974236-001 Installation Q230
974236-001 Installation Q230
974236-001 Installation Q230
Q230T
Installation Manual
Great care has been taken in the preparation of this manual however Tokheim
shall not be liable for any misunderstanding, errors and/or loss or defect
arising from the use of this manual.
Tokheim shall not be liable for damage to the product, nor for personal or
third party injury, caused by incorrect use of the product or by attempts to
maintain or to repair the product by parties other than those fully trained by
Tokheim or by its accredited third party representatives.
Tokheim reserves the right to apply changes to this document and the
equipment without further notice.
REVISION RECORD
CONTENTS
(CONT.)
CONTENTS
1 INTRODUCTION
Section 1 - Introduction
This section contains information on how to use the manual, the scope of equipment
covered, recommendations on qualified technicians and contact information. It also
includes relevant health and safety information required for the safe installation and
commissioning of the product.
Section 3 - Drawings
All necessary drawings required for reference during the installation and commissioning,
are listed and contained in this section.
Section 5 - Installation
The instructions for the correct installation of the equipment are contained within this
section.
Section 6 - Commissioning
This section highlights the actions and checks, to be carried out, in preparation for the
commissioning activity and the procedures required from commissioning of the equipment
to handover.
The Quantium 110 & 210 range of fuel dispensers, with the exception of the LPG versions.
For information on Quantium LPG dispensers refer to the relevant LPG manual as provided
by Tokheim.
All dispensers in the Quantium 110 & 210 ranges use the same standard sub-assemblies
and offer a wide range of configurations and includes provision for options such as vapour
recovery etc.
1.5.3 HAZARDS
Prior to starting work, the dispenser must be isolated (i.e. entirely disconnected
from the mains supply) and the mains supply switch locked in the OFF position.
The submerged pump (if applicable) and control signals from the dispenser
must also be isolated. This is done to provide safety for the technician. As a
further precaution, switch off the mains supply in the service station shop and
place a clear notice on the switch to avoid it being turned on again inadvertently.
At unattended service stations, every end-user should be able to read the User
Instructions. They should be visible on a notice board or integrated into the DIT
and should be sufficiently well lit so that they can be read at night.
• Protective helmet.
• Protective shoes (conductive).
• Protective gloves and/or protective hand cream.
• Anti static clothing.
• Eye protection.
SAFETY INSTRUCTIONS
The following safety instructions must be adhered to during installation and
maintenance procedures:-
The components used within the dispenser, including connection facilities, are selected in
accordance with the European Standard EN BS 60079-0 (Electrical Apparatus for explosive
gas atmospheres), and the supplementary Standards listed therein.
Diesel dispensers do not create an explosive hazard, but due to the probability of these
being in close proximity to gasoline dispensers, the same construction rules are applicable.
The dispenser is certified by SIRA as suitable for use in Potentially Explosive Atmospheres
Directive 94/9/EC, and marked to be in accordance with the European Dispenser
Construction Standard EN 13617-1.
This dispenser is also certified to OIML International Recommendations R117 and R118.
Certificate Numbers R117/1995-NL-01.04 & 08.
The production and end test is controlled through the Quality Assurance systems within
the Tokheim Manufacturing Centres, and has received Quality Assurance Notification
from a Notified Body.
“X” CONDITIONS -
refer to section 1.6.2
The Special Conditions for Safe Use are identified in the ATEX EC Type-
Examination Certificates and are repeated below:-
• Where a dispenser is supplied without hoses and/or nozzles, they shall be fitted
in accordance with:
- Hoses : EN1360 or EN13483
- Nozzles: EN13012
• When used for ethanol (blend) dispensing, the fuel specification must be less
than or equal to 85% ethanol, with minimum water content.
• The metering pumps and dispensers are designed for use in open air. Where a
metering pump or dispenser is positioned within a building, incorporated into
an enclosure, or integrated into a larger piece of equipment, additional measures
shall be taken to ensure that the zoning diagrams illustrated in the schedule
drawings are not compromised.
