Dover OPW 21 Series User manual

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
1
DEFINING | WHAT’S NEXT
214916 revision A
September 2019
21 Series Automatic Nozzles for Active Vapour Recovery Systems
Important Safeguards
•For your protection, please read these safety
instructions completely before installing and
operating this equipment.
•Keep this manual on file for future reference.
•This manual contains material that may be
required by authorities having jurisdiction to
be on site at all times.
•Carefully observe all warnings, precautions
and instructions for this equipment and in the
operating instructions and adhere to them.
THIS MANUAL MUST BE LEFT WITH FACILITY MANAGEMENT
Models: 21AG, 21AGV, 21BG, 21BGV – EN 13012:2012 Type I
0530 II 1G
Sira 19ATEX9106U
XXXXXXXXXXXXXX serial number with date code
OPW
Please visit www.opwglobal.com to view a copy of the examination certificate and efficiency certificates.
SITE NAME:
ADDRESS:
NOZZLE SERIAL NUMBER:
DATE INSTALLED:
INSTALLATION CONTRACTOR:

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
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DEFINING | WHAT’S NEXT
214916 revision A
September 2019
RESPONSIBILITIES
•Employees must enforce compliance
with the safety warnings and all other
instructions contained in this manual
and all federal, state and local
warnings/instructions.
•Keep this manual available for use by all employees
and/or customers.
•For personal safety and proper operation of this
equipment, read and follow all these instructions
carefully.
GENERAL REQUIREMENTS
•This nozzle is designed for use only at facilities
dispensing motor fuels.
•High flow rates in excess of the regulatory allowable may
result in splash-back or spillage. Damage and/or injury
may result.
•Nozzles shall be used in accordance with local and
national safety codes.
•OPW products should be used in compliance with
applicable federal, state, and local laws and regulations.
Product selection should be based on physical
specifications and limitations and compatibility with the
materials to be handled. OPW makes no warranty of
fitness for a particular use.
BEFORE AND DURING FUELING
•OPW recommends posting the following warnings in a
visible location for the fueling public. Additional warnings
may be required. Please contact authorities having local
jurisdiction for requirements.
WARNING
Static electricity, fire hazard, and chemical
exposure hazard. Failure to comply to the
following warning could result in property
damage, injury or death.
•Turn off your engine before refueling. Vehicle must
remain off during the entire fueling procedure.
•Discharge your static electricity before refueling.
•Before using the dispenser, touch any grounded metal
on the car or dispenser away from the nozzle and your
vehicle’s fuel pipe with bare hands. This will discharge
static electricity on your body. Failure to discharge may
ignite petrol vapours.
•DO NOT re-enter your vehicle while refueling. This can
re-charge your body with static electricity. If you must re-
enter your vehicle, discharge static again before
touching the nozzle.
•DO NOT fill containers in or on the vehicle. Static
electricity can ignite petrol vapours and cause a fire. Fill
approved portable containers on the ground. It is
dangerous to put petrol into an unapproved container.
•Keep nozzle in contact with the container until finished
filling to discharge any static generated during fueling.
•When filling an approved portable
container, flow fuel at low flow rate to
prevent static build-up. DO NOT put
trigger in rack position; manually hold
open.
•Turn off cell phones and other
electronic devices to avoid
distractions.
•DO NOT smoke or allow open
flame/sparking devices near the
product dispensers.
•Extinguish all pilot lights and open
flames. For example, the pilot light in
a motorhome or caravan must be
extinguished.
•If a fire starts, DO NOT REMOVE
THE NOZZLE FROM THE FILL
PIPE. Back away immediately and tell the attendant. If
no attendant is on site, use the emergency shut-off
button to stop the pump.
•DO NOT start engine during refueling. Vehicle must
remain off during the entire fueling procedure.
•DO NOT leave nozzle unattended. Nozzle performance
and the automatic shut-off feature are influenced by
many factors. If nozzle does not shut off during refueling,
stop pump immediately.
•DO NOT use foreign objects to hold open automatic
nozzles. Use of foreign objects could result in failure to
shut off.
•Fuels can be harmful or fatal if swallowed. Long-term
exposure to vapors has caused cancer in laboratory
animals.
oAvoid prolonged breathing of vapors.
oKeep away from eyes and skin.
oFailure to use caution may cause serious injury,
illness or death.
