Piusi MC BOX User manual

Bulletin M0188 EN - Rev. 0CONTROL PANELFOR DISPENSERSCONTROL PANELFOR DISPENSERS
MC BOXMC BOX
ENGLISHUSE AND MAINTENANCE MANUAL
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2EN
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3TABLE OF CONTENTSA.DECLARATION OF CONFORMITY ...............................B.FIRST AID RULES .........................C.GENERAL ......................................D.SAFETY INSTRUCTIONS ..............D.1SAFETY RULES ........................D.2TRANSPORT, HANDLING AND UNPACKING .....................D.3DISPOSAL ................................E. USING AND LOOKING AFTER THE MANUALS ..............................E.1IDENTIFICATION PLATE ..........F.DESCRIPTION OF MAIN PARTS ..F.1CONTROL SYSTEM .................G.TECHNICAL SPECIFICATIONS ....G.1PERMITTED USES ...................G.2CONTROL SYSTEM PERFORMANCE .......................G.2METERING PRECISION............G.3ABSORBED POWER ................4556677889101010101010H.INSTALLATION ..............................H.1GENERAL .................................H.2ELECTRICAL CONNECTIONS..I.COMMISSIONING .........................I.1ELECTRICAL POWER SUPPLY..I.2STATION CONFIGURATION ....I.3DISENGAGING THE “MC” SYSTEM ..........................I.4METER CALIBRATION ..............L.EVERY DAY USE ............................L.1FUEL DISPENSING ..................M.ROUTINE MAINTENANCE ............M.1“MC” CONTROL SYSTEM ........M.2TROUBLESHOOTING ..............N.SPECIAL MAINTENANCE .............N.1CHECKING AND REPLACING FUSES ......................................O.MC BOX SPARE PARTS ................P.MANUFACTURER AND SERVICE DATA .............................. 1010101616161718181920202022222323EN
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4DECLARATION OF CONFORMITY CERTIFIESThe undersigned, representing the following manufacturerthat the equipment described below:complies with the following directives:description:model:DIESEL FUEL DISPENSER MC BOXPIUSI S.p.A.46029 Suzzara (Mantova) ItalyLow-Voltage Directive (and subsequent amendments)2006/95/CEElectromagnetic Compatibility (and subsequent amendments)2004/108/CESuzzara, 01/11/2008Otto Varini, Chairman
The MC BOX dispensing units described in this manual are for professional use only.ADECLARATION OF CONFORMITY EN
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5BFIRST AID RULES CGENERALPersons who have ingested toxic liquids.Whenever fuel has been swallowed, do not induce vomiting, but have the injured person drink large quantities of milk or water.MC BOX Electronic Panels are designed for the private distribution of fuel (or other liquids). All of the models in the series are characterised by the same form for which the MC BOX is known: a solid metal structure, high-accuracy measurements in the dispensed product and PC software that is designed for simplicity. This electronic panel allows you to control and monitor private use fuel consumption via a fuel dispenser with pump and flow meter. The MC system consists of a multi-user panel, dedicated software and the option to connect to a PC.Persons who have suffered electric shock.Disconnect the power source, or use a dry insulator to protect yourself while you move the injured person away from any electrical conductor. Avoid touching the injured person with your bare hands until he is far away from any conductor. Immediately call for help from qualified and trained personnel.IN ALL CASES, SEEK MEDICAL ATTENTION IMMEDIATELY
Keyreader
CONTROLLED UNITS
RSC converterRemote printer
Pulse meterExternal nozzleswitchTank levelgaugePump unit
Remote PC connectionPC interface(optional)
DATA MANAGEMENTUP TO 80 OR 120 USERSThe MC BOX System has the ability to:• Switch the pump on;•Recognise authorised users;•Preset the dispense quantity;•Manage the pulse meter;•Manage an external level switch that turns off the pump in the event of minimum flow level;•Operate an external nozzle switch;•Connect directly to a PC;•Connect to an external printerEN
