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Product Manual - Pump Measure Control

1. a 8 x sx 4l NOZZLE HOOK n MAGNETIC SWITCH Z 2 Ela E a ale tal Ol 2 S Se S S Ea ea Ge al J 4 40948 b p COMMANDER SATELLITE WIRING DIAGRAM SIDE 2 DATE DRAWN BY Pump Measure Control Inc 09 27 11 2 STAGE 1070 Nine North Drive Suite 100 A SOLENOID Ga 3000 lt gt n lt 7 x PH 770 667 0667 770 667 0476 DRAWING CONTAINS PROPRIETARY __ ri DRAWING NUMBER 91 11G09271 OWNERSHIP BY PMC INC REVISIONS DESCRIPTION i OTHER DISPENSERS pa DISPENSER MAIN JUNCTION BOX EARTH GROUND CRE dd CITI KFTT I x ry la ll Y 7 Y ry ewe E 8 5 ______ BREAKER BROWN LL ORANGE MOTOR CONTROL WITH 12 RED YELLOW _ PUMP SIGNAL ISOLATION Eh BREAKER 14 PURPLE WHITE 15 BLUE 16 WHITE BLUE FROM OTHER 17 PURPLE DISPENSERS 18 YELLOW i PUMP 1 MOTOR CONTROL WITH PUMP SIGNAL ISOLATION BREAKER 2 BLACK 4 WHITE 6 GREEN 20 BROWN WHITE FROM OTHER 21 ORANGE WHITE DISPENSERS 22 RED YELL
2. Y 5 805888 PERITO 509000 EE NOA Pere i WH gt gt co m oc N O O O oc MII lt Za gt a 6 OY 55 DO O daju lt O m D _ O Gi Gi 9 gt m gt gt lt LL gt 4 O gt 2 bel 5 yn S z gt 11 Z 2 JE D gt gt e MOVIA I cla Me N JLIHM pal NOAdIY SOd gt lt BZ 48899 I 10 I 1 S gt S00 MOVIE 7 ALIHM e V N GZveSn dau MOTISA Ve z N ALIHM 62 w gt MOTIJA 82 gt m gzl Ze 888 55855 E rane om s m CN r ol N N O ALIHM 2 MOVIE 22 ILIHM SDNVHO 12 SLIHM 02 I E
3. m N T EROM OTHER 6 WHITE ORANG DISPENSERS 7 PURPLE x 8 YELLOW 9 WHITE PURPLE EARTH GROUND 120VAC GASBOY CFN TO CMDR WIRING DIAGRAM 2 STAGE VALVE CONTROL EMERGENCY DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT CONNECT THE SUBM TERMINAL OF THE GASBOY POSITION 2 TO MOTOR CONTROL 1 POWER DISPENSER MUST BE PROGRAMMED TO TRANSMIT VOLUMETRIC PULSES 100 PULSES PER GALLON DISCONNECT REFER TO MANUFACTURERS INSTALLATION MANUALS FOR GROUNDING REQUIREMENTS FOR ALL EQUIPMENT INSTALLED Pump Measure Control Inc 07 13 11 WIRE MODIFICATION IN HEAD SIDE 1 CPU BOARD MOVE YELLOW WIRE FROM TB2 LOW TB7 1 ON THE SIDE 1 BARRIER TERMINAL MOUNTED THE BACK OF THE CPU MOUNTING PLATE MOVE BLACK WIRE FROM TB2 HGH TO TB7 2 ON THE SIDE 1 BARRIER THIS CONNECTS THE YELLOW WIRE LOW FLOW COIL TO 12 RED YELLOW AND 1070 Nine North Drive Suite 100 Alpharetta GA 3004 NT THE BLACK WIRE HIGH FLOW COIL TO 13 RED BLACK 12 N LI WIRE MODIFICATION IN HEAD SIDE 2 CPU BOARD MOVE YELLOW WIRE FROM TB2 LOW TO TB7 1 ON THE SIDE 2 BARRIER TERMINAL MOVE BLACK WIRE FROM TB2 HGH EM 77266700667 Eo THIS DRAWING CONTAINS PROPRIETARY EGND TO TB7 2 ON THE SIDE 2 BARRIER THIS CONNECTS THE YELLOW WIRE LOW FLOW COIL TO 22 RED YELLOW AND THE BLACK WIRE HIGH FLOW COIL TO 23 RED BLACK 91 11G07133 1 Wiring Diagrams Page 9 19
4. RN AR ERIN RANIERI EA NE IRA MII IEEE il a k COMMANDER LOWER UNIT WIRING DIAGRAM SIDE 1 Pump Measure Control Inc dla 07 07 11 1070 Nine North Drive Suite 100 Alpharetta GA 30004 PH 770 667 0667 FAX 770 667 04764 THIS DRAWING CONTAINS PROPRIETARY DRAWING NUMBER INFORMATION AND IS SUBJECT TO 91 11207082 gt OWNERSHIP BY PMC INC REVISIONS SIDE 2 DATE DRAWN BY 07 08 11 GIG SCALE NTS lt lt a O Z INFORMATION AND IS SUBJECT TO COPYRIGHT OWNERSHIP PMC INC gt lt Q O 42 lt lt Z O 9 lt 2 L 2 gt OC o O gt OC 2 T O Q Q Al lt O A O eee gt gt lt lt eee D 7 SHS DI ATA SERIA 02 cdm gt D O lt lt ite 090 c n N D Gog g a 925 8 2 0S off ARR ee ee clans g Z lt 5 AR RIE
5. 4 12 Section 5 Startup Presstanup us u cui uu mu unupa 5 1 Purge Air from Supply Trunk 5 1 Purge Air from the Dispenser 5 2 Verify Display and Totalizer 5 4 Accuracy Verification of MetersS ie 5 4 Section 6 Calibration Minimum Size of Calibration Container a 6 1 Calibration Tolerances 6 1 S 100 tenet a 6 2 TS15A EDM 6 4 Section 7 Operating Instructions COME Ol Sa 7 1 Dispenser Operating 7 1 OWEN Tr ANC ss 7 2 Reading the Dispenser TotaliZef iatale aaa 7 2 Section 8 Operator Maintenance ass Qu u Rd 8 1 OWNEMINSDCCUONS uuu u 8 1 amp caprini y uu bunu iutan ai 8 2 8 2 Preventive NISI tienanCe u uu uu u u ea ea 8 3 PM Schedule u uuu t lilla 8 3 Monthly Inspections Owner
6. 9 ILIHM P I 525 12 SUPPLY ve NOZZLE HOOK WHITE MAGNETIC SWITCH z ol 9 5 or zu BLACK RED lt 5 METER PULSER gt WHITE Q S RED YELLOW 2 5 BLAGI ni SOLENOID SEE DRAWINGS 91 11G07081 and 91 11G07082 for details i gt SIDE 2 CONDUIT a gt SIDE 1 CONDUIT JUNCTION cib BOX VSTi Ria area nare aaa Ria GT Tape ac Taglia asa aaa 77 3995 gt m lt 5 T of 2 gt u Z o gt m x Z lt x z Z SE O E H O lt O H O lt 5 a a lt 5 lt 5 1 S 2 leo oo al tee aka I N V N af cu _ Lae A ee SS ANI ASS ASSAI SAN ARS ALAM ASSIONI nn I MA n_ m_
7. i 1 ek 8 YELLOW 9 WHITE PURPLE N N IN IN IN TI BLACK WHITE GREEN 0 BROWN WHITE 21 ORANGE WHITE 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 ORANGE 16 WHITE BLUE 7 PURPLE MOTOR CONTROL WITH PUMP SIGNAL ISOLATION BREAKER FROM OTHER 6 WHITE ORANG 7 DISPENSERS 7 PURPLE 5 j 8 YELLOW Q 9 WHITE PURPLE PUMP r PROD GG Sy ci 2 gt PIE D BOX TO CMDR WIRING DIAGRAM RS 485 COMMUNICATIONS EMERGENCY Pump Measure Control Inc 07 14 11 1070 Nine North Drive Suite 100 gt NOTES Alpharetta GA 30004 0 2 L N 11 1 DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT CONNECT THE 21 ORANGE WHITE WIRE FROM DISPENSER TO MOTOR CONTROLLER 1 PH 770 667 0667 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY END 2 DISPENSER MUST BE PROGRAMMED TO OPERATE WITH CONSOLE See OPERATIONS MANUAL INFORMATION AND IS SUBJECT TO 3 REFER TO MANUFACTURERS INSTALLATION MANUAL FOR GROUNDING REQUIREMENTS FOR ALL EQUIPMENT INSTALLED 91 11607141 gt INC REVISIONS PEDISTAL TERMNATION BOARD 2200 DESCRIPTION IN RESISTORS SHOWN CONNECTED TO DC PULSE TERMINAL STRIP IN THE FUELMASTER FMU MUST BE MAIN SUPPLIED BY INSTALLER POWER TO
8. 3 Souc HE z olla gt METER PULSER Fui solaio Basi BLACK 2 STAGE i YELLOW RED SOLENOID SEE DRAWINGS 91 11G07083 and 91 11G07084 for details SIDE 2 CONDUIT lt gt SIDE 1 CONDUIT lt _ p MAIN JUNCTION BOX biden csi aes NS cme aiar cme mee ee Oa q LU LU w LU LU 5 LU T s 3 a gt w o a z u S Lu al al al Si ol z Sn 15 gt G 2 pie Z a Z z Z x S Ul O s al a lt O Ul O 5 5 m ul lt T u S u ci lt gt z olar rm ol m 5 m gt 3 al ol O m T z ol o o s ol n s N TT N N Se S Pre S lo Vl m PERO x miss RIA a Ra E IALIA
9. 7 Observe the reset sequence and verify the displays work properly WARNING Fire explosions caused by sparks from static discharge are a potential danger anytime fuel is being dispensed possibly causing serious injury or death Use only approved me tallic containers and always keep the nozzle in contact with the container when fueling 8 Dispense some fuel into an approved container taking care not to spill any and not to over flow the container 9 Observe the displays to verify the counting looks smooth and consistent Erratic or otherwise jumpy counting may indicate a problem with the dis play board or with the communications between it and the CPU 10 When finished dispensing gently replace the nozzle in the boot and ver ify that the dispenser is deactivated 11 verify that the dispenser is no longer authorized try to dispenser more fuel into the container without lifting the nozzle boot lever There should not be any fuel dispensed 12 Verify that the supply pump has turned off 13 Check the current totalizer readings with the ones recorded in step 4 above Verify that the difference is the same as the amount of fuel dis pensed 14 Repeat steps 1 thru 13 for each hose position being started up Accuracy Verification of Meters Verify set the calibration of the dispenser meters using procedures from the CALIBRATION Section of this manual Page 5 4 Startup Page 5 5 Startup Page 5 6 Ca
10. 50 Default Value 20 Format nn At the beginning of a transaction the dispenser activates the slow flow valve Before the hi flow valve is allowed to open the CPU board must receive a minimum number of good pulses from the meter This parameter is used to set that number of pulses The purpose of this pa rameter is to prevent the dispenser from entering high flow if there is a problem with the me ter s pulser 270 Low Flow Volume Value Range 0 1 5 0 Default Value 0 4 Format n n This parameter configures the volume before a preset amount that the dispenser will drop out of hi flow and into low flow to allow the dispenser to stop at the exact preset amount This value should be set large enough that the dispenser can drop from hi flow and stabilize at the slow flow rate before the transaction ends However if the value is set too large the time that the dispenser is in slow flow will be unnecessarily long Example If the dispenser is preset to dispense 10 000 gallons and this parameter is set for 0 4 then the dispenser will drop into low flow at 9 600 gallons Units of Measure determines units for this parameter see page 4 1 600 Unit Address for Communications Value Range 1 31 Default Value 1 Format n This parameter configures the address the dispenser uses when communicating with a con sole or other device Valid address for the dispenser can range from 1 to 31 Page 4 11 Programming 610 Communicati
11. DISPLAY BOARD 20 aevesnt EU INTRINSIC SAFETY BOARD e ACVESNI ci P Gi iP CALL ci gt ALVESGNI gt LL ip SPAZI ci GLvESN aeveSNt DOES JLIHM f FONVUO 038 qat ILIHM ALIHM ALIHM 10 POS RIBBON COMMANDER UPPER UNIT WIRING DIAGRAM SIDE 1 DATE DRAWN BY 07 07 11 GIG SCALE NTS CONDUIT 7 CONDUIT lt 5 co G lt S lt 9 2 x OZ THIS DRAWING CONTAINS PROPRIETARY F N N N gt lt lt LL PH 770 667 0667 DRAWING NUMBER INFORMATION AND IS SUBJECT TO COPYRIGHT OWNERSHIP BY PMC INC 91 11G0708 CONDUIT lt x gt CONDUIT WHITE PL 4 _ F NOZZLE HOOK BLACK MAGNETIC SWITCH H o uz
12. 10 BROWN AUTHORIZE SIDE 1 5 11 ORANGE PUMP START SIDE 1 D 12 RED YELLOW SPARE SIDE 1 2 gt 13 RED BLACK SPARE SIDE 1 di 14 PURPLE WHITE SPARE SIDE 1 n 15 BLUE 2 PULSE OUTPUT SIDE 1 16 WHITE BLUE PULSE OUTPUT SIDE 1 17 PURPLE COMMUNICATIONS SIDE 1 18 YELLOW COMMUNICATIONS GND SIDE 1 19 WHITE PURPLE COMMUNICATIONS SIDE 1 sr ey x 2 BLACK AC POWER SIDE 2 4 WHITE AC NEUTRAL SIDE 2 6 GREEN D 20 BROWN WHT AUTHORIZE SIDE 2 5 21 ORANGE WHT PUMP START SIDE 2 T 22 RED YELLOW za PARE SIDE 2 gt 23 RED BLACK 5 gt D SPARE SIDE 2 22 24 PURPLE WHITE SPARE SIDE 2 0 25 ORANGE PULSE OUTPUT SIDE 2 26 WHITE ORANGE n PULSE OUTPUT SIDE 2 27 PURPLE COMMUNICATIONS SIDE 2 28 YELLOW COMMUNICATIONS GND SIDE 2 29 WHITE PURPLE COMMUNICATIONS SIDE 2 Electrical Ratings 1 AC POWER AC 1 2 AUTHORIZE 10 20 MAIN JUNCTION BOX SS SS SS SS SS SS Se nn ee CMDR MAIN JUNCTION BOX 2A 120VAC 60Hz 2A 10 120 60Hz 3 PUMP START 11 21 0 5A 120VAC 60Hz FIELD CONDUIT ENTRY g sa FIELD CONDUIT ENTRY VO TYPE INPUT 2 4 s OUTPUT NPUT OUTPUT DISCRIPTION AC POWER 120VAC SIDE 1 AC POWER 120VAC SIDE 2 AC NEUTRAL SIDE 1 AC
13. POSITION 1 POSITION 2 Z 6 MAIN POWER CONNECTION UXILLARY TO OTHER DISPENSERS CURRENT SENSE CONTACT AUXILLARY CONTACT CURRENT sense CONTACT CONTACT PULSER COM DISPENSER MAIN JUNCTION BOX 7 J EARTH Fi GROUND PULSER INPUT C 12VDC D EGND s 5 Si DD DD YI QO A co A C 12VDC A B CARD SYSTEM BREAKER PETROVEND CARD SYSTEM 1 BLACK WHITE GREEN 10 BROWN 11 ORANGE 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 BLUE 6 WHITE BLUE 7 PURPLE 8 YELLOW 9 WHITE PURPLE DISPENSER BREAKER MOTOR CONTROL WITH SIGNAL ISOLATION PUMP BREAKER FROM OTHER DISPENSERS BLACK WHITE GREEN 0 BROWN WHITE 1 ORANGE WHIT 2 RED YELLOW 3 RED BLACK 24 PURPLE WHITE 25 ORANGE N PUMP SIGNAL ISOLATION MOTOR CONTROL WITH BREAKER i FROM OTHER 6 WHITE ORANGE DISPENSERS 7 PURPLE 5 j 8 YELLOW 9 WHITE PURPLE r 2 GG NITTI 2 x LL gt 1 PETROVEND TO CMDR WIRING DIAGRAM EMERGENCY ee Pump Measure Control Inc 07 13 11 esa 1070 Nine North Drive Suite 100 gt x NOTES Alpharetta 30000 L N 11 1 DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT CONNECT CURRENT SENSE CONTACT 2 ON PETROVE
14. PURPLE FROM OTHER DISPENSERS EARTH GROUND 120VAC QT TECHNOLOGIES M3000 TO CMDR WIRING 2 STAGE VALVE CONTROL EMERGENCY DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT CONNECT PUMP MOTOR SIGNAL FROM 2nd Q TECH MODULE TO MOTOR CONTROLLER 1 POWER DISPENSER MUST BE PROGRAMMED TO TRANSMIT VOLUMETRIC PULSES 100 PULSES PER GALLON Pump Measure Control Inc DISCONNECT INSTALL SNUBBER CIRCUITS AS SUPPLIED INSTRUCTED BY QT TECHNOLOGIES 1070 Nine North Drive Suite 100 GA 30004 gt ons O PH 770 667 0667 770 667 04764 THIS DRAWING CONTAINS PROPRIETARY EGND _WIRE MODIFICATION IN HEAD SIDE 2 CPU BOARD MOVE YELLOW WIRE FROM TB2 LOW TO TB7 1 ON THE SIDE 2 BARRIER TERMINAL MOVE BLACK WIRE FROM TB2 HGH INFORMATION AND IS SUBJECT TO TB7 2 ON THE SIDE 2 BARRIER THIS CONNECTS THE YELLOW WIRE LOW FLOW COIL TO 22 RED YELLOW AND THE BLACK WIRE HIGH FLOW COIL TO 23 RED BLACK 91 11607101 gt ownersH By INC WIRE MODIFICATION IN HEAD SIDE 1 CPU BOARD MOVE YELLOW WIRE FROM TB2 LOW TO TB7 1 ON THE SIDE 1 BARRIER TERMINAL MOUNTED TO THE BACK OF THE CPU MOUNTING PLATE MOVE BLACK WIRE FROM TB2 HGH TO TB7 2 ON THE SIDE 1 BARRIER THIS CONNECTS THE YELLOW WIRE LOW FLOW COIL TO 12 RED YELLOW AND L2 N LI THE BLACK WIRE HIGH FLOW COIL TO 13 RED BLACK REVISIONS DESCRIPTION DATE PETROVEND INTERFACE BOARD PETROVEND INTERFACE BOARD
15. _T ___tt_ _ 1m _J6 t tt _ oe n u e Pgs s a FIELD CONDUIT FIELD CONDUIT a pr 2 ENTRY AC _ pe 2 ENTRY DC y _ cc il rc J s s COMMANDER LOWER UNIT WIRING DIAGRAM SIDE 2 Pump Measure Control Inc 07 08 11 1 GJG 1070 Nine North Drive Suite 100 Alpharetta GA 30004 PH 770 667 0667 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND IS SUBJECT TO DRAWING NUMBER 9 1 _ 1 1 G07084 COPYRIGHT OWNERSHIP BY PMC INC du SATELLITE 22 RED YELLOW 23 RED BLACK 21 ORANGE WHITE 4 POS RIBBON INTRINSIC SAFETY BOARD eae Di PONER secco 2 SUPPLY 0 0 O _ 2 1 5 BARRIER V NA 33 100 100 eD gt lt lt SG BA 299 m 2000 ee E N to DISPENSER HEAD LOWER UNIT gt SEE DRAWINGS 91 11G07081 SIDE 2 SOLENOID SIDE 2 1 5 BARRIER and 91 11G07082 for details bei 7 CONDUIT CONDUIT CT gt SIDE 2 CONDUIT a gt SIDE 1 CONDUIT JUNCTION as BOX elica SSE ISSN cadi nm Saar Gimnasia
