SPT1000 Fuel Management System

Transcription

1 SPT1000 Fuel Management System Installation Manual Revision 1 August 2012

2 Introduction The SPT1000 Fuel Management System provides a complete solution for the operation and management of attended and/or unattended fueling systems. It allows the operator to control, monitor, and manage all aspects of a fuel dispensing facility via secure internet connection from anywhere in the world. The SPT1000 has a number of advanced features, including: Ready to process Chip&PIN transactions. Accepts credit cards, debit cards, fleet cards and proprietary cards. Works with all major pumps including Kraus, Wayne, Gilbarco, and Tokheim. Provides customer with fueling safety instructions. Automatically sends alarm and warning messages via pager or . Operates in extreme weather conditions. Warning This manual contains important information about the SPT1000 Fuel Management System. Please read all of the information contained in this manual to ensure proper and safe operation. Failure to installation the system properly may create hazardous conditions resulting in injury to personnel and/or damage to the system. Page 2 of 25

3 Typical System Components Designed specifically for Kraus dispensers equipped with Micon 500 registers, the SPT1000 Fuel Management system also works with other major brands of dispensers, including Wayne, Gilbarco, and Tokheim when they are equipped with their respective Dispenser Control Interfaces. Contact Computrol to check if your model of dispenser is supported. Dispensers utilizing Kraus Micon 500 registers don t require a Dispenser Control Interface because the necessary interface is built into the SPT1000 Communications Box circuitry. Up to eight Micon 500 registers are supported and communication is via the Micon 500 MNET protocol using a three-wire interface (TTP talk to pump, TTC- talk to console, and COM- common). Important! Ensure that the Micon 500 has the SK472 MNET communications piggy-back chip (Computrol part number ) installed in the Kraus head. SPT1000 Fuel Management Terminal The SPT1000 Fuel Management Terminal consists of a LCD Display, Tamper-proof Stainless Steel Keypad, Chip/Magnetic-Stripe Card Reader, and Thermal Receipt Printer. These devices are controlled by a microprocessor located on the main board behind the display. The processor board contains serial data ports which are used to communicate between the SPT1000 Terminal and the Site Computer. Additionally, the SPT1000 contains a regulated power supply to convert AC power to clean Direct Current for the electronics and a thermostatically Page 3 of 25

4 controlled heater is incorporated to ensure proper operation in cold temperatures. SPT1000 Site Computer The Site Computer is a Windows7 based computer outfitted with special hardware to ensure reliability. It runs an InfoNet application called FuelCommanderiX. This program controls the SPT1000 Terminal and processes transactions. Additional applications for Fleet Management and Banking Services also run on the Site Computer. Refer to their respective manuals for information on these applications. SPT1000 Communication Interface Box The Communication Box provides converts two RS-232 serial data channels to RS-485. RS-485 can be transmitted over much longer distances than can RS-232, so one channel of the Communication Box is used to connect the Site Computer to the SPT1000 Terminal, while the other channel is used to connect the Site Computer to Kraus Micon 500 registers. Page 4 of 25

5 Dispenser Control Interface The Dispenser Control Interface is only required for systems using Wayne, Gilbarco, Tokheim, or other non-kraus dispensers. It is not required if the dispensers are equipped with Kraus Micon 500 registers. Dispenser Control Interfaces vary according to the pump manufacturer, and generally consist of an electronic interface which converts the serial data language, plus a separate distribution box (D-box) which allows for connection of several dispensers. Cable or DSL modem A Cable or DSL modem is often used to process card transactions as well as allow remote access to the system. Remote access can be used for online reporting, monitoring, and dispenser control. It can also be used to change product pricing, and for connecting to the banking service. Although Cable or DSL modems can be obtained through the assistance of Computrol, they are most often supplied by the Internet Service Provider (ISP) when the service is ordered. A static IP address is required for the Cable or DSL modem. Page 5 of 25