•DO NOT allow children to dispense fuel. Only persons of
license age (of legal driving age) should use dispenser.
Keep children away from the dispenser area.
INSTALLATION INSTRUCTIONS
•Before beginning installation of the
product, please carefully read all
warnings.
•Failure to comply with warnings could
result in property damage, injury or
death.
•Do not use power tools (Hazardous location: Zone 1
and/or Zone 2) during installation process and
maintenance of equipment.
•Always wear appropriate safety equipment during
installation or maintenance of equipment.
•Do not install unlisted ad/billboard or other unlisted after-
market device on any automatic nozzle. Doing so may
change the sensitivity of the shut-off mechanism. Nozzle
may not shut off, causing a fuel spill.
•Follow all manufacturers’ instructions.
•Use safety cones to mark-off work area.

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
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DEFINING | WHAT’S NEXT
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•Shut off power to the dispenser and close the
emergency shut-off valves under the dispenser. Relieve
system pressure before servicing or replacing dispensing
products, such as nozzles, swivels, or breakaways.
•Refer to the most recent edition of National Safety
Standard.
•If nozzle replacement, secure retractor before removing
the nozzle.
•If nozzle replacement, remove old
nozzle with a wrench. Carefully
drain fuel from hose & nozzle into
approved container.
•For a new facility installation,
purge/flush hose point before
installing nozzles. If nozzles are
used to purge/flush system, this
could result in foreign material in
nozzle’s main valve and cause a
nozzle not to shut off.
•Verify selection of nozzle for application.
•Do not use pipe sealant or PTFE tape on the inlet
threads of the nozzle.
•Verify that O-rings are present on hose and not torn or
damaged. Coat O-rings with light oil for installation to
prevent damage.
•Engage the external thread into the
nozzle or breakaway and tighten
the hose nut per hose instructions.
•Flow test nozzles before putting
nozzles in service. See testing
instructions.
•Check continuity. See testing instructions.
•Check for leaks between all connections of hanging
hardware. Repair or replace, as required, if any leaks are
found.
•Dispenser modifications may be necessary for proper
nozzle storage. Always comply with the dispenser
instructions and local codes.
•Register your OPW product at www.opwglobal.com
•After installation, each nozzle should be tested for proper
operation prior to being put into service.
EQUIPMENT REQUIRED
•Stopwatch, approved 20 L grounded, vented, metal test
container, and megohmmeter.
CONTINUITY TEST
•After installation of hanging hardware and prior to flow
test, check continuity following EN 60204-1 for proper
test equipment and method of testing.
WARNING
Fueling equipment is designed to operate in a
pressure range of 0,5 to 3,5 bar. If the pressure
exceeds 6 bar, the nozzle will open regardless of
lever position. Exceeding maximum pressure may
result in property damage, injury, or death.
FLOW TEST
•Start stopwatch, initiate flow into an approved test
container, with the nozzle lever held in the fully open
position.
•Check each hose point to verify a minimum flow rate*
and maximum flow rate**:
Model(s)
Maximum
Flow Rate
Minimum
Flow Rate
21AG, 21BG,
21AGV, 21BGV 45 L/min 8 L/min
If hose point does not comply, check system and repair
prior to putting into service.
*Minimum flow rate must be met in lowest hold-open clip position. If
hold-open clip is not present, minimum must be met in fully open
position.
**Maximum flow rate must not exceed when nozzle is in highest clip
position or in the fully open position.
WARNING
STATIC ELECTRICITY/FIRE HAZARD
Maintain contact between the nozzle spout and
approved test container during flow test.
SHUT-OFF TEST
•Start flow into approved test container; place nozzle in
low clip position.
•Immerse nozzle spout tip in the
dispensed fluid in the approved test
container. The nozzle tip must be at
least 75 mm from the bottom of the
container to prevent back-pressure in
the spout.
•Nozzle must shut off.
•Repeat procedure for all clip positions.
Nozzle must always shut off in all clip
positions.
•Test each nozzle a minimum of five
(5) times in each clip position.
•For models without hold-open racks, test at fully open
position only.
•For Type I nozzles: If no shut off occurs, check to ensure
flow rate is greater than 8 L/min.
