Autogas dispensers Installation and Operation Manual

Transcription

Autogas dispensers
Installation and Operation Manual
Manual:
Manual code:
Number of pages:
Issue date:
Review number:
Last review date:
Dispenser installation and operation Manual
DIOM-09-e
40
December 23, 2005
4
August 1, 2007
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READ THIS MANUAL BEFORE INSTALLING LPG DISPENSERS
Dispensers are energized by electricity and have a hazardous, flammable and potentially
explosive liquid. Failure to follow the below precautions and the warning instructions in this
manual may result in serious injury. Follow all rules, codes and laws that apply to your area and
installation.
SAFETY PRECAUTIONS – INSTALLATION AND MAINTENANCE
ALWAYS disconnect and lock power supply before opening the dispenser cabinet for
maintenance. Be sure to close the valves under the dispenser BEFORE beginning maintenance.
Make sure that you know how to turn off power to the dispenser and remote LPG pump in case of
an emergency. Have all leaks or defects repaired immediately.
Contact Yenen
Trouble in installing and operating the dispenser should be referred to your authorized Yenen
dealer or to Yenen technical support (+90 216 487 5924).
Explanation of symbols
Notice: indicates a special comment or instruction.
Warning: Indicates the presence of a hazard that can cause severe personal injury or
property damage if not observed carefully.
This manual provides instructions and guidelines. The remarks and warnings inform the operator of the
hazards involved in installing and handling LPG dispensers. Reading these instructions and preventing
hazardous situations is strictly in the hands of the operator of the equipment. Neglecting this responsibility is not
within the control of Yenen.

No part of Yenen manuals may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated
into any language in any form, by any means, without Yenen’s prior written permission.
Yenen reserves the right to change the specifications of the products described in this manual at any time and
without prior notice.
Yenen cannot and will not be held liable for any damages resulting from the use of this product.
While every effort has been made to ensure that the information in this manual is accurate and complete, Yenen
shall not be held liable for errors contained herein or for incidental or consequential damages in connection of the
use of this manual.
The logo(s) of Yenen Engineering Ltd. are property of Yenen Engineering Ltd.
Yenen Engineering Ltd. is ISO9001:2000 certified. For a copy of Yenen’s quality policy and / or Yenen’s HSE policy,
please, visit www.yenen.com or send an email to info@yenen.com or fax your request to +90 216 487 5986.
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Table of Contents
Page
1.0 About this manual
1.1 Applied standards and regulations
1.2 Accuracy requirements
1.3 Safety precautions
1.4 Required tools
1.5 UPS system
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4
4
5
6
6
2.0 Installation
2.1 Hazardous zones
2.2 Island construction, dispenser anchoring and piping
2.3 Hose installation
2.4 Dispenser tightness test
2.5 Electrical wiring
2.5.1 Cable glands
2.5.2 Maser Automation – RegiSmart registers
2.6 Functionality test
2.6.1 Totalizer readings
2.6.2 Preset
2.6.3 Non-volatile memory check
2.6.4 Emergency shut-down system (ESD)
2.6.5 Flow interruption
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7
9
10
10
11
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12
12
13
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3.0 Operation
3.1 Before operating the dispenser
3.2 Standard operation
3.2.1 Operating the dispenser without preset
3.2.2 Operating the dispenser with preset
3.3 Restarting after power failure
3.4 Setting and changing the unit prices
3.5 Error messages
3.6 Programming the ATC controller
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14
14
14
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15
16
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4.0 General maintenance
4.1 General safety considerations
4.2 Preventive maintenance and care
4.3 Filter
4.4 Calibration and meter maintenance
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Appendix A: Installation wiring diagram
Appendix B: Maser Automation head configuration
Appendix C: Dispenser troubleshooting
Appendix D: DOs and DON’Ts
Appendix E: Engineering drawings
LPG station safety distances according to TS11939
H-style footprint
H-style sample foundation
I-style footprint
I-style sample foundation
1-nozzle with preset – wiring diagram
1-nozzle with preset and ATC – wiring diagram
Dispenser connection diagram
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35
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1.0 About this manual
This manual describes the installation and operation of Yenen autogas (LPG) dispensers. Yenen
autogas dispensers operate with Maser Automation electronic registers (RegiSmart). Information
concerning Maser Automation control systems and protocols has been included where
appropriate in this manual. However, for complete installation and operation of such control
systems refer to the subsequent manuals provided with the control systems.
Any questions concerning installation and operation of the dispenser that are not covered in this
manual should be referred to Yenen at info@yenen.com or call at +90 216 487 5924.
For more technical documentation, check the Yenen website at
http://www.yenen.com/LPG_EN/Dispensers/Technical_documentation.htm.
1.1 Applied standards and regulations
The Yenen dispenser is part of an autogas filling system. All parts, such as tanks, pumps, pipe
and fittings, valves, corrosion protection devices, wiring, (electrical and electronic) control system,
etcetera must be installed in accordance with the manufacturer’s instructions and in compliance
with international and local standards and regulations.
Yenen has no obligation to monitor local laws, or modify the products based on developments or
changes in such laws.
Yenen autogas dispensers comply with prEN14678-1:2006 and suitable for use with Liquefied
Petroleum Gas (LPG) conforming to prEN589:2004.
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1.2 Accuracy requirements
Depending on local regulations, standards and codes, accuracy requirements differ from country
to country. Proper understanding of these local regulations is essential before assembling and
servicing meters and dispensers.
Yenen dispensers comply with the OIML R117 directive, which states the following for LPG
dispensers:
Accuracy class 1.0.
Maximum permissible error 1.0%.
1.3 Safety precautions
Only trained and qualified personnel familiar with handling liquids under pressure,
such as LPG, may service Yenen equipment.
ALWAYS disconnect and lock power supply before starting to service the dispenser.
More than one disconnect switch may be required to de-energize the dispenser for
maintenance and service. Use a multimeter to make sure ALL circuits in the
dispenser are disconnected. Failure to do so may result in personal injury.
Ensure that all valves to and from the dispenser are closed.
More than one valve may be required to lock the system. Review the station piping
diagram to make sure ALL valves are closed. Failure to do so may result in personal
injury.
All vehicle traffic and unauthorized persons shall be prevented from approaching
within 6 meters of the dispensing device.

