Professional Documents
Culture Documents
Make sure that you know how to turn off power to the dispenser and remote LPG pump in case of
an emergency. Have all leaks or defects repaired immediately.
Contact Yenen
Trouble in installing and operating the dispenser should be referred to your authorized Yenen
dealer or to Yenen technical support (+90 216 487 5924).
Explanation of symbols
Warning: Indicates the presence of a hazard that can cause severe personal injury or
property damage if not observed carefully.
This manual provides instructions and guidelines. The remarks and warnings inform the operator of the
hazards involved in installing and handling LPG dispensers. Reading these instructions and preventing
hazardous situations is strictly in the hands of the operator of the equipment. Neglecting this responsibility is not
within the control of Yenen.
No part of Yenen manuals may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated
into any language in any form, by any means, without Yenen’s prior written permission.
Yenen reserves the right to change the specifications of the products described in this manual at any time and
without prior notice.
Yenen cannot and will not be held liable for any damages resulting from the use of this product.
While every effort has been made to ensure that the information in this manual is accurate and complete, Yenen
shall not be held liable for errors contained herein or for incidental or consequential damages in connection of the
use of this manual.
The logo(s) of Yenen Engineering Ltd. are property of Yenen Engineering Ltd.
Yenen Engineering Ltd. is ISO9001:2000 certified. For a copy of Yenen’s quality policy and / or Yenen’s HSE policy,
please, visit www.yenen.com or send an email to info@yenen.com or fax your request to +90 216 487 5986.
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Table of Contents
Page
2.0 Installation 7
2.1 Hazardous zones 7
2.2 Island construction, dispenser anchoring and piping 9
2.3 Hose installation 10
2.4 Dispenser tightness test 10
2.5 Electrical wiring 11
2.5.1 Cable glands 11
2.5.2 Maser Automation – RegiSmart registers 11
2.6 Functionality test 12
2.6.1 Totalizer readings 12
2.6.2 Preset 13
2.6.3 Non-volatile memory check 13
2.6.4 Emergency shut-down system (ESD) 13
2.6.5 Flow interruption 13
3.0 Operation 14
3.1 Before operating the dispenser 14
3.2 Standard operation 14
3.2.1 Operating the dispenser without preset 14
3.2.2 Operating the dispenser with preset 14
3.3 Restarting after power failure 14
3.4 Setting and changing the unit prices 15
3.5 Error messages 16
3.6 Programming the ATC controller 17
Any questions concerning installation and operation of the dispenser that are not covered in this
manual should be referred to Yenen at info@yenen.com or call at +90 216 487 5924.
For more technical documentation, check the Yenen website at
http://www.yenen.com/LPG_EN/Dispensers/Technical_documentation.htm.
Yenen autogas dispensers comply with prEN14678-1:2006 and suitable for use with Liquefied
Petroleum Gas (LPG) conforming to prEN589:2004.
5
Yenen dispensers comply with the OIML R117 directive, which states the following for LPG
dispensers:
Accuracy class 1.0.
Maximum permissible error 1.0%.
ALWAYS disconnect and lock power supply before starting to service the dispenser.
More than one disconnect switch may be required to de-energize the dispenser for
maintenance and service. Use a multimeter to make sure ALL circuits in the
dispenser are disconnected. Failure to do so may result in personal injury.
Ensure that all valves to and from the dispenser are closed.
More than one valve may be required to lock the system. Review the station piping
diagram to make sure ALL valves are closed. Failure to do so may result in personal
injury.
All vehicle traffic and unauthorized persons shall be prevented from approaching
within 6 meters of the dispensing device.
Make sure that all necessary safety precautions have been taken. Make sure that proper
ventilation, fire prevention, evacuation and fire procedures are provided.
Provide easy access to fire extinguishers. Understand and adapt all local safety codes.
Read this manual as well as other available literature and drawings.
Yenen recommends employing a qualified mechanical and electrical technician. A hazardous
liquid is being handled, so it is important to ensure safety at all times.
