Service Manual: Additive Injection System (AIS)

Additive Injection System (AIS)
Service Manual
Version 4, June 2022
`
Total Meter Services Inc., 70 Worcester Rd., Toronto, Ont., M9W 5X2, tmsautomation.com
Manual No. 577014-489 • Revision A

NOTICE
The documents in this library may be based on or include information originating from
third-parties or other original equipment manufacturers (“OEMs”). The Veeder-Root
Company disclaims all liability for such third-party/OEM information and users of this
library are cautioned to verify the information within these documents with the OEM.
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................................................... 3
AIS BLOCK DIAGRAM ......................................................................................................................................................3
PURPOSE OF DOCUMENT ...................................................................................................................................... 4
SAFETY ................................................................................................................................................................... 5
NETWORK CONNECTIONS ...................................................................................................................................... 6
MODIFYING THE IP OF A DEVICE........................................................................................................................................6
TEAMVIEWER CONFIGURATION .......................................................................................................................................11
VNC CONFIGURATION ..................................................................................................................................................14
NAVIGATING THE AIS INTERFACE ......................................................................................................................... 15
AIS UTILITY.................................................................................................................................................................15
TLS UTILITY ................................................................................................................................................................16
AIS CONFIGURATION AND CALIBRATION UTILITY ................................................................................................................17
CONFIGURATION ..........................................................................................................................................................17
RELAY ASSIGNMENTS ....................................................................................................................................................18
CALIBRATION ...............................................................................................................................................................19
MANUAL ADDITIZATION ................................................................................................................................................20
LOGS .........................................................................................................................................................................21
SERVICE ............................................................................................................................................................... 22
PROCEDURAL CONSIDERATION ........................................................................................................................................22
AIS FLOW METER ENCLOSURE........................................................................................................................................23
SOLENOIDS .................................................................................................................................................................23
SUBMERSIBLE TURBINE PUMP ........................................................................................................................................23
Check Button .......................................................................................................................................................24
Diagnostics Button ..............................................................................................................................................25
Service Mode Button ...........................................................................................................................................26
LINE PURGING .............................................................................................................................................................28
TROUBLESHOOTING & DIAGNOSTICS................................................................................................................... 29
SYSTEM OK STATUS .................................................................................................................................................29
TROUBLESHOOTING QUICK REFERENCE..................................................................................................................30
CONTACT TMS ..................................................................................................................................................... 35
APPENDIX A – BADGER METER SERVICE............................................................................................................... 36
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INTRODUCTION
The TMS Additive Injection System (AIS) uses a combination of mechanical and electrical components
and custom software, to optimize the conventional additive blending procedure applied to gasoline and
diesel fuels. These refinements automate the blending procedure, saving the retailer significant
amounts of money, time and most importantly, improving the quality of blended fuel for the customer.
The main controller in the AIS is the modular PC, and the main I/O is controlled via relays.
AIS Block Diagram
Additive Delivery Fuel Delivery
Level
Veeder-Root Level
Monitoring Monitoring
Tank Level
Additive Tank System Fuel Tank
Fluid Level Monitoring and Printing
AIS Additive Controller

Start/ Open/
Stop LED Warning Lights
Close
Pump Component shutdown
Solenoid
Data Storage
Valve
Volume & Rate of

Flow Monitoring
Filter
Cartridge
Flow Control
Flow Meter Valve
Calibration Port
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PURPOSE OF DOCUMENT
This manual covers the service procedures and technical troubleshooting of the TMS Additive Injection
System (AIS) including;
• Safety considerations
• Network Connections to the AIS
o Changing device IP
o TeamViewer configuration
o VNC Configuration
• Navigating the AIS interface
o System icons
o Interface screens
• System Calibration
o Using the built-in AISConfig utility
o Relay assignment charts
• Service
o Procedural considerations
o Equipment-specific service information
o Using the AIS Check feature
o Using the Diagnostics feature
o Built-in service mode
o Line purging
• Appendix
o Quick troubleshooting guide for faults
o Contact TMS
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SAFETY
It is important for everyone on the project to make safety a priority! Read all relevant Operation and
Maintenance Manuals and ensure a thorough understanding of all procedures and safety requirements
before starting work. Note that specialized skill sets may be required for service of this system (e.g.
working in a confined space, electrician, pipe fitter). Confirm that the service team members have the
appropriate qualifications, if necessary, for each task before beginning the project.
Most incidents are caused by failure to observe basic safety rules and precautions. Recognizing possible
hazards before acting will help to create a safe work environment. Ensure that the project site is
identified with hazard pylons and follow appropriate confined space precautions when working in
sumps.
The labels on equipment and information located in this document are NOT inclusive. All personnel
MUST be satisfied that any procedure is safe for themselves and others. All personnel must also ensure
that procedures do not compromise the safety or function of equipment for future use. If in doubt, it is
the responsibility of the individual performing service to obtain clarification from a supervisor or
manager.
In general:
• Always focus on the job at hand