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The panel is easy to install and is adequately protected. The wiring connections can be easily accessed. The group can also be supplied with a meter, to be installed together with the pump.SpecificationsPanel with dual display, keyboard and i-button reader. The electric box can be opened, allowing easy access to the wiring. Maximum power supply: 6.5 amps.Optional•PC Software with dedicated RS converter or i-button reader to export data.•I-button keys for users.•High-accuracy oval gear flow meters.Performance• 80 or 120-user capacity (depending on model), managed via password or i-button key.•Total consumption calculation for defined periods for each user.•Local memory that can store data until the last 255 dispenses.•Vehicle identification and mileage tracking option.•Dispensing date and time control.•Dedicated software that allows you to print dispense data for each user.•Ability to manage up to 16 control panels with one single software.•Key reader with USB plug for exporting data.•RS converter with USB plug for direct connection to the PC via cable (up to 1000 m).DSAFETY INSTRUCTIONS All the MC BOX models have been designed and built according to applicable EEC directives relating to essential safety and health requirements.Page 4 of this manual shows a copy of the manufacturer's DECLARATION OF CONFORMITY.6D.1SAFETY RULES
Electrical Precautions. There are dangerously high voltages inside the unit. Only qualified and authorized technical personnel are allowed to open the fuel unit.Permitted Uses. The unit must always be used for the purpose intended. Follow the instructions listed in the chapter Instructions for Use.Service. Service of the dispenser must be performed by qualified personnel.EN
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When the machine is not used, whether it is packed or unpacked, it must be stored in a place protected from the weather (rain, damp, sun, etc.) and from dust.To remove the cardboard packaging, use a pair of scissors or cutters, being careful not to damage the appliance. Fully open the packaging and take out the MC BOX so that it can be taken to the place of final installation. Packaging parts (cardboard, wood, cellophane, etc...) must be placed in specific containers and not left lying around or within reach of children, as these represent a potential risk hazard. They must be disposed of according to the regulations applicable in the country of use.Check the integrity of the machine by making sure the shipped parts are not damaged in any way that could affect safety and operation. In case of any doubts, do not start the appliance but contact the manufacturer's after-sales service.Should the device be demolished, its parts and components should be entrusted to a firm that specialises in the disposal and recycling of industrial waste. Please note:DISPOSAL OF PACKING MATERIAL:the packaging is made of biodegradable cardboard and can be sent to companies for the normal recovery of cellulose-based packaging.DISPOSAL OF METAL COMPONENTS:metal parts, whether paint-finished or in stainless steel, can be consigned to scrap metal collectors.DISPOSAL OF ELECTRIC AND ELECTRONIC COMPONENTS:these have to be disposed by companies that are specialised in the disposal of electronic components, in accordance with the instructions of 2002/96/EC (see text of Directive below).INFORMATION REGARDING THE ENVIRONMENT FOR CLIENTS RESIDING WITHIN THE EUROPEAN UNION:D.2TRANSPORT, HANDLING AND UNPACKING D.3DISPOSAL7172260146
256
