Sprint User Manual

USER MANUAL
SPRINT PUMP & DISPENSER
MANUFACTURED BY
LARSEN & TOUBRO LTD.,
GATE NO.1, ‘C’ BUILDING 1ST FLOOR, SAKI VIHAR ROAD
POWAI, MUMBAI –400072
www.lntebg.com
Sprint Manual -------1------- Petrol Pump Division

CONTENTS
1. Introduction
2. General Arrangement – External & Internal
3. Description
4. Features
5. Specifications
6. Installation
a. Foundation plans
b. General
c. Underground tank
d. Pipe fittings & Pipe connections
e. Important instructions
f. Electrical connection and grounding requirements.
g. Installation instructions for electronic register
7. Operation
a. Manual mode
b. Presetting a sale value
c. Presetting a litres value
8. User Interface
a. Errors
b. Warnings
9. Handling the printer

a. General
b. Warning
c. Caution for handling
10. Programming instructions - Pump

h. Reading the software version number
i. Reading the cumulative volume totaliser
j. Reading the cumulative sale totaliser
k. Reading the shiftwise volume totaliser
l. Reading the shiftwise sale totaliser
m. Clearing the shift
n. Entering into programming mode – level 1
o. Entering into programming mode – level 2
p. Entering into programming mode – level 3
q. Rate programming
r. Parameters
11. Programming instructions - Printer

a. Inching
b. Printing a receipt
c. Aborting a print
d. Printing a totaliser receipt
e. Printing a backup
f. Taking a test printout
g. Clock settings
12. User interfaces - Printer

a. Paper out
b. Printer error
13. Maintainance of the pump

a. Paper roll changing
b. Printer cartridge replacement
14. Communication details
15. Oil level Sensor card

a. Connections
b. Oil tank refilling instructions
16. Trouble shooting
17. Spares
a. Mechnical
b. Electronic Card List
c. Cable List

INTRODUCTION
The L&T Sprint is a sophisticated sleek looking pump fully loaded with state of the art features.
Your petrol station gets an automatic facelift with Sprint, designed to catch and delight the eye.
What makes it special is its unique design - tall pillars with curved side frames. In addition, the
compact style requires smaller footprint on the forecourt while offering larger advertising space for
the retailing company. L&T's Sprint range is modular and based on platform technology. On a
common platform, this series of pumps offers the following variants,
Multi product pump & dispenser
Duo pump & dispenser
Mono pump & dispenser
This manual gives features, working, operation, maintenance & trouble shooting information for
this series of pumps & dispensers. It covers all the aspects of the pump operation from installing
the pump to servicing.

General Arrangement
BANNER
ASSEMBLY
ELECTRONICS
SECTION
HYDRAULIC
SECTION
SPRINT DUO
INTERNAL ARRANGEMENT

Description
Each dispensing pump is divided into two distinct zones viz. hydraulic zone (lower portion) and
electronics zone (upper portion). These two zones are housed in a sheet metal enclosure. The
sheet metal frame itself is mounted on a sheet steel base frame. The hydraulic portion consists of
a motor, suction unit, solenoid valve (only for preset pumps), metering unit, hose & nozzle
assembly. The display unit consists of an electronic register comprising of various components
like power supply, displays, controller card etc.
The hydraulic portion of pump is covered on front & rear sides by sheet steel panels with
individual locking arrangement. The top portion (display zone) is covered by sheet steel frames
with a display hood for viewing the measured / registered quantity.
The subassemblies are made from aluminum pressure die casting and cast iron bodies and
contain parts made from plastic, rubber, brass, stainless steel and sheet steel. The motor used in
the pump is a ¾ hp single phase continuously rated intermittent capacitor start, induction run
motor. The motor has flameproof construction as per IS: 2148 (1981).
The pumping unit body is made up of aluminum / cast iron. It consists of a rotor with six sliding
vanes made of carbon. In the alternate version the gear pump is used. The assembly also
consists of filter / strainer assembly. The unit is provided with a bypass valve to divert the liquid
flow into the suction side of the pump when the delivery through the nozzle is stopped.
The metering unit has aluminum die cast body that house 4 stainless steel liners in 4 cylinders.
The metering unit consists of pistons, connecting bars that are made up of aluminum; carbon
valve seat, valve seal bronze rollers, brass gears, investment cast kidney valve and bearings. The
unit is provided with an adjusting wheel for accuracy adjustment and calibration.
In case of preset pumps, there is an additional solenoid valve made up of brass or aluminium with
an encapsulated / flameproof coil. Valve can be put after pumping unit or after metering unit as
required.

In case of oil mixing pump, the hydraulic zone also includes a hydraulic cylinder for pumping and
metering the oil, non-return valves, cylinder driving mechanism and an oil tank. The meter drives
the hydraulic cylinder by means of the driving mechanism. Non-return valves ensure purity of
fluids up to mixing point. The driving mechanism can be adjusted for setting the oil percentage as
0%, 1 %, 2%, 3%, 4% or 5% of the total mixture. It is provided with fine-tuning arrangement for
calibrating the setting. In addition to this the automatic version zone also includes an oil suction
pump.
The outlet of the metering unit is connected to rubber hose and nozzle assembly by a connector
fitting. Nozzle assembly consists of aluminium die cast body, stainless steel shafts, springs,
valves and brass spout to guide the liquid into the vehicle tank.
The electronic register assembly is a microprocessor based register. It is housed in a sheet steel
enclosure and is located at the top of pump. The input for the register is taken from the sensor
box, which contains an optical sensor. The sensor box has disc that is coupled with a metering
unit. The rotary output from metering unit thus optically sensed and is displayed in terms of litres
by the display unit. The sensor box is made of cast iron and is approved for flameproof
construction. The sensor box is located just above the metering unit.
The electronic register assembly displays the Volume dispensed, Sale value and Set rate (in case
of oil mixing pump, the rate displayed is the weighted average rate of product and oil).
In case of dispenser models, the motor and pumping unit is replaced by a submersible pump
which caters to various dispensers depending upon the configuration.

FEATURES
Pump has smaller Footprint giving a sleek look.
The pumps has a more rigid frame for better stability of pump and noise reduction.
The pump has a separate area for display of advertisements.
The pump has better water drainage capability. The Top box will be IP 54
protected and Hydraulic area will be IP 23 protected
Adequate ventilation to prevent heating of the hydraulic zone. It is 3.5 %of
Pump base area.
Magnetic switch is used instead of micro switch.
The pump has an optional feature of electronic calibration
The pump has a communication feature.
The pump has optional features like Card reader (smart/credit/magnetic),
printer for enabling e- payment and electronic receipt respectively.
The pump has more access for service
The pump has emergency button to shut down the pump in case of any
accident or hazard.
Apart from the above feature the pumps also have overload protection devices
like fuses for electronic, and Pressure relief valves for hydraulic system.
Advance micro controller based electronics with self-diagnostic feature.
Full electronic operation with memory backup facility.
SMPS for wide voltage range, supply fluctuations and radiated noise.
Input supply voltage band of 180 to 250V.
1” LCD displays rupees and liters, ¾”LCD for rate.
Option easy to read Backlit LCD available.
Error indications provided.
12 digit electronic tantalizer.
¾ HP motor with thermal protection and overload protection.

Auto motor shutoff incase of no dispensing, for power saving.
Programmable decimal point.
Price setting through keypad.
The Pump will confirm to European norms (CE), as well as UL - 87 norms.

Technical Specifications for SPRINT series pumps
Product Configurations :
Mono, Duo, 2/3 product MPD, Quad…
With Suction Pump or as Dispenser with Submersible Pump
Suction Pump features :

Self Priming, positive displacement vane pump with air separator.
Inbuilt adjustable bypass valve and suction strainer
Rate of Delivery : 40 lpm nominal for standard duty, and 80 lpm nominal for heavy duty. These
flow rates are for “Preset” configuration.
Rated Suction lift is 3.5mts nominal
Motor (For Suction Pump) :

3/4HP Single Phase, flameproof motor.
180 – 250 volts operating band
Class ‘B’ insulation.
Inbuilt Thermostat protection,.
Optional Three phase motor.
Meter :
Four piston positive displacement metering unit.
Accuracy +-0.25% between 5lpm and nominal flow rate.
Calibration range : +100ml to –500ml for 20Liters in steps of 5ml.
Hose :
Double braided, petrol resistant, anti-static hose.
¾” for standard duty, and 1” for heavy duty.
Nozzle :
Spout sizes : 13/16”for standard duty, & 1” for heavy duty
Auto / Preset nozzle with Preset pumps.
Totaliser :
Mechanical seven digits (minimum)
Electronic twelve digit
Electronic register :
Backlit Liquid Crystal Display
Six digit volume display 1” high
Six digit sale display 1” high
Four digit rate display ¾” high
Floating Decimal Point
180-250 volts operating range.