6 Uninterruptible Power Supply (UPS) The UPS serves two purposes. It provides a filtering function to eliminate voltage spikes and noise commonly found on mains lines. Secondly, it continues to provide power to the SPT1000 system in the event of a power outage so that any transactions in progress at the time of the outage can be completed. The UPS provides power to the Site Computer, Communications Box, SPT1000 Terminal, and Micon500 registers if Kraus dispensers are used. A UPS rated for at least 1000 VA is recommended for systems with one SPT1000 terminal and up to 4 Kraus heads. For systems with more than 4 Kraus heads, a capacity of 1400VA or higher is recommended. Page 6 of 25

7 ******************************************************************************************** This page is where the 11 X 17 foldout drawing goes. ******************************************************************************************** Page 7 of 25

8 Location and Site Preparation The site owner is responsible for all site preparation, electrical wiring and connections. This work must be done in accordance with applicable National, State/Provincial, and Local Building and Electrical codes. The SPT1000 Fuel Management Terminal is designed for installations outside of Class II hazardous locations. The unit must be at least 18 inches (46cm) away from conventional pumps, and 24 inches (61cm) from overhead pumps or dispensers. Approved Electrical Y Seal (EYS) connectors must be used in accordance with all applicable electrical codes. All peripheral equipment connected to the system must be UL or CSA listed and be equipped with suitable interfaces for use with the SPT1000. All field-installed electrical wiring connected to the SPT1000 Pump Control Unit must be rated for operation at a minimum temperature of 90 C (194 F). High voltage (120VAC) conductors must be 12 AWG minimum. Low voltage conductors should be a minimum of 20 AWG. Free space in the junction box(es) feeding the Pump Control Unit (usually located in the pedestal) must not be less that the minimums shown in the table below: Conductor Size (AWG) Free space within Junction Box for each conductor. Box with Hubs Box without Hubs 16 or smaller 22 ml (1.3 cu in.) 25 ml 1.5 cu in.) ml (1.8 cu in.) 33 ml (2.0 cu in.) ml (2.0 cu in.) 37 ml (2.25 cu in.) ml (2.2 cu in.) 41 ml (2.5 cu in.) 8 45 ml (2.7 cu in) 60 ml (3.6 cu in) Each conductor that passes through the box is counted as one conductor as is each conductor that terminates in the box. No unplugged openings are permitted. Table 1 Junction Box minimum free space per conductor. Page 8 of 25

9 Conduit Routing The bottom of the SPT1000 Terminal enclosure has an opening. The opening is designed to accommodate standard 1 inch conduits. The left-side conduit should be used for the low voltage circuits while the right-side conduit is reserved for high-voltage circuits. A customer-supplied junction box may be utilized to collect conductors from several smaller conduits and route them through the appropriate high or low voltage conduit into the SPT1000 PCU. The junction box may be installed in the pedestal provided that it is installed in accordance with all applicable electrical codes. Rigid steel conduit is recommended for both high and low-voltage wiring to the SPT1000 Pump Control Unit as it provides better immunity from electrical noise than does aluminum or PVC. Page 9 of 25

10 Base Plate Installation The SPT1000 Terminal is supplied with a Base Plate designed specifically for use with the SPT1000 Terminal. The Base Plate comes with four pre-drilled mounting holes and embedded bolts to secure the SPT1000 to the pump island. 1) Prepare the pump island by installing four bolt-studs and conduits (as many as required). 2) Position the Base Plate on the four mounting bolts of the fuel island and secure it to the pump island using split washers and nuts. Page 10 of 25

11 SPT1000 Terminal Mounting 1) Position the Terminal on the four mounting bolts of the Base Plate and secure it to the Base Plate using split washers and nuts. The removable panel must be oriented to the front of the SPT1000 Terminal. 2) Mount junction boxes, etc in the pedestal, being sure to observe national and local electrical codes. SPT1000 Terminal Wiring The bottom of the SPT1000 Terminal facilitates two 1 wiring conduits. Usually, the one on the right is used for high-voltage AC power, while the one on the left is used for the low voltage serial data wires that run to the Communication Box. 1 rigid steel conduit is required. Aluminum or PVC is not acceptable. Explosion proof EYS connectors must be installed on both ends of the conduits. The power conduit must be able to accommodate six 12 AWG stranded conductors. The low voltage serial data conduit must be able to carry two 20 AWG two-pair shielded cables and a CAT 5 cable. Junction boxes can be installed above the EYS connectors in the pedestal for the convenience of joining electrical connections. Flexible, armored and seal tight (rubber covered) conduit must be used from the EYS connector carrying the AC power to the utility boxes. See the drawing below. Page 11 of 25

