INSTALLATION OPERATION ¸ Ovation Dispensers
DANGER READ THIS MANUAL BEFORE YOU BEGIN Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Failure to follow the below precautions and the Warning and Caution 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 make sure ALL power to the dispenser is turned OFF before you open the dispenser cabinet for maintenance.
Ovation Series Dispensers Installation & Operation February 2006 Part No.
February 2006 Part No.
Table of Contents Title 1 Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 1.2 1.3 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3 Dispensers Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents (continued) Title 3.11 3.12 3.13 3.14 3.15 3.16 3.17 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.10 5 Page Totalizer Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.11.1 Totalizer Readings by Product Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION 1.1 Dispensers Covered This manual describes the installation and operation of blending and non-blending Ovation model dispensers. Non-blending dispensers do not combine base products. These dispensers are multi-grade dispensers unless otherwise noted. Blending dispensers combine the base products to provide a blended grade or grades. Blending dispensers have two base products labeled LO and HI.
Pertinent information and codes are available from the following sources: Association for Composite Tanks (ACT) North State Street Suite 720 Chicago, IL 60602 (301) 355-1307 (for information requests) American Petroleum Institute (API) 1220 L Street, N.W. Washington, DC 20005 (202) 682-8000 Fiberglass Petroleum Tank and Pipe Institute One SeaGate, Suite 1001 Toledo, OH 43604 (419) 247-5412 National Assoc.
1.3 SAFETY PRECAUTIONS NFPA 30A states that: “When maintenance to Class I dispensing devices becomes necessary and such maintenance may allow the accidental release or ignition of liquid, the following precautions shall be taken before such maintenance is begun: • Only persons knowledgeable in performing the required maintenance shall perform the work. • All electrical power to the dispensing device and pump serving the dispenser shall be shut off at the main electrical disconnect panel.
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2 2.1 INSTALLATION Inspect the Equipment Examine the shipment immediately upon arrival to make certain there has been no damage or loss in transit. Make sure that all the component parts, including keys and optional equipment (if any), are accounted for. Check and save the Packing Slip, Bill of Lading, Invoice, and all other documents included in the shipment. Damaged or lost equipment must be reported to the carrier.
2.3 Emergency Shut-off Valves WARNING For remote dispensers, a Listed1, rigidly anchored emergency shut-off valve must be installed, in accordance with the manufacturer’s instructions, in each supply line at the base of each dispenser. For a typical emergency valve installation see Figure 2-2. Failure to install the proper emergency shut-off valve will present a hazardous condition that could result in serious injury. Figure 2-2 Typical Emergency Valve Installation.
2.5 Lifting and Installing the Dispenser Remove the shipping carton from the dispenser and, if the dispenser is equipped with an optional valance, survey the site to determine if it should be installed before or after the dispenser is set on the island. Wayne recommends installing the valance after the dispenser is installed, if practical, to protect it from installation damage. See the Valance Module drawing in the back of this manual.
2.6 Electrical Wiring 2.6.1 General Wayne recommends employing a qualified electrician for all wiring. A hazardous liquid is being handled, so it is important to ensure that all wiring is in accordance with the National Electrical Code (NFPA 70) as well as all federal, state and local regulations. Note: U.L. requires that all electrical connections to the dispenser be made with threaded, rigid conduit and properly sealed conductors.
2.6 Electrical Wiring, continued WARNING Electric Shock Hazard! No connections (including neutral) may be shared between groups of dispensers. A separate Control Power Circuit Breaker must be provided for each group. Failure to do so may result in serious injury. 2.6.3 Field Wiring for Dispensers Without a Junction Box All field wiring must enter the Electronic Head via potted conduit fittings.
2.6 Electrical Wiring, continued 7. Trim wires to appropriate length, terminate ends and connect to the terminal block as per Wiring Diagram drawing 888445-001 located in the Appendix B of this manual. Note: Field wires are to be connected to the lower terminals on the block. 8. Prepare the potting compound by pouring 4 oz. Rockite into an eight oz. paper cup. 9. Add 1-1/2 oz. of water. 10. Stir one to two minutes until reaching a consistency similar to pancake batter. 11.