The dispenser is shipped with its own “MID datasheet” which documents the serial numbers
of the prime components fitted in the dispenser. This datasheet must remain with the
dispenser. Similarly dispensers are shipped with a Declaration of Conformance to the
MID. This document must not be lost as it is an essential document to allow the continued
use of the dispenser.
CONTENTS
2 SITE PREPARATION
2.1 General
Tokheim dispensers must only be installed on a level island or forecourt surface.
The ground plan will depend on the model ordered. See drawings in Section 3. Refer to
separate LPG Dispenser Manuals for information on LPG dispenser classifications.
VENTILATION
There are no vapour traps in the structure of the dispenser. The hydraulic cabinet is
ventilated via the hydraulic doors. Note : The hydraulic doors must not be blocked
during installation.
VAPOUR BARRIERS
Hazardous areas, as defined in this manual, are applicable only when the dispenser is
located in open air. The control of the hazardous areas in and around the fuel dispenser is
by the use of Vapour Barriers. No specific precautions are taken to reduce the Zone 1
classification of the internal hydraulic housing of the dispenser.
Q230T DISPENSER
432
Calc Head
50 50
56.5
1570.5
Zone Zone 1 Zone
2 2
Zone Zone 1 Zone 1080 Hydraulic
2 2 housing
Island Level
350
200 427 200 200 673 200
Note:- On this drawing all zone 2 areas are external of the dispenser.
Zone 1 is internal in the dispenser.
The diagram below shows the possible functioning positions of the Q210 dispenser.
Side B
B1 B2
Vapour Recovery
product 1 (only if return
line to product) or
Satellite connection
product 1
P1 P2
A1 A2
Side A
Vapour Recovery (Default) or
Satallite connection product 2 (Outlet) Electrical Supply
Please note : If the inlet riser pipe has a female connection, an adaptor must be used
(1.5” or 2”).
If an adaptor is used, the dimensions shown will need to be reduced (maximum 36mm).
Satellite connection-Product 1
Accessible from Side B
Satellite connection-Product 2
Accessible from Side A
40
55.5 70 Min - 90 Max
Product 2
201
Side A
78
M10
Filter Level
82
201
Driptray
height 70
Island Level
Ø50
Rc 1.5" Ø38
Option - Flexible coupling to
1.5" female thread
Driptray 78
70
height
Island Level
134
117
End Threaded
Ø1.5"
(Ø40/49)
Filter Level
Adapter NEFIT
201 Pipe 903583
Driptray
70
height
Island Level
117
CONTENTS
3. Q230T Dispenser
1032
2410 Rigid mast
825 Nozzle
1137
1082
Product 2
Product 1
Side A
Side B
Side A
Island level
(Cladding) (Cladding)
673 427
NOTES:-
Side A is the side where the pulleys are (if TQP config).
When facing Side A the pump pulley is on the right hand side (if PASV3 config)
When facing Side A, filter brackets are on the right hand side (if submerged config)
For option "Display one side only" displays are on side A
Product outlet always on side 2 for single product
Outlet elbows are oriented upwards for springmast and oriented downwards for hose hook
For retaining hose option, the standard one is with the hook otherwise other options are either
spring or rigid mast.
350
325
252
249
175
25
112
903930
Washer Pl M10
(900008-014)
Apply SILICON sealant all around the leak plate before placing the dispenser.
Leak plate
Ensure the seal between the leak plate and dispenser is complete to avoid water
(903567)
ingress.
CONTENTS
• Shipping List
• Packing/Checking List
• CE Sticker
• Certificate of Conformity
The Serial Number on the dispenser should be identical to the Serial Number on the
Shipping List, CE sticker and Certificate of Conformity. Please inform Tokheim UK Ltd
before unpacking if there are any discrepancies in the notation.
4.2 Packaging
The type of packing depends on the destination of the goods. All products containing a
frame are fixed on a pallet by means of screws and by the use of beams or blocks screwed
onto the frame.
The goods are protected from moisture and scratching by bubble wrap and polystyrene
corner blocks and a standard carton is used for packing. Where the use of a forklift truck
or pallet truck is necessary, special arrangements make this possible through the use of
pallets, beams, dispenser beam bridges or blocks.