• Obey all warning labels
• Replace unreadable or missing labels with new ones before operating equipment
• Do not block burst hoses, pipes or fittings with hands. Fluids under pressure can penetrate skin
and cause serious injury
• Do not touch hot surfaces
• Always wear the task specific, recommended, personal protective equipment (PPE). Protective
clothing can include a hard hat, safety glasses, ear protection, close fitting clothes, steel toed
boots, gloves and a high visibility vest
• Follow the recommended site-specific steps to ensure safe off loading of fuel
• Do not smoke on the project site.
• Never use unauthorized containers for fluid storage or transfer
• Do not attempt to overfill storage tanks
• In the event of a spill, follow site-specific cleanup guidelines
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NETWORK CONNECTIONS
Modifying the IP of a Device
To troubleshoot the additive Injection System (AIS) it may be necessary to configure the IPv4 settings of
either or both ethernet ports on the AIS controller, as well as the device used by the technician to
connect to the controller. The steps to access and configure the IPv4 settings on a windows 10 device
are as follows:
1. Access the network and sharing center

2. Change the network adapter settings as required
3. Verify the network settings
*Note: the steps listed below are for modifying the network on a Windows 10 device. Older or
different versions of Windows will have different procedures to access the adapter settings. Consult
your IT department, or TMS for assistance. For sites where a customers internal network will be used,
contact the IT department of the client for all network info.
Step 1: In the Start menu search bar, type

“Control panel”, and click the icon when it
appears.
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Step 2: In the control panel, locate and

select Network and Internet. Next, Select
Network and Sharing Center to bring up the
connection status screen.
Step 3: In the left hand menu, select

“Change adapter settings”, as highlighted.
This will show all installed adapters on the
current device.
3.1) If you are changing a laptop’s IP to

connect to the AIS, right click on the
ethernet adapter and select “properties”.
3.2) If you are modifying the IP address on

the AIS, right click either wireless OR
ethernet adapter 2 as required and then
select “properties”.
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Step 4: Scroll down the list to “IPv4” and

click it once to highlight it. Then, click
“properties” to access the IP address
settings.
Step 5: Use the following settings,

depending on the device being changed:
5.1) AIS: The AIS has 2 built-in LAN ports on

the computer box, as well as a wireless
adapter for Wi-Fi connection.
The default settings are:
Ethernet 2:
IP- 192.168.1.52
Netmask- 255.255.255.0
Ethernet 3:
IP- 192.168.1.51
Netmask- 255.255.255.0
Wireless* (if adapter is present)
The wireless connection should be set to

“obtain an IP automatically” instead of a
manual entry. Verify that this setting is
checked.
*Note: The wireless adapter option may not be present on
the system if no adapter is installed. If there is no wireless
adapter, ignore this step.
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*Attention: record the settings of your

laptop/computer’s initial settings before
changing the IP, so that it can be returned to
default after disconnecting from the AIS.
5.2) Laptop / External Computer:
Change the port you are connecting to a

cable so that it matches the following:
IP- 192.168.1.235
Netmask- 255.255.255.0
Gateway- 192.168.1.1
Step 6: Verify network settings
After configuring network settings, it is good

practice to verify that all adapter settings
are correct. To do this, open the command
prompt by searching for “CMD” in the start
menu search bar and selecting the
command prompt.
Next, in the prompt, type in “ipconfig /all”