22MC BOX is shipped inside stackable cardboard packaging.DIMENSIONS OF PACKAGING:TOTAL WEIGHT:WEIGHT OF PACKAGING:h=400 mm/l = 290 mm/p=200 mm5.386 Kg0.482 KgEuropean Directive 2002/96/EC requires that all equipment marked with this symbol on the product and/or packaging not be disposed of together with non-differentiated urban waste. The symbol indicates that this product should be disposed of separately from regular household waste streams. It is the responsibility of the owner to dispose of these products as well as other electric or electronic equipment by means of the specific refuse collection structures indicated by the government or the local governing authorities.DISPOSAL OF OTHER PARTS:Other components, such as pipes, rubber gaskets, plastic parts and wires, must be disposed of by companies specialising in the disposal of industrial waste.EN
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EUSING AND LOOKING AFTER THE MANUALS This manual is common to all MC box models and illustrates the main characteristics of the various models, providing information on:• electrical and mechanical installation• first start up operations• daily useThis manual DOES NOT cover other aspects such as:• configuration and operation of the Control systemFor these aspects, refer to the specific manuals which accompany each station model.For the installer's convenience, all supplied manuals are grouped together in an envelope. This collection of manuals represents an integral and essential part of the product and, according to the provisions of directive EEC 89/392, must be given to operators and maintenance staff in order to comply with the obligations relating to training/information referred to in directive EEC 89/391.Carefully read the instructions contained in these manuals, as these are most important for installation safety, operation and maintenance.The manufacturer shall not be responsible for damage caused to persons, to property or to the product that derive from improper use.Look after this manual carefully in a place protected from damp, heat, dust, oils, greases, etc., as it will be useful for future reference and consultation. Do not remove, tear or amend any parts of the manual for any reason. In case of loss or damage, ask the manufacturer for a copy, quoting the manual code.This manual must always remain with the machine; in the event of the machine being sold, it must be given to the new user.The MC BOX has an identification plate that reads:• Model• Serial number / Year of manufacture• Technical Specifications• CE mark 8The company reserves the right to change MC BOX features and specifications at any time.WARNINGE.1IDENTIFICATION PLATEMANUFACTURERPRODUCT CODE (see table)YEAR OF MANUFACTURETECHNICAL SPECIFICATIONS (see table)“CE” MARKSERIAL NUMBERPRODUCT NAMEMC BOXVn: 230 VFn: 50/60In stand-by: 40 mAPulser Max. Freq.: 60 HzPulser Duty Cycle: 20%-80%IMotor Max: 6.5 AIP 55YEAR 2008Read instructionM0187 - M0188
CODE F1398000B
LOT NUMBER0000001CERTIFIED COMPANYUNI-EN ISO 9001PIUSI S.P.A.SUZZARA(MN) ITALYEN
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9Before installing, always make sure the dispenser model is correct and suitable for the available power supply (voltage / frequency).WARNINGClient reference code DescriptionNominal current consumption in stand-by mode at 25°C ambient temperature Power supply fuse on electronic boardNominal power supply (Voltage)Nominal frequency (Hz)Max. motor current (A)Motor fuse F1398000BMC BOX 230V80 USER40 mA100 mA T (Rit.)40 mA100 mA T (Rit.)80 mA200 mA T (Rit.)150 mA1 A T (Rit.)75 mA1 A T (Rit.)230 Vac230 Vac110 Vac12 Vdc24 Vdc50/60 Hz6.5 A8 A T (Rit.)50/60 Hz6.5 A8 A T (Rit.)50/60 Hz7.0 A8 A T (Rit.)50 ASized according to the power of the connected DC 12V motor, but must NOT exceed 60 A (automotive) Sized according to the power of the connected DC 24V motor, but must NOT exceed 30 A (automotive) 25 AMC BOX 230V120 USERMC BOX 110V120 USERMC BOX 12V120 USERMC BOX 24V120 USERF1398005AF1398003AF1398001AF1398002AMC BOX230 Vac - 50/60 Hz80 userMC BOX230 Vac - 50/60 Hz120 userMC BOX110 Vac - 50/60 HzMC BOX12 VdcMC BOX24 VdcFDESCRIPTION OF MAIN PARTS The MC BOX is designed for the private dispensing of fuel.Recognised for their ease of use and maximum safety, MC BOX dispensers are reliable, high-performing, quick to install and ready-to-use.Equipment and features are:• Sturdy, lockable metal box with hinged door; • Electronic Control Panel with:-Dual display -Membrane keyboard -Recognition and access control system with electronic key, allowing for a simple man-machine interface.The electronic panel is also equipped with other out-facing interfaces, such as:-Pump ignition control -Nozzle contact input command -Level contact input command -RS485 output for PC connection (subject to software installation and available drivers) EN