All separate components belonging to the same delivery are packed together.
4.2.1 UNPACKING
When the dispensers arrive at the installation site, the unpacked units should be
inspected for possible shipping damage. If damage is evident, it must be reported
to the carrier. Shipping damage is not covered under the Tokheim warranty
policy.
After unwrapping, the dispensers must be checked for any faults or damage.
Any faults or damage found must be reported to the Installation Supervisor
immediately.
Make sure that all packing materials are removed from the service station. It is
recommended that you discuss this with the station’s supervisor.
All products within a package are listed on the Checking List. Follow the
procedure on the Checking List to ensure all required components have been
delivered then return the completed Checking List to the Quality Dept., Tokheim,
Grentheville, France.
4.5 Handling
The recommended procedure for safe handling of the dispenser is by use of a forklift
under the pallet.
The installer must supply all handling equipment and ensure safe working practice at all
times.
INSTRUCTIONS
1) Locate the key for the hydraulic access panel.
2) Unlock the hydraulic access panel.
5) Lift up the panel to release from the drive pins in the base and
remove the hydraulic access panel completely.
6) Repeat for opposite side of dispenser as required.
7) Place the hydraulic access panel(s) in a safe position.
8) To re-fit the hydraulic access panels, follow the instructions in
reverse.
INSTRUCTIONS
1) Locate the key for the calculator head door.
2) Unlock the calculator head door on the relevant side of the
dispenser and carefully open it.
INSTRUCTIONS
1) Follow the instructions given to access the hydraulic
area.
2) Locate the Junction Box in the hydraulic area.
3) Using a screwdriver, loosen and remove the four
screws on the junction box cover and remove
completely.
4) Refer to the wiring diagrams in section 5.
5) To re-fit the junction box cover, follow the instructions
in reverse.
CONTENTS
5 INSTALLATION
5.1 General
Before the dispenser can be installed, the Safety Instructions as described in Section 1.5
and the Installation Instructions in this section must be carefully read.
After unwrapping and before installation, the dispensers must be checked for any faults or
damage. Any faults or damage found must be reported to the Installation Supervisor
immediately.
• Check that the electric cabling and the piping arrangements have been made in accordance
with the Installation drawings in section 3.
• Check that the leakage plates have been produced in accordance with the Installation
drawing. Any differences or defects should be reported to the Installation Supervisor
immediately. The function of the leakage plate is to drain leakages to the outside of the
dispenser where they act as a warning to the station attendant.
• Check that all flame arresters are correctly installed according to the drawings.
Side A
• Side B of the dispenser has the electrical supply (visible upon removal of hydraulic doors).
All single hose models have the hose on the left side when facing side B.
Side B
5.3 Lifting
The responsibility for carrying out the procedures described
in this manual lies with the persons lifting and placing the
dispenser.
Lifting equipment can be
The installer must supply all lifting equipment and ensure hazardous, and must be
safe working practice at all times. rated to lift the weight of
the dispenser. Equipment
could fall and cause
Quantium 110 & 210 dispensers can be lifted by forklift
severe injury or death.
truck under the pallet.
Stand clear from the
dispenser when lifting and
5.4 Placement lowering.
IMPORTANT - Make sure Side A of the dispenser is positioned onto the island per
customer specifications. See Section 5.2 for locating Side A.
5.4.1 BY FORKLIFT
1) Lift the dispenser using a forklift truck under the pallet. Position the dispenser
close to the dispenser island. Ensure side A with the inlet connections is correctly
positioned - refer to section 5.2 for the identification of side A.
2) Remove the hydraulic doors. Unbolt the pallet from the base of the dispenser.
IMPORTANT - Where supplied, the leak plate must be placed in the ground PRIOR
to positioning the dispenser. Once placed, the leak plate must be sealed to the ground
frame and to the dispenser using a suitable sealant.
3) Where supplied, place the leak plate onto fixing studs provided on the island
prior to positioning the dispenser ensuring the riser pipes and cables pass through
the correct holes in the leak plate.
