TRAINING PORTAL

Complete System Overview & Introduction

Understanding Modern Fueling Infrastructure

When you join our team at Southern Tank Testers and STT Services, you're entering a field that combines mechanical expertise, environmental responsibility, and safety-critical work. This first section introduces you to the complete ecosystem of a modern fueling facility. Think of a gas station not as a simple place where cars fill up, but as a complex, interconnected system of storage, monitoring, safety, and dispensing technologies.

The modern fueling site operates on what we call "Total System Solutions" - this means every component, from the underground storage tanks to the payment systems customers use, must work in perfect harmony. As a technician, you'll need to understand not just individual parts, but how they interact as a complete system.

The Seven Core Systems

1. Service Station Hardware: This encompasses all the physical infrastructure at tank-top level. You'll work with composite manways (these replaced the old heavy steel versions), overfill prevention valves that automatically stop fuel delivery when tanks reach capacity, and spill containment systems that catch any drips or spills during delivery. Each component has specific installation requirements and maintenance schedules you'll need to master.

2. Piping & Containment Systems: Modern environmental regulations require double-wall piping with continuous monitoring. You'll learn about flexible piping systems that can handle ground movement and thermal expansion, rigid piping for specific applications, and the critical entry boots that seal penetrations. Understanding when to use each type of piping - flexible versus rigid, single versus double wall - is crucial for both new installations and repairs.

3. Submersible Pumping Systems: The heart of any fueling system is the submersible turbine pump (STP). These aren't just simple pumps - modern units include variable speed controls, intake filters to prevent debris damage, leak detection capabilities, and sophisticated electronic controls. You'll learn about different horsepower ratings, when to use fixed versus variable speed pumps, and how to integrate them with electronic monitoring systems.

4. Dispensing Systems: Where customers interact with the system. This includes not just the dispensers themselves, but breakaway valves (critical safety devices that prevent fuel spills if a car drives away with the nozzle), swivel connections that prevent hose damage, and vapor recovery systems in areas that require them. Understanding the flow path from tank to nozzle is essential.

5. Fuel Management Systems: Electronic monitoring has revolutionized our industry. Automatic tank gauges (ATGs) continuously monitor fuel levels, detect leaks as small as 0.1 gallons per hour, track inventory, and can even predict when deliveries are needed. You'll learn to install, calibrate, and troubleshoot these systems, including probe installation, float kit selection, and sensor placement.

6. Wire Management Systems: Often overlooked but critical - proper wire management prevents electrical failures and makes troubleshooting much easier. You'll work with specialized conduit systems designed for hazardous locations, learn proper sealing techniques to maintain explosion-proof ratings, and understand how to route cables to minimize interference and maximize accessibility.

7. Integrated Electrical Controls: Modern sites integrate emergency stops, power management, surge protection, and pump controls into unified systems. You'll learn about the National Electrical Code requirements for hazardous locations, how to properly install explosion-proof fittings, and the critical importance of proper grounding and bonding.

Safety and Compliance Foundation

Throughout your training, remember that every system we work on has three primary goals: environmental protection (preventing fuel from contaminating soil and groundwater), operational efficiency (keeping sites running smoothly and profitably), and safety (protecting workers, customers, and the community). Every component, every installation technique, and every maintenance procedure ties back to these fundamental objectives.

Tank Top Hardware Detailed Systems

Comprehensive Tank Access and Monitoring Components

Tank top hardware represents the critical interface between underground storage tanks and the surface equipment. As a field technician, you'll spend significant time working with these components, so understanding their function, installation requirements, and maintenance needs is essential.

Monitoring Wells and Groundwater Protection

Monitoring wells are your first line of defense against undetected leaks. These aren't just holes in the ground - they're carefully engineered observation points that allow continuous or periodic checking for fuel contamination in the surrounding soil and groundwater. The typical installation includes a 4-inch screen pipe (perforated to allow liquid entry) wrapped in filter fabric that prevents soil infiltration while allowing water and fuel to enter.

The monitoring well sensor (often 15 feet in length, though this varies by site geology) can detect hydrocarbons at parts-per-million levels. When installing these, you'll need to understand local water table depths, soil types, and the proper placement relative to tanks and piping. The sensor connects to the site's automatic tank gauge, providing 24/7 monitoring. During your training, you'll learn to test these sensors using approved methods and understand the difference between false alarms (often caused by naturally occurring methane) and actual fuel presence.

