Autogas Dispensers

Installation and Operation Handbook

Document Name : Autogas Dispensers Installation and Operation Handbook

Document Code : DIS-14-te
Number of Page : 45
Issue Date : 14.04.2006
Revision No :4
Last Revision Date : 19.10.2018
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READ THIS HANDBOOK BEFORE INSTALLING YENEN LPG DISPENSERS

Dispensers are powered by electrical energy and contain dangerous, inflammable and potentially
explosive liquid. Failure to observe the precautions and warning instructions given in this handbook
may cause serious accidents. Observe all rules, codes and laws applicable in your area and your
installation.

SAFETY PRECAUTIONS – INSTALLATION AND MAINTENANCE

ALWAYS disconnect the power supply before opening dispenser cabinet for maintenance. Ensure that
the valves under the dispenser are closed BEFORE commencing maintenance.

Make sure that you know how to disconnect power input to the dispenser and pump, in case of an
emergency. Have all leaks and faults repaired immediately.

Contact Yenen
Any problem relevant to the installation and operation of the Dispenser should be notified to an
authorized Yenen Service Partner or Yenen Technical Support Department. (+90 216 487 5924).

Explanation of Symbols

Notice: indicates a special comment or instruction.

Warning: Indicates a hazard, which may cause serious personal injury damage to
property if not observed cautiously.

This handbook provides instructions and rules. Remarks and warnings inform the operator about the
dangers relevant to the installation and operation of LPG Dispensers. Reading these instructions and thus
preventing possible dangerous events is absolutely in the operator’s power. Any omission of this
responsibility is beyond Yenen’s control.

 No part of Yenen handbooks may be reproduced, issued, copied and changed in any way and form without Yenen’s prior
written consent.
 Yenen reserves the right to change the specifications of the products mentioned in this handbook at any time and without
prior notice.
 Yenen may not be held liable for any damage arising from the use of this product.
 Although every effort to make sure that the information in this handbook has been made, Yenen may not be held
responsible for any error in the content or incidental and consequential damages resulting from the use of this handbook
 Yenen Engineering logo(s) are property of Yenen Engineering..
 Yenen Engineering is ISO9001:2008 certified. If you request a copy of Yenen Quality Policy and/or Yenen HSE Policy,
please, visit www.yenen.com or send an e-mail to info@yenen.com or fax your request to +90 (216) 487 5986.
Page 3 of 45 19.10.2018 DIS-14-te Rev Nr:4

Table of Contents
Page

1.0 About this handbook ................................................................................................................ 4

1.1 Applied Standards and Codes ................................................................................................. 5
1.2 Accuracy Requirements ........................................................................................................... 5
1.3 Safety Precautions ................................................................................................................... 5
1.4 Required Tools for Installation ................................................................................................. 6
2.0 Installation ................................................................................................................................ 7
2.1 Dangerous Zones ..................................................................................................................... 7
2.2 Dispenser island construction, dispenser anchoring and piping .............................................. 9
2.3 Hose Connection .................................................................................................................... 10
2.4 Dispenser Sealing Test .......................................................................................................... 10
2.5 Electrical Connection ............................................................................................................. 11
2.6 Function Test ......................................................................................................................... 12
2.6.1 Preset ..................................................................................................................................... 13
2.6.2 Non-volatile memory check. ................................................................................................... 13
2.6.3 Emergency Shut-down System (ESS) ................................................................................... 13
2.6.4 Flow Interruption .................................................................................................................... 13
3.0 Operation................................................................................................................................ 14
3.1 Before Commissioning the Dispenser .................................................................................... 14
3.2 Programming the ATC System .............................................................................................. 14
4.0 Rules to consider during transportation and shipping ............................................................ 14
5.0 General Maintenance ............................................................................................................. 15
5.1 General Safety Precautions ................................................................................................... 15
5.2 Preventive Maintenance ......................................................................................................... 15
5.3 Filter ....................................................................................................................................... 15
5.4 Calibration and Counter Maintenance ................................................................................... 16
5.5 Electronic Calibration ............................................................................................................. 16
6.0 S4S Electronics ...................................................................................................................... 17
6.1 Keypad Information Display ................................................................................................... 18
6.2 Display Connections and Address Settings ........................................................................... 20
6.3 Technical Features ................................................................................................................. 21
6.4 Emergency Stop Operation .................................................................................................... 22
6.5 Password Entry ...................................................................................................................... 22
6.5.1 Administrator Menu Entry....................................................................................................... 22
6.5.2 Service Menu Entry ................................................................................................................ 22
6.6 Sales Programming (Preset ) Operation ................................................................................ 23
6.7 Programming with Preset Button ........................................................................................... 23
6.8 Amount, Liter and Sales Totals .............................................................................................. 24
6.9 Previous Sales ....................................................................................................................... 24
6.10 Flowrate Indicator ................................................................................................................... 24
6.11 ATC Temperature .................................................................................................................. 25
6.12 Printer ..................................................................................................................................... 25
6.13 Information ............................................................................................................................. 26
6.14 Error Codes ............................................................................................................................ 26
6.15 Shift Totals ............................................................................................................................. 27
6.16 Price Units .............................................................................................................................. 27
6.17 Previous Prices ...................................................................................................................... 28
6.18 Protocols ................................................................................................................................ 28
6.19 Time / Date Setup .................................................................................................................. 29
6.20 Password Change .................................................................................................................. 29
6.21 Default Settings ...................................................................................................................... 30
6.22 Errors Messages and Codes.................................................................................................. 31
6.23 Errors Messages and Codes - Additional .............................................................................. 32