Battery back-up.
RS-485 Communication port
Optional Printer
Self diagnostic features for trouble shooting & maintenance.
Preset :
Volume / Sale preset
Keypad with 16 keys and decimal point.
Panelling :
CR / HR steel sheets.
Powder coated panels
Optional Stainless Steel finish
Operating environment :
Temperature : -25degc to +55degc
Relative humidity : 5% ~ 95%
Optional features :
Safe-Break couplings for high hose.
Safety shear valves with submersible pumps

SPECIFICATIONS OF THERMAL PRINTER
Printing method Direct thermal line printing

Characters per line 40cpl
Character size 9 * 24dots, 12 * 24dots
Resolution 203dpi, 8dots/mm
Print width 2-inch (48mm, 384dots)
Printing speed 50mm / sec
Dimensions 107.2 * 109.1 * 90.6 mm (Standard model)
Weight 451g (including roll paper)
Interface RS 485 Modbus properitery protocol
Paper supplied Thermal roll paper (57mm wide, 60ø)
PDF417(2-dimension), Code128, Code39, 12 of 5,
Barcode supplied
UPC, EZN, KAN, JAN, CODABAR, ITF
Receive buffer size 10K bytes
Power 12~24V DC, Stand by 80mA and Max 2A (Standard model)
Temperature 0C - 40C (operating) and -10C - 50 (storage)
Environment conditions
Humidity 30% - 80% (operating) and 10% - 90% (storage)
Mechanical 37,000,000 lines
MCBF
Head Approximately 50 Km

Ordering Sheet

Installation

Foundation Plan For Sprint (DUO) with Compact Pumping Unit

Sprint Mono Dispenser

Sprint Duo Dispenser

Sprint Mono Pump

Electrical connections
Before making any electrical connections, make sure that the voltage and frequency stamped on
motor nameplate correspond with the current characteristics of the place where the pump is being
installed.
The standard pump is equipped with a 230-volt, 50 cycles, ¾ hp, single phase, flameproof motor.
All power and lighting wires of operating the pump should be run in threaded rigid steel conduit.
All threaded connections must be drawn up tight.
The electrical system complies with the requirements of the petroleum regulations. All switches
and junctions boxes are of flameproof type. Never use knockout-boxes or flexible conduit when
installing the petrol pump. Never use gaskets between boxes and covers of flameproof type.
Never disturb the sealing compound, which is found around wires at all switch box entrances. This
compound is a requirement of petroleum regulations. Use min. 1.6 sq mm insulated wire for
motor circuit and lighting circuit protected by 16-ampere fuse.Tighten junction box covers
before replacing panels. Follow the petroleum regulations while installing the pump.
All the electrical connections must be as per IS: 2148 and IS: 2206.
The input supply required is 230V single phase and 50 Hz.
All the electrical connections should be through rigid metal conduits/armoured cables.
Separate cable of recommended rating should be used for each pump.
Make connections to the terminal block in the junction box with suitable crimp type lugs.
Cables should be color-coded or with suitable markers at both the ends for proper identification.
It is recommended to use a separate circuit breaker (which can break both phase and neutral) for
each pump to switch off the pump in case of emergency or any other reason. (Rated 20 Amps per
pump – single motor).
Clearly identified switches and circuit breakers should be provided at easily accessible location to
cutoff power supply in event of fire and accident or other emergency.
Figure 5 shows the arrangement of a typical pipe electrode.

Grounding requirements.
• The earthing arrangement must be as per IS : 3043.

• Earth ground is necessary for safe and correct operation. It provides a single
reference point for all the pumps.
• One earth connection is required per pump.
• The color code used for earthing cable from pump junction box to main electrical
panel should be green or yellow + green for easy identification.
• The electrical ground should have a separate terminal. All the earth signals within
the pump should be connected to this terminal including the body of the pump.
• The earthing terminal of all the pumps should be connected to the electrical panel
ground.
• After installing the pump and making all the connections it is advised to check the
proper grounding at the junction box end of the pump. This can be done by
checking the voltage between neutral and ground; it should not be more than
4V. Also the voltage between phase and earth should be 230V.
• Do not connect the pump body or frame to a separate grounded rod under each
pump. Ground reference should be same for all the pumps.

TYPICAL ARRANGEMENT OF PIPE ELECTRODE

Cable Specifications.
Mains cable (per motor)
1.6 Sq mm(per core)-insulated 3 core (min) stranded copper wire is recommended for mains
supply from main electrical panel. The cable used should be shielded.
The minimum temperature withstand should be 80 deg C.
All cables and connections made should be continuous. Splices should be avoided.
The cable used should be stranded. Single strand wire should be avoided.
Communication cable
The communication cable is polarized and should not be connected in reverse way.
The looping/connection of more than one pumps should be phased i.e. the connection is to be
consistent with all pumps.
The communication cable and mains cable can run through the same conduit but both should be
shielded.
The outlets having POS or communication should have isolated ground circuit. The
communication ground of the pump must be connected to the equipment or peripheral ground and
should be separate from the pump ground.
It is recommended to run additional communication wire during installation for further use or for
signal verification.
The insulation of the wire should be stripped only for the required length.
Cable of 28 AWG – 7X36, operating temp of –30 to 80 deg C, Operating voltage of 150 Vrms, 1A
max continuous current, with tinned copper drain wire and 90% shield coverage

SCHEMATIC WIRING DIAGRAM
WIRING DIAGRAMS LOCATION
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 8

SCHEMATIC DIAGRAM OF ELECTRONICS WITH THERMAL PRINTER

Operation
The dispensing pump model “SPRINT” is suitable for dispensing petroleum products like petrol,
diesel, kerosene, mineral turpentine etc.
It consists of a motor, pumping unit, metering unit, electronic register cum display unit, rubber hose
and nozzle assembly. The motor drives the pumping unit, which sucks the product from underground
storage tank and delivers at high pressure to the metering unit. The pumping unit includes an integral air
separator, which separates the air-liquid mixture (froth) from product. The separated froth gets collected in
the float chamber. Pure product is collected and recycled back to suction side through float mechanism. Air
and vapour is vented to atmosphere.
PURE PRODUCT from the pumping unit is passed through the metering unit. The product flows
through the meter and drives the pistons. The linear motion of the pistons is converted into rotary motion.
Liquid quantity is measured and indicated in output as number of revolutions. The volume of the product
dispensed is directly proportional to the revolutions of metering unit shaft. Optical sensors housed in the
sensor box sense these revolutions. The pulses generated are sent to the microprocessor for computation
and for displaying on the LCDs / LEDs. The display unit indicates the volume dispensed, the set rate and
total sale value simultaneously or in case of single display only the total volume. The liquid from the
metering unit passes through the rubber hose and nozzle assembly for delivery to the consumer.
In case of preset pumps, the preset value (either volume or total sale value) is compared against
the delivery in progress and at the set point, the micro processor shuts off the motor and the solenoid valve
give accurate shut off.

Present day gasoline pumps, like that shown here, employ the wet hose system in which the hose
must be full of liquid for full delivery of the measured quantity of gasoline.
The wet hose system permits continuous measurement of the gasoline during delivery to the
vehicle. During the process of delivery it is possible to read on the display, at any given instant,
the exact amount, which has been delivered to the vehicle. The functions of delivery and
measurement are combined into one continuous process instead of two separate steps. To
accomplish this purpose it is essential that that system from the meter to the nozzle be completely
filled with air free gasoline at all times.
Assume that that system pictured in the figure is filled with gasoline from the meter to the nozzle.
Obviously if any quantity of gasoline delivered by the meter – exactly the same quantity will be
moved past every point in the system and will be discharged at the nozzle outlet provided the
system between the meter and nozzle remains completely full after the delivery. Therefore, it is
not important at what point we measure the flow so long as the system is completely filled at all
times between the point of measurement and the point of discharge. This is the basic principle
upon which the wet hose system operates.
Before taking up a step-by-step description of the wet hose gasoline pump, let us take a quick
look at the flow of gasoline through the pump. Starting at the suction union, which connects to the
piping from the storage tank, we see that the pumping unit lifts the gasoline from the tank and
places it under pressure. The gasoline then flows through a device, which eliminates any air,
which may be entrained and through a solenoid & Pressure Regulating Valve enters the meter,
where it is measured. From here the gasoline moves upward through the hose to the nozzle.
The filtered fluid from the tank goes into the metering unit and then through the solenoid valve,
copper tube, outlet casting hose and then is dispensed through the nozzle
This is the way it works. When the discharge nozzle is open and gasoline is being delivered to a
car the pressure of flowing gasoline causes the entire pressure-regulating valve to open and
permit an unobstructed flow of gasoline. When the discharge nozzle is closed upon completion of