Make sure that all necessary safety precautions have been taken. Make sure that proper
ventilation, fire prevention, evacuation and fire procedures are provided.
Provide easy access to fire extinguishers. Understand and adapt all local safety codes.
Read this manual as well as other available literature and drawings.
Yenen recommends employing a qualified mechanical and electrical technician. A hazardous
liquid is being handled, so it is important to ensure safety at all times.
See appendix D: DOs and DON’Ts
In the event of a gas leak:
1. Stop the leak by closing the nearest valve or shut-off device.
2. Use protective clothing to prevent cold burns.
3. Prevent accidental ignition.
4. Beware that LPG is heavier than air and therefore seeks lower level.
5. Evacuate all people from the danger zone.
6. Ensure that the area is safe before resuming the operation. If in doubt, notify the local fire
department.
In the event of a gas fire:
1. Stop the leak if it is within safe reach.
2. Notify the local fire department if it is a large fire that cannot be controlled safely.
3. In case of a small, contained fire, use the appropriate extinguisher. If in doubt, notify the local
fire department.
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1.4 Required tools used during installation

5mm Allen screwdriver
Standard screwdriver set
Mole wrench
Electric testing screw driver
13mm spanner
17mm spanner
19mm spanner
Wire cutter
2 adjustable spanners
Phillips tip screwdriver (star tip)
Knife (to remove packing)
M12 (10.9) bolt and nut
Textile cloth for cleaning
1.5 UPS system
The electronic register, named as RegiSmart, and other electronic parts have a wide power
operating range: 180 – 250 VAC.
Often Yenen dispensers together with Maser Automation (Italy) electronics are put into operation
where a stable power supply cannot be guaranteed.
Therefore, it is important to ensure a stable and consistent power supply through a UPS.
Especially, spikes in the power supply are harmful for the register. A dedicated UPS system for
the dispenser is essential in operating the dispenser virtually trouble free.
The most important characteristic of a UPS for Yenen dispensers is the transfer time or
response time. This should not be more than 4 milliseconds.
Another important feature of the UPS is that it must totally isolate output from input.
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2.0 Installation
Examine the dispenser immediately upon arrival to make certain there has been no damage or
loss during transportation of the equipment. Damaged or lost equipment must be reported to the
carrier. Any damage or loss that may occur in transit is not covered under warranty.
Make sure that all the component parts, including keys and optional equipment, are accounted
for. Check and save the packing list, bill of lading, invoice and all other documents included with
the order.
Remove the Silica gel moist absorption bags from the electronics and hydraulics area.
2.1 Hazardous zones
Check local regulations, standards and codes as these may differ from the European standard –
see chapter 1.1.
See Appendix E for a sample station layout with safety distances. Know the hazardous zone area
around the dispenser. Figure 2.1 shows the hazardous zones according to the European CEN
regulations.
Zone 0
Zone 1
Zone 2
Non hazardous zone
A flammable atmosphere is constantly or for a longer period of time
present
Definition: > 1000 hours per year
Where: inside the hydraulic system
An area where the presence of a flammable atmosphere under normal
circumstances is rather great
Definition: 10 – 1000 hours per year
Where: inside the housing (columns) and around the hydraulic set
An area where the presence of a flammable atmosphere is unlikely or it is
present for a very short period of time
Definition: < 10 hours per year
Where: around all sides of the dispenser housing and 1 meter from the top
of the housing
An area where the presence of a flammable atmosphere is never present
for any time
Where: inside the head of the dispenser.
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Figure 2.1 Hazardous zone diagram
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2.2 Island construction, dispenser anchoring and piping
Take the necessary safety measures around the work area. Take note of the safety
precautions in 1.3 and the DOs and DON’Ts from Appendix D.
Disconnect and lock power supply.
More than one disconnect switch may be required to de-energize the power supply.
Use a multimeter to make sure ALL circuits in the dispenser are disconnected.
Failure to do so may result in personal injury.
Ensure that all valves to and from the dispenser are closed.
More than one valve may be required to close the system. Review the station piping
diagram to make sure ALL valves are closed.
Failure to do so may result in personal injury.

A foundation must be provided for the dispenser.
See Appendix E for sample foundations as well as dispenser footprints.
Do not pour concrete around liquid inlet and vapor return lines or electrical conduit risers.
Instead, it is preferred to use sand or sandbags to avoid possible vapor buildup under the
dispenser.

To gain access to the bottom section of the dispenser unlock and remove the front panels.
Place these panels in an area where these will not be damaged.

The base of the dispenser contains bolt holes for anchoring the dispenser to the foundation.
Firmly mount the dispenser to the island.

