VST GREEN MACHINE VST-GM-CS2-101 Installation, Operation, Maintenance, & Troubleshooting Manual Download Page 174

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4.5 - GREEN MACHINE

™

- North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 9: Replacement Procedures

Page 174

Figure 9-20: Items Associated with Cleaning the GREEN MACHINE Tubing and Manifold

Figure 9-21: Tubes 1-6 removed

Summary of Contents for GREEN MACHINE VST-GM-CS2-101

Page 1: ...1 GREEN MACHINE North America Patents Pending Model VST GM CS2 101 Installation Operation Maintenance Troubleshooting Manual Rev 4 5 Published April 2019 Manual 9600 003 Vapor Systems Technologies Inc 650 Pleasant Valley Drive Springboro Ohio 45066 937 704 9333 PH 937 704 9443 FX www vsthose com ...

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Page 3: ...ring the GREEN MACHINE for Installation 21 1 3 Installing the Legs on the GREEN MACHINE 22 1 4 GREEN MACHINE Dimensions Weight 23 1 5 Ground Mount Locations 23 1 6 Setting the Concrete Pad 24 1 7 Installing the GREEN MACHINE on the Concrete Pad 25 1 8 Roof Top Installation 28 1 9 Canopy Top Installation 28 1 10 Vent Stack Mount Installation 29 1 11 Pre Installation Site Survey 31 1 12 Pre Installa...

Page 4: ...F ESO RELAY 54 3 5 4 Wiring the Electrical Components at the GREEN MACHINE Location 55 3 5 5 Wiring the Overfill Alarm Field Wiring 55 3 5 6 Wiring the VST Control Panel to the GREEN MACHINE 56 3 5 7 Wiring the Pressure Sensor 56 3 5 8 Vacuum Pump Motor Wiring Diagram 56 3 5 9 Applying Power to the VST Control Panel 56 Chapter 4 Control Panel 67 4 VST Control Panel Overview 67 4 1 Main Screen Over...

Page 5: ...eplacement 107 7 5 1 Removing the Rubber Flange Sleeve 107 7 5 2 Replacing the Rubber Flange Sleeve 108 7 6 Cleaning the Control Valves 109 7 6 1 Removing the Valve Solenoid and Core Assembly 110 7 6 2 Replacing the Valve Solenoid and Core Assembly 111 7 7 Check the Air Outlet for Liquid Condensation 112 Safety 112 7 7 1 Removing the Drain Plug 112 7 7 2 Replacing the Drain Plug 112 7 8 Separator ...

Page 6: ...Rubber Flange Sleeve 166 9 6 Vacuum Pump Motor Only Replacement 167 9 6 1 Removing the Vacuum Pump Motor 167 9 6 2 Replacing the Vacuum Pump Motor 168 9 7 Control Valve Replacement 170 9 7 1 Removing the Valve Solenoid and Core Assembly 171 9 7 2 Replacing the Valve Solenoid and Core Assembly 172 9 8 Vacuum Pump Only Replacement 173 9 8 1 Preparation for Cleaning the Tubes and Manifold 173 9 8 2 R...

Page 7: ...ns 199 11 2 VST Control Panel 201 11 2 1 VST Control Panel Overview 201 11 2 2 Main Screen 202 11 2 3 Maintenance Screen 203 11 2 4 Alarm Screen 205 11 3 Alarms Overview 205 11 3 1 GM Status 205 11 3 2 Pressure Sensor Alarm 205 11 3 3 Vacuum Pump Alarm 206 11 3 4 Maintenance Switch Alarm 206 11 3 5 Overfill Alarm 206 11 3 6 SD Card Alarm 207 11 4 Station UST Environmental Compliance Testing and Se...

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Page 9: ...w 67 Figure 4 2 Main Screen 68 Figure 4 3 Maintenance Screen Overview 69 Figure 4 4 Pressure Sensor Alarm shown on the Alarm Screen 71 Figure 6 1 Main Screen with the GM DISABLED ENTER CODE 75 Figure 6 2 Vapor Piping Overview 78 Figure 6 3 Maintenance Screen 79 Figure 6 4 Bump Confirmation Screen 80 Figure 6 5 Vacuum Pump Motor Wiring Diagram 81 Figure 6 6 Maintenance Screen 82 Figure 6 7 GREEN MA...

Page 10: ...ls 145 Figure 8 17 GREEN MACHINE Controller Alarm Screen 147 Figure 8 18 Fuel Level Tank Alarms 149 Figure 9 1 North America GREEN MACHINE Replacement Parts 151 Figure 9 2 VST Control Panel Front Cover Replacement Parts 153 Figure 9 3 VST Control Panel Inside the Front Cover Replacement Parts 153 Figure 9 4 VST Control Panel Inside Panel Replacement Parts 154 Figure 9 5 Removing the PLC Connectors...

Page 11: ...tenance Screen 189 Figure 9 38 Leak Test Screen 189 Figure 9 39 GREEN MACHINE Vapor Inlet Return and Air Outlet Connections 191 Figure 9 40 Leak Check Fixture 192 Figure 9 41 GREEN MACHINE with Vapor Inlet Vapor Return and Air Outlet 192 Figure 10 1 Main Screen 195 Figure 10 2 Maintenance Screen 195 Figure 10 3 Faults Alarm Screen 196 Figure 10 4 Password Screen 196 Figure 10 5 Inserting and Remov...

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Page 13: ...f the petroleum industry The VST focus provides our customers and users with exceptional products services and innovative solutions for improving the fueling station experience as well as the world s air quality VST s product offering includes curb pump and vapor recovery hoses safety breakaways nozzles and emission control system GREEN MACHINE The ENVIRO LOC vapor recovery product offering repres...

Page 14: ...n the work area during installation and service of the device create a potential for personal injury NO SMOKING Gasoline and its vapors can be ignited by sparks and embers of burning cigarettes READ ALL RELATED MATERIALS Read understand and follow all instructions warnings and requirements before you begin work NO OPEN FLAMES Open flames from sources like lighters and matches can ignite gasoline a...

Page 15: ...rating the GREEN MACHINE prior to installation CAUTION ALL SERVICEABLE REPLACEMENT PARTS MUST BE OBTAINED FROM VST TO MAINTAIN SUITABILITY FOR A DIVISION 2 LOCATION Table of Terms Abbreviations ASC Authorized Service Contractor Permeate Air return to atmosphere ATG Automatic Tank Gauge PMC Pressure Management Control CVLD Continuous Vapor Leakage Detection another name for Vapor Leak Detection PTO...

Page 16: ...ts on local vapor recovery requirements Be sure to read and understand all site requirements before beginning an installation The area inside the GREEN MACHINE cover has been evaluated as a Class I Division 2 hazardous area as defined by the National Electric Code NFPA 70 Article 514 table 514 3 B 1 and verified by Intertek Always obtain approval from the local authority having jurisdiction Instal...

Page 17: ...Control Panel to the GREEN MACHINE 6 1 NPT Vapor Return Connection Port for returning vapors to the UST 7 1 NPT Air Outlet Connection Port for venting air to atmosphere 8 Control Valves 5 ea Control the flow of vapor to and from the UST 9 Vac Pump Motor Only Drives the Vacuum Pump 10 Vac Pump Only For transporting vapors to and from the UST 11 Internal Junction Box Houses all wiring connections fo...

Page 18: ...nderground Storage Tank UST system pressure The GREEN MACHINE controller provides UST pressure data via a pressure transducer located in the GREEN MACHINE and manages the GREEN MACHINE operation The pressure data is provided to the VST Control Panel for system monitoring functions The closed loop vapor piping solution continuously operates the system to control UST pressure below 0 2 IWC ...

Page 19: ...s are in the shipping crate GREEN MACHINE VST GM CS2 101 Aluminum Cover VST Control Panel 4 24 Steel Legs 16 3 8 bolts washers nuts to attach the legs to the GREEN MACHINE base 1 0 063 dia Orifice 6 Locks with keys same 3 1 Brass Full Port Ball Valves Locking Packet 1 Station Owner Operator Paperwork Packet 2 General Contractor Paperwork Packet 3 Vapor Piping Installation Packet 4 Electrical Insta...

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Page 21: ...osive vapors being present Read and understand all materials related to installing testing and operating the GREEN MACHINE prior to installation 1 2 Preparing the GREEN MACHINE for Installation Follow these steps to prepare the GREEN MACHINE for installation 1 Verify that all the items are in the shipping crate GREEN MACHINE VST GM CS2 101 Aluminum Cover VST Control Panel 4 24 Steel Legs 16 3 8 bo...