Appendix A – Cable Connection Diagram ............................................................................................. 33

Appendix B – Failure Guide................................................................................................................... 37
Appendix C – DOs and DON’Ts ............................................................................................................ 42
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1.0 About this handbook

This handbook describes the installation and operation of Yenen autogas (LPG) dispensers. For the
installation and operation of the employed electronic systems refer to the operation guides of the
relevant systems.

For any questions relevant to the installation and operation of the dispenser that are not covered in
this handbook, please contact Yenen through info@yenen.com or call +90 216 487 5924.
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1.1 Applied Standards and Codes

Yenen dispenser is a component of autogas filling system. All parts such as tanks, pumps, pipes and
fittings, anti-corrosion devices, cables (electrical and electronic), control system, etc. should be
furnished in compliance with the instructions of manufacturers and international and regional
standards. Yenen has no obligation to follow above-mentioned standards and codes or modify
products pursuant to the amendments made to those codes.

Yenen autogas dispensers may be used with Liquid Petroleum Gas (LPG) that is compliant with
TS11939, EN 14678-1 and EN 589.

1.2 Accuracy Requirements

Yenen dispensers comply with the OIML R117 directive, which specifies following LPG dispensers:
Accuracy Class: 1.0
General Accuracy: %1

1.3 Safety Precautions

Only qualified staff, which obtained training for the liquids operating under pressure
such as LPG may service Yenen equipment.

ALWAYS disconnect the power supply before commencing maintenance. There may
more than one latch to disconnect. Use a multimeter to make sure that all circuits in
the dispenser are closed. Failure to take this precaution may cause personal injury.

Ensure that all valves are closed. It may be required to close more than one valve to
lock the system. To make sure that ALL valves are closed, review the station piping
diagram. Failure to take this precaution may cause personal injury.

Keep all vehicle and unauthorized staff at least 6 meters away from the dispenser.

 Make sure that all required safety precautions have been taken. Make sure that all required
ventilation, fire protection, evacuation and fire procedures are provided.
 Make sure that all fire extinguishing tools are easy to reach. Obtain comprehensive knowledge
about all safety regulations.
 Read this handbook and all available literature and drawings.
 Yenen recommends you to employ a qualified mechanical and electrical technician. As an
explosive liquid is being handled, it is compulsory to make sure that all safety precautions are
completely taken at any time.
 Read DOs and DON’T’s in the appendix.
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In case of a gas leakage:

1. Shut the leakage by closing closest valve or pushing the shut-down button.
2. Use protective gloves to avoid cold burns.
3. Avoid using fire or any igniting tools around the dispenser.
4. Beware that LPG is heavier than air and therefore settles lower.
5. Evacuate everyone off the danger zone.
6. Make sure that the area is safe for operation. If in doubt, inform the fire department thereof.

In case of gas flare;

1. Shut the leakage if its location is safe to reach.
2. If it is a flare that cannot be controlled safely, contact fire department.
3. If it is a small, controllable ignition, use a proper extinguisher. If in doubt, inform the fire
department.

1.4 Required Tools for Installation

 5mm Allen screwdriver
 Standard screwdriver kit
 Pincers
 Voltage tester screwdriver
 13mm monkey wrench
 17mm monkey wrench
 19mm monkey wrench
 Side cutter (to cut cables)
 2 adjustable wrenches
 Philips screwdriver
 Curved knife (to open packaging)
 M12 (10.9) bolt and nut
 Cleaning cloth
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2.0 Installation
Examine the dispenser immediately upon delivery to make certain that no damage has been occurred.
Damaged or lost equipment should be informed to the carrier. Any damage or loss, which may occur
during shipping, is not covered under warranty.

Make sure that all components like switches and any optional equipment are present. Check invoice,
bill of lading and any similar document relevant to the purchase order and save a copy of them.

2.1 Dangerous Zones

Review relevant codes, standards and regulations first.
Figure 2.1 shows dangerous zones in accordance with European CEN regulations.

Constant or long-term presence of an inflammable and explosive

Zone 0 atmosphere.
>1000 hours/year
Where: In the hydraulic system, in the pipe, meter and control devices.