2.6.4 Full Service (Stand-Alone) Dispenser Wiring For full service operation, make electrical connections as shown on the Installation Wiring Diagram in Appendix B. The electrical connections illustrated are typical when additional like model dispensers are used. Data wires shown on the wiring diagram are for connecting the dispenser to the Data Distribution Cabinet and the Site Controller Cabinet in a Wayne Control System. These data wires are not required for the full service (stand-alone) dispenser.
2.6.6 Optional Equipment Dispensers contain an extra pair of data wires in the junction box for Wayne TRAC as shown below. These wires are also identified in the installation wiring diagram in Appendix B. Dispensers with the letter I in the model number will have an intercom call button. Brown wires are speaker connections. Yellow wires are call button connections see Figure 2-6. Both circuits are low voltage NEC Class 2 only.
2.7 Hose Installation Hose assemblies should be U.L. Listed and installed in accordance with the manufacturer’s instructions. To ensure a proper joint, wash all cutting oil off the threads and use a U.L. classified gasoline-resistant pipe joint sealing compound. Place the compound on male threads only; be careful not to get any excess compound inside fittings. Install the fixed end of the hose to the dispenser outlet; secure according to the instructions of the sealing compound and hose manufacturers.
2.9 iMeter Calibration All iMeters are tested, calibrated and sealed at the factory before a dispenser is shipped. Local codes and regulations may require verification of meter accuracy at Start-up. If verification or calibration is required, sufficient product must be run through each meter to thoroughly flush out all air and completely fill the system prior to the calibration process. Each iMeter module contains two meters. The Intelligent pulser contains two sets of sensors, one set for each meter.
Figure 2-7 iMeter Module. The Intelligent Pulser has two calibration doors - one for each meter. Only one door may be opened at one time during meter calibration. 15 February 2006 Part No.
2.10 Balance Vapor Recovery System Installation Requirements 2.10.1 Dynamic Back Pressure Testing At initial installation, balance vapor recovery dispensers should have a dynamic back pressure test performed at each nozzle to ensure there are no blockages in the vapor recovery system. The dispenser should be connected to the underground and the hanging hardware (hoses, nozzles, breakaways, etc.) should be installed.
2.10 Balance Vapor Recovery System Installation Requirements, continued 6. If back pressure readings are very low (less than .02 @ 20 CFH; 0.18 @ 60 CFH; 0.4 @ 100 CFH): 1. Check test fixture for tight seal at nozzle entry point. 2. Check bellows and face seal for tears. 3. Check vapor piping for leaks. 7. If back pressure readings are high: 1. 2. 3. 4. 5. 6. Check hoses and nozzle bellows are completely drained. Check dry break is open. (If only allowed to have one dry break open during the test, try all.
2.11 Wayne Vac Vapor Recovery System Installation Requirements 2.11.1 Dispenser Vacuum Decay At initial installation, Wayne Vac vapor recovery dispensers should have a 27” decay test performed on each point to ensure there are no vapor leaks in the dispenser/hanging hardware - hose, nozzle, breakaway, etc. This test is used to verify the dispenser/hanging hardware integrity so the vapor assist system will operate at its peak performance.
3 START-UP 3.1 Initial Checkout Before applying power to the dispenser, double-check the wiring to make sure the wires are correctly routed and terminated. Turn on the dispenser control power circuit breaker and the submersible pump or suction pump motor circuit breakers. Make sure the dispenser comes on and all lights work. The dispenser displays will show some numbers, usually the last sale run during factory test.