Page 22: ...N MACHINE with a forklift or a set of saw horses so the legs can be installed 2 Install the 4 legs on the GREEN MACHINE The four 3 8 carriage bolts for each leg MUST BE INSTALLED AND TIGHTENED IN THE SEQUENCE INDICATED ON Figure 1 1 3 All the carriage bolts must be installed so the head of the bolt is flush with the base as shown Figure 1 1 Bolting sequence to attach legs to the GREEN MACHINE base...

Page 23: ...ssible to the vent risers to minimize piping and pressure drop The GREEN MACHINE must be protected from damage Install bollards or another suitable method to protect the GREEN MACHINE VST recommends a clear 18 perimeter around the GREEN MACHINE for maintenance and testing The GREEN MACHINE must be located within 100 feet of the vent risers To minimize the installation cost and to maximize operatin...

Page 24: ...rete pad provided The existing concrete is of sufficient strength and thickness to support the GREEN MACHINE VST recommends a minimum of 6 thick concrete to accommodate 3 1 2 4 expansion type anchor bolts Cracked concrete without re bar may NOT be of sufficient strength to properly support the GREEN MACHINE The GREEN MACHINE is installed level NOTE VST CANNOT BE HELD RESPONSIBLE FOR DAMAGE CAUSED ...

Page 25: ... number 00304583 or approved equal The contractor or design engineer is responsible for sizing the expansion anchors and the concrete pad to meet seismic and cracked concrete specifications required by local state and federal jurisdictions Since seismic regulations may be different by location VST has not included a specific drawing for this application For seismic design reference www us hilti co...

Page 26: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 26 Figure 1 2 Concrete mounting pad dimensions ...

Page 27: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 27 Figure 1 3 GREEN MACHINE Ground Mounting Pad ...

Page 28: ...secured to a steel structure attached to the roof A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere A Design Engineer is responsible for designing the support structure support base all required hardware and bolting connections and the support structure foundation to meet all regulatory specifications that may be required by local jurisdi...

Page 29: ... that can support the weight of the GREEN MACHINE or a structure can be installed to support the weight of the GREEN MACHINE Due to a variety of construction designs VST cannot recommend how the GREEN MACHINE should be installed or mounted on a vent riser support structure however the structure that supports the GREEN MACHINE must be designed and installed at a height allowing the piping inlet and...

Page 30: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 30 Figure 1 4 Vent Stack Installation ...

Page 31: ...n the planning of a GREEN MACHINE installation The Pre Installation Site Survey is to be completely filled out in advance of an installation so that installation problems and delays are reduced or avoided 1 12 Pre Installation Site Survey Your Name Company Name Company Address City State Zip Country Phone E Mail Projected Processor Installation Date 1 13 GDF Contact Information GDF Name GDF Addres...

Page 32: ...ection A minimum clearance of 18 around the GREEN MACHINE for maintenance and testing is required The GREEN MACHINE must be protected from damage Install bollards or other suitable method to protect the GREEN MACHINE Automatic Tank Gauge Fuel Management Controls Must have an appropriate automatic tank gauge fuel measurement control with an overfill alarm contact installed The GREEN MACHINE Control...

Page 33: ...E location is not permitted in any vapor lines connected to the GREEN MACHINE UST Manifolding All gasoline UST s MUST be manifolded either above or below ground Ground Installation Requirements The GREEN MACHINE must be protected from damage VST recommends a clear 18 perimeter around the GREEN MACHINE for maintenance and testing The GREEN MACHINE must be located within 100 feet of the vent risers ...

Page 34: ...e A Design Engineer is responsible for designing the support structure support base all required hardware and bolting connections and the support structure foundation to meet all regulatory specifications that may be required by local jurisdictions Canopy Top Installation Requirements The GREEN MACHINE may be installed on a station s canopy provided the structure can support the weight of the GREE...

Page 35: ...ight allowing the piping inlet and outlets to connect to the existing vent risers The GREEN MACHINE has 24 legs that can be bolted on the base but the legs may be removed for the GREEN MACHINE to be secured to a steel support structure A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere All safety and code concerns must be taken into consid...

Page 36: ...b hose length 8 Whip hose length 9 Hose configuration Standard Lazy J Curly Q 1 15 3 Vent Risers 1 Number of vent risers 2 Location size of vent risers show on sketch 3 Where are the USTs manifolded Above Ground Below Ground 1 15 4 VST GREEN MACHINE 1 What are the possible locations that can be used for the VST GREEN MACHINE Ground Roof Canopy Vent Riser 2 Will a waiver or variance be needed for a...

Page 37: ... GREEN MACHINE location for example lights signs vacuum Yes No 3 Available breaker space for a 115V 1 phase circuit Yes No 4 Will a sub panel need to be installed Yes No 1 15 6 Additional Documentation Include photos of each of the above items as needed Draw a sketch of the GDF layout Include a The location of the vent risers b Tank pad c Dispensers d Building with the electrical panel location e ...

Page 38: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 38 Figure 1 5 Example of a GDF Layout ...

Page 39: ...GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 39 Figure 1 6 Example of a GREEN MACHINE with Vapor Piping Layout ...

Page 40: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 40 1 16 Sample Sketch ...

Page 41: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 1 GREEN MACHINE Installation Instructions Page 41 1 16 1 Your Sketch ...

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Page 43: ...nal Pipe Thread NPT 2 1 General Notes The piping contractor is responsible for providing all necessary piping non hardening pipe joint compound and pipe fittings Make sure the gasoline UST tanks vapor piping is manifolded either above ground or below ground Locks must be installed on the valves to prevent unauthorized tampering of the equipment Under normal operation the valves must be locked in t...

Page 44: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 2 Vapor Piping Installation Page 44 Figure 2 1 Vapor Piping Overview ...

Page 45: ...ments install the flexible piping between the GREEN MACHINE locking ball valve and the vent riser s The flexible connector must be approved for a service station above ground application Support the flexible piping per manufacturer s recommendation The slope of the flex connection from the GREEN MACHINE back to the vent riser must be a minimum of 1 4 per foot slope Liquid traps are not allowed Fig...

Page 46: ...he vapor return lines have a 1 union a 1 locking ball valve and a 1 tees caps and any other piping fittings to complete the installation The 1 vapor return pipe connecting to the bottom of the vent riser MUST BE INSTALLED below the 1 vapor inlet pipe that connects to the top of the vent riser A drain line MUST BE INSTALLED between the vapor inlet and the vapor return so any condensate from the vap...

Page 47: ...NE to the new vent riser From the vent riser install the 1 locking ball valve then the 1 union then the 1 tee as shown in Figure 2 1 A rain cap or equivalent must be installed on the new air outlet vent riser If a PV vent valve is used the internal components must be removed to allow open venting to the atmosphere 2 5 Vapor Piping Post Installation After all the piping has been installed make sure...

Page 48: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 2 Vapor Piping Installation Page 48 Figure 2 3 Pressure Sensor w 3 Way Isolation Valve Open ...

Page 49: ...existing vent riser Straight tee with cap sized to match new vent riser Rain cap on the new air outlet vent riser 1 diameter pipe elbows and misc pipe fittings Vent Stack pipe supports and hardware as required NPT Compression Fittings 2 each 1 x NPT Reducer Bushing Diameter Copper Tubing Vapor Systems Technologies Supplied x NPT Brass Adapter with a 0 063 diameter orifice 6 Locks 3 Ball Valves 2 C...

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Page 51: ...risk of flammable or explosive vapors being present Read and understand all materials related to installing testing and operating the GREEN MACHINE prior to installation 3 1 Electrical Requirements Note 1 The 8 8 amp listed is only for the HP 115 VAC 1 Phase 60 Hz Leeson Motor Table 1 VST Control Panel Power Requirements VST Control Panel Power Requirements VST CONTROL PANEL POWER SOURCES Option 1...

Page 52: ... All power 115 VAC and 24 VDC the neutral and the ground wires connected to the GREEN MACHINE will be disconnected when The Power Switch on the front of the VST Control Panel is turned OFF The station Emergency Shut Off is activated The Safety Disconnect Switch at the GREEN MACHINE is opened Power is turned OFF to the VST Control Panel at the electrical distribution panel CAUTION SAFETY PRECAUTION...

