DEF Recirculation GuideUsing Franklin Fueling Systems TS-550evo™ Series Fuel Management System
Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA
Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
2
Important Safety MessagesDiesel Exhaust Fluid (DEF) is a non-flammable, non-combustible liquid. DEF is stored and dispensed in areas close to volatile hydrocarbon liquids such as gasoline and diesel fuel. Read and follow this entire instruction booklet before installing or working on this equipment.
Follow all federal, state, and local laws governing the installation of this product and the entire system. When no other regulations apply, follow NFPA 30, 30A, and 70 from the National Fire Protection Association. Failure to do so could result in severe injury, death, serious property damage and/or environmental contamination.
If the electrical circuit breakers are accidentally turned on while the motor controller is being installed, electrical power could be applied to the motor controller, creating the risk of potentially lethal electrical shock hazard. ALWAYS tag and lock breakers so they are not turned on accidentally.
Always disconnect both power supplies (110-250V Hook and the 208-240V input) before installing or servicing. Failure to do so could result in severe injury or death.
Warning
Warning
Warning
Warning
ContentsImportant Safety Messages .................................................................................................... 2
Overview of DEF Recirculation system ................................................................................. 3Why it’s needed ............................................................................................................... 3Specifications .................................................................................................................. 3DEF Handling Guidelines ................................................................................................ 4
Installation Guidelines ............................................................................................................ 5
STP Installation ........................................................................................................................ 6Piping ................................................................................................................................ 6Ball Valve Adjustment ..................................................................................................... 8
DEF (Diesel Exhaust Fluid) Shear Pipe Instructions (If Used) ............................................ 9
Hanging Hardware ..................................................................................................................11
Probe Installation ...................................................................................................................12Bottom-mount inventory probes ...................................................................................12
Installing the TS-550 evo™ ....................................................................................................13Standard Installation Materials .....................................................................................13Cables Required for Liquid Level Probes, VFMs & 4-20 mA Sensors .......................13Cable or Wire for 2-Wire or 3-Wire Sensors .................................................................13
FMP-TEM Temperature Sensor Overview ...........................................................................14
TS-550evo™ Console Setup ..................................................................................................15Module Wiring .................................................................................................................15
Programming Modules ...........................................................................................................16
Logic Conditions Setup ........................................................................................................16
DEF Probe Module Setup........................................................................................................ 18
Control Box Wiring .................................................................................................................19
Troubleshooting .................................................................................................................... 20
PEI Recommended Practices ............................................................................................... 21
Other Franklin Fueling Systems Resources ....................................................................... 21
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Overview of DEF Recirculation systemWhy it’s neededBecause Diesel Exhaust Fluid will freeze at approximately 12 °F, there is the risk of the fluid freezing in colder climates. A recirculation system like that in Figure 1, will ensure automated recirculation and prevent freezing.
Figure 1: DEF Recirculation Setup: UPP Piping DEF Recirculation Setup: APT XP Piping
* The temperature sensor should be installed at the coldest location. The illustration shows one possibility, though more than one temperature sensor can be used.
The temperature sensors are installed in the recirculation tee assembly and are connected to the 4-20mA Input Module in the TS-550 evo™. When the temperature reaches the programmed low temperature set-point, the pump will start and circulate the DEF. This continual flow of DEF will keep the fluid from freezing. When the temperature rises above the programmed high temperature set-point, the recirculation will stop. Refer to the section “TS-550evo™ Console Setup” for details.
About DEFDiesel Exhaust Fluid (DEF) is a non-flammable, non-combustible liquid. DEF is used in vehicles that use diesel fuel and which are equipped with Selective Catalytic Reduction (SCR) equipment to reduce emissions
SpecificationsSpecific gravity _____________________ 1.09 at 68° F
Urea ______________________________ 32.5%
Distilled or deionized water ____________ 67.5%
Freezing Point ______________________ 12° F (-11° C)
DEF will degrade with prolonged storage above 77° F (25° C) or exposure to sunlight. Refer to the DEF manufacturer’s guidelines for proper storage.
ISO 22241-1 defines DEF as the same as AUS 32 (aqueous urea solution).
Return to Tank
From DEF-PMAFrom DEF-PMA
* Temperature Sensor (Connect to 4-20mA Module)
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DEF Handling GuidelinesContamination of the DEF must be avoided, as it could result in damage to the SCR equipment.
