Veeder-Root 880-051-1 Installation instructions

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
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merchantability and fitness for a particular purpose.
Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages
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Contact Red Jacket Technical Support for additional troubleshooting information at 800-323-1799.
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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
iii
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

Table of Contents
iv
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

1
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
Live power to a device creates a potential shock hazard.
Turn Off power to the device and associated accesso-
ries when servicing the unit.
ELECTRICITY
High voltage exists in, and is supplied to, the
device. A potential shock hazard exists.
NOTICE
Is used to address practices not related to physical
injury.
DANGER
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury or property dam-
age.
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury or
substantial property damage.
READ ALL RELATED MANUALS
Knowledge of all related procedures before you begin
work is important. Read and understand all manuals
thoroughly. If you do not understand a procedure, ask
someone who does.
STATIC SENSITIVE COMPONENTS
Wear grounded anti-static wrist strap before han-
dling the printed circuit boards and mounted
components.

IQ Control Box Installation and Owner’s Manual Specifications
2
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.
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.

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

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

IQ Control Box Installation and Owner’s Manual IQ Manifold Control Information
5
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.

6
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