16. 1 Normal dispenser operation is sus pended and no transactions can occur As long as the programmer remains plugged in normal operation of the dis penser for that hose position is sus pended and SE TL will be shown on the main display s of the dispenser DISPENSER CPU BOARD 2 All 2 wire communications to from the console POS or other controller is halted This will usually result in an OFF LINE indication on the console controller to alert the operator that the dispenser is being programmed 3 The only way to return the dispenser to normal operation is to unplug the pro grammer from the dispenser When the dispenser exits programming mode the transaction information for the previ ous sale is shown on the main LCD dis plays and communication is restored with the console controller Normal HANDHELD dispenser operation then resumes using PROGRAMMER any new values programmed Page 4 3 Programming Changing Parameter Values Using the Handheld Programmer Page 4 4 When the dispenser enters the programming mode the user will be prompted on the handheld to choose whether they want to access the parameters or change the current pricing If a menu selection is incorrectly selected pressing the lt ESC gt button on the handheld will return you to the previous screen lt F1 gt PROGRAM lt F2 gt SET PRICE Press the lt F1 gt key to program the various parameters in the dispenser Refe
17. 52 to the plus position and S3 amp S4 to 09 Press the RESET button to use the new calibration setting Example 6 Imperial Gallons The accuracy of anew TS15A EDM meter is checked using a 50 imperial gallon prover The prover s sight glass reading of 75 in is outside of the allowed toler ance and the meter must be adjusted The meter s calibration switches cur rently set to 26 75 x 12 015 New S3 amp S4 26 44 02 50 Round result to nearest whole number 44 Change the meter s calibration to this new value Keep 52 on the plus position and set S3 amp S4 to 44 Press the RESET button to use the new calibration setting Page 6 9 Calibration Page 6 10 Operating Instructions 7 OPERATING INSTRUCTIONS WARNING Per UL87A requirements a dispenser must not be changed from its original application by changing fuel types once installed For instance if installed for a gasoline ethanol blend such as E25 or E85 the dispenser can not be changed to traditional gasoline at a later date Leaks and potential environmental hazards can result or components may fail prematurely Do not change fuel types for a dispenser once it has been installed Prior to operating the dispenser review the section SAFETY INFORMATION at the front of this manual Dispenser Controls The only user accessible control on the dispenser is the nozzle boot leve
18. 8 3 Semi Annual Inspections Owner 8 3 Service Inspections By Service 8 4 Section 9 Wiring Diagrams 91 11G07181 CMDR Junction Box Wire Descriptions 9 3 91 11G07081 CMDR Upper Unit Internal Wiring SIDE 1 9 4 91 11G07082 CMDR Lower Unit Internal Wiring SIDE 1 9 5 91 11G07083 CMDR Upper Unit Internal Wiring SIDE 2 9 6 91 11G07084 CMDR Upper Unit Internal Wiring SIDE 2 9 7 91 11G07131 CMDR Standalone 9 8 91 11G07141 PIE D Box to CMDR RS 485 9 9 91 11G07092 FUELMASTER FMU2500 to CMDR 1 Stage 9 10 91 11G07093 FUELMASTER FMU2500 to CMDR 2 Stage 9 11 91 11G07101 QT TECHNOLOGIES M3000 to CMDR 9 12 91 11G07102 PETROVEND to CMDR 9 13 91 11G07133 GASBOY to CMDR 9 14 READ THIS FIRST Equipment Inspection When the dispenser s arrive at the installation site unpack the units and inspect for possible shipping damage Make all claims concerning damage to the freight carrier Pump Measure Control PMC as shipper is not liable for the h
19. EDM Meter 50 100 gallon high flow dispenser Note that these are minimum sizes It is permissible to use larger calibra tion containers than required Calibration Tolerances TABLE 1 This table is for reference only The tolerances that apply to the actual installation are determined by the local authority having jurisdiction Acceptance Tolerance Maintenance Tolerance SB 100 Meter SB 100 Meter 5 gallon test 3 0 in 5 gallon test 6 0 in 10 gallon test 5 5 in 10 gallon test 11 0 in 25 gallon test 0 3 17 3 in 25 gallon test 0 5 28 8 in TS15A EDM Meter TS15A EDM Meter 50 gallon test 0 2 23 1 in 50 gallon test 0 3 34 6 in 100 gallon test 0 2 46 2 in 100 gallon test 0 3 69 3 in Page 6 1 Calibration SB 100 Meter 5 GALLONS ONLY short cut Test draft 1 gallon dispensed Half hole adjustment 0 12 Test draft 5 gallons dispensed Half hole adjustment 0 6 Test draft 10 gallons dispensed Half hole adjustment 1 2 Test draft 25 gallons dispensed Half hole adjustment 3 0 Calibration Adjustment The SB 100 meter used in tte Commander dispenser is equipped with a mechani cal calibration dial located on the cover for cylinder 1 The cylinder cover is clearly marked with and symbols to indicate which direction to turn the dial to in crease or decrease the meter s delive
20. L preceding the least significant See pho tos below In the example photos below the totalizer value is 0000145 098 Note The length of time that the dispenser keeps each half of the totalizer value displayed is configurable using parameter 230 Default value is 5 sec Hold Magnet over area indicated by the circle Totalizer Low Value Page 7 2 Owner Maintenance Instructions 8 OWNER MAINTENANCE INSTRUCTIONS The following section outlines maintenance procedures and routines for the Com mander dispenser that can be performed by the operator All maintenance and re pairs involving the dispenser should only be preformed by qualified and trained ser vice personnel Safety Precautions Prior to inspecting or performing any maintenance on the dispenser review the section SAFETY INFORMATION at the front of this manual Failure to con form to safety procedures as outlined in this manual can result in severe injury or death Owner Inspections The owner has a key role in maintaining the safe operation of the dispenser by performing equipment inspections on a periodic basis looking for leaks worn or damaged parts and any other hazards that may be present When a hazard is identified the dispenser should immediately be taken out of service and blocked off to prevent access to it Only trained service personnel are to make the re pairs necessary to fix the hazard Following is a recommended inspection routine to be
21. OTHER CONNECTION PISTENSERS 2 DISPENSER MAIN JUNCTION BOX EARTH GROUND FUELMASTER FMU2500 w o 2 STAGE VALVE CTRL CARD SYSTEM BREAKER 1 BLACK WHITE 5 GREEN 10 BROWN 11 ORANGE 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 BLUE 6 WHITE BLUE 7 PURPLE 8 YELLOW 9 WHITE PURPLE i DISPENSER BREAKER MOTOR CONTROL WITH PUMP SIGNAL ISOLATION BREAKER FROM OTHER DISPENSERS BLACK WHITE GREEN 0 BROWN WHITE 1 ORANGE WHIT 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 ORANGE 6 WHITE ORANG 7 PURPLE 8 YELLOW 9 WHITE PURPLE NO MOTOR CONTROL WITH SIGNAL ISOLATION h x MIM N NM IN TI FROM OTHER DISPENSERS EARTH GROUND __NEUTRAL _____ 120VAG FUELMASTER FMU2500 TO CMDR WIRING w o PRESET VALVE CTRL EMERGENCY DATE DRAWN BY POWER Pump Measure Control Inc 07 09 11 DISCONNECT 1070 Nine North Drive Suite 100 gt x NOTES Alpharetta GA 30004 PO 12 N 11 1 DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT CONNECT THE 21 ORANGE WHITE WIRE FROM DISPENSER TO MOTOR CONTROLLER 1 PH 770 667 0667 FAX 770 667 04764 THIS DRAWING CONTAINS PROPRIETARY GND 2 DISPE
22. PROPRIETARY EGND WIRE MODIFICATION IN HEAD SIDE 1 CPU BOARD MOVE 11 ORANGE FROM TB1 1 TO TB2 LOW oe WIRE MODIFICATION IN HEAD SIDE 2 CPU BOARD MOVE 21 ORANGE WHITE FROM TB1 1 TB2 LOW 91 11607093 gt ownership BY REVISIONS DESCRIPTION DATE M3000 INTERFACE BOARD M3000 INTERFACE BOARD POSITION 1 Z 6 man T POWER 3 2 5 2 OTHER CONNECTION To 5 5 8 58 5 85 DISPENSERS 303525 _ 8555 DISPENSER MAIN JUNCTION BOX 5 2592 5 3302 7 EARTH age o 2 7 GROUND SETE 900900000 0000 90090000909 0000 BREAKER 5 GREEN 0 BROWN Esa i ss 1 BLACK WHITE DISPENSER tr BREAKER 1 ORANGE 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 BLUE 6 WHITE BLUE 7 PURPLE 8 YELLOW 9 WHITE PURPLE BLACK WHITE GREEN po MOTOR CONTROL WITH SIGNAL ISOLATION PUMP BREAKER N N m Q FROM OTHER DISPENSERS 7 PROD 1 0 BROWN WHITE 21 ORANGE WHITE MOTOR CONTROL WITH 5 22 RED YELLOW SIGNAL ISOLATION RED BLACK 4 PURPLE WHITE 5 ORANGE 6 WHITE ORANG 7 PURPLE 8 YELLOW 9 WHITE
23. Source TB 2 SOLENOID COM HIGH FLOW Solenoid Coil L1 VAC TB 3 DC CONNECTIONS TB 4 COMMUNICATIONS De GROUND 22 2 CMDR CPU BOARD ERMINAL CONNECTORS DATE DRAWN BY 12 11 2010 SCALE PART NO 667 0667 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY UMB INFORMATION AND IS SUBJECT TO 91 41 06 1 21 1 1 COPYRIGHT OWNERSHIP BY INC Pump Measure Control Inc I S BARRIER Ribbon Cable to INTRINSIC SAFETY BARRIER ide DISPLAY Ribbon Cable to DISPLAY BOARDS PH 770 DRAWING N meli 1 1 0 U 4 rl L 1 5 L 5 4 1 L UDO LED INDICATORS CMDR CPU BOARD LED FUNCTIONS Pump Measure Control 8 28 00 1070 Nine North Drive Suite 100 Alpharetta GA 30004 NONE eer 0667 FAX 770 667 04764 THIS DRAWING CONTAINS PROPRIETARY pra INFORMATION AND IS SUBJECT TO 91 1 OG 1 21 1 2 COPYRIGHT OWNERSHIP BY PMC INC REVISIONS BLACK 12 RED YELLOW 13 RED BLACK 14 PURPLE WHITE o gt aon CPU BOARD 11 ORANGE 1 BLACK WHITE 5 GREEN 10 BROWN BARRIER BLOCK 9 Slo OQ MOUNTED ON REAR OF CPU MTG PLATE 10 POS RIBBON DISPLAY BOARD uwa 11 oc 6 _
24. This includes but is not limited to NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Code for Motor Fuel Dis pensing Facilities and Repair Garages NFPA 70 The NEC National Electric Code Failure to do so may lead to violations and or prevent safe operation of the equipment Replacement Parts Use only genuine PMC repair parts and retrofit kits when making repairs or servicing this dispenser Using non PMC replacement parts may create a safety hazard and violate local regulations Safety Symbols and Signal Words This safety alert triangle is used throughout this manual to alert you to a precaution or procedure that must be followed to avoid potential safety hazards The signal words DANGER WARNING and CAU TION are used in this manual and on warning labels to alert you to the seriousness of the hazard All safety procedures following these signal words must be followed to prevent serious injury or death DANGER indicates a hazard or unsafe prac tice that will result in death or serious injury WARNING indicates a hazard or unsafe prac tice that may result in death or serious injury CAUTION indicates a hazard or unsafe prac tice that may result in minor injury or equipment damage Electrical Safety Use safe and established practices in working with electrical devices Be sure grounding connections are properly made Refer to GROUND in Section 3 of this manual for specific information Failure to do so ma
25. as E25 or E85 the dispenser can not be changed to traditional gasoline at a later date Leaks and potential environmental hazards can result or components may fail pre maturely To avoid these issues follow the instructions in this manual and do not change fuel types once installed Description Shipping Weight single Hose Dual Hose approx 250 Ibs approx 400 Ibs Power Requirement AC Power Supply Power Consumption max Operating Environment Ambient Temperature Relative Humidity non condensing 120 60Hz 10 240 Watts 30 C to 55 C 0 to 95 Page 2 1 Introduction Page 2 2 The Commander series remote dispensers are available with three primary hydraulic configurations single product single hose single product dual hose dual product dual hose Each fueling position is available in standard up to 20GPM or high speed up to 6G0GPM flow rates Standard Features Dimensions 28 x 19 1 2 D x 49 Powder coated heavy gauge steel frame Powder coated galvannealed door panels single or dual hose configurations Meter Standard 4 piston positive displacement up to 20 GPM High Flow Rotary positive displacement up to 60 GPM Dual channel error checking pulsers Filtration Standard spin on filter High Flow strainer 80 mesh Solenoid Valve Standard 1 Dual Stage High Flow 1 1 2 Dual Stage Satellite feed on High Flow configuration Registrati
26. checked using a 20 liter test can The test 5 sight glass reading of 80ml is outside of the allowed tolerance and the meter must be adjusted Use the simplified LITERS formula from page 6 3 80 x 1 923 Total adjustment 7 69 half holes 20 Round result to nearest whole number 8 half holes Cut the seal wire from the meter and gently remove the pin securing the calibration dial Since the dispenser over delivered 80ml turn the dial 8 half holes clockwise towards the to decrease the meter s output Re insert the pin securing the cali bration dial Test the new calibration setting and reseal the meter Example 3 Imperial Gallons The accuracy of anew SB 100 meter is checked using a 25 imperial gallon test can The prover s sight glass reading of 45 in is outside of the allowed tolerance and the meter must be adjusted Use the simplified IMPERIAL GALLONS formula from page 6 3 45 x 6 932 Total adjustment 12 48 half holes 25 Round result to nearest whole number 12 half holes Cut the seal wire from the meter and gently remove the pin securing the calibration dial Since the dispenser over delivered 45 turn the dial 12 half holes clock wise towards the to decrease the output Re insert the pin securing the calibration dial Test the new calibration setting and reseal the meter Page 6 4 Calibration SB 100 Meter Example calibration cal
