ABBERFIELD WD3000N Installation And Support Manual

Tanker filling station

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WD3000N Tanker Filling Station

INSTALLATION & SUPPORT MANUAL

WD3000N WATER FILLING STATION

INSTALLATION & SUPPORT MANUAL

Email: contact@abberfield.com.au Internet: www.abberfield.com.au

Revision: 1.8

PREPARED BY

ABBERFIELD INDUSTRIES PTY LTD

ABN - 61 000 112 569

ABBERFIELD TECHNOLOGY PTY LTD

ABN - 31 050 336 091

32 Cross St, Brookvale NSW Australia 2100

Phone +61 2 9939 2844 Facsimile +61 2 9938 3462

Manual # 170818 rev 1.8

The Abberfield Group

Page 1 of 70

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Page 1 The Abberfield Group 32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au WD3000N Tanker Filling Station INSTALLATION & SUPPORT MANUAL Revision: 1.8 PREPARED BY ABBERFIELD INDUSTRIES PTY LTD...
Page 2: Amendment Record
Plumbing installation amendments 10/02/19 John Colyer Revision solar panel Added cage details Optional anchor plate 16/06/20 John Colyer New photos of RPZ and tabernacle WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 2 of 70...
Page 3: Table Of Contents
INSTALLERS TO TAKE TO SITE ....................24 ITEMS TO RETURN TO ABBERFIELD INDUSTRIES ..............24 TELEPHONE SUPPORT ......................24 APPENDIX 1 – WD3000N EXTERNAL RESIDUAL PRESSURE ZONE DEVICES (RPZ) ....25 CAGES ............................26 APPENDIX 2 – SUGGESTED CONCRETE PLINTH DIMENSIONS (MACHINE ONLY) ....28 APPENDIX 3 –...
Page 4 BATTERY MAINTENANCE ................. 57 BATTERY TYPE ........................57 BATTERY MODULE ........................ 57 BATTERY CHARGING ......................57 BATTERY EXCHANGE ......................58 BATTERY STORAGE ....................... 58 WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 4 of 70...
Page 5 MAINTENANCE ....................66 MAINTENANCE CONTRACT ....................66 BREAK DOWN SUPPORT ....................... 66 TELEPHONE SUPPORT ......................67 APPENDIX 11 – FAULT DIAGNOSIS ................... 68 WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 5 of 70...
Page 6: Document Purpose
Email: contact@abberfield.com.au Internet: www.abberfield.com.au 1. DOCUMENT PURPOSE This document provides an installation guide for the WD3000N Series Water Filling Stations. Information provided is typical for an 80mm plumbing supply. 100mm plumbing systems are also available, fitting within the same cabinet and onto the same ground plate.
Page 7 2. Cabinet Note: Cabinet cut outs allow plumbing to enter on either side (right or left). Drawing has the optional cabinet mounted solar panel. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 7 of 70...
Page 8 • Rotating or reversing the front fascia 180 degrees (to point in the opposite direction). • The 25mm tap handle will now be on the bottom side but can be accessed and operated. Optional refit the 25mm tap. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 9: Site Assembly
OPTIONAL ANCHOR PLATE The Filling Station stainless steel anchor plate can be fastened by any normal means, including chem set stainless steel studs (studs available from Abberfield). However, use of the optional anchor plate is the ultimate in security. Anchor plates for embedding into the concrete slab come in two forms; just for mounting the Filling Station, or for mounting the Filling Station and the Abberfield recommended Residual Pressure Zone device (RPZ).
Page 10 MOUNTING FILLING STATION & RPZ Water in to the cabinet this end ANCHOR PLATE FOR MOUNTING FILLING STATION ONLY Water out to the outlet stand this end WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 10 of 70...
Page 11 STEP 1 • Install inlet plumbing so that the RPZ base has 300mm clearance to ground ((legal requirement). Note: If Abberfield supply the RPZ it will be on substantial stainless-steel stands with up and down adjustment. The plumbing of the Filling Station will be at a lower level and adapted by a goose-necked pipe.
Page 12 The plumbing base should be mounted relative to the inlet plumbing if that already exists. Once the base is mounted the pluming assembly has limited sideways adjustment. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 13 • Install outlet assembly and outlet stand. Secure using supplied S/S M16 hex head bolts and nuts. • Adjust outlet height as required. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 13 of 70...
Page 14 Email: contact@abberfield.com.au Internet: www.abberfield.com.au STEP 5 • Install plumbing cover plates. Secure using M5 S/S nuts supplied by Abberfield. • Adjust outlet height as required. It is normal to have the outlet pointing down slightly to ensure any dirt or contaminant flushes free of the plumbing system.
Page 15 Installation is completed by neatly parging in the underside of the outlet stand with sand and cement, finishing with a smooth 45-degree bevelled edge. STEP 6 • Install inlet plumbing, (if not done as Step 1). WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 15 of 70...
Page 16: Completed Installation
Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au 5. COMPLETED INSTALLATION The image below shows a completed installation for a WD3000N Tanker Filling Station 6. ELECTRICAL The WD3000N can include a switchboard comprising: • Mains switch •...
Page 17: Power Board
If a machine is known to be using an external solar panel this cable will be pre-fitted. If Abberfield supply the external solar, included would be the pre-wired battery and regulator. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8...
Page 18 32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au TERMINAL SWITCH PLATE INSIDE CONTROL PANEL WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 18 of 70...
Page 19: Installation Of Control Electronics
TERMINAL SWITCH PLATE WIRING LABEL INSTALLATION OF CONTROL ELECTRONICS The electronics are usually fitted by Abberfield staff, just to ensure that the installation has been professionally carried out. All part of Abberfield Technology’s total service support. The primary and extensive part of commissioning relates to the back office data processing, configuring modems and end to end testing of Tripple dez data encryptions.
Page 20: Control Module
32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au CONTROL MODULE CONFIGURATION MODULE WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 20 of 70...
Page 21 32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au MAINS POWER SUPPLY BATTERY MODULE WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 21 of 70...
Page 22: Installation Method
180 degrees in the opposite direction. The outlet tap assembly will also need 108 degree rotation (gear head handle and 25mm tap facing away from the cabinet). WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 23: Note Two
(the top of the door does not overhang the cabinet side, left or right). Once the cabinet is mounted correctly, if further alignment is required, fit shim washers to the door ‘feet’ (left or right) as needed. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 24: Installers To Take To Site
3. Kit of parts from Abberfield Industries comprising of: a. M12 security screws and M12 normal screws to replace eye bolts on top of the cabinet (unless Abberfield change these as part of the post installation commissioning) b. M16 studs and adjusting nuts for the outlet stand.
Page 25: Appendix 1 - Wd3000N External Residual Pressure Zone Devices (Rpz)
These water backflow devices are attached external to the WD3000N payment and delivery station. They can be to the left or right of the WD3000N, as a straight through connection. For neatness the RPZ can be positioned behind the Filling Station.
Page 26: Cages
Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au CAGES In keeping with the quality of the Filling Station Abberfield cages: • Use a rectangular hollows section frame (not angle iron). • Have the base section raised off the ground.
Page 27 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au ON-SITE PHOTO OF RPZ & CAGE (RPZ and cage by customer not by Abberfield) ON-SITE PHOTO OF RPZ & CAGE (Abberfield supplied RPZ and cage) The RPZ with control taps is preassembled and mounted on two substantial stainless steel stands.
Page 28: Appendix 2 - Suggested Concrete Plinth Dimensions (Machine Only)
These suggested concrete plinth dimensions do not constitute an engineered design, but merely provide a suggestion for the slab design. Please consult with an engineer for specific installation requirements. As always Abberfield is available for assistance. Note 1: When pouring the concrete it is recommended (but not essential) that the outer edges taper down slightly to prevent pooling of water.
Page 29 Note 4: Provision should be made for sheer loads (hit by vehicle etc.). Suggest casting edge ribs or integral or adjacent sheer pegs. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 29 of 70...
Page 30 Bollard diameter and distance for the slab vary dependant on the level of protection chosen. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 31: Appendix 3 - Suggested Concrete Plinth Dimensions (Machine & Rpz With Cage)
These suggested concrete plinth dimensions do not constitute an engineered design, but provide a suggestion for the slab design. Please consult with an engineer for specific installation requirements. As always Abberfield is available for assistance. CABINET AND PLINTH Note: Right hand entry plumbing shown. Plinth is symmetrical so can be spun 180 degrees to accommodate left hand entry plumbing.
Page 32: Machine Mounting - With Anchor Plate
Following is an example of quality extended throughout, whether visible or concealed. This design is used by a major customer and utilises an Abberfield anchor plate to accept a Residual Pressure Zone Device (RPZ - for backflow prevention) and the Abberfield machine.
Page 33 32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au Formal engineer’s plans available by negotiation. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 33 of 70...
Page 34 32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au Formal engineer’s plans available by negotiation. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 34 of 70...
