EsiWelma TW1-M Manual de usuario

Type / N°

Rev.

Date

Page

Total pages

EW055.600D

6th June 2018

EsiWelma®s.r.l.

TW1-M and TW1nA-M

Computer Head User Guide

CNG Version (Methane)

EsiWelma®s.r.l.

Via F.lli Canepa 134d-e

16010 Serra Riccò (Genoa)

ITALY

Tel: +39 010 754211

Fax: +39 010 7542178

email:[email protected]

Type / N°

Rev.

Date

Page

Total pages

EW055.600D

6th June 2018

EsiWelma®s.r.l.

CONTENTS

1. TECHNICAL DESCRIPTION -----------------------------------------------------------------------------------------------4

1.1. Structural specifications -----------------------------------------------------------------------------------------------4

1.2. Technical data ------------------------------------------------------------------------------------------------------------- 4

2. FUNCTIONAL DESCRIPTION---------------------------------------------------------------------------------------------6

2.1. Data display ----------------------------------------------------------------------------------------------------------------6

2.2. Operating sequence description ------------------------------------------------------------------------------------6

2.2.1 Manual delivery ----------------------------------------------------------------------------------------------------8

2.2.2 Pre-set value delivery --------------------------------------------------------------------------------------------8

2.2.3 Programming by Host--------------------------------------------------------------------------------------------8

2.2.4 Programming by a 16-key keyboard ------------------------------------------------------------------------9

2.2.5 Automatic stop sequence--------------------------------------------------------------------------------------- 9

2.2.6 Supply voltage blackout management ------------------------------------------------------------------- 10

2.3. Connection to Host ---------------------------------------------------------------------------------------------------- 10

2.4. Euro €----------------------------------------------------------------------------------------------------------------------- 10

2.5. Delivery in Self-Service mode -------------------------------------------------------------------------------------- 10

2.5.1 Electrical devices involved----------------------------------------------------------------------------------- 11

2.5.2 Sequence of delivery------------------------------------------------------------------------------------------- 11

2.5.3 Warning light management----------------------------------------------------------------------------------- 12

3. TROUBLESHOOTING ----------------------------------------------------------------------------------------------------- 13

3.1. Fatal errors---------------------------------------------------------------------------------------------------------------- 13

3.2. Non fatal errors---------------------------------------------------------------------------------------------------------- 13

3.3. Error review table------------------------------------------------------------------------------------------------------- 14

3.4. Operating modes ------------------------------------------------------------------------------------------------------- 17

3.4.1 System adaptation ---------------------------------------------------------------------------------------------- 17

3.4.2 CNG dispenser adaptation ----------------------------------------------------------------------------------- 17

3.5. Types of refuelling ----------------------------------------------------------------------------------------------------- 17

4. PROCEDURES -------------------------------------------------------------------------------------------------------------- 18

4.1. Reading from the absolute totalizer ------------------------------------------------------------------------------ 18

4.2. Computing head set-up----------------------------------------------------------------------------------------------- 19

4.2.1 Simple parameters ---------------------------------------------------------------------------------------------- 26

4.2.2 Parameters for temperature compensation------------------------------------------------------------- 26

4.2.3 Complex parameters ------------------------------------------------------------------------------------------- 27

4.2.4 Password----------------------------------------------------------------------------------------------------------- 27

4.2.5 Price change ------------------------------------------------------------------------------------------------------ 29

4.3. Metrical check procedure-------------------------------------------------------------------------------------------- 30

5. HARDWARE PERSONALIZATION------------------------------------------------------------------------------------- 31

6. OPTIONALS ------------------------------------------------------------------------------------------------------------------ 33

6.1. External 4x4 keyboard ------------------------------------------------------------------------------------------------ 33

6.2. 16-digit-on-2-line Display--------------------------------------------------------------------------------------------- 33

6.3. Anomaly signalling device------------------------------------------------------------------------------------------- 34

6.4. I/O expansion device -------------------------------------------------------------------------------------------------- 34

7. ELECTRICAL CONNECTIONS------------------------------------------------------------------------------------------ 35

7.1. Low voltage connections -------------------------------------------------------------------------------------------- 35

7.2. High voltage connections-------------------------------------------------------------------------------------------- 39

8. IDENTIFICATION OF COMPUTING HEAD TW1 ------------------------------------------------------------------- 41

9. MECHANICAL CLAMPING----------------------------------------------------------------------------------------------- 42

10. LEGALIZING PROCEDURE OF THE COMPUTING HEAD TW1 ---------------------------------------------- 43

10.1.