See appendix D: DOs and DON’Ts
Often Yenen dispensers together with Maser Automation (Italy) electronics are put into operation
where a stable power supply cannot be guaranteed.
Therefore, it is important to ensure a stable and consistent power supply through a UPS.
Especially, spikes in the power supply are harmful for the register. A dedicated UPS system for
the dispenser is essential in operating the dispenser virtually trouble free.
The most important characteristic of a UPS for Yenen dispensers is the transfer time or
response time. This should not be more than 4 milliseconds.
Another important feature of the UPS is that it must totally isolate output from input.
7
2.0 Installation
Examine the dispenser immediately upon arrival to make certain there has been no damage or
loss during transportation of the equipment. Damaged or lost equipment must be reported to the
carrier. Any damage or loss that may occur in transit is not covered under warranty.
Make sure that all the component parts, including keys and optional equipment, are accounted
for. Check and save the packing list, bill of lading, invoice and all other documents included with
the order.
Remove the Silica gel moist absorption bags from the electronics and hydraulics area.
Ensure that all valves to and from the dispenser are closed.
More than one valve may be required to close the system. Review the station piping
diagram to make sure ALL valves are closed.
Failure to do so may result in personal injury.
Do not pour concrete around liquid inlet and vapor return lines or electrical conduit risers.
Instead, it is preferred to use sand or sandbags to avoid possible vapor buildup under the
dispenser.
To gain access to the bottom section of the dispenser unlock and remove the front panels.
Place these panels in an area where these will not be damaged.
The base of the dispenser contains bolt holes for anchoring the dispenser to the foundation.
Firmly mount the dispenser to the island.
Remove plastic caps from liquid inlet and vapor return line. There is a possibility that some
test liquid may still be present in the dispenser and can pour out from any of these pipes.
Cut the rubber tips from the pressure gauges on the dispenser column and
differential valve(s).
Connect the liquid and vapor return line. Use flexible hoses between the
dispenser connections and (underground) piping ends to allow for ground
movement. Underground piping (vapor return and liquid line) must be at least 1¼”.
When making piping connections, make sure that all connections are tight and leak-proof.
Use a liquid sealant compound, like Loxeal 58.11 or equivalent rated for LPG applications
on male threads only. Be careful not to get any excess compound inside the fittings.
When making piping connections, make sure that all connections are tight and leak-proof.
Use a liquid sealant compound, like Loxeal 58.11 or equivalent rated for LPG applications
on male threads only. Be careful not to get any excess compound inside the fittings.
Connect the hose assembly to the dispenser outlet and the hose hooks to the side cabinet
doors. If the dispenser is equipped with a hose retraction system refer to
the separate instruction for connection guidelines.
Connect the dispenser to an earthing conductor that goes into the ground,
where it can dissipate charges.
Test continuity in the hose/nozzle assembly. Continuity must be present between the
dispenser outlet and nozzle to prevent static discharge while fueling.
Each hose assembly must be checked to ensure that the nozzle is
grounded.
For some regions crocodile clips are supplied with the dispenser for
additional earthing. Connect these to the dispenser frame.
Figure 2.2
11
ALWAYS disconnect and lock power supply before starting to service the dispenser. More
than one disconnect switch may be required to de-energize the dispenser for
maintenance and service. Use a multimeter to make sure ALL circuits in the dispenser
are disconnected. Failure to do so may result in personal injury.
The register is located in the non-hazardous zone – see section 2.1. Wires enter the
non-hazardous zone through cable glands. Yenen installed and plugged extra cable
glands for future use – see photo.
If cable glands are not used for wires and are not plugged then the non-
hazardous zone becomes a hazardous zone. This poses and immediate
danger as the electrical components are not explosion proof or intrinsically
safe.
Yenen expressly disclaims and excludes any liability for failing to follow these
important safety instructions.