Page 35 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au Whilst this installation manual is for information only, formal certified drawings can be provided by Abberfield to meet any customer’s requirements. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION &...
Page 36: Appendix 4 - Recommended Bollards Specification
• Minimum footing 600mm x 600mm or 600 diameter / 800mm deep • Foundation undercut recommended 600mm 800mm UNDERCUT RECOMMENDED Optional reo rod BOLLARD CUTAWAY WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 36 of 70...
Page 37: Appendix 5 - Solar Panels
3. Fit the new top heat shield with cut out for the solar panel. 4. Slide in the battery box. To operate machines full time, a larger pole mounted panel is needed. Sometimes customer supplied, but also available from Abberfield. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION &...
Page 38: Solar Pole System Option 1
The solar panel has a purpose-built mounting bracket that connects the panel to the top of the pole, bolted in position. Option1 SOLAR PANEL MOUNTING BRACKET WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 38 of 70...
Page 39: Electrical
In many installations a pole length less than 6 meters is sufficient and the pole can be cut down as required. The lower the pole the more wind stable is the assembly. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION &...
Page 40: Theft Protection
For maximum protection include large diameter vertical reinforcing rods. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 40 of 70...
Page 41: Solar Pole System Option 2
• Solar Panel 678 mm x 890 mm, 85 Watt output. • Solar panel 1150 mm x 650 mm, 120 Watt output. Note: 85 Watt is considered adequate for Abberfield Water Filling Stations applications in northern latitudes. In southern latitudes or for shaded positions the large panels (120 Watt) can be installed;...
Page 42: Pole Mount
Email: contact@abberfield.com.au Internet: www.abberfield.com.au POLE MOUNT Optional embedded footing Optional reo rod SOLAR MOUNT HEAD ASSEMBLY (with hinged dress panels) SOLAR PANEL POLE WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 42 of 70...
Page 43: Pole Mounting
Perhaps the easiest method is to Chemset 4 x M16 stainless steel studs into the ground and when set attach the pole directly. Studs, washers and nuts form part of the kit supplied by Abberfield and the under plate and above plate nuts can be used to adjust the pole being square.
Page 44: Embedded Footing
The plate can be embedded flush with the concrete surface or elevated slightly, if this simplifies concreting. If elevated, the gap can be filled with sand cement and parged with a neat 45-degree edging. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 45: Cable Provision
Down the conduit should be a pull through wire. These measures ensure that a cable can be freely drawn through without catching on any obstructions. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 45 of 70...
Page 46: Near Surface Conduit
The large diameter of the conduit and using the largest radius elbow ensures ease of feeding the solar supply cables. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 47: Electrical
First there should be a mounting based embedded into the concrete. If not there should be 4 bolts Chemset into the concrete slab. Either way there will be 4 x M16 stainless steel studs protruding. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 48: Adjustment Method
3. Remove the long 2 x M12 bolts that clamp the head assembly. 4. Close the mounting assembly over the pole and positioned with the opposing slots over the collar. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 49: Fitting Cable
8. If required, refit the cable cover, intended to limit access by cockatoos who can hang upside down on the cables and chew through the cables. 9. If required, refit the bird roosting preventer. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 50: Mounting Pole
It may assist to engage the first 2 mounting plate holes over the first two mounting studs, as the pole is rotated into position. 5. Fit washers, spring washers and mounting nuts. Process Complete WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 50 of 70...
Page 51: Optional Tabernacle (Highly Recommended)
Since the tabernacle mounts to the in-ground anchor pole (or directly to the ground), the tabernacle can be mounted on those same fastenings, between the ground and the pole base plate. This allows for retrofitting to any installation. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 52 If the ground is not level sand cement can be used to bed down the tabernacle to the ground, or washers can be used. TABERNACLE WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 52 of 70...
Page 53: Appendix 6 - Quick Release Mechanism
(instead of two) could lift the top cabinet off the base, literally in seconds. The following label attaches to the quick release cabinets. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 54 The Abberfield Group 32 Cross St, Brookvale NSW Australia 2100 Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 54 of 70...