• DEF systems must use DEF-compatible materials to prevent product contamination, degradation or unintended release. The use of incompatible materials will contaminate and degrade the DEF and may cause it to fail ISO quality standard 22241-3.
• Do not use any equipment with DEF that was formerly used to store or dispense any other fuels or liquids.
• Do not use towels, rags, wipes, tools or other accessories that have been used with petroleum products. Residual amounts of petroleum can transfer to surfaces in contact with the DEF and contaminate it.
• DEF handling equipment must be dedicated for use with DEF only and should not be used for storage or handling of other products or materials.
• Lubricants and thread sealants must be explicitly compatible with DEF.
• Follow the thread sealant or lubricant manufacturer’s instructions concerning the amount of thread sealant / lubricant to use. Excess product, even if compatible with DEF, could contaminate the DEF.
• Do not modify the DEF-compatible product. Modifying or altering the product in any way will defeat the rigorous quality control tests performed during assembly and could cause a dangerous safety situation.
• Regular maintenance of DEF equipment is required to ensure proper functioning of the system and to maintain DEF quality. Special care must be taken to ensure any DEF contact surfaces are kept clean to prevent possible contamination.
Possible Temperature Sensor Location
DEF Tank Sump
DEF Dispenser Sump 1 DEF Dispenser Sump 2
Pump Discharge Line
Recirculation Return Line
Tank Fill
Pump Riser (6")
Level Probe
Pump Controller
TS-550evo
Not to Scale
Hook Signal
Power
Figure 2: DEF System Schematic (Details found on following pages)
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Installation GuidelinesSplice Connector Kits Must Be Used — Warranty RequirementUse the Franklin Fueling System-approved, moisture-resistant, no-strip splice connectors for liquid level probe and sensor wires. You may order the TSP-KW30, which contains 30 of the approved, moisture-resistant connectors. Using moisture resistant splice connectors will:
• Reduce / eliminate corrosion of the wire connections from repeated exposure to water condensation, which causes eventual signal loss and system failure.
• Reduce / eliminate equipment damage from water flooding around the connectors, which causes short-circuit damage.
Thread Sealant (UL Classified)Use a non-hardening DEF-Compatible thread sealant to seal and waterproof all tank riser pipe threads. Apply thread sealant to seal / waterproof all outdoor electrical conduit fitting threads including the hole plugs at the weatherproof junction boxes.
Riser PipesANSI Schedule 40 (or chemically non-reactive) 4 inch (101.6 mm) riser pipes for liquid level probes. The DEF-PMA riser is 6 inch (152.4 mm).
Probe Installation Kit(s)See the TSP-LL2’s installation instructions that came with the probe for the items included with the probe installation kit. For DEF applications, see the TSP-LL2C’s installation instructions for the TSP -K4AS stainless steel riser cap adapter kit and the TSP-SSP stainless steel product float.
TSP-LL2 Probe FloatsDEF Installations require the TSP-SSP stainless steel float for chemical products
Manufacturer’s Tank Chart for Each TankThe manufacturer’s Tank Chart and other documentation will be used for installation and programming, and possibly for future reference. Keep this information — do not discard it.
Temperature SensorThe temperature sensor is located in the coldest spot in the furthest dispenser. If the dispenser is heated, the location can be as shown in Figure 1. If the dispenser is not heated, the temperature sensor and the recirculation connection may be connected just below the breakaway. More than one temperature sensor can be used.
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STP InstallationProcedure
1. Tag and lock out electrical circuit breakers so they are not turned on accidentally.Note: Wiring for single phase units may include a run / start capacitor. Make sure the capacitor is safely discharged
before disconnecting supply wiring.
Note: Never lift or suspend the DEF Pump Assembly by the power cable.
2. Verify that DEF Pump Assembly properly incorporates a Non-Return Check Valve and Bypass Relief Valve (Reference Figure 2).
Note: Ensure proper flow orientation of the Non-Return Check Valve. With wrong orientation of this valve, the DEF-PMA will not produce flow.
Note: A Bypass Relief Valve must be installed to provide flow for cooling the unit. Running the DEF-PMA without product to properly cool the unit can cause irreparable damage.
Note: Measure the Pump Motor length. Verify that the length of the DEF Assembly will not touch the bottom of the tank. The DEF-PMA will typically be suspended about 3" (76 mm) off the bottom of the storage tank.