Page 53: ...1 Outlet 115 VAC Hot 2 1 Outlet Neutral 3 1 Outlet Ground 3 5 1 INSTALLING THE VST CONTROL PANEL The contractor must drill holes in the VST Control Panel for all wiring connections Install the VST Control Panel only inside the GDF The location may vary within the GDF given the allowable space When possible place the VST Control Panel as close to the Fuel Management System as possible After the Con...

Page 54: ... and ground from the GREEN MACHINE 2 Two wires MUST BE INSTALLED from the VST Control Panel to the ESO relay or control system The technician making these connections MUST BE CERTIFIED to work on this system 3 Reference the ESO terminal block wire numbers 4 Wiring 115 VAC to Wire Number 02011 115 VAC Switch Leg to Wire Number 02032 3 5 3 OPTION 2 POWER THE VST CONTROL PANEL FROM THE STATION EMERGE...

Page 55: ...ed ground Lead wire is a bare ground 3 Safety Disconnect Switch a Install 2 wires from the VST Control Panel to the Safety Disconnect Switch 115 VAC to wire number 02032 115 VAC switch leg to wire number 02023 Ground to Ground 3 5 5 Wiring the Overfill Alarm Field Wiring Figure 3 6 Shows the Overfill Alarm Field Wiring from the VST Control Panel to the Fuel Management System 1 The VST Control Pane...

Page 56: ...r can be turned ON at the VST Control Panel The following items have been installed and wired 1 VST Control Panel 2 Emergency shut Off Relay 3 Overfill Alarm Relay 4 GREEN MACHINE Internal Junction Box 5 Pressure Sensor 6 Safety Disconnect Switch 7 Outlet After power is turned ON to the VST Control Panel the Main Screen will show GM DISABLED ENTER CODE This means 1 The VST Control Panel has power ...

Page 57: ...ooting Manual Chapter 3 Electrical Page 57 CAUTION TURN OFF POWER TO THE VST CONTROL PANEL AT THIS TIME The power to the VST Control Panel will be turned ON AGAIN during the GREEN MACHINE Post Installation Start Up Figure 3 1 VST Control Panel GM Disabled Enter CODE Main Screen ...

Page 58: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 58 Figure 3 2 GREEN MACHINE Installation Overview Option 1 Option 1 ...

Page 59: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 59 Figure 3 3 The Control Panel Power and ESO Connections Option 1 Option 1 ...

Page 60: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 60 Figure 3 4 The GREEN MACHINE Installation Overview Option 2 Option 2 ...

Page 61: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 61 Figure 3 5 The Control Panel Power Connection Option 2 Option 2 ...

Page 62: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 62 Figure 3 6 The VST Control Panel Field Wiring ...

Page 63: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 63 Figure 3 7 GREEN MACHINE Internal Junction Box Field Wiring ...

Page 64: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 64 Figure 3 8 Pressure Sensor Wiring Diagram ...

Page 65: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 3 Electrical Page 65 Figure 3 9 Vacuum Pump Motor Wiring Diagram ...

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Page 67: ...pressure is above 0 20 IWC The GREEN MACHINE will operate until the UST pressure falls below 0 20 IWC The Power Switch Lockable Provides a means to disconnect ALL power from the VST Control Panel and ALL power to the GREEN MACHINE The Power Switch can be locked in the OPEN or CLOSED position Use lock out tag out procedures The Maintenance Switch Lockable Turning the Maint Switch OFF will disconnec...

Page 68: ...g on the PLC unless there is an Alarm Condition GM Status Normal Green Box indicates the GREEN MACHINE is operating normally no active Alarms Alarm Red Box indicates an Alarm is active Date and Time Push the Date and Time soft button to change the Date and Time Maintenance Screen and an Alarm Screen Push the Maintenance Screen soft button to access the Maintenance Screen A password 878 is required...

Page 69: ...UST pressure being less than 0 20 IWC Blue Text Box GREEN MACHINE Alarm Go to the Alarm Screen to identify the Alarm An Alarm has activated Red Text Box See the Operator Instruction Sheet for directions Displayed Data UST Pressure IWC Displays the UST pressure in real time Run Cycles Displays the number of GREEN MACHINE completed cycles Date and Time Date MM DD YY and 24 Hour Clock HH MM SS 4 2 Ma...

Page 70: ... Maintenance Screen This feature is used when conducting maintenance on the GREEN MACHINE Vac Pump Bump is used to check the vacuum pump motor rotation during start up or after performing maintenance on the vacuum pump motor The Reset Motor Alarm is used when the Vacuum Pump is in Alarm Function Button labels are shown at the bottom of the screen The F1 F2 F3 F4 Function buttons and the ESC button...

Page 71: ... Alarm Red Box indicates an Alarm is active When an Alarm is active see Chapter 10 the Operator Instruction Sheet for directions Pressure Sensor Alarm An Alarm will occur When the Pressure Sensor is not connected to the Control Panel When the Pressure Sensor is not wired properly at the Control Panel or at the GREEN MACHINE Internal Junction Box The GREEN MACHINE will NOT operate during this Alarm...

Page 72: ... will not operate and the switch will show as an active alarm To remove the Maintenance Switch Alarm turn the switch to ON Overfill Alarm An Alarm will occur Whenever there is a UST gasoline overfill at the station the VST Control Panel is configured to alarm If an overfill alarm activates while a test is running The test will terminate The Alarm will display RED OVERFILL ACTIVE The GREEN MACHINE ...

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Page 74: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 5 Intentionally Blank Page 74 Left intentionally blank ...

Page 75: ...Screen will show on the PLC with the label GM DISABLED ENTER CODE See Figure 6 1 The CODE was initiated to prevent the electrical contractor from starting the GREEN MACHINE before the Start Up was completed The Start Up can be completed with the GM DISABLED The CODE to the VST Control Panel must be entered before the GREEN MACHINE can become operational The CODE will be supplied to the Start Up Co...

Page 76: ...he GREEN MACHINE will now be in the Manual OFF mode 9 Make sure the Maintenance Switch is ON at the VST Control Panel The GREEN MACHINE cannot operate in the Automatic Mode when the Maintenance Screen is showing regardless of the UST pressure 6 3 Post Installation Start Up Tests During post installation testing the GREEN MACHINE will use outside air no gasoline vapor from the USTs to conduct these...

Page 77: ...Under North America GREEN MACHINE Click on Supporting Documents and Instructional Video 4 Click on Start Up Commissioning Contractor 5 Click on Appendix B Start Up Contractor Check Out Form 6 Fill out and submit Appendix B with the required photos 7 Receive an email from VST with the Verification CODE and a copy of the filled out Appendix B These items are to be checked in Appendix B as they are c...

Page 78: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 6 Testing and Startup Page 78 Figure 6 2 Vapor Piping Overview ...

Page 79: ...ce Screen is showing on the PLC See Figure 6 3 The GREEN MACHINE is now in the Manual OFF mode and will not operate If the PLC is not in the Maintenance Screen At the Main Screen push the Maintenance Screen button to access the Password Screen then enter the password to access the Maintenance Screen Password is 878 2 One person needs to be at the VST Control Panel to begin the Bump Test 3 A second...

Page 80: ...e Figure 6 4 3 The Vacuum Pump Motor will rotate for 5 seconds which is just enough time for the second person at the GREEN MACHINE to check the motor rotation The motor rotation is indicated by a directional arrow on the pump 4 If the motor is rotating in the correct direction the test is completed If the motor is not rotating in the correct direction switch two of the motor wires T5 and T8 at th...

Page 81: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 6 Testing and Startup Page 81 Figure 6 5 Vacuum Pump Motor Wiring Diagram ...

Page 82: ...in the Manual OFF mode and will not operate If the PLC is not in the Maintenance Screen At the Main Screen push the Maintenance Screen button to access the Password Screen then enter the password to access the Maintenance Screen Password is 878 2 At the GREEN MACHINE make sure the locks from the three ball valves have been removed all three valves are closed and the caps from the three tees have b...

Page 83: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 6 Testing and Startup Page 83 Figure 6 7 GREEN MACHINE Vapor Piping Layout ...

Page 84: ...tee opening at the Vapor Return and feel for zero airflow Next place your hand over the tee opening at the Air Outlet and feel for air blowing 8 During the Run cycle 1 Suction at the Vapor inlet NORMAL 2 Air blowing out the Air Outlet NORMAL 3 No air blowing suction at the Vapor Return NORMAL 4 All other blowing or suction conditions at each location check the following items Make sure the Vacuum ...

