OPW Petro Vend 100, M1900 Maintenance Manual

Part Number: M1900, Rev. 8

Issue Date: 12/4/2018

Supersedes: 5/3/2017

M1900 - Petro Vend 100® Fuel Control System

Installation, Operation and Maintenance Guide

3.01.03f / 2.01m

Doc. No.: M1900 Rev.: 8

NOTE: Before you use this guide, make sure you have the latest revision. Check the revision

level of this document against the most current revision found at

http://www.opwglobal.com/opw-fms/tech-support/manuals-how-to-videos . Download the

latest revision if necessary.

OPW Fuel Management Systems is a part of Dover Fueling Solutions.

Copyright Information

Copyright © 2018 Delaware Capital Formation, Inc. All Rights Reserved. DOVER, the DOVER logo are
registered trademarks of Delaware Capital Formation, Inc., a wholly-owned subsidiary of Dover Corporation.

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Contact OPW Fuel Management Systems

Visit us at www.opwglobal.com, or contact us at:

Call 1-877-OPW-TECH (877-679-8324)
For calls outside US and Canada, call [phone]

Monday through Friday, 7 a.m. to 6 p.m., US CST

For technician registration, see

http://opwglobal.com/TechSupport/TechnicianRegistration.aspx.

For in-depth training via OPW University, see

http://www.opwglobal.com/opw-u-training-registration.html.

Table of Contents

Doc. No.: M1900 Rev.: 8

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Section 1 Precautions

1.1 USB Flash Drives

1.2 Safety Warnings

1.3 Hazardous Areas

1.3.1 NFPA/NEC – Class I, Div. 1 & Div. 2

1.3.2 Installation Requirement

1.4 FCC Compliance

Section 2 Introduction

2.1 Terminology

2.2 Versioning

2.3 System Technical Specifications

2.3.1 Fuel Control System

2.4 Pump Control

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2.4.1 Mechanical Pump Control

Section 3 Pre-Installation Information

3.1 Conduit/Wiring Requirements

3.1.1 Conduit Sealing

3.1.2 Pedestal Conduits

3.1.3 Grounding

3.1.4 PV100® Power Requirements

3.1.5 Pulser Wire

Section 4 System Installation

4.0.1 Typical Installation Overview

Section 5 Mechanical PCM Pump Control

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5.1 Power Conduit Installation

5.2 PCM Conduit Installation

5.2.1 Pump Control/Pulser Conduit

5.2.2 Pump Pulser Conduit

5.3 System Power Wiring

5.4 PCM Pump Dispenser Wiring

5.4.1 Pump/Dispenser Wiring

5.4.2 Pump/Dispenser Pulser Wiring

5.5 PCM Startup/Configuration

5.5.1 Configuration (DIP Switches)

5.5.2 PCM Testing

Section 6 Complete the Installation

Section 7 System Configuration

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7.1 Terminal Setup/Test Menu

7.1.1 Display Menu

7.1.2 Keypad Menu

7.1.3 Reader Menu

7.1.4 Tones Menu

7.1.5 System Network Number Menu

7.1.6 Petro-Net™ Setup Menu

7.1.7 Miscellaneous Menu

7.1.8 Pump Control Menu

7.1.9 Software Updates

7.2 Management Menu

7.2.1 Site Management

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7.3 Pump Management

7.4 Proprietary Card File (PCF) Management

7.4.1 Clearing Totals

7.4.2 Reporting

7.5 Dual Card Security Feature

Section 8 System Maintenance

Appendix A - PV100® Primary Board

Appendix B - Termination Codes

Appendix C - Menu of Display Screens

Warranty

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Section 1 Precautions

1.1 USB Flash Drives

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There are two (2) internal USB ports on the PV100 Main Board.

The J7 USB port (top) is used to connect the Main Board to the Door Port with the installed cable.

The J9 USB port (bottom) is for the provided metal industrial-grade USB key that is used to store data for
Totals and Transactions.

NOTICE: Use the metal industrial-grade USB Flash Drive that was provided with your unit

to store Totals and Transactions. Use this key only in the PV100 J9 USB port to prevent
loss of data.

To prevent data loss DO NOT use the plastic Manuals USB key (identified by the OPW
"diamond" logo) in the USB ports of the PV100. This key must only be used in a PC.

Doc. No.: M1900 Rev.: 8

IMPORTANT: The sub-sections that follow contain important safety and compliance

information related to the installation and operation of this unit. Read these instructions
carefully before you continue with the installation.

