Burkert 1094 User Manual [en, de, fr]

Operating Instructions

Bedienungsanleitung

Instructions de Service

Type 1094 Standard

Electronic Controller for Vapor Recovery

Elektronische Steuerung für Gasrückführung

Régulateur èlectronique pour la récupération des

vapeurs d’essence

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.

© 2004 Bürkert Werke GmbH & Co. KG

Operating Instructions 0507/01_EU-ML_00804775

Electronic Control for Vapour Recovery Type 1094 Standard

1 GENERAL INFORMATION ........................................................................................................................... 3

1.1 Symbol used .................................................................................................................................3

1.2 Safety instructions .......................................................................................................................3

1.3 Correct usage ................................................................................................................................3

1.4 Protection against damage through electrostatic charge ..................................................4

1.5 Scope of delivery .........................................................................................................................4

1.6 Guarantee provisions ..................................................................................................................4

2 SYSTEM DESCRIPTION ...............................................................................................................................5

2.1 General description of the area of use ....................................................................................5

2.2 Method of operation of the controller .......................................................................................5

2.3 Principle of operation of a petrol pump with vapour recovery ............................................6

3 TECHNICAL DESCRIPTION .........................................................................................................................7

3.1 General technical data .................................................................................................................7

3.2 Electrical data ................................................................................................................................7

3.3 Inputs ...............................................................................................................................................7

3.4 Outputs ...........................................................................................................................................8

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4 COMMISSIONING AND INSTALLATION ............................................................................................ 9

4.1 Additional important documentation .........................................................................................9

4.2 Electrical connections ..................................................................................................................9

5 OPERATION AND FUNCTION ..................................................................................................................11

5.1 Display elements ........................................................................................................................ 11

5.2 Setting and operation of the controller ................................................................................. 11

5.3 Calibration of the controller ..................................................................................................... 11

5.4 Puls rate and frequency input ................................................................................................. 11

5.5 K-factor for the suction rate ..................................................................................................... 12

5.6 Pump after-run time ................................................................................................................... 12

5.7 Petrol pump operation .............................................................................................................. 12

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6 MAINTENANCE AND TROUBLE-SHOOTING ...................................................................................12

6.1 Maintenance ................................................................................................................................ 12

6.2 Faults ........................................................................................................................................... 12

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1 GENERAL INFORMATION

1.1 Symbol used

The following symbols are used in these operation instructions:

marks a working step that you must carry out.

ATTENTION!

NOTE

Indicates information that must be followed. Failure to do this could
endanger your health or the functionality of the device

Indicates important additional information, tips and recommen­dations.

1.2 Safety instructions

To ensure that the device functions correctly and will have a long service life, please
comply with the information in these operating instructions as well as the operating
conditions and the permissible ranges that are specified in the data sheet.

• When planning the application and the operation of the device, observe the gen­eral technical rules!

• The device may not be used in areas endangered by explosion with the character­istics of Zones 0 or 1.

• Take suitable measures to exclude any unintentional operation or impermissible
impairment!

• Installation and maintenance work may only be carried out by specialists and with
suitable tools!

• Observe the valid regulations for the prevention of accidents and for the safety of
electrical devices during the operation and maintenance of the device!

• Always switch of the electrical power before carrying out any work on the system!

• Only use the device in its original configuration!

• If these instructions are ignored or if impermissible interventions are made to the
device, no liability will be accepted from our side, and the guarantee on the device
and its accessories will also become invalid!

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1.3 Correct usage

This device is only intended for the electronic control of a proportional valve for va­pour recovery on fuel pumps. Any other use, or any use going beyond this will be con­sidered to be improper usage. Bürkert will thereby accept no liability for any resulting
damage. The risk will be borne by the user alone.

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1.4 Protection against damage through electrostatic charge

The device contains electronic components that are react sensi­tively to electrostatic discharge (ESD). Contact with electrostati­cally charged persons or objects will endanger these compo­nents. In the worst case, they will be immediately destroyed or
will fail after commissioning.

Observe the requirements according to EN 100 015 - 1 in order
to minimise or avoid the possibility of damage through sudden
electrostatic discharge. You should also ensure that the elec­tronic components do not come into contact with nearby supply
voltages.

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CAUTION WHEN

HANDLING!

ELECTROSTATI-

CALLY SENSITIVE

COMPONENTS /

MODULES

1.5 Scope of delivery

Immediately after receipt of the consignment, ensure that the contents have not been
damaged, and that they agree with the scope of delivery quoted on the enclosed
packaging slip.

In case of a discrepancy, please contact our Customer Service immediately:

Bürkert Steuer- und Regelungstechnik

or your local Bürkert distribution centre.