Where inflammable and explosive atmosphere is high under normal

Zone 1 working conditions.
=10 – 1000 hours/year
Where: Left and right casing columns and around the hydraulic system

Where inflammable and explosive atmosphere is seen rarely or for a short-

Zone 2 term under normal working conditions.
< 10 hours/year
Where: All around the dispenser casing and 1 meter above the casing

Where inflammable and explosive atmosphere is non-existent.

Non-dangerous zone
Where: Inside of the electronic system
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Figure 2.1 Dangerous Zone Diagram

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2.2 Dispenser island construction, dispenser anchoring and piping

Take necessary safety actions at the work site. Consider the safety precautions
stated in the article 1.3 and DOs and DON’Ts in Appendix C.

Disconnect and anchor.

More than one switch may be utilized to disconnect power supply. Use a multimeter
to make sure that all the circuits in the dispenser are closed. Failure to take these
precautions may result in personal injury.

Be sure that all valves are closed.

More than one switch may be required to be closed to shut the system down. Refer
to station piping drawings to make sure that all valves are closed. Failure to take
these precautions may result in personal injury.

 A chassis is required for the dispenser.

Do not pour concrete around the liquid inlet and steam return lines or electrical conduits.
Instead, it is recommended to use sand or sandbags to prevent steam build-up under the
dispenser.

 Unlatch and remove cap locks to reach the bottom section of the dispenser. Place the caps in a
place where they would not be damaged.

 There are bolt holes on the bottom of the dispenser from anchoring it to the chassis. Tightly mount
the dispenser to the island.
.
 Remove the plastic caps located on the liquid inlet and steam return line. There may be some test
liquid left in the dispenser and may pour out from one of the pipes.

 Connect the liquid and steam return lines. Use flexible pipes in the connection of dispenser and
underground pipe tips in order to allow ground movement. Underground piping (steam return and
liquid lines) should be at least 1”.

Make sure that all connections are leak-proof when making pipe connections.

Use a liquid sealant compound, such as Loxeal 58.11 or other similar liquid compounds
(liquid sealant) that is used for LPG applications on male threads only. Be careful not to
let compound to leak into the fittings.
.
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2.3 Hose Connection

 For an accurate connection, clean all threads and use a liquid sealant (liquid washer).

Make sure that all connections are tight and leak-proof when making pipe connections.

Use a liquid sealant compound, such as Loxeal 58.11 or other similar liquid compounds
(liquid sealant) that is used for LPG applications on male threads only. Be careful not to
let compound to leak into the fittings.

 Connect hose assembly to the dispenser outlet and hose hooks to the side doors. If the dispenser
has a pipe retraction system, refer to the instructions for the connection as
well.

 Connect the steel rope of the safety cable of the break-away coupling to
the dispenser frame. It is designed so that LPG is present on both sides of
the point, where break-away is located and it should be connected to each
hose. Only a couple cubic centimeters of LPG escape during removal.

 Check the electrical continuity on the hose/nozzle connection. There

should be no continuity between the dispenser outlet and the nozzle to
prevent static discharge during filling. In order to make sure that the
nozzle is grounded, each hose assembly should be checked.

 Connect crocodile clips to the dispenser chassis.

2.4 Dispenser Sealing Test

After completing the steps in the sections 2.2 and 2.3, the dispenser
connections should be checked for leakages.

 Slowly open the valves on the tank section.

 Slowly open steam return line and liquid line (V1) valves (See. Figure
2.2.)
 Open the valve between the filter and gas separator (V2) (See. Figure
2.2)
 Check all connections with lather for leakages.
 In case of a leakage, close all valves, repair the leakage and check
again.
 When all connections are tightened, close all valves and continue with
electrical connection. (Section 2.5).

The above steps are just guidelines. Consider standards and

regulations for legal tests.

Figure 2.2
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2.5 Electrical Connection

All dispensers and electrical connection boxes should be grounded.

ALWAYS make sure that the power supply is disconnected and locked before
commencing maintenance of the dispenser. There may be more than one button to
disconnect the power supply. Use a multimeter to make sure that ALL circuits of the
dispenser are closed. Failure to take these precautions may cause personal injury.

Electrical specifications:

a. Voltage: 220 Volts AC (180 – 250 Volts AC)

b. Frequency: 50Hz or 60Hz
c. Energy consumption: <40 Watt (in maximum configuration)

A stable power supply is required for the operation of the electrical components within the
dispenser. Precautions should be taken thereof, where a stable and constant power
supply is not available.

 Review the location of the dispenser junction box.

 For full service and stand-alone operation, make electrical installation in accordance with the
electrical connection scheme in the Appendix A.

 A display lighting circuit that is connected to the power control circuit at the terminal adjustment
strip in the dispenser junction box is delivered along with the dispenser. The display lighting may
be connected to a separate circuit breaker or switch via those terminals. Jumping these terminals
shall keep display light activated permanently – see. Appendix A.

 In addition to the connections required for stand-alone operation, the dispenser may be connected
to a remote host or POS system.

 If optional data cables are required for future use, those should not be connected to the data
terminals in the junction box. Instead, separate glands should be used for each of them.