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Doc. No.: M1900 Rev.: 8

1.2 Safety Warnings

This manual contains many important Safety Alerts. There can be a risk of injury or damage to property if you
do not obey these alerts. The panels below show the types of safety warnings that can be seen and how
each is specified.

DANGER: Indicates an immediately hazardous condition that, if not prevented,
will result in death or serious injury.

WARNING: Indicates a possibly hazardous condition that, if not prevented,
could result in death or serious injury.

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CAUTION: Indicates a possibly hazardous situation that, if not prevented,
could result in minor or moderate injury.

NOTICE: Indicates important information not related to hazards.

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1.3 Hazardous Areas

Any fuel dispenser is a hazardous area as defined in the National Electrical Code. Installation must be in
accordance with the following:

l National Electrical Code (NFPA No. 70)

l Motor Fuel Dispensing Facilities and Repair Garages Code (NFPA No. 30A)

1.3.1 NFPA/NEC – Class I, Div. 1 & Div. 2

The Class I, Division 1 and Class I, Division 2 hazardous areas are specified below:

Class I locations. Class I locations are those in which flammable gases or vapors are or may

be present in the air in quantities sufficient to produce explosive or ignitable mixtures. Class I
locations include the following:

1. Class I, Division 1. A Class I, Division 1 location is a location:

a. In which ignitable concentrations of flammable gases or vapors may exist under

normal operating conditions.

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b. In which ignitable concentrations of such gases or vapors may exist frequently

because of repair or maintenance operations or because of leakage.

c. In which breakdown or faulty operation of equipment or processes might release

ignitable concentrations of flammable gases or vapors, and might also cause
simultaneous failure of electric equipment.

2. Class I, Division 2. A Class I, Division 2 location is a location:

a. In which volatile flammable liquids or flammable gases are handled, processed, or

used, but in which the hazardous liquids, vapors, or gases will normally be
confined within closed containers or closed systems from which they can escape
only in case of accidental rupture or breakdown of such containers or systems, or
in case of abnormal operation of equipment; or

b. In which ignitable concentrations of gases or vapors are normally prevented by

positive mechanical ventilation, and which might become hazardous through
failure or abnormal operations of the ventilating equipment; or

c. That is adjacent to a Class I, Division 1 location, and to which ignitable

concentrations of gases or vapors might occasionally be communicated unless
such communication is prevented by adequate positive-pressure ventilation from a
source of clean air, and effective safeguards against ventilation failure are
provided.

WARNING: To prevent possible fire or explosion, do not mount your
system site controller or any other electrical part of the system, including
printers and modems, within or above the defined "hazardous" areas.

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IMPORTANT: It is the installer's responsibility to know and obey all local codes.

OPW Fuel Management System’s fuel control systems are listed for use in a non-classified area. All of the
equipment must be installed outside of the hazardous areas.

NOTE: Local codes can dictate specific installation requirements. Installation is subject to

approval by the local authority that has jurisdiction at the site.

1.3.2 Installation Requirement

OPW Terminals are designed to be installed above the hazardous area when using the terminal’s
associated pedestal.

The pedestal can be mounted in the hazardous area but a seal-off must be the first fitting for all conduits that
go into the area.

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IMPORTANT: All unused knockout holes that have been removed must be sealed.

Figure 1-1 Dispenser Installations

WARNING: Knockouts and installation hardware are provided for all
cabinetry. Do NOT drill holes in the enclosures. This would violate the safety
listing of the system.

CAUTION: Be sure to wear all required personal protective
equipment (PPE). This includes safety glasses, hardhat, safety
shoes and reflective vest.

Barricade the work area before installation.

Be sure to obey all applicable Lockout/Tagout (LOTO)
procedures before installation.

Doc. No.: M1900 Rev.: 8

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IMPORTANT: It is recommended to do a check of the electrical system with a multimeter to

make sure all connections are de-energized before you proceed with the installation.

Doc. No.: M1900 Rev.: 8

1.4 FCC Compliance

This system complies with Part 15 of the Federal Communications Commission (FCC) Rules & Regulations.
Operation is applicable to these conditions:

l This device must not cause harmful interference.

l This device must accept interference received, including interference that can cause undesired

operation.

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Doc. No.: M1900 Rev.: 8

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Section 2 Introduction

This installation, operation and maintenance (IOM) manual details the installation startup, testing,
configuration, and general troubleshooting instructions for the PV100®Fuel Control System by OPW Fuel
Management Systems. The PV100®system is designed with an integrated fuel-site controller to control the
system operation.

The PV100®provides a turnkey system; the only configuration required for immediate use after installation is
configuration of the network number. Upon network number configuration, all purchased cards can be
manually configured with unique PINs on the first use of the card. After configuration of the card’s PIN, a
second swipe will provide access to purchased pumps within the system.