Model Number Discharge Outlet Outside Diameter Inlet-to-Outlet LengthDEF-PMA150A 2" NPT female 5.1" (130mm) 18.7" (474mm)DEF-PMA150B 2" BSPT female 5.1" (130mm) 19.8" (504mm)DEF-PMA150C 2" BSPT female 5.1" (130mm) 19.8" (504mm)DEF-PMA150D 2" NPT female 5.1" (130mm) 18.7" (474mm)
3. Apply DEF compatible thread sealant to product piping and thread on DEF-PMA.
Note: Do NOT use PTFE Thread Seal Pipe Tape. Use only DEF-compatible materials to prevent product contamination and / or unintended release.
Note: Prevent Power Cable damage while threading on DEF-PMA. Do not over-tighten product piping into DEF-PMA or the discharge port may be damaged.
4. Fasten Power Cable to the DEF Pump Assembly product piping to prevent it from being damaged during install or extraction. (Reference Figure 2)
Note: Do not fasten power cable too tightly. Provide enough freedom to prevent stretching or cutting of power cable.
PipingDEF Piping must be DEF-Compatible, such as:
• Franklin Fueling System’s UPP semi-rigid High Density Polyethylene Piping with Electrofusion couplings or stainless steel fittings.
• Franklin Fueling System’s APT brand XP pipe with stainless steel fittings and APT Rigid Entry Boots.Refer to References at the end of this manual for further instructions available.
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Cable Grip (Included in DEF-PMA Install kit)Cable outside diameter0.31 - 0.33" (8-9mm)
DEF-PMA
To Relay Controller (Power Supply)
Bypass Relief Valve Cracking Pressure 30-40 PSI (2.1 - 2.8 bar) 4 gpm minimum flow
Non-Return Check Valve Cracking Pressure 3 PSI (0.2 bar) Maximum
Pressure Gauge Connection
To DEF Filling Point(s) (Using UPP Piping)
Figure 2: DEF Discharge Piping* The Outlet ball valve is either open or closed and is not used to regulate system flow.
*Outlet Ball Valve
Using APT XP Pipe and Rigid Entry Boot
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Return Line Ball Valve
Figure 3: DEF Return Line: UPP Piping
Figure 4: DEF Return Line: APT XP Piping
Return Line Installation Using the Ball Valve AdjustmentTo adjust the Return Line Ball Valve:
1. Install a pressure gauge on the top of the riser as shown in figure 2. 2. Start the pump and Close the Return Line Ball Valve. 3. Record the dispense pressure shown on the gauge.4. Slowly open the Return Ball Valve and set the valve to achieve 1 - 2 PSI less than the pressure recorded in step 3.
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DEF (Diesel Exhaust Fluid) Shear Pipe Instructions (If Used)
Figure 5: DEF Shear PipeThe Shear Pipe must be rigidly anchored to a structural member within the island and dispenser. The recommended practice is to use the separately sold FFS Mounting Bracket (#66320000) and attach pipe to either the Stabilizer Bar Kit or ground. This will ensure breakage at the shear section in the event of a severe impact to the dispenser causing the single poppet to close to stop fluid flow.
To Attach Shear Pipe to Stabilizer Bar Kit using Bracket Assembly (66320000)1. Attach shear pipe to the 1 ½" riser and tighten with a wrench across the bottom flats. Riser length should be made
to position the shear section at grade level.2. Attach 1" pipe (minimum 12") to the top and tighten while holding the shear pipe stable with a wrench across the
top flats.
Caution: Do NOT apply strong opposing torques across the shear section. Doing so can permanently damage the shear valve.
3. Install DEF Shear Valve on Mounting Bracket as shown below, making sure to put reinforcement pieces over U-bolt after it has been put on shear pipe.
4. Using bolts included with the Stabilizer Bracket Kit, mount DEF Shear and Bracket assembly on Stabilizer Bracket Kit as shown.
Figure 6: DEF Shear Valve Mounted to Stabilizer Bracket
To Mount on Ground (Concrete) using Bracket Assembly (66320000)1. Drill 2 holes 3/8" at least 2.25" deep, located as shown below Holes should be 4.75" apart set back from hole
approximately 1.5"
0.375Ø"(9.5 mm)
4.750"(121 mm)
1.5"(38 mm)
Figure 7: Concrete Hole Placement2. Drive the concrete anchors in so that ¾" of thread remains out of the holes.
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3. Install the bracket over the anchors.4. Install washers and nuts, tighten nuts so that a few threads protrude through the nut.