 Do not connect the connections of the equipment irrelevant to the dispenser to the dispenser
wiring circuit. Those cables should be connected to another circuit.

 Connect the dispenser to a grounding line in order to dissipate charge.

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2.6 Function Test

Before applying power to the dispenser, double-check the connections to make sure that
the wires are connected and polarized correctly. See Section 3.

Commissioning procedures specified in this section should be performed sequentially for

correct operation of the new installations.

Before dispensing any product, make sure that above-ground pumps are commissioned.
– Refer to the manufacturer’s handbook thereof.

 Turn on the dispenser power control circuit breaker, lighting circuit breaker, if connected, and
pump engine circuit breaker. Make sure that the dispenser is started-up. Dispenser displays shall
show a couple test messages and usually the last sale in the factory tests.

If the dispenser has not been powered or used for a while, an error message like “no electricity”
shall be shown due to discharged condensers. Wait for a while until the condensers are charged.

 Remove the plug from the nozzle tip.

 Connect the nozzle to the filler inlet on the
dispenser casing.
 Open the globe valve under the inlet.
 Switch the dispenser “on” with the “on/off” switch.
 Now the reset sequence shall start. Display shall
reset itself.
 Observe that the solenoid valve opens – hear the
click sound of the valves.
 The dispenser shall circulate LPG back into the
tank through the steam return line. Observe the
process on the display(s).
 Before continuing, make sure that sufficient LPG is
circulated to ensure that all the air in the dispenser
and lines is completely disposed.
 Switch the dispenser “off”.
 Close the globe valve under the nozzle tip.
 Pull out the nozzle and place the plug back.
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2.6.1 Preset

 Enter price and amount to the preset control panel.

 Switch the dispenser “on” with “on/off” switch.
 Reset sequence shall start. Display shall reset itself.
 The dispenser shall circulate LPG into the tank through the steam return line. Observe the process
on the display(s).
 The flow rate shall slow down toward the end of the process in order to complete the process at
the preset value.
 The dispenser shall cease to fill at the preset value.
 Switch the dispenser “off”.

2.6.2 Non-volatile memory check.

 Switch the dispenser “on” with the “on/off” switch.

 Reset sequence shall start. Display shall reset itself.
 The dispenser shall circulate LPG into the tank through the steam return line. Observe the process
on the display(s).
 Shut down the main power supply to the dispenser during the process.
 Solenoid valves shall be closed and filling shall stop immediately.
 Switch the dispenser “off”.
 The display shall show “no electricity” message and the last process for 20 minutes.
 The data shall be stored in EPROM and displayed again when the power is restored. The last
process is saved permanently.

2.6.3 Emergency Shut-down System (ESS)

 Switch the dispenser “on” with the “on/off” switch.

 Reset sequence shall start. Display shall reset itself.
 The dispenser shall circulate LPG into the tank through the steam return line. Observe the process
on the display(s).
 Press ESS button during the process.
 Solenoid valves shall be closed and the delivery shall stop immediately.
 Switch the dispenser “off”.
 The display shall show “no electricity” message and the last process.

2.6.4 Flow Interruption

 Switch the dispenser “on” with the “on/off” switch.

 Reset sequence shall start. Display shall reset itself.
 The dispenser shall circulate LPG into the tank through the steam return line. Observe the process
on the display(s).
 Close the globe valve on the liquid line during the process.
 Observe that the product is not dispensed.
 The CPU shall cease the delivery in 60 seconds.
 Switch the dispenser “off”.
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3.0 Operation

3.1 Before Commissioning the Dispenser

 Learn how to shut down the power supply to the dispenser and pump in case of an emergency.
 Test break-away coupling by pulling its both ends.
 Regularly check hose, nozzle and break-away coupling.
 Regularly check dispenser casing and hydraulic section against damages and leakage.

3.2 Programming the ATC System

For the dispensers equipped with Automatic Temperature Compensation - ATC System, the LPG
compound should be defined into the ATC System. Default from factory, this compound is preset to
30% butane and 70% propane.

For accurate measurements, it important to set ATC in accordance with the LPG
compound.

Neglect this responsibility may result in inaccurate readings and it is beyond Yenen’s
control.

4.0 Rules to consider during transportation and shipping

 Dispenser should not be removed from its packing during transportation and storage
packaging.

 Dispenser must be transported by paying attention to the directional arrows on the meter box
during the transportation.

 Do not place heavy objects on the dispenser package.

 Dispenser should be protected from water and moisture during transportation.

 Dispenser should be moved slowly and carefully. Otherwise CPU and displays may be
damaged.
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5.0 General Maintenance

5.1 General Safety Precautions

A safe operation is critical for the safety of the staff and customers. Read and comprehend following
recommendations:

 Do not allow pumpers to use damaged/broken components like hose assembly.

 Prevent them from using dispensers with open or missing caps.
 Place an explicit and comprehensible operation instructions on the dispensers.