Page 85: ... sure there is no debris in the valve seat Clean the valves as shown in Chapter 7 Maintenance Make sure the flare nuts are tight Check each 45 flare nut to make sure they are snug but not over tightened 11 After the Functionality Test has ended The PLC will automatically go back to the Maintenance Screen and will remain in the OFF mode Lock open the three ball valves between the GREEN MACHINE and ...

Page 86: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 6 Testing and Startup Page 86 Figure 6 9 Functionality Test Confirmation Button ...

Page 87: ...om the VST Control Panel to the Fuel Management System Overfill Alarm output module The VST Control Panel supplies 24 VDC to the Overfill Alarm relay The Overfill Alarm output dry relay N O shuts down the GREEN MACHINE when a UST reaches the Overfill Level 90 during a fuel drop Label the Overfill relay GM Overfill Alarm The wiring from the VST Control Panel to the Fuel Management System MUST be in...

Page 88: ... as relay number 2 5 Press MODE to return to ALL FUNCTIONS NORMAL screen 6 At the ALL FUNCTIONS NORMAL screen press FUNCTION until the screen reads TEST OUTPUT RELAYS 7 Press the STEP button until the screen reads TEST OUTPUT RELAYS ENTER RELAY NUMBER 0 8 Press the number on the keypad that corresponds to the relay assigned to the GREEN MACHINE output relay then push ENTER 9 The screen should read...

Page 89: ...ays are automatically reset to their original state Procedures 1 At the TLS 450 Home Screen select the Diagnostic button to access the Diagnostic Screen 2 At the TLS 450 Diagnostic Home Screen select the Relay and Input button to access the Relay Input Screen 3 At the Relay Input Screen select the Test Relay to conduct the Sequential Testing Procedure 4 Check the box for the Overfill relay connect...

Page 90: ...or or the electrical contractor to correct the wiring from the VST Control Panel to the TLS 450 Overfill relay then conduct the test again until the test passes and the Overfill Alarm is active on the VST Control Panel PLC 6 7 3 TLS 450 Plus Overfill Alarm Test Procedures 1 At the TLS 450 Plus Home Screen select the Diagnostic button to access the Diagnostic Screen 2 At the Diagnostic Screen selec...

Page 91: ...rom the Main Screen push the Date and Time soft button This will bring up the Date and Time Interface Screen See Figure 6 12 2 On the Date and Time Interface Screen insert the Date MM DD YY then the Time HH MM SS Use the ARROW keys to move from left or right if a number is not correct The Time is a 24 hour format so 1 00 PM is set at 13 00 hours See Figure 6 13 3 After the Date and or Time has bee...

Page 92: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 6 Testing and Startup Page 92 Figure 6 13 Time Date ...

Page 93: ...Date Time per the time zone 6 9 How to submit Appendix B to VST to obtain the Verification CODE 4 Complete Appendix B Checklist Form then push the SUBMIT button All the fields contained in Appendix B MUST BE CHECKED OR FILLED OUT INCLUDING PICTURES 5 An email with the Verification CODE is sent to the person conducting the Start Up after Appendix B is SUBMITTED to VST 6 On the Maintenance Screen pu...

Page 94: ...REEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 6 Testing and Startup Page 94 Figure 6 14 VERIFICATION CODE screen Figure 6 15 Enter the Verification CODE screen ...

Page 95: ...ne which component may need to be repaired or replaced Sections that will be covered in this Chapter 7 1 Maintenance Procedures 7 2 Recommended Replacement Parts 7 3 Functionality Test 7 4 Pressure Sensor Verification Test 7 5 Rubber Flange Sleeve Replacement 7 6 Cleaning the Control Valves 7 7 Check the Air Outlet for Liquid Condensation 7 8 Separator Check Procedure 7 1 Maintenance Procedures 1 ...

Page 96: ...nal replace the rubber flange sleeve yearly 6 Cleaning the Control Valves See Section 7 6 Cleaning the control valves will reduce valve noise Check the valve components for wear and damage and keep the valves operational for a longer period of time 7 Check the Air Outlet for Liquid Condensate See Section 7 7 Check annually for liquid condensate in the air outlet pipe 8 Check the Separator for debr...

Page 97: ...below for replacement parts The entire list of GREEN MACHINE replacement parts can be found in Chapter 9 Replacement Procedures Ref Description Part No Quantity Manuf 1 VACUUM PUMP MOTOR ONLY 115VAC SINGLE PHASE GM 027 1 VST 2 MODEL 2 VACUUM PUMP ONLY GM 022 1 3 RUBBER FLANGE SLEEVE GM 004 1 4 CONTROL VALVES CORE REBUILD KIT GM 006 5 5 PRESSURE SENSOR GM 015 1 6 SEPARATOR GM 049 1 Figure 7 2 Maint...

Page 98: ... in the Manual OFF mode and will not operate If the PLC is not in the Maintenance Screen At the Main Screen push the Maintenance Screen button to access the Password Screen then enter the password to access the Maintenance Screen Password is 878 2 At the GREEN MACHINE make sure the locks from the three ball valves have been removed all three valves are closed and the caps from the three tees have ...

Page 99: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 99 Figure 7 4 GREEN MACHINE Vapor Piping Layout ...

Page 100: ...e tee opening at the Vapor Return and feel for zero airflow Next place your hand over the tee opening at the Air Outlet and feel for air blowing 8 During the Run cycle 1 Suction at the Vapor inlet NORMAL 2 Air blowing out the Air Outlet NORMAL 3 No air blowing suction at the Vapor Return NORMAL 4 All other blowing or suction conditions at each location check the following items Make sure the Vacuu...

Page 101: ...ke sure there is no debris in the valve seat Clean the valves as shown in Chapter 7 Maintenance Make sure the flare nuts are tight Check each 45 flare nut to make sure they are snug but not over tightened 11 After the Functionality Test has ended The PLC will automatically go back to the Maintenance Screen and will remain in the OFF mode Lock open the three ball valves between the GREEN MACHINE an...

Page 102: ...ACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 102 Figure 7 6 Functionality Test Confirmation Button Figure 7 7 GREEN MACHINE Operation Diagram ...

Page 103: ...3 way ball valve See Figure 7 9 6 Wait at least 2 minutes for the pressure to equalize before reading the pressure on the PLC Main Screen 7 At the VST Control Panel PLC Main Screen make sure the Pressure reading is 0 0 0 10 IWC See Figure 7 10 The Pressure Sensor Specification at atmospheric Pressure is 0 0 0 10 IWC If the pressure reading is within specifications the Pressure Sensor is reading co...

Page 104: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 104 Figure 7 8 Pressure Sensor 3 Way Valve Normal Operation ...

Page 105: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 105 Figure 7 9 Pressure Sensor 3 Way Valve TEST Position ...

Page 106: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 106 Figure 7 10 Main Screen w Pressure Reading CS2 ...

Page 107: ...l will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Unlock the hasps and remove the cover from the GREEN MACHINE NOTE The vacuum pump and vacuum pump tubing will not be affected by moving the vacuum pump motor 4 Remove the fan guard over the drive coupling flanges 5 Remove the two bolts holding the Internal Junction Box stand to the ...

Page 108: ...shims that moved while moving the motor 3 Re install and tighten the 4 motor mounting bolts to the base plate Make sure the Motor Shaft and Vacuum Pump shafts are in alignment 4 Re install the 2 bolts holding the Internal Junction Box stand to the GREEN MACHINE base 5 Re install the fan guard over the coupling flanges 6 Put the cover on the GREEN MACHINE and lock the hasps 7 Remove the lock s and ...

Page 109: ...ion Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 109 7 6 Cleaning the Control Valves Safety Use lockout tagout procedures prior to starting work Figure 7 13 GREEN MACHINE Control Valves Identification Tags ...

Page 110: ...and slide the nameplate off 7 Slide the solenoid off the solenoid base DO NOT lose the spring washer located below the solenoid on the solenoid base 8 Using a wrench remove the solenoid base from the valve body the core assembly with core spring and the body gasket 9 Inspect and clean the following parts with a rag and carburetor cleaner or an equivalent cleaning solution Be sure to use eyes and h...