27. conductors must be solid WHITE or LIGHT GRAY Page 3 8 Installation Instructions WARNING Performing work on a dispenser without first removing all power may result in elec tric shock causing severe injury or death All electricity must be turned off and tagged out prior to beginning any electrical work on the dispenser More than one disconnect may be required Use a digital multimeter to verify all power is off e Ground conductors must be solid GREEN or GREEN with one or two YELLOW stripes e Use only insulated STRANDED COPPER WIRE that is properly sized UL labeled and gasoline oil resistant Rated to 300V e All field wires must be color coded and or labeled to facilitate equipment checkout and service e All wires must be pulled and connected as a continuous run to the dispenser junction box Splices and field box terminal connectors are not permitted e Do not use gaskets or other sealing compounds on the cover of the explosion proof junction box The mating surfaces between the junction box and the cover must be clean and free of nicks or scratches e All required conduit seal offs must be in place and poured when installation is complete e Make sure that all covers plugs etc are in place and tight before replacing the dispenser s lower panels e All Unused openings in the dispenser s main junction box must be plugged when finished with the installation of the dispenser Ground The Commander dispe
28. is defined to be the side of the dispenser that the main junction box faces Emergency Power Cut Off Switch Grounding system for all equipment Circuit Breakers Impact Box and Containment Verify all fuel lines are marked in containment box Shear Valves Verify that piping layout in impact box containment matches the foot print of the dispenser being installed Verify supply line fuel grades and shear valve and conduit locations Corrections are much easier prior to placing the dispenser on the island Verify proper conduit is used for the area classification in which it is in Stalled i e Conduit and fittings are Class 1 Group 8 D where req d Seal off is installed as the first fitting on the conduit as it leaves the ground below the dispenser Pump control relay box with provisions for isolation of control signals from dispensers Pump Dispenser must be installed in a system with a power operated pump incorporating a pressure relief that maintains system pressures at or below 50 psi The pressure relief device must be located and veri fied as being installed as required If a pump other than a submersible turbine pump is used provisions must be made to prevent air from being pumped through the dis penser be Figure 1 CMDR junction box as viewed from REAR of dispenser Verify Plumbing Configuration Installation Instructions Prior to placing the dispenser on the fuel island ve
29. isolated from those of other dispensers e f used the PUMP START control signal must be capped off to prevent it from shorting to the junction box DC Pulse and Communications Wiring The Commander series DC pulse and communications wires can be run in the same conduit as the AC power and signal wires However the wire used for these DC signals must meet the following requirements Environmental Gas amp oil resistant suitable for wet or dry environment Operating Temp 30C to 90C dry Voltage Rating 600V Conductors 18 AWG stranded copper wire 2 twisted pair Shield Foil wrapped 100 coverage Tinned Copper Braided 90 coverage Drain Wire Foil 20AWG or larger DC Pulse Out Circuit DISPENSER OPTO ISOLATED TRANSISTOR NPN TRANSISTOR 3 12 Installation Instructions Wiring the Dispenser All field wire connections to the Commander dispenser are made in the main junction box located in the rear of the lower cabinet of the dispenser WARNING Performing work on a dispenser without first removing all power may result in elec tric shock causing severe injury or death All electricity must be turned off and tagged out prior to beginning any electrical work on the dispenser More than one disconnect may be required Use a digital multimeter to verify all power is off CAUTION Do not attempt to wire the dispenser without first reviewing the appropriate wiring diagrams and associated n
30. of its simplified variations above calculate the amount that the meter must be adjusted Turn the calibration dial the required amount in the appropriate direction 6 Empty the fuel back into storage For hand held containers allow it to drain for 10 seconds after flow stops For containers with a bottom drain valve allow container to drain for 30 seconds after flow stops 7 Runa gallon or two of product through the meter to set the calibration 8 Repeat steps 2 thru 7 to verify the new calibration of the meter 9 Repeat steps 2 thru 8 for each meter as necessary Page 6 3 Calibration 58 100 Meter Example calibration calculations for the SB 100 meter Example 1 US Gallons The accuracy of a new SB 100 meter is checked using a 5 gallon test can The test can s sight glass reading of 7 in is outside of the allowed tolerance and the meter must be adjusted Use the simplified US GALLONS formula from page 6 3 7 x 8 325 Total adjustment 11 66 half holes Round result to nearest whole number 12 half holes Cut the seal wire from the meter and gently remove the pin securing the calibration dial Since the dispenser under delivered 7 in turn the dial 12 half holes counter Clockwise towards the to increase the meter s output Re insert the pin securing the calibration dial Test the new calibration setting and reseal the meter Example 2 Liters The accuracy of a new SB 100 meter is
31. or more ethanol consult the manufacturer of all fuel system components to verify compatibility with the fuel be ing dispensed This includes the fuel dispenser itself e All hoses and related hanging hardware must be Listed and installed per the manufacturer s instructions and in accordance with all applicable codes e Use only UL pipe sealant rated for the fuel being dispensed e Use pipe sealant on male threads only e DONOT USE Teflon tape to seal fittings on the hose assembly Teflon tape reduces the friction to the point that the fittings can easily be over tightened resulting in fractures or other failures of the fittings e Check ground continuity of the hose nozzle assembly when finished Page 3 14 Installation Instructions Install Hanging Hardware Install the hanging hardware on the dispenser using the following procedure 1 Cleanall fittings to remove dirt and oil from their threads 2 Install the short hose whip for the breakaway to the dispenser outlet 3 Attach the breakaway to the hose whip Follow the breakaway manu facturer s instructions 4 Install the swivel in to the base of the nozzle Follow the swivel and nozzle manufacturers instructions 5 Assemble the hose to the swivel nozzle assembly Follow the hose manufacturer s instructions 6 Assemble the free end of the hose to the breakaway WARNING An improperly grounded nozzle spout can result in static discharge while fueling i
32. performed by the station owner in order to identify potential hazards or other items that need to be re paired to maintain top performance and appearance of the dispenser All safety precautions and procedures must be followed when performing the inspections Any inspection or maintenance item not specifically covered should only be per formed by trained service personnel WARNING Inspecting servicing or repairing a fuel dispenser is potentially dangerous due to the presence of flammable fuel vapors and high voltage electricity Read and obey all safety precautions to prevent serious injury or death Barricade the lane s next to the dispenser to prevent access by vehicles and non authorized personnel Wear gloves and proper eye protection Disconnect all power to the dispenser prior to opening any of its panels More than one disconnect may be required Use proper lockout tag out procedures to secure the disconnect s in the off position Disconnect all power to the associated supply pump prior to opening any of the panels on the dispenser s lower hydraulic cabinet More than one disconnect may be required Use proper lockout tag out procedures to secure the discon nect s in the off position If accessing the lower cabinet of the dispenser remove the doors and allow any vapors that may be present to disperse for a few minutes before beginning any work Page 8 1 Owner Maintenance Instructions WARNING Using a
33. simplified formulas modified for specific units of measure Page 6 2 Calibration SB 100 Meter Formulas simplified for specific units of measure U S GALLONS Sight Glass Reading in x 8 325 Adjustment of half holes Test Draft Size U S Gallons LITERS Sight Glass Reading ml x 1 923 Adjustment of half holes Test Draft Size Liters IMPERIAL GALLONS Sight Glass Reading in Adjustment of half holes s Test Draft Size Imp Gallons Procedure 1 Dispense product into a certified calibration container to wet the interior Empty the fuel back into storage For hand held containers allow it to drain for 10 seconds after flow stops For containers with a bottom drain valve allow container to drain for 30 seconds after flow stops 2 Dispense product into the prover until the dispenser reads exactly the rated volume of the container i e 5 000 gallons for a 5 gallon con tainer 50 000 gallons for a 50 gallon prover etc 3 Record the reading from the sight glass on the calibration container and compare it to the allowed tolerances in Table 1 4 Ifthe reading on the sight glass is within the applicable tolerance range the meter calibration is good and no change is necessary Go to step 9 below 5 If the reading is outside the applicable tolerance range the calibration of the meter must be adjusted Using Formula 6 1 or one
34. the dispenser enters the programming mode the user will be prompted on the handheld to choose whether they want to access the parameters or change the current pricing If a menu selection is incorrectly selected pressing the lt ESC gt button on the handheld will return you to the previous screen lt F1 gt PROGRAM SET FREGE Press the lt F2 gt key to set the price for the fuel being dispensed The hand held will then display the current price programmed into the unit and prompt the user to enter the new price Note If the dispenser is connected to a con troller that can set the price remotely the controller must be used to set the dispenser s price Any price set using the handheld will be over written by the controller when communication is restored after the handheld is unplugged The user can enter the new price using the handheld s directional keys Use the left right arrow keys to move the cursor to the digit to be modified Once a digit is highlighted with the cursor use the up down arrow keys to modify the digit s value The example screen below prompts the user to enter a new price by changing the current price setting of 4 239 Enter New Price 4 239 For the example above assume that the user enters a new price of 4 379 and presses lt gt key to proceed Store 4 379 lt ESC gt N lt SAVE gt Y Pressing the lt SAVE gt key will store the new value and pressing the lt ESC gt key will abort th
35. the output of the meter The ON position increases the meter output and the OFF position decreases the meter output See drawing above for reference 53 amp 54 Used to set the size of the adjustment to the meter s base calibration The value represented by the switches can range from 00 to 99 with each increment ap proximately 0 03 S3 represents the 10 s position and S4 represents the 1 s posi tion The setting of S2 determines whether the adjustment increases or decreases the meter s output The RESET button must be pressed after any changes Formula 6 2 Dispenser Reading Volume in Prover Error x 100 Volume in Prover Error New 53 8 54 Current 53 amp 54 0 03 Note Be sure to keep track of the or sign of the numbers see following page for simplified formulas modified for specific units of measure Page 6 6 Calibration TS15A EDM Meter Formulas simplified for specific units of measure U S GALLONS Sight Glass Reading 14 43 New 53 amp S4 Current 53 amp 6 4 LITERS New S3 amp S4 Current S3 amp S4 Test Draft Size U S Gallons Sight Glass Reading ml x 3 33 Test Draft Size Liters IMPERIAL GALLONS Sight Glass Reading in x 12 015 New 53 amp 54 Current 53 amp 54 T Test Draft Size Imperial Gallons Procedure 1 Dispense product into a certified calibration
36. value for the dispenser When the totalizer mode is activated the most signifi cant 5 digits of the totalizer is displayed and remains on the display for the time period defined by this parameter At the end of the time period the display then switches to the lower 5 digits of the totalizer and remains on that screen for the same period The dispenser then returns to normal operation Value is in seconds 240 Leak Test Delay Value Range 0 10 0 Default Value 5 0 Format nn n The Leak Test Delay sets the time period that the dispenser s valve remains closed after the dispenser is activated to dispense fuel Once activated the dispenser will turn on the STP then wait for this delay period before opening the valve This delay provides leak detector with the time to perform its test The dispenser s main display performs a segment test during this period Value is in seconds Page 4 10 Programming 250 Hose Pressurization Delay Value Range 0 5 0 Default Value 1 5 Format n n The Hose Pressurization Delay sets the time period that the dispenser allows for the hose to come to pressure at the beginning of a transaction The purpose is to prevent the dispenser from beginning a transaction at a non zero value because of fuel passing through the meter when the hose is pressurized The hose pressurization delay begins at the end of the Leak Test Delay period Value is in seconds 260 Good Pulses Before Hi Flow Value Range 1
37. with the inside edge reamed to remove burrs Installation Instructions WARNING Gasoline blends containing 15 or more ethanol may not be compatible with certain materials and hydraulic components Leaks or component failure may result caus ing fire or explosion or environmental damage When dispensing gasoline blends containing 15 or more ethanol consult the manufacturer of all fuel system components to verify compatibility with the fuel be ing dispensed This includes the fuel dispenser itself e All contractor supplied pipe and fittings must be Schedule 40 Standard units require 1 1 2 NPT and high flow units require 2 NPT pipe and fit tings All contractor supplied piping and fittings shall be black steel or stainless steel All material must be compatible with the fuel being used WARNING A shear valve may be damaged or broken if not properly supported when tightening fittings into it The installer must use two wrenches to prevent stress from being ap plied to the shear point during tightening e The Commander dispenser is supplied without unions on the supply and satellite feed connection points A contractor provided union must be installed on top of each shear valve Refer to valve manufacturer in structions for proper procedure to tighten union to shear valve e The shear point of each shear valve must be within 3 4 of the plane of the bottom of the dispenser base or within valve manufacturer s ins