5.2 Preventive Maintenance

Consider the safety precautions specified in the Section 1.3 when conducting any maintenance on the
dispenser. As long as the maintenance of a correctly installed dispenser is done appropriately and
regularly, it rarely needs an emergency service.

Perform following inspections regularly.

 Keep the dispenser clean at all times. Apply a non-abrasive, silicon based polish at least 4 times a
year, in order to maintain glossy looks and prevent corrosion on all stainless steel parts. Painted
parts may be applied with a regular automobile polish. Application intervals may be adjusted in
accordance with climate and regional conditions.
 Wipe dusty and dirty areas regularly with a soft cloth. Do not use excessive water.
 Check all LPG carrier parts like hose, break-away and nozzle against possible leaks and
damages.

If you detect damage on the hose assembly, immediately cease to use the dispenser.
Continuing to operate it may result in personal injury and property loss. Close all valves
and fix hose assembly.

 Check for sharp edges that may cause slashes on the casing.
 Check hydraulics for leakage.

If you detect damage on the hose assembly, immediately cease to use the dispenser.
Continuing to operate it may result in personal injury and property loss. Close all valves
and fix the leakage. (See Section 2.4)

 As the LPG taken from the refinery may contain water, dirt and aggressive hydrocarbons, check
the tank regularly. Contaminated LPG may cause serious damage in the dispenser. (See Section
1.1)
 Use only genuine spare parts provided by Yenen on the dispenser. Using spare parts other than
genuine Yenen spare parts may impose safety risks and therefore shall violate all obtained
permissions and warranty.

5.3 Filter
 Generally speaking, a clogged filter shall slow down the flow rate. For new installations, it may be
necessary to replace filter several times within the first week of operation, as there may be some
debris and pipe insulation parts left from the installation.
 Depending on the quality of gas, the filter should be replaced for every 1 million liters, 6 months or
if flow rate slows down.
 A 2 bar or more difference at the pump outlet and dispenser liquid line during the operation of the
dispenser and pump indicates that the filter is clogged.
 Read Yenen’s filter replacement instructions. ITL-SRV-7.5.1-008
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5.4 Calibration and Counter Maintenance

Calibration intervals of the dispenser are regulated by local specifications. OIML R117 specifies
calibrations at least once a year or if there are any changes in the LPG inventory.

Some precise measurement parts are sealed in order to restrict their repair and
modification. Only authorized and certified persons may break and reseal those.

For the adjustment of the dispenser, follow the procedures that are defined by local authorities and
read Yenen LPG flow meter and operation handbook. LFM-02.

5.5 Electronic Calibration

For electronic calibration process, follow the given instructions;

 Enter the Service Menu.

 Go to WM Setup
 At WM Setup menu, select the WM Calibration.
 Enter the Code (password)
 When 20 liters are given from the mastermeter, a calibration value on the dispenser’s preset
screen will be seen (+60, -40, etc..).
 Press the SET button. CPU will make the calibration automatically according to that value.

The calibration limits at 20 liters are ±200ml.

These calibration process should be done by authorized and certified persons.

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6.0 S4S Electronics

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6.1 Keypad Information Display

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6.2 Display Connections and Address Settings

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6.3 Technical Features

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6.4 Emergency Stop Operation Pump Menu

6.5 Password Entry Pump Menu

The order of processing the keys:

6.5.1 Administrator Menu Entry

6.5.2 Service Menu Entry

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6.6 Sales Programming (Preset ) Operation Pump Menu

6.7 Programming with Preset Button Pump Menu

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6.8 Amount, Liter and Sales Totals Pump Menu

6.9 Previous Sales Pump Menu

6.10 Flowrate Indicator Pump Menu

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6.11 ATC Temperature Pump Menu

6.12 Printer Pump Menu

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6.13 Information Pump Menu

6.14 Error Codes Pump Menu

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6.15 Shift Totals Administrative Menu

6.16 Price Units Administrative Menu

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6.17 Previous Prices Administrative Menu

6.18 Protocols Administrative Menu

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6.19 Time / Date Setup Administrative Menu

6.20 Password Change Administrative Menu

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6.21 Default Settings

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6.22 Errors Messages and Codes

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6.23 Errors Messages and Codes - Additional

Sales
Priority Description İnformation Screen Result of Error Occurence Action Required
Screen
45 ATC Unmatched E-45 ATC Unmatched Filling not possible Anytime Service required
46 No Limit Select E-46 No Limit Select Filling not possible Anytime Select Limit
47 Tube Not Ready E-47 Tube Not Ready Filling not possible Anytime Put on Tube
48 Tube over Limit E-48 Tube over Limit Filling not possible Anytime Change Tube
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Appendix A – Cable Connection Diagram

1 NOZZLE DISPENSER
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Appendix A – Cable Connection Diagram

2 NOZZLE DISPENSER
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Appendix A – Cable Connection Diagram

EMERGENCY STOP EMERGENCY STOP TEOSIS S4S (Single Dispenser)