Page 111: ... then slide the solenoid on to the solenoid base 4 Slide and lock the nameplate on the solenoid 5 Snap the red cap on the solenoid base 6 Open the three ball valves between the GREEN MACHINE and the vent risers and lock in the OPEN position 7 CAUTION THREE BALL VALVES BETWEEN THE GREEN MACHINE AND THE VENT RISERS MUST BE OPEN BEFORE APPLYING POWER TO THE VST CONTROL PANEL TO AVOID DAMAGE TO THE GR...

Page 112: ... GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Place a container below the drain tee at the bottom of the Air Outlet vent riser 4 Slowly remove the drain plug from the bottom of the Air Outlet vent riser to see if any liquid drains from the line 5 Keep the drain plug for re use 7 7 2 Replacing the Drain Plug See Figure 7 17 1 After all the liquid has drained if any put ...

Page 113: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 113 Figure 7 17 Air Outlet Drain Tee and Plug ...

Page 114: ... on the front of the VST Control Panel The power ground and neutral will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Unlock the hasps and remove the cover from the GREEN MACHINE 4 Remove the two 45 flare tubing connections from the separator being careful not to damage the copper tubing 5 Remove the separator and while holding it ve...

Page 115: ... to the VST Control Panel The GREEN MACHINE is now operational 7 8 4 Installing a New Separator See Figure 7 19 1 If the existing separator needs to be replaced remove the 90 and straight pipe fittings from the existing separator for reuse The existing separator can be discarded 2 Wrap the pipe fittings with gasoline resistant PTFE tape and install the pipe fittings into the new separator 3 Place ...

Page 116: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 7 Maintenance Procedures Page 116 Figure 7 19 Separator Fitting Orientation ...

Page 117: ...GREEN MACHINE or the VST Control Panel are not functioning properly In detail this guide will cover 8 2 Alarm Overview 8 3 Troubleshooting Procedures Replacement parts procedures are found in Chapter 9 8 1 1 Troubleshooting the GREEN MACHINE and the VST Control Panel Included in this manual are the troubleshooting procedures for the following items 8 4 Power to the VST Control Panel or PLC Control...

Page 118: ...atus window See Figure 8 1 When an Alarm is posted the NORMAL message changes to ALARM and the Message box changes from Green to Red See Figure 8 2 If an Alarm occurs the Alarm Screen will show what is in the alarm condition See Figure 8 3 If more than one alarm condition exists the display will show all the alarm conditions and the appropriate messages The system automatically posts an alarm to t...

Page 119: ...Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 119 8 2 1 Alarm List 1 Pressure Sensor 2 Vacuum Pump 3 Maintenance Switch 4 Overfill 5 SD Card Figure 8 2 VST GREEN MACHINE Control Panel Main Screen with an Alarm Active ...

Page 120: ...shooting Procedures is preceded by a Decision Tree The tree itself is a high level overview of the required steps The steps themselves are fleshed out in greater detail immediately following the Decision Tree If there are any questions or concerns while performing these Troubleshooting Procedures contact VST at 937 704 9333 Figure 8 3 VST Control Panel Alarms and Faults Screen Example ...

Page 121: ...a Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 121 8 4 Power to the VST Control Panel or PLC Controller is OFF Figure 8 4 Power to the North America VST Control Panel or Controller is OFF ...

Page 122: ...allation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 122 Power to the Control Panel or the Controller is OFF continued Figure 8 4 continued Power to the North America VST Control Panel or Controller is OFF ...

Page 123: ...andard 508A and CSA C22 2 No 14 If an electrical component has malfunctioned inside the VST Control Panel all the electrical components MUST BE ordered from the Replacement Parts List Chapter 9 in this manual Check the wire terminals 02011 and 02032 then proceed to the appropriate procedures Option 1 If there are two wires landed in these terminals the VST Control Panel is powered directly from th...

Page 124: ...NE to operate See Figures 8 5 8 6 a Verify the VST Control Panel is connected to the station ESO b Verify the ESO is not engaged If the ESO is engaged the GREEN MACHINE will not have 115 VAC power c Verify all the wire connections from the VST Control Panel to the ESO are correct and tight d Verify the ESO circuit has 115 VAC power from the VST Control Panel across terminals 02011 and 02032 on the...

Page 125: ...e damaged If so replace the 24 VDC power supply c With the power ON to the VST Control Panel check the 24 VDC wire connections to the GREEN MACHINE Controller At the PLC Controller check to make sure there is 24 VDC power across wire numbers 02092 and the ground The PLC Controller may be damaged If so replace the PLC Controller If the VST Control Panel worked prior to this issue after checking STE...

Page 126: ...Emergency Shut Off ESO dry relay for the VST Control Panel to have power and for the GREEN MACHINE to operate See Figures 8 7 8 8 a Verify the VST Control Panel is connected to the station ESO b Verify the ESO is not engaged If the ESO is engaged the GREEN MACHINE will not have 115 VAC power c Verify all the wire connections from the VST Control Panel to the ESO are correct and tight d Verify the ...

Page 127: ...er supply check the OUTPUT terminals marked V and V The voltage should be 24 5 VDC The 24 VDC power supply may be damaged If so replace the 24 VDC power supply c With the power ON to the VST Control Panel check the 24 VDC wire connections to the GREEN MACHINE Controller At the PLC Controller check to make sure there is 24 VDC power across wire number 02092 and the ground The PLC Controller may be ...

Page 128: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 128 Figure 8 5 Electrical Field Wiring Diagram Option 1 ...

Page 129: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 129 Figure 8 6 Incoming Power Connections Option 1 ...

Page 130: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 130 Figure 8 7 VST Control Panel Powered from ESO Relay Option 2 ...

Page 131: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 131 Figure 8 8 Electrical Overview Installation Drawing Option 2 ...

Page 132: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 132 Figure 8 9 VST Control Panel Components Front Cover ...

Page 133: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 133 Figure 8 10 VST Control Panel 115 VAC Power Circuit Diagram ...

Page 134: ...ting Page 134 8 5 Pressure Sensor Alarm A Pressure Sensor Alarm will occur if the PLC is not receiving a 4 20 mA input from the Pressure Sensor or the mA reading is less than 2 5 mA or if there is not 24 VDC power to the Pressure Sensor See Figure 8 11 Figure 8 11 Pressure Sensor Alarm Troubleshooting Procedure ...

Page 135: ...r at the PLC c Check the Pressure Sensor power circuit as shown in Figure 8 12 d Repair the Pressure Sensor power circuit as needed e If the power and signal circuits are OK replace the Pressure Sensor 2 Verify the Pressure Sensor signal at the PLC is below 2 5 mA See Figure 8 12 a Remove wire 04052 from the PLC then using a multimeter check the current between wire 04052 and AN1 on the PLC b If t...

Page 136: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 136 Figure 8 12 Pressure Sensor Wiring Diagram 24VDC Power and 4 20 mA Signal ...

Page 137: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 137 8 6 Vacuum Pump Alarm Figure 8 13 Vacuum Pump Troubleshooting Procedures ...

Page 138: ...as not tripped If the breaker lever is down and the window is GREEN the breaker has tripped e If the breaker has not tripped go to Step 2 f If the Vacuum Pump breaker has tripped move the lever up to reset the breaker g Close the Control Panel front door h Turn on the Power Switch on the front of the Control Panel and re install the carabiner clip The PLC will turn ON in the Main Screen i Push the...

Page 139: ...ach terminal Wire Number Terminal Location Expected Voltage 02051A Top Left to 115 VAC ground 120 VAC 02052 Top Right to 115 VAC ground 120 VAC 02093 05051 Bottom Left to Bottom Right 24 VDC 05051 Bottom Right to 24 VDC ground 24 VDC j If any of the voltages are not correct check the associated breakers fuses and wiring for proper connections If the voltages are correct go to Step m k If the wirin...

Page 140: ...g h Turn the motor vacuum pump by hand to see if it is seized cannot rotate If you cannot turn the shaft between the pump and the motor loosen the set screws on the motor side of the rubber flange sleeve and slide the coupling towards the motor Turn both the motor and vacuum pump sides of the shaft g If the vacuum pump is seized REPLACE THE VACUUM PUMP h If the motor is seized REPLACE THE VACUUM P...

Page 141: ...d control valve may cause the vacuum pump motor to trip out on thermal overloads Purpose of the Test The purpose of this test is to check to see if there is power at the control valves and the control valves are working properly This test is also used for the Leak Check When the F1 button is pushed all the control valves are energized open which will allow the technician to see if all 5 of the con...

