Omni Series™Nozzles for Active Vapour Recovery Systems

Installation, Operation, and Maintenance Manual

English .....................................................2

EN 13012TÜV P-TÜ7-00310

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Product OverviewOMNI Series™ vapour recovery nozzles operate with normal liquid product operating pressures from 0.5 bar to 3.5 bar and will open automatically when liquid product pressures exceeding 6.0 bar are applied to the nozzle inlet.

OMNI Series™ vapour recovery nozzles are designed to be compatible with liquid product consisting of gasoline fuels with up to 15% ethanol concentration, with liquid flow rates up to 50 liters per minute maximum, and with -30 ºC to +55 ºC operating temperatures.

OMNI Series™ vapour recovery nozzles are designed with the following standard features (item numbers refer to Figure 1):

1. The OMNI Series™ (OS) Vapour Recovery (V) nozzle can be used in numerous dispenser configurations to meet Stage II vapour recovery applications. There are two different vapour path options available:

• An open path with no vapour valve (Model OS-VO) is typically used with external vapour proportioning devices, such as solenoids in the vapour path.

• A check valve acting as an on / off vapour valve (Model OS-VC) is typically used with external vapour proportioning devices such as variable speed vapour pumps without solenoids or check valves in the vapour path.

2. The nozzle has an automatic Pressure Sensing Feature which requires liquid product pressure to be present at the main valve in order to engage liquid product flow. Once pressure is present, the main valve opens with liquid product flow and closes against liquid product flow to allow for easier customer dispensing.

3. The nozzle will also automatically shut off due to the Over-Horizontal Shutoff if the spout is pointed upwards beyond a normal fueling position.

4. The Stainless Steel Spout Tip provides strength to the end of the spout for protection of the full tank shutoff port and long service life.

5. When fuel reaches the Full Tank Shutoff Port at the spout tip, the main valve will be automatically closed.

6. The Hold Open Latch is integral to the lever assembly for flow control in two positions and can be disabled by removing the metal Clip from the Hand Guard when unattended lever operation is not permitted.

7. The Coaxial Inlet contains a fine inlet strainer and mates with M 34 x 1.5 threaded active vapour recovery hoses.

Figure 1: Nozzle Features

1 – Vapour Path Options

6 - Hold Open Latch

7 - Coaxial Inlet

2 — Pressure Sensing Feature

5 - Full Tank Shutoff Port

4 - Stainless Steel Spout Tip

3 - Over-Horizontal Shutoff

Hand Guard

Lever

Clip

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Model Designation

Date Sequence Number

Warning

Warning

Warning

Warning

Warning

Important Safety Messages Gasoline is flammable, explosive and harmful if spilled, ingested or inhaled. Failure to comply with the guidelines below could result in property damage, injury or death.

• For your protection, read these safety instructions completely before installing the equipment.

• Keep this manual on file for future use by all employees and / or customers. This manual contains material that may be required to be on-site at all times

• Carefully observe all warnings, precautions and instructions for this equipment in the operating instructions and adhere to them.

• Follow all applicable regulations that govern the installation, service and testing of this equipment.

• Always secure the work area from moving vehicles. This equipment is installed on dispensers, which puts service personnel in danger of moving vehicles in the work area. Secure the area by using a service truck to block access to the work environment, or by using any other reasonable means available to ensure the safety of service personnel while installing, servicing, or testing this equipment.

Fire Hazard

• Do not smoke or allow open flame or spark-producing devices near product dispensers.

• Turn off engine while fueling. Vehicle must remain off during the entire fueling event.

• If a fire starts, do NOT remove the nozzle. If safely possible, deactivate dispenser by pressing Emergency Stop button on dispenser. Back away and notify station attendant.

Static Electricity Discharge Danger

• Ground yourself by touching metal on your car or the dispenser before removing nozzle.

• Do not re-enter the vehicle during refueling as this can re-charge your body with static electricity.

Filling Container Cautions

• Do not fill containers in or on the vehicle: place container on the ground to eliminate static.