Yenen LPG dispensers operate with Maser Automation electronic registers – see appendix B for
Maser Automation head configuration. Maser offers three types of registers:
RegiSmart-ST
RegiSmart-Ex
RegiSmart-Plus
Electrical specifications:
A stable and constant power supply is essential for proper functioning of the electronic
parts in the dispenser. Areas where a stable and constant power supply cannot be
guaranteed, measures should be taken to ensure that. Yenen recommends using
electronic UPS systems dedicated for the dispenser, which filters outages, sags, surges,
and bad harmonics in power supply – also refer to ‘PB – UPS recommendation’and refer
to section 1.5 UPS system on page 6.
Review the location of the dispenser junction box. Some models do not have a junction box.
In that case all the connections are located in the non-hazardous zone.
For full service / stand-alone operation, make electrical connections as shown in the
Installation wiring diagram in Appendix A.
The dispenser is delivered with a display lighting circuit connected to the control power circuit
at the terminal strip in the dispenser junction box. The display lighting may be connected to a
separate circuit breaker or switch through these terminals. Jumping these terminals will
permanently activate the display light – refer to Appendix A.
In addition to the required connections for stand-alone operation, the dispenser can also be
connected to a remote host or POS-system. Data wires need to be connected to the RS485
data port on the electronic register through the junction box. For further details, please, refer
to the Maser Automation instruction manuals.
12
If optional data wires are run for future use, these should not be physically connected to the
data terminals in the dispenser junction box. Instead these wires should be properly
terminated individually using wire nuts.
Do not run wiring for any non-dispenser equipment in the same conduit as the dispenser
wiring. This wiring must be run in a separate conduit.
Connect the dispenser to an earthing conductor that goes into the ground, where it can
dissipate charges.
Before applying power to the dispenser, double-check the wiring to make sure the wires
are correctly routed and terminated; refer to the safety precautions in section 1.3
For new installations, the start-up procedures in this section should be performed in
sequential order to ensure proper operation of the dispenser.
Make sure above ground pumps are primed before dispensing any product – refer to the
manufacturer’s instructions.
Turn on the dispenser control power circuit breaker, the lights circuit breaker (if connected)
and the pump motor circuit breaker. Make sure the dispenser comes on. The dispenser
displays will show a few test messages and usually the last sale run during factory test.
If the dispenser has not been used for some time, it may display an error code E00 indicating
discharged capacitors. Wait for some time to charge the capacitors.
RegiSmart-Plus maintains electronic totalizers for money and volume as well as the electro-
mechanical totalizer.
2.6.2 Preset
Through the preset control panel enter a price or volume.
Turn the dispenser ‘on’ through the on/off switch or press and hold the ‘dead man’s’ button.
The reset sequence starts now. The display resets itself.
The dispenser circulates LPG through the vapor return line back to the tank. Observe the
transaction on the display(s).
Towards the end of the transaction, the flow rate slows down to complete the transaction at
the preset value.
Turn the dispenser ‘off’ or release the dead man’s button.
3.0 Operation
Avoid stretching the hose assembly to reach a vehicle. This may result in damage to any of the
hose assembly parts.
If the dispenser does not operate properly when power is resumed, check if remote operating
valves are open, the pump is operational and that the dispenser is authorized (applies only for
dispenser connected to a remote system, like a Point-of-Sale (POS).
15
SEL
P1 EL
P2 PP
5. Press
6. With the programming keys on the preset keyboard enter the new price starting with the first
digit from the left:
Use the increase button In to enter correct value
Use the programming button Pr to move the cursor one position.
7. When the last digit has been entered the programming of the unit price is completed.
8. The head will process the new data with a short display test (showing all 8s, followed by
blanks) and return to the normal operation mode in a few seconds.
9. The display shows the new unit price.
If the dispenser is a 2-nozzle dispenser, then the programming sequence continues from step 6
as follows:
11. With the programming keys enter the new price starting with the first digit from the left:
Use the increase button In to enter correct value
Use the programming button Pr to move the cursor one position.