a delivery, the pressure regulating valve closes, preventing gasoline from dropping back from any
point between the valve and nozzle. This is the first function mentioned previously.
The second function is effective under certain conditions of temperature variation. For example,
gasoline stored underground has a relatively low temperature. When a pump is
idle and exposed to the sun the gasoline within the pump gets heated. This causes product
expansion, resulting in an increase of pressure in the hose. If there were no method of relieving
this pressure, the hose would become so stiff it would be practically impossible to handle it. It
might even burst. To prevent this high pressure, the pressure regulating valve contains a small
relief valve inside the check valve previously described. This small valve bleeds a small quantity
of gasoline back from the hose whenever the pressure in these parts rises to more than 2.0
kg/cm2. Thus dangerously high pressure cannot be built up in the discharge system. The small
amount of liquid which is bled out passes through the air separator and to atmospheric pressure
in the sump.
The third function of the pressure-regulating valve is to maintain sufficient pressure in the
discharge system to prevent the formation of vapour pockets. It is for this reason that the
pressure regulating valve relief pressure is set at 2.0 kg/sq,cm. If the valve opened at 1 kg/cm2,
close to atmospheric pressure, the probable result would be vapourisation of the gasoline in
extremely hot weather. The vapour thus formed would rise to the top of the pump and cause a
void and the pressure created by this expanding vapour would force an additional quantity of
gasoline into the sump. If this should occur it would violate the first principle of metering in a wet
hose system, namely, that the discharge system be completely filled with gasoline before and
after delivery.
The air free gasoline from the Pressure Regulating Valve is discharged under pressure into the
meter. The LT meter is a four-piston displacement type and is operated by the pressure of the
gasoline flowing through it.
As the gasoline passes though each cylinder in rotation it causes a movement of the piston, which
press in turn against a cam. This cam causes the cam shaft to revolve, and this shaft in turn
operates through a gear train to turn the register at twice the speed of the meter. The continuous

flow of liquid through the meter causes a continuous rotation of the meter shaft, which is
continuously recorded on the display.
In the L&T pumps the pressure regulating valve is located just before the meter. This ensures a
wet hose from the point of measurement to the point of delivery.
The discharge nozzle is an automatic device for filling gasoline tanks at any rate desired by the
attendant. He can throttle the flow from maximum output of the pump down to a mere trickle
simply by varying pressure on a finger operated lever. This variation of delivery rate, from
maximum to minimum, does not affect the accuracy of the meter, nor does it result in any undue
load or strain on the pumping unit, which is protected from excessive pressures by its by-pass
valve. The only noticeable effect is a slight rise in pumping pressure to approximately 1.27
kg/sq.cm.
Within the pump itself, from the pumping unit to the nozzle, there are approximately nine litres.
When a pump stands out in the sun, the gasoline expands. The increase in this volume is taken
care by the sump or float chamber. In a LT pump, the float chamber has sufficient capacity to
accommodate somewhat more than the normal expansion of the gasoline within the pump under
practically all temperature conditions encountered throughout the world.
But what happens when the gasoline in the underground piping also expands ? There is a lot of
gasoline in the piping of an average installation. In every 4 metres of 40 mm pipe there are 5
litres of gasoline. If the horizontal piping is not buried deep enough under the driveway, the sun’s
heat will expand the gasoline within the piping.
When the expansion of the gasoline within the piping exceeds the capacity of the float chamber in
the pump, the excess gasoline leaks out of the sump vent & drips down to the outside of the
pump.
The best thing to do is to remove the poppet from the check valve in the underground tank. In
that event it would be advisable to install a vertical check valve in the piping just below the pump.

When this is done, any expansion that takes place in the piping is free to flow back into the tank.
The expansion of the gasoline within the pump itself will be taken care of by the sump or float
chamber.
L&T Standard pumping unit does not require this vertical check valve since it incorporates a
combination strainer and check valve.
In some cases this valve has been used very satisfactorily as the only check valve in the line. In
other cases, depending upon the amount of horizontal run and vertical lift, the combination
strainer and check valve cannot do the job by itself. Thus it is advisable to provide a separator
check valve in the underground tank.
EFFECT OF ATMOSPHERIC PRESSURE ON PIPING
Where atmospheric pressure is greatest, at sea level, it exerts a pressure of 1.1 kg/cm2. At 3000
metres above sea level, the force of atmospheric pressure is reduced by 0.35 kg/cm2. There it is
only 0.75 kg/cm2. At 8700 metres atmospheric pressure becomes zero.
But in a gasoline pump installation, height above sea level is not the only factor which affects the
force of atmospheric pressure.
Of far more importance in most installations are piping restrictions – too much vertical lift from the
tank, too many elbows in the line, spring-loaded foot or check valves plus, of course, the
restriction imposed by pipe friction itself. When a part of the available pressure must be used to
overcome the effect of small piping, too many elbows, too much horizontal run, too much vertical
lift from the tank, you get into trouble. Sometimes that trouble is merely slow delivery.
Sometimes, however, it is vapour lock.
Vapour lock is a result of gasoline pulling apart in the piping. And it does literally pull apart –
actually changes from a solid liquid to a frothy liquid.

Too much lift, small piping, too many elbows create so much friction that the gasoline is held back
from moving into the vacuum. The result is that the gasoline actually separates.
When vapour lock is not too excessive, you may get erratic operation of the pump. In other words
a pump will deliver at normal speed then slow down, pick up again to normal, slow down again
and so forth. When vapour lock is really bad, delivery stops completely.
Vapour lock is most mysterious when it suddenly happens in an installation that has worked
perfectly for years. What causes it ? The answer is variation in the volatility of gasoline.
As you know, the more volatile a gasoline is, the better the performance of the automobile engine.
You also know that the volatility of every liquid increases as it is heated. For example, take water.
Evaporation arises from the surface of a pail of water that is almost cold enough to freeze.
However, if that same pail of water is heated the evaporation rate will be faster. And of course, if
you boil that water, its volatility becomes so great that within a short time you can boil it all away.
Now gasoline refineries customarily keep their gasoline as volatile as possible bearing in mind the
temperature at which it will be used. In cold weather, most gasoline coming from the refinery is
much more volatile than so-called summer gasoline. Summer gasoline will be used in hot
weather. If it is too volatile, it will vapourise in an automobile engine’s fuel lines, causing vapour
lock in the car. Refineries actually change the volatility of their gasoline several times per year.
Now let us imagine this happening and it happens quite often. In the spring or winter a refinery
naturally anticipates the weather will be fairly cool. Therefore, it can increase the volatility of its
gasoline without expectation of motorists complaining of vapour lock. Suddenly, however, a spell
of unseasonably hot weather arrives. What happens?” Gasoline pump installations that have
never given trouble in years of use suddenly develop vapour lock.
One last point – why is vapour lock becoming an increasingly prevalent problem? Because the
tendency among oil companies is to give motorists the best product they can – gasoline which will
work better in engines, deliver more kilo metres per litre. Thus gasoline is becoming, by and
large, increasingly more volatile, the point to remember is this – when vapour lock occurs, it is
seldom the fault of the pump. The trouble is in the piping system – too many restrictions – or it is

a matter of outdoor temperatures being too high for the gasoline. By that we mean that the
gasoline is too volatile for the temperature at which it is being pumped.
When the drive way of gasoline station is exposed to the sun the ground temperature rises.
When the heat becomes intense enough it will penetrate down to the suction lines, causing
vapourisation of the gasoline to the extent that it may contribute to vapour lock conditions. Thus
heat also can be a prime cause of vapour lock.
Now let us look a little further into piping troubles, a leak in the check valve which permits product
to flow back into the tank. When this happens, the suction line fills with air.
Now, what happens when you start the pump? You get a hesitation – no delivery of gasoline –
then the product starts to flow. In effect, you are merely waiting for the pump to prime. When it
does prime, gasoline starts to flow. But during this priming time, there is no gasoline flow.
Any time you get a complaint like this, don’t bother to look for trouble in the pump. The trouble is
leak in the piping.
You may encounter trouble with another form of hesitation. In this case, the pump starts, delivers
gasoline at the normal rate, then hesitates, and finally continues delivery of the product at the
normal rate.
What causes this? A leak below the combination strainer and check valve, perhaps at the filter
cap or at the suction union which permit some gasoline to leak out of the pumping unit suction
chamber below the check valve of the strainer assembly. There is gasoline in the pumping unit
above the check valve and also in the suction line below the check valve of the strainer assembly.
There is gasoline in the pumping unit above the check valve and also in the suction line below the
points of leakage. When you start the pump the gasoline above the check valve is delivered.
Then the void in the suction chamber caused by the leakage described earlier causes hesitation
of the delivery until this void is filled up by the action of the pumping unit and flow resumes.
Here is another piping difficulty – a leak in the middle of the suction line itself. Again, it would be
revealed by pump hesitation. The pump would start to deliver normally – hesitate – and then
resume delivery. All these moments of hesitation we have spoken of are caused by air being
separated in the air elimination system of the pump.