Electric Connection Plan
TERMINALS BLUE
BLUE
1. Phase 220V
2. Neutral 17 16
3. Motor Signal 220V
19 18
4. Emergency Stop Phase 220V

0.5 Ampers
GROUNDING

1 Amper
9 8 7 6 5 4

220 V
Relay
5. Emergency Stop Neutral
9 8 7 6 5 4 2
6. Emergency Stop Parallel 21 20 3 1
7. Emergency
8. Grounding 24 23 22

9. Solenoid Neutral
BROWN FAST SLOW
BROWN

SOLENOID VALVE (A)

ON

Motor-C1
Motor-C2
Common

Common

Common

Common
P1-Motor

P2-Motor

P3-Motor

P4-Motor
P1-Valve

P2-Valve

P3-Valve

P4-Valve
Neutral
Phase

SD Card
Earth

Socket
1 2 3 4
220 VAC
Pump 1 - 4 Motor & Valve
DISPLAY (A) ATC

12C Bus- 1
TOTALIZER

ATC1
BOARD
S4S

12C Bus- 2
Status

RXD
TXD

ATC1
COMPUTER
MKS DISPLAY

12C Bus- 3
ATC2
PULSER-1 PULSER-2 PULSER-3 PULSER-4 NOZZLE 1 - 4 RS485 / CL

12C Bus- 4
ATC2
RS485-A
RS485-B
P1-PWR

P2-PWR

P3-PWR

P4-PWR
P1-GND

P2-GND

P3-GND

P4-GND
P1-CHA
P1-CHB

P2-CHA
P2-CHB

P3-CHA
P3-CHB

P4-CHA
P4-CHB

P1- SW
P2- SW
P3- SW
P4- SW

C
GND
GND

CL +
CL - 1 2 3 4
BROWN
GREEN
5 6 7 8
WHITE Grnd.
YELLOW Grnd.
Prest 4
9 0
Prest 3
Prest 2 PRESET PRESET
(+) (-)
Prest 1

ON - OFF (A) ON - OFF (B) 5 5

10 10
PULSER (A)

B A
PRESET BUTTON
Page 36 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix A – Cable Connection Diagram

EMERGENCY STOP EMERGENCY STOP

TEOSIS S4S (Double Dispenser)
Electric Connection Plan

TERMINALS BLUE
BLUE
BLUE
1. Phase 220V BLUE
2. Neutral 17 16
3. Motor Signal 220V
19 18
4. Emergency Stop Phase 220V

0.5 Ampers
GROUNDING

1 Amper
9 8 7 6 5 4

220 V
Relay
5. Emergency Stop Neutral
9 8 7 6 5 4 2
6. Emergency Stop Parallel 21 20 3 1
7. Emergency
8. Grounding 24 23 22

9. Solenoid Neutral BROWN

BROWN SLOW SLOW
BROWN FAST FAST
BROWN

SOLENOID VALVE (A) SOLENOID VALVE (B)

ON

Motor-C1
Motor-C2
Common

Common

Common

Common
P1-Motor

P2-Motor

P3-Motor

P4-Motor
P1-Valve

P2-Valve

P3-Valve

P4-Valve
Neutral
Phase

SD Card
Earth

Socket
1 2 3 4
220 VAC
Pump 1 - 4 Motor & Valve
DISPLAY (A) ATC

12C Bus- 1
TOTALIZER

ATC1
BOARD
S4S

12C Bus- 2
Status

RXD
TXD

ATC1
COMPUTER
MKS DISPLAY

12C Bus- 3
ON

ATC2
1 2 3 4 PULSER-1 PULSER-2 PULSER-3 PULSER-4 NOZZLE 1 - 4 RS485 / CL

12C Bus- 4
ATC2
RS485-A
RS485-B
P1-PWR

P2-PWR

P3-PWR

P4-PWR
P1-GND

P2-GND

P3-GND

P4-GND
P1-CHA
P1-CHB

P2-CHA
P2-CHB

P3-CHA
P3-CHB

P4-CHA
P4-CHB

P1- SW
P2- SW
P3- SW
P4- SW

DISPLAY (B) C
GND
GND

CL +
CL -
1 2 3 4
BROWN 5 6 7 8
YELLOW
BROWN
GREEN
WHITE

GREEN
WHITE Grnd.
YELLOW Grnd.
Prest 4
9 0
Prest 3
Prest 2 PRESET PRESET
(+) (-)
Prest 1

ON - OFF (A) ON - OFF (B) 5 5

10 10
PULSER (A) PULSER (B)

B A
PRESET BUTTON
 Page 37 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix B – Failure Guide