3.3 Logical Nozzle/Hose Positions The physical number of hoses on one side of the dispenser is not the same as the number of electronic hose positions on that side. Unit prices and blend ratios are set in electronic hose position or logical nozzle order. B23/3, B23/4 and B23/5 model Blenders each have 2 hoses per side and 3 inlets, but either 3, 4 or 5 grade selects/logical nozzles as shown in Figures 3-2 A-C.
positions 6,5,4,3 position positions 7,3 1 Model B23/5220D1 Model B12/2220D3 positions 7,6,5,4 positions 6,5,4 position 1 Model B23/4220D1 Model B12/4220D3 positions 6,4 position positions 7,5,3 1 Model B23/3220D1 Model B12/3220D3 Figure 3-2 Blending Models. 21 February 2006 Part No.
position position position 1 1 2 Model R11/1220D1 Model R22/2220D1 positions 1,2,3 Model R13/3220D1 Figure 3-3 Non-blending Models. 22 Part No.
3.4 Setting the Clock The time and date is set in function F02 Clock Configuration. The sub-functions F02.00 is the time HH.MM, F02.01 is the date MM.DD and F02.02 is the year YY.YY. 1. Press ENTER PASS 1 (enter password) 2. Press ENTER PASS 2 (enter password) 3. Press ENTER. The unit price display will show F— (indicating it needs a function number to proceed) 4. Press 02 to access F02 5. Press ENTER. The unit price display will show F02 (indicating the function has been accessed) 6.
3.5 Setting Unit Prices, continued Changing the Value of the Unit Price Type in the new unit price with at least three digits for three money display digits to be shown after the decimal point. For example, to set the new unit price to $1.50, type in 1500. Type in 1509 for $1.509 unit price. 1. Press # key. The volume display will show the unit price with the correct number of digits after the decimal point. Again, for the example above, the volume display will show 1.500. 2.
3.6 Setting Blend Ratios The procedure below is used to set the dispenser blend ratios. When enabled, the POS system verifies and confirms that its blend ratio data corresponds to the manually set blend ratios. The Wayne POS system will not allow fuel to be dispensed if these numbers do not match. The pump computer recognizes code stored in memory that defines a dispenser model and assigns logical nozzle numbers to the hose positions as explained in Section 3.3.
3.6 Blend Ratio Setting, continued Saving the New Blend Ratio 1. Press ENTER. The price display will show “– – – – – –“, the volume display will be blank and the unit price display will show the last sub-function accessed. 2. Press 00 (to access F00) 3. Press ENTER. The unit price should now display F00, the price display will show “– – – – – –“ and the volume display will be blank. 4. Press ENTER and the volume display will show a 1. 5. Press UP twice to change the value in the volume display from 1 to 3.
3.7 Setting the Fueling Point ID The procedure below is used to set the dispenser fueling point address. The dispenser FPID should be input and saved before control is transferred to the POS system. Functions F05 and F06 are accessed to set the FPID on Side 1 and Side 2, respectively. To set the FPID, the desired FPID must be input and saved. Accessing the FPID Function. 1. Press ENTER PASS 1 (enter password) 2. Press ENTER PASS 2 (enter password) 3. Press ENTER.
3.8 Authorizing the dispenser The dispenser must be authorized before it will dispense product. The dispenser filling mode is set in programming function F01. In stand-alone mode (not connected to a control system), the dispenser is always authorized, unless the dispenser is equipped with the (optional) Authorize keyswitch on the bezel. This momentary contact keyswitch can be used for one time authorizations. When connected to a control system, the system programming determines authorization.
3.11 Electronic Totalizer Readings 3.11.1 Totalizer Readings by Hose (Product) Position Each fueling point of the dispenser maintains electronic totalizers for both money and volume. Dispensers equipped for Cash/Credit operation also keep separate cash and credit totalizers by grade. Rather than mechanical totalizers, each position has an electro-mechanical totalizer for each feedstock. See Figure 24 for EMT locations.
3.11.2 Totalizer Volume Readings by Meter Position Meter volume totals are stored in statistical functions that are accessed using the remote control interface. The totals for Side 1 are stored in function S05 and those for Side 2 are stored in function S06. The value of the meter totals are stored in the sub-functions that take the format .M0, where M is the meter number. Assigned values of M are shown in Table 3-2.