12 As an alternative to rigid conduit, an armored cable suitable for direct earth burial may be used. TEK 90 power and instrumentation cable is one such cable. See Appendix B for details. Warning! Do not use conduit as a grounding wire. Provide grounding wire sized in accordance with local electrical codes for power wiring. Connect one end of grounding wire to Load Center s ground and the other to the grounding Terminal in the SPT1000 Terminal enclosure. Page 12 of 25

13 120 VAC wiring The SPT1000 Terminal power supply must be wired to a 120 VAC 60 Hz UPSbacked power supply. Maximum current draw is 5 Amps. The UPS is usually housed in the same building as the Site Computer and also supplies power to the Site Computer and Communications Box. Ensure that the 120VAC power cable to the SPT1000 Terminal is properly sized to carry the required current. The SPT1000 Terminal is internally equipped with two sets of receptacles, one for UPS power and one for non-ups power. Terminate the UPS AC power line to the UPS AC receptacle box and non-ups AC power line to the non-ups AC receptacle box. Ensure that the ground wire from each incoming line is properly connected to the ground screw inside its respective receptacle box. See the drawing below. Page 13 of 25

14 The Heater/Fan module must be plugged into the non-ups AC receptacle. The internal power supply must be plugged into the UPS AC receptacle. In the event of a power loss, Micon 500 registers are equipped with a small battery designed to power the register for a short time so that any transactions in progress can be completed. However, usable battery life can be affected by temperature and age. To ensure that all transactions are processed properly, we recommend that the Micon 500 registers be powered from an Uninterruptible Power Supply. The same UPS that powers the SPT1000 Terminal and Site Computer may be used. However, some rewiring of the Micon 500 registers may be necessary: The 120VAC supply input to the Micon 500 registers must be separated from the 120 VAC that supplies the rest of the Kraus head, pump motors, lights, etc. See the drawing on the next page. Page 14 of 25

15 MICON 500 CIRCUIT BOARD 120VAC HOT from UPS 120VAC NEUTRAL from UPS CTR 120VAC HOT PUMP STARTER CTR 120VAC NEUTRAL 110VAC Ground 1 2 3A 3B HEAD POWER (18AWG, BLACK) NEUTRAL (18AWG, WHITE) GROUND (18AWG, GREEN) GROUND (18AWG, GREEN) SOLENOID CONTROL OUTPUT (18AWG, ORANGE) PUMP MOTOR/SOLENOID POWER INPUT (14AWG, BLACK) PUMP MOTOR CONTROL OUTPUT (14AWG, ORANGE) AUTHORIZE INPUT (18AWG BROWN) AUTHORIZE RETURN (18AWG, GREY) MONEY PULSER + (18 AWG, YELLOW) MONEY PULSER - (18AWG, RED) VOLUME PULSER + (18AWG, BLUE) VOLUME PULSER - (18AWG, WHITE/BLUE) TTP from COMMUNICATIONS BOX TTC to COMMUNICATIONS BOX DCC from COMMUNICATIONS BOX TTP - TALK TO PUMP (18AWG, PINK) TTC - TALK TO CONSOLE (18AWG, TAN) DCC - DATA COMM. COMMON (18AWG, GREEN) -- (WHITE/BROWN) SOLENOID VALVE DISPENSER LIGHT Page 15 of 25

16 UPS Wiring The UPS should be supplied from a dedicated 120VAC circuit breaker. Whenever the UPS is shipped or transported to a new location, the internal battery must be disconnected in order to comply with government regulations. Before the UPS is turned on, the battery must be reconnected as shown in the photos below or the SPT1000 system power will not be backed-up in the event of a mains power loss. Emergency Stop Circuit (optional) An Emergency Stop circuit must be installed in accordance with local and national safety regulations. A multi-contact switch or switch-activated relay circuit should be used to interrupt both the UPS-backed power to the SPT1000 Terminal and Micon 500 registers, as well as the 120 VAC power used for the dispenser pumps circuits. Page 16 of 25