38. COMMON TO ALL MODELS MOUNTING HOLE FOR 1 2 STUD BOLT DISPENSER FRONT Figure 4 Structural footprint of tte CMDR Dispensers WARNING Improperly anchoring the dispenser can result in damage to the equipment severe injury or death if the unit were to fall over due to impact or drive off The dispenser must be securely anchored per the instructions that follow Anchor the dispenser to the fueling island using all four 4 of the mounting holes in the bottom frame 1 Use only 1 2 inch Grade 5 or above steel hardware that is treated to prevent corrosion Do not use plastic or lower grade hardware 2 Securely anchor the bolts studs to the island or impact box 3 Securely anchor the dispenser to the island using heavy duty washers and nuts on the anchor bolts studs Tighten the nuts Page 3 7 Installation Instructions Requirements for Electrical Installation WARNING The electrical work must conform with all applicable Federal State and Local building fire code requirements This includes but not limited to NFPA National Fire Protection Agency 30 Flammable and Combustible Liquids Code NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages and NFPA 70 National Electrical Code Failure to adhere to these requirements could result in severe injury or death CAUTION Do not attempt to wire the dispenser without first reviewing the appropriate wiring diagrams and associated notes Failu
39. Connecting Fuel Line s to 3 6 Mounting the Dispenser to the 15 3 7 Requirements for Electrical 3 8 0110 3 9 Hazardous Area 2 0 2 0 0 0 1000000 000 3 10 Emergency Power Disconnect 3 11 ICU 5 4 uu 3 11 PUMO CONTO uuu uu au 3 11 DC Pulse and Communications 3 12 DO FUB __ 3 12 WIRING DISPENSER era 3 13 Hose Assembly 3 14 AU L uuu uyu ENI 3 15 Section 4 Programming WITS OP WIC AS UNS 4 1 Handheld Programmer DescriptioN 4 2 Using the Handheld Programmer i 4 3 Changing Parameters Using the Handheld 4 4 Changing Fuel Prices Using the Handheld 4 5 CMDR Parameter List Table 4 6 Configuring the Dispenser for 2 Wire Communications
40. INSTALLATION amp MAINTENANCE MANUAL CMDR SERIES REMOTE DISPENSERS TOTAL SALE TOTAL SALE i GALLONS GALLONS Puc Pump Measure Control Inc 1070 Nine North Drive Suite 100 Alpharetta GA 30004 Phone 770 667 0667 Fax 770 667 0476 m g lt EUM EQUIPMENT INS Z7TUTE TABLE OF CONTENTS Section 1 Safety Information Section 2 Introduction OCODE 2 1 WO Ado 2 1 2 1 Power ii da 2 1 aloes 2 1 la 2 2 ai 2 2 Model Codes 2 3 Section 3 Installation Instructions General umasa a ina 3 1 Site Survey Prior To InstallationN 3 2 Determining FRONT and REAR of 3 2 Verify Plumbing Configuration a aaa 3 3 Placing Dispenser on 2 2 0 000000000 a 3 4 Requirements for Plumbing 3 4
41. LED EARTH GROUND lt Z 120VAC FUELMASTER FMU2500 TO CMDR WIRING DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT MOVE THE PUMP CONTROL SIGNAL FOR SIDE 2 FROM MOTOR CONTROLLER 2 TO MOTOR CONTROLLER 1 FUELMASTER FMU2500 MUST HAVE 2 STAGE VALVE OPTION INSTALLED DISPENSER MUST BE PROGRAMMED TO TRANSMIT VOLUMETRIC PULSES 100 PULSES PER GALLON SEE DISPENSER MANUAL FOR DETAILS BS REFER TO MANUFACTURERS INSTALLATION MANUALS FOR GROUNDING REQUIREMENTS FOR ALL EQUIPMENT INSTALLED p M LI DATE DRAWN BY DISCONNECT WIRE MODIFICATION IN HEAD SIDE 1 CPU BOARD MOVE YELLOW WIRE FROM TB2 LOW TO TB7 1 ON THE SIDE 1 BARRIER TERMINAL MOUNTED TO THE BACK OF THE CPU ump Measure Control Inc PE 070911 1 Peet WITH 2 STAGE VALVE CTRL MOUNTING PLATE MOVE BLACK WIRE FROM TB2 HGH TO TB7 2 ON THE SIDE 1 BARRIER THIS CONNECTS THE YELLOW WIRE LOW FLOW COIL TO 12 RED YELLOW AND THE BLACK WIRE HIGH FLOW COIL TO 13 RED BLACK WIRE MODIFICATION IN HEAD SIDE 2 CPU BOARD MOVE YELLOW WIRE FROM TB2 LOW TB7 1 ON THE SIDE 2 BARRIER TERMINAL MOVE BLACK WIRE FROM TB2 HGH 1070 Nine North Drive Suite 100 gt Alpharetta GA 30004 _____ L2 N LI TO TB7 2 ON THE SIDE 2 BARRIER THIS CONNECTS THE YELLOW WIRE LOW FLOW COIL TO 22 RED YELLOW AND THE BLACK WIRE HIGH FLOW COIL 23 RED BLACK 770 667 0667 FAX 770 667 0476f THIS DRAWING CONTAINS
42. LISTED thread sealant that is approved for use with the appropriate fuel type Follow manufacturer s instructions for the compound s use WARNING Prying or otherwise using excessive force to align an inlet pipe will stress compo nents and may damage the shear valves unions or other parts of the dispenser Stressed or damaged components may fail and leak fuel causing a fire or explosion that can result in severe injury or death Properly positioned shear valves should not require the inlet piping to be forced It may be necessary to temporarily remove the dispenser from the island to align the shear valve s properly Page 3 6 Loosely connect the union halves together and double check the align ment of the piping before tightening Tighten the unions Verify the shear point of each shear valve is within 3 4 of the plane of the bottom of the dispenser base See Figure 3 for details Verify the shear valves are properly secured to the valve anchor bracket All liquid carrying lines must be checked for leaks Remember to allow all pipe compound to cure or set before performing the leak tests Close the shear valve and leave closed until startup of the dispenser Installation Instructions Mounting the Dispenser to the Island The dispenser footprint indicating the mounting anchor points on the dis 5 base can be seen in Figure 4 This structural footprint is common to all Commander models FRAME DIMENSIONS
43. ND POSITION 2 TO MOTOR CONTROL 1 PH 770 667 0667 FAX 770 667 04764 THIS DRAWING CONTAINS PROPRIETARY EGND 2 DISPENSER MUST BE PROGRAMMED TO TRANSMIT VOLUMETRIC PULSES 100 PULSES PER GALLON DRAWING NUMBER INFORMATION AND IS SUBJECT TO 3 REFER TO MANUFACTURERS INSTALLATION MANUALS FOR GROUNDING REQUIREMENTS FOR ALL EQUIPMENT INSTALLED 01 11 5071021 gt coryricHt ownERSHIP BY PMC INC REVISIONS DESCRIPTION DATE GASBOY CFN Interface GASBOY CFN Interface Z 6 MAIN POSITION 1 POSITION 2 POWER _ O TO OTHER CONNECTION Te lt m DISPENSERS z 5 lt 9 9 DISPENSER MAIN JUNCTION BOX a Ta LE N lt F sess 5 e886 POO OOS GASBOY CFN SYSTEM CARD SYSTEM BREAKER gt EARTH 1 BLACK GROUND WHITE GREEN 0 BROWN 1 ORANGE 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 BLUE 6 WHITE BLUE 7 PURPLE 8 YELLOW 9 WHITE PURPLE DISPENSER BREAKER MOTOR CONTROL WITH SIGNAL ISOLATION PUMP BREAKER Pa FROM OTHER Waaa LL BLACK PUMP WHITE PROD J GREEN 1 0 BROWN WHITE x ORANGE M SIGNAL ISOLATION x ee 2 RED YELLOW PUMP SIGNAL ISOLATION 5 ORANGE IVI O RED BLACK ro o
44. NEUTRAL SIDE 2 EARTH GROUND EARTH GROUND AUTHORIZE 120VAC SIDE 1 PUMP START 120VAC SIDE 1 SPARE SIDE 1 SPARE SIDE 1 SPARE SIDE 1 AUTHORIZE 120VAC SIDE 2 PUMP START 120VAC SIDE 2 SPARE SIDE 2 SPARE SIDE 2 SPARE SIDE 2 FPO N IN CO FP J JO TS IN 10 11 O U J CONNECTIONS INPUT OUTPUT PULSE OUTPUT SIDE 1 PULSE OUTPUT SIDE 1 COMMUNICATIONS SIDE 1 COMM GND SIDE 1 COMMUNICATIONS SIDE 1 PULSE OUTPUT SIDE 2 PULSE OUTPUT SIDE 2 COMMUNICATIONS SIDE 2 COMM GND SIDE 2 COMMUNICATIONS SIDE 2 N fo UTPUT OUTPUT NPUT OUTPUT 27 O JO U N N N FIN Fa JH J 1 FO cO CMDR JCTN BOX WIRE DESCRIPTIONS E DRAWN BY Pump Measure Control Inc 07 18 11 1070 Nine North Drive Suite 100 Alpharetta GA 30004 NTS F PH 770 667 0667 770 667 0476 91 11G07181 DAT THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND IS SUBJECT TO COPYRIGHT OWNERSHIP BY PMC INC 8 7 6 5 4 3 2 1 1 DONSSQODOD DI a O 0000 CPU BOARD L5 16 17 18 19 110 4 4 om PART ve TB3 1234 I S BARRIER DISPLAY TB4 1 2 3 TB 1 AC CONNECTIONS 6 EARTHGround Imut __ 5 80 AC NEUTRAL From Source AC HOT L1 VAC From
45. NSER MUST BE PROGRAMMED TO TRANSMIT VOLUMETRIC PULSES 100 PULSES PER GALLON DRAWING NUMBER INFORMATION AND IS SUBJECT 3 REFER TO MANUFACTURERS INSTALLATION MANUALS FOR GROUNDING REQUIREMENTS FOR ALL EQUIPMENT INSTALLED 01 11 507092 ownERSHIP INC REVISIONS DESCRIPTION DATE PEDISTAL TERMNATION BOARD RESISTORS SHOWN CONNECTED TO DC PULSE TERMINAL STRIP IN Z 6 THE FUELMASTER FMU MUST TO OTHER SUPPLIED BY INSTALLER DISPENSERS Pe CONNECTION DISPENSER MAIN JUNCTION BOX EARTH GROUND FUELMASTER FMU2500 w 2 STAGE VALVE CTRL CARD SYSTEM BREAKER 1 BLACK WHITE 5 GREEN 0 BROWN 1 ORANGE 2 RED YELLOW 3 RED BLACK 4 PURPLE WHITE 5 BLUE 6 WHITE BLUE 17 PURPLE 8 YELLOW 9 WHITE PURPLE i DISPENSER BREAKER MOTOR CONTROL WITH PUMP SIGNAL ISOLATION BREAKER FROM OTHER DISPENSERS 2 BLACK PUMP WHITE PROD C 6 GREEN 1 20 BROWN WHITE 21 ORANGE WHITE MOTOR CONTROL WITH PUMP SIGNAL ISOLATION 3 RED BLACK 4 PURPLE WHITE 5 ORANGE 6 WHITE ORANG 7 PURPLE 8 YELLOW 9 WHITE PURPLE BREAKER FROM OTHER DISPENSERS N N NIN RELAY1 AND RELAY2 MUST BE LOCATED EXTERNAL TO THE DISPENSER IN AN ENCLOSURE RATED FOR THE NEC AREA CLASSIFICATION WHERE THEY ARE INSTAL
46. OW 23 RED BLACK 24 PURPLE WHITE ua eee 25 ORANEE N PROD 26 WHITE ORANGE 27 PURPLE ila lu lla st da al ato _ 28 YELLOW 29 WHITE PURPLE EARTH GROUND 120VAC CMDR STANDALONE MODE WIRING DIAGRAM EMERGENCY DATE DRAWN BY POWER Pump Measure Control Inc 07 13 11 DISCONNECT 1070 Nine North Drive Suite 100 gt L N 11 1 DUAL PRODUCT CONFIGURATION SHOWN IF SINGLE PRODUCT CONNECT 21 ORANGE WHITE ON DISPENSER SIDE 2 TO TO MOTOR CONTROL 1 PH 770 667 0667 FAX 770 667 04764 THIS DRAWING CONTAINS PROPRIETARY ance 2 REFER TO MANUFACTURERS INSTALLATION MANUALS FOR GROUNDING REQUIREMENTS FOR ALL EQUIPMENT INSTALLED DRAWING NUMBER INFORMATION AND IS SUBJECT 3 DISPENSER MUST BE PROGRAMMED TO OPERATE IN STANDALONE MODE SEE MANUAL FOR DETAILS 91 11607131 INC REVISIONS PIE 485 DBOX INTERFACE DESCRIPTION DATE GND i Db 2 1 DISPENSERS 0 Ps i 7 9 3 DISPENSER MAIN JUNCTION BOX 7 EARTH de GROUND O13 714 DIA 7 14 D15 D15 x He he 5 GREEN DISPENSER 11 ORANGE 2 12 RED YELLOW t ae IE 14 PURPLE WHITE MOTOR CONTROL WITH O PUMP SIGNAL ISOLATION BREAKER DISPENSERS PUMP 7
47. Programming Num Description Range Units Format Type 020 Units of Measure 0 GALLONS 1 LITERS 2 IMPERIAL GAL 080 Pulse Out Type 0 VOLUME LIL W 1 MONEY 081 Volumetric Pulse Out Resolution 0 1 1 eo T_T on nw fot femmes nw STD TO nw 200 Operational Mode 0 CONSOLE R W 1 STANDALONE Unit Address for Communica 1 31 nn R W tions 610 Communications Protocol 0 Comm Disabled n R W 1 PMC Protocol Page 4 7 Programming 001 Meter K Factor Value Range 0 9999 999 Default Value 1000 000 The Meter K Factor tells the CPU board how many pulses per gallon are being generated by the meter connected to the board The value is specified in pulses gallon The value is hard coded at 1000 000 and is READ ONLY Therefore the value can not be modified 020 Units of Measure Value Range 0 US Gallons Value 0 US Gallons Format n 1 Liters 2 Imperial Gal The Units of Measure parameter identifies units that the dispenser is measuring the fuel The parameter accessed via the handheld is READ ONLY and can be used to verify what units the dispenser is set to The Units of Measure can only be configured using the shorting jumpers on the CPU board See page 4 1 for details 030 Display Decimal Points Value Range 0 6 Default Value 0 The Display Decimal Points parameter configures the decimal position
48. anels may cause damage to the dispenser Use a forklift to place the dispenser on the island 1 Adjust the spacing on the forklift s tines so that the outside edges about 22 inches apart Place the dispenser on the tines so that the wide side of the dispenser spans between them Center the dispenser on the tines taking care to evenly distribute the weight of the dispenser Using a strap secure the dispenser to the forklift to reduce the risk it may tip over or fall Carefully lift and position the dispenser on the island Do not securely anchor the dispenser to the island until installation and alignment of inlet piping is complete However provisions must be made so the dispenser cannot fall over Requirements for Plumbing Installation WARNING Shear valves that are improperly installed or anchored may fail to operate correctly causing a fire or explosion that results in severe injury or death All shear valves must be installed and anchored per the manufacturer s instructions Page 3 4 The Commander dispenser must be installed with a shear valve on each line beneath the unit This applies to both product supply and sat ellite feed lines Verify that all shear valves are mounted correctly ac cording to the valve manufacturer s instructions and code requirements Remove all shipping plugs and caps that may be present in piping shear valves and unions Ensure all pipe threads are properly cut and undamaged
49. ay The product supply pump is turned off e The solenoid valves in the dispenser are closed e current sale information will remain on the displays until the dis penser is authorized for another sale Power Failure When there is a power failure dispenser ends the current transaction stores all transaction information to non volatile memory and continues to display the sale information for 15 minutes When power is restored the sales information is recalled from memory and presented on the displays until the dispenser is authorized for the next sale All transactions in progress when the power failed are ended and should be paid If the user wishes to get more fuel the dis penser will need to be reauthorized for a new sale Reading The Dispenser Totalizer The dispenser is equipped with a 10 digit non resettable totalizer value that indicates the total volumetric throughput for the dispenser The value is read by activating the totalizer display mode by holding a strong magnet near bot tom left corner of the VOLUME display window on the dispenser s faceplate See photo below Hold the magnet within 1 4 of the faceplate until the display mode is activated Once activated the dispenser will display the value in two parts The most significant 5 digits of the value will be displayed first followed by the least significant 5 digits The two parts are differentiated by H pre ceding the most significant and an
