Manual No: 051-330 • Revision: K

IQ Control Box
Installation and Owner’s Manual
Model: 880-051-1
880-052-1
880-058-1
880-059-1
Notice
Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of
merchantability and fitness for a particular purpose.
Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages
in connection with the furnishing, performance, or use of this publication.
Veeder-Root reserves the right to change system options or features, or the information contained in this publication.
This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication
may be photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root.
Contact Red Jacket Technical Support for additional troubleshooting information at 800-323-1799.

DAMAGE GOODS/LOST EQUIPMENT

Thoroughly examine all components and units as soon as they are received. If any cartons are damaged or missing, write a
complete and detailed description of the damage or shortage on the face of the freight bill. The carrier's agent must verify the
inspection and sign the description. Refuse only the damaged product, not the entire shipment.
VR must be notified of any damages and/or shortages within 30 days of receipt of the shipment, as stated in our Terms and
Conditions.

VEEDER-ROOT’S PREFERRED CARRIER

1. Fax Bill of Lading to V/R Customer Service at 800-234-5350.
2. Call V/R Customer Service at 800-873-3313 with the specific part numbers and quantities that were received damaged or
lost.
3. VR will file the claim with the carrier and replace the damaged/missing product at no charge to the customer. Customer
Service will work with production facility to have the replacement product shipped as soon as possible.

CUSTOMER’S PREFERRED CARRIER

1. Customer files claim with carrier.
2. Customer may submit a replacement purchase order. Customer Service will work with production facility to have the
replacement product shipped as soon as possible.
3. If “lost” equipment is delivered at a later date and is not needed, VR will allow a Return to Stock without a restocking fee.
4. VR will NOT be responsible for any compensation when a customer chooses their own carrier.

RETURN SHIPPING
For the parts return procedure, please follow the instructions in the “General Returned Goods Policy” pages of the “Policies and
Literature” section of the Veeder-Root North American Red Jacket Mechanical Products Price Book. Veeder-Root will not accept
any return product without a Return Goods Authorization (RGA) number clearly printed on the outside of the package.

RESPONSIBILITIES OF THE INSTALLER AND STATION OWNER

This installation, operation and service instruction manual shall be left with the owner of the service station at which this equipment
is installed. Retain these instructions for future use and provide them to persons servicing or removing this equipment.

©Veeder-Root 2021. All rights reserved.

 Table of Contents

Introduction
Safety Precautions ............................................................................................................1
Specifications ....................................................................................................................2
IQ Manifold Control Information ........................................................................................3
Manifolded PLLD – TLS Decides (multiple hook signals).........................................4
Manifolded Direct – Unit 1 always turns on first (One shared hook signal) ..............4
Manifolded Alternating – The devices alternate turning on first every time
the hook signal is disabled. (One shared hook signal) .............................................4

Installation and Wiring Instructions

Determine the Motor Type ..............................................................................................10
Programming the Motor Type .........................................................................................13
Setup Switch Chart .........................................................................................................15
Initial Calibration .............................................................................................................16

Troubleshooting
Basic Indicator Functions ................................................................................................17
Description of Fault Conditions .......................................................................................17
Uncalibrated Controller...........................................................................................17
Over-Current Condition ..........................................................................................17
Dry Run ..................................................................................................................18
Low AC Current ......................................................................................................18
Setup/Communication Error ...................................................................................18
Low Line Voltage ....................................................................................................18
Bypass Mode..........................................................................................................18
Extended Run.........................................................................................................18

Appendix A - TLS-450PLUS Diagnostic Monitoring of

Red Jacket IQ Control Boxes
Introduction .....................................................................................................................A-1
Pre-Installation Consideration .........................................................................................A-1
Equipment Requirements .......................................................................................A-1
Installation Precautions ..........................................................................................A-1
Determining Number of RS-485 Ports Needed ...............................................................A-1
Installing RS-485 Wiring Between IQ Control Boxes & TLS-450PLUS ..........................A-3
Upgrading IQ Control Box Software - Repeat For Each IQ Control Box .........................A-4
Replacing the Software PROM...............................................................................A-4
Programming the Motor Type.................................................................................A-5
Calibrating the IQ Control Box................................................................................A-7
TLS-450PLUS Software Upgrade Procedure .................................................................A-8
TLS-450PLUS RJ IQ Monitoring Feature Installation Procedure ....................................A-8
Verifying RS-485 Single or Dual Comm Module Jumper Positions ................................A-9
Installing RS-485 Comm Module ..................................................................................A-11
Connecting RS-485 Wiring To The IQ Control Boxes ...................................................A-12
TLS-450PLUS Setup For IQ Control Box Monitoring ....................................................A-13
Serial Port Setup ..................................................................................................A-13
Pump Controller Setup .........................................................................................A-13
DB Backup............................................................................................................A-14
Diagnostics ...................................................................................................................A-15
STP Status ...........................................................................................................A-15
Alarms ..................................................................................................................A-15

iii
 Table of Contents

Figures
Figure 1. Simple Wiring Configuration Diagrams ...................................................3
Figure 2. Terminal Block TB1, Models -051, -052 .................................................6
Figure 3. -Terminal Block TB1, Models -058, -059 ................................................7
Figure 4. Wiring Diagram for Manifolded Systems ................................................7
Figure 5. Wiring Diagram for IQ Control Box with
TLS-350 Manifolded PLLD Systems .......................................................8
Figure 6. Wiring Diagram for IQ Control Box with
TLS-450PLUS Manifolded DPLLD Systems ...........................................9
Figure 10. Identifying UMP Models By Their End View .........................................10
Figure 11. Dip Switch SW1 and Bypass Jumper J3 ..............................................15
Figure A-1. RS-485 Serial Cable Pin-Outs ............................................................ A-3
Figure A-2. Example IQ Control Box Comm Wiring Example .............................. A-3
Figure A-3. Locating Software Upgrade Components Inside
Typical IQ Control Box ........................................................................ A-4
Figure A-4. Removing Software PROM U1 From IQ Control Box ......................... A-5
Figure A-5. SW1 Switch Setup chart ..................................................................... A-7
Figure A-6. Single RS-485 Port Module Jumper Positions .................................... A-9
Figure A-7. Dual RS-485 Ports Module Jumper Positions .................................. A-10
Figure A-8. Comm Module Clamp Securing Screw ............................................. A-11
Figure A-9. Comm Module Bracket Keyed Slot ................................................... A-11
Figure A-10. Attaching Comm Cables To RJ IQ Control Boxes ............................... A-12
Figure A-11. RJ IQ Comms Setup Screen ............................................................ A-13
Figure A-12. RJ Control Box Setup Screen - Unit 1 Example ............................... A-14
Figure A-13. IQ Control Box Communications Status Screen ............................... A-15