Page 142: ...wn to the retainer clip If valve A or C and fuse FU2 has 115 VAC power and is not energized replace the bad valve core If valve B or D and fuse FU3 has 115 VAC power and is not energized replace the bad valve core If valve E and fuse FU5 has 115 VAC power and is not energized replace the bad valve core c If the magnetic fields are present listen for any of the control valves making a chattering so...

Page 143: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 143 Figure 8 14 Vacuum Pump Power and Control Circuit ...

Page 144: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 144 Figure 8 15 VST Control Panel Electrical Components ...

Page 145: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 8 Troubleshooting Page 145 Figure 8 16 GREEN MACHINE isometric with Control Valves Identification Labels ...

Page 146: ...s function is usually used if there is a problem with the GREEN MACHINE and is used during troubleshooting See Figure 8 9 When the Maintenance Switch Alarm is Active 1 On the Main Screen the GM Status text box will turn RED and display ALARM 2 Push the Alarm Screen button to view the Alarm Screen 3 The Maintenance Switch Alarm box will be RED and display Maintenance Switch Alarm To reset the Maint...

Page 147: ...is connected to the Tank Overfill Alarm output relay When an overfill occurs the output N O relay closes and GREEN MACHINE will turn OFF The Overfill Alarm box will display RED indicating an Overfill Alarm is active When the gasoline level drops below the overfill alarm level the output relay opens and the alarm clears The GREEN MACHINE will remain OFF for 2 additional hours After the 2 hours elap...

Page 148: ...th the overfill limit and the high product limit VST has determined that overfill protection is needed to reduce the chance of gasoline entering the GREEN MACHINE Below are the precautionary measures taken to protect the GREEN MACHINE against an overfill situation The VST Control Panel will disable the GREEN MACHINE when the UST level reaches the OVERFILL Alarm setting OVERFILL 90 when the relay c...

Page 149: ...erfill Report Date Contractor Name Contractor Company GDF Name Address City State ZIP Code GDF Contact Person Name GDF Contact Person Title GDF Contact Person Phone GDF Contact Person E mail Overfill Details Date of Overfill Octane of the fuel being dispensed Serial Number of the GREEN MACHINE Figure 8 18 Fuel Level Tank Alarms ...

Page 150: ...will operate when there is a SD Card Alarm but the card will not or cannot record the data The SD Card Alarm will activate when the following items occur 1 An SD Card in not installed in the Controller slot 2 The SD Card write protection is ON 3 When the SD Card is not inserted in to the slot properly Correct the above problem s and the SD Card Alarm will clear ...

Page 151: ...wn in the picture and table below must be supplied by VST See Figure 9 1 VST North America GREEN MACHINE Replacement Parts Ref Description Part No Manufacturer 1 VACUUM PUMP MOTOR ONLY 115VAC SINGLE PHASE GM 027 VST 2 MODEL 2 VACUUM PUMP ONLY GM 022 3 RUBBER FLANGE SLEEVE GM 004 4 UL CONTROL VALVES CORE REBUILD KIT GM 006 5 PRESSURE SENSOR GM 015 6 VAPOR FILTRATION CARTRIDGE ASSEMBLY GM 035 7 SEPA...

Page 152: ...PLY 5A PS5R VF24 IDEC 6 TERMINAL RELAY 24V AC DC SPDT 700 HLT2U24 ALLEN BRADLEY 7 20A MOTOR CIRCUIT CONTROLLER KTA7 25S 20A SPRECHER SCHUH 8 SIDE MOUNT AUX CONTACT 2 N O KT7 PA1 20 SPRECHER SCHUH 9 SOLID STATE RELAY 30A SPST 90 280 INPUT N O 24 280 VAC LOAD AD SSR230 22 ACR AUTOMATION DIRECT 10 DOOR COUPLING HANDLE RED YEL KT7 HTRY SPRECHER SCHUH 12 TERMINAL ADAPTER KT7 25 TE1 SPRECHER SCHUH 21 SO...

Page 153: ...ca Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 153 Figure 9 2 VST Control Panel Front Cover Replacement Parts Figure 9 3 VST Control Panel Inside the Front Cover Replacement Parts ...

Page 154: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 154 Figure 9 4 VST Control Panel Inside Panel Replacement Parts ...

Page 155: ...cement 9 11 Leak Test 9 2 PLC Controller Replacement Safety Use lockout tagout procedures prior to starting work 9 2 1 Removing the PLC 1 Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel The power ground and neutral will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Open the VST...

Page 156: ... of the PLC and lightly tighten Do not over tighten 3 Reinstall the two terminal blocks on the PLC Make sure they are fully inserted into the PLC 4 Close the VST Control Panel door 5 After all the work is complete remove the lock s and tags from the lockout tagout 6 Turn ON power to the VST Control Panel The GREEN MACHINE is now operational and will operate if the UST pressure is greater or equal ...

Page 157: ...N MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 157 Figure 9 6 The PLC with Connectors Removed Figure 9 7 Removing the PLC Hold Down Clips ...

Page 158: ... the VST Control Panel The power ground and neutral will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Unlock the metal clasps on the right hand side of the Control Panel and open the Control Panel door 4 Find the vacuum pump motor breaker See Figure 9 4 item 22 and note the wire numbers and locations See Figure 9 8 5 Using a screwdri...

Page 159: ...gout 6 Turn the Power Switch to the ON position 9 3 2 Vacuum Pump Motor Solid State Relay Replacement Safety Use lockout tagout procedures prior to starting work 9 3 2 1 Removing the Solid State Relay See Figure 9 2 9 9 1 Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel The power ground and neutral will be completely disconnected from the GR...

Page 160: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 160 Figure 9 9 Vacuum Pump Solid State Relay ...

Page 161: ...res prior to starting work 9 4 1 Removing the Pressure Sensor See Figure 9 10 1 Turn OFF power to the VST Control Panel at the Power Switch located on the front of the VST Control Panel The power ground and neutral will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Unlock the hasps and remove the cover from the GREEN MACHINE 4 Close t...

Page 162: ...en the Liquidtight conduit on the Pressure Sensor bushing and the Internal Junction Box 5 Connect the Pressure Sensor wires to the terminal blocks inside the Internal Junction Box See Figure 9 11 6 Install the Internal Junction Box cover 7 Remove the lock s and tags from the lockout tagout 8 Turn the Maintenance Switch OFF at the VST Control Panel so the GREEN MACHINE cannot operate 9 Turn power O...

Page 163: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 163 Figure 9 10 Pressure Sensor Replacement ...

Page 164: ... 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 164 Figure 9 11 Wiring the Pressure Sensor Inside the Internal Junction Box ...

Page 165: ...al will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Unlock the hasps and remove the cover from the GREEN MACHINE NOTE The vacuum pump and vacuum pump tubing will not be affected by moving the vacuum pump motor 4 Remove the fan guard over the drive coupling flanges 5 Carefully move the junction box stand out of the way to allow for e...

Page 166: ...shims that moved while moving the motor 3 Re install and tighten the 4 motor mounting bolts to the base plate Make sure the Motor Shaft and Vacuum Pump shafts are in alignment 4 Re install the 2 bolts holding the Internal Junction Box stand to the GREEN MACHINE base 5 Re install the fan guard over the coupling flanges 6 Put the cover on the GREEN MACHINE and lock the hasps 7 Remove the lock s and ...

Page 167: ...g will not be affected by removing the motor 4 Remove the fan guard over the drive coupling flanges 5 Disconnect the motor wires inside the motor junction box See Figure 9 15 6 Remove the flexible conduit and 90 liquid tight fitting from the vacuum pump motor junction box and keep for re use 7 Remove the two bolts holding the Internal Junction Box stand to the GREEN MACHINE base Keep the bolts for...

Page 168: ...ainst the rubber flange sleeve 6 Install the shaft key and tighten the set screw 7 Install the 90 liquid tight fitting and flexible conduit on the motor junction box 8 Re connect the vacuum pump motor wires inside the motor junction box See Figure 9 15 9 Re install the fan guard 10 Remove the lock s and tags from the lockout tagout 11 Turn ON power to the VST Control Panel At the VST Control Panel...

Page 169: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 169 Figure 9 15 Junction Box Motor Wiring Diagram ...