Spill Container Systems and Evolution

Spill containment has evolved significantly over the past decade. Single-wall spill containers provide basic protection - they're essentially buckets that catch fuel during delivery. However, most new installations require double-wall containers with interstitial monitoring. The space between walls (the interstitium) contains sensors that detect any breach of the primary wall, providing early warning before fuel can escape to the environment.

These models represent current best practices. These units feature chemical-resistant construction (important for ethanol-blended fuels), integrated drain valves for removing rainwater, and mounting systems that maintain water-tight seals even as pavement shifts over time. You'll learn proper installation techniques including how to ensure the container is level, how to properly seal penetrations, and how to test the integrity of both walls.

A critical feature many overlook: these spill containers are designed for field upgrades. A single-wall unit can be converted to double-wall configuration as regulations change, avoiding expensive tank-top excavation. This modularity is something you'll need to explain to customers when discussing compliance upgrades.

Overfill Prevention Valves - Critical Safety Systems

Overfill prevention valves (OPVs) are mechanical devices that automatically restrict fuel flow when tanks near capacity. Various models are available for different tank depths and fuel types. Understanding these specifications is crucial - installing the wrong OPV can result in either premature shutoff (angry delivery drivers and lost revenue) or insufficient protection (environmental disaster).

Key specifications you'll need to master:

• Overall length corresponds to tank diameter and burial depth
• Different models for gasoline versus diesel (different specific gravities)
• Special models for biofuel compatibility (E85/biodiesel require special seals)
• Some models are CARB EVR Phase 1 certified for specific installations

During installation, you'll learn to properly set the drop tube length, ensure the float mechanism moves freely, and test operation using the "blow test" method. Regular maintenance includes checking for corrosion, ensuring the float hasn't absorbed fuel (which changes its buoyancy), and verifying proper operation during each delivery.

Composite Manways and Access Systems

The FLEX-ING composite manways represent a significant advancement over traditional steel units. At a fraction of the weight (important when you're lifting these into place), they provide superior chemical resistance and won't corrode. The 47-inch model is becoming industry standard, providing adequate space for equipment while minimizing excavation.

Installation requires attention to detail: proper gasket placement, bolt torque specifications (over-tightening can crack composite materials), and ensuring the assembly remains water-tight. You'll learn to identify signs of manway failure (cracks, gasket deterioration, bolt corrosion) during routine inspections.

Venting Systems and Pressure Management

The Defender Series P/V (pressure/vacuum) vents with in-line vaults represent current best practices in tank venting. These devices prevent tank damage from pressure changes during filling and temperature fluctuations while minimizing vapor emissions. The in-line vault design allows grade-level maintenance - a huge safety improvement over climbing on tank tops.

Understanding vent line hydraulics is crucial: undersized venting can collapse tanks during pump-out, while oversized venting may not maintain adequate pressure for vapor recovery systems. You'll learn to calculate required vent capacity based on pump rates and tank configuration, properly install vent lines to prevent liquid traps, and maintain required distances from building openings and property lines.

APT XP Flexible Piping Systems for Dispensers

Advanced Piping Technology for Dispenser Connections

The APT (Advanced Piping Technology) XP system represents the evolution of flexible underground piping. As a technician, you'll work with these systems extensively, as they've become the industry standard for new installations and many retrofits. Understanding both the installation techniques and the reasoning behind design choices will make you more effective in the field.

Understanding Flexible Connector Fundamentals

Flexible connectors serve multiple critical functions in modern fueling systems. First and foremost, they act as shock absorbers, protecting rigid piping from damage due to ground movement, frost heave, or seismic activity. They also compensate for thermal expansion and contraction - remember that underground temperatures are relatively stable, but the piping can still experience significant length changes.

The model numbers follow a logical pattern that indicates fitting type, diameter, length, and connection specifications. Understanding this nomenclature helps you order the correct parts and communicate effectively with suppliers.

EZ FIT Connection System Deep Dive

The EZ FIT system revolutionizes field connections. Traditional threaded joints require perfect alignment, proper thread sealant application, and significant torque - all challenging in the confined space of a dispenser sump. EZ FIT connections use a simple clamp-and-gasket system that creates reliable seals with minimal tools and effort.