TROUBLESHOOTING
HOW TO FIX THE PROBLEM IF
PROBLEM POSSIBLE CAUSES? WHAT TO CHECK?
DETERMINED?
a) Fuse in the CPU is blown. a) Check the fuse in the CPU. a) Replace the fuse.
b) Power section of CPU card that
b) Check the CPU card. b) Replace the CPU card.
powers solenoids may be broken.
c) Solenoid coil may be burnt. c) Check if solenoid inducts or not. c) Solenoid should be replaced if broken.
d) Open valves if closed, replace nitrogen
Dispenser is not activated d) Pneumatic valves may be closed. d) Check if the valves are open.
tube if necessary.
even though it is switched
e) Engine should be replaced if not
“on”. e) Engine may not generate pressure. e) Check the engine.
generating pressure.
f) Check if a signal is received from the f) Make sure that signal is received from
f) No signal from the relay.
relay. relay.
g) On-off switch is broken. g) Check the button. g) Replace the button if broken.
h) Thermic on the table may be
h) Check the thermic. h) Thermic should be corrected if blown.
blown.
a) Pulser may be broken. a) Check the pulser. a) Pulser should be replaced.

b) Replace display and check if the problem

b) Display may be broken. b) Display should be replaced if broken.
is fixed.
Nozzle dispenses gas but
nothing is displayed. c) Replace new display card and check if c) Display card should be replaced if
c) Display card may be broken.
the problem is fixed. broken.
d) Check the pin. (If motion transferring
d) Meter distribution valve pin may be
shaft can be moved to both sides when d) Pin should be plugged back.
removed..
checked with hand, it is removed.)
 Page 38 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix B – Failure Guide

TROUBLESHOOTING
HOW TO FIX THE PROBLEM IF
PROBLEM POSSIBLE CAUSES? WHAT TO CHECK?
DETERMINED?
a) Distribution valve, Charcoal, Felt may be a) Check distribution valve, charcoal
a) Replace broken part.
damaged. and felt.
b) Adjustment roller may need readjustment. b) Check the adjustment roller. b) Readjust the adjustment roller.
Dispenser delivers too much or too c) Pulser may be broken. c) Check the pulser. c) Replace the pulser.
little d) Pulser shaft may have torsion.. d) Check the pulser shaft. d) Fix the torsion.
e) Piston arms may be twisted. e) Check the piston arms. e) Replace the piston arms.
f) Piston cups may be torn or worn
f) Check the piston cups. f) Replace the piston cups.
.
a) Filter may be clogged. a) Check the filter. a) Change the filter.
b) Solenoids may be clogged or solenoid core b) Clean solenoid, replace the core,
b) Check the solenoids.
may leak. and replace solenoid if necessary.
c) Diver may not generate sufficient pressure. c) Check the manometer on the diver. c) Replace the diver pump.
Dispenser flow rate is less than d) Change the position of two phase
d) Check the diver pump revolution
expected. d) Direction of the diver pump may be wrong. cables of the diver pump on the
direction.
control panel.
e) Differential rubbers may be torn. e) Check the differential valve. e) Replace the differential rubbers.
f) Break-away coupling may be clogged, f) Clean the break-away coupling,
f) Check the break-away coupling.
broken or misplaced. replace it if broken.
g) Nozzle may be damaged. g) Check the nozzle. g) Replace the nozzle.
h) Vehicle tank may be full. h) Check the lever on the tank. h) Stop filling the vehicle with full tank.
I) Loosen and tighten adjustment
I) Pulser shaft may be jammed. I) Check the pulser shaft.
bolts.
Page 39 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix B – Failure Guide

TROUBLESHOOTING
HOW TO FIX THE PROBLEM IF
PROBLEM POSSIBLE CAUSES? WHAT TO CHECK?
DETERMINED?
a) Preset or its connections may be short a) Correct the connections and
Price counter does not stop. a) Check the connections.
circuited. change preset if situation persists.
a) Pr-In keys on the CPU may be jammed. a) Check the keys on the CPU. a) Fix the problem by pressing keys.
Unit price window blinks.
b) CPU cap may be broken. b) Check the CPU cap. b) Replace the CPU cap.
a) Parameters are entered incorrectly into a) Check the parameters entered into
a) Re-enter parameters accurately.
Display shows incorrect price. CPU card. CPU card.
b) Solenoids may leak. b) Check the solenoids. b) Replace solenonids.
a) Display temperature may be more than 40o. a) Problem shall be fixed when
a) Check the display temperature.
(display is erased in this case) display temperature is normal.
Nothing on display. b) Display card may be broken. b) Check the display card. b) Replace the display card..
c) There may be problem on display
c) Check the display connections. c) Connect cables correctly.
connections.
a) Break-away coupling on the hose may be a) Check if break-away coupling is a) Firmly place or replace break-away
closed. placed correctly. coupling.
Nozzle does not deliver gas even b) Solenoid valves may not open. b) Check if solenoid valves are opening. b) Replace solenoid valves.
though it is switched “on” and
diver is activated. c) Pneumatic valves may be closed. c) Check if nitrogen tube is full or not. c) Replace nitrogen tube.
d) Replace in-nozzle check valve if
d) Check valve in the nozzle may be broken. d) Check the in-nozzle check valve.
broken.
Page 40 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix B – Failure Guide