2.1 Terminology

The abbreviations below identify terms assigned to specific components and functions within the Fuel
Control System.

l Fuel Island Terminal (FIT): Generic term used to describe the fuel management system.

l Fuel Site Controller (FSC): Hardware/firmware used to control the fueling system.

l Pump Control Module (PCM) Slave: Hardware used for controlling mechanical pumps.

l Direct Pump Control (DPC): Hardware used for communicating to electronic pumps.

2.2 Versioning

The PV100®uses two (2) separate pieces of software. One controls the Fuel Island Terminal (FIT) and
Pump Control Module (PCM), and another controls the operation of the Fuel Site Controller (FSC).

The FIT/PCM piece supplies the user interface that controls the card reader (or HID proximity reader),
keyboard and display. The interface also controls and monitors pump activity.

The FIT/PCM software uses a version number that shows three pieces of information. The number has a
format of “X.XXx.”

l The first digit identifies the number of the FIT/PCM product and stays the same for the life of the product

(the number for the PV100®is “2”).

l The next two digits after the decimal point show a major revision to the product (the starting value is

“.01”).

l The last piece is a lower case alpha character that increases when a minor modification to the

FIT/PCM occurs (the starting value is “a”).

The FSC piece of software controls the daily operations of the PV100®. This software uses a version number
that shows four pieces of information. The number has a format of “X.XX.XXx.”

l The first digit identifies the number of the FSC software and stays the same for the life of the product

(the number for the PV100®FSC is “3”).

NOTE: The FSC uses battery backed-up RAM to save the vital configuration of the FSC (e.g.,

card file setup, pump configuration, transaction data, etc.) in the event of a power failure.

l The next two digits after the decimal point show that the card file configuration has been changed. An

increase in this value shows that:

PV100®Technical Specifications

Cabinet Dimensions (H x W x D): 27 cm x 36 cm x 25 cm (10.75” x 14.25” x 9.75”

Pedestal Dimensions (H x W x D): 122 cm x 36 cm x 20 cm ( 48” x 14” x 8”)

Power Requirements: 115/230 VAC, 50/60 Hz, 200 W Max

Operating Temperature Range -40°C – +50°C (-40°F – +122°F )

Keypad Numeric/Function: Standard

Magnetic Card Reader: Optional

Proximity Card Reader: Optional

Chipkey Reader: Optional

Graphics Display: Standard 15.2 cm (6") monochrome

Enclosure: Powder Coated Steel

Pedestal: Powder Coated Aluminum

Internal Fuel Site Controller: Standard

Internal Pump Control:

Standard Mechanical - 2 hoses
Optional - Mechanical or Electronic - 4 hoses

Doc. No.: M1900 Rev.: 8

n ALL card file information such as PIN, Prompt and available pumps must be reconfigured.

n Card Pump Totals are lost.

l The next two digits show when any other system configuration has changed. The pump configuration,

stored transaction data and all saved data will be lost when this software update occurs.
Reconfiguration of this information will be necessary.

l The last piece is a lowercase alpha character that increases when a minor modification to the FSC

occurs (the starting value is “a”).

NOTE: If the card file number increases, the system configuration number can also change.

This will show that a full-system cold start will occur. A complete reconfiguration of the FSC
stored data will be necessary.

If only the system configuration number increases, a partial cold start of the FSC will occur. A
reconfiguration of pump and system control settings will be necessary.

2.3 System Technical Specifications

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This section details the technical specifications (i.e., dimensions, operating temperature range, power and
wiring requirements) of the system and pump control.

2.3.1 Fuel Control System

Mechanical Pump Control Specifications (PCM)

Relay Contact Rating: 240-volts A; 20 A, 3.0 HP Max.

“In-Use” Detection: Voltage Sense 120-240 VAC or Handle Switch

Pulser Type: Single Channel

Pulser Input: Mechanical (contact); Electronic (5-12 VDC)

Pulser Divide Rate: Pulser Divide Rate:

Max. Pulse Speed: 6,000 Mechanical; 100,000 Electronic

Doc. No.: M1900 Rev.: 8

NOTE: Optional items may require additional cost

2.4 Pump Control

2.4.1 Mechanical Pump Control

Mechanical Pump Control is used when the dispensers connected to the system provide pulse inputs

with in-use detection of handle switch or voltage sense.