Kundencenter

Chr.-Bürkert-Str. 13-17

D-76453 Ingelfingen

Tel. : [phone]

Fax: [phone]

E-mail: [e-mail]

1.6 Guarantee provisions

This document contains no agreement to provide a guarantee. We would refer you
here to our General Selling and Business Conditions. The precondition for the guar­antee is the correct usage of the device under compliance with the specified applica­tion conditions.

ATTENTION!

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The guarantee only applies to the freedom of the Type 1094
Standard electronic controller and its components from faults. No
liability will be accepted, however, for consequential damage of
any kind that could arise from the failure or malfunctioning of the
device.

2 SYSTEM DESCRIPTION

2.1 General description ot the area of use

When refuelling a vehicle, the petrol flowing into the fuel tank displaces an equal
volume of petrol vapour out of the tank. In order to prevent this petrol vapour from
escaping into the atmosphere, it must be sucked away.

In the solution offered by Bürkert, this suction process takes place by means of
underpressure via a proportional valve mounted in front of the reservoir tank of the
fuel pump. A suction pump transports the petrol vapour out of the vehicle tank and
presses it into the reservoir tank of the petrol pump.

To avoid excessive pressure in the reservoir tank, the volumetric pressure between the
petrol being delivered and the returned petrol vapour must be balanced.

The amount of petrol filled into the vehicle tank is measured using a calibrated piston
meter in the petrol pump, is converted into pulsed signals by the petrol pump compu­ter and is reported to the controller.

2.2 Method of operation of the controller

The controller shown on Figure 1 evaluates the pulsed signals from the petrol pump
computer and, by means of electrical PWM control signals, controls the area of flow
of a control valve (explosion-protected proportional valve of Type 2832) and thereby
the flow rate of the returned petrol vapour.

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Figure 1: Electronic controller Type 1094 Standard

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2.3 Principle of operation of a petrol pump with vapour recovery

The valve flow - gas flow characteristic of a pump installation is originally non-linear. In
order to ensure an even suction over the complete control range, a linear characteris­tic is needed. To do this, various points on the characteristic are automatically stored
in the controller memory when dimensioning the installation with the control unit. The
number of points depends on the characteristic, and will be automatically determined
by the control unit. The correction of the characteristic also takes place automatically
through linear interpolation between these points.
At the start of the refuelling process, the quantity of petrol tanked will be calculated in
the controller from the measured pulse rate. Taking the linearised characteristic and

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the K-factor of the suction rate into account, the set-value for the valve flow can now
be determined, and the proportional valve can be controlled for the suction of the
petrol vapour. Together with the control of the proportional valve, the vacuum pump
will also be put into operation to generate an underpressure. At the end of the refuel­ling procedure, the petrol pump computer no longer generates any pulses and the
proportional valve for the vapour recovery will be closed. The vacuum pump will also
be switched off with an after-run time delay.

Suction line

one or more pulse generator
lines from the pulse generator/
petrol pump computer

Proportional
valve

Control electronics

24 V DC

power supply

(Type 1610)

Figure 2: Functional diagram for a petrol pump with vapour recovery

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(Type 2332)

24 V DC contactor/
relay for switching the
pump motor

Power supply for the vacuum pump

Vacuum pump

To the

ground

tank

3 TECHNICAL DESCRIPTION

3.1 General technical data

Ambient temperature -25 °C ... +85 °C
Dimensions 68 x 76 x 35 mm

Housing Open housing for mounting on mounting rails according

Protection class IP 20

Order No. 060 651

3.2 Electrical data

Supply voltage

Voltage level 24 V DC ± 10 %
Ripple < 5 %
Current comsumption < 30 mA (without valve current)

3.3 Inputs

Frequency input of the controller

High level impulse 2.5 V ... 25 V

Low level impulse -1.0 V ... +1.0 V

Input impedance

Max. input current 5 mA
Min. pulse width 400 µs
Rate of measurement 1 measurement/sec
Resolution 1 Hz
Measurement range 0 ... 51 l/min

to DIN EN 50 022 / DIN EN 50 035 / DIN EN 50 045

< 300 mA (with valve current)

Ω

> 10 k

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Input 1

Figure 3.
Frequency input of
the controller

VDD

to the
CPU

The volumetric flow of the
tanked petrol is measured by
the piston meter, is converted
into a frequency-proportional
pulsed signal by the petrol pump
computer and is sent to the
frequency input of the controller
(Figure 3).
In the controller, this pulsed sig­nal will be processed to obtain
the actual value of the volumetric
flow of the petrol.

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3.4 Outputs

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Output for the proportional valve

Output transistor Positiv-switching transistor

Load current 0 to 250 mA

Output voltage 24 V DC

Clock frequency 270 Hz

Number of outputs One valve output each for + and -

To regulate the Type 2832 proportional vlave, the controller outputs a current-regu­lated PWM signal via a transistor.