Now, here is a tip you will want to remember. Any time you are faced with the problem of a leak
in the suction line indicated by hesitation of the pump, whether at the start of delivery or shortly
after delivery begins, naturally the question arises – where is the leak? If you have 15 metres of
suction line running between the pump and the tank, it will be very helpful if you don’t have to dig
up the whole 15 metres of pipe to find the leak.
Here is the way that this can be avoided. You will remember that there is 5 litres of gasoline in 4
metres of 40 mm pipe and 5 litres of gasoline in 2.5 metres of 50 mm pipe. Now, let us say
hesitation occurs after 10 litres have been delivered through the nozzle. In other words, you start
the pump, open the nozzle, 10 litres of gasoline flow from it and then you get a hesitation. You
can find the point of the leak by remembering the quantity of gasoline that is in a length of pipe.
In this particular installation, let us say that the pipe is 50 mm in diameter. You deliver 10 litres of
gasoline before the hesitation occurs. Now, remembering that there is 5 litres of gasoline in every
2.5 meters of 50 mm pipe you start at the pump and pace back towards the tank 5 metres. There
is the place to dig. In every probability, that will be the point of the leak. Now, just to make it
clearer, let us use another example. In this case the hesitation is occurring after 5 litres have
been delivered. The pipe is 50 mm in diameter. There are 5 litres of gasoline in every 4 metres
of 40 mm pipe, so you pack back from the pump towards the tank 4 metres to find the place to
dig.

Pumping Unit
Functional Description
The CPU pumping unit has been designed for robustness and operational reliability, even
to work in the most demanding conditions. It is more compact and has got various integrated
functions like:
• Integrated inlet filtering
• Unidirectional check valve
• Pumping
• Inbuilt air elimination

• Bypass valve
• Outlet valve
The unit is capable of giving standard flow-rates of 45 lit/min (3 m³/hr) and 85 lit/min (5
m³/hr). The change in flow-rates is achieved by changing the pump rotation speed. The changing
the motor pulley does this.
The unit employs rotary vane pump with radially sliding carbon blades. Hence, the unit
produces high suction power even when subjected to run dry.
The unit uses centrifugal effect to separate the air and thus it eliminates air.
Filtering is done in two stages; Inlet filtering is prior to pumping. This filter is with mesh of
80µm and can be supplied in other sizes as well.
Suction pump:
• Self-priming.
• Positive displacement vane pump with air separator bypasses valve and suction strainer.
• Rate of Delivery: 45 LPM, nominal at full flow (std. Duty)
• Rate of Delivery: 80 LPM, nominal at full flow (Heavy. Duty)
• Extra heavy duty: 130 LPM, nominal at full flow. (Extra Heavy Duty)
• Suction lift: 4 meters, nominal

Flow scheme

Metering Unit
(Flowmeter A)
Now let us take a look at the meter. It is a four-piston meter with two opposite pistons connected
by a connecting bar. A rotary valve operating above the pistons controls inlet and discharge
gasoline. The operation of this meter is simple. Gasoline comes through the entrance port, goes
down through the side of the valve along the valve intake, then into the end of the cylinder. When
it does this, it forces the piston inward. A similar movement of gasoline to the end of the opposing
piston moves the product out through the discharge port.
The meters have a spread of about 500 ml preset at the factory. There is a plus of 100 ml and a
minus of 500.The 500 ml minus permits compensation for wear of the meter.
Adjustment or calibration of the L&T meter is very easily accomplished by means of this knurled
wheel. Movement of this wheel controls the length of the piston stroke of two of the four pistons
within the meter. Calibration begins with the removal of the locking pin. Turn the wheel to the
right to reduce the quantity of gasoline delivered, or to the left to increase. Moving the wheel one
hole either way alters the calibration approximately 10 ml. in twenty litres.
Finer adjustment of 5 ml in 20 litres is also possible After the desired calibration is obtained, insert
the locking pin in the hole selected and run a seal wire through the hole in the pin wrapping it
around the rim of the wheel to seal the meter.
At least once a year the inner chamber of the meter should be drained and refilled with a light
grade of lubricating or flushing oil. The plus in the bottom cover can be removed to permit
drainage. Then replace the bottom plug and fill through the opening provided in the side of the
meter body.

ROTARY VALVE
GEAR ARRANGEMENT
PISTON VALVE SEAT
(Flowmeter B)
L&T four Piston Metering Unit ‘B’ is essentially a volumetric measuring device precision built for
sustained accuracy.
The metering unit has aluminium die cast body that house 4-burnished stainless steel
liners in 4 cylinders fitted with single lipped “Rulon” Piston Cups. The metering unit comprises of a
single sealing face. The sealing face comprises of a stainless steel valve seat & a carbon with
graphite kidney valve. The kidney valve has 2 ports one for inlet and one for outlet at 180° to each
other. The valve seat has 4 ports at 90° to one another. The ports are in turn connected to the
above measuring chambers suitably. The positive drive is provided by the fluid, which brings
about movement of the connecting bars, so screwed to piston assemblies. The linear motion of
connecting bar is transformed into rotary one by a crank-rod assembly. The crank-rod assembly
comprises of a stainless steel crank-rod & bronze rollers. A pin on the rod drives the valve on the
valve seat.
The rotary movement of crank-rod may be either transferred to an electronic register directly
mounted on meter or to a mechanical register.

The inlet product to the meter through the inlet port of the valve enters the cylinder, which is at
extreme outer end. The pressure of the product forces the Piston forward turning the crank-rod
and the valve. At the same time the piston at the adjacent cylinder, which is at its inner most
position, is pushed outward discharging the product in this cylinder through the outlet port of the
valve to the Meter Outlet. The product is cyclically directed to a measuring chamber discharged
from the same resulting rotation of the crank-rod proportionate to the metered product.
As the measuring chambers are 90° apart there is an interval in the cycle when both pistons will
be moving inwards simultaneously when the product from the opposite chambers is directed to
outlet. The 90° disposition between measuring chambers and 180° between inlet and outlet ports
of valve prohibits dead centric / static conditions in the Meter.
Meter calibration is achieved through an Adjusting wheel assembly, so screwed onto an

Adjustable cover mounted on the Meter body. The adjusting wheel assembly comprises of an
adjusting wheel and adjusting screw assembled by a groove pin. In calibrated condition there is a
positive contact between the screw & clamping bolt of piston & connecting bar assembly. Rotation
of the wheel causes the corresponding linear movement of the screw. This changes the clearance
between the rollers mounted on the crank rod & connecting bar groove, thereby changing piston
stroke & volume delivered (Piston Stroke= 2*Eccentricity + Clearance). After calibration is
achieved the Adjusting wheel assembly is locked by a pin and sealed in place with sealing wire.

MOTOR:
Caution: Be sure supply circuits are shut off at their source before working on any exposed bare
current carrying parts.
Overload Protection: motors are equipped with thermal overload devices. This device will open
the circuit automatically, if the motor is drawing an excessive overload current, or if the motor
overheats from excessively prolonged running periods. The overload device is automatic and
independent of any movement of the switch-operating lever.
If overload continues to open the circuit automatically, it is an indication of some outside abnormal
condition. The trouble may be for example: - some foreign particle has lodged in the pump
causing it to bind. Turn the shaft of the pump and motor by hand to see if both are rotating freely.
If free, examine pump by-pass valve to see that it is clean and not sticking. Remove and clean
pump strainer. If all are in order and switch continues to
open, have the line voltage checked for its normal rating. Have motor examined to see that it is
working properly.
Note:
The motor is designed for continuous running. The motors are incorporated with starting windings
to facilitate starting on load. The switch over from starting to running winding is carried out by
means of a centrifugal switch. Correct location of the stator and rotor parts of the centrifugal
switch is important for its proper functioning.
SOLENOID VALVE
The solenoid valve is an electrically operated flow control valve.
The solenoid valve used in SPRINT pumps is of SINGLE type. The valve has a single inlet port
and outlet port.
The main functions performed by the solenoid valve are:

1. To provide preset function facility.
2. To maintain wet hose system.
The solenoid valve prevents reverse flow of the fluid. It acts as a non-return valve there by
maintaining wet hose system in pumps.
Another important feature of the solenoid valve is brought to the forefront is during hot climatic
conditions. During such conditions the fluid in the hydraulic system tends to expand thus
increasing the fluid pressure. The solenoid valve allows a small quantity of fluid to bleed back to
relieve the inside pressure.
The use of solenoid valve allows one to carry out preset function. This feature allows the operator
to set accurately the amount of fuel to be delivered.
The solenoid valve comprises of a central body of aluminium. It comprises of one set of electrical
coil. The set in turn comprises of high flow and low flow coils. The coils magnetize the orifice
plunger there by controlling the opening and delivery. The coils when receive electrical signals
from computer gets magnetized in a particular fashion. After presetting when the nozzle is lifted
the low and high flow orifices both remain open there by allowing maximum flow. In the later part
of delivery say for 5litres when 4.3 litres have been delivered, the high flow shuts and only low
flow is operational. This reduces the flow rate until the end of delivery.
The minimum flow rate through the solenoid is 4lpm and maximum 85lpm.
PRESSURE REGULATING VALVE (Only when used with Submersible Pumps)
As product flows through the system, the valve opens, permitting gasoline to flow upward through
the rest of the system. When the nozzle is closed and delivery stops, the valve closes. Thus
pressure remains in the upper part of the pump when the pump is idle.
The small valve in the upper stem serves a function. Suppose gasoline at 150C in an
underground storage tank is drawn up into the gasoline pump during a delivery and that after the

motor is shut down the pump stands idle in the hot summer sun. The temperature builds up and
as the product is trapped, pressure builds up also. Existing Standards require that internal
pressures shall not exceed 3.5 kg/cm2. This bleeds a small amount of product from the closed
system to keep the pressure within permissible limits.
RUBBER SEAL
FILTER MODULE (Only when used with Submersible Pumps)
The primary function of the filter module is to precipitate out the suspended, undissolved foreign
particles from the fuel delivered by the suction unit. The filter has a stainless steel wire mesh,
which is formed into a cylindrical shape. The mesh size is 70 microns to ensure that the smallest
of the particles gets filtered.
The cylindrical mesh is snug-fitted on to a casting of similar shape and size. This prevents any
change in shape due to deformation, warpage etc. The filter can be easily removed and
cleaned.The filter module consists of two caps and a central body. The caps are sealed to the
body with gaskets. The flexible feed line conduit that feeds the solenoid valve is inserted from the
top of the module. This is held in position by a sealing cap.
The central screw at the bottom cap of the filter module allows easy draining of fuel. The filters are
cleaned at least once in a month. It involves draining the fuel and taking out the mesh by
removing the bottom cap. The mesh is cleaned with a brush first in kerosene and then cleaned
with compressed air.

FILTER MODULE ASSEMBLY FILTER MESH 70 MICRON
NOZZLE
The nozzle employed in MPD pumps is imported one of preset and automatic type. The nozzle
has a long curved aluminium discharge tube which screws into an aluminium die cast body. The
main nozzle body is compact yet large enough for station operators to grasp easily. The main
stem, which is pushed upward by the trigger, is sealed from product leakage by a special type of
synthetic seal. No adjustment is required. It has a packing of graphite with Teflon and disc of
viton material.
The nozzle has a one-piece spout, which eliminates possible leak points. Also it comprises of a
rack arrangement for one hand control thereby allowing easy setting of flow rate for customer
convenience. The nozzle also a two stage lever assembly, which provides for a positive shut-off,
even if it is still held in wide-open position by the user. The nozzles also as a unique feature of
flow lock, which is designed to shut-off automatically when the spout is tipped up, limiting spillage.
It also as a low reliable shut-off to ensure proper shut-off as low as 3 gallons per minute.

The nozzles are provided with different spout sizes depending of type of delivery.
LEVER
NOZZLE BODY
SPOUT
MISCELLANEOUS COMPONENTS
TWO PLANE SWIVEL CUM BREAKAWAY COUPLING.

A swivel joint is employed between the hose and the nozzle. The swivel used is a two-plane one.
It allows a rotation of 360º on both swivel plane and,. The first plane (at nozzle inlet) allows 360º
swivel action for easy rotation of the nozzle away from the dispenser.
The second plane (at hose connection) provides 360º swivel action, for easy nozzle positioning in
fill pipes.
The body is made of aluminium and the adaptors of zinc it also comprises of dual seals for added
protection against thermal and chemical degradation. The unique two-plane rotation also helps in
reducing hose kinking and premature hose wear.

SAFE
BREAK
TWO PLANE
SWIVEL
The breakaway coupling so used in MPD dispensers gets separated out when subjected to a
designated pull force. It comprises of dual valves, which seat automatically, stopping the flow of
fuel and limiting any fuel spillage, while protecting the dispensing equipment.
It comprises of an aluminum body and a die-cast middle coupling. The breakaway coupling has a
breakaway force of 350lbs. It also designed for certainty of operation. It is supposed to be
replaced after separation, instead of reassembled one, to protect against reassembly errors. Also
its design allows for minimal pressure drop for faster, high-volume fill-ups.

ERA – Electronic Register Assembly
System architecture

Schematic diagram

Functional description
• SMPS CARD:
SMPS refers to Switch mode power supply. The function of the SMPS card is to
convert the AC 230V 50Hz input signal to DC voltage. This card can easily handle
voltages varying from 180 V ac to 250 V ac. The SMPS card generates DC voltage for
relays, backlit and controller. The output of the SMPS is given to the power supply
card.
• DISPLAY + POWER SUPPLY CARD:
The power supply card converts the SMPS voltage signal to a voltage level suitable
for the controller circuit. This also performs a dual function of a display card, battery
charger circuit and generates an NMI on power failure. The rating of battery used is
6V , 4A Hr.
• DISPLAY + CONTROLLER CARD:

The Display + Controller Card is considered to be the brain of the pump. It stores
vital data like Currently Dispensed Sale and Volume of Fuel, Totaliser, various
parameters etc.
On sensing the nozzle boot condition it gives signals to the motor and solenoids, collects
dispensing data from the sensor calculates the data and displays the information on the LCD. It can
also communicate to a Point of sale system. It updates the transaction details in the totalisers. It can
also receive the preset information from the keypad.
• RELAY CARD:
The relay card controls the operation of the hydraulic system. The operation of the motors and the
solenoids is controlled by the relay card depending on the controller input.

• SENSOR CARD:
The Sensor card gives feedback to the controller proportional to the amount of fuel
delivered. The Sensor card consists of Opto sensors. A slotted sensor disc is mounted
in between the Opto Trans receivers. This Disc is connected to a gear arrangement of
the Metering Unit. Whenever fuel is dispensed the gear arrangement causes the Disc
to rotate. This disc rotation causes the optical signals to be generated, which in turn
generates the pulses. These are then given as inputs to the controller. The controller
is responsible for calculating the sale and volume.
• KEYPAD:
The keypad is used to preset a desired value of fuel. This input is sensed by the
controller which stops the delivery at the required amount or volume.
Pulser description
The Sensor box consists of two main parts namely the Sensor Card & the
Sensor Disc. The Sensor Card consists of three Optical trans-receiver packages.

These three Optical devices are placed in a certain angle in order to ensure free
movement of the Sensor disc. When fuel is dispensed from the nozzle the rotation
of the metering unit is conveyed to the Sensor card via the meter output shaft on
which the Sensor disc is concentrically mounted. This Disc has 25 accurately
machined slots. As this disc rotates, at various positions the disc cuts the optical
signal of the trans-receiver causing pulses to be generated. These pulses are then
given to the controller.
Volume dispensed = One pulse corresponds to 10ml.

Sale = (the set Rate * Volume dispensed).

USER INTERFACE
MANNUAL MODE
On power on
1. Display on power on begins in self-segment test mode.
2. Two seconds ‘’8.8.8.8.8.8’.
3. One second blank.
4. Before delivery ‘0000.00’on Rupees & Litres display and actual rate on rate display.
8.8.8.8.8.8 Rupees
0
8.8.8.8.8.8 Litres 1 2 3 Sal
8.8.8.8 4 5 6 Litr
Rs./Lit. 7 8 9 C
Dispensing mode
F1 0 F2
1. Lift the nozzle.

2. Motor will turn on.
3. Open the nozzle and start dispensing.
4. Stop dispensing at required value.
5. Keep the nozzle back in the boot.
6. The rupees display will indicate the amount of rupees to be paid by the customer.
7. The litres display indicates the amount of litres dispensed.
8. The rate display indicates the rate per litre for fuel.
103.71 Rupees
3.00 Litres
34.57 Rs./Lit.

Display on nozzle reset
1. The display will indicate previous delivery till the boot is reset.
2. Now lift the nozzle.
3. The display will reset and show “0000.00”
0000.00 Rupees
0000.00 Litres
34.57 Rs./Lit.
PRESETTING A RUPEES VALUE
1. Ensure the nozzle to be in the boot.

2. Press “sale”.
3. The keypad display will show “ A “.
4. Now enter the Rupees value to be preset.
5. Example if 500 is entered the keypad display will show “ A 500”.
500 Rupees A 500

1 2 3
Litres
Sal
4 5 6 Litr
34.57 Rs./Lit. 7 8 9 C
F 0 . F
6. The Rupees display will show a blinking 500.