Tables
Table 1. Electrical Service Information (for UMPs Containing a
Franklin Motor with End View A) .............................................................10
Table 2. Electrical Service Information (for UMPs Containing a
Faradyne Motor with End View B) ...........................................................11
Table 3. UMP Model Dimensions ..........................................................................12
Table 4. Approximate Pump Shut Off Pressures ..................................................12
Table 5. Motor Type Programming ........................................................................13
Table 6. Reset/Cal Button and LED Indicator Actions ...........................................14
Table 7. Motor Type Selections .............................................................................15
Table 8. Indicator Fault Conditions ........................................................................17
Table A-1. TLS-450PLUS Comm Module Compatibility ......................................... A-2
Table A-2. Motor Type Programming ...................................................................... A-6
Table A-3. Reset Button and LED Actions .............................................................. A-7
Table A-4. IQ Control Box Diagnostic Alarms ....................................................... A-15

iv
 Introduction

RED JACKET’S IQ™ Control Box raises the standard for typical relay control boxes. Incorporating a
microprocessor on board that continuously monitors the submersible pump provides insurance against conditions
that can permanently damage the pump. In addition, the increasing number of dispensers at a station has
demanded more than one pump per tank. Red Jacket’s IQ Control Box can be connected to additional control
boxes to allow up to four pumps per tank with demand driven sequencing. This function can be set to alternate
between pumps that initiate next dispensing events to average the wear on all of the pumps in the system. The
pump control circuit features non-volatile memory retention eliminating the need to recalibrate if power is lost.
IQ Control Box version 3 software adds support for Faradyne motors. The software will also support Franklin
motors. Software version 3 requires the motor type to be programmed into the unit. The five-position unit
configuration switches, reset/calibration button, and bypass/normal jumper are used to program the Motor Type.
The microprocessor chip containing software version 3 is marked 805-001C or higher.
Appendix A provides application, technical and installation guidelines for Veeder-Root certified technicians who
will be installing and setting up the Red Jacket IQ Control Standard Diagnostic Feature with a TLS-450PLUS
system.
Retain this instruction manual with the equipment after installation for future use.

Safety Precautions

The following safety symbols are used throughout this manual to alert you to important safety hazards and
precautions.

TURN POWER OFF ELECTRICITY

Live power to a device creates a potential shock hazard. High voltage exists in, and is supplied to, the
Turn Off power to the device and associated accesso- device. A potential shock hazard exists.
ries when servicing the unit.

NOTICE DANGER
Is used to address practices not related to physical Indicates a hazardous situation which, if not
injury. avoided, will result in death or serious injury.

CAUTION WARNING
Indicates a hazardous situation which, if not avoided, Indicates a hazardous situation which, if not
could result in minor or moderate injury or property dam- avoided, could result in death or serious injury or
age. substantial property damage.

READ ALL RELATED MANUALS STATIC SENSITIVE COMPONENTS

Knowledge of all related procedures before you begin Wear grounded anti-static wrist strap before han-
work is important. Read and understand all manuals dling the printed circuit boards and mounted
thoroughly. If you do not understand a procedure, ask components.
someone who does.

1
IQ Control Box Installation and Owner’s Manual Specifications

WARNING
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS
COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT, RESULTING IN SERIOUS
INJURY OR DEATH.
1. All installation work must comply with the latest issue of the National Electrical Code
(NFPA 70), the Code for Motor Fuel Dispensing Facilities and Repair Garages (NFPA
30A), and any European, national, state, and local code requirements that apply.
2. To protect yourself and others from serious injury, death, or substantial property
damage, carefully read and follow all warnings and instructions in this manual.

Specifications

Parameter Value Unit

Electrical

Input Voltage Range 200 to 250 V

Input Voltage Frequency 47.5 to 61.8 Hz

Maximum Motor Rating 2 HP

Dispenser Interface (-051, -058) 101 to 132 VAC

Dispenser Interface (-051, -058) 3 mA

Dispenser Interface (-052, -059) 192 to 264 V

Dispenser Interface (-052, -059) 5 mA

Voltage Reading Accuracy 0.1 %

Current Reading Accuracy 0.8 %

Communications RS-485

Environmental

Ambient Temperature Range 0 to 40 °C

Storage Temperature Range -20 to 65 °C

Mechanical

External Dimensions (-051, -052) 6.75 x 7.63 x 4.00 Inches (Height x Width x Depth)

External Dimensions (-058, -059) 6.75 x 7.63 x 6.05 Inches (Height x Width x Depth)

Terminal Block Screw Size 8-32

NOTES:

1. All specifications at an ambient temperature of 25 °C.

2. Wiring must be rated 90°C minimum.

2
IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information

IQ Manifold Control Information

The main difference between Manifold PLLD, Manifold Direct and Manifold Alternation modes shown in Figure 1 is
which IQ Box unit turns on first when there is an active hook signal.

Figure 1. Simple Wiring Configuration Diagrams

3
IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information

Manifolded PLLD – TLS Decides (multiple hook signals)

Overview
In this mode the devices operate while being networked together over RS485 and with a PLLD installation. In this
scenario, each IQ box receives a separate hook signal from the TLS. The TLS is then able to turn on the devices
with a hook signal to activate a PLLD test. Essentially any device can be turned on first via hook switch. The
helping units will then initialize the turn on sequentially over their own RS485 communication.

Operating Example
When a pump request is made by a dispenser the TLS receives the signal. The TLS then decides which pump to
turn on first. This can be based on which tank has the highest fuel height. After the TLS sends the hook signal to
the designated device it begins pumping. As more nozzles are opened there becomes a point where the power
drawn by the motor reaches its threshold. At this point the IQ box sends a request for the next device in line to turn
on in conjunction with itself. For example, the TLS turns on IQ Box Unit 2 first because that was in the tank with
the most volume. When the power threshold is reached Unit 2 will send a request over RS485 for the next unit in
line to turn on. Unit 3 will then turn on and acknowledge the request was complete. If more nozzles are opened yet,
unit 3 will send a request for the next unit in line to turn on over RS485. All pumps once turned on continue to stay
on until the active hook signal is disabled. Once disabled they will all turn off. This process repeats at the next
active hook signal.

Manifolded Direct – Unit 1 always turns on first (One shared hook signal)

Overview
In this setup the Unit 1 always turns on first with a hook signal. The helping units will then turn on sequentially. All
units share a hook signal in this mode, so all units have the hook signal engaged and the hook is controlled by the
Master Hook switch.

Operating Example
When a pump request is made by a dispenser every IQ Box receives this information. Unit 1 will always accept or
try to accept pending any faults. Once it acknowledges it sends out an acknowledged signal over RS485 and all
other IQ boxes will wait in standby for an RS485 message to request to turn on. As more nozzles are opened there
becomes a point where the power drawn by the motor reaches its threshold. At this point the IQ box sends a
request for the next device in line to turn on in conjunction with itself. So, in this case Unit 2 will always turn on
next. Then when Unit 2 is running and more flow is needed it, Unit 3 will be the next to turn on. Lastly Unit 4 will
turn on. All pumps once turned on continue to stay on until the active hook signal is disabled. Once disabled they
will all turn off. This process repeats at the next active hook signal.