Remove plastic caps from liquid inlet and vapor return line. There is a possibility that some
test liquid may still be present in the dispenser and can pour out from any of these pipes.

Cut the rubber tips from the pressure gauges on the dispenser column and
differential valve(s).

Connect the liquid and vapor return line. Use flexible hoses between the
dispenser connections and (underground) piping ends to allow for ground
movement. Underground piping (vapor return and liquid line) must be at least 1¼”.
When making piping connections, make sure that all connections are tight and leak-proof.
Use a liquid sealant compound, like Loxeal 58.11 or equivalent rated for LPG applications
on male threads only. Be careful not to get any excess compound inside the fittings.
See Appendix E for the dispenser connection diagram.
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2.3 Hose installation

To ensure proper joints clean all threads and use a liquid sealant compound.
When making piping connections, make sure that all connections are tight and leak-proof.
Use a liquid sealant compound, like Loxeal 58.11 or equivalent rated for LPG applications
on male threads only. Be careful not to get any excess compound inside the fittings.

Connect the hose assembly to the dispenser outlet and the hose hooks to the side cabinet
doors. If the dispenser is equipped with a hose retraction system refer to
the separate instruction for connection guidelines.

Connect the safety cable of the break-away coupling to the dispenser
frame. The break-away coupling should be secured to the frame. It is
designed to retain LPG on both sides of the breakaway point and it must
be installed on each dispensing hose. Note that only a few cubic
centimeters of LPG escape at the instant of separation.

Connect the dispenser to an earthing conductor that goes into the ground,
where it can dissipate charges.

Test continuity in the hose/nozzle assembly. Continuity must be present between the
dispenser outlet and nozzle to prevent static discharge while fueling.
Each hose assembly must be checked to ensure that the nozzle is
grounded.

For some regions crocodile clips are supplied with the dispenser for
additional earthing. Connect these to the dispenser frame.
2.4 Dispenser tightness test
After completing the installation steps in section 2.2 and 2.3 the dispenser
connections need to be checked for leaks.
Slowly open the valves in the tank area.
Open the vapor return line and liquid line valves slowly (V1) see figure
2.2.
Open the valve between the filter and gas separator in the dispenser
(V2) see figure 2.2.
Prepare a soap solution and check all connections with the solution for
leaks.
In case of a leak, close all valves, repair the leak and test again.
When all connections are tight, close all valves and continue with the
electrical connections (section 2.5).
The above steps are rough guidelines. Refer to your local
regulations for exact testing requirements that apply in your region.
Figure 2.2
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2.5 Electrical wiring
All dispensers and electrical connection boxes must be grounded.
ALWAYS disconnect and lock power supply before starting to service the dispenser. More
than one disconnect switch may be required to de-energize the dispenser for
maintenance and service. Use a multimeter to make sure ALL circuits in the dispenser
are disconnected. Failure to do so may result in personal injury.
2.5.1 Cable glands
The register is located in the non-hazardous zone – see section 2.1. Wires enter the
non-hazardous zone through cable glands. Yenen installed and plugged extra cable
glands for future use – see photo.
If cable glands are not used for wires and are not plugged then the nonhazardous zone becomes a hazardous zone. This poses and immediate
danger as the electrical components are not explosion proof or intrinsically
safe.
Yenen expressly disclaims and excludes any liability for failing to follow these
important safety instructions.
2.5.2 Maser Automation – RegiSmart registers
Yenen LPG dispensers operate with Maser Automation electronic registers – see appendix B for
Maser Automation head configuration. Maser offers three types of registers:
RegiSmart-ST
RegiSmart-Ex
RegiSmart-Plus
Electrical specifications:
a. Voltage: 220 volt AC (180 – 250 volt AC)
b. Frequency: 50Hz or 60Hz
c. Power consumption: <40 Watt in the maximum configuration
A stable and constant power supply is essential for proper functioning of the electronic
parts in the dispenser. Areas where a stable and constant power supply cannot be
guaranteed, measures should be taken to ensure that. Yenen recommends using
electronic UPS systems dedicated for the dispenser, which filters outages, sags, surges,
and bad harmonics in power supply – also refer to ‘PB – UPS recommendation’and refer
to section 1.5 UPS system on page 6.

Review the location of the dispenser junction box. Some models do not have a junction box.
In that case all the connections are located in the non-hazardous zone.

For full service / stand-alone operation, make electrical connections as shown in the
Installation wiring diagram in Appendix A.

The dispenser is delivered with a display lighting circuit connected to the control power circuit
at the terminal strip in the dispenser junction box. The display lighting may be connected to a
separate circuit breaker or switch through these terminals. Jumping these terminals will
permanently activate the display light – refer to Appendix A.

In addition to the required connections for stand-alone operation, the dispenser can also be
connected to a remote host or POS-system. Data wires need to be connected to the RS485
data port on the electronic register through the junction box. For further details, please, refer
to the Maser Automation instruction manuals.
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If optional data wires are run for future use, these should not be physically connected to the
data terminals in the dispenser junction box. Instead these wires should be properly
terminated individually using wire nuts.

Do not run wiring for any non-dispenser equipment in the same conduit as the dispenser
wiring. This wiring must be run in a separate conduit.

Connect the dispenser to an earthing conductor that goes into the ground, where it can
dissipate charges.
2.6 Functionality test
Before applying power to the dispenser, double-check the wiring to make sure the wires
are correctly routed and terminated; refer to the safety precautions in section 1.3
For new installations, the start-up procedures in this section should be performed in
sequential order to ensure proper operation of the dispenser.
Make sure above ground pumps are primed before dispensing any product – refer to the
manufacturer’s instructions.