Page 170: ...MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 170 9 7 Control Valve Replacement Figure 9 16 GREEN MACHINE Control Valves Identification Tags ...

Page 171: ... cover from the GREEN MACHINE 4 Unlock and close the three ball valves between the GREEN MACHINE and the vent risers NOTE The Liquid Tight conduit or fitting do not have to be removed from the solenoid See Figure 9 17 5 Remove the red cap from the solenoid that is not working 6 Remove the nameplate by pushing the solenoid down towards the valve body then lift and slide the nameplate off 7 Slide th...

Page 172: ...e then slide the solenoid on to the solenoid base 4 Slide and lock the nameplate on the solenoid 5 Snap the red cap on the solenoid base 6 Open the three ball valves between the GREEN MACHINE and the vent risers and lock in the OPEN position 7 CAUTION THREE BALL VALVES BETWEEN THE GREEN MACHINE AND THE VENT RISERS MUST BE OPEN BEFORE APPLYING POWER TO THE VST CONTROL PANEL TO AVOID DAMAGE TO THE G...

Page 173: ...wer ground and neutral will be completely disconnected from the GREEN MACHINE 2 Use Lockout Tagout Procedures prior to starting work 3 Unlock and close the 3 isolation valves between the GREEN MACHINE and the vent risers 4 Unlock the hasps and remove the cover from the GREEN MACHINE 5 Remove tubes 1 2 3 4 5 and 6 from the GREEN MACHINE See Figures 9 20 9 21 CAUTION The tube ends are a Parker 45 fl...

Page 174: ...rth America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 174 Figure 9 20 Items Associated with Cleaning the GREEN MACHINE Tubing and Manifold Figure 9 21 Tubes 1 6 removed ...

Page 175: ...er 45 flare use caution not to damage the 45 flare fittings or the threads after removal 4 Remove the fan guard the large center guard 1 in Figure 9 22 for access to the coupling flanges and removal of the Vacuum Pump 5 Loosen the drive coupling set screws on the motor side of the rubber flange sleeve then slide the drive coupling towards the motor Penetrating oil may be needed to slide the flange...

Page 176: ...olts so the pump shaft aligns with the motor shaft 5 Slide the drive coupling flange over the rubber flange sleeve so both halves of the coupling are snug not tight against the rubber flange sleeve and tighten the set screws Double check to make sure both coupling set screws are tight 6 Wrap the pipe fitting threads with gasoline resistant PTFE tape a maximum or three revolutions and reinstall the...

Page 177: ... a 1 wrench to remove the Solenoid Base from the Valve Body Keep the Solenoid Base the Core Assembly and Body Gasket for reuse See Figures 9 26 7 Place the empty Solenoid Base inside the Solenoid then attach the RED Cap Do this for all four Solenoids See Figures 9 27 and 9 28 WARNING The Solenoid Base MUST BE INSTALLED inside the Solenoid so the magnetic field around the Solenoid will not breakdow...

Page 178: ...tenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 178 Figure 9 24 GM Control Valve Assembly and Components Figure 9 25 How to remove the Red Cap from the Solenoid Base Figure 9 26 Manifold with the Solenoids Removed showing the Solenoid Bases ...

Page 179: ...ance Troubleshooting Manual Chapter 9 Replacement Procedures Page 179 Figure 9 29 Solenoids with the Solenoid Bases Installed Arranged Out of the Way Figure 9 27 Solenoid with Solenoid Base and Red Cap Figure 9 28 Solenoid with Solenoid Base and Red Cap installed ...

Page 180: ...HINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 180 Figure 9 30 Manifold Ready for Cleaning Figure 9 31 Vacuum Pump with the Blowout Tube Installed ...

Page 181: ...will operate This will allow the Vacuum Pump to blow outside air through the plastic tube WARNING Safety Glasses MUST BE USED when blowing out the Tubes and Manifold 6 Using the plastic tube blow air through the 6 removed copper tubes to remove any potential debris See Figure 9 21 7 Using the plastic tube blowout each of the openings in the manifold starting at right side and progress to the other...

Page 182: ...th a wrench an additional turn for a metal to metal seal 9 8 7 Conduct a Functionality Test Conduct a Functionality Test as shown in Chapter 6 of this document 9 8 8 Ending Stage 1 Lock open the three ball valves between the GREEN MACHINE and the Vent Risers and replace the caps on the three tees 2 Open the 3 way valve below the Pressure Sensor so the handle is turned VERTICALLY ON or OPEN CAUTION...

Page 183: ...ster housing from the GREEN MACHINE base 8 Purge the removed canister with compressed air for 24 hours to remove any hydrocarbons if any before discarding 9 9 2 Installing the new 8 Canister Housing The new 8 canister housing will arrive with all the tubing fittings attached and with new bolts washers and aluminum risers 1 Install the 8 canister housing on the GM base with the new risers bolts and...

Page 184: ...r 9 Replacement Procedures Page 184 5 Install the cover on the GREEN MACHINE and lock the hasps 6 Remove the locks from lockout tagout 7 Turn ON power at the Power Switch on the front of the VST Control Panel The GREEN MACHINE is now operational Figure 9 33 Removing Installing the Canister Housing ...

Page 185: ... the Power Switch located on the front of the VST Control Panel The power ground and neutral will be completely disconnected from the GREEN MACHINE 2 Follow lockout tagout procedures prior to starting work 3 Unlock the hasps and remove the cover from the GREEN MACHINE 4 Remove the two 45 flare tubing connections from the separator being careful not to damage the copper tubing 5 Remove the 90 and s...

Page 186: ...o 45 flare tubing connections CAUTION Do not use any thread sealing compound when assembling the 45 flare nuts CAUTION When tightening the 45 flare nuts Clamp the tube flare between nut and nose body of the tube by screwing the nut on finger tight Tighten with a wrench an additional turn for a metal to metal seal 4 Put the cover on the GREEN MACHINE and lock the hasps 5 Remove the lock s and tags ...

Page 187: ...one open tee is required for this test See Figure 9 36 2 CAUTION Make sure the 3 way valve below the Pressure Sensor is turned HORIZONTAL OFF or Closed Leaving the valve ON during this test may damage the Pressure Sensor 3 Make sure the Maintenance Screen is showing on the PLC See Figure 9 37 The GREEN MACHINE is now in the Manual OFF mode and will not operate If the PLC is not in the Maintenance ...

Page 188: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 188 Figure 9 36 Vapor Piping Overview ...

Page 189: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 189 Figure 9 37 Maintenance Screen Figure 9 38 Leak Test Screen ...

Page 190: ... GREEN MACHINE O RINGS AND OR PUMP SEALS WHICH WILL VOID ALL WARRANTIES OF THE GREEN MACHINE 8 At the GREEN MACHINE Controller press the F1 button to start the Leak Test which will disable the Vacuum Pump and open all of the control valves See Figure 9 38 The Leak Test will continue until one of the following conditions is met The F4 button is pushed OR The GREEN MACHINE Controller internal timer ...

Page 191: ... is turned VERTICAL ON or Open Leaving the 3 way valve turned OFF HORIZONTAL will not allow the GREEN MACHINE to operate in the Normal Operating Mode 6 Put the cover back on the GREEN MACHINE and lock the hasps 7 Open the 3 ball valves at the GREEN MACHINE and place the locks on the valves 8 At the GREEN MACHINE Controller push the ESC button to return to the Main Screen where the GREEN MACHINE wi...

Page 192: ...E North America Installation Operation Maintenance Troubleshooting Manual Chapter 9 Replacement Procedures Page 192 Figure 9 40 Leak Check Fixture Figure 9 41 GREEN MACHINE with Vapor Inlet Vapor Return and Air Outlet ...

Page 193: ...r will be restored to the VST Control Panel If items 1 4 are true and the Controller screen is still blank call your GREEN MACHINE Authorized Service Contractor ASC 10 2 Pressure Sensor Alarm When a Pressure Alarm is active on the Controller 1 Call your GREEN MACHINE Authorized Service Contractor ASC 10 3 Vacuum Pump Alarm When a Vacuum Pump Alarm is active on the Controller 1 From the Main Screen...

Page 194: ...rned ON call your GREEN MACHINE Authorized Service Contractor ASC 10 5 Overfill Alarm When an Overfill is active on the Controller 1 An Overfill has occurred at the station during a fuel drop 2 The Overfill Alarm should clear 2 hours after the overfill clears Check the Fuel Management System to see if there is a UST overfill 3 If the Overfill Alarm has not cleared in 24 hours call your GREEN MACHI...

