Autogas dispensers Installation and Operation Manual Manual: Dispenser installation and operation Manual Manual code: DIOM-09-e Number of pages: 40 Issue date: December 23, 2005 Review number: 4 Last review date: 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 4

1.1 Applied standards and regulations 4 1.2 Accuracy requirements 4 1.3 Safety precautions 5 1.4 Required tools 6 1.5 UPS system 6

2.0 Installation 7

2.1 Hazardous zones 7 2.2 Island construction, dispenser anchoring and piping 9 2.3 Hose installation 10 2.4 Dispenser tightness test 10 2.5 Electrical wiring 11

2.5.1 Cable glands 11 2.5.2 Maser Automation – RegiSmart registers 11

2.6 Functionality test 12 2.6.1 Totalizer readings 12 2.6.2 Preset 13 2.6.3 Non-volatile memory check 13 2.6.4 Emergency shut-down system (ESD) 13 2.6.5 Flow interruption 13

3.0 Operation 14

3.1 Before operating the dispenser 14 3.2 Standard operation 14

3.2.1 Operating the dispenser without preset 14 3.2.2 Operating the dispenser with preset 14

3.3 Restarting after power failure 14 3.4 Setting and changing the unit prices 15 3.5 Error messages 16 3.6 Programming the ATC controller 17

4.0 General maintenance 18 4.1 General safety considerations 18 4.2 Preventive maintenance and care 18 4.3 Filter 18 4.4 Calibration and meter maintenance 19

Appendix A: Installation wiring diagram 20 Appendix B: Maser Automation head configuration 22 Appendix C: Dispenser troubleshooting 23 Appendix D: DOs and DON’Ts 26 Appendix E: Engineering drawings 28

LPG station safety distances according to TS11939 29 H-style footprint 31 H-style sample foundation 32 I-style footprint 33 I-style sample foundation 34 1-nozzle with preset – wiring diagram 35 1-nozzle with preset and ATC – wiring diagram 36 2-nozzle with preset – wiring diagram 37 2-nozzle with preset and ATC – wiring diagram 38 Dispenser connection diagram 39

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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

A flammable atmosphere is constantly or for a longer period of time present

Definition: > 1000 hours per year Where: inside the hydraulic system

Zone 1

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

Zone 2

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

Non hazardous zone

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 non-hazardous 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 electro-mechanical 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 reset sequence starts now. The display resets itself. 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. Turn the dispenser ‘off’ or release the dead man’s button.

2.6.3 Non-volatile memory check 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. The dispenser circulates LPG through the vapor return line back to the tank. Observe the

transaction on the display(s). During the transaction terminate the main power to the dispenser. The solenoid valves close and the delivery stops immediately. Turn the dispenser ‘off’ or release the dead man’s button. 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) 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. The dispenser circulates LPG through the vapor return line back to the tank. Observe the

transaction on the display(s). During the transaction press the ESD button. The solenoid valves close and the delivery stops immediately. Turn the dispenser ‘off’ or release the dead man’s button. The display shows an error code (E00) and the last transaction.

2.6.5 Flow interruption 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. The dispenser circulates LPG through the vapor return line back to the tank. Observe the

transaction on the display(s). 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. Turn the dispenser ‘off’ or release the dead man’s button.

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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 stand-alone 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. The reset sequence starts now. The display resets itself. Turn the dispenser ‘off’ or release 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. The reset sequence starts now. The display resets itself. 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.

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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.

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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.

Description: Connector Disabled yes / no E51 Communication problem with master display 1 M1 NO E52 Communication problem with slave display 2 S2 NO E53 Communication problem with master display 2 M2 NO E54 Communication problem with slave display 1 S1 NO E58 Communication problem with preset 1 CN1 YES E59 Communication problem with preset 2 CN7 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.

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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.

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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.

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Appendix A – Installation wiring diagram

1-NOZZLE DISPENSER JUNCTION BOX

Description 1 Phase (220 V) 18 Phase (220 V) 2 Neutral 19 Neutral 3 Signal (220 V) 20 Low flow solenoid1 Phase (24V) 4 Emergency Stop Phase (220 V) 21 Low flow solenoid1 Neutral 5 Emergency Stop Neutral (220 V) 22 Solenoid Grounding 6 Dispenser Light Phase 23 Solenoid Grounding 7 Dispenser Light Neutral 24 Not in use 8 Not in use 25 Not in use 9 Not in use 26 Not in use 10 Not in use 27 Not in use 11 Not in use 28 Not in use 12 High flow solenoid1 Phase (24V) 29 Not in use 13 High flow solenoid1 Neutral 30 Not in use 14 Relay1 Phase (220V) 31 Not in use 15 Not in use 32 Not in use 16 Not in use 33 Not in use 17 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

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Appendix A – Installation wiring diagram

2-NOZZLE DISPENSER JUNCTION BOX

Description 1 Phase (220 V) 18 Phase (220 V) 2 Neutral 19 Neutral 3 Signal (220 V) 20 Low flow solenoid1 Phase (24V) 4 Emergency Stop Phase (220 V) 21 Low flow solenoid1 Neutral 5 Emergency Stop Neutral (220 V) 22 Relay2 Phase (220V) 6 Dispenser Light Phase 23 Not in use 7 Dispenser Light Neutral 24 Not in use 8 Not in use 25 Not in use 9 Not in use 26 Phase (220 VAC) 10 High flow solenoid1 Phase (24V) 27 Neutral 11 High flow solenoid1 Neutral 28 Low flow solenoid1 Phase (24V) 12 High flow solenoid2 Phase (24V) 29 Low flow solenoid1 Neutral 13 High flow solenoid1 Neutral 30 Solenoid Grounding 14 Relay1 Phase (220V) 31 Solenoid Grounding 15 Not in use 32 Solenoid Grounding 16 Not in use 33 Solenoid Grounding 17 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