• Keep nozzle in contact with container while filling to discharge any static generated.

• Flow gas slowly when dispensing into a container to prevent static buildup.

• Do not use hold-open latch when filling a container.• Use only approved containers.

Prevent Spillage

• Do not leave nozzle unattended.• Do not prop handle open with any objects (Only use the

nozzle’s hold-open latch).• Avoid skin or eye contact with gasoline.• Ventilate any spill area: Gasoline vapours can be

harmful: Avoid breathing vapours.• Do not attempt to top off the vehicle tank.• Keep children away from the fueling operation.

Nozzle Installation1. Before installing the OMNI Series™ vapour recovery

nozzle, confirm the dispenser is powered off to avoid accidental dispensing of liquid product and relieve pressure from within the hose.

Note: Prior to nozzle installation, visually inspect the nozzle for damage, missing parts, or incorrect model. Nozzle model can be identified by the markings on the nozzle body. If the nozzle has any of these problems, contact your distributor to address the problems properly.

2. Before installing the nozzle, lubricate any mating O-rings on the end of the sight-glass, breakaway or hose with motor oil (any grade). DO NOT USE THREAD SEALANT including “pipe dope”, Teflon® tape or other sealant.

3. Thread the nozzle onto the sight glass, breakaway, or hose (based on the application) by turning it clockwise until hand tight. Make sure to not cross thread while tightening. Use a torque wrench to tighten to 48-95 Newton meters (35-70 foot pounds) of torque. DO NOT over-tighten.

4. Re-apply power to the dispenser. Activate the fueling point and dispense fuel into an approved container until any air is purged from the serviced hanging hardware. After purging, examine the hanging hardware for any leaks. If leaks are present, power off the dispenser and correct the leaks immediately.

Model Identification

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Startup TestingAfter confirming that no leaks are present, test the nozzle for proper operation.

1. Flow rate testConfirm that liquid product flow rate is within 15 to 50 liters per minute operating range. High flow rates in excess of this operating window may result in splash-back or spillage. Damage and/or injury may result.

a. Start a stopwatch and initiate flow into an approved container, with the nozzle lever held in the full open position.

b. Check the flow rate with the nozzle in the low flow clip position.

c. Confirm that with the lever at full open position the flow rate does not exceed 50 liters per minute. With the lever at the low flow clip position, confirm that the flow rate is not below 15 liters per minute.

d. If the nozzle does not comply, check the system and repair prior to putting the fueling point into service.

e. For jurisdictions where hold-open latches are not allowed, test the nozzle at the full open position only.

2. Shut off testConfirm the full tank shutoff operation works properly by dispensing into an approved container. Once liquid product reaches the full tank shutoff port, liquid product flow should stop immediately.

a. Initiate flow into an approved container, with the nozzle lever held in the full open position.

b. Once the container has at least 6 cm of fluid immerse the spout tip into the fluid.

c. The nozzle must shut off within one second of immersion.

d. Repeat this procedure for all hold open latch positions a minimum of five times.

e. For jurisdictions where hold-open latches are not allowed, test the nozzle at the full open position only.

3. Pressure Sensing Feature TestConfirm that the pressure sensing feature is working properly. The nozzle should not dispense fluid if the lever is actuated before liquid pressure is applied to the nozzle.

a. Place spout in approved container. b. Actuate the lever with no liquid pressure applied

to the nozzle i.e. the pump is not on.c. With the lever still actuated, turn on the pump and

confirm that the nozzle does not start dispensing.d. Disengage the lever, then engage the lever

confirming that the nozzle then starts dispensing.

4. Vapour Recovery TestConfirm the vapour recovery rate is in the acceptable range by performing either a wet or dry test described in the “Nozzle Vapour Recovery Testing” section of this manual.

Nozzle Operating Instructions1. Insert the spout into the fill neck of the vehicle.2. Lower the hose end of the nozzle so the spout

engages the fill neck.3. Pull up on the lever and begin fueling.4. Nozzle will shut off automatically when the tank is full. Wait

10 seconds to allow any gasoline remaining in the spout to drain before removing the nozzle from the fill neck.