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To support this type of operation, one (1) or two (2) stand-alone relay boards, referred to as the “Pump
Control Slave Module” or “PCM Slave” (OPW Part #: 20-4405), is mounted on the back wall of the PV100
enclosure, providing control for up to two (2) hoses. A second "PCM Slave" board can be added to control a
total of four (4) hoses.

®

Doc. No.: M1900 Rev.: 8

Section 3 Pre-Installation Information

The installation instructions in this manual are written for a typical installation. Due to the flexibility of the
system and the unique nature of every site, it is not possible to show every potential installation scenario.

Local codes may dictate specific installation requirements. Installation is subject to approval by jurisdictional
authorities at the site of installation. See Safety Precautions at the beginning of this manual.

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If you have a QR code scanner/reader app for your smartphone you can scan this code to view the
instructional video, PV100
tablet, simply click on the code.

®

Installation and Startup. If you are viewing this manual on a computer or

3.1 Conduit/Wiring Requirements

IMPORTANT: All wiring and conduit runs must conform to the National Electric Code (NFPA

No. 70), Code for Motor Fuel Dispensing Facilities and Repair Garages (NFPA No. 30A) and
all national, state and local codes.

All wiring running to the system must be installed in threaded, rigid metal conduit and have the
required sealoffs. AC and DC power wires can share conduit, provided they meet the Petro­Net™ wiring specified; otherwise AC and DC power wires must be installed in separate
conduits.

3.1.1 Conduit Sealing

Conduit entering the hazardous area must have a seal-off installed 18 inches (46 cm) above grade to prevent
liquid or fumes from entering the area.

When running shielded cable through a seal-off, strip the cable jacket back so about three (3) inches (7.6 cm)
of jacketed cable protrudes past each seal-off.

WARNING: Shielded cable is NOT vapor-tight! DO NOT damage the shield
wire! Stripped section must be in the sealed-off area.

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ConduitSealing

3.1.2 Pedestal Conduits

All conduits in the PV100®pedestal should terminate at the conduit plate. A seal-off must be installed in
these conduit runs. Install ½-inch or ¾-inch rigid steel conduits as applicable.

IMPORTANT: Any unused knockout holes that have been removed must be sealed in order

to meet NEC code.

3.1.3 Grounding

ThePV100®incorporates internal noise suppression circuitry. To ensure safety and proper operation of the
equipment, all devices of the OPW system must be grounded.

A ground wire (preferably Green) must be connected between the device’s ground terminal and the main
electrical service panel. One earth ground connection is required per OPW device.

CAUTION: Do not rely on the conduit to provide ground connections.

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3.1.4 PV100®Power Requirements

Power to the system must be supplied from a dedicated circuit breaker. No other equipment should be
powered from this breaker, including the pumps that are being controlled. A separate conduit from the service
panel directly to the PV100®is preferred, however, it is acceptable to share the conduit with dispenser wiring.

3.1.5 Pulser Wire

For mechanical pump installations, pulser wires must meet the pulser manufacturer’s wire requirements if
installed in separate conduit from the pump-control wires. If installed in the same conduit as the pump-control
wires, then the wire must be UL-style #2567 or equivalent. You can order shielded pulser cable from OPW
Part #: 12-1025 (two-conductor) or OPW Part #: 12-1026 (four-conductor).

Section 4 System Installation

4.0.1 Typical Installation Overview

WARNING: Install your system a minimum of 18 inches (46 cm) from the
nearest conventional or overhead pump or dispenser.

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PV100®Installation

1. Unpack your new PV100®and inspect the contents for shipping damage. Make sure that all of the
following are in the box:

n A package of cards (if this will be a carded system)

n Internal USB drive

n Cabinet keys

n Noise suppressors

n Installation manual

2. Install the pedestal:

n Square the baseplate where it will be mounted

PedestalMounting Hole Locations and Dimensions

n Mark the four (4) most appropriate locations for the anchor bolts. There are eight (8) mounting

holes (see the illustrations above).

n Drill the holes

n Anchor the pedestal using 3/8” anchor bolts

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IMPORTANT: Use a type of anchor bolt that is appropriate for the material in which you will

be drilling (e.g. concrete, asphalt etc.).

Enclosure Mounting to Pedestal

3. Use the provided mounting hardware to mount the PV100®enclosure to the pedestal. Align the
provided gasket with the mounting holes of the pedestal top plate. Carefully position the enclosure in
place so that the open mounting holes are aligned with the mounting holes of the pedestal. Insert the
four (4) bolts and secure them using the provided washers and nuts.

NOTE: Make sure that the open holes are being used to mount the enclosure to maintain

proper alignment of the enclosure and pedestal.

4. Disconnect the USB cable that runs from the door port to the main board.