12. When the last digit has been entered the programming of the unit price is completed.
13. The head will process the new data with a short display test (showing all 8s, followed by
blanks) and return to the normal operation mode in a few seconds.
14. The display shows the new unit price.
16
In addition to the above the RegiSmart-Plus has a few specific error messages:
Er05: Communication error with a display card:
This error code indicates a communication failure with one of the displays or preset
keyboards. In some cases the dispenser cannot be used at all until the problem is solved
– see the table below.
Resetting the dispenser followed by activating and de-activating the dispenser may solve
the problem. If the problem persists, the display cable, the display card or preset
keyboard need to be checked.
For details on parameter programming refer to Maser Automation instruction’s manuals. Manuals
can be downloaded from www.yenen.com.
Neglecting this responsibility will result in inaccurate readings and this is not within
the control of Yenen.
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Stop using the dispenser when damage to the hose assembly is found. Continuing
operation can cause severe personal injury or property damage. Close all valves and
repair the hose assembly.
Check for sharp or similar edges on the cabinet that may cause cuts.
Check the hydraulics for leaks.
Stop using the dispenser when a leak is found. Continuing operation can cause severe
personal injury or property damage. Close all valves and repair the leak – see section 2.4.
Regularly test the tank for water, dirt and aggressive hydrocarbons that may be supplied from
the refinery. Contaminated LPG can cause severe internal damage to the dispenser – see
section 1.1.
Use only genuine Yenen replacement parts and repair kits on the dispenser. Using other than
genuine Yenen replacement parts may create a safety hazard and will violate approvals and
warranty on the dispenser.
4.3 Filter
A clogged filter will slow down the delivery rate. With new installations, it may be required to
replace the filter several times during the first week of operation to remove small pieces of
installation fragments and pipe sealant.
Depending on the gas quality, the filter needs inspection every 1 million liters, six months or when
LPG delivery rate slows down.
With the dispenser and pump in operation a difference in pressure at the pump outlet and the
dispenser liquid line of 2 bar or more may indicate a clogged filter.
For adjustment of the dispenser, follow the procedures described by local authorities and read
Yenen’s ‘LPG flow meter installation and operation manual’, LFM-02-e.
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Description
1 Phase (220 V) 18 Phase (220 V)
2 Neutral 19 Neutral
3 Signal (220 V) 20 Low flow solenoid1 Phase (24V)
4 Emergency Stop Phase (220 V) 21 Low flow solenoid1 Neutral
5 Emergency Stop Neutral (220 V) 22 Solenoid Grounding
6 Dispenser Light Phase 23 Solenoid Grounding
7 Dispenser Light Neutral 24 Not in use
8 Not in use 25 Not in use
9 Not in use 26 Not in use
10 Not in use 27 Not in use
11 Not in use 28 Not in use
12 High flow solenoid1 Phase (24V) 29 Not in use
13 High flow solenoid1 Neutral 30 Not in use
14 Relay1 Phase (220V) 31 Not in use
15 Not in use 32 Not in use
16 Not in use 33 Not in use
17 Not in use
Description
1 Phase (220 V) 18 Phase (220 V)
2 Neutral 19 Neutral
3 Signal (220 V) 20 Low flow solenoid1 Phase (24V)
4 Emergency Stop Phase (220 V) 21 Low flow solenoid1 Neutral
5 Emergency Stop Neutral (220 V) 22 Relay2 Phase (220V)
6 Dispenser Light Phase 23 Not in use
7 Dispenser Light Neutral 24 Not in use
8 Not in use 25 Not in use
9 Not in use 26 Phase (220 VAC)
10 High flow solenoid1 Phase (24V) 27 Neutral
11 High flow solenoid1 Neutral 28 Low flow solenoid1 Phase (24V)
12 High flow solenoid2 Phase (24V) 29 Low flow solenoid1 Neutral