Figure 8: Installing Bracket
5. Install the Shear Valve onto bracket to determine necessary length of riser so that U-Bolt will fit into matching holes (upper set) of Bracket.
Figure 9: Install Shear Valve
6. Attach shear pipe to the 1 ½" riser and tighten with a wrench across the bottom flats. During installation, valve may be removed from bracket, it must be re-attached after riser installation.
7. Attach a 1" pipe (min 12") to the top and tighten while holding the shear pipe stable with a wrench across the top flats.
Caution: Do NOT apply strong opposing torques across the shear section. Doing so can permanently damage the shear valve.
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Hanging HardwareHanging hardware includes the hoses and nozzles.
Hose and Nozzle Installation Procedure1. The work area must be clean and have sufficient lighting.2. Remove nozzle from carton.
Note: Tapered threads should be covered with non hardening UL approved, DEF / AdBlue®-compatible, sealing compound. Straight threads must NOT use sealing compound. Flat Seals on hoses must be lubricated with light oil before assembly.
3. Assemble the nozzle to the hose assembly and torque to 35 to 70 foot pounds (47 - 95 Nm).
Note: The integrity and operation of the nozzle are the responsibility of the installer and customer.
4. Visually inspect all new hardware connections for signs of potential leak points. Repair any issues immediately before proceeding.
5. Authorize the dispenser.6. Visually inspect all new hardware for leaks. If leaks are present immediately repair leaks before proceeding.7. Purge air from new hardware by pumping about one gallon from each fueling point into an approved container.
¾" automatic nozzle
¾" automatic nozzlewith miss-fillingprevention spout
¾" BSPP x ¾” NPT hose
¾" break away valve
1" BSPP x ¾" NPT hose¾" BSPP x 1" BSPP(or M34 x 1)swivel break awayvalve
Whip Hose
Figure 11 : DEF Hose Options
Note: The Miss-Filling Prevention insert temporarily installs in the vehicle’s DEF fill neck if it is over-sized. These inserts are available from many DEF retailers as well, and those inserts can be inserted into the DEF fill neck permanently.
Figure 10: DEF Nozzle
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Probe Installation
* TSP-UVPK is used to cover the probe head if it is exposed above ground)
TSP-K4AS Riser Cap
* TSP-UVPK probe head protective cover
TSP-SSP Stainless steel float
Figure 12: Probe Installation Overview
Installing the Probe in the TSP-K4AS1. Remove and save the C-Clip and washer from the
bottom of the probe.
C-Clip
Washer
Figure 13: Probe Clip and Washer2. Install the compression fitting in the top of
TSP-K4AS metal cap labeled 4SC. Use a DEF / AdBlue™ -compatible thread-compound to seal the lower threads of the compression fitting.
3. Install the end of the probe through the fitting.4. Install the TSP-SSP float.5. Replace metal washer and C-Clip.6. Screw the metal cap labeled 4SC onto the top of
the riser pipe and tighten to 20-25 ft. lbs. (27- 34 Nm) torque.
Note: Do not use thread sealant when installing the cap. The cap has a washer that will seal against the riser.
7. With the probe installed and sitting on the bottom of the tank make a small mark (can use a black marker) on top of the compression fitting.
8. Then lift up the probe so that the mark is ¼" (6.4 mm) from the compression fitting. (This insures that the end of the probe is ¼" (6.4 mm) off the bottom
of the tank.)*
Compression Fitting Mark
¼" (6.4 mm)TSP-K4AS
Figure 14: Probe Installed9. Tighten the compression fitting.
* All probes, including TSP-LL2-xxx-I inventory probes, that come with bottom mount hardware, should be installed 1/4" (6.4 mm) off the bottom of the tank when using the TSP-K4AS install kit to allow for expansion.
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Installing the TS-550 evo™Conduit must only enter the console enclosure through the designated knockouts as shown below in Figure 2. When installing additional modules, Franklin Fueling Systems recommends installing non-IS modules from left to right (from the open slot closest to the power supply) and IS modules from right to left. In this scenario, all unused slots will be concentrated in the middle of the enclosure, which lets the IS barrier be easily moved and allows for the possibility of adding future modules to the system without needing to rewire those devices already in place. It’s also a good idea to always start wiring your module at the bottom-most set of channels (usually Channel 1) to further future-proof your installation and avoid any unnecessary confusion.Intrinsically safe wiring must only enter the console through IS knockouts, and non-intrinsically safe conduit only enter through non-IS knockouts. Maintain the integrity of the intrinsically safe modules by keeping probe and sensor wiring in conduit separate from all other wiring. Probe and sensor wiring may be run in the same conduit as long as they are both receiving power from the same console and the wire complies with NEC 504.30 or applicable local codes.
