defined as follows:
UL - Underload- Typically an empty tank, but could be caused by an obstruction
on PMA intake
LI - Low input voltage- This indicates issues with input power. It self-resets
LU or Lr - Overload- Is a result of high motor current draw, and may be a wiring
nick under water or a locked motor
OC - Open circuit- This condition indicates an open in the field wiring, which
could be the motor thermal overloads (only indicated on reset or power-up)
rl - Capacitor Bank warning indicates VFC capacitors may be failing
SC or SU -Short Circuit- Is a short in the wiring between the VFC and PMA
HO - High Temperature is indicating that the components of the VFC are VFC
too hot, this is self-resetting (VFC should be mounted indoors below 95 F)
Er Extended Run indicates the controller detects a hook signal from a dispenser
for 60 minutes without the flow out of the pump changing in that time.
OS Over Speed indicates the MagVFC is operating at a frequency outside of the
designed frequency range for the controller.
See IST-VFC Installation and Owners manual for further details on fault indications
and troubleshooting the conditions

MagVFC Configuration Options


O

Option select SW3


O

Pole 1
O
O

Pole 2 (product type)


O
O

O
O

Stand Alone Operation (default)


Master & Slave Operation (up to 15 slaves)
Master & Slave Alternating Circuit

Poles 4 & 5 (pipe compensation)


O
O
O

2004

ON - Gasoline (default)
OFF - Diesel (or Kerosene)

Pole 3
O

ON - 6 sec. psi increase to 34 psi for MLDs (default)


OFF - 8 psi increase for 6 seconds (required for PLLD)

4 possible levels
least restrictive (ie. 2 fiberglass less than 200) (default)
most restrictive (ie. 1 convoluted flex more than 75)

TechM001r3

There are 4 switches on board the MagVFC that control the operation of the
VFC. The first switch we will discuss is SW3, which is a 8 pole dip switch.
The first 5 pole positions are the same as on the original IST-VFC.
Pole 1 is factory set in the ON position, which is a 6 second startup pump run
at 34 psi (only applicable if rotary switch is set below position 5), used to help
mechanical leak detectors through test. Pole 1 OFF position is startup pump
run at 8psi higher than the rotary setting for 6 seconds, used for PLLD.
Pole 2 is the product type switch, ON for gasoline, OFF for diesel or kerosene
Pole 3 should be set to ON if the controller is a master in a M/S or M/S
alternating circuit configuration. Default is OFF for standalone or slave
operation of the MagVFC
Poles 4 and 5 are the piping compensation settings. There are 4 positions
from least restrictive piping, for example 200 of 2 fiberglass, to most
restrictive which is equivalent to 75 or more of convoluted bore flex pipe.*
Some additional settings and options available will be discussed next.
*See MagVFC Installation and Owners Manual in the Manuals section of
this manual for further details on switch configuration details.

Additional MagVFC Features


O

Option select SW3


O

Pole 6 (PMA horsepower)


O
O

ON PMAVS4
OFF PMAVS2 (default)

Pole 7 Automatic Restart of UL


OFF (default) UL alarm must be manually reset
ON - MagVFC will attempt to reset the UL alarm when
hook is present

Pole 8 (Alternating Circuit)


O

2004

ON for alternating lead pump (set on Master


controller only)
OFF no alternating (default)
TechM001r3

The MagVFC adds features that improve upon the IST-VFC. Here are brief
descriptions of those features.
SW3 pole 6 sets the controller to the horsepower of the pump. Factory default is
the PMAVS2. If this is set incorrectly the MagVFC will give false alarm conditions or
not perform as expected. Possible false alarms are: SC short circuit when a
PMAVS4 is installed and the MagVFC is set to 2hp, UL under load when a
PMAVS2 is installed and the MagVFC is set to 4hp.
Automatic restart of UL when SW3 pole 7 is ON the MagVFC attempts to clear
the UL alarm when a new hook signal is applied. When the UL condition is
corrected the MagVFC will reset the alarm condition. If the condition still exists it will
continue to indicate the UL condition. When the SW3 pole 7 switch is OFF the
UL alarm must be manually cleared by pushing the reset button.
SW3 pole 8 allows a master/slave configuration to alternate the lead pump when a
hook signal is present. This switch is set on the controller designated as Master
only.
See MagVFC Installation and Owners Manual in the Manuals section of this
manual for further details on switch configuration details.