AA Z Y X 8 M 4 7 M 3 6 M 2 5 M 1 Junction Box Table 3-2 Meter Positions for Ovation Dispensers 3.11.3 Electro-Mechanical Totalizer Operation Electro-Mechanical totalizers are standard on 3/Vista model dispensers. See Figure 2-4 for location. Electro-Mechanical totalizers are located on the junction box side of the dispenser. There is one totalizer for each meter. The totalizer positions on the bezel relate to the meter position numbers shown in Table 3-2.
3.12 Nozzle Boot Switch Check In the Ovation style nozzle boot, a proximity switch and a magnetic actuator are used for nozzle on/off operation. The proximity switch is attached to the back of the nozzle boot casting. The magnetic actuator is located inside the spring-loaded flipper, which is installed from the top front of the boot casting. When the nozzle is removed, the flipper rotates the magnetic actuator and aligns the actuator with the proximity switch, turning the switch on.
3.16 Audit Report Display Mode (For Weights and Measures Officials & Service Purposes Only) On the computer the Weights and Measures audit trail is accessed by the use of a hand held remote. By entering the Weights and Measure mode, one can view both the blend ratio audit trail and volume metering unit change counter required by Weights and Measures. The Weights and Measures mode is side specific, therefore, it shows the blend ratio logs and volume metering unit logs for the side that your are facing.
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4 OPERATION 4.1 Safety Items You Should Know • Know how to turn OFF power to the dispenser and submersible pumps in an emergency. • Inspect regularly, all external fuel carrying components such as, hoses, nozzles, breakaways, etc., for damage or leaks. • Inspect regularly, the dispensers housing parts for damage or leaks. • Have all leaks or defects repaired immediately. • Test the Emergency (shear) valve, by opening and closing several times, at least once per year.
4.3 Introduction to Operation Unit prices must be set and the dispenser must be authorized for the dispenser to operate. If the dispenser is connected to a control system, each dispenser must have a unique fueling point number set for communication with the system as discussed in Section 3. If the dispenser is connected to a 2400 MCS, Wayne Plus or Nucleus POS system and you want to operate the dispenser in the stand-alone mode, independently from the control system, perform the following steps: 1.
4.5 Restarting After Power Failure or Shutdown After loss of power, the display accurately displays the amount of the sale, in money and volume, for approximately 15 minutes. When power is restored, all sales information returns to the displays. Any sales in progress will be ended; old sales should be paid and the dispenser reauthorized if more product is to be dispensed.
4.7 Error Codes Computer error codes are displayed on the side of the dispenser where the error occurred when any subsequent nozzle on signal is received on that side. The last sales data is retained and displayed with nozzle off. Product flow stops on that side only. That side will not dispense until reset by cycling power or the fault condition is corrected. Computer error codes are displayed sub-functions S21.XX for Side A and S22.
4.8 Resetting After All Stop This section applies to models connected to a Wayne Control system. Pressing the All Stop key on the 2400 MCS or Wayne Plus or Nucleus sends a signal to the dispenser computer to interrupt product flow. To resume product flow: • 2400 MCS - All of the unpaid/stopped indicators will be illuminated on the 2400 MCS console. Press Clear until the console display is totally blank. Press Pump Start. At this point all unpaid/stopped indicators will go out and fuel flow may resume. 4.
4.10 Printer Paper 4.10.1 Loading Paper The following procedure refers to Figure 4-1(A -D). 1. Unlock and open the printer door on the dispenser bezel. 2. Pull down the inside printer door from top (A). 3. Important: While holding the paper roll, pull the roll tight (B) and ensure there are no loops underneath the roll. 4. Place paper roll inside the printer and feed from top of roll through the chute(C) and (D). 5. While pulling slightly on the paper, push the door up to the closed position. 6.