Manifolded Alternating – The devices alternate turning on first every time the hook signal is
disabled. (One shared hook signal)

Overview
In this setup the devices take turn passing a token that designates which one will turn on first from a hook signal.
The helping units will then turn on sequentially. All units share one common hook signal in this mode, so all units
have the hook signal engaged and the hook is controlled by the Master Hook switch.

Operating Example
When a pump request is made by a dispenser every IQ Box receives this information. Unit 1 will accept, or try to
accept pending any faults, this initial hook signal and then pass a token for Unit 2 to turn on first at the next pump
cycle. Once Unit 1 acknowledges the hook signal, it sends out an acknowledgment over RS485 and all other IQ
boxes will wait in standby for an RS485 message to request to turn on. As more nozzles are opened there

4
IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information

becomes a point where the power drawn by the motor reaches its threshold. At this point the IQ box sends a
request for the next device in line to turn on in conjunction with itself. So, in this case Unit 2 will always turn on
next. Then when Unit 2 is running and more flow is needed it, Unit 3 will be the next to turn on. Lastly Unit 4 will
turn on. All pumps once turned on continue to stay on until the active hook signal is disabled. Once the hook signal
is disabled, they will all turn off. On the next hook signal the next unit in line will turn on. So, if 1 turned on first, 2
will be the first to accept the hook request on the next cycle. On the next cycle Unit 3 will be the first to turn on
and so forth. If it is the last Unit in the setup, it will pass the token back to Unit 1.

5
 Installation and Wiring Instructions

This equipment must be installed in a non-hazardous location.

1. Locate an area that allows all of the wiring to enter through the bottom knockouts of the IQ Control Box.
Consider the ability to view the indicator on the side of the base and access to the reset button when
choosing a location.
2. Remove the cover of the enclosure and mount the base.
3. While viewing the wiring diagram or inside the enclosure cover, connect the input power L1 and L2 wires to
the terminal block labeled TB1 (see Figure 2). This control box is designed to operate from 200 to 250Vac.
Since the submersible turbine pump is powered by the M1 and M2 terminals (and M3 terminals -058, -059
models) on the circuit board, refer to the installation and instruction manual that was supplied with the pump
for correct supply voltage. Typical pump ratings are 200 to 250 Vac.
4. Locate the grounding lug on the enclosure base and make an electrical ground connection to this point.
5. Motor leads M1 and M2 should be terminated to the M1 and M2 terminals on TB1. The M3 lead for models -
058 and -059 should terminate to the splice provided lead from the capacitor in the cover (see Figure 3).
6. The D1 and D2 terminals are reserved for the dispenser signal. These terminals are not polarity sensitive and
can accept 120V or 240V signals. For pump manifolded installations it is important to wire the dispenser
signal to all of the controllers.
7. Jumper J3 should be in the Normal position. Use the Bypass position only to program the Motor Type, or if
temporarily controlling the pump directly from dispenser. Pump protection operation is not available in this
position.
8. Installations that will operate pumps in a manifolded or TLS450PLUS monitoring configuration require a two
conductor, twisted pair with shield (min. 22 AWG) connected to the COM+, COM-, and SHIELD terminals of
TB1. Daisy chain the communication cable to all of the controllers and/or the TLS-450PLUS as shown in
Figure 4. Belden 3106A, or equivalent cable is acceptable. If adding a TLS-450PLUS monitoring
configuration to an existing controller installation, reuse the existing cable between the controllers. The RS-
485 link between pump controllers is not intended to be connected to other Red Jacket electronic equipment
such as Prolink, CPT, VSFC or other ATG devices. However, it may be necessary to break communications in
PLLD or DPLLD applications as shown in Figure 5 and Figure 6. This cable must be installed in conduit.

Approved component only. Total systems installed shall comply with all codes.

Figure 2. Terminal Block TB1, Models -051, -052

6
IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information

Figure 3. -Terminal Block TB1, Models -058, -059

Figure 4. Wiring Diagram for Manifolded Systems

7
IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information

Figure 5. Wiring Diagram for IQ Control Box with TLS-350 Manifolded PLLD Systems

8
IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information

IQ2
C23
Z2

Z3
TB1

COM+ COM- SHLD D2 D1 M2 M1 L1 L2 GND

I/O Module

N TO PUMP
#2

230VAC

PUMP OUTPUT IQ2

NO C COM +
COM +
VR RELAY

RS-485
COMMUNICATION
CABLE

COM -

IQ1
C23
Z2

Z3
TB1

COM+ COM- SHLD D2 D1 M2 M1 L1 L2 GND

N TO PUMP
PUMP OUTPUT IQ1 #1
L1 230VAC
N
DISPENSER HOOK 330-1.eps

Figure 6. Wiring Diagram for IQ Control Box with TLS-450PLUS Manifolded DPLLD Systems

9
IQ Control Box Installation and Owner’s Manual Determine the Motor Type

Determine the Motor Type

Warning! Disconnect, lock out, an tag power to the IQ Control Box at the panel
before starting these steps.

Determination of the Motor Type can be accomplished by measuring the resistance readings at the junction box in
the STP and comparing to Table 1 or Table 2 below. Motor Type can also be determined by observing the flow
paths in the top of the UMP (Figure 10). UMPs containing a Faradyne motor will also have an ‘FM’ designation
printed on the UMP shell.

Figure 10. Identifying UMP Models By Their End View

Table 1 and Table 2 show pump electrical service requirements for UMPs with end views A and B, respectively.

Table 1. Electrical Service Information (for UMPs Containing a Franklin Motor with End View A)

Required power supply rating for 60 Hz, 1 phase pumps is 208 - 230 Vac. For 50 Hz, 1 phase pumps, required rating is 220 - 240 Vac.

Voltage
Fluctuation
Range Winding Resistance (Ohms)
Max. Locked
Load Rotor Black- Red-
UMP Model No. HP Hz PH Min. Max. Amps Amps Orange Orange Black-Red Capacitor Kit (µF)

AGUMP33S1, 1/3 60 1 200 250 4.0 13 7.7 - 9.4 17.4 - 21.2 25 - 30.7 144-224-5 (17.5)
UMP33U1

E85AGUMP75S1, 3/4 60 1 200 250 6.5 25 2.9 - 3.6 14.9 - 18.2 17.7 - 21.9 410164-001 (17.5)
UMP75U1

E85AGUMP150S1, 1-1/2 60 1 200 250 10.5 37 2.0 - 2.5 11.6 - 14.2 13.5 - 16.8 410164-002 (25)
UMP150U1

E85X3AGUMP150S1, 1/1/2 60 1 200 250 10.5 37 2.0 - 2.5 11.6 - 14.2 13.5 - 16.8 410164-002 (25)
X3UMP150U1

10
 IQ Control Box Installation and Owner’s Manual Determine the Motor Type

Table 1. Electrical Service Information (for UMPs Containing a Franklin Motor with End View A)

Required power supply rating for 60 Hz, 1 phase pumps is 208 - 230 Vac. For 50 Hz, 1 phase pumps, required rating is 220 - 240 Vac.