without quotation marks, and press enter.
This will display all adapters on the current
machine, and all their settings. Make sure
that the network adapter IPv4 addresses
match what was entered.
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To make sure that the AIS and the Laptop are on the same network and have compatible configuration,
it is good practice to send a “ping” command to the AIS controller from the laptop. To do this, make sure
that the AIS and the Laptop are both plugged into the network, and that the Laptop IPv4 settings have
been configured for the address of the local network. Next, open the command prompt on the laptop as
outlined previously.
From the command prompt on the laptop, type “ping 192.168.1.51” if the AIS is connected to internet
via port 1, and “ping 192.168.1.52” if it is connected to port 2. If it is successfully connected, the
command prompt text will indicate a “reply” from the device with a “TTL” value. If the settings are
incorrect, or the device is not connected to the network, the prompt will indicate that either the
destination host is unavailable, or that the request has timed out. If the ping command is unsuccessful,
the IP settings and physical connection will need to be checked and corrected.
The picture below shows an example of a successful ping command, and a failed ping command to
devices on the network.
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Teamviewer Configuration
Step 1: Make sure that the device has Teamviewer installed already. If it is not already installed, go to
https://www.teamviewer.com/en/download/ and make sure that you download and install
TeamViewer. Note: the default installation is Teamviewer 13, a newer version is NOT required. If
connecting via a laptop to view the AIS, the laptop must also have TeamViewer installed and set up.
To install TeamViewer, run the

TeamViewer_Setup.exe file downloaded
from the link above, and follow the prompts.
Select the “Basic Installation”, and
“Personal/Non-Commercial use” options
from the installation screen, and then click
on “Accept – finish” to complete the
installation process.
Once installed, TeamViewer will run on

startup of the device it is installed on. This
can be disabled within the settings under
the “Extras” menu tab in TeamViewer.
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Step 2: Open Teamviewer and make note of

the “Your ID” field. Record this number for
reference.
Step 3: Check the Teamviewer server

connection status in the bottom left corner
of the Teamviewer window. The icon should
be a green circle with “Ready to connect” if
you are connected to a wireless hotspot or
will display “Only LAN Connections are
possible”. If the icon is red or yellow, check
network settings and verify that there is
connectivity to the outside network.
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Step 4: to connect to the AIS using teamviewer, in the “partner ID” field type in the IP address of the AIS
network port that the ethernet cable is connected to. Click “connect” and teamviewer will open a new
window to the AIS desktop. The remote desktop can be used exactly lke a regular desktop. The default
connection password is 6697010 for version 13 or older, and TM$6697010 for newer versions of
teamviewer.
*Note: Incorrect AIS Network settings will render the device inaccessible
remotely, and will terminate the Teamviewer session.
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VNC Configuration
Step 1: Make sure that the device has UltraVNC installed already. If it is not already installed, go to
https://www.uvnc.com/downloads/ultravnc.html and install the latest version. If connecting via a laptop
to view the AIS, the laptop must also have VNC installed and set up.
To install UltraVNC, run the

UltraVN_Setup.exe file downloaded from
the link above, and follow the prompts.
Leave the default options selected from the
installation screen, and then click on “Next”
to complete the installation process.
Step 2: To connect to the AIS using

UltraVNC, open UltraVNC and enter the IP
address of the AIS computer and press
“Connect”.
*Note: Incorrect AIS Nework settings will render the device inaccessible
remotely, and will terminate the UltaVNC session.
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NAVIGATING THE AIS INTERFACE
The AIS interface is made up of several key

applications:
• AIS Utility
• TLS Utility
• AIS Config and Calibration Utility
It is important to be familiar with each application

and their functions, as explained below.
AIS Utility
*Note: AIS Software interface may look different

based on the version installed.
The AIS utility always runs in the background while

the unit is powered on and gives a window that
displays all internal logic of the AIS as it operates. It
automatically launches the TLS Utility on startup.
It indicates pump runs, solenoid operation, delivery

volume, additive volume, additive pulses, and target
blend percentage. It constantly polls the TLS utility to
ensure volume data is being captured. The AIS Utility
also contains information about the Check Process,
Diagnostics process, and will indicate if the system is
put into service mode (these are explained in the
Service section starting on page 21). The utility keeps
track of transactions and will create the transaction
tickets at the end of each delivery.
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Clicking on the AIS window will cause it to

enter select mode, indicated by the file path
changing to “Select TMSAdditiveSystem” and
will cause the AIS to pause. To restore
functionality, press the enter key, and the file
path will return to normal.
TLS Utility
The TLS Utility functions to constantly poll

the TLS system, and monitors tank volume
and delivery volume to ensure that the AIS
continually monitors the blend recipe and
dispenses additive at a regular interval during
product offload, to ensure a consistent
product mixture at all times.
The utility window indicates connection

status to the TLS system, polling the device
every second and returning status. It is used
by the AIS Utility to monitor volumetric data.
The TLS Utility must be running for the AIS