50. azards of transportation After unpacking and prior to installation inspect all equipment to verify all required materials are on hand and the dispensers have all the ordered options and markings Compare the model number on the dispenser model serial plate to the model num ber notation information in section 1 of this manual If discrepan cies in dispenser options and markings are determined contact Pump Measure Control at 770 667 0667 Read all instructions and tags carefully prior to performing any work on the dispenser An improperly installed or maintained dispenser can be dangerous and will likely be a source of ongo ing problems Safety Information 1 SAFETY INFORMATION The following procedures are mandatory and shall be followed when installing maintaining operating or servicing this equipment Fire ex plosion and electrical shock can occur and result in death or serious injury if the safe service prac tices outlined in this manual are not followed The hazards and safety precautions associated with installing maintaining or servicing the dis penser are detailed in the corresponding sections of this manual Read all safety information and applicable sections in this manual before per forming any work Only trained or authorized individuals should install inspect maintain or service this equipment Emergency Shut Off Before performing any work at a location identify the switch or circuit breakers that disc
51. corrosion A high grade non abrasive automobile wax Page 8 3 Owner Maintenance Instructions should be used Be careful not to get wax on textured surfaces or the finish may be ruined Waxing the dispenser panels should be done more often in high corrosion environments such as salt water marinas Service Inspections By Service Contractor In addition to the periodic inspection and preventive maintenance schedule per formed by the owner the dispenser and fuel system should be fully inspected by qualified service personnel at least once a year Many times a trained ob server can find problems issues that may be overlooked Anytime repairs up grades or modifications are made to the dispenser the following WARNING in formation must be adhered to WARNING When making repairs to the dispenser s internal hydraulic system only identical parts can be used Substitute parts may compromise the reliability safety of the dispenser and create a condition that results in severe injury or death from fire ex plosion or electric shock WARNING Unauthorized dispenser modifications may compromise the safety of the dispenser and create a condition that results in severe injury or death from fire explosion or electric shock Do not make or allow to be made any changes or modifications to the dispenser that are not factory authorized WARNING Draining fuel from a section of the dispenser while performing service or repairs can r
52. culations for the SB 100 meter Cont Example 4 US Gallons The accuracy of an SB 100 meter is checked using a 5 gallon test can The test can s sight glass reading of 11 is outside of the allowed tolerance and the meter must be adjusted Using the simplified US GALLONS formula from page 6 3 11 x 8 325 Total adjustment 18 32 half holes 5 Round result to nearest whole number 18 half holes Cut the seal wire from the meter and gently remove the pin securing the calibration dial Since the dispenser over delivered 11 in turn the dial 18 half holes clock wise towards the to decrease the meters output Re insert the pin securing the calibration dial Test the new calibration setting and reseal the meter Example 5 Liters The accuracy of a new SB 100 meter is checked using a 20 liter test can The test 5 sight glass reading of 0ml 15 outside of the allowed tolerance and the meter must be adjusted Using the simplified LITERS formula from page 6 3 70 x 1 923 Total adjustment ns lt O R L 6 73 half holes 20 Round result to nearest whole number 7 half holes Cut the seal wire from the meter and gently remove the pin securing the calibration dial Since the dispenser under delivered 70ml turn the dial 7 half holes counter clockwise towards the to increase the meter s output Re insert the pin securing the calibration dial Test the new ca
53. dispenser with leaking damaged or worn parts can create a condition that may result in serious injury or death from fire explosion or electric shock If leaks or damaged parts are discovered during an inspection remove the dispenser from service and contact service personnel for repair WARNING Servicing or repairing a dispenser incorrectly can result in serious injury or death from fire explosion or electric shock Only qualified and trained service personnel should service or perform repairs on the dispenser WEEKLY INSPECTIONS e External Leaks Check the dispenser for any external leaks Check around the base of the dispenser for signs of a recent spill or leak All leaking dam aged or worn parts must be repaired immediately by qualified service per sonnel Hanging Hardware Check all hanging hardware closely for leaks cracks wear and damage The components checked should include the hose whip hose breakaway swivel and nozzle Consult component manufacturer for any additional inspections required All leaking damaged or worn parts must be replaced immediately by qualified service personnel Breakaway Verify that the breakaway connection is secure If brake away is not secure notify service personnel to correct or repair as necessary Nozzle Boot Lever Check nozzle boot lever for ease of movement by mov ing up and down several times If lever sticks or does not have free move ment over full range contact t
54. e foil s de BOARD MUST BE RESET BY sired The possible selections for Units of CYCLING POWER OR PRESS Measure to be used by the dispenser are ING THE RESET BUTTON defined below Shunt Block Location on CPU Board Table 6 1 Units of Measure Units of Measure SHUNT SHUNT Position 1 Position 2 US GALLONS SHORTED SHORTED LITERS SHORTED IMPERIAL GALLONS SHORTED default Note Shunt Block positions 3 amp 4 are not used Page 4 1 Programming Handheld Programmer The HHP 1 Handheld Programmer is used to configure the Commander dis penser during installation and to manually set pricing information in standalone applications See figure below The dispenser s configuration can be customized to the particular installation by setting non volatile parameters stored in the dispenser s CPU board Modification of these parameter values will probably only need to be done during the initial installation setup of dis penser The HHC 1 Programmer is a generic device and therefore can be used to configure any Commander dispenser Only one programmer is re quired per facility When not being used the handheld and its cable should be stored in a secure dry location The HHC 1 Programmer is equipped with a 2x16 character backlit LCD dis play and a 9 button keypad The programmer connects to the dispenser s CPU board using a RJ 45 cable Power to the handheld and communications with the dispenser is tran
55. e modification NOTE Pressing the lt ESC gt key at anytime will always return the handheld to the previous screen Page 4 5 Programming CMDR Parameter List V2 00 How to read the Parameter tables Number Parameter number Register Desc The meaning or purpose of the parameter Range the minimum and maximum values that the register can hold Units units of the value for the parameter Format the exact format of the value as it is enterred N ASCII character between 0 and 9 30 hex 39 hex A an ASCII alphanumeric character 32 hex 7A hex Note the semi colon 3B hex is reserved and not allowed B ASCII character representation of a binary value 0 or 1 ASCII character representation of a hex value 0 9 A F HH MM SS Standard time format hours minutes seconds MM DD YY Standard date format months days years Example Port Security Num Description Range Format Parameter Accessibil Access Level ity The Parameter number for this register is 600 and is identified as the Unit Address The value anywhere from 1 to 31 The format of the value must be two numerical digits The register can be read anytime but can only be changed when the dispenser handle is in the OFF position The parameter can only be accessed using the handheld remote If password security is en abled the user must have at least a level 1 password to read the value and a level 3 password to change the value Page 4 6
56. esult in a dry seal condition leading to leaks Leaking fuel posses both an environ mental and safety hazard Always replace seals and gaskets with new when servic ing or repairing the dispenser Page 8 4 Wiring Diagrams 9 WIRING DIAGRAMS The following wiring diagrams drawings are provided to assist the installer in wiring the Commander dispenser Ensure that the proper diagram s is are used for the installation Failure to properly wire the dispenser may result in damage to both the dispenser and other equipment connected to it Be sure to pay attention to any and all notes associated with the diagrams OMDR CPU Board Termina essre 4 OMDR PU Boara LED Descipion ss _ OMDR Upper Uni ema Wing SIDE _ _ OMDR Upper Unt ema Wing SIDE 2 OMDR Lower Uni ema Wing 9082 _ ovon saene nera wmo SPE ST ovon _ PIE D Bor to COR RS 465 Comm 011607002 FUELMASTER FVU2S00 10 CDR Sage FML2s00 0 CDR Stage 945 _ OT arareori o Page 9 1 Wiring Diagrams Page 9 2 1 BLACK INS NA AC POWER SIDE 1 3 WHITE AC NEUTRAL SIDE 1 5 GREEN 20 Be
57. for proper installation and wiring of your Com mander series dispensers and related equipment It is essential that you un derstand the requirements of the system before attempting the installation You should be familiar with and have available for reference the appropriate program ming manuals and installation manuals for all other equipment to be installed and connected with the dispenser WARNING Gasoline blends containing 15 or more ethanol may not be compatible with certain materials and hydraulic components Leaks or component failure may result caus ing fire or explosion or environmental damage When dispensing gasoline blends containing 15 or more ethanol consult the manufacturer of all fuel system components to verify compatibility with the fuel be ing dispensed This includes the fuel dispenser itself WARNING The installation must conform with all applicable Federal State and Local build ing fire code requirements This includes but not limited to NFPA National Fire Protection Agency 30 Flammable and Combustible Liquids Code NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages and NFPA 70 National Electrical Code Failure to adhere to these requirements could result in severe injury or death WARNING Gasoline and petroleum products that may be present during the installation of a dispenser are flammable and explosive creating a dangerous environment re quiring safe practices to prevent
58. gniting a fire explosion resulting in severe injury or death Continuity must be pre sent between the nozzle spout and the dispenser to prevent static discharge All components of the hose assembly should be Listed Continuity of each hose as sembly must be tested and verified prior to use 7 Check the entire hose assembly for continuity Publication RP400 titted Recommended Procedure for Testing Electrical Continuity of Fuel Dispensing Hanging Hardware published by the Petroleum Equipment Institute should be used as a reference guide to perform the continuity tests Page 3 15 Installation Instructions Page 3 16 Programming 4 PROGRAMMING The dispenser s main CPU board s are accessed by opening the display panel located on the rear of the dispenser s head The CPU board must be pro grammed so that the dispenser will operate correctly with the system in which it is installed The programmable features that affect the metrological function of the dispenser are set by cutting traces in the Shunt Block located in the upper right area of the CPU board All other parameters are set by using the Hand held Programmer as defined on the following pages Units of Measure The Units of Measure that a Commander IMPORTANT dispenser uses is selected by cutting foils in a SHUNT block located in the upper right AFTER CHANGING THE UNITS portion of the CPU board Use the sharp OF MEASURE THE CPU point of a razor or awl to break th
59. ions for the TS15A EDM meter Example 1 US Gallons The accuracy of a new TS15A EDM meter is checked using a 50 gallon prover The current switch setting for the meter s calibration board is 40 The sight glass reading of 30 is outside of the allowed tolerance and the meter must be adjusted 30 x 14 43 New 53 amp 54 40 48 658 50 Round result to nearest whole number 49 Change the meter s calibration using this new value Keep 52 on the plus posi tion and S3 amp S4 to 49 Press the RESET button to use the new calibration setting Example 2 Liters The accuracy of anew TS15A EDM meter is checked using a 200 liter prover The current switch setting for the meter s calibration board is 7 The provers sight glass reading of 1425ml is outside of the allowed tolerance and the meter must be adjusted 1425 x 3 33 New S3 amp S4 7 cuni 90 75 200 Round the result to nearest whole number 31 Change the meter s calibration to this new value Keep 52 on the minus position and S3 amp S4 to 31 Press the RESET button to use the new calibration setting Example 3 Imperial Gallons The accuracy of a new TS15A EDM meter is checked using a 50 imperial gallon prover The prover s sight glass reading of 42 in is outside of the allowed toler ance and the meter must be adjusted The meter s calibration switches are c