Voltage
Fluctuation
Range Winding Resistance (Ohms)
Max. Locked
Load Rotor Black- Red-
UMP Model No. HP Hz PH Min. Max. Amps Amps Orange Orange Black-Red Capacitor Kit (µF)

E85AGUMP200S1-3, 2 60 1 200 250 11.4 46 1.4 - 1.7 2.5 - 3.2 3.8 - 5 410164-003 (40)
UMP200U1-3

AGUMP75S3-3, 3/4 50 1 200 250 5.8 17 3.6 - 4.5 20.4 - 25 23.9 - 29.6 410164-001 (17.5)
UMP75U3-3

AGUMP150S3-3, 1-1/2 50 1 200 250 10 28 2.5 - 3.1 11.5 - 14 13.9 - 17.2 410164-002 (25)
UMP150U3-3

X4AGUMP150S3, 1-1/2 50 1 200 250 10 28 2.5 - 3.1 11.5 - 14 13.9 - 17.2 410164-002 (25)
X4UMP150U3

AGUMP200S3-4, 2 50 1 200 250 11 37 1.9 - 2.4 3.1 - 3.9 5.0 - 6.3 410164-003 (40)
UMP200U3-4

Table 2. Electrical Service Information (for UMPs Containing a Faradyne Motor with End View B)

Required power supply rating for 60 Hz, 1 phase pumps is 208 - 230 Vac. For 50 Hz, 1 phase pumps, required rating is 220 - 240 Vac.

Voltage
Fluctuation
Range Winding Resistance (Ohms)
Max. Locked
Load Rotor Black- Red-
UMP Model No. HP Hz PH Min. Max. Amps Amps Orange Orange Black-Red Capacitor Kit (µF)

AGUMP33S1, 1/3 60 1 200 250 4.0 10 8.9 -10.8 11.7 - 14.2 17.4 - 21.1 144-224-5 (17.5)
UMP33U1

E85AGUMP75S1, 3/4 60 1 200 250 6.5 19 4.6 - 5.6 7.0 - 8.5 11.6 - 14.0 410164-001 (17.5)
UMP75U1

E85AGUMP150S1, 1-1/2 60 1 200 250 10.5 33 2.6 - 3.2 6.6 - 8.0 9.2 - 11.2 410164-002 (25)
UMP150U1

E85X3AGUMP150S1, 1/1/2 60 1 200 250 10.5 33 2.6 - 3.2 6.6 - 8.0 9.2 - 11.2 410164-002 (25)
X3UMP150U1

E85AGUMP200S1-3, 2 60 1 200 250 11.4 44 1.7 - 2.1 3.2 - 4.0 5.0 - 6.1 410164-003 (40)
UMP200U1-3

AGUMP75S3-3, 3/4 50 1 200 250 5.8 18 4.9 - 5.9 11.0 - 12.2 15.0 - 18.2 410164-001 (17.5)
UMP75U3-3

AGUMP150S3-3, 1-1/2 50 1 200 250 10 31 2.7 - 3.3 13.2 - 16.1 16.0 - 19.4 410164-002 (25)
UMP150U3-3

X4AGUMP150S3, 1-1/2 50 1 200 250 10 31 2.7 - 3.3 13.2 - 16.1 16.0 - 19.4 410164-002 (25)
X4UMP150U3

AGUMP200S3-4, 2 50 1 200 250 11 38 2.0 - 2.4 5.8 - 7.0 7.8 - 9.5 410164-003 (40)
UMP200U3-4

11
IQ Control Box Installation and Owner’s Manual Determine the Motor Type

Table 3 lists UMP weights and lengths and Table 4 lists pump shut off pressures.

The weights and lengths listed below are approximate values and will vary due to
manufacturing tolerances.

The optional trapper intake screen is available as a field installed accessory. Trapper options will increase the
length of the UMP by 3.3 inches (83 mm). For installation instructions, see Red Jacket installation instructions
#051-256-1. For models with floating suction adapter, add 2-3/8 inches (59 mm) and 4 pounds (1.8 kg).

Table 3. UMP Model Dimensions

Franklin Motor Faradyne Motor

(Use these lengths for UMPs (Use these lengths for UMPs
with end view A shown in with end view B shown in
Figure 10) Figure 10) Weight

UMP Model HP in. mm in. mm lb. kg

UMP33U1, AGP33R1 1/3 15-1/2 390 15-3/8 391 24 11.0

UMP75U1, E85AGUMP75S1 3/4 17-3/4 447 17-5/8 448 28 12.7

UMP75U3-3, AGUMP75S3-3 3/4 20 507 19-7/8 505 30.5 13.9

UMP150U1, E85AGUMP150S1 1-1/2 20-1/2 519 20-5/8 524 34 15.5

X3P150U1, E85X3AGUMP150S1 1-1/2 21-1/4 540 21-1/2 546 35 15.8

UMP150U3-3, AGUMP150S3-3 1-1/2 22-1/4 565 22-1/4 565 34 15.5

X4P150U3, X4GUMP150S3 1-1/2 22-3/4 576 22-7/8 581 35 15.9

UMP200U1-3, E85AGUMP200S1-3 2 24-1/4 618 24-5/8 626 36 16.3

UMP200U3-4, AGUMP200S3-4 2 26 660 26-1/4 667 38 17.2

Table 4. Approximate Pump Shut Off Pressures

UMP Model Approximate Shut Off Pressure

AGUMP33S1, UMP33R1 25 psi (172 kPa) .74 SG @ 60°F (15°C)

E85AGUMP75S1, UMP75U1 28 psi (193 kPa) .74 SG @ 60°F (15°C)

E85AGUMP150S1, UMP150U1 30 psi (207 kPa) .74 SG @ 60°F (15°C)

E85X3AGUMP150S1, X3UMP150U1 43 psi (297 kPa) .74 SG @ 60°F (15°C)

AGUMP75S3-3, UMP75U3-3 30 psi (207 kPa) .74 SG @ 60°F (15°C)

AGUMP150S3-3, UMP150U3-3 32 psi (220 kPa) .74 SG @ 60°F (15°C)

X4AGUMP150S3, X4UMP150U3 40 psi (275 kPa) .74 SG @ 60°F (15°C)

E85AGUMP200S1-3, UMP200U1-3 43 psi (297 kPa) .74 SG @ 60°F (15°C)

AGUMP200S3-4, UMP200U3-4 43 psi (297 kPa) .74 SG @ 60°F (15°C)

12
IQ Control Box Installation and Owner’s Manual Programming the Motor Type

Programming the Motor Type

Warning! Disconnect, lock out, an tag power to the IQ Control Box at the
panel before starting this procedure.

1. Open the IQ Control Box cover.

2. Place the Bypass Jumper in the Bypass Position (Figure 11)
3. Set the five Motor Type Programming DIP switches (Figure 11) to the positions indicated in Table 5 for your
Motor Type.
4. Close and secure cover.
5. Reapply power to the IQ Control Box. (Hook signal must be Off).
6. Locate the Code LED Indicator and the Reset/Calibration button on the side of the enclosure. Depress the
Reset/Cal button 20 seconds and then observe the Code LED flashing sequence shown in Table 6. Note the
number of Green flashes for your Motor Type.