Utility to function. It will automatically start
when the AIS utility is run. If it is not running,
or if the AIS utility has crashed, restart both
utilities by running the “AIS” shortcut from
the desktop. It will automatically open a
window to both utilities and attempt to
connect to the TLS and begin calculating
additive levels.
If the TLS is not connected to the system or

has crashed, the TLS utility will indicate that
the socket operation has failed to reach the
target network device. This can be fixed by
reconnecting the TLS or resetting the TLS. If
the TLS Utility is still not functioning, reset
power to the AIS and wait for it to reboot.
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AIS Configuration and Calibration Utility
AISConfig is an application used for troubleshooting and testing

the configuration of the AIS relay board output, as well as for
calibrating the additive meter when used in conjunction with a
certified prover.
Configuration
When opened, AISConfig shows the current relay configuration, relay timer settings, solenoid settings,
meter factor, and allows for toggling individual relays to test pump starts, solenoids, and AIS indicator
lights. If the system is single meter (gasoline only) there will be 8 relays, and if the system is dual meter,
there will be 16 relays. Below or in the troubleshooting section for relay assignments.
Clicking on the ON/OFF button on each relay under the “status” column will change the output status and
toggle the relay. “Status” indicates the current output status of the relay. “Condition” indicates the
enable/disable status of the indicated component. Meter factor is determined during calibration and
cannot be manually edited.
*Note: there is a delay of approximately 1 second when toggling relay status
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Relay Assignments
Single meter:
1 Tank 1
2 Tank 2
3 Tank 3
4 Tank 4
5 Pump 1
6 TLS Fault
7 Sys OK/Fault
8 Warning
Dual Meter:
1 Tank 1
2 Tank 2
3 Tank 3
4 Tank 4
5 Pump 1
6 Fault (product 1)
7 Warning (product 2)
8 Tank 5
9 Tank 6
10 Tank 7
11 Tank 8
12 Pump 2
13 TLS Fault
14 Fault (product 2)
15 Warning (product 2)
16 System OK
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Calibration
• The Calibration units are defaulted to Liters. When calibrating in Gallons, ensure the Convert to
Gallons is checked.
• Use the calibration line with ball valve from the AIS meter to control flow into the calibration
beaker. The beaker is incremented in 10 mL markings up to 1000 mL.
• Once calibration line, ball valve closed and beaker are setup, press the green Start button.
• Wait a few seconds to ensure the meter does not creep. If the meter does creep, press the Stop
to clear out, then press Start again.
• Once the Measure Volume holds steady open the calibration line ball valve.
• Fill the beaker to at least 3/4 full to ensure that there is sufficient volume to compare to the meter
reading.
• Once ball valve is closed, press the red Stop button.
• Read the volume on the beaker and enter it into the Prover Volume section. Make sure volume
entered matches calibration volume.
• If the volumes are nearly identical (within 15mL), calibration is complete
• If the volumes are off, select the latest calibration run from the table then press Update Meter
Factor. Re-calibrate as needed.
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Manual Additization
• The AIS will automatically compensate additization as needed when a fuel delivery is received. If
Manual additization is required, use this feature.
• Select the desired tank from the Tank drop down list.
• If the AIS was actively tracking the tank movements, the proper additive amount will automatically
be added to the Additive Amount section.
• If the additive amount needs to be adjusted manually, enter the new additive amount in the
Additive Amount section.
• Ensure the Set Blend to 100% is checked. This will ensure the AIS does not attempt to add
additional additive during the next fuel delivery and will set the blend to 100% when the stop
button is pressed, or the pump is allowed to stop.
• Once all data entered is correct, press the green Start button. This will start the pump and open
the appropriate solenoid valve.
• Once complete the pump and valve will automatically close. If you need to stop sooner, press the
red Stop button.
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Logs
• Use this section to view all the logs generated by the AIS.
• Choose a Start Time and End Time then press Show Logs.
• It may take a few minutes to generate depending on the size of the logs.
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SERVICE
BEFORE SERVICING: ensure that the additive injection system (AIS) “service mode” is ON
