Red Jacket STP Troubleshooting w/ Isotrol Relay

Use this troubleshooting guide to troubleshoot the FDS (Fuel Delivery System). The FDS is a group of components used to move fuel from the tank to the dispenser shear valve. This in includes the STP or motor, PMA assembly, and STP or motor controller. Following the steps below will reveal which part of the system is failing. You will only proceed to the next step if the test is successful.

1. Verify there is more than 8" of fuel in the tank if there is less than 8" the site will need to get a delivery before we can continue troubleshooting. Remember the UMP (motor) should be 5" off the bottom of the tank. 

2. Verify the product relay breaker is turned on and proceed to the following steps.
    
   • Verify L1 to Neutral (should be approximately 120VAC) inside controller if not you will need to call an electrician.
   • Verify L2 to Neutral (should be approximately 120VAC) inside controller if not you will need to call an electrician.
      
3. Utilize lockout tagout procedures to remove power from the controller and install a jumper wire across L1 and S to apply a temporary hook signal engaging the relay. When complete, remove the lockout/tagout and reapply power to preform testing. 
    
   • Measure voltage from M1 - Neutral (should be approximately 120VAC) - the relay needs to be replaced if voltage is not present.
   • Measure voltage from M2 - Neutral (should be approximately 120VAC) - the relay needs to be replaced if voltage is not present.
   • Measure voltage from M1 - M2 (should be approximately 220VAC) - if voltage is 0VAC and electrician is needed due to a phasing problem. 
      
4. With the relay still activated measure the amperage on M1 and M2 independently (both should be between 5-12 AMPS depending on motor size). 
    
   • If there no AMPS are present, you will need to proceed to step 5. It appears you have an electrical issue at the PMA. 
   • If the AMPS are higher than 20A, the UMP (motor) is locked up. Replace UMP (motor).
   • If the AMPS are between 5-12 proceed to step 9. Your motor is functioning properly and there seems to be a hydraulic or hook signal issue. 
      
5. Remove voltage from the Isotrol via lockout/tagout. Barricade the STP sump, and access UMP (motor) field wiring. Visually inspect all wiring including the ground. Once visual inspection is complete restore power and preform the following tests.
    
   • Verify orange wire at STP (motor) (M1) is receiving 120VAC - if not present call electrician it appears voltage is not making it to the PMA and will need to be replaced. 
   • Verify black wire at STP (motor) (M2) is receiving 120VAC - if not present call electrician it appears voltage is not making it to the PMA and will need to be replaced. 
      
6. Again, remove power from the UMP (motor) via lockout/tagout. Steps 6-8 will be completed without power. Change your multimeter setting to microfarads to verify the capacitor. The rating should be legible on the side. This will also be a good indicator of what size UMP (motor) is in the tank. Replace the capacitor if the reading is less than capacitor rating.
    
   • .75 HP motor - 17.5 microfarad capacitor. 
   • 1.5 HP motor - 25 microfarad capacitor. 
   • 2 HP motor - 40 microfarad capacitor.
      
7. Carefully disconnect and remove the capacitor. Change your multimeter to Ohms's. Check orange/black, orange/red, and black/red to determine if motor windings are good. Motor specs can be found here: "The" Red Jacket STP - New Style

 

.75 HP Motor	1.5 HP Motor
black/orange 4.7-5.7 ohms  red/orange 7.1-8.6 ohms  black/red 11.7-14.1 ohms	black/orange 2.8-3.4 ohms  red/orange 6.8-8.2 ohms  black/red 9.4-11.3 ohms
2 HP Motor
black/orange 1.9-2.3 ohms  red/orange 3.4-4.1 ohms  black/red 5.1-6.2 ohms

8. Leaving the lockout/tagout in place, close the line ball valve and pull the motor. With the motor removed complete step 7 again, but this time you will test the pins on the motor. If you get the correct values based on the chart, you will need to replace the pig tail assembly only. If your motor testing fails, you will need to replace the motor. It is best practice to replace the pigtail and capacitor as preventative maintenance while the assembly is removed. 
    
9. Remove the jumper wire between L1 and S. We will need verify dispenser hook signals. Activate each dispenser (not fueling point). You should get 120VAC on the power supply as well as on TB2 channel 1-8 inside the Isotrol controller.
    
   • No voltage at dispenser - replace power supply
   • No voltage at TB2 - you will need an electrician. 
   • 120VAC at both the dispenser and TB2 proceed to step 10. It appears you have a hydraulic related issue. 
      
10. With the power still removed via lockout/tagout close the product line ball valve or lock down the check valve to isolate the line.
     
11. Turn the check valve service screw 7.5 turns to relieve pressure from the PMA (packer manifold assembly) and lock down the check valve. 
     
12. Locate the line port on the PMA, remove the 1/4" plug and install your line gauge. 
     

    

    

13. Turn the check valve service screw counterclockwise until you hear the check valve drop back into place. You are now ready to activate the motor and begin pressure checks. Open the air purge screw, activate motor. Let the motor run 3-4 minutes before closing the air purge screw. This will vent all PMA air back into the tank.
     
    • Lockdown the check valve and turn on the motor. Note the pressure reading. Turn off the motor and wait 60 seconds. Record the new PSI. If there is a greater than 2 PSI loss you will need to replace the O-rings on the air purge screw.
    • If there is no pressure loss, place the check valve back into operation and test again. If there is a greater than 2 PSI loss, replace the check valve. 
    • Wait an additional 15 minutes pressure should have dropped to around 18 PSI. If pressure drops below 18 PSI the check valve will need to be replaced. 

 

14. Install a filter gauge at the furthest dispenser from the PMA. Activate the motor and slowly open the product line ball valve. Both PMA gauge and filter gauge should read similar values. 
     
    1. If the pressure at the dispenser is 50% lower than the pressure reading at the PMA it appears you have a faulty mechanical leak detector. 
    2. If the pressure is the same, close the product line ball valve, then deactivate the motor. Take your first pressure reading. Waith 15 minutes and take a second pressure reading. Pressure in the closed line should not drop. If pressure drops, then you might have a line leak. To verify this close all shear valves for the impacted product and retest. If the line pressure is unchanged then your leak is located in a dispenser. Open each shear valve one by one and verify pressure after each to determine where the leak is located. 
        
15. Once all tests are complete make sure to open the ball valve and return the site to service.