CO
MM
2B
US
EX
T
CAN H
CAN L
GND
TP
I R
S-4
85
CO
MM
1U
SB
ET
HE
RN
ET
HO
RN
FAX
/MO
DE
M
NON-INTRINSICALLY SAFE WIRING ONLY!FOR USE ONLY WITH EQUIPMENT SPECIFIED
IN THE INSTALLATION INSTRUCTIONS Figure 15: TS-550evo™ Knock-Outs and Module Placement
Standard Installation MaterialsRecommended standard materials should be selected and installed per all applicable local, state and federal codes governing the installation of this product and its associated systems. Please see the corresponding console/module wiring section or the associated devices section of this manual for complete installation details.
Cables Required for Liquid Level Probes, VFMs & 4-20 mA SensorsUse cables and wires compliant with national and local codes. Franklin Fueling Systems recommends using the types of cable shown below up to a recommended length of:
• Belden No. 87760 (0.15” or 3.048 mm OD) to 260 feet (80 m) • Belden No. 87761* (0.12” or 3.048 mm OD) to 400 feet (120 m) • Belden No. 88761 (0.12” or 3.048 mm OD) to 400 feet (120 m) • Belden No. 89182* (0.31” or 7.874 mm OD) to 1500 feet (450 m)
Note: An asterisk (*) denotes a cable that may be ordered from Franklin Fueling Systems.Note: Conductors of different intrinsically safe (IS) circuits may be run together within the same conduit, and, when they
do, they should have at least .01 inches (.25 mm) of insulation.
Cable or Wire for 2-Wire or 3-Wire Sensors2-wire or 3-wire sensor wire (type THHN, TFFN, or THWN, gas and oil resistant, 18 AWG minimum, 1500 feet max. wire run length) can be used when enclosed within rigid metal conduit from the sensor to the console.Leak detection sensor cable is required when not run through rigid metal conduit. Refer to the Direct Burial Cable – Installation Manual (P/N 000-1041) for further information. Alpha 58411 (P/N 600-0062) cable will work.
Cable SpecificationsCables must be shielded twisted pair; 22AWG or greater and the cable jacket must be oil / water resistant
Cable length Max capacitance per foot Max InductanceUp to 500 feet 100 picofarad (pF) per foot 0.2 microhenry (uH) per foot
Up to 1000 feet 60 pF per foot 0.2 uH per foot
Up to 1500 feet 20 pF per foot 0.3 uH per foot
Bottom of console
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FMP-TEM Temperature Sensor OverviewThe FMP-TEM Temperature Sensor is an advanced 4-20mA temperature measurement device. The primary application for the FMP-TEM is Franklin Fueling Systems’ DEF Recirculation System. The sensor is used to monitor the temperature of DEF/Ad Blue and trigger the systems to recirculate the fluid to prevent freezing. The sensor can also be used in other applications to monitor temperature.
The included stainless steel tube fitting is designed as a leak-free connection for installation into DEF piping. The tube fitting offers a single ferrule design that requires only two metal-to-metal seal points to affect a leak-tight seal. With fewer components, the tube fitting design reduces potential leak paths.
2.00"51mm
6.00"152mm
0.44"11.2mm
0.25" 6.4mm
FMP-TEM Temperature Sensor
0.70"17.8 mm
1.76"45 mm
1.47"37.3 mm
Internal Fitting
0.75"19 mm
Compression FittingFMP-TEM Installation
1. Relieve pressure and ensure the line is empty prior to beginning installation.
2. Tag and lock out electrical circuit breaker so they are not accidentally activated
3. Do not remove the nut or apply thread sealant to the tube end of the tube fitting.
4. Select the appropriate reducer fitting for the FMP-TEM’s tube fitting and the site’s DEF piping. The tube fitting is a ½” Male NPT.