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GTECHNICAL SPECIFICATIONS 10The performance of the MC control system is detailed in the M0187 manual supplied together with the MC BOX.Implementation of a fluid dispensing system, intended for private use, not subject to special regulations (e.g. ATEX) for potentially explosive environments.Mainly influenced by the pulsation type used. For further details, please refer to the specific user manual for the pulsation type used.The MC BOX can be installed outdoors. Nevertheless, it is advisable to locate it under the shelter of a roof to ensure the dispenser's longevity and provide greater comfort during refueling in the event of bad weather. The installation of the dispenser must be carried out by skilled personnel and performed according to the instructions provided in this chapter. The power connections must be workmanlike performed by skilled personnel, in strict compliance with the laws applicable in the country of installation and with the instructions on the wiring diagrams in this manual.G.2CONTROL SYSTEM PERFORMANCE G.1PERMITTED USES G.3METERING PRECISION H.1GENERALH.2ELECTRICAL CONNECTIONS G.4ABSORBED POWER HINSTALLATIONSee table, paragraph E.1. The maximum acceptable variations from the electrical parameters are:• Voltage +/-10 % for AC versions • Voltage +/-15 % for battery-operated DC versions • Frequency +/-1% (+/-2% for short periods) (for AC versions)The electronic control system -MC- ensures the dispenser can only be used by authorised personnel. All the data relating to each dispensing operation are stored and can be transferred to a PC (optional). F.1CONTROL SYSTEM EN
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11-The MC BOX Electronic Panel does NOT come with protective switches; it is therefore mandatory that the MC BOX be installed with an electrical panel that is suitable to the individual MC BOX and has a differential power switch or, at the very least, a fast-access device such as a socket/plug, to be used in the event of anomalies;-All the electronic components found within the MC BOX container have been pre-wired and tested at the factory; as such, it is NEVER necessary to have the MC BOX opened by the person who installed it or the plant operator, unless the fuse protection on the I/O card needs to be replaced;-The installer should carry out a plug/socket connection for a quick sectioning of the electric system in case of failures.WARNINGThe MC BOX is equipped with 3 junction boxes. These can easily be accessed by opening the door to where the screw terminals for the external cable connections are located.The connections that need to be made vary according to the model (AC or DC):Before accessing the electrical parts, be sure that you have disconnected all of the general switches that power the device.WARNING
AC :VersionsENInputsOutputsNoteAC mains supply AC motor power the same voltage as the mainsThe RS 485 data line to the PC (optional) Nozzle contact:clean contact: Open with nozzle replaced and Closed when nozzle dispensing Level contact: clean contact: Open with nozzle in normal conditions and Closed below the minimum flow level Pulse meter input:clean contact or Open Collector output signal, with 60 Hz maximum frequency and between 20% and 80% duty cycleVoltage: 230Vac or 110Vac, depending on the maximum power of the pluggable motors:• 230Vac version = 1400 W• 110Vac version = 750 W