before servicing ANY components of the system, and ALWAYS use service mode if the TLS
system is being serviced.
If service must be performed on the AIS system or any of the mechanical components associated with it,
there are some important considerations and procedures that must be followed. Failure to properly
follow service procedures can result in injury, product loss, spills, or blending inaccuracies. At all times,
care should be taken to minimize or contain all possibility of product spillage through drips or leaks.
Service must only be performed by qualified personnel familiar with mechanical fuel systems. More than
one person may be required for safe service procedures, such as in situations where confined space
entry is required or when remote equipment controls must be activated to run pumps and solenoids.
The technician must assess the situation and ensure they are able to perform any service work without
risking injury or product loss/spillage.
Procedural consideration
-Always put the system into service mode when service is being performed.
-Never cross-thread any fittings. Cross threading will cause leaks and product loss, as well as irreversibly
damaging equipment.
-Any compression-type fittings should be tightened hand tight + ¾ turn with the proper tool. NEVER use
PTFE-tape or pipe-doping compounds with a compression-type fitting, as it will cause improper seating
and will not seal. PTFE-tape or doping-compounds must only be used to secure pipe threads in a
standard fitting, and must be selected to meet the requirements of the environment they will be used
in.
- For any electrical work or servicing of moving equipment that could pose a safety hazard, proper Lock-
Out Tag-Out procedures must be followed. Failure to do so may result in serious injury or death.
-When servicing the tank monitoring system (TLS) it is important to first put the AIS into “Service mode”
as described in the Service Mode section. Failure to do so may result in severe over-injection of additive.
-Always isolate product flow before working on any mechanical fuel system components by closing
upstream and downstream valves. Always double check and “walk the lines” to visually ensure that
there is no possibility of product spills by siphoning or gravity feed.
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AIS Flow Meter Enclosure
It may be necessary to open the AIS Flow Meter enclosure box to adjust the flow valve, if the system is
found to be flowing too slow or too fast to accurately measure additive. The flow valve is factory-set by
TMS to a default position of 6.5 L/min (1.717 gal/min) and sealed to prevent movement. If the flow valve
must be adjusted for troubleshooting, it must be set to no higher than the factory rate of 6.5 L/min.
The AIS Flow Meter within the enclosure is a Badger Meters ¼“ NPT threaded oval gear meter. During
installation, debris may get lodged in the oval gears. Review Appendix A - Badger Meter Service for
additional assembly details. If the meter is found to be inaccurate, and calibration is unable to bring it
within acceptable tolerance limits or if the calibration is not repeatable, contact TMS for a replacement
meter.
Solenoids
The solenoid valves used in the system are 24VDC Asco Red Hat, normally closed type. If product is
found to be bypassing through the solenoid, it may be necessary to remove and service the solenoid
body. *Note: removing the solenoid coil from the body stem while it is energized may result in
irreparable damage to the coil and can cause a fire hazard. Always ensure the system is in Service Mode
before removing solenoids. When servicing the solenoid stem, make sure to check for ANY debris or
metal that could impede movement of the cylinder or damage the plunger seal. Check the outside of the
plunger cylinder for scoring or marred surfaces and check the inside of the stem body for any debris or
marring. When re-assembling the solenoid body, pay close attention to the orientation and position of
the Teflon sealing ring. If the Teflon ring is damaged, the solenoid will not seal correctly. Do not over-
tighten the solenoid body and stem assembly, as this may cause thread galling and prevent proper
sealing.
Submersible Turbine Pump
If the submersible pump must be serviced or replaced, it is important to make note of the position and
height of the pump intake in relation to the tank walls and bottom according to the manufacturer’s
instructions. The submersible turbine pump must NEVER be operated dry of product or used to pump
water. Failure to follow these instructions may cause irreversible damage to the pump.
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Built-in Service Functions
The AIS has 3 built-in functions to aid in diagnosing,