5. Apply DEF-compatible thread sealant to the tube fitting threads.
6. Thread and tighten the ½” Male NPT end of the tube fitting into the reducer fitting.
7. Apply DEF compatible thread sealant to the reducer fitting.
8. Thread and tighten the tube fitting and reducer assembly into the DEF piping.
9. Insert the FMP-TEM into the tube fitting until approximately ½” (12.7 mm) of the sensor is still protruding from the fitting. Depending on the piping configuration it may not be possible to insert the sensor fully. In this case insert the sensor as far as possible without bottoming out the sensor.
10. Tighten the compression fitting only 1¼ turns after finger tight.
1 ¼ Turns After Finger-Tight
FMP-TEM WiringThe FMP-TEM Temperature Sensor includes 2 electrical connectors for installation inside the junction box only.
1. Use the 2 moisture-resistant connectors provided for each sensor. For these splices, the wire insulation is NOT cut-back (NOT Stripped)
2. Insert the 2 brown wires into two separate opening of the first connector. Make sure the wires are fully inserted and seated at the end of the connector.
3. Insert the 2 black wires into two separate opening of the first connector. Make sure the wires are fully inserted and seated at the end of the connector.
4. Squeeze each connector together using 8” slip-joint pliers (position the pliers jaws on the connector perpendicular to the wires and drive the black cap down almost flush to the edge of the connector body).
After Crimp ToConsole
ToFMP-TEM
Before Crimp
End view of splice White wire of Sensor (-)
Brown wire of field cable (+)
Black wire of field cable (-)
Black wire of Sensor (+)
Splice Connection
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TS-550evo™ Console SetupFuel Management System
Module WiringThe Probe Module gathers data from the DEF Inventory level probe.
The Relay Module connects to the motor controller.
The 4-20mA Input Module takes a signal from the temperature sensor.
Figure 16: DEF O
verall Wiring Schem
atic
Relay M
oduleR
UN
ER
R
NO
8C
8N
C8
NO
7C
7N
C7
NO
6C
6N
C6
NO
5C
5N
C5
NO
4C
4N
C4
NO
3C
3N
C3
NO
2C
2N
C2
NO
1C
1N
C1
Sw
itching Current 2A M
ax.S
witching P
ower 1500 VA M
ax.
Probe M
oduleR
UN
ERR
987–Blk+R
ed
–Blk+R
ed
–Blk+R
ed
121110
–Blk+R
ed
–Blk+R
ed
–Blk+R
ed
321–Blk+R
ed
–Blk+R
ed
–Blk+R
ed
654
–Blk+R
ed
–Blk+R
ed
–Blk+R
ed
4-20mA Input
Module
RU
NE
RR
–+ –+ –+ –+ –+ –+ –+ –+
Controller M
oduleRU
NE
RR
MO
DE
M
TXD
DTR
RX
D
DC
D
LCD/PRINTER
Power Supply
Module
RU
NE
RR
5V24V
PO
WE
RL1
N/L2
RE
LAY OU
TPU
TSN
C1
C1
NO
1
NC
2
C2
NO
2
LOW
VO
LTAG
E IN
PU
TSIN
1
GN
D
IN2
GN
D
DEF D
ispenser
Electrical Power Panel
TS-550evo Console
STP
-CB
3/5 Magnetic S
tarter (110/120 volt signal)S
TP-C
BB
3/5 Magnetic S
tarter (220/240 volt signal)
To DE
F Filling Point(s)
DEF-PMA
Power
Power
Hook SignalH
ook Signal Interlock
Tank Level Probe
T
Temperature
Sensor
Additional
Temperature
Sensors (Optional)
T
Not to S
cale
AC
Input M
odule
RU
NE
RR
Chan3
Chan2
Chan1
Chan6
Chan5
Chan4
Chan12
Chan11
Chan10
Chan9
Chan8
Chan7
16
Programming ModulesThe Fuel Management System for DEF is composed of a custom set of modules. Each module has individual characteristics. Parameters must be set to match the site configuration. The programming table below will assist in this setup.
Note: The setup below is specific to an installation monitoring Diesel Exhaust Fluid.
4-20 mA Input Modules The Analog Input Module has 8 identical channels for loop powered IS sensors with a 4-20 mA interface.
Group NameParameter
NameDEF Entry DEF Description Notes
4-20mA Input Modules
Module 1 Channels 1 Temperature sensor for DEF One channel required for DEF
Channel 1
Name DEF Temperature Sensor
Given name of the DEF Temperature Sensor Provide a name for the sensor
Service Type Temperature Sensor Determines the input signal as being a temperature sensor
Select Temperature Sensor from drop down list
Sensor Type FMP-TEM Selects the DEF temperature sensor Select from drop-down listLow Range -40 Minimum Temperature Reading
High Range 120 Maximum Temperature Reading
Logic Conditions SetupThe Logic Conditions set up the parameters for DEF recirculation.
