Smart Controller Troubleshooting

To aid field service personnel the STP-SCI Smart Controller for fixed speed single phase submersible pumps is equipped with a microprocessor control that makes it possible for the unit to diagnose abnormal operating conditions, and communicate them via LEDs on the front panel and by an audible alarm. The following is a definition of all operation and abnormal operating codes.

1 Flash / Beep = Under Load

Potential causes:

  • Low fuel level in the storage tank
  • Obstructions in Motor Intake
  • Calibrated with product flow

Proposed action: Check fuel level in storage tank; schedule fuel delivery, when delivery is complete and fuel level is above PMA end bell push reset button on STP-SCI. Check for correct system operation. If fuel levels are within acceptable range, the STP-SCI may need to be recalibrated if it was previously calibrated with air in the lines or with product flow.
Note: If Auto Restart Switch is set in the ON position once fuel is again above the PMA end bell and the hook signal is reapplied the STP-SCI will restart with out pushing the reset button.

2 Flashes / Beeps = Low Incoming Voltage

Potential causes: voltage fluctuations or low input voltage.

Proposed action: Use AC voltmeter to verify incoming voltage is within the 208-240VAC
acceptable range. If voltage is not within this range, contact an electrician to correct problem. If voltage is within acceptable range and condition is still present after resetting, recalibrate controller per “Calibration” section.

Note: STP-SCI will automatically restart when the voltage returns to
acceptable operating range.

3 Flashes / Beeps = Overload

Potential causes:

  • Short in wiring from STPSCI to PMA
  • Incorrectly wired through capacitor
  • Foreign material in PMA or rotor within motor is locked up

Proposed action:

1. Check and verify wiring is correct from STP-SCI to motor (shorts or incorrectly wired capacitor). If condition is corrected, check for proper operation. If operating correctly, do not continue with next step. If condition is still present, continue to next step.

PMA Replacement/Inspection

2. Disconnect input voltage at load center, lock and tag out circuit breakers.

3. (See PMA Replacement Instructions P/N 400289002, included with New PMA) Disengage the 3/4” securing bolt of the electrical connector and swing out of the way. Remove two 9/16” bolts from extractable portion of the manifold.

4. Pull extractable part of the pump.
Note: Pump Motor Assembly shell can be damaged by blows from hard surfaces, use care in removing.

5. Remove black end cap from PMA and attempt to spin rotor with a 3/16” Allen wrench to determine if there’s any binding. If rotor does not spin freely and/or there is physical damage (note this on a warranty claim form for FE PETRO use), proceed with step 7. If no binding or physical damage to PMA, reinstall extractable by following the previous steps in reverse order and then continue to the next step.
Note: PMA can have a locked rotor during startups if it has been exposed to a corrosive environment, such as a tank ballasted in water.

6. Turn on power to the STP-SCI unit and verify correct system operation. If condition is corrected, do not continue to next step. If condition is still present, remove the extractable by repeating steps 2 through 4 and then continue to next step.

7. Remove four 5/16” cap screws that connect the PMA with a ¼” Allen wrench and remove the PMA from the motor discharge head. Note: Prior to mounting a new PMA, check lead assembly (wires inside the extractable portion to PMA) for shorted wires and proper alignment, which may have caused the condition.

8. Replace with new PMA.
Note: Pump motor shell can be damaged by blows from hard surfaces, use care in replacing.

9. Re-install extractable and secure by following reverse order of disassembly.

10. Turn on power to the STP-SCI unit and verify correct system operation.

4 Flashes / Beeps = Open Circuit

Potential causes:

  • Connection broken from STP-SCI to PMA
  • Locked Rotor w/ Thermal Overload Open
  • Incorrectly wired through capacitor
  • Relay Failure

Proposed action:

1. Wait 5 minutes before pushing the reset button on the STP-SCI. This will allow the motor thermal overload to reset if locked rotor has occurred. Check for proper operation of system; if operating correctly do not continue to next step. If condition is still present continue to next step.

2. Disconnect power at load center, lock and tag out circuit breakers.

3. Remove the two motor control outputs (M1 and M2) from the STP-SCI unit.

4. Using an ohmmeter (low range setting), place leads between two wires going to the STP, this is the first step in determining where the open circuit has occurred. Correct readings between M1 and M2 wires (orange and black) should match that of the motor being used +/-1 ohms. These readings can be found in TB004 or the STP/IST Fixed & Variable Length Installation and Owner’s Manual. Readings between any of the motor wires and ground should be an open circuit. If readings in this step are incorrect,
continue with the next step. If readings are correct go to step 7.

5. Check and verify capacitor wiring is correct in STP junction box. Refer to the STP/IST Fixed & Variable Length Installation and Owner’s Manual for wiring diagram or SB003. If condition has been corrected, do not continue with next step. If wired correctly and condition is still present, continue with next step.

6. Go to the submerged turbine and remove the cover at the top of the extractable manifold. Remove the three wire nuts and continue conductivity tests on the three wires going to the motor. Readings between any of the motor wires and ground should be an open circuit. If readings are incorrect and there are no problems with the lead assembly wiring, go to “PMA Replacement/Inspection” in 3 flash section. If readings are correct, there is problem with the wiring between the STP-SCI and this point, continue with
next step.

7. Remove the junction box cover and do conductivity test on wires in the junction box after the capacitor through the extractable discharge head (orange to orange, red to red, and black to black). If wires are not conducting, replace the male and female connectors of the STP. See STP/IST Fixed & Variable Length Installation and Owner’s Manual for
replacement parts. Check for proper operation. If operating correctly, do not continue. If conductivity readings are correct and the condition is still present, continue to next step.

8. Upper Board relay may be stuck open or damaged. Replace Upper Board (Relay Assembly); see “Replacement Parts” section for part number. Turn on power to the STP-SCI unit and verify correct system operation.

8 Flashes / Beeps = Uncalibrated

Potential causes: New installation

Proposed action:
Note: All STP-SCI’s must be calibrated prior to operation.

1. Calibrate STP-SCI per “Calibration” section. If controller calibrates, do not continue to next step. If abnormal condition is indicated, Count Flashes/beeps before pushing reset button. Follow troubleshooting guide for the indicated condition. Correct condition and
recalibrate.

2. Check the following:

  • Calibration is done at no flow (close STP clamp valve or ball valve in line).
  • Dispenser hook signal is applied within 10 min. of putting controller in
    calibration mode.
  • No open circuits between controller and motor.
  • Lines have been purged of air.
  • Locked Rotor

9 Flashes / Beeps = Extended Run

Potential causes: Continuous Hook Signal applied for more than 60 min. without pumping product

Proposed action:

1. Disconnect power at load centers, lock and tag out circuit breakers.

2. Check voltage across hook terminal with all dispenser handles off. There should be no voltage applied. If voltage is present, contact an electrician to correct the problem. After the problem has been corrected, turn on power to the STP-SCI and verify system is operating correctly.

10 Flashes / Beeps = Relay Fault

Potential causes: Relay contact failure

CAUTION: The STP will continue to run after this fault indication is displayed.

Proposed action:

1. Disconnect power at load centers, lock and tag out circuit breakers.

2. Replace Upper Board (Relay Assembly), see “Replacement Parts” section.

3. Turn on power to the STP-SCI unit and verify correct system operation.

Contact Franklin Fueling Systems for additional troubleshooting information at 1-800-225-9787.

For full installation instructions, see the Smart Controller™ Installation and Owner’s Manual. 

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