Page 195: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 10 Operator Instruction Sheet Page 195 Figure 10 1 Main Screen Figure 10 2 Maintenance Screen ...

Page 196: ...Operation Maintenance Troubleshooting Manual Chapter 10 Operator Instruction Sheet Page 196 Push ESC to return to the Main Screen when in the Maintenance Faults Alarms or Password Screens Figure 10 3 Faults Alarm Screen Figure 10 4 Password Screen ...

Page 197: ...of the SD Card To install place the SD Card into the PLC slot note the orientation of the SD Card CAUTION Once the SD Card is partially inserted in the PLC slot use your finger nail not a hard tool to fully insert the SD Card into PLC slot To remove the SD Card from the PLC slot The SD Card can be removed from the PLC by using your finger nail and pressing the SD Card in releasing it and then pull...

Page 198: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 10 Operator Instruction Sheet Page 198 This page left intentionally blank ...

Page 199: ...vides our customers and users with exceptional products services and innovative solutions for improving the fueling station experience as well as the world s air quality VST s product offering includes curb pump and vapor recovery hoses safety breakaways nozzles and emission control system GREEN MACHINE The ENVIRO LOC vapor recovery product offering represents the most innovative concept in the in...

Page 200: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 11 Operator Training Guide Page 200 Figure 11 1 GREEN MACHINE Gasoline Station Overview ...

Page 201: ...Panel with the following items GREEN MACHINE Controller Controls the GREEN MACHINE based on UST vapor pressure Power Switch Provides a means to disconnect ALL power from the Control Panel and ALL power to the GREEN MACHINE Can be locked in the OPEN or CLOSED position Use lockout tagout procedures Maintenance Switch Turning OFF the Maintenance Switch will remove ALL power from the GREEN MACHINE Tur...

Page 202: ...n Alarm Condition GM Status Normal Green Box indicates the GREEN MACHINE is operating normally no active Alarms Alarm Red Box indicates an Alarm is active When an Alarm is active see the Operator Instruction Sheet for directions Date and Time Push the Date and Time soft button to change the Date and Time Maintenance Screen and an Alarm Screen Push the Maintenance Screen soft button to access the M...

Page 203: ...REEN MACHINE Idle Due to the UST pressure being less than 0 2 IWC Green Text Box GREEN MACHINE Alarm Go to the Alarm Screen to identify the Alarm An Alarm has activated Red Text Box See the Operator Instruction Sheet for directions Displayed Data UST Pressure IWC Displays the UST pressure in real time Run Cycles Displays the number of GREEN MACHINE completed cycles Date and Time Date MM DD YY and ...

Page 204: ...nce Screen This feature is used when conducting maintenance on the GREEN MACHINE Vac Pump Bump is used to check the vacuum pump motor rotation during start up or after performing maintenance on the vacuum pump motor The Reset Motor Alarm is used when the Vacuum Pump is in Alarm Function Button labels are shown at the bottom of the screen The F1 F2 F3 F4 Function buttons and the ESC button are acce...

Page 205: ...See Figure 11 5 11 3 1 GM Status Normal Green Box indicates the GREEN MACHINE is operating normally no active Alarms Alarm Red Box indicates an Alarm is active When an Alarm is active See the Operator Instruction Sheet for directions 11 3 2 Pressure Sensor Alarm The fault will occur if the Pressure Sensor is not connected to the VST Control Panel or is wired incorrectly at the VST Control Panel or...

Page 206: ...e the Maintenance Switch The GREEN MACHINE will not to operate during this alarm 11 3 5 Overfill Alarm An overfill condition exists when during a fuel drop the gasoline level in the UST exceeds the overfill alarm setting which is 90 capacity of the UST The VST Control Panel is connected to the Tank Overfill Alarm output relay When an overfill occurs the output N O relay closes and GREEN MACHINE wi...

Page 207: ...ay contacts close at the Fuel Management System Eventually as fuel is dispensed the product would drop below the OVERFILL Alarm threshold thereby resetting the relay and re enabling the GREEN MACHINE The Fuel Management System OVERFILL Alarm will not guarantee that the GREEN MACHINE is protected from gasoline entering into it The GREEN MACHINE will not operate during this alarm 11 3 6 SD Card Alar...

Page 208: ... the SD Card To install place the SD Card into the PLC slot note the orientation of the SD Card CAUTION Once the SD Card is partially inserted in the PLC slot use your finger nail not a hard tool to fully insert the SD Card into PLC slot To remove the SD Card from the PLC slot The SD Card can be removed from the PLC by using your finger nail and pressing the SD Card in releasing it and then pullin...

Page 209: ...will turn OFF all power to the VST Control Panel and to the GREEN MACHINE The PLC will not show any screens and will be blank 2 There is no need to close the isolation valves at the GREEN MACHINE since powering off the VST Control Panel will close the control valves inside the GREEN MACHINE This will isolate the GREEN MACHINE from the UST the vent risers and all external vapor piping After Testing...

Page 210: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Chapter 11 Operator Training Guide Page 210 This page left intentionally blank ...

Page 211: ... Click on VST Education 3 Under North America GREEN MACHINE Click on Supporting Documents and Instructional Video 4 Click on General Contractor 5 Click on Appendix A General Contractor Check Out Form 6 Fill out and submit Appendix A with the required photos 7 Receive an email from VST with a copy of the filled out Appendix A The following pages contain the contents of Appendix A and the questions ...

Page 212: ...______________________________ General Contractor Company Phone Number ___________________________________________________ General Contractor s Name ___________________________________________________ General Contractor s E Mail Address ___________________________________________________ Date of Completion ___________________________________________________ GREEN MACHINE Serial Number ____________...

Page 213: ...he front of the VST Control Panel The Maintenance Switch Alarm will be active when power is turned ON When power is applied to the Control Panel the GREEN MACHINE cannot operate with the Maintenance Switch OFF regardless of UST pressure MAINTENANCE SWITCH IS TURNED OFF 7 Turn the GREEN MACHINE breaker ON at the Main Distribution Panel MAIN POWER IS ON 8 Check that the VST Control Panel wiring is c...

Page 214: ...4 5 GREEN MACHINE North America Installation Operation Maintenance Troubleshooting Manual Appendix A Page 214 This page left intentionally blank ...

Page 215: ... Click on Supporting Documents and Instructional Video 4 Click on Start Up Commissioning Contractor 5 Click on Appendix B Start Up Contractor Check Out Form 6 Fill out and submit Appendix B with the required photos 7 Receive an email from VST with the Verification CODE and a copy of the filled out Appendix B The following pages contain the contents of Appendix B and the questions you ll be asked Y...

Page 216: ...______ Start Up Contractor Phone ________________________________________________________ Start Up Contractor s Name ________________________________________________________ Email Address ________________________________________________________ NOTE This is the e mail address that the Start Up Validation CODE will be sent Make sure you have immediate access to your e mail listed above to complete ...

Page 217: ...ng No Underground Storage Tanks Levels Readings and Calculations If a UST tank level exceeds 90 and the Overfill Alarm is installed the GREEN MACHINE will not operate The tank information entered below will calculate the tank levels Obtain and fill in the volumes and ullages from the Fuel Management System in order to calculate the tank levels Tank 1 Volume Gal Tank 1 Ullage Gal Tank 1 Level Calcu...

Page 218: ...removed the 3 way valve below the Pressure Sensor must be turned in the VERTICAL ON or Open Leaving the 3 way valve turned HORIZONTAL Closed or OFF at the Pressure Sensor will not allow the GREEN MACHINE to operate in the Normal Operating Mode OPEN THE PRESSURE SENSOR VALVE 8 Place the cover on the GREEN MACHINE and lock the hasp on the cover INSTALL THE COVER 9 Turn the Maintenance Switch on the ...

Page 219: ... 11 4 Picture of the VST Control Panel PLC Main Screen 11 5 Picture inside the VST Control Panel inside the front door 11 6 Picture inside the VST Control Panel inside the panel 11 7 Picture inside the VST Control Panel showing the field wiring connections CAUTION The locking ball valve handles at the GREEN MACHINE inlet return and outlet must not be removed All items have been checked and verifie...

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VST GREEN MACHINE VST-GM-CS2-101, Installation, Operation, Maintenance, & Troubleshooting Manual

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