5. Return the nozzle to the dispenser mount.Nozzle MaintenanceDaily:• Check for leaks / stains• Check for loose spouts• Check for damage• Check for bent lever• Check for broken hold open latchMonthly:• Verify function of the pressure sensing feature• Check nozzle auto shutoff • Verify that product flow rate is between 15 - 50 LPMAnnually:• Perform all startup testingAdditionally, perform all applicable testing / inspections that relate to this equipment.

If any issues are found during nozzle maintenance or testing, use only OMNI Series™ vapour recovery nozzle field repair parts to correct issues before putting the fueling point back into service.

Note: Never reuse elastomers (i.e. O-rings) when replacing components.

Troubleshooting GuideProblem Solution

Nozzle will not dispense liquid product

Pressure sensing feature is standard on all OMNI Series™ vapour recovery nozzles. Ensure that a minimum of 0.5 bar liquid product pressure is being provided to the nozzle.

Nozzle clicks off after attempt to dispense liquid product

Full Tank Shutoff Port and Over-Horizontal Shutoff are standard features on all OMNI Series™ vapour recovery nozzles. Ensure that Full Tank Shutoff Port is not blocked. Ensure that nozzle is anchored in fill-pipe so that spout is pointed below horizontal.

Nozzle has delayed activation of Full Tank or Over-Horizontal Shutoff

Activation of automatic shutoffs is triggered by means of an internal venturi vacuum source. Ensure liquid product flow rates are greater than 8 liters per minute for proper internal venturi vacuum levels and automatic shutoff operations.

For other issues, contact Franklin Fueling Systems for assistance.

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CAUTION

Nozzle Vapour Recovery TestingPerform nozzle testing per applicable regulations and equipment manufacturer instructions.

Note: When performing nozzle testing, measurement uncertainty can be decreased with a mean value of multiple test results.

Dry Test 1. Confirm dispenser is powered off to avoid accidental

dispensing of liquid product.2. Connect the signal cable of the gas meter to the

handheld control and connect the hose from the spout adaptor to the gas meter (refer to Figure 2 for connections).

DispenserElectronics

HandheldController

Gas Meter

Approved Container

Figure 2: Dry Test Setup3. Power on the handheld simulator. Enter the correction

factor and simulated liquid product flow from the vapour recovery certificate, as applicable.

4. Connect the spout adaptor to the OMNI Series™ vapour recovery nozzle. Over an approved container, engage the nozzle lever fully and hold it open throughout simulation.

Do not release the nozzle handle at any time during testing or the nozzle will re-engage allowing the liquid product path to open and dispense.

5. Energize the dispenser and begin the simulation of petrol flow on the handheld control.

6. After simulation is completed, calculate the vapour recovery rate as follows (if not automatically provided by the handheld):

R = AL K*

*100

R = vapour recovery rate, in %A = measured volumetric air flow during the

measurement, in liters per minuteL = simulated volumetric liquid product flow by the

handheld control, in liters per minute.K = correction factor (as specified in the certificate if

not automatically adjusted by the handheld)

Wet Test1. Confirm dispenser is powered off to avoid accidental

dispensing of liquid product.2. Connect the spout adaptor to the OMNI Series™

vapour recovery nozzle and connect the hose from the spout adaptor to the gas meter (refer to Figure 3 for connections).

Gas Meter

Approved Container

Figure 3: Wet Test Setup3. Energize the dispenser and dispense a minimum of

15 liters of liquid product into an approved container while recording the start and end volumes required to calculate the vapour recover rate as outlined in the following equation:

R =

(Le - Ls) K** 100Ae -As

R = vapour recovery rate, in %

A e = ending air volume from gas meter, in liters

A s = starting air volume from gas meter, in liters

K = correction factor (as specified in the certificate)

Le = ending liquid product volume on dispenser, in liters

Ls = starting liquid product volume on dispenser, in liters

©2010 FFS 405321001 Rev 1