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DC :VersionsInputsOutputsNoteDC Power Supply DC motor power is the same as the supply voltage The RS 485 data line to the PC (optional) Voltage: 12Vdc or 24Vac, depending on the maximum power of the pluggable motors:• 12Vdc version = 600 W• 24Vdc version = 600 WBy removing a jumper and inserting the “in ignition” contact in its place, the electronics can be powered only when the vehicle is switched on Power input WITH IGNITION ON. Given the DC systems' high power absorption, the motor should be powered while the battery is being rechargedNozzle contact: clean contact: Open with nozzle replaced and Closed when nozzle dispensing Level contact: clean contact: Open with nozzle in normal conditions and Closed below the minimum flow level Pulse meter input: clean contact or Open Collector output signal, with 60 Hz maximum frequency and between 20% and 80% duty cycle12POWER INPUT 230V/110VTO MOTOR11BROWNGREEN/YELLOWBLUEGREY orBLACKGREEN/YELLOWBLACKBROWNGREEN/YELLOWBLUEBLUEGREEN/YELLOWBROWNRS485, PC/PRINTER OUTPUT (OPTIONAL)TO LEVEL PROBE CONTACT (OPTIONAL)3RS485+RS485 -REDROSEGREYYELLOWREDROSEGREYYELLOWMax. current Motor Imax = 6.5A (230 Vac)Max. current Motor Imax = 7A (110 Vac)MC BOX 230Vac - 110Vac: EXTERNAL ELECTRICAL CONNECTIONS DIAGRAM TO PULSERK600TO NOZZLE CONTACT22BROWNWHITEGREENBLUEBROWNWHITEBROWNBLUEApply a bridge to the contacts in the event that there is no nozzle contactEN
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13
MC BOX 12Vdc - 24Vdc: EXTERNAL ELECTRICAL CONNECTIONS DIAGRAM 12V version MOTOR 12V 24V version MOTOR 24V
12V version 12V BATTERY 24V version 24V BATTERY BLUEBLACKBROWNBLUEBLUEYELLOW12V version: TO POWER12VREDBLACKYELLOWREDNOZZLE CONTACT 85868730YELLOWBLUEREDBLACK+-BATT IN-+BATTERY
MOTOR
+-
R-CFILTERIf you want to use the nozzle contact, remove the jumper If you wish to turn the device on and off with the vehicle key, replace the jumper with an ignition switch The fuse (max. 40A @ 24V and max. 60A @ 12V) can be placed on the motor or inside the electrical box as shown. (See "Electrical Power" chapter). Choose fuse size in accordance with the motor's absorption level (See "Electrical Power" chapter). 24V version: TO POWER 24V12V version: TO POWER RELAY 12V24V version: TO POWER RELAY 24VWHITEREDBROWNROSEGREYYELLOWBROWNWHITEREDROSERS-485 +RS-485 -TO K600 PULSERRS485 PC/PRINTER OUTPUT (OPTIONAL)LEVEL CONTACT ON-OFFkeyFUSEXXFUSEXX85868730FUSEXX
MOTOR
FUSEXXMax. current Motor Imax = 50A (12 V)Max. current Motor Imax = 25A (24 V)
EN
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14
CPU CARDDISPLAY CARDKEYREADERKEYBOARDI/O CARD
BROWNREDGREENBLUE
1234561.2.3.4.5.6.KEY READER (I-BUTTON)DISPLAY CARDCPU CARDKEYBOARDI/O CARDELECTRICAL BOXESK600PULSERNOZZLECONTACTBLACKGREY
REDROSEGREYYELLOWBLUEGREENYELLOWGREYBROWNWHITEREDROSE
BLUEYELLOW/GREENBROWNVERSION 230V: POWER IN 230VVERSION 110V: POWER IN 110VRS-485 OUT TOPC/PRINTER(OPTIONAL)TO LEVELPROBE CONTACT(OPTIONAL)
BROWNYELLOW/GREENBLUEGREYBLACK
BROWNWHITE
VERSION 230V: MOTOR 230VVERSION 110V: MOTOR 110V
MC BOX 230Vac - 110Vac: INTERNAL ELECTRICAL CONNECTIONS DIAGRAM
EN
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15CPU CARDDISPLAY CARDKEYREADERKEYBOARDI/O CARDVERSION 12V: POWER INPUT 12V
WHITE
VERSION 12V: MOTOR 12VVERSION 24V: MOTOR 24V85868730+-IN BATT-+BATTERY
MOTOR
+-
OPTIONAL (RS485 +LEVEL PROBE)K600PULSERLEVELCONTACT
BROWN
REDROSEGREYYELLOW
NOZZLECONTACT
BLACKREDBLUEYELLOW
BROWN
BLUE
1234561.2.3.4.5.6.KEY READER (I-BUTTON)DISPLAY CARDCPU CARDKEYBOARDI/O CARDELECTRICAL BOXESYELLOW
BLUEBROWNGREYYELLOWBROWNWHITEREDROSE
REDBLACKFILTERR-CVERSION 24V: POWER INPUT 24VVERSION 12V: BATTERY 12VVERSION 24V: BATTERY 24VVERSION 12V: RELAY 12VVERSION 24V: RELAY 24VBLUEMC BOX 12Vdc / 24Vdc: INTERNAL ELECTRICAL CONNECTIONS DIAGRAM The fuse (max. 40A @ 24V and max. 60A @ 12V) can be placed on the motor or inside the electrical box as shown Choose fuse size in accordance with the motor’s absorption level (see “Electrical Power” chapter) (see “Electrical Power” chapter).