Legalizing procedure of CPU

------------------------------------------------------------------------------------- 43

10.2.

Legalizing procedure of display

--------------------------------------------------------------------------------- 43

Type / N°

Rev.

Date

Page

Total pages

EW055.600D

6th June 2018

EsiWelma®s.r.l.

List of figures

Figure 1: Summary electric connections ......................................................................................................5

Figure 2: Max data display ...........................................................................................................................6

Figure 3: Refuelling start sequence; CNG metric counting version .............................................................7

Figure 4: Example of a 5.00€ .......................................................................................................................8

Figure 5: Example of a 10Kg........................................................................................................................8

Figure 6: 16-key Keyboard...........................................................................................................................9

Figure 7: Temporary amount conversion to Euro.......................................................................................10

Figure 8: “deadman’s break” push button ..................................................................................................11

Figure 9: Activation Key of Self-Service/Served mode ..............................................................................11

Figure 10: Visualization “waiting procedure selecting”...............................................................................18

Figure 11: Set-up buttons...........................................................................................................................18

Figure 12: Display absolute total counter Kg..............................................................................................19

Figure 13: Enter password .........................................................................................................................19

Figure 14: Notice insert jumper JP2...........................................................................................................19

Figure 15: Visualization of some set-up parameters..................................................................................26

Figure 16: Zeroing Massmeter procedure.................................................................................................26

Figure 17: Specific weight setting...............................................................................................................27

Figure 18: Visualization of the conversion rate Currency/Euro..................................................................27

Figura 19: Changing password request .....................................................................................................27

Figure 20: Visualization saving data...........................................................................................................27

Figure 21: Changing Password..................................................................................................................28

Figure 22: Inserting Password....................................................................................................................29

Figure 23: Password changing request......................................................................................................29

Figure 24: Visualization saving unit price...................................................................................................29

Figure 25: Entering Password....................................................................................................................30

Figure 26: Confirm of anomaly simulation procedure ................................................................................30

Figure 27: Passage from delivery to block during an “anomaly simulation” phase....................................30

Figura 28: TW1-M; “Standard” Identification plate .....................................................................................41

Figura 29: TW1nA-M; “Atex” Identification plate ........................................................................................41

Figure 30: Clamping of the CPU box..........................................................................................................42

Figure 31: Clamping of the display box......................................................................................................42

List of photos

Photo 1: CPU................................................................................................................................................4

Photo 2: Set-up / Price Changing.................................................................................................................4

Photo 3: Display ...........................................................................................................................................4

Photo 4: Set-up jumper on CPU.................................................................................................................31

Photo 5: Pre-set keyboard adjustement on customer’s demand ...............................................................33

Photo 6: Second Display............................................................................................................................33

Photo 7: Anomaly remote signalling device ...............................................................................................34

Photo 8: I/O expansion device ...................................................................................................................33

Photo 9: Identification plate of the electronic computing head TW1..........................................................41

Photo 10: Computing head TW1 CPU .......................................................................................................43

Photo 11: Computing Head TW1-M and TW1nA-M display front view......................................................43

Photo 12: Computing Head TW1-M and TW1nA-M display rear view.......................................................43

Photo 13: Computing Head TW1-M and TW1nA-M display rear view . Neon tube back-lighting version.43

Type / N°

Rev.

Date

Page

Total pages

EW055.600D

6th June 2018

EsiWelma®s.r.l.

1. TECHNICAL DESCRIPTION

TW1 electronic computing head is designed to operate on one-nozzle fuel dispensers, using

one or two-sided display systems. It can communicate with a Host sending data concerning

the refuelling during the process and/or at the time of the device.