TROUBLESHOOTING
HOW TO FIX THE PROBLEM IF
PROBLEM POSSIBLE CAUSES? WHAT TO CHECK?
DETERMINED?
a) Break-away coupling may have a) Check the break-away coupling on a) Place the break-away coupling into
come away. the hose. position.
b) Nitrogen tube may be empty. b) Check the nitrogen tube. b) Replace the nitrogen tube.
Dispenser does not deliver gas.
c) CPU fuse may be blown. c) Check the fuse. c) Replace the CPU fuse.
d) Nozzle may be broken. d) Check the nozzle. d) Replace the nozzle.
e) Solenoids may be broken. e) Check the solenoids. e) Replace the solenoids.
a) PR button on the CPU card may be
Display flashes at any parameter. a) Observe dispenser display. a) Press PR key until EP is displayed.
stuck.
a) Press gas alarm reset key for 3
a) There may be gas leakage. a) Check for leakages on all systems.
Gas alarm sounds. seconds.
b) Gas detector may be broken. b) Check the gas detector. b) Replace the gas detector.
a) Thermic relay may be out of a) Check the current drawn from the
a) Replace the diver pump.
Thermic relay on the panel blows adjustment. network by the pump.
continuously. b) Thermic relay may be out of
b) Check the thermic relay. b) Adjust thermic relay.
adjustment.
a) Remove washer and reverse it.
a) Washer located on the tip of the
a) Check the nozzle washer. Replace the washer if problem
nozzle may be worn.
Nozzle leaks gas. persists.
b) Threads of the nozzle may be
b) Check the nozzle. b) Replace the nozzle.
broken.
a) Totalizer’s coils may be broken. a) Check the totalizers. a) Replace the totalizers.
b) Dispenser control unit may not be
Totalizer does not work. b) Check the CPU card. b) Replace the CPU card.
sending signals to totalizers.
c) Graphics card may be broken. c) Check the graphics card. c) Replace the graphics card.
Page 41 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix B – Failure Guide

TROUBLESHOOTING
HOW TO FIX THE PROBLEM IF
PROBLEM POSSIBLE CAUSES? WHAT TO CHECK?
DETERMINED?
a) Safety valve may leak. a) Check the safety valve. a) Clean any dirt if exists.
b) Parameter values may be
Display continues to count even b) Check the parameter values. b) Adjust parameter settings.
interfered.
though the nozzle is disconnected.
c) CPU card may be broken. c) Check the CPU card. c) Replace the CPU card.
d) Pulser may be broken. d) Check the pulser. d) Replace the pulser.
a) Pump pressure may be drooped. a) Check the pump pressure. a) Replace the pump if broken.
b) Electrical interruption. b) Check the voltage. b) Restore electrical connection.
c) Pressure sensor may be broken. c) Check the pressure sensor. c) Replace the pressure sensor.
Delivery stops while dispensing gas. d) Analog adjustment may be
d) Check the analog values. d) Adjust the analog values.
incorrect.
e) Gas sensor may be interrupting gas
e) Perform leakage test on al systems. e) Fix found leaks.
flow due to a leakage.
a) Fluorescent may be died out. a) Check the Fluorescent. a) Replace Fluorescent.
Dispenser Fluorescent is off. b) Fluorescent fuse may be blown. b) Replace the fuse.
c) Fluorescent may be loosened. c) Place fluorescent correctly.
Dispenser Manometer is not working. a) Manometer may be broken. a) Check the manometer. a) Replace the manometer.
Page 42 of 45 01.01.2014 DIS-14-te Rev Nr:3

Appendix C – DOs and DON’Ts

DO FOLLOWING

DO…
 Consult with station director or administrator about the project and procedures before servicing a
dispenser.

 Review dangerous zones on the work site and determine necessary safety precautions relying on
your safety training and experience.

 Locate extinguishers on the work site before commissioning any process involving LPG.

 Be informed of steam and other dangerous conditions.

 Disconnect and lock power supply before opening the dispenser for maintenance. Make sure that
valves under the dispenser are closed BEFORE commencing maintenance.

 Be informed of relevant dangerous zone classifications.

 Utilize equipments like safety cones, barricades and barrier bands in order to isolate work site and
protect technician.

 Wear safety clothing like phosphorescent vest, goggles and gloves.

 Check the perimeter of the work site.

 Place nozzle into the dispenser carefully.

 Get totalizer results and record them in co-ordination with station director or administrator.
Page 43 of 45 01.01.2014 DIS-14-te Rev Nr:3

DO NOT FOLLOWING

DON’T…
 Do not allow unauthorized persons to stay close to the dispenser or work site during demounting
or gas discharge of the dispensers.

 Do not left the dispenser caps open after completing maintenance.

 Do not allow smoking, igniting or fire devices within the perimeter of the work site.

 Do not work outside of the barricaded area.

 Do not remove safety cones, barrier band or service vehicle until the work is completed.

 Do not leave station without having report signed by station director or administrator.
 44

Notes :
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