Page 55: Installation Of Quick Release Mechanism
Just add mains or solar input connections. Note: It is normal for Abberfield to have a mains or solar test lead pre-installed in the Quick Release Mechanism Filling Stations. This lead can then be spliced to the incoming solar or mains cables, or the incoming connections can be made direct to the electrical termination strip.
Page 56 “home” positon and only then tighten the metal frame mounting. This will ensure the best alignment of the blue self-guiding plugs and sockets and the mains plug and socket. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 57: Appendix 7 - Battery Maintenance
BATTERY TYPE (As used in Abberfield Technology’s Water Filling Stations) The batteries used in Abberfield Technology’s Water Filling Stations are quality Gel Cell or for the larger batteries may be glass fibre mat batteries. Lithium batteries are not used because they incorporate internal electronics that disconnects their output when the battery voltage falls too low or when the battery gets hot.
Page 58: Battery Exchange
Abberfield Technology. TECHNICAL SUPPORT More technical information is available from the Abberfield Technology Support Team Telephone: +61 (0)2 9939 2844 or Email: contact@abberfield.com.au In case of need unanswered telephone calls to the office will transfer to the Duty Engineer 24/7.
Page 59: Appendix 8 - Exchange Of A Water Filling Station Control Module
2. Install the new Control Module with the new Credit Card Modem, BUT, advise Abberfield Technology of the new Credit Card Modem serial number and the site details, so that Abberfield Technology can arrange to have this new serial number registered on the credit card processing server.
Page 60: Procedure
SIM is underneath. TECHNICAL SUPPORT More technical information is available from the Abberfield Technology Support Team Telephone: +61 (0)2 9939 2844 or Email: contact@abberfield.com.au In case of need unanswered telephone calls to the office will transfer to the Duty Engineer 24/7.
Page 61: Transportation - Filling Station Deliveries
(but may not) pass over any paintwork. Alternately, Abberfield offer a loan of a stabilising bar that passes through the tie down eye bolts and then has end of bar eye bolts for tying down, which ensures paintwork protection.
Page 62: Advice To Installers
ADVICE TO INSTALLERS If in doubt ASK Abberfield Technology offer 24/7 support - ring or email. If the office telephone is unanswered it will automatically transfer to the Duty Engineer’s mobile. Most installations are not carried out in accordance with Abberfield Technology’s recommendations.
Page 63: Appendix 9 - Features And Settings
• Account cards typically are at one price, but can be different prices per card or per site. • Water prices are set over the internet based portal. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 64: Fault Reporting
Phone +61 2 9939 2844 Facsimile +61 2 9938 3462 Email: contact@abberfield.com.au Internet: www.abberfield.com.au FAULT REPORTING • Critical reports emailed to Abberfield Technology and the back office provider (Card Access Services), plus other nominated parties. REPORTING • Back office reports of a transaction includes water volume, card users and financial auditing.
Page 65: By-Pass Function
On the larger Filling Stations the servo solenoid valve has a manual by-pass button (press in and twist). Manual bypass operates without consuming mains or battery voltage. * Software currently under development. WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL...
Page 66: Appendix 10 - Maintenance
Stations are designed so that the control electronics can be removed by unskilled labour for return to Abberfield’s factory for repair if required and this permits distance support to all customers. Alternatively, Abberfield can travel to site in a mobile office and workshop, complete with comprehensive spare parts.
Page 67: Telephone Support
Office Portal, as this allows machine operating data to be accessed along with the audit and reporting data. The first line support is the Critical Alerts, such that Abberfield Technology and Card Access Services are informed by email of potential issues that may initiate an automatic response for support by Abberfield Technology or Card Access Services.
Page 68: Appendix 11 - Fault Diagnosis
In addition, Abberfield maintain a no cost telephone support service 24/7, with the expectation that late night contact is for emergencies only. Call the Abberfield main line (02) 9939 2844 at any time and if unanswered the call will divert to the duty engineer.
Page 69 Flow meter pulse reader not connected to Connect with 2 x screws okay and the flow meter manual meter on top of the WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION & SUPPORT MANUAL Page 69 of 70...
Page 70 On the WD3000N foreign object caught in Remove flow meter and the turbine impeller, but not large enough clean to stop it turning WD3000N WATER FILLING STATION Manual # 170818 rev 1.8 INSTALLATION &...