1.1. Structural specifications

The computing head is composed of:

One CPU board of a supplier and communication

interface. Each assembly is settled into a metallic

box to be protected both mechanically and against

EMI interferences;

One board for set-up/price changing settled into a Photo 1: CPU

plastic box. This assembly can be put by the

customer in the most comfortable place or inserted

by convenience;

One or two display boards, optionally settled

in a metallic box. Photo 2: Set-up / Price Changing

1.2. Technical data

Power supply: 230Vac 10%

Power consumption: 10VA

Temperature: min. –40°C max 70°C Photo 3: Display

Humidity (no dew): 95%

Max flow rate: 3.5Kg/s or 3.5Sm³/s (see Setup)

Measure: 1dag or 10dm³ (see Setup)

Solenoid valve control: N.O. max 270Vca/3A Standard /1A Atex (*)

Measuring device inlet:

Pulses →one channel: 1 pulse = 10g

Serial

→

ModBus: A-B channel

Protection grade IP20(**)

Total counter depending on version:

Electromechanical not resetable (7 numbers): 1 counting unit = 1Kg/Smc (see Setup)

Electronic not resetable (10 numbers): 1 counting unit = 1Kg/Smc (see Setup)

Computing Head CPU Dimensions: (230 x 154 x 66)mm

Computing Head CPU Weight: 1950g

Computing Head Display Dimensions: (225 x 250 x 50)mm

Computing Head Display Weight: 960g

(*) Outputs device depending:

Relays for TW1-M “Standard”, or Solid State relays for TW1nA-M “ATEX”.

(**) The declared protection degree is referred to the metallic box. The devices enclosed by

the dotted line in Figure 1 must be installed in a cabinet with at least protection degree IP54,

compliant to standard EN60079-15 of ATEX directive.

Type / N°

Rev.

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EW055.600D

6th June 2018

EsiWelma®s.r.l.

Figure 1: Summary electric connections

to Display

Connector

Display-1

Keyboard Interface

SET - UP

Keypad

Display-2

p.u./L

TB2

TB3

TB6

TB4

TB1

TB7TB8

Field Links

Power Links

Display Link

TB1

5 not Used

4Tx

3Rx

1 Aut/Man

2 0V Field

TB2

Inputs available for

new applications

TR1

PT100

Temperature 2

(Optional)

Temperature 1

TR2

PT100

6 0VField

5 TR2-

2 TR1-

3 0VField

4 TR2+

1 TR1+

TB4

Computing Head

TW1 CPU Board

3 EV2 - 2 Level

1 Electrovalves Common

4 EV3 - 3 Level

TB6

2 EV1 - 1 Level

3 Green

1 Lamp Common

TB7

2 Red

Lamp Power Supply

230Vac o 24Vac

Electrovalves Power Supply

230Vac o 24Vac

3 Gnd

1 Phase

TB8

2 Neutral

Computer Head

Power Supply

230Vac

Impulsive

Mass

Flowmeter

7 not Used

6 0V Flow Meter

8Max Pressure

TB3

5 not Used

4 IN from IMF

3 not Used

1 Nozzle

2 0V Field

Pulse Version

ModBus Version

ModBus

- Mass +

Flowmeter

2 0V Field

1 Nozzle

3 +12Vcc Flow Meter

4 RS485 - A

5 RS485 - B

TB3

8Max Pressure

6 0V Flow Meter

7 not Used

1PT

ATMxi

0-400bar

VART286-5

Flow Pressure

2IN2 N.U. (4-20mA)

1IN1 PT (4-20mA)

3 0V Field

4 +24V Field

TB5

5 Low Flow

See NOTE

§ 7.1

See NOTE

§ 7.1

} {

Optional

Failure Output I/O Expansion

board

Auto/Man (Auto=closed)

Reset (NO)

Dead-Man control (NO)

Self-Service

connections

N.U.

Self-Service

Device

Temp. N.O.

N.O.

1Aut

Reset

Man

4x4 Keyboard

1Delete

Euro

Litres

Enter

Not

Used

The box containing the devices

enclosed in the dotted line must

have protection degree IP54

Type / N°

Rev.