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Appendix B – Maser Automation head configuration Electronic register 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 RegiSmart-ST

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 M20552 (with totalizer) REL 1.29 RegiSmart-EX

Double side M30232 Double side M20179 REL 7.67 REL 8.07 M20553 (without totalizer) REL 1.29

Single side M30176F Single side M20569/P REL 7.60.7 REL 7.61 M21071 (with totalizer) REL 1.28 INDO RegiSmart-Plus

Double side M30174F Double side M20179/P REL 7.60.7 REL 7.61 M21031 (without totalizer) 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.

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Appendix C – Dispenser troubleshooting

Nr Type of failure Probable cause What to check? How to correct? 1. Power loss 1. Check power supply 1. Restore power 2. Capacitor is discharged 2. Energize the dispenser for some time 3. Damaged display card 3. Replace display card 4. Electronics card is damaged 4. Replace electronics card

1 Error code E00

5. ESD button has been pressed, but not released 5. Check ESD button 5. Open ESD button or replace button

1. Fluctuations in power supply 1. Check power supply and pulser connections 1. Restore power and connections 2 Error code E03 2. Pulser failure 2. Check pulser 2. Replace pulser

1. Pulser signals are in conflict 3 Error code E04 2. One pulser channel does not send signals to the head

Check pulser and pulser connections Restore connections or replace pulser

1. Activate and de-activate the dispenser 4 Error code E05 1. Failure in display(s) 1. Check displays and display cable 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 3. Replace display 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. Check the fuse on the electronics card 2. Check the electronics card 3. Check the coil 4. Check switches 5. Check motor and refer to manufacturer’s handbook 6. Check pneumatic valves and nitrogen bottle 7. Check relay in the site controller 8. Check thermal protection relay in the site controller

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 2. Replace display card

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

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Appendix C – Dispenser troubleshooting continued

Nr Type of failure Probable cause What to check? How to correct? 1. Program key (Pr) or increase key (In) may be jammed 1. Check Pr and In buttons 1. Press buttons again to release 10 Unit price flashes continuously 2. Cover of electronic head may be damaged 2. Check cover for damage 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

1. Parameters at electronic card may be programmed

incorrectly 12 Dispenser does not terminate delivery at preset value 2. Solenoid valve may leak

3. Diaphragm of differential valve may be damaged

1. Check parameters 2. Check solenoid valve 3. Check differential valve

1. Correct parameters. Consult with Yenen if needed

2. Clean or replace solenoid valve 3. Replace diaphragm

1. Replace pulser

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

2. Restore pulser to flow meter connection 3. Repair flow meter

14 Displays continues registering while the nozzle is disconnected

1. Diaphragm of differential valve may be damaged 2. Parameters at electronic card may programmed

incorrectly 3. Electronic card may be damaged 4. Pulser may be damaged

1. Check differential valve 2. Check parameters 3. Electronic card 4. Check pulser

1. Replace diaphragm 2. Correct parameters. Consult with Yenen

if needed 3. Replace electronic card 4. Replace nozzle

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

1. Check pump 2. Check power supply 3. Check site controller 4. Check for leaks

1. Follow manufacturer’s guidelines 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

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Appendix C – Dispenser troubleshooting continued

Nr Type of failure Probable cause What to check? How to correct?

17 Dispenser flow rate is low

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 5. Diaphragm of differential valve may be damaged 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

1. Check filter 2. Check solenoid valve 3. Check pressure gauge at the pump 4. Check rotation direction of the submersible pump 5. Check differential valve 6. Check break-away coupling 7. Check nozzle 8. Check if pulser shaft can rotate freely

1. Replace filter 2. Clean or replace solenoid valve 3. Follow manufacturer’s guidelines 4. Change phases of the pump 5. Replace diaphragm 6. Clean or replace break-away coupling 7. Replace nozzle 8. Untie bolt at pulser table

18 No delivery

1. Break-away and nozzle may be jammed or blocked 2. Valve inside the nozzle may be damaged 3. Solenoid valve may not open 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

1. Replace break-away and or nozzle 2. Replace nozzle 3. Clean or replace solenoid valve 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

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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.

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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.

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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 2-nozzle with preset – wiring diagram 2-nozzle with preset and ATC – wiring diagram Dispenser connection diagram

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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 (underground) Table 1 Table 1 5 5 5 Table 1 Table 1 40 Table 1

LPG tank (above ground) Table 1 Table 1 7.5 7.5 7.5 Table 1 Table 1 50 Table 1

Petrol dispenser 5 7.5 6 - 5 5 5 50 5

LPG Dispenser 5 7.5 - 6 - - - - - Building Table 1 Table 1 - 5 - - - - - Road Table 1 Table 1 - 5 - - - - - Significant buildings3 40 50 - 50 - - - - -

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.

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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.

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H-style footprint

32

H-style sample foundation

33

I-style footprint

34

I-style sample foundation

35

1-nozzle with preset – wiring diagram

36

1-nozzle with preset and ATC – wiring diagram

To disable the ATC controller bridge terminal 34 and 35

37

2-nozzle with preset – wiring diagram

38

2-nozzle with preset and ATC – wiring diagram

To disable the ATC controller bridge terminal 34 and 35

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Dispenser connection diagram

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