7. The litres display will be blank.
8. The rate display will be as it is.
9. Now lift the nozzle. Motor will turn on.
10. Place the nozzle in the car tank. Keep the nozzle open.
11. The rupees display will start incrementing till the preset value is reached.
12. As soon as the preset amount value is reached the solenoids and motor will shut down
and the nozzle will trip.
13. The display will indicate the preset value and the corresponding litres value.
14. Replace the nozzle in the boot.
15. The pump is ready for next preset.
A * 500
0500.00 Rupees
1 2 3
Litres
Sal
0014.46
4 5 6 Litr
34.57 Rs./Lit. 7 8 9 C
F 0 . F
PRESETTING A LITRES VALUE

2. Press “LITRES” on the keypad.
3. The keypad display will show “ L “.
4. Now enter the litres value to be preset.
5. Example if 10 is entered the keypad display will show “ L 10”.
L 10
Rupees
10 Litres 1 2 3 Sale
4 5 6 Litr
34.57 Rs./Lit. 7 8 9 C
F1 0 . F2

6. The Litres display will show a blinking 10.
7. The rupees display will be blank.
8. The rate display will be as it is.
9. Now lift the nozzle. Motor will turn on.
10. Place the nozzle in the car tank. Keep the nozzle open.
11. The rupees display will start incrementing till the preset value is reached.
12. As soon as the preset litres value is reached the solenoids and motor will shut down and
the nozzle will trip.
13. The display will indicate the preset value and the corresponding rupees value.
14. Replace the nozzle in the boot.
15. The pump is ready for next preset.
L * 10
0345.70 Rupees
1 2 3 Sal
0010.00 Litres 4 5 6 Litr
34.57 Rs./Lit. 7 8 9 C
F 0 . F
ERRORS
1.SENSOR BLINKING: No dispensing time out.

1. After lifting the nozzle if there is no dispensing for 60 seconds the rate display will show an
error and the motor and solenoids will shut down.
2. The rate display will indicate a sensor blinking signal at the sides of rate LCD vertically.
3. Fresh dispensing can begin only if boot is reset.
34.57
E
N
S
O
R

2. E 08.(TWO SENSOR):
1. If the sensor pulses coming to the counter are not correct the rate display will show “E 08”
on the display.
2. The incorrect pulses may be due to sensor failure.
3. The motor will shut down and there will be no dispensing
possible until the error is corrected.
138.28 Rupees
4.00 Litres
E 08 Rs./Lit.
WARNING
SENSOR (SINGLE SENSOR)
1. This is a warning message to indicate that a stand by sensor has failed.

2. If any one sensor among the three on the sensor card fail or the sensor disc and card
alignment in the sensor box is not proper the rate display will show this error.
3. The normal operations can go on and the pump can be used for dispensing in this case.
4. Also inform the LT service engineers to rectify.
LOW BATTERY
1. The pumps have a battery backup facility for data saving under power failure condition.
2. If the battery level goes below 5.5V dc a warning message appears to indicate that the
battery has discharged and the data on the display will disappear after some time.
3. But the Electronic totaliser value will be safe even in case of battery not available.

4. It is recommended to place the nozzle in the boot when
5. There is low battery indication on the rate display.
34.57
O
W
B
A
T
T
HANDLING THE THERMAL PRINTER

1. Printer mechanism handing
1) Do not pull the paper out when the cover is closed.
2) Because the thermal elements of the print head and driver ICs are easy to break, so do not
touch them with any metal objects.
3) Since the areas around the print head become very hot during and just after printing, do not
touch them.
4) Do not use the cover open button except when necessary.
5) Do not touch the surface of the print head because bust and dirt can stick to the surface and
damage the elements.
6) Thermal paper containing Na, K, Cl ions can harm the print head thermal elements. Therefore, be sure to use only the
specified paper.
2. Thermal paper handling

Notes on using thermal paper
Chemicals and oil on thermal paper may cause discoloration and faded printing.
Therefore, pay attention to the following;
1) Use water paste, starch paste, polyvinyl paste, or CMC paste when gluing thermal paper.
2) Volatile organic solvents such as alcohol, ester, and ketone can cause discoloration.
3) Some adhesive tapes may cause discoloration or faded printing.
4) If thermal paper touches anything which includes phthalic acid ester plasticizer for a long
time, it can reduce the image formation ability of the paper and can cause the printed image to fade. Therefore, when
storing thermal paper in a card case or sample notebook, be sure to use only products made from polyethylene,
polypropylene, or polyester.
5) If thermal paper touches diazo copy paper immediately after copying, the printed surface
may be discolored.
6) Thermal paper must not be stored with the printed surfaces against each
other because the printing may be transferred between the surfaces.

7) If the surface of thermal paper is scratched with a hard metal object
such as a nail, the paper may become discolored.
Notes on thermal paper storage
Since color development begins at 70C (158F), thermal paper should be protected
from high temperature, humidity, and light, both before and after printing.
1) Store paper away from high temperature and humidity.
Do not store thermal paper near a heater or in enclosed places exposed to direct sunlight.
2) Avoid direct light Extended exposure to direct light may cause discoloration or faded
printing.
3. Others
Because this printer uses plated steel, the manual cutting edge may be subject to rust.
However, this does not affect the printer performance.
PROGRAMMING INSTRUCTIONS
READING THE SOFTWARE REVISION NUMBER
1. Ensure that the nozzle is in the boot.

2. Press F1 and F2 simultaneously.
0
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2

3. Display will show L1
L1
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
4. Press Litre key to scroll down.
L2
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
L3
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2

Ur 18006 Version number
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
READING THE TOTALISERS
0
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
1. Press F1 + F2
L1
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

2. Keypad display will show L1. Now press the litres (down) key.
L2
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
L3
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
tOt
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

5. Now press F2 the keypad will show CU – Cumulative volume totalizer.
CU 000045 Rupees
1 2 3 Sale
2334.57 Litres
4 5 6 Litr
7 8 9 C Rs./Lit.
F1 0 . F2
6. Read the value from the main display. Example in the display Cumulative sale totaliser. =
34561436.87
CS 003456 Rupees
1 2 3 Sale
1436.87 Litres
4 5 6 Litr
7 8 9 C Rs./Lit.
F1 0 . F2
7. Press the litre key.
8. Read the value from the main display. Example in the display Shiftwise volume totaliser. =
12356.85

SU
000001 Rupees
1 2 3 Sale
4 5 6 Litr 2356.85 Litres

7 8 9 C
Rs./Lit.
F1 0 . F2
9. Press the litre key.

10. Read the value from the main display. Example in the display Shiftwise Sale totaliser. =
122769.82
SS 000012 Rupees
1 2 3 Sale
2769.82 Litres
4 5 6 Litr
7 8 9 C Rs./Lit.
F1 0 . F2
ENTERING INTO PROGRAMMING MODE – LEVEL 1
1. Press F1 + F2
0
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

L1
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
2. Keypad display will show L1. Now enter the password – 0000(default value).
8888
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
3. Keypad display will show rtC. It is the first parameter in the programming mode.
rtC
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

0
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
2. Press F1 + F2
L1
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
2 Keypad display will show L1. Now press the litres (down) key.
L2
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

3. The display will show L2.Press down and tot keys simultaneously from the controller card.
TOT OR
TOTALISER
UP AND DOWN
4. Now press the password for level 2 – 1369 (default value).
8888
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
rtC
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

2. Press F1 + F2
0
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
L1
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
L2
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

L3
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
4. The display will show L3.Press down and tot keys simultaneously from the controller card.
TOT OR
TOTALISER
UP AND DOWN
5. Now press the password for level 3 – 2468 (default value).
8888
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

rtC
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
CLEARING THE SHIFT.
1. When the display shows SS or SU press C (enter key). The Shift gets cleared.
2. Confirm the shift clearing by scrolling through and reading the Shift wise values again
after clearing.
RATE PROGRAMMING.
1. Go to level 1 programming mode.
rtC
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

2. Keep pressing the Down (Litre) Key from the keypad display till the parameter ‘rt’ is
observed on the Keypad display.
rt 12.34
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2
3. Now enter in the new rate using Number Keys and Dot Key.
4. After entering the new rate press the ‘C’ Key on the Keypad to save the new rate.
5. Example – if the new rate entered is 36.78 the display will show as below.
rt 36.78
1 2 3 Sale
4 5 6 Litr
7 8 9 C
F1 0 . F2

PARAMETERS
S.No Parameters Level Range Default PC
Second (SEC) 0-59 10

Minute(nnIt) 0-59 10
Hour (Hr) 0-23 10
1 RTC L1 R/W
Date (dt) 1-31 10
Month(nnOn) 1-12 10
Year (Yr) 0-99 10
2 Upper Sale L1 US 0-999999 0 R/W
3 Upper Volume L1 UU 0-999999 0 R/W
4 Preset Sale F1 L1 S1 0-9999 100 -
5 Preset Sale F2 L1 S2 0-9999 200 -
6 Preset Volume F1 L1 U1 0-9999 5 -
7 Preset Volume F2 L1 U2 0-9999 10 -
Or 0 - 9999
8 Oil Rate L1 10.00 R/W
Decimal 0-3
9 Oil Percentage L1 OP 0-5 0 R/W
10 No Pulse Timeout L2 nP (0, 30, 60, 120) 60 -
11 HF Cut OFF L2 HF 1-10 7 -
rt 1-9999
12 Rate L1 10.00 R/W
Decimal 0-3
Ldd
0 to 10
Leak detector delay
13 Leak Detector Delay L3 0 -
should be equal to
or 1sec greater than
motor switch on
programmability.