Group Name Parameter Name DEF Entry DEF Description Notes
Logic Conditions
Group - DEF Recirculation Application
Name
Enabled
DEF Recirculation Application
Yes
Given name of the DEF Recirculation Condition This is the Name for the
Condition. Enter Yes to enable
Conditions
Condition - DEF Needs Recirculation Name DEF Needs Recirculation Name of the condition
Description Activates when temperature drops below the active threshold and resets above the reset threshold
Describes function of the Condition
Type Value Parameter to perform Condition Select from drop-down listValue Type Temperature Sensor Select from drop-down list
Channel Real DEF Temperature Sensor Defines channel used for the Condition
Active above limit No Choose if Condition will be active above the limit
Active Below 33.00 ºF Defines temperature where recirculation begins
Enter the Active Below temperature threshold
Reset Above 40.00 ºF Defines temperature where the Condition will reset
Enter the Reset Above temperature threshold
Logic Conditions Setup: Set the Recirculation TimeoutCondition- DEF Recirculation Timeout
Name DEF Recirculation Timeout Name of the ConditionDescription Starts when DEF Recirculation
begins to limit total run-timeFunction of the Condition
Type Timer Parameter to perform Condition Select from drop-down listTimer Type Active After Identifies type of timer activity Select from drop-down list
Duration 15:00 min Identifies time duration used Enter time durationReset on Input Yes Allows reset on new input
Input Input Type Condition Type of Input used Select from drop-down listInput Condition DEF needs circulation Identifies Condition used for
Input Select from drop-down list
Invert Input No Only changed if the Input is to be inverted
17
Logic Conditions Setup: Define the Condition Output
Group NameParameter
NameDEF Entry DEF Description
Notes
Outputs
Condition Output Invert Input No Only changed if the Input is to be inverted
Input Condition DEF Needs Recirculation Identifies which condition to use for Output Select from drop-down list
Type Relay Selects Type of output Select from drop-down listModule Relay Module Identifies module used Select from drop-down list
Channel DEF Recirculation Pump Identifies Channel used Select from drop-down listAction Type Activate Identifies action performed Select from drop-down list
Logic Conditions Setup: Set DEF Condition Output
Group NameParameter
NameDEF Entry DEF Description
Notes
Outputs
Condition Output Invert Input No Only changed if the Input is to be inverted
Input Condition DEF Recirculation Timeout Identifies which condition to use for Output Select from drop-down list
Type Alarm Selects Type of output Select from drop-down listCondition Output Invert Input No Is Input to be inverted?
Input Condition DEF Needs Recirculation Identifies which Condition is used as Input Select from drop-down list
Type Application Event Identifies type of Condition used Select from drop-down list
Setup the Relay Module that Contols the DEF Pump Motor
Group Name Parameter Name DEF Entry DEF Description Notes
Relay Modules
Module 110 Amp
Channels
No
1
Selects for TS-10RLY or TS-RLY
Number of module channels used
Deselect for the TS-RLY
Channel 1
Name DEF Recirculation Pump Name of the Module Channel usedEnabled Yes Enables the channel
Type Submersible Pump Select the type of action for the channel Select from drop-down listPolarity Normal Allow the polarity to be inverted from
normally closed to normally open Select from drop-down list
Logic OR Logic The type of logic that is used to process incoming signals. In OR, if any combination of inputs is active, the relay is active.
Select from drop-down list
Physically Wired As Normally Open Identifies the wiring configuration of the channel Select from drop-down list
Number of inputs 0 Number of inputs used by the channel
18
DEF Probe Module Setup
Group Name Parameter Name DEF Entry DEF Description Notes
Probe Modules
Module1 Channels 1 Number of channels in use per module. 1 per DEF tank
Channel # Name DEF Probe Given Name of Probe.Type TS-LL2 Type of device connected. Select from drop-down list
Monthly Compliance No Yes / No
Probe Setup under Fuel Management System - Tanks
Group Name Parameter Name DEF Entry DEF Description Notes
Fuel Management SystemTanks Number of Tanks 1 Number of DEF tanks
Probe Module FMS Probe Module Identifies module used Connect the DEF Probe to the Probe Module
Channel DEF Tank Identifies channel used Select from drop-down list
Type Standard XXX Identifies type of probe used. this will be specific to the installation. Select from drop-down list
Ratio 1 to 1 tip to head Select from drop-down listFloat Type Stainless DEF uses a Stainless Steel float Select from drop-down list
Water Float No Indicates if a water float is used DEF does not use a water float
Gradient (9.03000 µs / in) An adjustment specific to this probe Use the number printed on the probe label
Product Offset (0.00 in) Used for tank tilt compensation
19
Control Box WiringFigures 5 & 6 show wiring for single phase and 3-phase 60 Hz control box wiring.