60. ite 13 Return all fuel dispensed to the appropriate product supply tank 14 Disconnect power from the pump and dispenser using the appropriate breakers 15 If testing is complete with this shear valve remove the hose ball valve assembly from its test port 16 If the hose valve assembly was removed in step 15 re install the test port plug on the shear value using listed sealant rated for the fuel be ing dispensed 17 Closely inspect the dispenser s hose assembly and internal piping for any signs of leaking fuel 18 Repeat steps 1 to 17 for each hose meter on the dispenser Page 5 3 Startup Verify Display and Totalizer Operation Use the following procedure to properly startup the dispenser and prepare it to be placed into service Before testing or operating the dispenser air must have already been purged from the supply piping and the dispenser 1 Restore power to the dispenser and pump with the appropriate breakers 2 Configure the dispenser for the application in which it is used If used in Console mode the dispenser requires an authorize signal from any other device Standalone mode does not require this 3 Press the RESET button on the dispenser CPU board 4 Record the current totalizer readings for the dispenser 5 If the dispenser is used in Console mode authorize the dispenser using the external control device 6 Remove the nozzle from the boot and lift the handle to activate the dis penser
61. libration 6 CALIBRATION All meters are tested calibrated and sealed before a dispenser is shipped from the factory However the accuracy of the meter must be verified as part of the startup procedure Additionally the meters used in the Commander dispenser require a break in period after initial installation during which the meter s calibration can change slightly It is strongly recommended that the accuracy of each meter be re checked after 90 days with calibration changes made as necessary In custody transfer applications involving the resale of fuel the meter must be sealed by the appropriate Weights and Measures authority before initial use and after any changes are made to its calibration Minimum Size of Calibration Container The accuracy of the meters used in the dispenser must be verified using a cer tified calibration container NIST Handbook 44 defines the minimum size of the calibration container required to verify the meters accuracy The size is deter mined by the maximum flow rate achieved by the installed meter For flow rates less than 20 GPM the container must be large enough to hold at least 5 gallons For flow rates of 20 GPM or greater the container must be large enough to allow the meter to operate at least one minute at full flow Generally the minimum calibration container size required to test the meters used in the Commander dispensers are e SB100 Meter 5 gallon standard flow dispenser TS15A
62. libration setting and reseal the meter Example 6 Imperial Gallons The accuracy of anew SB 100 meter is checked using a 5 imperial gallon test can The test can s sight glass reading of 10 in is outside of the allowed tolerance and the meter must be adjusted Using the simplified IMPERIAL GALLONS formula from page 6 3 10 x 6 932 Total adjustment 13 86 half holes 5 Round result to nearest whole number 14 half holes Cut the seal wire from the meter and gently remove the pin securing the calibration dial Since the dispenser under delivered 10 in turn the dial 14 half holes counter clockwise towards the to increase the meter s output Re insert the pin securing the calibration dial Test the new calibration setting and reseal the meter Page 6 5 Calibration TS15A EDM Meter w 9 S3 S4 907 907 co N v EL0303 Calibration Circuit Calibration Adjustment Procedure The TS15A EDM meter used in the Commander dispenser is equipped with an elec tronic calibration board located under a protective cover on the front of the meter The electronics board has two slide switches S1 amp S2 and two rotary switches S3 amp S4 that can adjust the base calibration of the meter a maximum of 3 0 Switches 51 MUST be set to the OFF position 52 Used to determine if the adjustment set by switches 53 amp 54 15 to increase or de crease
63. llation Instructions Emergency Power Disconnect Switch e One or more emergency power disconnect switches must be installed to control power to the entire fueling system See NEC Article 514 5 and NFPA for specifics e The emergency power disconnect switch is a single control point that si multaneously disconnects all power to the fueling system including the dispensers pumps STPs lights etc f more than one disconnect is used they must be interconnected so that activation of any one of them will disconnect electrical power e The emergency disconnect switch must be clearly marked and located in an accessible location between 20 and 100 feet from the fuel dispensers it serves e The disconnect switch must be one that can only be reset with manual intervention in a manner subject to approval by local authorities Circuit Breakers e Power to each dispenser must be supplied from a dedicated switched neutral circuit breaker No other equipment or dispensers shall be pow ered from it A dedicated breaker allows for isolation of the dispenser e Use of two single pole breakers with handle ties is not permitted e The circuit breaker must be properly sized for the power load Consult specifications for load of dispenser model being installed Pump Control A motor control relay must be installed on each pump being controlled by the dispenser The control relay allows the low amperage PUMP START cont
64. nser MUST be connected to an equipment grounding conductor located in the conduit as per National Electric Code Article 250 e Grounding conductor must be at minimum 12 AWG with insulation colored green or green with one or two yellow stripes e Grounding conductor must be connected to the equipment grounding ter minal lug in the dispenser s main junction box e dedicated ground conductor from each dispenser to the electrical panel is required This conductor must be connected to the green grounding screw in the dispenser s main junction box and the ground bus bar in the electrical panel e Verify that the main electrical panel and all sub panels are properly grounded per NEC requirements e Verify that the neutral bus in the main panel is bonded to the ground bus Page 3 9 Installation Instructions Class 1 Division 2 lt Class 1 Division 1 Class 1 Division2 20 Ft horizontally in all directions from dispenser UNCLASSIFIED Electronics Encl UNCLASSIFIED UNCLASSIFIED TOTAL SALE TOTAL SALE All area above vapor barrier 12748 17386 i p le tHe 17286 All area above vapor barrier GALLONS GALLONS VAPOR BARRIER 18 000 Class 1 Division 1 NOZZLE BOOT 18 000 Class 1 Division 1 NOZZLE BOOT Class 1 Division 2 20 0 ea Class 1 Division 2 00 ak 18 000 18 000 CONCRETE CONCRETE FIGURE 5 HAZARDOUS AREA CLASSIFICATIONS Page 3 10 Insta
65. on TOTAL SALE 0 99999 99 GALLONS 0 9999 999 PPG 0 999 999 Non resettable totalizer 0 9999999 999 gallons Dual sided RETAIL displays Island oriented nozzle boots RS 485 communication Hard wire interface can look like mechanical dispenser to controller Pulse output open collector programmable for volume 10 or 100 pulses unit or penny pulse 120VAC 60Hz operation Options All stainless steel construction Single product inlet manifold COMMERCIAL volume only Displays Liters or Imperial Gallons Registration 240VAC 50Hz operation Introduction Model Codes The serial plate on the Commander dispenser is located on the upper right corner of the frame inside of the SIDE 1 door The plate contains both the model number and serial number identifying the dispenser CMDR MODEL NUMBERING SCHEME APPLICATION CMDR SIDE 1 TYPE 2 STD FLOW rated to 20GPM 6 HIGH FLOW rated to 60 9 SATELLITE M MARINE SERVICE A AVIATION SERVICE GENERAL SERVICE SIDE 2 TYPE 0 NOTHING single hose unit 2 STD FLOW rated to 20GPM DISPLAY TYPE R RETAIL DISPLAY COMMERCIAL DISPLAY 6 HIGH FLOW rated to 60GPM 9 SATELLITE NOT DEFINED NOT DEFINED UNIT OF MEASURE G US GALLONS L LITERS IMPERIAL GALLONS S SPECIAL Page 2 3 Introduction Page 2 4 Installation Instructions INSTALLATION INSTRUCTIONS This section provides information
66. onnects power to all fueling equipment dispensing de vices and submerged turbine pumps STPs Explosive Flammable Envi ronment The fuel and associated vapors present in and around a dispenser are very flammable In addition the vapors can become explosive in the right concen trations Clean up all spilled or leaking fuel immediately using an absorbent Dispose of all contaminated material as required by regulatory agencies If the work being performed requires access to the dispenser s lower cabinet allow it to air out by opening it up before you begin Open flames and sparks can ignite any fuel or vapors that may be present and therefore must be prevented Never permit smoking or use of lighters and or matches in the dispensing area Other sources of ignition include welding torches and sparks generated by various sources including power tools automobile starters and static electricity Read the Manual safety is of utmost importance It is imperative that you understand the procedures necessary to complete a task before beginning any work Read understand and follow this manual and all applicable materials labeling supplied with this dispenser If you have questions or do not under stand a procedure call PMC Tech Support at 770 667 0667 Codes and Regulations This equipment must be installed operated and maintained in accordance with all federal state and local codes and regulations
67. ons Protocol Value Range 0 disabled Default Value 1 Format 1 PMC Protocol This determines which if any protocol is used to communicate with the system controller console POS Currently the PMC protocol is the only protocol supported To communicate with the dispenser the console POS must also support this protocol If this value is set to 0 communications with the dispenser is disabled Configuring the Dispenser for 2 Wire Communications The Commander dispenser can communicate with a console control device using the communications port on the CPU board The protocol used by the dispenser allows the console control device to control the dispenser and change pricing remotely To properly configure the dispenser to communi cate parameters 200 600 and 610 must be set to the proper values as de talled below Communications with the dispenser is done via the communi cations wires located in the junction box see drawing 91 11G07141 on page 9 13 for details The TxD and RxD LEDs located next to terminal block TB4 on the cpu board are provided to indicate when communications is occurring with the dis penser Anytime a valid data packet is received from the console the green RxD LED will flash When the dispenser answers a request the red TxD LED will flash The following parameters must be configured properly for the dispenser to communicate e Parameter 200 Operational Mode Set value to 0 to place
68. or avoid serious injury or death Read and un derstand all sections of this manual prior to beginning an installation Follow all instructions and heed all DANGER WARNING and CAUTION blocks General Requirements e Read and understand the entire Safety Information section located at the front of this manual e The complete instructions for other equipment used in the installation of the dispensers such as STPs shear valves etc must be provided by the manufacturer of that equipment e Plan the installation carefully and follow instructions Many dispenser problems are caused by faulty installations e The dispenser installation MUST be done by a qualified installer electrician Page 3 1 Installation Instructions Survey Site Prior to Installation Prior to beginning installation of the dispenser survey the site and verify that other components of the fueling system are installed properly according to the component manufacturer s instructions and applicable codes Determining FRONT and REAR of Dispenser The front and rear sides of the dispenser are identi cal in appearance when viewed from the exterior of the unit Identifying the two sides is important be cause the main junction box and main dispenser electronics are accessed from the rear of the dis penser Page 3 2 Remove one of the lower panels from the dis penser Locate the main junction box in the lower cabinet of the dispenser The dispenser s REAR side
69. otes Failure to follow the correct wiring diagrams may result in damage to the dispenser 1 Select the appropriate wiring diagram s for the installation Select the drawings from the Wiring Diagrams section of this manual Study the diagram s and any notes that may be present 2 Remove the rear door of the lower cabinet on the dispenser Store the door in a safe manner so that it is not damaged 3 Remove the cover from the main junction box Store the cover and its six bolts for re assembly later 4 Verify that a conduit seal off fitting is the first fitting on each conduit as it leaves the ground below the dispenser 5 Verify that all field wires to be connected to the dispenser are e long enough to make connections in junction box e rated for a minimum of 300V e gas oil resistant e identified in some manner to differentiate the connectors 5 Connectthe field wiring conduit s below the dispenser to the junction box using 3 4 conduit and fittings rated for Class 1 Division 1 Group C amp D environments Be careful not to damage or pinch the wires 6 Test each wire conductor to verify that its insulation has not been damaged while being pulled through the conduit A Wires to be tested MUST be disconnected at both ends Use a multimeter to measure resistance of each wire to ground Use a multimeter to measure resistance between all wires reading of 50 Megaohms or greater for each test is acceptable An