troubleshooting, and servicing the system. Mounted
inside the AIS panel, on the right-hand side of the
enclosure, there are 3 buttons. They are the Check
Process, Diagnostics Process, and Service Mode. Each
of the built-in processes will display within the AIS
Utility window and will also give a printout of the
process from the Veeder-Root TLS printer.
Check Button
the check process will test all the outputs of the AIS as
well as the pulser and the stop and reset buttons on
the front of the panel. During the check process, the
AIS will attempt to inject a small quantity of additive
into each tank while running the pump, to test
solenoid operation. The entire process can be viewed
from the AIS Utility window as well as from the TLS
ticket printer and monitored for discrepancies.
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Diagnostics Button
The diagnostics function is used to check the system

for active faults, the current blend percentages in
each tank, and the injector system status. The
diagnostics will print out from the TLS ticket printer
and can be used to determine overall system
operation.
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Service Mode Button
The service mode button is used any time that

ANY of the connected systems must be
disconnected for service. Pressing the Service
mode button will put the system into service
mode, which prevents the AIS from attempting
to inject additive or calculate required additive
volume. Service mode is indicated by the
“System OK” and “Alarm” LEDs on the front of
the panel blinking on and off. Service mode is
turned off by pressing the reset button, which
then returns the system to normal operation.
The service mode operation will also print from
the TLS printer.
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Examples of Check and Diagnostic tickets printed from the AIS to the TLS printer:
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Line Purging
Any time the additive line is disconnected from equipment or a section of it is drained of additive, or any
time meter service is performed and the flow meter and its lines are drained, the system will need to be
purged of air and re-primed before being used to inject more additive into the product storage tanks.
During initial start-up, the meter box must be purged of air using the following steps:
1) Close the ball valve downstream of the Flow Meter enclosure leading to the product tanks. This
will keep the lines running to each tank primed.
2) Place the proving port on the outlet line of the flow meter enclosure into the additive sump
riser, or into a large container to hold the additive. Open the ball valve to the proving port while
keeping the downstream ball valve leading to the tanks closed.
3) Run the pump for five minutes to prime the meter and lines leading from the pump and filter.
4) Close the proving ball valve and open the downstream valve to allow additive to flow to the
product storage tanks.
It may become necessary to purge the additive lines downstream of the meter box due to entrapped air
from service or leaks. To do this, start by purging the tank line for the furthest tank first (in relation to
the additive sump location) and then the next furthest tank and so on, until all tank lines have been
purged. As the tank lines are much longer than the meter lines, they will require a larger volume of
additive. Up to 100 gallons / 375 litres of fuel per tank line must be purged if air is found to be
entrapped in the additive piping. The steps to purge each tank line are as follows:
1) Starting at the furthest product tank away from the additive tank, connect a fuel hose from the
purge port (type of connection varies based on site installation, contact the site owner for
drawings) and run the hose back to the additive tank so that additive will return to storage.
2) Ensure all ball valves to other tanks are closed. Only the supply valves and ball valves for the
tank line being purged should be open.
3) Run the additive pump until additive flows freely from the end of the purge hose.
4) Continue to flow additive until approximately 100 gallons have been dispensed.
5) Repeat for each tank, until no excess meter flow due to air is detected.
6) Drain the additive hose entirely into the additive tank and move to the next line to be purged
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TROUBLESHOOTING & DIAGNOSTICS
The AIS will perform periodic self checks to ensure that all functions are performing correctly. If the
issue cannot be automatically corrected, the AIS will indicate the problem with the warning and fault
lights on the front of the panel.
SYSTEM OK STATUS
System OK = OFF Press reset. If the System OK light does not