Note: The lockout switch does not substitute for proper safety lockout. ALWAYS tag and lock breakers so they are not turned on accidentally during maintenance.
Model STP-CBSSingle Phase Motor Control Panel
Line Starter120 V COIL
Lockout Switch
Neon Pilot Light
S M2 M1 L2L1N
L2L1 GND
Neutr
al
120 VoltDEF Hook Signal
SINGLE PHASEPOWER SUPPLY
Ground Green
Brown
Supply (Black)Supply (Blue/Gray)
DEF-PMA150ASingle Phase
60Hz, 208-240 Volts
Capacitor 25µF
Relay Module
Figure 27: DEF-PMA 150A Single-Phase Wiring
Ground GreenSupply (Black)
Supply (Blue/Gray)
Supply (Brown)
120 VoltDEF Hook Signal
3-PhasePower Supply Box
Contactor
Overload Relay
A2
A1
Factory-InstalledJumper
Reset extends through cover
95 96
2T1 4T2 6T3
1L2 3L2 5L3
Motor Current Setting: 9 Amps
DEF-PMA150D3-Phase 60 Hz, 200-240 Volts
STP-CB 3/5 Magnetic StarterRelay Module
Figure 28: DEF-PMA150D 3-Phase Wiring
20
TroubleshootingCondition Solution
No flow at nozzle
• Check the pump circuit breakers and make sure they are on• Verify the wiring conforms to that described in this manual• If cold weather, check that DEF has not frozen in the lines• Verify that the feed-line ball valve is fully open• If using the STP-CBS controller, make sure the lockout switch is not on
Slow flow when dispensing• Verify that the return ball valve is adjusted per page 8• If cold weather, check that DEF has not partially frozen in the lines• Verify that the feed-line ball valve is fully open
Excessive flow when dispensing • Verify that the return ball valve is adjusted per page 8
Recirculation doesn’t start
• Double check the module setup as described in this manual, especially the 4-20 mA module temperature sensor set-points
• If cold weather, check that DEF has not frozen in the lines• Verify that the feed ball valve is fully open and the return ball valve is adjusted
per page 8
Console Alarm • Refer to the TS-550 evo™ Operator’s Guide (document number 000-2171) for alarm conditions and solutions
21
PEI Recommended PracticesThe piping and storage tank must be installed following standard industry practices, including but not limited to those listed below:
• Recommended Practices for Installation of Underground Storage Systems, The Petroleum Equipment Institute, PEI / RP100 (latest edition)
• Recommended Practices for Installation of Aboveground Storage Systems, The Petroleum Equipment Institute, PEI / RP200 (latest edition)
• Recommended Practices for the Storage and Dispensing of Diesel Exhaust Fluid (DEF), The Petroleum Equipment Institute, PEI / RP1100 (latest edition).
Please refer to PEI / RP1100 Sections 4, 5, and 7 for more specific information regarding:
• Material Compatibility (Sec. 4)• Equipment (Sec. 5)• Maintenance (Sec. 7)
Other Franklin Fueling Systems ResourcesOn-Line Manuals• Fuel Management System Programming Guide for TS-550 evo™ and TS-5000 evo™, 000-2173• Fuel Management System Operator’s Guide for TS-550 evo™ and TS-5000 evo™, 000-2171• Fuel Management System Quick Reference Guide for TS-550 evo™ and TS-5000 evo™, 000-2172• ElectroFusion Process Manual 408001007• UPP Piping Install Guidelines 408001016• UPP Tank Sump Installation 408001028• LL2 Probe Installation 000-2081These documents are available from the Franklin Fueling web site: www.franklinfueling.com
For answers to technical questions, contact Franklin Fueling Technical Support at 800-984-6266
©2014 AG-015 Rev 1