17 Serial Data Wiring Serial Data communication between the SPT1000 Terminal and the Communication Box is accomplished by means of two conductors over a shielded cable. The signals are DAT+ and DAT-. The shield should be connected at the Communications Box only. Warning! Do NOT connect the Serial Data shield inside the SPT1000 Terminal to the chassis, signal ground, or any part of the 120 VAC circuitry. Belden cable, catalog number 8723 or its equivalent is a suitable cable for use as serial data cable in this application. Because the serial data is transmitted in RS- 485 format, distances up to 600 feet should not cause any problems in communications provided that adequate shielding is provided. Connect the Serial Data cable to the SPT1000 Terminal wiring block located between the Fan/Heater module and the Annunciator as shown below. Page 17 of 25

18 Communication Box Wiring Computrol supplies serial data cables that are 6 feet (2 meters) for connection of the Communication Box to the Site Computer. These cables may be extended up to 50 feet (15 meters) if mounting circumstances require it. Exceeding this distance may cause unreliable operation of the system. The Communication Box is provided with four mounting holes on flanges for easy mounting, and may be mounted in any orientation provided that there is sufficient access for the various cables to be run through the access hole, and that the lid can be opened for inspection, installation, and servicing. Box dimensions are shown below: Page 18 of 25

19 Below is a diagram showing the electrical connections inside the Communications Box. Refer to the following paragraphs for more detail. Power Supply Warning! The Communications Box circuitry is designed to run only off of a regulated 12VDC power supply. Do not replace the power supply with an unregulated supply. Using the wrong supply will cause damage to the circuitry which is not covered under warranty. Page 19 of 25

20 Connections to Site Computer Connect one serial cable from COM1 on the Site Computer to the DE-9 connector on the Communication Box circuit board labeled KIOSK. If the SPT1000 system is controlling Kraus dispensers with Micon500 registers, connect a second serial cable from COM2 on the Site Computer to the DE-9 connector on the Communication Box circuit labeled PUMP. If the SPT1000 system is controlling dispensers that do not have Micon500 registers, the PUMP connector is not used. By default, COM1 on the Site Computer is dedicated to communicating with the SPT1000 Terminal, and COM2 is dedicated for communication with the dispensers/pumps. If you change these settings in the system configuration software files, you will need to re-route the cables to their new COM ports so they match the system configuration. Be sure to mark the changes on diagram above for future reference. When the Communications Box is communicating with the Site Computer, the red and green LED lamps near the KIOSK and PUMP connectors on the Communications Board will blink. These LEDs are labeled TX and RX. When the Site Computer is transmitting to the Terminal or to the dispensers, the TX lamp will blink. When the Site Computer is receiving data from the Terminal or the dispensers, the RX lamp will blink. Page 20 of 25

21 Connections to SPT1000 Terminal As stated previously, serial data communication between the SPT1000 Terminal and the Communication Box is accomplished by means of two conductors over a shielded cable. Use only twisted, individually shielded pair cable, suitable for use in high-speed RS485 networks. The signals are DATA+ and DATA- which correspond to DAT+ and DAT-, respectively, in the SPT1000 Terminal. The shield should be connected at the Communications Box only. The serial data connections are wired to plug P305, which is subsequently inserted into jack J305. Connections to Micon 500 registers Connection to the Micon 500 registers is made by means of a three-conductor data cable. Belden cable, catalog number 8723 or its equivalent is a suitable cable for use in this application. Use two twisted pairs for each dispenser, taping off the unused conductor. Best performance is realized if each dispenser has a dedicated data cable running from Communication Box to the Micon 500 register. However, if the distance from the Communication Box to the dispensers is long, it may be more economical to connect the dispensers in a daisy-chain fashion. Combinations of dedicated and daisy-chained runs are also possible. The three signal lines are TTP (Talk-To-Pump), TTC (Talk-To-Communication- Box) and DDC (Data Communications Common). Eight such connections are provided, and are clearly labeled on the Communication Box circuitry board, and connection is made via one of the two twelve-position plugs which fit into jacks on the board. Page 21 of 25