Carefully lift the dispenser and position on the leak plate.
Leak Plate
4) IMPORTANT:-
Secure the dispenser to the ground as described in section 5.4.2.
Placement complete.
Underside of
dispenser driptray
Nut insert
Tokheim groundframe
Underside of WASHERS
dispenser driptray min thickness = 2mm
min dia = 25mm
5.4.3 EARTHING
Earthing requirements are dictated by local National regulations and must always
be observed.
• 6mm2 earth conductor(s) back to main site earth (up to 85m cable run)
• 10mm2 earth conductor(s) back to main site earth (85 to 150m cable run)
The primary earth connection point for Quantium dispensers is the M2000T
Junction Box provided for installation cable connections. Threaded inserts or
studs (M8) are also provided in the base frame as an additional external
connection facility for an earthing or equipotential bonding conductor.
Flow rates achieved are dependent upon the type of submerged pumping system used and
other site-specific conditions.
Junction Flange
Flange
O-Ring OD49, 00x6.00
Threaded Flange
Terminal Earth Clamp
The dispenser is positioned with the filter box positioned above the relevant
fuel supply risers. If required, adapters should be fitted to the supply pipes.
The flexible connection (rigid for pressurised systems) should then be fitted
between the fuel supply risers and the filter box.
1) Remove the protective covers on the fuel supply riser pipe and on the filter
box.
7) Insert the gasket between the filter box and the flange
on the flexible coupling.
8) Fit the flange to the filter box using the two screws
provided in the installation kit.
The installation of the cables must be carried out carefully to ensure the Eex-norm is
enforced (insertion of cables via glands).
The electrical connections are compatible with all European installation practices and
typical country specific cable types. The following information is the Tokheim
recommended installation, however where differences exist in the standards relating to
installation according to country specific legislation, the local/national standards must be
employed. Electrical connections are made by either :-
CABLING
The type of cabling used will differ by country according to local and/or national laws and
regulations. The drawings in this section show the minimum number of cores required in
cables and the minimum core cross sectional area. Cables with more than the minimum
can be used provided that the cables are suitable for use with the cable gland sizes fitted.
Individual cables can be combined provided that the minimum number of conductors
remains.
MOTOR WIRING
The number of motors per dispenser will vary according to different models and options.
Always connect to the furthest left terminal first. Jumper sizes and positions vary according
to the number of motors connected.
1) Follow the instructions given in section 4.7 to access the calculator head. Locate
the relevant terminal rail inside the head:-