Turn on the dispenser control power circuit breaker, the lights circuit breaker (if connected)
and the pump motor circuit breaker. Make sure the dispenser comes on. The dispenser
displays will show a few test messages and usually the last sale run during factory test.
If the dispenser has not been used for some time, it may display an error code E00 indicating
discharged capacitors. Wait for some time to charge the capacitors.

Remove the plug from the nozzle receptacle.
Connect the nozzle to the receptacle in the dispenser
cabinet.
Open the ball valve under the receptacle.
Turn the dispenser ‘on’ through the on/off switch or press
and hold the ‘dead man’s’ button.
The reset sequence starts now. The display resets itself.
Observe that the solenoid valve opens – listen for the
audible click of the valve(s).
The dispenser circulates LPG through the vapor return line
back to the tank. Observe the transaction on the display(s).
Dispense enough product through the dispenser to ensure
that dispenser and lines are free of air before continuing.
Turn the dispenser ‘off’ or release the dead man’s button.
Close the ball valve under the nozzle receptacle.
Disconnect the nozzle and place the plug back.
2.6.1 Totalizer readings
The RegiSmart-ST and RegiSmart-Ex come with electro-mechanical totalizer only. There is one
totalizer for each meter. The totalizer reads 7 digits and reads in whole units. Fractional amounts
that are left from a previous sale are stored and used during the following transaction.
RegiSmart-Plus maintains electronic totalizers for money and volume as well as the electromechanical totalizer.
For all models:
While dispensing observe the electro-mechanical totalizer incrementing.
RegiSmart-Plus: to read the electronic totalizers perform the following steps:
Enter ‘9135’ on the preset keyboard
Press the volume-button or money-button to view the totalizer
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2.6.2 Preset
Through the preset control panel enter a price or volume.
Turn the dispenser ‘on’ through the on/off switch or press and hold the ‘dead man’s’ button.
The dispenser circulates LPG through the vapor return line back to the tank. Observe the
transaction on the display(s).
Towards the end of the transaction, the flow rate slows down to complete the transaction at
the preset value.
2.6.3 Non-volatile memory check
During the transaction terminate the main power to the dispenser.
The solenoid valves close and the delivery stops immediately.
The display shows an error code (E00) and the last transaction for generally 20 minutes.
The data is stored on the EPROM and will be displayed again when power is restored. The
last transaction is permanently retained.
2.6.4 Emergency shut-down system (ESD)
During the transaction press the ESD button.
The solenoid valves close and the delivery stops immediately.
The display shows an error code (E00) and the last transaction.
2.6.5 Flow interruption
During the transaction close the ball valve on the liquid line.
Observe that product will not be dispensed.
The register will terminate the delivery after 60 seconds.
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3.0 Operation
3.1 Before operating the dispenser

Know how to turn off the main power supply to the dispenser and remote pump in case of an
emergency.
Test the break-away coupling by pulling both ends apart.
Regularly inspect the hose, nozzle and break-away coupling.
Regularly inspect the cabinet and hydraulic section for damage or leaks.
3.2 Standard operation
Unit prices must be set (section 3.4) and the dispenser must be authorized to operate. In standalone operation the dispenser is always authorized. When the dispenser is connected to a remote
system, like a Point-of-Sale (POS), the system’s software determines authorization.
Avoid stretching the hose assembly to reach a vehicle. This may result in damage to any of the
hose assembly parts.
3.2.1 Operating the dispenser without preset
Where supplied, connect the crocodile clips to the tailpipe or exhaust pipe of the vehicle.
Connect the nozzle to the vehicle.
Turn the dispenser ‘on’ through the on/off switch or press and hold the dead man’s button.
Disconnect the nozzle from the vehicle and stow the hose to prevent tripping.
Disconnect the crocodile clips.
3.2.2. Operating the dispenser with preset
Where supplied, connect the crocodile clips to the tailpipe or exhaust pipe of the vehicle.
Connect the nozzle to the vehicle.
Through the preset control panel enter a price or volume.
Turn the dispenser ‘on’ through the on/off switch or press and hold the dead man’s button.
Turn the dispenser ‘off’ or release the dead man’s button when the requested value has been
reached.
Disconnect the nozzle from the vehicle and stow the hose to prevent tripping.
Disconnect the crocodile clips.
3.3 Restarting after power failure
After loss of power the display shows an error code (E00) and the last transaction. When power is
restored all sales information returns to the display(s). A delivery in progress would have been
terminated – see section 2.7.4.