Table 5. Motor Type Programming

Number of Switch Position

Code LED Manufacturer Motor
Flashes 1 2 3 4 5

1 OFF OFF OFF OFF OFF 1/3 60 Hz

2 OFF OFF OFF OFF ON 3/4 60 Hz

3 OFF OFF OFF ON OFF 1.5 60 Hz

4 OFF OFF OFF ON ON 2.0 60 Hz

5 OFF OFF ON OFF OFF FARADYNE X3

6 OFF OFF ON OFF ON 3/4 50 Hz

7 OFF OFF ON ON OFF 1.5 50 Hz

8 OFF OFF ON ON ON 2.0 50 Hz

9 OFF ON OFF OFF OFF X4

13
IQ Control Box Installation and Owner’s Manual Programming the Motor Type

Table 5. Motor Type Programming

Number of Switch Position

Code LED Manufacturer Motor
Flashes 1 2 3 4 5

10 ON OFF OFF OFF OFF 1/3 60 Hz

11 ON OFF OFF OFF ON 3/4 60 Hz

12 ON OFF OFF ON OFF 1.5 60 Hz

13 ON OFF OFF ON ON 2.0 60 Hz

14 ON OFF ON OFF OFF FRANKLIN X3

15 ON OFF ON OFF ON 3/4 50 Hz

16 ON OFF ON ON OFF 1.5 50 Hz

17 ON OFF ON ON ON 2.0 50 Hz

18 ON ON OFF OFF OFF X4

UNKNOW
SOLID ANY OTHER SETTING UNKNOWN N

Table 6. Reset/Cal Button and LED Indicator Actions

Reset/Cal Button -
LED Time Depressed Action

Off Start Press And Hold The Reset Button

Green 5 seconds Clears Alarms

Red 10 seconds Queues Calibration

Cancel calibration. If in Bypass mode,

Off 20 seconds reads and stores Motor Type.

Flashes saved Motor Type code (see Table

Green 20 seconds 5)

7. Release the Reset/Cal button after confirming the Green LED has flashed the correct number of times for your
Motor Type as shown in Table 5.

Warning! Disconnect, lock out, an tag power to the IQ Control Box at the
panel before starting these steps.

8. Disconnect power from the IQ Control Box.

9. Place the Bypass Jumper in the Normal Position.

14
IQ Control Box Installation and Owner’s Manual Setup Switch Chart

10. The unit must be calibrated every time the Motor Type programming is performed even if the Motor Type does
not change. Set the five DIP switches to the desired pump type and mode / role select configuration (see
Figure 11). NOTE: The unit will not calibrate if a Motor Type has not been programmed.

Setup Switch Chart

Each controller must have its duty established through the dip switch bank labeled SW1 on the circuit board
(Figure 11).

Figure 11. Dip Switch SW1 and Bypass Jumper J3

Follow Table 7 below to properly set the five switches for the controller.

Table 7. Motor Type Selections

Switch Switch Switch

Role
Pump Type 1 Mode Select 2 3 Select 4 5

Standard ON Stand Alone ON ON Unit 1 ON ON

X-Series OFF Manifolded PLLD ON OFF Unit 2 ON OFF

Manifolded Alternating OFF ON Unit 3 OFF ON

Manifolded Direct OFF OFF Unit 4 OFF OFF

Manifolded PLLD mode allows interfacing with an ATG console. This mode has special communication wiring
requirements. Refer to Figure 5 for IQ Control Box with manifolded PLLD systems or Figure 6 for IQ Control Box
with manifolded DPLLD systems
Manifolded Direct mode allows for a primary pump to initiate all dispensing events and secondary pumps to help
when required. The control box set as Unit 1 (switch 4 & 5 on) is the Primary.

15
IQ Control Box Installation and Owner’s Manual Initial Calibration

Initial Calibration

Once all of the wiring is complete and the dip switch and jumpers are set the cover can be attached to the
enclosure. Every controller in the system must be calibrated at this time.

WARNING! Power to the controller should only be applied when all wiring is con-
nected and the cover is installed.

1. Energize the supply voltage to the control box. At this time the indicator on the side of the enclosure should
illuminate green acknowledging circuits are energized. A single red flash from the indicator signals that the
controller has not been calibrated.
2. Press and hold the Reset/Cal button on the side of the enclosure for 10 seconds until the indicator turns red.
3. Release the Reset/Cal button. The controller will automatically start the pump and perform a calibration
procedure. Once the procedure is complete the pump will shut off and the indicator will display solid green.
Should a dispenser handle be lifted during the calibration procedure the controller will suspend the calibration
and dispense fuel as long as the handle remains lifted. A suspended calibration procedure is indicated by
alternating red and green indication through the duration of the dispense event. Once the dispensing event is
over the controller will perform the calibration procedure. Anytime that the pump or dispensing equipment has
been replaced perform a new calibration to update the stored information in memory.
4. The saved Motor Type can be verified with the Bypass jumper in the Normal position.
5. Depress the Reset/Calibration button for 20-seconds – continue holding the button in until the Green LED
has flashed the Motor Type code.
6. If the number of green flashes matches your Motor Type code noted in Step 6. on page 13 above, The IQ
Control Box is now ready for operation.

16
 Troubleshooting

WARNING! If at any time during a troubleshooting procedure the enclosure

must be opened, disconnect controller power prior to removal of the cover.
The input terminals D1 and D2 are powered from the dispenser which is on
a different circuit and may be energized even with the control box power
disconnected. Remember to remove power to dispenser circuits that ener-
gize the D1 and D2 terminals of TB1 whenever removing power to service
the unit.

Basic Indicator Functions

• Solid green – controller circuit is energized

• Flashing green – pump is running

Description of Fault Conditions

The indicator on the side of the enclosure flashes the following alarms in red:

Table 8. Indicator Fault Conditions

# of Flashes Condition

1 Uncalibrated Controller

2 Over-current Condition – Pump Shutoff

3 Dry Run Detected – Pump Shutoff

4 Low AC Current

5 Setup/Communication Error

6 Low Line Voltage < 200Vac

7 Bypass Mode

8 Extended Run Condition

Uncalibrated Controller
This fault indicates that the controller has not been run through an initial calibration to setup all critical points for
pump protection. The device will operate the pump if a dispenser signal is detected but cannot correctly monitor
pump until initialized. See Calibration Section. NOTE: The unit will not calibrate if the Motor Type has not been
programmed.

Over-Current Condition
This fault indicates that the device detected a high current in the pump’s wiring which could be either a short in the
wiring between the M1 and M2 terminals to ground or a locked rotor in the pump.
The following procedure will determine if wiring must be replaced or the pump must be removed and replaced.

17
IQ Control Box Installation and Owner’s Manual Description of Fault Conditions

WARNING! Before starting this troubleshooting procedure disconnect all

electrical power to the controller including the dispenser inputs. Failure to
do so may COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT, RESULTING
IN SERIOUS INJURY OR DEATH.