Warning = ON illuminate, there may be a system malfunction.
Fault = ON Power down and restart the unit, and call TMS.
System OK = OFF System fault has occurred. Press reset to clear. If
Warning = OFF the fault returns, call TMS. Read printout on ATG
Fault = ON for details of fault.
System OK = ON Warning condition has occurred, or a fault has
Warning = ON occurred with only one product tank. Check ATG
Fault = OFF printout for details on warning.
System OK = OFF System has no power. Check low voltage
Warning = OFF disconnect switch, if there is still no power call
Fault = OFF TMS.
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TROUBLESHOOTING QUICK REFERENCE
When the AIS system encounters a fault, it will print a message on the ATG printer that is networked
with the unit, as well as logging and displaying the error message in the program window. The messages
that can be printed by the software, as well as the possible causes are as follows:
• TLS Not Connected

o This occurs when there is no communication with the VR TLS ATG
Possible Cause Possible Resolution
Ethernet Cable unplugged or Damaged Verify cable is seated properly.
Verify cable with a tester.
Ethernet Card on TLS not working or Review serial card parameters (Baud
Programmed correctly (serial parameters) rate). Contact Insite360 for specific
configuration if needed.
TLS IP not programmed correctly Review IP address, Subnet Mask and
Default Gateway matches IP provide by
IT Department.
LAN port on AIS not working Verify port connectivity with laptop
using PING commands. Verify
functionality on second LAN port.
LAN port IP on AIS not programmed Review IP address, Subnet Mask and
correctly Default Gateway matches IP provide by
IT Department.
• Relay Board Not Connected

o This occurs when there is no connection to the internal relay board module
USB cable not seated properly Reseat USB cable at AIS computer
and communication module (black
board).
Faulty communication board module Gently press on edges of module to
(black board) ensure it is seated properly in the
socket.
Faulty relay board module Verify there are no lose wires.
Incorrect software configuration Contact TMS.
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• Solenoid Failed Closed

o This occurs when the meter continues to read flow after a solenoid is supposed to be closed.
Faulty Solenoid Replace solenoid.
Debris stuck in solenoid Run check procedure a few times or
manually open and purge through
solenoid.
• No Pulses
o This occurs when there are no pulses read from the meter when a check or delivery is called
for.
Closed ball valves Verify ALL ball valves/3-way valves
are open/correction position.
Debris stuck in meter Open meter assembly and verify
gears rotate freely.
Meter wired incorrectly Verify wiring between AIS Meter
Box and AIS Controller.
No voltage to solenoids Measure coil voltage in the AIS and
in the Low Voltage Disconnect
Faulty I.S. Barrier By-pass I.S. to test and replace if
needed.
• E-Stop Pressed
o This occurs when the E-STOP on the controller is pressed.
E-Stop on controller pressed Press RESET button on controller.
• Unknown Error
o This occurs when the internal logic is incorrect.
Internal logic is incorrect Contact TMS.
31 | P a g e
• Pulser Board Not Connected

o This occurs when there is no connection to the internal pulser board module
and pulser board module. (Installed
below relay board module)
Incorrect wiring Verify there are no lose wires.
• TLS Software Is Not Running

o This occurs when the TMS TLS utility is not running on the AIS computer.
and communication module (black
board).
Faulty communication board module Gently press on edges of module to
(black board) ensure it is seated properly in the
socket.
Faulty relay board module Verify there are no lose wires.
• Pre-Check Flow Test Failed

o This occurs when the AIS primes the lines before a Check Process or Fuel Delivery and
receives flow from the meter.
solenoid.
Air in the lines Perform Purge process.
32 | P a g e
• Continuous Flow Test Failed

o This occurs when the AIS detects flow through the meter when the system should be idle.
solenoid.
Additive Leak Verify all sumps and lines for
additive leak
• Volume Variance Check Failed

o This occurs when the AIS detects a detects a discrepancy between the additive readings
from the TLS and AIS Meter.
solenoid.
Additive Leak Verify all sumps and lines for
additive leak
TLS Probe or Float issue Verify TLS Probe or Float or working
correctly.
Incorrect TLS tank charts Verify tank strapping charts.
• TC Volume IS Zero
o This occurs when the TLS readings return 0 for the TC volumes (Temperature Compensated)
TC Volume not enabled in TLS Enable TC Volume in TLS. Contact
Insite360 for specific configuration
if needed.
33 | P a g e
• Minimum Transaction Flow Rate is 0