•If flow rate is above minimum flow rate and there is no
shut-off, replace the nozzle.
•Verify that the pump switches off when the nozzle is
returned to the dispenser nozzle boot.

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
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DEFINING | WHAT’S NEXT
214916 revision A
September 2019
OTHER TEST(S)
•Perform other test(s) as required by authorities having
jurisdiction.
WARNING
Replace the nozzle if the nozzle fails any of the
above tests. Failure to comply could result in
property damage, injury or death.
See OPW’s website at www.opwglobal.com or contact an
OPW Distributor for troubleshooting guides and/or how to
use the OPW nozzle.
A/L TESTING WITH A GAS FLOW METER
(WET TEST):
1. Vent the UST system to atmosphere before starting the
A/L Testing procedure.
2. You will need to purchase/obtain an A/L Test Adaptor.
3. Securely attach the tubing from the gas flow meter to the
hose-barb fitting on the A/L Test Adaptor.
4. Slide the A/L Test Adaptor over the nozzle spout so that
the adaptor covers the vapor return path.
5. Initialize the gas flow meter to begin to measure the
volume of vapor collected.
6. The dispenser must be turned on and authorized to be
able to open the nozzle and dispense fuel.
WARNING
Static electric spark could ignite fuel, causing a
fire. Place a container approved for fuel on the
ground prior to and during test. Nozzle must be in
contact with the container until the testing is
complete to discharge any static generated
during the test.
7. Dispense approximately 20 litres of fuel into an
approved test container with the nozzle lever held in the
full open position.
8. Calculate A/L ratio by dividing the volume of vapour
collected by the volume of fuel dispensed.
9. If the A/L ratio is between the desired range, then no
further adjustments are necessary.
10. If the A/L ratio is outside the desired range, then follow
the vacuum system manufacturer’s instructions for
adjusting vapour flow rates. Retest and verify that
adjustments now bring the A/L ratio into compliance.
11. Reseal the UST vapour system after the A/L ratios are
set for all fueling points.
Correction Factor ‘K’:
As ambient air is sucked in during the wet test, the
calculated air volumetric flow must be divided by the
correction factor. If this is not already done automatically by
the handheld control, the vapor recovery rate is calculated
using one of the following equations:
(1) =
∙ ∙ 
(2) =
∙ ∙
 ∙ 
For further details, please refer to prEN 16321-2
R Vapor recovery rate, in %
Va Measured air volume in litres
Vk Simulated petrol volume in litres
Qa Measured air volume flow rate in L/min
(mean value)
K Correction factor
(as specified in the certificate)
t Measuring time in seconds

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
5
DEFINING | WHAT’S NEXT
214916 revision A
September 2019
SIMULATED A/L TESTING (DRY TEST)
1. Vent the UST system to atmosphere before starting the
A/L Testing procedure.
2. You will need to purchase/obtain an A/L Test Adaptor.
3. Push the A/L adapter over the vapour return path on the
nozzle spout.
4. To open the vapour valve, point downward as shown in
the figure above.
NOTE: Use caution when relieving system pressure.
5. Follow the instructions included with the hand-held
control for proper operation with the vapour recovery
system being testing.
6. If the A/L ratio is between the desired range, then no
further adjustments are necessary.
7. If the A/L ratio is outside of the desired range, then
follow the vacuum system manufacturer’s instructions
for adjusting vapour flow rates. Retest and verify that
adjustments now bring the A/L ratio into compliance.
8. Reseal the UST vapour system after the A/L ratios are
set for all fueling points.
WARNING
Static electric spark could ignite fuel, causing a
fire. Place a container approved for fuel on the
ground prior to and during test. Nozzle must be in
contact with the container until the testing is
complete to discharge any static generated
during the test.
Correction Factor ‘K’:
As ambient air is sucked in during the dry test, the
calculated air volumetric flow must be divided by the
correction factor. If this is not already done automatically by
the handheld control, the vapor recovery rate is calculated
using one of the following equations:
(3) =
∙ ∙ 
(4) =
∙ ∙ 
For further details, please refer to prEN 16321-2
R Vapor recovery rate, in %
Va Measured air volume in litres
Vk Simulated petrol volume in litres
Qa Measured air volume flow rate in L/min
(mean value)
QK Simulated petrol volume flow rate in 1/min.