Using an ohmmeter measure the resistance between the M1 and M2 terminals to ground. Ground can be found at
the screw on the enclosure base. Both measurements should be greater than 1Meg ohm. Any measurement less
may indicate a short in wiring between the control box and the submersible pump. The location of the short can be
determined by breaking the wiring connections in the junction box at the pump’s packer/manifold and taking
ohmmeter readings on both sides of the circuit.
Refer to the manual for the extractable pump on instructions for its wiring, servicing, or replacement. Reset the
controller by pressing the reset button momentarily and verify operation once condition is resolved, all wiring
reconnected, and after power is reapplied.

Dry Run
This fault will shut off the pump since the level of the product has fallen below the suction end of the pump. The
controller will automatically reset and start the pump when the next dispenser signal is received. Add fuel to the
tank to restore operation.

Low AC Current
This fault indicates that the submersible pump will not operate. One of the following conditions are present: wire
disconnected resulting in open circuit, thermal switch in motor has opened due to overheating, or the control relay
has failed and the contacts will not close.

Setup/Communication Error
Five red flashes indicate that the controller has detected an improper dip switch setup or a missing connection on
the RS-485 communication cable when set to manifolded operation. Verify that each controller has a unique unit
number setting on the SW1 dip switch. Insure that all controllers have a communication cable connection unless
in standalone mode.

Low Line Voltage

This fault will not shut off the pump but will indicate if at any time the line falls below 200V which is the minimum
specified operating voltage.

Bypass Mode
If jumper J3 is set to bypass this mode will be displayed. Use this only to verify operation between dispenser and
pump since controller cannot provide pump protection in this mode. Return the jumper to the normal condition to
reset this alarm and have the controller monitor the pump.

Extended Run
Use this indicator to signal any pump that has run for more than 6 hours continuously. This may also indicate a
nozzle that has not been properly stowed after dispensing.
Contact Red Jacket Technical Support for additional troubleshooting information at 1-800-323-1799.

18
 Appendix A
TLS-450PLUS Diagnostic Monitoring of Red Jacket IQ Control Boxes
Equipment Requirements, Installation and Setup

Introduction

This Appendix provides application, technical and installation guidelines for Veeder-Root certified technicians who
will be installing and setting up the Red Jacket IQ Control Standard Diagnostic Feature with a TLS-450PLUS
system.

Pre-Installation Consideration

Verify site layout and feasibility to install RS-485 communications cables from IQ Control Boxes to TLS-450PLUS
Communications bay.

Equipment Requirements
• TLS-450PLUS System Software Upgrade (9W or Higher)- P/N 330020-744. Software upgrades can be
downloaded from the Veeder Root Web Site Support page https://www.veeder.com/us/software-downloads.
• TLS-450PLUS I button Intelligent Pump Control Feature P/N 332972-028
• P/N 332869-001; Dual Port RS-485 Communications Module
• Red Jacket IQ Control for each STP installed.
• Red Jacket IQ Control Software Prom Version 3.5 or Higher, P/N 349805-001.
• RS-485 Cabling, shielded cable (Belden 3106A or equivalent SF/UTP cable) - Length as needed between
each RJ IQ Control Box and/or the TLS-450PLUS console - customer supplied.
• RJ-45 Connectors as needed to connect comm cables to TLS-450PLUS RS-485 ports - customer supplied.
• Verify site profile to ensure proper equipment is ordered for the application.

Installation Precautions
It is recommended that the site is shut down during these procedures to ensure no
interruptions during the IQ Control Box programming and calibration procedures.
Prior to performing System Software update, I-button upgrade, installation of Dual RS-485 communications
Module in the TLS-450PLUS and the Firmware upgrades in the IQ Control Box(s), it is recommended that the RS-
485 cabling between the TLS-450PLUS and the IQ Control Boxes has been installed to minimize shutdown time
during the system update. (Do not terminate at this time).

Determining Number of RS-485 Ports Needed

Table A-1 contains the allowable TLS-450PLUS Comm Modules and their permissible slots in the console’s comm
bay.

If both RS-232 ports of the dual RS-232 port module (shipped with the console) are being
used you will be limited in the number of RS-485 ports available (Max 3, 2 in Slot 2 and 1
in Slot 3). If only one RS-232 port is being used, you can switch the Dual RS-232 module
for a single RS-232 module, move it to slot 3, leaving slots 1 and 2 open for two dual RS-
485 port modules.

A-1
Appendix A Determining Number of RS-485 Ports Needed

Table A-1. TLS-450PLUS Comm Module Compatibility

TLS-450PLUS Console

Slot 13 Slot 2 Slot 3 Slot 4 Slot 5

Modules
COMM Port Port Port Port Port Port Port Port Por Port Per
Modules 1 2 1 2 1 2 1 2 t1 2 System Type

RS-232 l l l 3

Dual RS-232 l l l l 3

Ethernet Module (3 Ports)

RS-485 l l l 3

USB Module (2 Ports)

Dual RS-485 l l l l 3 Hardware

(Fixed)

(Fixed)
RS-232/RS-485 l l l l 3

Internal Modem l l l 3

CDIM l l 2

EDIM1 l l l l l 3 Software

IFSF LON2 l l l 1 Hardware

1EDIM can be programmed in any position with an RS-232 port - up to 3 per system

2Can be combined with EDIM

3Console ships standard with dual RS-232 or dual RS-232/RS-485 in Slot 1

Turn off, tag and lockout the breaker that supplies power to the IQ Control
Box.

1. Go to each IQ Control Box and determine/record its mode/role setting (DIP SW 1 – See “Setup Switch
Chart” on page 15.) or refer to site documentation to identify IQ Control Boxes that are set to standalone and/
or manifolded mode and their assigned STP/tank.
2. If in Standalone mode, up to four independent IQ Control Boxes may be daisy chained to a single RS-485
port.
3. If in one of the manifolded modes, IQ Control Boxes must only be connected to IQ Control Boxes on the same
manifold (one RS-485 port per manifold).
4. Manifolded and direct mode IQ Control Boxes may be combined on the same TLS-450PLUS and may share a
single RS-485 Comm Module as long as they are connected to different RS-485 ports.
5. After determining the number of RS-485 ports needed for the site, it is recommended to install the site RS-
485 cables.

A-2
Appendix A Installing RS-485 Wiring Between IQ Control Boxes & TLS-450PLUS

Installing RS-485 Wiring Between IQ Control Boxes & TLS-450PLUS

6. Prepare a satisfactory length of CAT5 or better 3-wire cable having a RJ-45 connector on one end (connects to
TLS-450PLUS and no connector on the end that connects to the IQ Control Box (see Figure A-1).

Figure A-1. RS-485 Serial Cable Pin-Outs

7. Run completed RS-485 cables from the TLS-450PLUS to the first IQ Control Box in a daisy chain (see
Figure A-2) and between IQ Control Boxes, but do not connect the comm cables to the IQ Control Boxes or
to the TLS-450PLUS at this time.