LCd
LCD Segment Check
14 L3 2 -
Delay
0 – 10 sec
15 Hose Swell Value L3 HS 0-9 5 -
16 Sale Decimal Setting L3 Sd 0-3 2 R/W
17 Volume Decimal Setting L3 Ud 2-3 2 R/W
PSt 0-5
0-Round Off As
Calculated
1-Ceil As Calculated
2-Truncate As
18 Preset Sale Termination L3 Calculated 0 -
3- Round Off As
Entered
4-Ceil As Entered
5-Truncate As
Entered
19 Pump Id L3 PId 1-247 1 R
0000 – 9999
The display for
these parameters in
L1 "0000"
programming level
20 Password: L0/L1/L2 L3 L2 “1369” -
are changed from
L3 “2468”
PC1, PC2 & PC3 to
L1, L2 & L3
nnOt , equal to leak

detector delay or
Motor Switch ON
21 L3 lesser than leak 0 -
programmability
detector delay by 1
sec

PROGRAMMING INSTRUCTIONS -PRINTER
INCHING

2. Place the paper in the paper entry slot.
3. Check that the paper passes through the paper sensor.
4. Enter programming mode – level 1
5. Scroll through the parameters till you see InCh.
InCh
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
InChIn
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
6. Now press F2..

7. The printer will give 4 line feeds and show InChIn on the keypad display.
PRINTING A RECEIPT

1. Complete the delivery.
3. Press 0 key.
4. The keypad display will ask for vehicle number.
Un0 0
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
5. Enter the four digit vehicle number. Example 3614
Un0 3614
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
6. Now press C (enter key)

7. The keypad display will show printin
8. The printout for the current dispense can be acquired using C key (enter) if the
user does not want to enterPrIntIn
the vehicle number.
1 2 3 Sal
Sprint Manual 4 -------75-------

5 6 Litr Petrol Pump Division
7 8 9 C
9. Print command cannot be given when the pump is dispensing.
10. The user can continue with the next delivery after giving the print command
while the printer is printing.
ABORTING A PRINT
1. If the user wants to abort a printing operation press 9 key.
PRINTING TOTALISER VALUES
1. Enter level 1 programming.

2. Scroll through the parameters till you see totPrn.
tOtPrn
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
3. Now press C.
4. The keypad display will show PrIntIn
PrIntIn
1 2 3 Sal
4 5 6 Litr
PRINTING A BACKUP

2. Scroll through the parameters till you see PrnbCUP.
PrnbCUp
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
3. Now press C.
PrIntIn
TAKING A TESTPRINTOUT
1 2 3 Sal
4 5 6 Litr
7 8 9 C
Sprint Manual F1 0-------77------- F2 Petrol Pump Division
2. Scroll through the parameters till you see tEStPrn.
tEStPrn
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
5. Now press C.
PrIntIn
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
REAL TIME CLOCK SETTING

2. Press F2 when you see rtC.

rtC
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
3. The keypad display will show seconds. example 12
SEC 12
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
4. Enter the desired value and press C (enter key)

5. Now press litre (down) for the next parameter.
6. The keypad display will show minutes. example 52
nnIt 52
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2

9. The keypad display will show Hour. example 10
Hr 10
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2

12. The keypad display will show date. example 24
dt 24
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2

15. The keypad display will show month. example 8
nnOt 8
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2

18. The keypad display will show yr. example 04
yr 4
1 2 3 Sal
4 5 6 Litr
7 8 9 C
F1 0 F2
USER INTERFACES –PRINTER
PAPER OUT
1. If the keypad shows paper out check

a. The paper roll is not finished. If the roll is finished insert a new paper
roll of good quality using paper roll changing instructions.
b. The paper is inserted correctly through the paper sensor. If not place the
paper in such a way that the paper moves through the paper sensor
smoothly.
PRINTER ERROR
2. If the keypad shows printer error when you give a print command check
a. The connections and cables to the printer and printer controller are
proper.
b. The paper may be jammed up in the printer. Remove the paper carefully
and power reset the pump. Now reload the paper using paper loading
instructions.
1. Turning the ribbon cassette knob in the arrowed direction, remove slack..
2. On replacing a ribbon cassette, pull it out as holding the "PULL" part.
MAINTAINENCE OF THE THERMAL PRINTER

MOUNTING PAPER ROLL
1. Make sure that the printer is not receiving data; otherwise, data may be lost.
2. Open the paper roll cover by applying your finger on both side of printer,
push it up when the lock is released as shown in the drawing.
Note : Be sure to use paper rolls that meet the specifications.

Do not use paper rolls that have the paper glued to the
core because the printer cannot detect the paper end
correctly.
Recommended paper
Type : Thermal Paper
Paper width : 57mm
Paper thickness : 65±5 micro m
Outer diameter : Ø60mm or less
Recodeing side : Outside of roll
Cautions for using a thermal paper

1. Do not paste the paper to the core. And the roll paper whick has
Near end mark printing on its near end is recommended.
2. Chemicals or oil may change the color of paper, or printed Characters may fade.
3. Change of paper color starts from approx . 70 °C. Pay attention to heat, humidity and
sun light.
4. Color of paper may be changed by being scratched by nail or hard metal, etc
Cautions for Roll Paper

1. Make sure that the beginning of roll paper to the inner core must be as follows.
a. No fold.
b. Paper must be rolled into the inner core.
c. 2. No flap

2. Do not paste the paper to the core. (If an inner core is available)
3. Recommended paper:
One ply paper............... 45 ~ 55 Kg/1000 pcs/1091 x 788 mm
2 ply paper ................... No carbon paper Original paper (34 Kg paper)+copy paper 1 pcs (34 Kg paper)
Total thickness 0.13 mm or less
3. Remove the used paper roll core if there is one.

4. Insert the paper roll as shown.
(Be sure to note the correct direction that the paper

6, Pull out a small amount of paper and then close the cover, as shown.
3. Tear off the paper as shown
MOUNTING PAPER ROLL

COMMUNICATION DETAILS
REQUIREMENTS

1. Z Line preset pump with communicable controller board.
2. PC with
POS pakage which can communicate with the pump.
RS 485 com port.
3. Communication cable.
Recommended – Belden 8132 paired computer cable.
4 cores , i.e. two pairs.
28 AWG
Tinned copper conductor.
With Aluminum foil polyester tape/braid.
Insulation – Cellular polyolefin.
Jacket material – PVC chrome.
With low capacitance for EIA RS 485 applications.
CONNECTING THE L&T PUMP TO POS(Point of Sales).

1. Each pump will have a unique ID on the network which is user defined.
2. PC will be the master.
3. The pumps will be connected in a multi drop configuration using a 2 wire
loop with RS 485 to the RS 485 port of the PC.
4. No two pumps can have the same ID.
CUSTOMER CONNECTIONS
FOR SINGLE PHASE MAINS 230V INPUT SUPPLY AND COMMUNICATION.
The junction box has a terminal row for connecting the lines.
The terminals have identification tags on it.
Connect Mains - phase to P

- neutral to N
- earth to E
Connect communication cable as
• Incoming transmit line O – Orange to T1.
• Incoming receive line W+O – white with orange dots to R1.
• Outgoing transmit line BU – Blue to T2.
• Outgoing receive line W+BU – white with blue dots to R2.
• Earth line to E.
COMMUNICABLE PARAMETERS.
1. Cumulative electronic volume totaliser
A 10+2 digit electronic totaliser can be read.
This value is non resetable and a read only value.
2. Cumulative electronic sale totaliser
This value is non resetable and a read only value.
3. Shiftwise electronic volume totaliser
This value is resetable and a read only value.
4. Shiftwise electronic sale totaliser
This value is resetable and a read only value.
5. Product rate Setting.
The rate value is of four digits. It can be read or written to.
6. Oil rate Setting.
The rate value is of four digits. It can be read or written to.
7. Oil percent Setting.
The range is 0 to 5. Mechanical setting is required to physically get the set quantity.
It can be read or written to.
8. Last dispensed sale and volume.
The last delivery details can be read.
9. Preset Setting.
A preset sale or preset volume value can be set using the POS.
10. Real time clock Setting.