More MagVFC Features


O

Option select SW6


O

Pole 1 Extended Run disable


OFF (default) Extended run alarm active
ON the Extended run alarm is disabled

Pole 2 Fault Shutdown


OFF (default) only the pump in alarm will shut down
ON in the event of fault all pumps will shut down

2004

Poles 3-8 unused leave in OFF position

TechM001r3

An application may require a submersible turbine pump to run for a long


period of time with no change in the flow rate. When SW6 pole 1 is OFF
(default) and the submersible runs for 60 minutes without a change in flow
rate of the pump, the controller turns off the pump with an extended run
alarm. When SW6 pole 1 is ON the extended run alarm is disabled and the
submersible runs as long as a hook is present and no other alarm condition
exists.
Some sites with Master/Slave operations require total product shut down of
the pumping system when a submersible indicates an alarm. SW6 pole 2
does this. When ON and one of the pumps indicates an alarm condition all
pumps will turn off. When it is OFF (default setting) the controllers will work
as back up pumps when certain alarm conditions occur, UL, LU, HO, LI, OS.
SW6 poles 3-8 are not used and should be left in the OFF position.
See MagVFC Installation and Owners Manual in the Manuals section of this
manual for further details on switch configuration details.

MagVFC Configuration Switches


Option Select (SW6)
Option Select (SW3)
Address Select (SW2)
Pressure Select (SW1)
position # 0 ~ 24 psi
position # 4 ~ 32 psi
position # 9 ~ 42 psi
SW1 @ position # 4
(factory default)
2004

TechM001r3

Pictured in this slide, is the user interface board of the MagVFC.


Along the left side of the user interface board are four banks of switches.
Starting at the bottom you will find SW1 this is a rotary switch labeled 0
through 9 . Just above SW1 you will see the address select switch SW2,
used only when your configuration involves master/slave or master/slave
alternating circuit. SW2 addresses the VFC of your configuration so the
Master can find all of its slaves. SW3 and SW6 configure the MagVFC
controllers and set feature options.
Rotary switch SW1 is used to select pressure output of the pump. SW1
comes from the factory set on position 4, approximately 32 psi output, and is
adjustable from position 0 at about 24 psi to position 9 at about 42 psi. The
SW1 setting is read where the slot across the top of the switch, continues
down the side, pointing at the position numbers on the base.*

*See the Installation and Owners manual in the Manuals section of this
manual for further details on the MagVFC configuration switch settings.

MagVFC Stand Alone Startup


SW3 (set opt. 1, 2, 4, 5 & 6)

Dispenser Hook
120V
Neutral
GND Output Power
to PMAVS2 or
BLK
VS4
ORG
190V, Three
RED Phase, Variable
Frequency
GND
L3

User Interface
panel

L2
Field Wire Panel

Home Run conduits, input & output

SW1 (psi select)


TIP

2004

L1

Input Power
200-250V,
Single or Three
Phase
(no interrupt)

3 phase input power required with PMAVS4

TechM001r3

When starting up a MagVFC for stand alone operation, you will need to
connect input power, including a ground, and a neutral for hook return. Input
power to the MagVFC can be either single or three phase. When single
phase is used, connection must be at L1 and L2. Although three phase input
is not required, the performance of the IST is enhanced when three phase is
used. NOTE: Three phase power is required for the PMAVS4 pump
motors. You will also need to connect the 120V dispenser hook signal and
the field wiring for the motors, including a ground. Since the MagVFC creates
a three phase signal for the motor, there will be no capacitor out at the pump,
unlike the typical 4 STP single phase wiring.*
To ensure no electrical noise problems arise from our wiring, FE Petro
recommends that all the motor leads and input power wires be in their own
rigid conduit, and the conduit be home runs, not routed through troughs or
raceways. If wiring is routed through raceways, every effort must be made to
keep the wiring isolated from other wiring, especially data communications.**
*See Technical Bulletin TB009 in the Reference Documents section of this
manual for further details on wiring recommendations.
**See Installation and Owners Manuals in the Manuals section of this
manual for further wiring details of the controller and pump.