Date

Page

Total pages

EW055.600D

6th June 2018

EsiWelma®s.r.l.

2. FUNCTIONAL DESCRIPTION

2.1. Data display

TW1 computing head can be combined with one-nozzle fuel dispensers, data are always

visualised on a 6-digit display for the amount to be paid, a 5-digit display for delivered fuel

and a 4-digit display for unit price.

TOTAL AMOUNT

DELIVERED FUEL

UNIT PRICE

Figure 2: Max data display

25mm high back lighted LCDs made up the display bars. The backlighting system is made up

of a printed circuit with a led matrix welded on. It is settled on the backside of the metal box

and gives out a green light. As an alternative it is possible to use the dispenser’s own light.

2.2. Operating sequence description

Once initialised, the computing head carries out some checks:

EPROM - it checks the EPROM CRC and compares it to the data reported

on the program.

RAM - it checks the writing and reading ability of data RAM.

EEROM - it checks the congruence of the data reported in EEROM.

DISPLAY - it checks the connection status of the display.

RX-TX - presence of active connection with Host.

DATA COMPLIANCE - compliance of the data used by RAM with the originals in

E2ROM.

UNIT PRICE - it checks that the unit price is not zeroed.

ANALOG INPUTS - it checks the presence of pressure and temperature transmitters.

MEASUREMENT - it checks that the mass flow meter (in case of MODBUS system)

is present and communicating.

MAX. PRESSURE - it checks that pressure does not exceed the maximum

functioning pressure of the plant.

If the above mentioned checks give a positive result, display temporarily shows the program

code and the data about the last delivery, then it switches-off. In case of anomalies display

shows the relevant error code (See further, “Anomalies management” §3).

When the dispenser is in stop-mode , the computing head performs continuously the

same controls described above.

p.u.

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EW055.600D

6th June 2018

EsiWelma®s.r.l.

The refuelling operation begins by turning the switch to START

If the dispenser is available and nozzle is connected to the refuelling receptacle on the

vehicle, it’s possible to actuate the “START” switch, activating the delivering sequence of the

computing head, which will perform the following controls:

The same as described above - see §2.2

PULSER - in case of a pulse measuring device, the presence of

pulses is verified in time compliance.

TOTAL COUNTER - verifies the presence of the electromechanical total

counter

HF - verifies that the compressed natural gas flow does

not exceed the set value, so that in case of a gas

loss due to the cut of a nozzle connected to the

vehicle, flow can be immediately stopped.

If the above mentioned checks give a positive result, the refuelling procedure can start with a

visual control by display and a subsequent activation of the solenoid valves.

Display - All digits show 8, then blank and at last 0.00 Euro

and 0.00 kg. Each phase takes about 1 second: in

this way user can verify immediately the good

working of each step.

Figure 3: Refuelling start sequence; CNG metric counting version

During the refuelling process the computing head executes the following functions:

Activation of the command modules of the following devices: solenoid valves and

operating lights.

As defined during the set-up: Pulse acquisition coming from the transducer

Every pulse is equivalent to 10g.

Acquisition of the delivered quantity through

communication with the mass flow meter.

Calculation and visualization of the delivered quantity and the relevant amount.

Control of the validity of the visualized data (implicit with the control of Ram and Eprom).

Functional control of the single or both displays.

Presence control of the electro mechanical total counter and managing of both electro

mechanical and/or electronic total counter.

p.u.

Type / N°

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EW055.600D

6th June 2018

EsiWelma®s.r.l.

Delivery ends because of:

Opening of the “start” switch.

Reaching of a pressure in the vehicle cylinder that makes the flow tend to zero.

Reaching of the maximum allowed pressure value in the vehicle cylinder.

Reaching of the maximum amount or of the maximum delivered quantity.

Anomalies (see §3).

Blocking order by Host.

…If delivery is stops due to anomalies:

display shows, if possible, the relevant error code. (see troubleshooting §3.).

2.2.1 Manual delivery

Operator decides the beginning of the delivering process, acting on the “START” switch and

ends the refuelling by acting on the “START” switch again, when the desired quantity is

reached or when the tank in completely filled.