13 High flow solenoid1 Neutral 30 Solenoid Grounding
14 Relay1 Phase (220V) 31 Solenoid Grounding
15 Not in use 32 Solenoid Grounding
16 Not in use 33 Solenoid Grounding
17 Not in use
Electronic register Head unit CPU board Standard New Display board Display FW
CPU FW CPU FW
Single side M30176A Single side M20569 REL 7.67 REL 8.07 M20552 (with totalizer) REL 1.29
RegiSmart-ST
Double side M30174A Double side M20179 REL 7.67 REL 8.07 M20553 (without totalizer) REL 1.29
Single side M30230 Single side M20569 REL 7.67 REL 8.07 M20552 (with totalizer) REL 1.29
RegiSmart-EX
Double side M30232 Double side M20179 REL 7.67 REL 8.07 M20553 (without totalizer) REL 1.29
Single side M30176F Single side M20569/P REL 7.60.7 REL 7.61 M21071 (with totalizer) REL 1.28 INDO
RegiSmart-Plus
Double side M30174F Double side M20179/P REL 7.60.7 REL 7.61 M21031 (without totalizer) REL 1.28 INDO
Previous display release for RegiSmart-ST and EX is 1.28. This display version is compatible with the head unit and may still be installed in some units.
However, it is advisable to use only the same release version in the dispenser.
23
1. Fluctuations in power supply 1. Check power supply and pulser connections 1. Restore power and connections
2 Error code E03
2. Pulser failure 2. Check pulser 2. Replace pulser
1. Ambient temperature may have exceeded the working 1. Problem should resolve itself when
5 Display does not operate 1. Check temperature at the display
range. Display is blank – no error message temperature is within the range.
1. Totalizer coil may be damaged 1. Check electro-mechanical totalizer 1. Replace electro-mechanical totalizer
6 Electro-mechanical totalizer 2. Electronic register may not send signals 2. Check electronic card 2. Replace electronic card
3. Display card may be damaged 3. Check display card 3. Replace display card
1. Fuse on the electronics card may have failed 1. Check the fuse on the electronics card 1. Replace fuse
2. Transistor on the electronics card which energizes the 2. Check the electronics card 2. Replace electronics card and repair
solenoid valve may be damaged transistor
3. The coil of solenoid valve may be damaged 3. Check the coil 3. Clean or replace solenoid valve
Dispenser is in operation mode, but does not
7 4. On/off switch or dead man’s button may have failed 4. Check switches 4. Replace switches
dispense. Pump is not operating
5. Pump may not create sufficient pressure 5. Check motor and refer to manufacturer’s handbook 5. Follow manufacturer’s guidelines
6. Pneumatic valve may be closed 6. Check pneumatic valves and nitrogen bottle 6. Pressurize lines or fill nitrogen bottle
7. Relay in site controller may not signal the pump 7. Check relay in the site controller 7. Replace relay
8. Thermal protection relay in site controller may be off 8. Check thermal protection relay in the site controller 8. Adjust relay or replace relay
1. Pulser connection with flow meter may be damaged 1. Check pulser connection with flow meter 1. Restore pulser to flow meter connection
8 Delivery is not registered
2. Display card may be damaged 2. Check display card 2. Replace display card
During programming, the display flashes at 1. Program key (Pr) may be pressed 1. Check Pr button and observe display 1. Press Pr button until ‘EP’ is displayed
11
every parameter
1. Parameters at electronic card may be programmed 1. Check parameters 1. Correct parameters. Consult with Yenen
Dispenser does not terminate delivery at preset incorrectly if needed
12
value 2. Solenoid valve may leak 2. Check solenoid valve 2. Clean or replace solenoid valve
3. Diaphragm of differential valve may be damaged 3. Check differential valve 3. Replace diaphragm
1. Diaphragm of differential valve may be damaged 1. Check differential valve 1. Replace diaphragm
2. Parameters at electronic card may programmed 2. Check parameters 2. Correct parameters. Consult with Yenen