MagVFC Master/Slave and/or Alt. Circuit Startup


Field Wire Panels*
Hook
120V

No Slave
Hook

Neutral

Master
Output
to PMA

GND

Slave
Output
to PMA

D
GN

Master
Input
Power

GN
D

D
GN

Slave
Input
Power
Master MagVFC
Field wire panel

Slave MagVFC
Field wire panel

* Additional wiring required on User Interface panel, see next slide


2004
TechM001r3

The Master/Slave (M/S) function allows multiple submersible turbine pumps


to work together. When a hook signal is sent to the Master controller it will
turn on the pump. As more nozzles open up the Master MagVFC will speed
up the pump and when it reaches a point where it needs help keeping up with
demand the Master MagVFC will turn on a Slave MagVFC to help. The
Alternating (AC) feature allows the MagVFC controllers to take turns being
the first pump to turn on.
For M/S and/or AC operation switches, SW1, SW2, and SW3 need to be set
as detailed in the MagVFC installation manual. On both the Master and
Slave units you will also need to connect the single or three phase input line
power with a ground, and the field wiring for the motors including a ground. A
neutral and 120 volt dispenser hook signal will be pulled to the Master only,
the Slave unit does not get a hook. The slave doesnt get a hook because
the Master communicates to the Slave across the RS485 wiring. Additional
wiring is required on the User Interface panel to complete the M/S wiring,
covered on the next slide.
See the MagVFC Installation and Owners Manual in the Reference Section
of this manual for more details on wiring and configuration of the
Master/Slave and/or Alternating Circuit features.
NOTE: FE Petro is in the process of renaming the Master/Slave and
Alternating Circuit feature to Manifolded Pumps On Demand and Alternating
lead in all of its documentation. This document will change over to the new
terminology when all the other documents are changed.

MagVFC Master/Slave and Alt. Circuit Setup


User Interface Panel*
Slave MagVFC
(user interface panel)

Master MagVFC
(user interface panel)

Yellow
Communication
Light
SW3
Configuration

SW2
(set address)

SW1
(set the same)

SW2
(set address)

RS485

Frequency
G

+
-

When connected properly, Yellow communication light will blink on all MagVFCs
* Additional wiring is required on the Field Wire Panel, see previous slide for details

2004

TechM001r3

Between the Master and Slave, a communication cable is connected, match


1,2,3 and 4 on the master and the slaves. Pressure select switch SW1 and
poles 4 & 5 of SW2 should be set the same on both MagVFCs. CAUTION: If
SW1 and SW2 poles 4 & 5 are not set the same it is possible to exceed the
EPA 10 gpm rule. The Master VFC will tell slave controllers how to run,
matching the pressures when they run together. The Slave setting will be
used if the Master faults or alternates the lead to the Slave. SW3 options
must be set, including pole #3 for Master or Slave. SW2 must be set to
address the Master or Slave. The yellow communication light on the user
interface panel of both controllers will blink when the switches and
connections are made properly. You can also press the reset switch on the
master controller, the slave controllers should reset as well if communicating
properly.*
*See the MagVFC Installation and Owners Manual in the Reference Section
of this manual for more details on wiring and switch settings for the M/S
and/or AC features.
NOTE: FE Petro is in the process of renaming the Master/Slave and
Alternating Circuit feature to Manifolded Pumps On Demand and Alternating
lead in all of its documentation. This document will change over to the new
terminology when all the other documents are changed.