• WWC - terminal rail located on side wall of WWC head
WWC
MOTOR
POWER
LIGHTS
MOTOR CECLI
POWER
LIGHTS
2) Make the connections according to the correct wiring diagram shown in this
section.
CALC** LIGHTS
MOTOR POWER POWER
POWER
* Note 1
16A Motor Circuit Breaker for
FUSE
FUSE
** Note 2
WWC Registers
L L
5x1.5mm² cable
FORECOURT 3x2.5mm² or
WIRING cable or MICC 4x1.0mm² MICC
KIOSK
EQUIPMENT
* Note 1 2A 2A
CALC** LIGHTS
MOTOR POWER POWER
POWER
* Note 1
FUSE
FUSE
PE L1 L2 L3 N PE N PE with 2 x EPZ : Q200T 2-2 models
TERMINALS IN
models
CALC HEAD
** Note 2
WWC Registers
L L
KIOSK
EQUIPMENT
* Note 1 2A 2A
WWC - Submerged
* Note 1
FUSE
FUSE
L L
2A 2A
Calc** MCB Lights MCB
TERMINALS IN CA150
BERNSTEIN JUNCTION BOX
* Note 1
16A dispenser circuit breaker
1 2 3 4 5 6 7 8 for models with 2 x EPZ :
Q200T 2-2 models
TERMINALS IN
JUNCTION BOX 10A dispenser circuit breaker
for all other models
PE L N
KIOSK
EQUIPMENT
* Note 1
Dispenser MCB
TERMINALS IN CA150
BERNSTEIN JUNCTION BOX * Note 1
10A dispenser circuit breaker
for models with 2 x EPZ :
1 2 3 4 5 6 7 8 Q200T 2-2 models
6A dispenser circuit breaker
TERMINALS IN for all other models
JUNCTION BOX
PE L1 L2 L3 N Use glands M20 900064-001
KIOSK
EQUIPMENT
* Note 1
Dispenser MCB
TERMINALS IN CA150
BERNSTEIN JUNCTION BOX
* Note 1
* Note 1 Terminals 3 & 4 for
1 23 4 56 7 8 two product
TERMINALS IN
models only
JUNCTION BOX
SUB1
SUB2
SUB3
SUB4
PE
SUB PUMP
(1 pump : 3x1.0mm²
FORECOURT cable
WIRING 2 pumps: 5x1.0mm²
cable)
KIOSK
EQUIPMENT
* Note 1 2A 2A
Motor MCB Calc MCB Lights MCB 940330 Rev 1
KIOSK
EQUIPMENT
* Note 1 2A 2A
Motor MCB Calc MCB Lights MCB 940330 Rev 1
CONNECTOR
ON COMMS
BOARD
4 WAY 8 WAY
CONNECTOR CONNECTOR
4 4 way connector
3 (Kienzle, TOK, EIN, 82D, Autotank, Dresser, ZSR, M32, Metax,
2 DUN, LON)
1
cable
RxTx
GND
GND
GND
GND
TTD
TTC
XR
RX
YR
TX
XL
YL
LR-
LT-
OH
OL
R+
L+
IH
R-
IL
L-
METAX
Interface RIGHT side DUN LON
4 PUMP - Comms Board Comms Board
3 PUMP + SI- 1 SC30 / FM LON
-2 0V 2 4 3 2 1 3 2 1
+1 SO- 3
net-A
net-B
SI+ 4
R+
L+
R-
L-
4 SO+ 5
3 +28V 6
2 +5V 7
1
2x2x0.5mm²
screened cable 2x2x0.5mm² 2x2x0.5mm²
(cut unused wires) screened cable screened cable
RR+
RT+
LR+
LT+
LR-
RR-
RT-
OH
LT-
OL
IH
GPIN2 to VBU for Product Position menu not available
IL
3 * VBU to GPIN1 for Auto Mode dispenser (disconnect
wire in shop)
2
GPIN1
GPIN2
GPIN3
GPIN4
VBU
1
Installation
cable
4x2x0.5mm² 4x2x0.5mm²
8 way connector screened cable screened cable
(EPS/Tatsuno,
LOG)
NUOVO
1 PIGNONE
2
Comms Board
3
NUP
4
1 2 3 4 5 6 7 8
5
RxB-2
RxB-1
RxA-2
RxA-1
TxB-1
TxA-1
TxA-2
TxB-2
6
7
8
Installation
cable
SIDE A
1 2 3 4 4 3 Terminal 1 U+ extern
Terminal 2 Volume A
2 Terminal 3 Volume B
b1 b1 b1 b1
5 6 7 8 K1 Terminal 4 GND extern
a1 a1 a1 a1
Terminal 5 Release gnd extern
1 2 3 4
- Terminal 6 Release input extern
a2 a2 a2 a2 +
1 5 Terminal K1-3 Nozzle +24V extern
b2 b2 b2 b2
Terminal K1-4 Nozzle GND extern
5 6
4) Make the connections according to the correct wiring diagram shown in this
section.