Lable each Comm wire with its polarity and the source IQ Control Box.

Figure A-2. Example IQ Control Box Comm Wiring Example (Belden 3106A Cable Shown)

A-3
Appendix A Upgrading IQ Control Box Software - Repeat For Each IQ Control Box

Upgrading IQ Control Box Software - Repeat For Each IQ Control Box

1. With power applied to the IQ Control Box, confirm that no dispensing occurs during the next step.
2. Locate the Code LED and the Reset/Calibration button (Figure A-3). Depress the Reset/Calibration button for
20 seconds and then observe the Code LED flashing sequence as shown in Table A-3. Note the number of
Green flashes, as this will identify the Motor Type (for use in Steps 6 and 14 in the Programming The Motor
Type section).

Replacing the Software PROM

Before removing electronic components from their anti-static bags read the following static electricity precautions.
• Before handling any components, discharge your body's static electric charge by touching the ground lug on
the enclosure.
• Do not remove parts from their anti-static bags until you are ready to install them.
• Do not lay parts on the anti-static bags! Only the insides are anti-static.
• When handling parts, hold them by their edges and their metal mounting brackets.
• Avoid touching components or edge connectors that plug into slots.
• Never slide parts over any surface.

Turn off, tag and lockout the breaker that supplies power to the IQ Control
Box.

1. Open the IQ Control Box cover.

2. Attach an anti-static wrist strap onto your wrist and the other end around the ground lug on the enclosure.
3. Locate the Software PROM U1 (see Figure A-3).

Figure A-3. Locating Software Upgrade Components Inside Typical IQ Control Box

A-4
Appendix A Upgrading IQ Control Box Software - Repeat For Each IQ Control Box

4. Position the small hooks in the ends of the chip removal tool under the ends of U1 as shown in Figure A-4.
Rock the tool lengthwise as you pull on the chip to lift it out of socket.
5. Orient the new upgrade chip with the end having a semicircle indent pointing toward TP3 as shown in
Figure A-4. Carefully align the chip pins over the holes in socket and gently push the chip into the socket.
Firmly seat the chip in the socket. Remove and discard the anti-static wrist strap.

Figure A-4. Removing Software PROM U1 From IQ Control Box

Programming the Motor Type

1. Place the Bypass Jumper in the Bypass Position (see Figure 11 on page 15).
2. Set the five Motor Type Programming DIP switches (Figure A-3) to the positions indicated in Table A-2 for
connected STP Motor Type.
3. Close and secure the cover.
4. Reapply power to the IQ Control Box. (Hook signal must be Off).
5. Locate the Code LED and the Reset/Calibration button (see Figure A-3). Depress the Reset/Cal button 20
seconds and then observe the Code LED flashing sequence shown in Table A-3. Record the number of Green
flashes for your Motor Type.
6. Release the Reset/Cal button after confirming the Green LED has flashed the correct number of times for your
selected Motor Type.

A-5
Appendix A Upgrading IQ Control Box Software - Repeat For Each IQ Control Box

Disconnect, lock out, and tag power to the IQ Control Box at the panel be-
fore starting these steps.

7. Disconnect power from the IQ Control Box.

8. Place the Bypass Jumper in the Normal Position.

Table A-2. Motor Type Programming

Number of Switch Position

Code LED Manufacturer Motor
Flashes 1 2 3 4 5

1 OFF OFF OFF OFF OFF 1/3 60 Hz

2 OFF OFF OFF OFF ON 3/4 60 Hz

3 OFF OFF OFF ON OFF 1.5 60 Hz

4 OFF OFF OFF ON ON 2.0 60 Hz

5 OFF OFF ON OFF OFF FARADYNE X3

6 OFF OFF ON OFF ON 3/4 50 Hz

7 OFF OFF ON ON OFF 1.5 50 Hz

8 OFF OFF ON ON ON 2.0 50 Hz

9 OFF ON OFF OFF OFF X4

10 ON OFF OFF OFF OFF 1/3 60 Hz

11 ON OFF OFF OFF ON 3/4 60 Hz

12 ON OFF OFF ON OFF 1.5 60 Hz

13 ON OFF OFF ON ON 2.0 60 Hz

14 ON OFF ON OFF OFF FRANKLIN X3

15 ON OFF ON OFF ON 3/4 50 Hz

16 ON OFF ON ON OFF 1.5 50 Hz

17 ON OFF ON ON ON 2.0 50 Hz

18 ON ON OFF OFF OFF X4

SOLID ANY OTHER SETTING UNKNOWN UNKNOWN

A-6
Appendix A Upgrading IQ Control Box Software - Repeat For Each IQ Control Box

Table A-3. Reset Button and LED Actions

Reset Button - Time

LED Depressed Action

Off Start Press And Hold The Reset Button

Green 5 seconds Clears Alarms

Red 10 seconds Queues Calibration

Cancel calibration. If in Bypass mode, reads and

Off 20 seconds stores Motor Type.

Green 20 seconds Flashes saved Motor Type code (see Table A-2)

Calibrating the IQ Control Box

1. The unit must be calibrated every time the Motor Type programming is performed even if the Motor Type does
not change. Set the five DIP switches to the desired pump type and mode / role select configuration (see
Figure A-5). NOTE: The unit will not calibrate if a Motor Type has not been programmed.
2. Close and secure the cover.
3. Reapply power to the IQ Control Box. (Hook signal must be Off).
4. Perform a calibration by depressing the Reset/Calibration button for 10 seconds (LED turns red).
5. The saved Motor Type can be verified with the Bypass jumper in the Normal position.
6. Depress the Reset/Calibration button for 20-seconds – continue holding the button in until the Green LED
has flashed the Motor Type code.
7. If the number of green flashes matches your Motor Type code noted in Step 5. on page 5 above, The IQ
Control Box is now ready for operation.

Figure A-5. SW1 Switch Setup chart

A-7
Appendix A TLS-450PLUS Software Upgrade Procedure

TLS-450PLUS Software Upgrade Procedure

1. Insert the Software Maintenance thumb drive into one of the two USB ports (console Comm bay, slot 5).
2. Navigate to the Menu>Software Maintenance>Download screen.
3. Touch the Download Source down arrow and select the thumb drive. Notice the Version field displays new
software version.
4. Touch the Download button to begin the software download.
5. After successful completion of the download (approximately 30 minutes), the ‘Download Completed’ message
appears.
6. Navigate to the Menu>Software Maintenance>Activate/Revert screen. Notice the Current version and
Available (downloaded) version are displayed.

IMPORTANT! During feature activation, which only takes a few minutes, there must be no dispensing.
7. Touch the box beside the message ‘Click to acknowledge the system will be stopped.’
8. Touch the Activate button to overwrite the Current of software with the Available (just downloaded) version of
software.
9. The Confirmation Needed dialog box displays. Touch the button to confirm and activate the new software, or
touch the X button to cancel the activation.