22 Site Computer The Site Computer should be installed in an area that is secure, warm, and dry. The Site Computer should be dedicated to the operation of the SPT1000 Fuel Management System, and should not be used for other applications. The Site Computer should be supplied with power from the UPS. Site computer Wiring Refer to the fold-out drawing Installation Overview. This drawing shows the Site Computer connections. Following are details of those connections: 1) Connect COM1 to the KIOSK connector in the Communication Box. 2) If the site uses Kraus pump heads with Micon 500 registers, connect COM2 to the PUMP connector in the Communication Box. 3) If the site uses Wayne, Gilbarco, Tokheim, or other pump heads, then connect COM2 to the appropriate Dispenser Control Interface. 4) Connect the Site Computer s RJ-45 network port to your network via the Ethernet cable provided. 5) Connect the monitor, keyboard and mouse to the Site Computer. Page 22 of 25

23 Appendix A Specifications SPT1000 Terminal Specifications Dimensions (H x W x D) (approx.) Weight Ambient Temperature Rating Power Requirements 1500mm x 510mm x 357mm [59 x20 x14 ] 28 kg [61.7 lbs] -40 C to +45 C [-40 F to 110 F] 120 VAC, 60 Hz, 5 Amps Communications Box Specifications Dimensions (approximate) Weight Ambient Temperature Rating Power Requirements 221mm x 294mm x 157mm [8.7 x 11.7 x6.2 ] 3.86kg [8.5 lbs] 0 C to +30 C [32 F to 85 F] 12 VDC, 0.5 Amps Page 23 of 25

24 Appendix B TEK 90 Cable Specifications TEK 90 Armoured Control & Instrumentation Cable 300Volts, PVC Insulation Stranded Tinned Copper Conductor. OS AIA PVC Insulation. Individually Shielded Pairs or Triad. Aluminum Armoured with Inner and Outer PVC Jacket. FT-4 Flame Rated, 105 C dry, 75 C wet and -40 C Application: Suitable for installation in cable trays in dry, damp and wet locations or for direct burial and may be extended through sealing glands without removal of the individual shields, when installed in Hazardous Locations containing A, B, C & D atmospheres as defined by the Canadian Electrical Code. Specifications: Conductor: Conductor is 7 stranded tinned copper 22 AWG to 16 AWG Insulation: PVC compound suitable for 105 C dry, 75 C wet and -40 C Print: (Size) AWG 300V CSA INSTRUMENTATION CABLE ACIC LL C WET/105 C DRY PVC SHIELDED (-40 C) FT-4 HLABCD OUTDOOR Page 24 of 25

25 System & Replacement Parts Warranty Information SPT1000 fuel management Computrol Fuel Systems Inc. ( Computrol ) warrants that all electric or electronic equipment, including accessories manufactured by Computrol will be free from defects in material and/or workmanship under normal use and service for a period of 12 months from the date of installation, at the location chosen by the Purchaser (the "Warranty Period ). If a defect in the Equipment becomes apparent during the Warranty Period, Computrol will repair or replace the defective Equipment at its facility. The warranty will not extend to goods subjected to misuse, neglect, accident, or improper installation or maintenance or which may have been altered or repaired by anyone other than Computrol Fuel Systems Inc. or its authorized representative. The buyer s acceptance of delivery of the goods constitutes acceptance of the foregoing warranties and remedies, and all conditions and limitations thereof. Purchaser must notify Computrol in writing of any defect in the Equipment within fourteen (14) days of discovery of the defect and obtain a Return Approval (RA) number before returning the defective equipment prepaid to Computrol s facility. The Equipment must be suitably packed and insured for shipping to Computrol s facility at Purchaser s risk and expense. After repair or replacement of the defective Equipment, Computrol will ship the Equipment to the Purchaser F.O. B at the Purchaser s address. Computrol s liability under this Warranty shall be limited to repair or replacement of defective Equipment and shall in no case exceed the purchase price of the Equipment sold herewith. Computrol shall make reasonable repairs, replacement and corrections within reasonable time but shall not be liable for the delay in the repair or replacement. The foregoing Warranty is in lieu of all other warranties, express or implied. Computrol Fuel Systems Inc. shall not be liable for any direct, indirect, incidental or consequential damage or loss of product. *************************************************************************************************************** Page 25 of 25