MagVFC Service Info


O

Check Motor Phasing


O
O

Calibrating MagVFC to within 10 gpm Spitback


O
O

Adjust SW1 pressure select with one nozzle open


Adjust SW3 options 4&5 with 3-4 nozzles open

MagVFC Wiring Recommendations


O
O

PMAVS2 running backwards output 10-18 psi


PMAVS4 running backwards output 17-29 psi

Home Runs on Input and Output power


If in wiring trough, isolate from data wires

MagVFC is Unit Replaceable


O

Discard upgrade chip for IST-VFC shipped with


PMAVS2

Allow capacitor bank to discharge for at least 1 minute after


the 7 segment display turns off
2004

TechM001r3

The PMAVS2 and PMAVS4 are 3 phase motors and can run backwards.
Monitor the operating pressure to determine Motor rotation (running
backwards the PMAVS2 output pressure is 10-18 psi and the PMAVS4 is 1729 psi, depending on the SW1 select setting). Correct the motor rotation by
changing the positions of two of the motor leads. If the wiring color code is
followed, the PMA will not run backwards.
To calibrate the MagVFC for 10 GPM flow, measure GPM at the dispenser
closest to the tank with one nozzle open. Adjust the SW1 setting until flow is
as close to 10 GPM as possible. For best results, testing should be done with
completely clean dispenser filters, as a dirty filter will affect flow rates.To adjust
the piping compensation, measure GPM at the same test nozzle with two or
three additional nozzles open. If flow rate drops below the one nozzle
readings, adjust SW3 poles 4 & 5 until best results are achieved without going
over 10 GPM spitback rule.
When wiring a MagVFC, home runs of rigid steel conduit are recommended for
the input and output wiring. If wired through a trough, isolate from data wires.
MagVFCs are unit replaceable, which means there are no serviceable parts.
PMAVS2s have been shipping since Feb. 2002 with software chips, these
chips are for the original IST-VFC controller and should be discarded when
used with the MagVFC.
For your safety, before opening the MagVFC controller cover wait 1 minute
after the 7 segment display turns off so the capacitors discharge.

Relay Control Box w/ Switch


(STP-CBS)
O

ON / OFF Lockout Switch

Pump ON Indicator Light

2004

Dispenser Signal energizes


relay coil, latching Line
power to Submersible
wiring to run motor

One relay box per STP

Rated up to 2 hp

TechM001r3

Our standard, single phase relay control box, is our model STP-CBS. The
CBS is equipped with an external on/off switch as an added safety feature.
In the OFF position, the switch disconnects input line power and dispenser
hook power from the relay, but there is still line power and dispenser hook
voltage in the box. Proper lockout/tagout still needs to be done before
opening the enclosure. With input power applied to the CBS, when a
dispenser hook signal is received the indicator light is lit, the signal energizes
the coil of a relay which latches the relay closed, and allows input power to
flow to the output, thereby turning on the STP. One STP-CBS is required per
pump. Now the STP-CBS is rated for up to 2hp submersible turbine pumps.

STP-CBS Wiring

Connect 120 V
dispenser signal
Connect motor
wiring

M1
Ground
M2

STP

2004

208-240
Volts
Ground
L2
L1
Neutral

Connect Input
Power Supply

Dispenser

TechM001r3

To wire a CBS, you will need to connect in the field wring for the motor,
including a ground, connect your single phase input line power, with a
ground and neutral (for the hook return), and your 120 volt dispenser hook
signal. See STP/IST Installation and Owners Manual for complete wiring
diagrams and details.

3 Phase Control Box for 3/5 hp


(STP-CB 3/5)
O

Magnetic Starter
Three Leg Protection
Quick Trip Heaters,
sized to motor
application
Manual Trip and
Reset

2004

TechM001r3

Like the CBS, FE Petro offers a three phase version for 3 and 5 hp pump
control. The 3 phase control box comes with a magnetic starter relay and
three leg, quick trip heater protection, sized for your motor application. The
box also features manual trip and reset buttons for testing of the heater
circuit.