TLS-450PLUS RJ IQ Monitoring Feature Installation Procedure

IMPORTANT! During feature activation, which only takes a few minutes, there must be no dispensing.
1. Insert the USB Adapter and upgrade I-button from the upgrade kit. Remove the plastic end cap from the USB
Adapter.
2. Plug the USB Adapter into one of the two USB ports in the console Comm bay (slot 5).
3. Navigate to the Menu>Software Maintenance>Upgrade Features screen.
4. The screen displays the feature which are available to be activated, e.g., Intelligent Pump Control. Select
the box beside the desired feature.
5. Touch the Install Feature button to start the installation process.
6. The current status of the feature install displays:
- Activation in Progress
7. When you have completed the upgrade features procedure remove the upgrade thumb drive.
8. From the Home Screen, touch the following Menu > Overview > About and verify that the features in the
upgrade were installed.
9. With the new software version and feature installed perform a system backup onto the site’s V-R Backup
thumb drive.

A-8
Appendix A Verifying RS-485 Single or Dual Comm Module Jumper Positions

Verifying RS-485 Single or Dual Comm Module Jumper Positions

Prior to installing single or dual RS-485 modules, verify their jumper positions as shown in Figure A-6 and
Figure A-7 respectively.

Figure A-6. Single RS-485 Port Module Jumper Positions

A-9
Appendix A Verifying RS-485 Single or Dual Comm Module Jumper Positions

Figure A-7. Dual RS-485 Ports Module Jumper Positions

A-10
Appendix A Installing RS-485 Comm Module

Installing RS-485 Comm Module

Disconnect, tag and lockout power to the TLS-450PLUS console be-

fore starting this procedure.

1. Remove both left and right door screws (with a T-15 Torx driver) and swing open both doors to the left.
2. On the communications bay, use a T-15 Torx driver to loosen the module clamp securing screw and remove
the clamp (see Figure A-8).

Figure A-8. Comm Module Clamp Securing Screw

3. The Comm Bay is divided into 5 communication slots numbered from 1 to 5 going left to right. Only slots 1-3
are available for user-selectable Comm modules (ref. Table A-1). The Comm modules in Slots 4 and 5 are fixed
and cannot be moved.
4. Using a T-15 Torx driver, remove the module clamp securing screw (and clamp and set them aside.
5. Remove the blank cover from underneath the desired empty comm slot(s) by punching it into the console or by
using pliers to remove it from the inside of the console. Be careful not to damage any internal components in
the process of removing the blank cover.
6. Place the new RS-485 Comm module(s) in the slot(s). Align the edge connector on the back of the board with
the center of the vertical connector on the Comm Backplane board, then push the module board firmly in as far
as it can go. The sheet metal bracket of the module slides into the comm bay slot and the front edge of the
bracket goes into the keyed slot in the front of the Comm Bay (see Figure A-9).

Figure A-9. Comm Module Bracket Keyed Slot

A-11
Appendix A Connecting RS-485 Wiring To The IQ Control Boxes

7. After the comm module(s) is installed, replace the comm module clamp and the screw that secures it.
8. Connect the IQ Control Box comm cable RJ-45 connectors to the ports of the modules installed. Record the
slot/configurable port for each cable which will be needed in the communication setup procedure.
9. Close the console’s front doors, reversing the procedure in Step 1.
10.Do not apply power to the TLS-450PLUS at this time.

Connecting RS-485 Wiring To The IQ Control Boxes

Turn off, tag and lockout the breaker that supplies power to each of the IQ
Control Boxes.

1. Open each IQ Control Box cover and attach the RS-485 comm cable wires as shown in Figure A-10.

Figure A-10. Attaching Comm Cables To RJ IQ Control Boxes (Belden 3106A Cable Shown)

A-12
Appendix A TLS-450PLUS Setup For IQ Control Box Monitoring

TLS-450PLUS Setup For IQ Control Box Monitoring

Restore all power to the IQ Control Boxes and the TLS-450PLUS.

Serial Port Setup
1. At the TLS-450PLUS display touch Menu>Setup>Communication>Serial Port (see Figure A-11).

Figure A-11. RJ IQ Comms Setup Screen

2. Select the serial port setup sequence for each standalone/loop of sites RJ Control Boxes.
3. In the ‘Usage’ field, choose ‘RJ IQ Comms’.
4. Enter a label for this port, e.g., Unleaded tanks 1 - 4.
5. Grayed out fields are not changeable.
6. Select the Enabled radio button.
7. Continue to the next RS-485 port if necessary.

Pump Controller Setup

1. At the TLS-450PLUS display touch Menu>Setup>Pumps and Lines>Pump Controller and select Pump
Cntlr #1 (see Figure A-12).

A-13
Appendix A TLS-450PLUS Setup For IQ Control Box Monitoring

Figure A-12. RJ Control Box Setup Screen - Unit 1 Example

2. Touch the Enable button and enter a label for this RJ box to identify which STP it controls (e.g., RJ 1 - reg unld
tnk 1-4).
3. Select address from drop down menu.
4. Select the remaining Pump Controllers to label and enter addresses for each.

DB Backup
1. After setting up the RJ Control Feature insert the V-R Backup thumb drive into one of the two USB ports on
the USB ports in the console Comm bay (slot 5).
2. From the Home Screen touch Menu > Software Upgrade > DB Backup to view the Database Backup
Screen. Touch the down arrow in the Backup Destination field to select the thumb drive.
3. Follow the on-screen instructions to backup the TLS-450PLUS console data A perform a DB backup.

A-14
Appendix A Diagnostics

Diagnostics

STP Status
You can view the status of each STP by navigating to Diagnostics > Pump Controller > Communications (see
Figure A-13).

Figure A-13. IQ Control Box Communications Status Screen

The normal operating voltage range for Red Jacket pumps is 200 to 250 Vac.

Alarms
Table A-4 lists the IQ Control Box Diagnostic alarms. Reference “Description of Fault Conditions” on page 17.

Table A-4. IQ Control Box Diagnostic Alarms

Pump Controller
Comm Screen IQ Control Box
TLS Alarm PC Status Red LED Indicator Cause1
UNCALIBRATED Uncalibrated DEVICE IS UNCALIBRATED (1 Flash) Uncalibrated IQ Control Box
Over-Current Condition, e.g., Locked Rotor
OVERLOAD Overload OVERCURRENT FAULT (2 Flashes) – Pump Shutoff
DRY RUN Dry Run DRY RUN FAULT (3 Flashes) Dry Run Detected – Pump Shutoff
UNDERLOAD Underload LOW AC CURRENT (4 Flashes) Low AC Current
NETWORK SETUP/COMMUNICATION ERROR
Network Error Setup/Communication Error
ERROR (5 Flashes)
UNDER VOLTAGE Under Voltage LOW LINE VOLTAGE (6 Flashes) Low Line Voltage < 200Vac
IQ Control Box Normal/Bypass jumper left
BYPASSED Bypassed BYPASS MODE (7 Flashes) in Bypass position
EXTENDED RUN Extended Run EXTENDED RUN (8 Flashes) Extended Run Condition
1See “Description of Fault Conditions” on page 17.

A-15
For technical support, sales or
other assistance, please visit:
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