4.10 Printer Paper, continued Pull Out From Top B. A. C. D. Figure 4-1 Loading Printer Paper. 41 February 2006 Part No.
'LVSHQVHU ZLWKRXW YDSRU EDUULHU FRQVWUXFWLRQ 'LVSHQVHU ZLWK YDSRU EDUULHU FRQVWUXFWLRQ $IVISION $IV $IVISION +D]DUGRXV ORFDWLRQ FODVVL¿FDWLRQV DVVRFLDWHG ZLWK D KRVH QR]]OH ERRW Figure 4-2 Hazardous Zone Area Classifications for Dispensers. 42 Part No.
5 OPERATOR MAINTENANCE 5.1 Preventive Maintenance The safety precautions described in Section 1.3 apply to the following preventive maintenance procedures. A correctly installed dispenser, given proper preventive maintenance attention, will seldom require emergency service. Perform the following checks on a regular basis: • Check the dispenser for internal and external leaks regularly. Check nozzles, swivels, hoses, filters, and joints for leaks and wear. Have all defects repaired immediately.
5.2 Strainer/Filter, continued NOTE: 5.3 • The fuel filter is removed by unscrewing it (the same way an oil filter is removed from a car engine). Place a container under the filter to catch the product and sediment. To install the new filter, first apply a film of oil to the gasket and hand turn until gasket contacts base, then tighten one half turn. Open the emergency shut-off valve(s), turn the electrical power ON and check for leaks.
5.4 Vapor Recovery All hoses, nozzles, breakaways, etc., must be CARB certified for use on Wayne vapor recovery dispensers. 5.4.1 Wayne Vac See the Compliance Testing and Preventative Maintenance manual, p/n 917947. 5.4.2 Balance Tears or rips in the balance nozzle vapor bellows will cause the vapor system to be in non-compliance. Replace or repair the nozzles as necessary. The bellows face-plate (where nozzle seals on vehicle fuel tank) must make a good seal when inserted into the fuel tank.
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APPENDIX A QCAT SELF-TEST PROCEDURE The following are instructions for testing the CAT (Customer Activated Terminal) on the dispenser. 1. QCAT SYSTEM SELF-TEST The following paragraphs provide instructions for testing and setting the address of the QCAT. During the self-test, the system is designed to pause 25 seconds for a response to self-test prompts. When the 25 second time limit expires, the system automatically advances to either the next self-test or returns to the on-line mode. 1.1.
1.2 CAT SELF TEST, continued Step 3 Verify that the Keypad revision level is displayed on the screen. Step 4 Press ENTER to continue. KEYPAD REV __ 1.3. CONFIGURE CARD READER When the system displays the prompt below, proceed as follows: *CONFIGURE CARD READER (Y/N) Answering YES to the prompt causes the screen to display the prompt below or Answering NO to the prompt and the system automatically proceeds to the "Offline msg" prompt.
1.3 Configure Card Reader, continued Offline msg: of Service Out (Y/N) Step 3 Answer NO to the above prompt. Step 4 Answer the following prompts as they appear: Fixed Length Scanner? (Y/N) SOFT KEY PRESENT? (Y/N) This prompt should be set to yes only if the dispenser has softkeys along side the QVGA display. On dispensers without softkeys, answer No to the above prompt, otherwise, the numeric keypad will not work when the dispenser is online.
Self Test? (Y/N) Answering YES to the above prompt will begin the display, printer and card reader self test as discussed on the following pages. Answering NO to the above prompt will display the Exit prompt shown below. Exit Test Mode? (Y/N) Answer YES to the above prompt to exit and return the CAT to normal operation. Answer NO to the above prompt to return to the beginning of the Self Test mode. 50 Part No.
1.4. DISPLAY SELF-TEST A series of actions appear on the screen for the display self-test. Two rows of black squares followed by numbers and letters scroll from right to left across the screen during the display self-test. At the prompt “Press Key”, press each of the Softkeys to verify they are active and installed correctly.
1.6. CARD READER SELF-TEST Any type of valid credit card can be used for the card reader test. The card reader self-test begins with the screen prompt shown below. INSERT CARD Step 1 Insert the card. Once the credit card is inserted into the card reader, the CAT computer reads data from the card. PULL IT OUT Step 2 Remove the credit card in one smooth continuous motion when the above prompt appears on the display screen. A series of digits appear on lines 1 and 2 of the display screen.