Displays continues registering while the nozzle
14 incorrectly if needed
is disconnected
3. Electronic card may be damaged 3. Electronic card 3. Replace electronic card
4. Pulser may be damaged 4. Check pulser 4. Replace nozzle
1. Pump pressure may drop to where differential valve 1. Check pump 1. Follow manufacturer’s guidelines
closes
The delivery is abruptly terminated while in 2. Power loss 2. Check power supply 2. Restore power
15
progress 3. Site controller may have alarmed 3. Check site controller 3. Restore site controller
4. If applicable, gas sensor may detect a leak and close 4. Check for leaks 4. Repair leaks
valves
1. Break-away and nozzle may be jammed or blocked 1. Check hose assembly 1. Replace break-away and or nozzle
2. Valve inside the nozzle may be damaged 2. Connect nozzle to dispenser receptacle and check 2. Replace nozzle
if nozzle is operating
18 No delivery 3. Solenoid valve may not open 3. Observe that the solenoid valve opens – listen for 3. Clean or replace solenoid valve
the audible click of the valve(s)
4. Pneumatic valve may be closed 4. Check pneumatic valves and nitrogen bottle 4. Pressurize lines or fill nitrogen bottle
5. No differential pressure 5. Differential pressure from the pump 5. Increase differential pressure
19 No reading on pressure gauge 1. Gauge can be damaged 1. Check gauge 1. Replace gauge
1. Nozzle gasket can be damaged 1. Check gasket in the nozzle 1. Replace gasket
20 Nozzle leaks
2. Nozzle clips can be damaged 2. Check nozzle clips 2. Replace nozzle
26
Appendix D
DO…
• DO discuss the project and procedures with station manager or operator before
performing service on a dispenser.
• DO evaluate the hazards at the working area and use your safety training and
experience in determining any precautions to be implemented.
• DO locate and be familiar with fire extinguishers in the area prior to beginning any
LPG related work on the forecourt.
• DO wear appropriate safety clothing including brightly colored vests, goggles and
gloves.
DON’T…
• DON’T allow unauthorized individuals near the dispenser or work area when
degassing and disassembling of the dispensers.
• DON’T leave the station unless the station manager or operator signed the report.
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Safety distances may vary depending on local or regional regulations. Consult your local and or regional code requirements
to determine which codes are applicable.
Tank capacity m3 Underground autogas tank1 Above ground autogas tank2 Distances between autogas tanks
Less than 0.5 3 3 0
0.5 – 3 3 3 1
3.1 – 10 5 7.5 1
10.1 – 40 10 15 1.5
1. The measurement of the safety distances for underground tanks should start from the safety relief valve.
2. The measurement of safety distances for above ground tanks should start from the nearest point of the tank to the related location.
LPG tank
LPG Tank Petrol LPG Petrol Significant Neighbor field
(above Building Road
(underground) dispenser dispenser tank2 buildings3 boundary
ground)
LPG tank
Table 1 Table 1 5 5 5 Table 1 Table 1 40 Table 1
(underground)
LPG tank
Table 1 Table 1 7.5 7.5 7.5 Table 1 Table 1 50 Table 1
(above ground)
Petrol
5 7.5 6 - 5 5 5 50 5
dispenser
LPG Dispenser 5 7.5 - 6 - - - - -
Building Table 1 Table 1 - 5 - - - - -
Road Table 1 Table 1 - 5 - - - - -
Significant
40 50 - 50 - - - - -
buildings3
1. There is no minimum safety requirement between the tank and the pumping unit.
2. This distance is not applicable to the horizontal distance between LPG tanks with 0.5 m3 or less capacity and petrol tanks with a capacity of 2.5 m3 or
less.
3. Hospital, school, park, metro station, etc.
30
Safety distances may vary depending on local or regional regulations. Consult your local and or regional code requirements
to determine which codes are applicable.
31
H-style footprint
32
I-style footprint
34