o This occurs when the AIS configuration is incorrect which will cause the AIS to see a delivery
constantly
TC Volume not enabled in TLS Enable TC Volume in TLS. Contact
Insite360 for specific configuration
if needed.
• Additive over/underblend
o If the AIS printout and the tank gauge do not reconcile volumes, the CVVC or ATVVC alarms
may trigger; calibration is recommended
Additive meter requires recalibration Recalibrate the additive meter. The
meter should be recalibrated once
per 2 years.
The tank gauge probe is inaccurate Ensure the tank probe is correctly
installed and sized to the additive
tank. Ensure the correct thermal
coefficient of expansion is
configured for the additive
chemical; if unsure, contact the
supplier
34 | P a g e
CONTACT TMS
For all initial troubleshooting of units and all technical dispatches contact the Veeder-Root Insite-360
team at:
1-800-997-7725
Ask for technical support, and ask the tech for Level 1 support and give your location ID.
If an alarm is present that cannot be cleared and has been deemed to be a Level 3 issue, or if further
information on the AIS line of products is required please contact us at:
*Note: A Service Request Number is required when calling TMS.
Monday to Friday, 8 a.m. to 5 p.m. EST: (416) 225-5867

OR: (416) call TMS option #2
Toll Free: (844) 425-5867
After Hours: (416) 225-5867

OR: (416) call TMS option #2
Toll Free: (844) 425-5867
Note: If calling after hours, please clearly leave your name, telephone number and the nature of
your call. A technician will contact you as soon as possible.
35 | P a g e
APPENDIX A – BADGER METER SERVICE
When opening the meter, we suggest the

following markings of the gears and the housing to
ensure the same mounting position as the meter
was originally calibrated with.
When opening the meter, the oval gear on the right

side is the oval gear with encapsulated magnets
inside.
The marking on the housing (red arrow) shows the

side where the gear with magnet needs to be placed.
36 | P a g e
Oval Gear Meter housing and 2 oval gears.

The oval gear on the right side is the gear with
the encapsulated magnets. Here you can see
the gear with the magnet and without the
magnet. The side with the encapsulated
magnet must face the bottom of the housing
when mounting it.
Stainless steel bolts to

encapsulate the magnets
Position of the stainless-steel bolts facing the

bottom when mounting the oval gear.
37 | P a g e

Service Manual: Additive Injection System (AIS)

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Additive Injection System (AIS)

Manual No. 577014-489 • Revision A

AIS Block Diagram

Additive Delivery Fuel Delivery

Fluid Level Monitoring and Printing

AIS Additive Controller

Volume & Rate of

• Always focus on the job at hand

Modifying the IP of a Device

1. Access the network and sharing center

Step 1: In the Start menu search bar, type

Step 2: In the control panel, locate and

Step 3: In the left hand menu, select

3.1) If you are changing a laptop’s IP to

3.2) If you are modifying the IP address on

Step 4: Scroll down the list to “IPv4” and

Step 5: Use the following settings,

5.1) AIS: The AIS has 2 built-in LAN ports on

The default settings are:

Wireless* (if adapter is present)

The wireless connection should be set to

*Attention: record the settings of your

5.2) Laptop / External Computer:

Change the port you are connecting to a

Step 6: Verify network settings

After configuring network settings, it is good

Next, in the prompt, type in “ipconfig /all”

To install TeamViewer, run the

Once installed, TeamViewer will run on

Step 2: Open Teamviewer and make note of

Step 3: Check the Teamviewer server

To install UltraVNC, run the

Step 2: To connect to the AIS using

NAVIGATING THE AIS INTERFACE

The AIS interface is made up of several key

It is important to be familiar with each application

*Note: AIS Software interface may look different

The AIS utility always runs in the background while

It indicates pump runs, solenoid operation, delivery

Clicking on the AIS window will cause it to

The TLS Utility functions to constantly poll

The utility window indicates connection

The TLS Utility must be running for the AIS

If the TLS is not connected to the system or

AIS Configuration and Calibration Utility

AISConfig is an application used for troubleshooting and testing

*Note: there is a delay of approximately 1 second when toggling relay status

AIS Flow Meter Enclosure

Submersible Turbine Pump

Built-in Service Functions

The AIS has 3 built-in functions to aid in diagnosing,

The diagnostics function is used to check the system

Service Mode Button

The service mode button is used any time that

TROUBLESHOOTING & DIAGNOSTICS

System OK = OFF Press reset. If the System OK light does not

TROUBLESHOOTING QUICK REFERENCE

• TLS Not Connected

• Relay Board Not Connected