Identify the source for the power failure.
Resolve the fault if any.
Restore power.
If the dispenser does not operate properly when power is resumed, check if remote operating
valves are open, the pump is operational and that the dispenser is authorized (applies only for
dispenser connected to a remote system, like a Point-of-Sale (POS).
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3.4 Setting and changing unit prices
The below procedure is used to set the dispenser unit prices when operating as a stand-alone
dispenser or when communication with a remote operating device is disabled. With a remote
operating system enabled the dispenser will not allow unit prices to be changed at the dispenser.
This procedure applies for dispensers with software version 8.07. Refer to the Maser Automation
manuals for other versions.
Perform the following steps:
1. Ensure that the electronic head (dispenser) is powered.
2. Ensure that the nozzle is not activated.
3. On the electronic head press the programming key (Pr)
4. The display shows the following information:
SEL
P1 EL
P2 PP
5. Press
6. With the programming keys on the preset keyboard enter the new price starting with the first
digit from the left:
Use the increase button In to enter correct value
Use the programming button Pr to move the cursor one position.
7. When the last digit has been entered the programming of the unit price is completed.
8. The head will process the new data with a short display test (showing all 8s, followed by
blanks) and return to the normal operation mode in a few seconds.
9. The display shows the new unit price.
If the dispenser is a 2-nozzle dispenser, then the programming sequence continues from step 6
as follows:
10. The display shows the following information:
P-P 10 [parameter related to side 2]
XXXX [unit price side 2]
11. With the programming keys enter the new price starting with the first digit from the left:
Use the increase button In to enter correct value
Use the programming button Pr to move the cursor one position.
12. When the last digit has been entered the programming of the unit price is completed.
13. The head will process the new data with a short display test (showing all 8s, followed by
blanks) and return to the normal operation mode in a few seconds.
14. The display shows the new unit price.
16
3.5 Error messages
Error messages are displayed on the side of the dispenser where the error occurred. The last
transaction is retained in the non-volatile memory. Dispensing through the corresponding nozzle
is not possible until the error is solved. With a 2-nozzle dispenser, the side which shows no error
can continue to dispense unless the error involves the entire register.
The display can show the following error codes:
Er00:
Power supply failure:
This error code appears when main supply power to the dispenser is cut. The error code
appears on all the displays installed.
If power is restored and the error code does not disappear it may be caused by
discharged capacitors. This may occur when the dispenser has not been energized for a
long time. To solve this error, leave the dispenser energized for some time. The error
code will disappear by itself.
The error code can also appear on a single display card, which would indicate a power
supply failure to that specific display card only. This may indicate a display card failure
or display cable failure.
Er03:
Power supply failure on the pulser encoder:
This error code appears in situations with a fluctuating power supply.
Er04:
Communication error between pulse encoder and register:
The error occurs when the pulser signals are in conflict or when one is not sending a
signal to the head. One of the pulser channels can cause this error code when it is not
transmitting signals to the head.
Er05:
Communication error with a display card:
This error code indicates a communication failure with one of the displays. It appears on
all the displays except for the display with which communication has failed. The
dispenser cannot be used at all until the problem is solved. Activating and de-activating
the dispenser may solve the problem. If the problem persists, the display cable and the
display cards need to be checked.
Er06:
Tank low level indicator:
This error code only appears when an electronic storage tank level gauge is connected
to the register. Dispensing is not possible until the tank is filled.
Er07:
Indicates an LPG loss in the storage tank:
This error code only appears when an electronic storage tank level gauge is connected
to the register. Dispensing is not possible until the loss is recovered.
Er08:
Communication error with a remote system:
This error will not appear with stand-alone dispensers. The error can only appear when
the dispenser is connected with a remote system. The communication cables need to be
checked as well as the remote system.
Er09:
Error on the parameters stored on the EPROM:
This error may appear when a new software release is installed on the register. To solve
this error the parameters need to be re-programmed.
17
In addition to the above the RegiSmart-Plus has a few specific error messages:
Er05:
Communication error with a display card:
This error code indicates a communication failure with one of the displays or preset
keyboards. In some cases the dispenser cannot be used at all until the problem is solved
– see the table below.
Resetting the dispenser followed by activating and de-activating the dispenser may solve
the problem. If the problem persists, the display cable, the display card or preset
keyboard need to be checked.
E51
E52
E53
E54
E58
E59
Description:
Communication problem with master display 1
Communication problem with slave display 2
Communication problem with master display 2
Communication problem with slave display 1
Communication problem with preset 1
Communication problem with preset 2
Connector
M1
S2
M2
S1
CN1
CN7
Disabled yes / no
NO
NO
NO
NO
YES
YES
Er88
Electronic totalizer reaches maximum value
This error message appears during the delivery when a totalizer exceeds its maximum
displayable value:
Display
Preset display Indication
9135
Tank
Exceeds electronic volume totalizer on side 1
9135
Amount
Exceeds electronic value totalizer on side 1
9135
Tank
Exceeds electronic volume totalizer on side 2
9135
Amount
Exceeds electronic value totalizer on side 2
For details on parameter programming refer to Maser Automation instruction’s manuals. Manuals
can be downloaded from www.yenen.com.
3.6 Programming the ATC controller
For dispensers equipped with Automatic Temperature Compensation (ATC) the LPG composition
needs to be programmed into the ATC controller. Default from factory the composition is set to
30% butane, 70% propane.
Read the ATC manual KY-200-0505-0-Ö for programming instructions.
For accurate measurements it is important to adjust the ATC controller according to
the LPG composition.
Neglecting this responsibility will result in inaccurate readings and this is not within
the control of Yenen.
18
4.0 General maintenance
4.1 General safety considerations
Safe operation is very important for the customer and station attendants. Read and understand
the following recommendations:
Do not allow customers and pump attendants to use broken components such as the hose
assembly.
Do not allow customers and pump attendants to use dispensers with missing cabinet doors or
with doors open.
Have clear operating instructions on the dispenser.
4.2 Preventive maintenance and care
Understand the safety precautions described in section 1.3 while performing any form of
maintenance on the dispenser. Proper given preventive maintenance on a correctly installed
dispenser will rarely require emergency service.
Regularly perform the following inspections:
Keep the dispenser clean at all times. Use a non-abrasive silicone wax at least 4 times per
year to maintain a bright finish and prevent corrosion on all stainless steel cabinet parts. Plain
steel (painted parts) can be waxed with a standard automotive polish. Climate and regional
conditions may require polishing more often.
Frequently wipe off dust and dirt with a soft and damp cloth. Do not use excessive water.
Check all external LPG carrying components such as the hose, break-away and nozzle for
possible damage and leaks.
Stop using the dispenser when damage to the hose assembly is found. Continuing
operation can cause severe personal injury or property damage. Close all valves and
repair the hose assembly.