If you wish to turn the device on and off with the vehicle key, replace the jumper with an ignition switchON-OFF KeyFUSEXXFUSEXX85868730FUSEXX
MOTOR
FUSEXXMax. current Motor Imax = 50A (12 V)Max. current Motor Imax = 25A (24 V)EN
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16ICOMMISSIONINGTo correctly commission the MC BOX the sequence of operations indicated below must be followed and the MC control system functions must be known (see attached manual).Once the power connections have been made, the MC BOX can be energised by means of the master switch to be fitted by the installer on the upstream line. Switching on of the MC system will be indicated by the lighting up of the two backlit LCDs fitted on the front.NOTE:In the event of continuous current power supply (DC), a fuse size that is appropriate to the DC motor's absorption level should be introduced to the motor power line. For example: •If the connected motor is one that absorbs 10A max then a 12A delay fuse should be inserted. • If, however, the motor absorbs 50A max, then a 60A delay fuse should be inserted.•If the fuse is small, it can be fitted along the cable inside the junction box, in position (1) (see illustration) •If, however, the fuse is very big (e.g. 60A) and cannot physically fit inside the box, then it can be inserted along the motor’s power supply cable in position (2) (see illustration)I.1ELECTRICAL POWER SUPPLY
85868730+-BATT IN-+BATTERY
MOTOR
+-FILTERR-C(1)(2)
Every MC BOX station can be adapted to the specific requirements of the station manager. To do this the MC control system must be CONFIGURED.After completing configuration, user PIN CODES can be assigned to the persons charged with using MC BOX, in accordance with the detailed information in the MC manual.I.2STATION CONFIGURATION MC configuration is crucial and must be done by skilled personnel. To perform this operation, the MC manual must be carefully and thoroughly read.WARNINGEN
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17In MANUAL mode:•The MC's LCD may be switched off (only the backlight is clearly visible) or you may continue to see the indication that was present at the time of transition from AUTO to MAN.•No PIN CODE is required to activate the pump; the pump starts when the dispenser nozzle is removed from its lodging and stops when it is put back (naturally this is in the event that the "nozzle contact" function is used). •The amount dispensed is not shown in any way.Before accessing the electrical parts, be sure that you have disconnected all of the general switches that power the device.WARNINGAll the MC BOX functions are controlled by the MC control system. The MC system can nevertheless be disengaged for any startup or maintenance activities requiring repeated pump starting. In these case, it is often convenient to simplify pump startup by not having to enter any code and record any dispensing data. To do this, a JUMPER has been fitted on the card that permits switching from AUTOMATIC mode (code request to access dispensing) to MANUAL mode (no code request).I.3DISENGAGING THE “MC” SYSTEM The jumper is only accessible by opening the front panel and is positioned as shown in the photo. In this operating mode, MC does not record any data relating to performed dispensing operations.Before accessing this jumper, the voltage must be removed.WARNINGWITHOUTJUMPERJUMPERIN POSIT.AUTOEN
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LEVERY DAY USE Thanks to the MC control system, all the MC BOX models provide access to authorised users only.MC acknowledges User authorisation by means of two alternative systems:•The entering of a 4-figure SECRET CODE (PIN CODE)•The fitting of an electronic key (OPTIONAL)18All the users to whom a PIN CODE is assigned must be adequately instructed and be at least acquainted with the contents of this chapter.WARNINGTo correctly check accuracy, always keep to the following instructions: •Use a precision sample container, featuring a graduated scale, with a capacity of at least 20 litres.•Before making the check, always make sure you have eliminated all the air from the system and then run the fuel until a full and regular flow is achieved.•Dispense continuously at MC BOX maximum flow rate.•Stop the flow by quickly closing the nozzle.•Reach the graduated area of the sample container, avoiding prolonged dispensing at low flow rate, but rather performing short dispensing operations at maximum flow rate.•Compare the reading provided by the container, with that provided by MC BOX, after waiting for all the froth to disappearWARNINGDifferences of up to 1/10 of a litre affecting the dispensing of 20 litres of fluid fall within the guaranteed precision of +/- 0,5%.WARNINGBefore using the MC BOX station, check the METER ACCURACY.For this purpose, proceed as follows:•Enter a previously enabled USER PIN code;•Run the fuel into a calibrated container;•Compare the quantity of dispensed diesel fuel using a calibrated container.If accuracy is NOT satisfactory, proceed to CALIBRATE THE METER according to the instructions in the specific manual.I.4METER CALIBRATION EN
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19The pump will start (if previously enabled) just as soon as the control lever is moved to ON position, while it switches off as soon as the control lever is moved to OFF position. No further manual operation is required to start or stop the pump.In the case of the simplest configuration (no optional data required), the fuel dispensing procedure is the following:•Insert PIN CODE (or apply the electronic key) If the MC recognises the activated PIN (or key), a “GOOD MORNING MANAGER / USER” message is displayed and the pump enabled. For details on dispensing options, please refer to the M0187 manual.L.1FUEL DISPENSING Such enabling does not result in immediate pump startup. The pump is in fact controlled by a switch (positioned in the nozzle seat) operated by the user.WARNINGFuel MUST ONLY be dispensed under the careful control of the User.WARNING
The configuration of the MC system permits requiring the User to enter further optional data (vehicle licence plate, mileage, quantity to be dispensed). For details, see the MC control system manual. In the event that these options are not set, MC will recognise an activated PIN CODE and, once the nozzle contact (if applicable) has been closed, the pump is enabled, allowing it to dispenseEN
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