K Correction factor
(as specified in the certificate)
t Measuring time in seconds

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
6
DEFINING | WHAT’S NEXT
214916 revision A
September 2019
DAILY INSPECTION
•Visually inspect the dispensing
equipment for excessively worn,
abused, mistreated or leaking
equipment. Replace equipment
immediately.
MONTHLY INSPECTIONS
•Inspect the nozzle spout for wear and deformation.
Replace the spout assembly as necessary.
•If the nozzle spout is bent, the shut-off hole is blocked, or
the end of the spout is rolled over, the nozzle spout or
the entire nozzle should be replaced immediately.
Failure to replace the spout may result in a hazardous
spill.
•Replace spout if tip is worn. Do not cut off spout tip. This
will lead to nuisance shut offs, or non-shut off, which
could lead to a hazardous spill and/or injury or death.
•Inspect nozzle for evidence of leakage; confirm that
nozzle is leaking and replace nozzle if necessary.
•Check for broken attendant clip
spring and replace nozzle if
necessary.
•Verify that the minimum flow rate
greater than specified. See testing
instructions.
•Perform shut-off test. See testing instructions.
•All maintenance and inspection activity on the nozzle
must be documented. This includes replacement parts,
drive-off or other testing.
ANNUAL INSPECTIONS
•Perform continuity test. See testing instructions.
WARNING
FIRE HAZARD/SPILL HAZARD/
CHEMICAL EXPOSURE
Replace the nozzle if the nozzle fails any of the above
tests or inspections. Failure to comply could result in
property damage, injury or death.
REPLACEMENT PARTS
•DO NOT reuse O-rings or screws when replacing
components.
•Only use authorized OPW replacement kits from the
distributor. All other modifications may result in nozzle
failure and create a hazardous condition, resulting in
personal injury, property damage, or death, and will void
the warranty.
IN CASE OF DRIVE-OFF OR SUSSPECTED
CUSTOMER ABUSE
•Immediately lock hose point out of
service until a thorough inspection by
a qualified service technician can be
made. Inspect the nozzle, hose,
breakaway, dispenser outlet casting,
and piping.
•Even if there is no separation of the breakaway or
breakage of the nozzle spout, damage can be done that
may cause leaks. Inspect and replace any damaged
components, as necessary, prior to returning the hose
point to service.
•Check for leaks and other damage.
•Check nozzle for liquid shut-off. See shut-off test
instructions.
•Check for continuity. See continuity test instructions.
•DO NOT replace spout without OPW replacement kits
and instructions. (See OPW’s website for replacement
kits). Improper parts or assembly may result in leakage
or a hazardous condition. If the spout is removed or
replaced for any reason, the nozzle must be retested in
accordance with this manual.
•Make sure to comply with any requirements of
authorities having jurisdiction.

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
7
DEFINING | WHAT’S NEXT
214916 revision A
September 2019
WARRANTY POLICY & RETURN PROCEDURE
If a nozzle must be replaced during the warranty period, please contact an authorized OPW distributor
Warranty does not cover:
•Evidence of misuse or abuse.
Damaged nozzles are not warrantable
•Wear items such as spouts, splash guards or hand insulators
are not covered under warranty
•Nozzles with missing parts or components are not warrantable
•Evidence of repair or rebuild by others are not warrantable
The following information will need to be provided to your
OPW distributor:
•Serial number of the nozzle being returned
•Serial number and model number of the replacement nozzle
•OPW prorates all warranty returns. The replacement nozzle
only takes on the remaining warranty of the original nozzle
OPW STANDARD PRODUCT WARRANTY / OPW TERMS & POLICIES
Notice: NOTICE: FlexWorks by OPW, Inc., VAPORSAVER™ and all other OPW products must be used in compliance with all applicable
federal, state, provincial and local laws, rules and regulations. Product selection is the sole responsibility of the customer and/or its agents
and must be based on physical specifications and limitations, compatibility with the Environment and material to be handled. All
illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices,
materials and specifications are subject to change at any time, and models may be discontinued at any time, in either case, without notice
or obligation.