Check for sharp or similar edges on the cabinet that may cause cuts.
Check the hydraulics for leaks.
Stop using the dispenser when a leak is found. Continuing operation can cause severe
personal injury or property damage. Close all valves and repair the leak – see section 2.4.

Regularly test the tank for water, dirt and aggressive hydrocarbons that may be supplied from
the refinery. Contaminated LPG can cause severe internal damage to the dispenser – see
section 1.1.
Use only genuine Yenen replacement parts and repair kits on the dispenser. Using other than
genuine Yenen replacement parts may create a safety hazard and will violate approvals and
warranty on the dispenser.
4.3 Filter
A clogged filter will slow down the delivery rate. With new installations, it may be required to
replace the filter several times during the first week of operation to remove small pieces of
installation fragments and pipe sealant.
Depending on the gas quality, the filter needs inspection every 1 million liters, six months or when
LPG delivery rate slows down.
With the dispenser and pump in operation a difference in pressure at the pump outlet and the
dispenser liquid line of 2 bar or more may indicate a clogged filter.
Read Yenen’s ‘Replacement instructions for filter’, ITL-SRV-7.5.1-008-e.
19
4.4 Calibration and meter maintenance
Local regulations state the frequency of dispenser calibration. OIML R117 states calibration at
least once a year or if LPG inventory discrepancies exist.
Certain metrological sensitive parts are sealed against forbidden modification or
removal of such parts. Only trained and qualified personnel certified by the authorities
may break and reseal dispensers.
For adjustment of the dispenser, follow the procedures described by local authorities and read
Yenen’s ‘LPG flow meter installation and operation manual’, LFM-02-e.
20
Appendix A – Installation wiring diagram
1-NOZZLE DISPENSER JUNCTION BOX
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Description
Phase (220 V)
18
Neutral
19
Signal (220 V)
20
Emergency Stop Phase (220 V)
21
Emergency Stop Neutral (220 V)
22
Dispenser Light Phase
23
Dispenser Light Neutral
24
Not in use
25
Not in use
26
Not in use
27
Not in use
28
High flow solenoid1 Phase (24V)
29
High flow solenoid1 Neutral
30
Relay1 Phase (220V)
31
Not in use
32
Not in use
33
Not in use
Phase (220 V)
Neutral
Low flow solenoid1 Phase (24V)
Low flow solenoid1 Neutral
Solenoid Grounding
Solenoid Grounding
Not in use
Not in use
Not in use
Not in use
Not in use
Not in use
Not in use
Not in use
Not in use
Not in use
Connect main power supply to terminal 1, 2
Connect a return signal to terminal 3 to energize the remote pump through
a site control system (such as a run box or control box)
Connect emergency stop terminals (4, 5) to a site control system
Connect dispenser lighting terminals (6, 7) to a circuit breaker. Bridge
terminal 6 to 1 and 7 to 2 if dispenser lighting should always be on
21
Appendix A – Installation wiring diagram
2-NOZZLE DISPENSER JUNCTION BOX
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
Phase (220 V)
18 Phase (220 V)
Neutral
19 Neutral
Signal (220 V)
20 Low flow solenoid1 Phase (24V)
Emergency Stop Phase (220 V)
21 Low flow solenoid1 Neutral
Emergency Stop Neutral (220 V)
22 Relay2 Phase (220V)
Dispenser Light Phase
23 Not in use
Dispenser Light Neutral
24 Not in use
Not in use
25 Not in use
Not in use
26 Phase (220 VAC)
27 Neutral
28 Low flow solenoid1 Phase (24V)
29 Low flow solenoid1 Neutral
30 Solenoid Grounding
Relay1 Phase (220V)
Not in use
Not in use
Not in use