Output for the control of the vaccum pump motor

Output transistor „Open-Collector“ transistor output

Load current 100 mA

Output voltage 24 V DC

Special freatures Freewheeling diode, after-run time adjustable (in con-

nection with the manual control unit Type MKNE-1094)

Number of outputs One pump output each for + (24 V) and – (GND)

The „open-collector“ output shown in Figure 4 is used for the control of a relay/con­tactor for switching the vacuum pump motor.
The „open-collector“ output is switched active by the controller as long as the propor­tional valve is open.

2.2 k

10 k

Ω

BC 337 or similar

Ω

from CPU
(Port Bx)

Figure 4: "Open-Collector" transistor output to the pump controller

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+ 24 V

Output

4 COMMISSIONING AND INSTALLATION

4.1 Additional important documentation

ATTENTION!

NOTE

Have the following documentation at hand for the commissioning of the controller:

• Data sheet/operating instructions for the piston meter/petrol pump computer of
the petrol pump

• Data sheet/operating instructions for the proportional valve Type 2832 von Bürkert

• Data sheet/operating instructions for the vacuum pump - required for setting-up
the correction factor

• Operating instructions for the Type MKNE-1094 manual control unit from Bürkert

In order to connect the individual petrol pump components to the
Type 1094 controller, you will require the respective interface con­ditions, such as voltage level, clock rate, impedances, currents, etc.
These can be found in the data sheets and/or the operating in­structions for the individual components.

You can obtain the complete documentation for the petrol pump
from the supplier or manufacturer of the petrol pump.

4.2 Electrical connections

Before the commissioning of the controller, carefully connect all the required ports

(see Figure 5).

Make the following connections to the controller.

• 24 V DC operating voltage

• Output signal for the Type 2832 proportional valve

• Output signal for relay or contactor for the vacuum pump

• Frequency input signal from the petrol pump computer

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NOTE

The operation and calibration of the controller takes place exclusively via the external
Type MKNE-1094e manual control unit, which is connected to the controller using a
9-pole SUB-D plug.
In the case of controllers for the two-sided operation of the petrol pump, a separate
SUB-D plug is provided for each side of the petrol pump (Side A and Side B).

Wires/cables

There are no special requirements for the wire connections to be
used within the petrol pump, as the currents and/or power to be
transmitted are very small.

All cables that are used should be fitted with cable lugs.

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Connection of the control unit
(9-pole SUB-D plug)

Wire fuse 0.4 A M

Electronic controller
Type 1094 Standard

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LED red = active

Inputs

LED "Proportional valve active"

LED "Pump active"

LED "Operating voltage on"

Proportional valve (+)
Proportional valve (-)
Protective contacts PE

Frequency input (GND)
Frequency output 1 (+)

not used
not used
not used
not used

Voltage output (+ 12 V) *

* The voltage input and voltage output are looped through here.

Figure 5: Electrical connections

Protective contacts PE
Operational voltage (GND)

Operational voltage (+ 24 V)
Output to the pump (+ 24 V)
Output to the pump (-)
not used
Voltage input (+ 12 V) *

Outputs

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5 OPERATION AND FUNCTION

5.1 Display elements

The controller has 3 red LEDs
For the display of

• „Proportional valve active“

• „Pump motor active“

• „Supply voltage connected“

5.2 Setting and operation of the controller

In order to set up the controller in a petrol pump, all the components, signal lines and
the gas gauge from the calibration case must be correctly connected.

The operation and calibration of the controller takes place exclusively using the exter­nal Type MKNE-1094 manual control unit, which is connected to the controller using
a 9-pole SUB-D plug.

NOTE

The settings that are possible with the manual control unit are described in detail in
the Type MKNE-1094 operating instructions.

In the case of controllers for the two-sided operation of the petrol
pump, a separate SUB-D plug is provided for each side of the petrol
pump (Side A and Side B).

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5.3 Calibration of the controller

The electronic vapour recovery controller is program-controlled and has to be adapt­ed (calibrated) to the real petrol pump process before being used for the first time.
The calibration is carried out with the separate (external) MKNE-1094manual control
unit. There is a separate set of operating instructions for this external manual control
unit. Carefully read through these operating instructions and selection the mode of
operation relevant to your application.

NOTE

Bevore the calibration, the pulse rate, the K-factor and the pump
after-run time must be determined and be entered.

5.4 Pulsrate and frequency input

The pulse rate output from the petrol pump computer will be defined by the petrol
pump manufacturer. The output pulse rate can be set up on the controller with the
Type MKNE-1094 manual control unit.

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