Comms Terminals in
Bernstein Junction Box
8 TERMINAL COMMS
12 34 5 6 78 (EPS/Tatsuno, Nuovo
Pignone, LOG, Metax)
Installation cable
NUOVO
TATSUNO LOG PIGNONE
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Low Lev R
Low Lev L
Prod Pos
Aut/Man
RxB-2
RxA-2
RxA-1
TxA-2
RxB-1
TxB-2
TxB-1
TxA-1
RR+
RT+
brown RR-
LR+
GND
yellow RT-
LT+
LR-
TTC
yellow LT-
24V
TTD
screen
screen
screen
screen
brown
green
green
white
white
Comms Terminals in
Bernstein Junction Box
UP TO 4 TERMINAL COMMS
12 34 5 6 78
Dresser, ZSR, M32, Metax, DUN,
LON)
Installation cable
not used
not used
TTC (in)
RX+TX
GND
GND
GND
GND
YR
RX
XR
XL
YL
TX
screen
screen
screen
screen
LEFT RIGHT
screen SCREEN
brown
white
LR+
LT+
LR-
OH
LT-
OL
R+
L+
IH
R-
IL
L-
screen
screen
screen
RIGHT
LEFT
R+
L+
R-
L-
tail seal
tail seal
screen
screen
earth
outer
earth
RIGHT
RIGHT
copper
screen
copper
tinned
LEFT
LEFT
bare
ISO-GND
TTD-1/2 OPT 012LX OPT 012LX
TTC-1/2
+A1
+A2
COMMS COMMS
-B1
-B2
X8 X8
DIT POWER
screen
screen
gnd
SUPPLY UNIT
2x2x0,5mm 2x2x0,5mm
1 2 3 4 5 6 7 8 9101112
OPT
Comms
Connection
+side1
-side2
+side2
-side1
ISO-GND
TTC-1/2
TTD-1/2
GND
EIN M32
TERMINATION
OPT 012LX SWITCHES
IN
COMMS
+
X8
-
tinned copper
bare copper
bare copper
In this case:-
screen
screen
tinned
copper
2x2x0,5mm
screened If RS232 to RS485 Converter is used
Do NOT fit Resistor R and set
Termination Switches to ON.
screened cable
screened cable
rs485+out
rs485+in
rs485-out
rs485-in
2 core
2 core
CONTENTS
6 COMMISSIONING
The procedures in this section are Tokheim recommended procedures for commissioning the
dispenser but differences may exist in the standards relating to commissioning in different countries
and local regions, in which case the local and/or national standards must be employed.
Follow the instructions given in section 4.7 to gain access to the calculator head.
• Ensure that all the cabling and hydraulic connections have been made correctly.
• Check that power is present.
Note : Disconnect the Comms before switching on power to the dispenser. This
will reduce the possibility of errors.
• Check that the voltage of power supply is in accordance with the WWC calculator voltage.
• Check that back-up batteries are in correct working order.
• Test the flow rates (litres/minute) - refer to the WWC Calculator Manual.
• Where applicable, test the Vapour Recovery for correct operation.
Note : Discard this filling since it will contain fuel substitute from the
dispenser pipes and components and air from the supply pipes.
IMPORTANT : DISCARD ALL TEST FILLINGS SAFELY.
• Perform a test filling into the calibrated container until 20 litres have been
dispensed according to the calculator display.
• Read the measurement on the calibrated container.
If the fuel dispensed into the container is above or below the calibration line (i.e.
greater or less than the 20 litres dispensed) then the meter must be adjusted to
ensure Weights & Measures (W&M) compliance.
INITIAL SET UP
PARAMET ERS The next parameter, EC, will turn the EC function on
S e t EC or off. Press F4 to enter EC sub menu.
PARAMET ERS The next parameter, TC, will turn the TC function on
S e t T C or off. Press F4 to enter TC sub menu.
1 : EC 2 : SET
Press F1 to return to MAINTENANCE menu.
3 : SERV 4 : ADC
1 : EC 2 : SET
3 : SERV 4 : ADC
Press 1 to enter EC menu.
MPE 0 1 . 0 7 D 3 3 F
Press ON to start configuration.
A choice of menus will be displayed.
1 : MA 2 : T ST 3 : S I M
Press 1 to enter MAINTENANCE menu.
1 : EC 2 : SE T
Press 2 to enter SET UP menu.
3 : SERV 4 : ADC
S e t T C ON
Press F4 to save and continue.
T C S e t t i n g OK Press F4 to continue.
E n t e r ( F 4 )
Together with the Station Manager, go through the Acceptation checklist to check that
everything has been delivered as ordered and is in good condition. Both the Service
Engineer/Technician and Station Manager must sign the checklist.