70. prover to wet the interior Empty the fuel back into storage Allow the prover to continue draining for exactly 30 seconds after flow stops Dispense product into the prover until the dispenser reads exactly the rated volume of the container i e 5 000 gallons for a 5 gallon con tainer 50 000 gallons for a 50 gallon prover etc Record the reading from the sight glass on the calibration container and compare it to the allowed tolerances in Table 1 If the sight glass reading is within the applicable tolerance range no change to the meter s calibration is necessary Go to step 8 below If the reading is outside the applicable tolerance range the calibration of the meter must be adjusted Using Formula 6 2 or one of its simplified variations above calculate the calibration new setting for the meter s internal calibration board If the result of the calculation is negative set S2 to the OFF position If the result is positive set 52 to the ON position Set the S3 and S4 switches on the calibration board to the new value Finally press the RESET button on the meter s calibration board to use the new setting Empty the prover back into storage Allow the prover to continue drain ing for exactly 30 seconds after flow stops Repeat steps 2 thru 6 to verify the new calibration of the meter Repeat steps 2 thru 8 for each meter as necessary Page 6 7 Calibration TS15A EDM Meter Example calibration calculat
71. r to the Parameter Table on page 4 7 The table and following descriptions de fine the valid ranges and uses of the parameters The handheld will then prompt the user for the number of the parameter code to be modified The number for the parameter can be entered using the hand held s directional keys Use the left right arrow keys to move the cursor to the digit to be modified Once a digit is highlighted with the cursor use the up down arrow keys to modify the digits value Parameter Code To Access 000 Once the number for the parameter has been entered press the lt ENTER gt key to proceed The handheld will prompt the user to enter the new value for the parameter with the 5 current value displayed The example screen below uses parameter 270 with a current value of 0 7 Again use the directional arrows and procedure outlined above to enter the new value for the parameter Parameter gt 70 7 2 0 Continuing with the example above assume the user enters a new value of 1 2 After the new value for the parameter has been entered press the lt ENTER gt key to proceed Store 1 2 lt ESC gt N lt SAVE gt Y Pressing the lt SAVE gt key will store the new value and pressing the lt ESC gt key will abort the modification NOTE Pressing the lt ESC gt key at anytime will always return the handheld to the previous screen Programming Changing Fuel Prices Using the Handheld Programmer When
72. r that the nozzle rests on when it is placed in the boot When a user wants to begin a transaction the nozzle is removed from the boot and the lever is raised When the user wants to end a transaction the lever is lowered and the nozzle is re placed in the boot WARNING A vehicle s engine can generate sparks when running potentially igniting fuel vapors Never fuel a vehicle with its engine running Dispenser Operating Sequence 1 Remove the nozzle from the boot and lift the lever to activate the dispenser 2 Ifthe dispenser is in Standalone mode or is in Console Mode and has been authorized by the console the dispenser will begin its reset cycle The fuel supply pump turns on pressurizing the system The dispenser does a display segment test showing all 85 for 5sec At the end of the 5sec test the displays clear to 0 and the solenoid is opened 3 Dispense fuel The sale information will be displayed on the face of the dis penser The dispenser will remain active and able to dispense fuel until one of the following occurs The nozzle boot lever is lowered turned off The external authorize is removed by the console console mode A quantity of 9999 990 Gallons or 99999 90 is reached PRESET AMOUNT set by a console is reached Power failure Page 7 1 Operating Instructions e Pulser error is detected e Timeout period with no activity is reached Defaulted to 300sec 4 The sale is complete and ready to p
73. rained service personnel to make repairs e Panels Locks Verify all panels and locks are in place on the dispenser Do not operate the dispenser if a exterior panel or lock is missing or severely damaged Labels Verify all required safety and product labels on dispenser are pre sent legible and unobstructed MONTHLY INSPECTIONS e Internal Leaks Slowly remove the lower doors from the dispenser and check for any internal leaks Refer to safety precautions detailed in the WARNING on page 8 1 Filter if present Check if filter needs replacement Filter should be re placed every 250 000 gallons every six months or when fuel flow slows sig nificantly Anytime a filter is replaced the date and totalizer reading should be written on the new filter Compare the current date and totalizer reading to that written on the filter last time it was replaced to determine if the filter should be replaced If the filter needs replacement contact the service per sonnel Page 8 2 Owner Maintenance Instructions LCD Displays Observe the dispenser s LCD displays and look for missing segments LCDs with missing segments must be replaced Preventative Maintenance The Commander Series dispensers are designed to give many years of trouble free service However like any mechanical device they require periodic main tenance to prevent problems from developing PM Schedule Owner The owner should only perform the following p
74. re the hour has a range 00 23 The time is entered in the format Page 4 9 Programming 200 Operational Mode Value Range 0 Console Default Value 1 Standalone Format n 1 Standalone The Operational Mode parameter defines how the dispenser operates If set for STAND ALONE mode simply lifting the dispenser s nozzle hook will activate the dispenser If set for CONSOLE mode the dispenser must receive authorization from the system controller in addi tion to lifting the nozzle hook before the dispenser will activate The authorization command can be via hardware interface or communications 210 Maximum Transaction Size Value Range 1 9999 Default Value 9999 Format nnnn 1 99999 The Maximum Transaction Size defines the maximum volume of fuel that can be dispensed in a single transaction The maximum value for the parameter depends on the decimal positions defined by parameter 030 If the VOLUME display is configured for 3 decimal positions n nnn then this parameter has a max value of 9999 IF the VOLUME display is set for 2 decimal positions n nn then the max value changes to 99999 Units are in whole units of vol ume 230 Totalizer Screen Rotation Delay Value Range 1 60 Default Value 5 Format n The Totalizer Screen Rotation Delay sets the time period that the totalizer information remains on the main display before rotation to the next screen See page 7 2 for details on accessing the totalizizer
75. re to follow the correct wiring diagrams may result in damage to the dispenser e All electrical wiring must be done by a qualified licensed electrician e Read understand and follow this manual and all applicable materials labeling supplied with this dispenser e dispensers must be wired on the same phase WARNING Unauthorized dispenser modifications may compromise the safety of the dis penser and create a condition that results in severe injury or death from fire explosion or electric shock Do not make or allow to be made any changes or modifications to the dispenser that are not factory authorized e Only factory provided equipment is to be installed in the head of the dis penser e The vapor barrier forming the base of the head is an important part of the safety design of the dispenser and MUST remain as shipped from the factory DO NOT drill or punch any holes in this barrier e All conduit and electrical fittings must be listed for use in Class 1 Division 1 Groups C amp D hazardous locations The conduit must be threaded rigid metal conduit PVC or other non metallic con duit is not acceptable See Figure 5 for clarification of what the hazardous area classifications are on the Commander dispenser and where they are located e All threaded conduit connections must be drawn tight with a mini mum of 5 threads of engagement e All field wiring must be connected in the main junction box e AC Neutral
76. reventive maintenance items on the Commander dispensers All other items not specifically outlined here should only be performed by trained service personnel MONTHLY MAINTENANCE Owner Operator 1 Locks The locks on the various panels of the dispenser require lubrica tion to prevent internal corrosion that may prevent proper operation Use a standard lock oil and squirt a small amount into the key slot Do not over lubricate and wipe off excess oil Lock lubrication is very important in high corrosion environments such as salt water marinas CAUTION Do not wash the dispenser with a pressurized water source Water may be forced passed seals into the dispenser and damage electronics or other components CAUTION Do not use petroleum based or abrasive cleaners to clean the exterior of the dispenser as they can damage the finish 2 Clean the Dispenser Use a mild soap such as Dawn dish detergent and water with a soft cloth to clean the exterior of the dispenser If stains persist use a non abrasive industrial cleaner such as Simple Green on the stains Wipe off the dispenser with a clean rag and clean water to remove any soap residue Cleaning the dispenser should be done more often in high corrosion environments such as salt water marinas SEMI ANNUAL MAINTENANCE Owner Operator 1 Wax the Dispenser The dispenser panels should be thoroughly cleaned and waxed every six months to maintain its original appearance and prevent
77. rify that the shear valves for the product supply and satellite feed lines if present match the footprint of the dispenser being installed Pay close attention to the dispenser orien tation Figure 2 gives the footprint configurations for the four inlet hose configurations of the Commander dispensers SINGLE PRODUCT SINGLE HOSE INLET SIDE 1 1B SATELLITE FEED SIDE 1 SIDE2 SIDEI DISPENSER FRONT DUAL PRODUCT DUAL HOSE 2A INLET SIDE 2 1A INLET SIDE 1 2B SATELLITE FEED SIDE 2 1B SATELLITE FEED SIDE 1 SID E2 SIDEI DISPENSER FRONT SINGLE PRODUCT DUAL HOSE INLET SIDE 1 amp SIDE 2 2B SATELLITE FEED SIDE 2 1B SATELLITE FEED SIDE 1 SIDE 2 DISPENSER FRONT MASTER SATELLITE COMBO 2A SATELLITE INLET SIDE 2 1A INLET SIDE 1 FED BY REMOTE MASTER 1B SATELLITE FEED SIDE 1 SIDE 1 DISPENSER FRONT Figure 2 Footprint Configurations for the Commander Dispenser Page 3 3 Installation Instructions Placing Dispenser On Island WARNING Heavy equipment that is being lifted or moved can fall causing severe injury or death Equipment used to lift and or move the dispenser must be rated for the load including safety factor Lift the dispenser only as high as necessary to complete the task Stand clear when lifting or lowering the dispenser CAUTION Only lift the dispenser by the base or the main frame Lifting the dispenser using the nozzle boot fuel outlet or p
78. rol signal to control a high amperage high voltage pump moior CAUTION Damage to the dispenser can result if the PUMP START control signal is used to directly power a pump motor accidentally shorted to the conduit or otherwise miswired e The PUMP START signal can supply up to 0 5 Amps AC to activate the coll on the motor control relay e When the control signal from more than one fueling point can activate a given pump motor means must be provided to isolate the dispenser s con trol signals from one another e isolation relay or other means of isolation must be provided for each pump control signal Combination pump motor control relay amp isolation re lay interface boxes are recommended for ease of installation Page 3 11 Installation Instructions WARNING Failure to isolate the dispensers control signals can result in electric shock from electricity back feeding from one dispenser to another via these signals resulting in severe injury or death Ensure all dispenser control signals are isolated from one another CAUTION Failure to isolate dispenser control signals can result in damage to the dispenser s electron ics from cross phasing that occurs when signals from two or more dispensers powered by different AC phases are connected together Ensure all dispensers are powered by the same phase as mandated in Requirements for Electrical Installation Additionally en sure all dispenser control signals are
79. ry The reading on the prover can sight glass is used to determine the direction and the number of holes to turn the calibration dial If the prover indicates the meter under delivered a negative reading the dial must be turned counter clockwise to increase the meter s output If the prover indicates an over delivery a positive reading turn the dial clockwise to reduce the meter s output The amount to turn the dial is deter mined using Formula 6 1 Note that the result of the calculation is the number of half holes of adjustment as explained in the next paragraph The dial is locked using a pin inserted through the dial and into one of two hubs on the cylinder cover The two hubs are located on opposite sides of the dial and are positioned so that when one hub aligns with a hole in the dial the other hub is be tween holes The offset of the two hubs is referred to as a half hole One half hole adjustment is accomplished by removing the lock pin turning the dial just enough to align a hole with the hub on the opposite side and reinserting the lock pin there One half hole adjustment is the smallest calibration change possible and represents a change of approximately 0 052 Formula 6 1 Dispenser Reading Volume in Prover Error T x 100 Volume in Prover Error Adjustment of half holes 0 052 Note Be sure to keep track of the or sign of the numbers see following page for