OPW warrants solely to its customer that the following products sold by OPW will be free from defects in materials and workmanship
under normal use and conditions for the periods indicated:
Product
Warranty Period
FlexWorks Primary Pipe
10 years from date of manufacture
All Products Certified to
California 2001 Standards*
1 year from date of manufacture or from date of installation registration
(not to exceed 15 months from date of manufacture)
All other Products
1 year from date of manufacture
*Products certified to California 2001 Standards will have an OPW registration card enclosed/attached to the product.
OPW’s exclusive obligation under this limited warranty is, at its option, to repair, replace or issue credit (in an amount not to exceed the
list price for the product) for future orders for any product that may prove defective within the applicable warranty period (repairs or
replacements are subject to prorated warranty coverage for remainder of the original warranty period). Complete and proper warranty
claim documentation and proof of purchase required. All warranty claims must be made in writing and delivered during the applicable
warranty period to OPW at OPW 9393 Princeton-Glendale Road Hamilton, Ohio, USA 45011, Attention: Customer Service Manager. No
products may be returned to OPW without its prior written authority.
This limited warranty shall not apply to any FlexWorks or VAPORSAVER™ product unless it is installed by an OPW attested installer.
This limited warranty also shall not apply to any FlexWorks, VAPORSAVER™ or other OPW product: unless all required site and
warranty registration forms are completed and received by OPW within 60 days of installation; unless all piping connections are installed
with a nationally-recognized or state-approved leak detection device in each tank and dispenser sump (which are not for storage and from
which all discharge hydrocarbons must be removed, and the systems completely cleaned, within 24 hours); unless testable sumps utilize
FlexWorks pipe and access fittings; unless a sump inspection log or an EPA recommended/required checklist is maintained and the
results are furnished to OPW upon request; and unless OPW is notified within 24 hours of any known or suspected product failure and is
provided with unrestricted access to the product and the site. This limited warranty also shall not apply to any product which has been
altered in any way, which has been repaired by anyone other than a service representative authorized by OPW, or when failure or defect
is due to: improper installation or maintenance (including, without limitation, failure to follow FlexWorks Quick Reference Manual
Installation Guide and all product warning labels); abuse or misuse; violation of health or safety requirements; use of another
manufacturer’s, or otherwise unauthorized, substances or components; soil or other surface or subsurface conditions; or fire, flood, storm,
lightning, earthquake, accident or any other conditions, events or circumstances beyond OPW’s control.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND ALL OTHER WARRANTIES
INCLUDING, WITHOUT LIMITATION, THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
ARE HEREBY EXCLUDED. OPW shall have no other liability whatsoever, whether based on breach of contract, negligence, gross
negligence, strict liability or any other claim, including, without limitation, for special, incidental, consequential or exemplary damages or
for the cost of labor, freight, excavation, clean-up, downtime, removal, reinstallation, loss of profit, or any other cost or charges. No person
or entity is authorized to assume on behalf of OPW any liability beyond this limited warranty. This limited warranty is not assignable.
Please see OPW’s website for instructions in other languages, troubleshooting guides,
how to use the nozzle and the Do’s and Don’t’s At The Gas Pump video: www.opwglobal.com
OPW EMEA Headquarters: Snaygill Industrial Estate, Keighley Road, Skipton, BD23 2QR, UK
Phone: [phone] Email: [e-mail]

Please visit OPW’s website:
www.opwglobal.com for further
information or contact OPW Customer
Service at [phone] (EU)
or 1-800-422-2525 (US)
opwglobal.com
8
DEFINING | WHAT’S NEXT
214916 revision A
September 2019
Fill out this information and return this sheet with the nozzle when submitting a warranty claim.
OPW NOZZLE WARRANTY TAG
SITE:
Phone Number:
City:
Contact:
Country:
Distributor:
Branch:
Customer #:
RGA Number:
Nozzle Model:
Serial Number:
Replacement
Serial Number:
WARRANTABLE DEFECTS (CHECK ONLY ONE)
Leaks Fuel Around Spout (200)
Dispenses Fuel Without Pulling Lever (200)
Leaks Fuel in Trigger Area (200)
Fails Pressure Decay Test (300)
Leaks Fuel at Hose Inlet (200)
Fails Air-to-Liquid Test (300)
Does Not Dispense (400)
Note:
Continues to Shut-off During Use (400)
Does Not Shut Off (500)