Connect main power supply to terminal 1, 2
Connect a return signal to terminal 3 to energize the remote pump through
a site control system (such as a run box or control box)
Connect emergency stop terminals (4, 5) to a site control system
Connect dispenser lighting terminals (6, 7) to a circuit breaker. Bridge
terminal 6 to 1 and 7 to 2 if dispenser lighting should always be on
22
Appendix B – Maser Automation head configuration
Electronic register
RegiSmart-ST
RegiSmart-EX
RegiSmart-Plus
Head unit
CPU board
Standard
CPU FW
New
CPU FW
Display board
Display FW
Single side
M30176A
Single side
M20569
REL 7.67
REL 8.07
M20552 (with totalizer)
REL 1.29
Double side
M30174A
Double side
M20179
REL 7.67
REL 8.07
M20553 (without totalizer)
REL 1.29
Single side
M30230
Single side
M20569
REL 7.67
REL 8.07
REL 1.29
Double side
M30232
Double side
M20179
REL 7.67
REL 8.07
REL 1.29
Single side
M30176F
Single side
M20569/P
REL 7.60.7
REL 7.61
REL 1.28 INDO
Double side
M30174F
Double side
M20179/P
REL 7.60.7
REL 7.61
REL 1.28 INDO
Previous display release for RegiSmart-ST and EX is 1.28. This display version is compatible with the head unit and may still be installed in some units.
However, it is advisable to use only the same release version in the dispenser.
23
Appendix C – Dispenser troubleshooting
Nr
Type of failure
1
Error code E00
Probable cause
1. Power loss
2. Capacitor is discharged
3. Damaged display card
4. Electronics card is damaged
5. ESD button has been pressed, but not released
What to check?
1. Check power supply
5. Check ESD button
How to correct?
1. Restore power
2. Energize the dispenser for some time
3. Replace display card
4. Replace electronics card
5. Open ESD button or replace button
2
Error code E03
1. Fluctuations in power supply
2. Pulser failure
1. Check power supply and pulser connections
2. Check pulser
1. Restore power and connections
2. Replace pulser
3
Error code E04
1. Pulser signals are in conflict
2. One pulser channel does not send signals to the head
Check pulser and pulser connections
Restore connections or replace pulser
4
Error code E05
1. Failure in display(s)
1. Check displays and display cable
1. Activate and de-activate the dispenser
2. Replace failed display cable or card
5
Display does not operate
1. Ambient temperature may have exceeded the working
range. Display is blank – no error message
1. Check temperature at the display
1. Problem should resolve itself when
temperature is within the range.
6
Electro-mechanical totalizer
1. Totalizer coil may be damaged
2. Electronic register may not send signals
3. Display card may be damaged
1. Check electro-mechanical totalizer
2. Check electronic card
3. Check display card
1. Replace electro-mechanical totalizer
2. Replace electronic card
1. Check the fuse on the electronics card
2. Check the electronics card
7
Dispenser is in operation mode, but does not
dispense. Pump is not operating
1. Fuse on the electronics card may have failed
2. Transistor on the electronics card which energizes the
solenoid valve may be damaged
3. The coil of solenoid valve may be damaged
4. On/off switch or dead man’s button may have failed
5. Pump may not create sufficient pressure
6. Pneumatic valve may be closed
7. Relay in site controller may not signal the pump
8. Thermal protection relay in site controller may be off
1. Replace fuse
2. Replace electronics card and repair
transistor
3. Clean or replace solenoid valve
4. Replace switches
5. Follow manufacturer’s guidelines
6. Pressurize lines or fill nitrogen bottle
7. Replace relay
8. Adjust relay or replace relay
8
Delivery is not registered
1. Pulser connection with flow meter may be damaged
2. Display card may be damaged
1. Check pulser connection with flow meter
2. Check display card
1. Restore pulser to flow meter connection
9
Price indicator on the display continues
counting while nozzle is disconnected
1. Preset or other connections may be in short circuit
1. Check connections and insulation
1. Restore connections; if needed change
preset
3.
4.
5.
6.
7.
8.
Check the coil
Check switches
Check motor and refer to manufacturer’s handbook
Check pneumatic valves and nitrogen bottle
Check relay in the site controller
Check thermal protection relay in the site controller
24
Appendix C – Dispenser troubleshooting continued
Nr
Type of failure
10
Unit price flashes continuously
Probable cause
1. Program key (Pr) or increase key (In) may be jammed
2. Cover of electronic head may be damaged
What to check?
1. Check Pr and In buttons
2. Check cover for damage
How to correct?
1. Press buttons again to release
2. Replace cover
11
During programming, the display flashes at
every parameter
1. Program key (Pr) may be pressed
1. Check Pr button and observe display
1. Press Pr button until ‘EP’ is displayed
12
1. Parameters at electronic card may be programmed
incorrectly
2. Solenoid valve may leak
3. Diaphragm of differential valve may be damaged
1. Check parameters
Dispenser does not terminate delivery at preset
value
2. Check solenoid valve
3. Check differential valve
1. Correct parameters. Consult with Yenen
if needed
3. Replace diaphragm
13
Dispenser delivers too much or too little
1. Pulser may be damaged
2. Pulser connection with flow meter may be damaged
3. Meter parts may be damaged
1. Check pulser
2. Check pulser connection with flow meter
3. Check distribution valve, carbon plate, and seals
1. Replace pulser
2. Restore pulser to flow meter connection
3. Repair flow meter
2. Parameters at electronic card may programmed
incorrectly
3. Electronic card may be damaged
4. Pulser may be damaged
2. Check parameters
14
Displays continues registering while the nozzle
is disconnected
3. Electronic card
4. Check pulser
2. Correct parameters. Consult with Yenen
if needed
3. Replace electronic card
4. Replace nozzle
1. Check pump
15
The delivery is abruptly terminated while in
progress
1. Pump pressure may drop to where differential valve
closes
2. Power loss
3. Site controller may have alarmed
4. If applicable, gas sensor may detect a leak and close
valves
2. Check power supply
3. Check site controller
4. Check for leaks
2. Restore power
3. Restore site controller
4. Repair leaks
16
Dispenser light is off
1. Light may be broken
2. Light may be loose
3. Ballast in junction box may be damaged
1. Check light
2. Check light
3. Check ballast
1. Replace light
2. Place light correctly
3. Replace ballast
25
Appendix C – Dispenser troubleshooting continued
Nr
Type of failure
17
Dispenser flow rate is low
18
No delivery
Probable cause
1. Filter is clogged
2. The coil of solenoid valve may be damaged
3. Pump pressure may be low
4. Rotation direction of submersible pump may be wrong
6. Break-away coupling may be clogged, damaged or
placed incorrectly
7. Nozzle may be damaged
8. Pulser may be fastened too tight to pulser table
What to check?
1. Check filter
2. Check solenoid valve
3. Check pressure gauge at the pump
4. Check rotation direction of the submersible pump
6. Check break-away coupling
How to correct?
1. Replace filter
4. Change phases of the pump
6. Clean or replace break-away coupling
7. Check nozzle
8. Check if pulser shaft can rotate freely
7. Replace nozzle
8. Untie bolt at pulser table
1. Break-away and nozzle may be jammed or blocked
2. Valve inside the nozzle may be damaged
1. Replace break-away and or nozzle
2. Replace nozzle
4. Pneumatic valve may be closed
5. No differential pressure
1. Check hose assembly
2. Connect nozzle to dispenser receptacle and check
if nozzle is operating
3. Observe that the solenoid valve opens – listen for
the audible click of the valve(s)
4. Check pneumatic valves and nitrogen bottle
5. Differential pressure from the pump
3. Solenoid valve may not open
4. Pressurize lines or fill nitrogen bottle
5. Increase differential pressure
19
No reading on pressure gauge
1. Gauge can be damaged
1. Check gauge
1. Replace gauge
20
Nozzle leaks
1. Nozzle gasket can be damaged
2. Nozzle clips can be damaged
1. Check gasket in the nozzle
2. Check nozzle clips
1. Replace gasket
2. Replace nozzle
26
Appendix D
DOs and DON’Ts CHECK LIST
DO…
•
DO discuss the project and procedures with station manager or operator before
performing service on a dispenser.
•
DO evaluate the hazards at the working area and use your safety training and
experience in determining any precautions to be implemented.
•
DO locate and be familiar with fire extinguishers in the area prior to beginning any
LPG related work on the forecourt.
•
DO be aware of vapors and other hazardous conditions.
•
DO disconnect and lock power supply before opening the dispenser cabinet for
maintenance. Be sure to close the valves under the dispenser BEFORE beginning
maintenance.
•
DO know the associated hazardous location classifications.
•
DO use safety cones, barricades, barrier tape or a vehicle to isolate work area and
protect the technician.
•
DO wear appropriate safety clothing including brightly colored vests, goggles and
gloves.
•
DO be aware of and monitor your work area surroundings.
•
DO connect the nozzles on dispenser carefully.
•
DO take totalizer readings and record it in coordination with station manager or
operator.
27
DON’T…
•
DON’T allow unauthorized individuals near the dispenser or work area when
degassing and disassembling of the dispensers.
•
DON’T leave dispenser doors open after maintenance is complete.
•
DON’T allow smoking, flame or spark-producing devices near the work area.
•
DON’T place tools or equipment outside the barricaded work area.
•
DON’T work outside the barricaded work area.
•
DON’T remove safety cones, barricades, barrier tape or the service vehicle until
work is completed.
•
DON’T leave the station unless the station manager or operator signed the report.
28
Appendix E: Engineering drawings