80. s for the dispenser s dis plays The table below defines the values and the decimal configurations they represent Total Sale Display Volume Display Price Display n nn Page 4 8 Programming 080 Pulse Out Type Value Range 0 VOLUME Default Value 0 Format 1 MONEY The Pulse Out Type defines the information that the programmable pulse output for the board transmits configured for MONEY the output transmits one pulse per penny If configured for VOLUME the resolution is determine by parameter 081 below 081 Volumetric Pulse Out Resolution Value Range 0 1 1 Default Value 2 100 Pulses Vol Format n 1 10 1 2 100 1 The Volumetric Pulse Out Resolution sets the resolution of pulses transmitted by the CPU board if the Output Pulse Type is set for VOLUME The pulses are per unit volume For ex ample if Units of Measure is set for US Gallons and this parameter is set for 1 the dispenser will transmit 10 pulses for every gallon of fuel it dispenses 100 Current Date Value Range any valid date Default Value Format mm dd yy The Current Date parameter is used to set the current calendar date into the dispenser CPU board The date is entered in the format month day year 101 Current Time Value Range any valid time Default Value Format hh mm ss The Current Time parameter is used to set the current time of day into the dispenser CPU board The time is in 24 hour format whe
81. smitted through this cable If the cable is damaged or lost a standard RJ 45 Ethernet cable can be used HHP 1 Handheld Programmer 4 ESC or ESCAPE Key 8 DOWN Arrow Key RIGHT Arrow Key ENTER Key OMe 5 Page 4 2 Programming Using the Handheld Programmer The handheld programmer must be plugged into the dispenser s CPU board to operate See drawing below The programmer receives all of its power from the CPU board and does not contain any batteries When the programmer is plugged in it will go through a short initialization during which it will display some diagnostic information on the screen for a couple of seconds At the end of the initialization period the programmer will clear its LCD screen and await information to be transmitted from the dispenser The dispenser periodically checks to see if the programmer is plugged in to the CPU board and will begin communicating only if the nozzle handle switch is in the OFF position If the nozzle handle is in the ON position the dispenser will ignore the programmer Once the handle switch is in the OFF position and the dispenser recognizes the programmer is plugged in the dispenser will clear the main transaction displays and print SIE TUF on the main Total Volume dis plays to indicate to any user s that the dispenser is in the programming mode PROGRAMMING MODE Once the dispenser has entered the pro gramming mode
82. structions CAUTION The Commander dispenser MUST NOT be used to remove water from the storage tanks or damage to the dispenser can occur e Enough fuel is in the storage tank for proper operation of the pump s Any water in the storage tank has been removed CAUTION Air must be purged from the fueling system slowly Failure to follow the proper procedure as described can result in extensive damage to the dispenser s meter will void the units warranty Purge Air from Supply Trunk Lines All air must be purged from the dispenser and its product supply piping prior to beginning the startup procedure for the dispenser The following proce dure must be used to purge air from the supply piping 1 Turn off all power to the product pump on the line being purged 2 Verify that all shear valves on the product trunk and branch lines are closed Page 5 1 Startup 3 Repeat steps 4 thru 10 for each product trunk and branch line 4 Goto the dispenser furthest from the product pump on the trunk or branch line being purged 5 Assemble a small ball valve to a 1 4 or 3 8 conductive hose that is compatible with the fuel in the line being purged Make sure that the ball valve is closed 6 Identify the shear valve associated with the line being purged and re move the plug from its test port Connect the other end of the bleed hose to the test port using the appropriate NPT to hose fitting WARNING Fire e
83. tal lation requirement whichever is less See Figure 3 for details Dispenser Grade Level Shear Point Shear Valve FIGURE 3 Shear Valve must be installed with the shear point within 3 4 from the bottom plane of the dispenser base Page 3 5 Installation Instructions Each supply inlet and satellite feed connection on the dispenser is pro vided with a removable NPT threaded flange for connection of piping to the dispenser The vertical supply riser must be cut to the proper height in order to avoid stress on the dispenser Clean all debris from pipes before assembly Debris can damage the fil ter strainer allowing other foreign material to pass through potentially damaging the dispenser Connecting Fuel Line s to Dispenser WARNING Do not use flexible or non metallic pipe to connect the shear valve to the dispenser inlet The shear valve may not operate correctly resulting in a fire or explosion that can cause severe injury or death Use only rigid metallic pipe and fittings between the shear valve and the dispenser inlet Use the following procedure to pipe each shear valve to the associated con nection point on the dispenser The installer must provide all piping and fittings necessary to connect the shear valve to the dispenser inlet Use only schedule 40 black iron or stainless steel parts Use only
84. the dis penser in CONSOLE mode If parameter 200 is set toa T STANDALONE mode the dispenser will not communicate Parameter 600 Dispenser address Set this parameter to the ad dress the dispenser will use for communications Valid communica tions addresses are 1 to 31 Usually this value is set to the same number as the hose position e Parameter 610 Protocol Set this parameter to the correct protocol being used by the console Current 1 is the only protocol supported by the dispenser Setting this parameter to a 0 will disable communications Page 4 12 Startup 5 STARTUP Pre Startup Checklist The items in the following checklist must be inspected and verified as having been completed correctly prior to starting up the dispenser All items should already be complete as required in previous sections Only after the check list is complete should power be applied to the dispenser e Power is turned off to the dispenser and associated product pump e The dispenser is securely anchored to the island using all four mount ing locations in its base e All shear valves for dispensers being installed should be closed e Filters and strainers in dispenser are installed and tight Dispenser is properly grounded e All conduit is complete e All unused conductors in the junction box are capped off e All ports or openings in junctions boxes or fittings must be plugged according to manufacturer s in
85. ur rently set to 04 42 x 12 015 New 53 amp S4 4 6 09 50 Round result to nearest whole number 6 Change the meter s calibration to this new value Change 52 to the minus posi tion and S3 amp S4 to 06 Press the RESET button to use the new calibration setting Page 6 8 Calibration TS15A EDM Meter Example calibration calculations for the TS15A EDM meter cont Example 4 US Gallons The accuracy of anew TS15A EDM meter is checked using a 100 gallon prover The current switch setting for the meter s calibration board is 23 The 5 sight glass reading of 85 in is outside of the allowed tolerance and the meter must be adjusted 85 x 14 43 New 53 amp 54 23 10 73 100 Round result to nearest whole number 11 Change the meter s calibration to this new value Keep 52 on the plus position and set 53 8 S4 to 11 Press the RESET button to use the new calibration setting Example 5 Liters The accuracy of anew TS15A EDM meter is checked using a 100 liter prover The current switch setting for the meter s calibration board is 18 The 5 sight glass reading of 810ml is outside of the allowed tolerance the meter must be adjusted 810 x 3 33 New S3 amp S4 18 8 97 100 Round the result to nearest whole number 9 Change the meter s calibration to this new value Change
86. wer to the product pump for the dispenser being purged Page 5 2 Startup 2 Place the dispenser in STAND ALONE mode See Programming Section of this manual 3 Make sure that the nozzles are hung in their proper boot 4 Restore power to the dispenser and associated product pump 5 Verify that the dispenser displays have powered up and are showing information 6 Slowly open the dispenser s shear valve on the supply line 7 Lift the associated nozzle from its boot and lift the boot lever to acti vate the pump and pressurize the line 8 Verify that the correct supply pump has been activated WARNING Fire explosions caused by sparks from static discharge are a potential danger anytime fuel is being dispensed possibly causing serious injury or death Use only approved me tallic containers and always keep the nozzle in contact with the container when fueling 9 Place the nozzle in the metallic container used earlier Be sure to maintain contact between the nozzle and the container 10 Slowly open the nozzle only part way and hold until air stops coming out and is replaced by a steady stream of fuel 11 Open the nozzle valve at least half way and dispense about 40 to 50 gallons per hose to eliminate all residual air in the lines dispenser 12 Hang up the nozzle in its boot lf a satellite is present slowly open the shear valve on the line feeding product to the satellite Repeat steps 7 thru 12 on the satell
87. xplosions caused by sparks from static discharge are a potential danger anytime fuel is being dispensed possibly causing serious injury or death Use only approved me tallic containers and always keep the nozzle in contact with the container when fueling 7 Place the ball valve in an approved metallic container Keep the ball valve in contact with the container at all times while bleeding air 8 Restore power to the product supply pump Activate the pump 9 Slowly open the ball valve and keep open until the air is purged and a steady stream of fuel is coming out of the ball valve Close the ball valve Be sure to maintain contact between the ball valve and the container to eliminate static buildup discharge 9 De activate the product supply pump 10 Disconnect power from the pump and dispenser using the appropriate breakers 11 Place ball valve on the bleed line into the fuel container and open to relieve pressure on the supply line Remove the hose ball valve as sembly from the test port of the shear valve 12 Re install the test port plug on the shear value using listed sealant rated for the fuel being dispensed CAUTION Air must be purged from the product trunk and branch lines PRIOR to purging air from the dispenser Failure to purge the supply lines can result in damage to the dispenser meter Purge Air from the Dispenser The following procedure must be used to purge air from the dispenser 1 Turn off all po
88. y result in injury damaged equipment or im proper erratic operation All conduit sealing devices and compounds must be in place Follow all OSHA Lock Out and Tag Out requirements procedures Make sure all station employees and service con tractors on site understand these procedures to en sure safety while the equipment is being serviced or repaired Page 1 1 Safety Information Page 1 2 Introduction 2 INTRODUCTION Scope This manual contains the information necessary to install operate service and maintain the PMC Commander series dispensers Please read understand and follow this manual and all applicable CODES and NFPA requirements be fore installing the equipment Improper installations are a major source of dis penser failures and ongoing problems The equipment must be installed and operated as directed by this manual to ensure proper and reliable operation Failure to install the dispenser per PMC specifications may void the warranty The manual covers both retail and commercial versions of the dispenser Any references to price settings or penny pulse outputs apply only to the RETAIL versions Differences are noted where necessary All procedures described should only be performed by trained authorized personnel WARNING Per UL87A requirements dispensers must not be changed from its original applica tion by changing fuel types once installed For instance if installed for a gasoline ethanol blend such
89. y wires that fail the test must be replaced 3 13 Installation Instructions F After all wires have passed the insulation test pour the seal off fittings below the junction box 7 Make all necessary connections as required by the wiring diagram s appropriate to the installation Use only properly sized Listed wire nuts to make the connections 8 Individually cap all unused wires in junction box otherwise damage to the dispenser may occur if they short out 9 Seal all unused conduit holes in the junction box using threaded listed 3 4 conduit plugs 10 Replace junction box cover using all six bolts removed in step 2 above Make sure to not pinch any wires 11 Replace the door on the rear lower cabinet of the dispenser Hose Assembly Requirements WARNING Improper installation of the hanging hardware may result in the failure of the break away in the event of a drive off causing the hose assembly to rupture or the dis penser to be pulled over A fire or explosion can occur resulting in severe injury or death All hanging hardware must be installed per manufacturer s instructions and in ac cordance with all applicable codes WARNING Gasoline blends containing 15 or more ethanol may not be compatible with certain materials and hydraulic components Leaks or component failure may result caus ing fire or explosion or environmental damage When dispensing gasoline blends containing 15

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