2.2.2 Pre-set value delivery

The computing head provides to stop delivery once the pre-set value is reached, both in case

of programming by pre-set buttons and in case of Host programming.

The requested quantity is shown as follows:

Unit price display - always active

Amount display - if pre-setting is in Euro, display shows the requested

value, otherwise it is shaded.

Quantity delivered display - if pre-setting is in litres, display shows the requested

value, otherwise it is shaded.

Figure 4: Example of a 5.00€ Figure 5: Example of a 10Kg

Amount pre-setting delivered quantity pre-setting

2.2.3 Programming by Host

Every time the computing head is connected to a Host with Post-pay function, it can receive

an order of price change, by sending a new unit price, or an order of delivering stop.

Metrological parameter settings cannot be modified by Host.

Unit price cannot be modified during the delivery.

p.u.

Type / N°

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EW055.600D

6th June 2018

EsiWelma®s.r.l.

2.2.4 Programming by a 16-key keyboard

When computing head switches on, it makes a presence control of the keyboard. If this test is

positive, the computing head manages the keyboard to pre-set a quantity or an amount to be

delivered.

DELETE

ENTER

Euro

Not

Used

Kg/Smc

Figure 6: 16-key Keyboard

With nozzles in place, keyboard works and can be used as follows:

1. Choose Euro or Liter pre-set by pressing the corresponding button.

2. Press number buttons (with comma, if necessary) to pre-set value.

3. Press « ENTER». Now the display of the computing head shows on the LCD the amount

(upper line) or the quantity delivered (central line).

4. If the value is correct, delivery can start. If an error occurs, press «DELETE» and repeat

steps 1÷3.

During the delivery, keyboard doesn’t work.

When operator puts the nozzle back in place another operation is possible.

2.2.5 Automatic stop sequence

Automatic stop occurs in two phases:

Flow rate reduction by controlling an optional solenoid valve. The point of intervention

can be varied by set-up (bP parameter) following the procedure described below.

Motor and solenoid valve stop.

Type / N°

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EW055.600D

6th June 2018

EsiWelma®s.r.l.

2.2.6 Supply voltage blackout management

If during normal operation a supply voltage black out or even a blackout occurs, both when

nozzle is inserted and during delivery, the computing head enters a procedure called PWF

which allows to memorise: amount, quantity delivered and absolute totalizer. The data

display is maintained for about 30 minutes from the moment the network shortage occurred.

The power supply lack is visualized writing “OFF” on the unit price display. The network

shortage state is displayed by writing OFF on the unit price bar. When power supply is

restored, data related to interrupted delivery are read by the memory and visualised on the

display and send to the Host, if present.

2.3. Connection to Host

This computing head as its standard can be connected by “Pumalan” 3 wire current loop TX,

RX, Gnd. Different connections are possible by adding an adapter. To use and implement

different protocols, a license released by manufacturer is needed.

Pumalan is a registered mark of GILBARCO (LOGITRON).

2.4. Euro €

The standard computing head connection is foreseen with three cables, TX, RX, Gnd.

The computing head, by its set-up, can work with different foreign currencies: operator can

set the decimal digits in the unit price and in the amount. In any case operator can choose

quickly the Euro set by setting jumper J3: while starting, the computer head will set the

correct decimal digits. Further, as requested from the

standard, in those countries,

which are approaching to the

Euro, after the refuelling

process shown in local

currency, it’s possible to

visualize the amount converted

in Euro by temporarily pushing

an appropriate button.

Figure 7: Temporary amount conversion to Euro

The standard rate DGII-C-4(99) is used as conversion factor.

By pushing the button for a second time, the visualization will switch back to the local

currency value. If another refuelling process should be started, the computing head switches

in any case to the normal visualization.

2.5. Delivery in Self-Service mode

In accordance with the Decree dated 11 September 2008, amendments and supplements to

Decree of Minister dated 24th May 2002 about the rules for fire prevention and planning,

construction and operation of distribution systems of natural gas for vehicles. (GU n. 232 del

3-10-2008)

Ps/Kg

p.u.

Ps/Kg

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