LPG station safety distances according to TS11939
H-style footprint
I-style footprint
29
LPG station safety distances taken from TS11939 – 2003
Safety distances may vary depending on local or regional regulations. Consult your local and or regional code requirements
to determine which codes are applicable.
Table 1: Minimum safety distances of tanks in meters
Tank capacity m3
Underground autogas tank1
Above ground autogas tank2
Distances between autogas tanks
Less than 0.5
3
3
0
0.5 – 3
3
3
1
3.1 – 10
5
7.5
1
10.1 – 40
10
15
1.5
1. The measurement of the safety distances for underground tanks should start from the safety relief valve.
2. The measurement of safety distances for above ground tanks should start from the nearest point of the tank to the related location.
Table 2: Minimum safety distances for LPG stations1 in meters
LPG Tank
(underground)
LPG tank
(above
ground)
Petrol
dispenser
LPG
dispenser
Petrol
tank2
Building
Road
Significant
buildings3
Neighbor field
boundary
LPG tank
Table 1
Table 1
5
5
5
Table 1
Table 1
40
Table 1
(underground)
LPG tank
Table 1
Table 1
7.5
7.5
7.5
Table 1
Table 1
50
Table 1
(above ground)
Petrol
5
7.5
6
5
5
5
50
5
dispenser
LPG Dispenser
5
7.5
6
Building
Table 1
Table 1
5
Road
Table 1
Table 1
5
Significant
40
50
50
buildings3
1. There is no minimum safety requirement between the tank and the pumping unit.
2. This distance is not applicable to the horizontal distance between LPG tanks with 0.5 m3 or less capacity and petrol tanks with a capacity of 2.5 m3 or
less.
3. Hospital, school, park, metro station, etc.
30
LPG station safety distances taken from TS11939 – 2003
Safety distances may vary depending on local or regional regulations. Consult your local and or regional code requirements
to determine which codes are applicable.
31
H-style footprint
32
33
I-style footprint
34
35
36
To disable the ATC controller
bridge terminal 34 and 35
37
38
To disable the ATC controller
bridge terminal 34 and 35
39
Akşemsettin Mahallesi Tavukçuyolu Sokak No: 23
Sultanbeyli 34925 Istanbul / Türkiye
T +90 216 487 5924
F +90 216 487 5986
E info@yenen.com
www.yenen.com
DIOM-09-e