Real time clock value can be set or read using the POS.
11. Status.
The status of the pump can be read using the POS.
12. Upper sale and volume Setting.
The max limit of manual delivery can be set or read using POS.
13. Header and footer setting.
A 5 line header and 1 line footer for the printer can be
programmed using the POS. The fuel type can also be programmed.
OIL LEVEL SENSOR CARD
CONNECTIONS

OIL TANK REFILLING INSTRUCTIONS
1) Green LED blinking indicates overflow.

2) Green LED indicates oil tank full.
3) Refill the oil tank when Yellow LED starts blinking.
4) Pump will stop delivery when Red LED turns on i.e. tank empty.

TROUBLE SHOOTING IN L&T METERING & DISPENSING PUMPS
TROUBLE POSSIBLE CAUSE ACTION TO BE TAKEN

1. Insufficient product in storage tank Check the underground tank. Pump
should not be allowed to run dry.
2. Reduced pump speed-belt tension is too Adjust the belt tension. Play on one
loose side of the belt should be around 1”.
3. Dirty Pump Strainer Clean the strainer thoroughly
4. Air leak on suction side of pumping unit The trouble can be confirmed by
checking whether the sump is vented
through the boot. Check the suction
union and the strainer cap for leak proof
SLOW OR NON DELIVERY
functioning.
5. Valve in float chamber sticking open The valve and seat of the sump should
be cleaned thoroughly and examined
for burrs. Also check that the float is
not damaged and it operates freely on
its guide.
6. By pass valve stuck open Clean the by-pass valve and its seat
and ensure that the valve moves
smoothly in its chamber
7. Clogged nozzle or crushed hose Ensure that both the nozzle and the
hose are in good condition
8. Reduced speed of motor due to low Motor will pick up rated speed as soon
voltage as the normal voltage is restored.
9. Meter Binding Service the meter to ensure that it runs
smoothly.
10. Worn pump blades Replace the blades

11. Underground piping trouble Ensure that underground piping
system, including the check valve and
the filter is OK. Any leak in the system
and too long piping or too many bends
can cause slow or non-delivery
1. Improper adjustment of the calibration Adjust the calibrating wheel as
wheel required.
INACCURATE MEASUREMENT
2. Swollen Ò’ ring. Replace the Ò’ ring with a new one.
3. Worn sealing surfaces (ie. valve, valve Lap and clean the surfaces thoroughly.
seal, valve seat) Use a finer mesh filter.
4. Worn piston leathers Replace the piston leathers if they are
beyond servicing. Use a finer mesh
filter strainer.
5. Inaccurate test can Check that the test can is free from
dent or defect. Its accuracy must be
within the limit.

1. Pumping pressure is too Measure maximum pressure attained momentarily in
high the pumping unit as soon as the pump is put on. If it
is higher than 2.0 kg/cm2 in Standard & Dual
pumping units and 3.5 kg/cm2 in Heavy Duty
Pumping Units clean the by-pass valve and seat. If
DISPLAY JUMP
the surge pressure is still high, replace the bypass

valve
2. Leakage of product Check meter cover for leakage. Rectify same by
through dome cover replacing Ò’ ring GM 50003 if swollen. Grease and
replace floating bearing GM 60009 if it is worn.
3. Leakage of product Check for leakage at PRV and meter gasket and
through threaded joints nozzle. Rectify leakage if any.
between PRV and Nozzle

4. Faulty relief valve GV Replace same if the rubber is deteriorated.
0001 in the PRV
5. Main valve of the PRV Clean the valve seat. Replace the rubber disc if
does not sit properly on its necessary.
seat
6. Excessive length or poor Hose length should never exceed 5 metres. If
condition of hose register jump is still noticeable (more than 25 cc)
replace the hose.
1. Pump not bolted down Check that the nuts are properly tightened and the
properly bolts are properly grouted
NOISY OPERATION
2. Too much belt tension or Ensure proper adjustment of belt tension and
misalignment of pulleys alignment of pulleys
3. By-pass valve pressure Adjust the spring pressure
too high (Heavy Duty)
4. Worn pumping unit or Replace the bearings
motor bearings

1. Needle valve in sump sticking closed Clean the valve and its seat
FUEL ESCAPES FROM SUMP
thoroughly
2. Float sticking on guide rod or partially Repair the float and the guide rod.
filled with liquid Replace these if found badly
VENT
damaged. The float must operate

freely on its guide
3. Copper tube return line from sump is Clean the return tube thoroughly.
bent or pinched or it is clogged with dirt Repair or replace the return tube
and foreign particles, thus restricting flow depending upon the damage

4. Defective pressure regulating valve Check the PRV to ensure that it is
functioning properly. Valve seat
should be thoroughly cleaned and
the rubber disc and the small relief
valve should be in good condition
5. Expansion of air and vapour traps in No action is needed since it is quite
underground suction line. Expansion of normal during the hot summer days.
fuel in a rather long hose may also
contribute to the trouble
1. No power supply **
PUMP DOES NOT START
Check the fuse or the circuit breaker

2. Blown fuse or tripped circuit breaker
and set it right
Check the throw of the switch rod
3. Switch rod out of adjustment
and adjust it properly
Repair or replace the switch as
4. Faulty Power Switch
required
Repair or replace the motor as
5. Burnt motor or thermostat stuck open
required
Check the throw of the switch rod
DOES
SHUT
and adjust it properly

Switch rod out of adjustment
PUMP
NOT
OFF
CAUTION
! DO NOT USE THE PETROL PUMP TO EMPTY WATER FROM THE TANK.

! CHECK PETROL TANKS REGULARLY FOR WATER, WITH WATER FINDING
PASTE.

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USER MANUAL

SPRINT PUMP & DISPENSER

Sprint Manual -------1------- Petrol Pump Division

2. General Arrangement – External & Internal

9. Handling the printer

10. Programming instructions - Pump

11. Programming instructions - Printer

Sprint Manual -------2------- Petrol Pump Division

12. User interfaces - Printer

13. Maintainance of the pump

14. Communication details

15. Oil level Sensor card

16. Trouble shooting

Sprint Manual -------3------- Petrol Pump Division

Sprint Manual -------4------- Petrol Pump Division

Sprint Manual -------5------- Petrol Pump Division

Sprint Manual -------6------- Petrol Pump Division

Sprint Manual -------7------- Petrol Pump Division

Error indications provided.

12 digit electronic tantalizer.

¾ HP motor with thermal protection and overload protection.

Sprint Manual -------8------- Petrol Pump Division

Programmable decimal point.

Price setting through keypad.

The Pump will confirm to European norms (CE), as well as UL - 87 norms.

Sprint Manual -------9------- Petrol Pump Division

Suction Pump features :

Motor (For Suction Pump) :

Sprint Manual -------10------- Petrol Pump Division

Safety shear valves with submersible pumps

Printing method Direct thermal line printing

Sprint Manual -------11------- Petrol Pump Division

Sprint Manual -------12------- Petrol Pump Division

Sprint Manual -------13------- Petrol Pump Division

Sprint Manual -------14------- Petrol Pump Division

Sprint Manual -------15------- Petrol Pump Division

Sprint Manual -------16------- Petrol Pump Division

Sprint Manual -------17------- Petrol Pump Division

Sprint Manual -------18------- Petrol Pump Division

• The earthing arrangement must be as per IS : 3043.

Sprint Manual -------19------- Petrol Pump Division

Sprint Manual -------20------- Petrol Pump Division

Mains cable (per motor)

Sprint Manual -------21------- Petrol Pump Division

Sprint Manual -------22------- Petrol Pump Division

Sprint Manual -------23------- Petrol Pump Division

Sprint Manual -------27------- Petrol Pump Division

Sprint Manual -------28------- Petrol Pump Division

Sprint Manual -------29------- Petrol Pump Division

Sprint Manual -------30------- Petrol Pump Division

EFFECT OF ATMOSPHERIC PRESSURE ON PIPING

Sprint Manual -------31------- Petrol Pump Division

Sprint Manual -------32------- Petrol Pump Division

Sprint Manual -------33------- Petrol Pump Division

Sprint Manual -------34------- Petrol Pump Division

• Integrated inlet filtering

• Unidirectional check valve

• Inbuilt air elimination

Sprint Manual -------35------- Petrol Pump Division

Sprint Manual -------36------- Petrol Pump Division

Sprint Manual -------37------- Petrol Pump Division

Sprint Manual -------38------- Petrol Pump Division

PISTON VALVE SEAT