Connect Input
Power Supply
Connect 120 V
dispenser signal
Connect motor
wiring

Dispenser

Ground
L3
L2
L1
Neutral

STP-CB3/5 Wiring

208-240
Volts

Ground
M3
M2
M1
Thermal
Thermal

STP

2004

TechM001r3

To wire a CB3/5, you will need to connect your three phase input line power,
with a ground and neutral (for the hook return), and a 120 volt dispenser hook
signal which is connected into the motor overload wiring (the thermal
overload of our 3 & 5 hp motors are external to the windings). When
energized, the hook signal will pass through the thermal overload, through
the heater block, and energize the coil. If the overload or the heaters should
open, the pump will stop. Complete the wiring of the motor by pulling the
three legs of the motor, including a ground, back to the controller.
See High Capacity Pump Installation and Owners Manual in the Manuals
section of this manual for complete wiring diagrams and details.

Dispenser Hook Isolation


(STP-DHI)
O

Isolates Dispenser Hook


circuits to prevent electrical
feedback
Prevents false STP run due to
dispenser leakage voltage
Prevents dispenser interface
board damage due to output
cross-phasing
Compatible with any pump
controller hook circuit

Skip DHI

2004

TechM001r3

The STP-DHI is a device that isolates dispenser hook circuits to prevent


electrical feedback. This allows for servicing of one dispenser without having
to shut the entire site down (dispensers must be wired on separate breakers
to enable lockout/tagout). The DHI also prevents false STP run due to
dispenser leakage voltage, and damage to dispenser interface boards due to
cross phasing. The DHI is compatible with any pump controller hook circuit,
including hook signals from electronic leak detectors.

STP-DHI Wiring

Fast Acting Fuse


(250V, 1 amp)

120 Volts
Input Power

Input Power
Indicator LED

Output To 120V
Pump
N
Controller
Hook Circuit

Dispenser Hook
Indicator LED

Dispenser #1
120V Hook

* STP-DHIs can be
cascaded together

* up to 8 Hooks per
STP-DHI
2004

L1

TechM001r3

To wire the DHI, attach the 120V input power to the box. Connect the 120V
output to the hook circuit of the pump controller for this product. Connect the
120V dispenser hook signal and a neutral for each handle. On board the
DHI, there is a fast acting fuse to protect against mis-wiring of the box.
When input power is applied, the green power indicator LED will light. When
a dispenser hook signal is applied, the green hook indicator LED will light.
Cascade multiple DHIs when more than 8 hooks per product are required.
See STP-DHI Installation and Owners Manual in the Manuals section of this
manual for complete wiring diagrams and details.

Cascaded STP-DHI (more than 8 inputs)


120 v
Neutral
From supply

120 v signal
Neutral
To Controller

#1 Dispenser
Neutral
120v
#N Dispenser
Neutral
120v

2004

TechM001r3

More than one DHI can be cascaded to create more dispenser hook inputs.
If more than 8 dispenser hook signals are at a site, 2 DHI can be wired
together to provide 16 dispenser hook inputs. Wire the input power as shown
and the output to the controller as shown and wire the dispenser hook signals
as normal using all 16 input positions.
See STP-DHI Installation and Owners Manual in the Manuals section of this
manual for complete wiring diagrams and details

STP-DHI Combo Units


O

Factory configured with standard relay Control Box


or single phase Smart Controller

STP-DHI-CBS
2004

STP-DHI-SCI

TechM001r3

FE Petro offers the DHI factory wired to either a STP-CBS control box (STPDHI-CBS) or the STP-SCI smart controller (STP-DHI-SCI). Factory wiring to
the MagVFC or other controllers is not available.

Technical Support
On Behalf of

techserve@fepetro.com
1-800-225-9787

and

608-838-8786

Thanks for Attending !!!

2004

TechM001r3

Thanks for your interest in Franklin Fueling System products and attending
our seminar.
Please do not hesitate to contact us with questions! As we stated earlier, we
are always happy to answer any and all of your questions. Dont forget to
also reference these materials for help, but use the Installation and Owners
Manuals that come with the equipment for the most current, complete details
on installation and safety.