1.7. KEYPAD SELF-TEST Testing the CAT keypad requires the operator to select keys on the keypad and verify the information on the display screen. Refer to the Keypad Test table on the following page. Complete the following steps to test the keypad. Step 1 Press a key listed under the column heading Native Mode Key. Step 2 Verify the two digit number on the display screen with the number listed under the column heading Keypad Coordinate.
1.8. SYSTEM MEMORY SELF-TEST A successful memory self-test will display the message below. MEMORY OK An unsuccessful memory self-test will display one of the following: “BIT 0" through “BIT 7". A BIT error message is an indication of a defective board in the CAT system. An example of a BIT error message that may appear on the display screen is shown below. BIT 4 1.9. EXIT SELF-TEST MODE Once the system successfully completes the memory self-test, the exit prompt shown below appears on the screen.
P/O 888525-001 APPENDIX B INSTALLATION DRAWINGS PEDESTAL (USED WHEN ISLAND IS NOT PRESENT) ILLUSTRATION OF SUGGESTED FIELD CONDUIT ENTRY TO JUNCTION BOX USING 3/4x2-1/2” NIPPLE, 3/4” STREET ELL, AND 3/4” CAPPED ELL. SEE INSTALLATION DRAWINGS FOR LOCATION OF CONDUITS. JUNCTION BOX Ovation Dimensional Drawing. 55 February 2006 Part No.
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February 2006 DISTANCE BETWEEN EYE BOLTS: 33.1” 57 Part No. 920559 Rev D P/O DRAWING NO.
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TERMINAL LUG CONNECTIONS, TYP ETHERNET CABLE TO ADS, OPTIONAL 62 Part No. 920559 Rev D To Forecourt Controller Ethernet Hub For VGA Option or Router for IDPOS Terminal Block Connection February 2006 (WIRES NOT USED WITH VGA CATs OPTION. SEE ETHERNET CONNECTION.) INSTALLATION WIRING DIAGRAM - OVATION Part of Drawing No.
February 2006 63 Part No. 920559 Rev D 2-7151-C.
64 Part No. 920559 Rev D February 2006 888686-XXX Rev A.
APPENDIX C LOCAL AUTHORIZE / STAND-ALONE OPERATION When the dispenser is not equipped with a Local Authorize Switch, the jumper (J7) shown below must be in place to enable Stand-alone operation. At new dispenser Startups, after product lines have been purged and dispenser operations checked, once the dispenser is switched over to control system operation, the jumper should be removed as an extra security measure. If stand-alone operation is required in the future, the jumper will have to be re-installed.
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APPENDIX D SITE INTERCONNECTION DIAGRAMS 67 February 2006 Part No.
68 Part No. 920559 Rev C February 2006 Figure D-1 Backroom Installation - Wayne Control System.
February 2006 69 Part No. 920559 Rev C Figure D-2 Interconnection Wiring Diagram - Data Distribution Cabinet To Dispensers.
70 Part No. 920559 Rev C February 2006 Figure D-3 Pump Relay Installation Wiring Diagram.
February 2006 71 Part No. 920559 Rev C Note: Ethernet cable required for VGA option is shown on detailed Installation Wiring Diagram in Appx C. Figure D-4 Interconnection Wiring Diagram - Dispenser Card Processing (CATs) .
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INSTALLATION & OPERATION MANUAL Ovation Series Dispensers Written by S. G. Martin This manual was produced on a PC using Adobe® FrameMaker® and Photoshop® Page design uses Times New Roman and Arial Fonts Manuals were electronically printed on a Xerox Docutech Publishing System Copyright © 2006 Dresser, Inc. All rights reserved. Printed in the United States of America. Adobe® FrameMaker® and Photoshop® are trademarks of Adobe Systems, Inc.
NOTE: “This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