The installation process requires attention to detail:

1. Ensure flange faces are clean and undamaged
2. Inspect the gasket for cuts or deformation
3. Position components with proper alignment
4. Install the clamp and tighten to specified torque (over-tightening can damage the gasket)

These connections are also reusable - critical for maintenance operations. When you need to service a shear valve or replace a dispenser, you can disconnect and reconnect EZ FIT joints multiple times using the same hardware. This reduces maintenance costs and minimizes downtime.

Quick Release Fittings and Modular Design

Quick release fittings take the modularity concept further. All fittings standardize on 2-inch flanges regardless of pipe diameter, enabling universal connections. This means a 1.5-inch pipe can connect to a 2-inch fitting using the same clamp and gasket as a 2-inch to 2-inch connection. This standardization reduces inventory requirements and eliminates ordering errors.

The quick release tees and elbows provide multiple disconnection points for maintenance. Consider a typical dispenser sump with two product lines: using quick release fittings, you can isolate and service either line independently without disturbing the other. This modularity becomes especially valuable during emergency repairs when minimizing station downtime is critical.

Ducted vs. Non-Ducted Installations

Two distinct installation methods are used, each with specific applications:

Non-Ducted (Direct Burial): Used when local codes permit and soil conditions are stable. The piping runs directly from tank to dispenser without additional protection. This method is faster to install and less expensive but provides no secondary containment for the flexible connectors. You'll use this primarily in retrofit situations where adding ducting would require extensive excavation.

Ducted Installations: Required in many jurisdictions and recommended where soil conditions are challenging (high water table, corrosive soils, unstable fill). The 4-inch corrugated ducting provides a chase for the piping, protecting it from external damage and providing a path for leak detection sensors. The ducting also simplifies future piping replacement - you can pull new lines through existing ducts without excavation.

Shear Valve Integration and Safety

Shear valves are critical safety devices that must be properly integrated into the piping system. These valves automatically seal if the dispenser is impacted, preventing catastrophic fuel releases. The installation height is crucial - too high and the valve won't shear during minor impacts; too low and normal dispenser vibration might cause premature failure.

You'll learn to:

• Calculate proper shear valve height based on dispenser model and mounting
• Ensure adequate support below the valve to prevent false triggers
• Test shear valve operation using manufacturer-specified procedures
• Understand when to use fire-rated versus standard shear valves

Entry Boot Selection and Installation

Entry boots maintain sump integrity where piping penetrates. The rigid entry boot (REB series) versus flexible entry boot (FEB series) choice depends on piping type and expected movement. Proper installation involves:

• Cleaning the sump wall thoroughly
• Applying appropriate sealant (different for polyethylene versus fiberglass sumps)
• Achieving proper compression without distorting the boot
• Testing the seal integrity before backfilling

UPP Semi-Rigid Piping Systems

Understanding UPP Technology and Applications

UPP (Ultra Performance Pipe) represents a middle ground between rigid steel and fully flexible piping systems. This semi-rigid thermoplastic piping offers unique advantages that make it ideal for specific applications, particularly vent lines and DEF (Diesel Exhaust Fluid) systems. As a technician, understanding when and how to use UPP will expand your installation and repair capabilities.

Electrofusion Welding Fundamentals

The electrofusion process creates joints stronger than the pipe itself. Unlike traditional solvent welding or threading, electrofusion uses resistive heating elements built into each fitting. When electrical current passes through these elements, they heat up, melting both the fitting and pipe surfaces. As the materials cool, they fuse into a monolithic joint that won't leak or separate under normal conditions.

The welding process requires precision:

1. Preparation: Pipes must be cut square using proper tools (not hacksaws which leave rough edges)
2. Scraping: The pipe surface must be scraped to remove oxidation - this is critical for proper fusion
3. Cleaning: Both surfaces must be cleaned with approved solvents
4. Assembly: Components must be properly aligned and clamped
5. Welding: The correct time and temperature parameters must be used
6. Cooling: Joints must cool completely before handling

You'll learn to use the electrofusion welding equipment, understand the barcode system that automatically sets welding parameters, and recognize signs of good versus poor welds. Common mistakes include inadequate scraping (leading to poor fusion), contamination from dirty hands or tools, and moving joints before cooling is complete.

Material Advantages for Specific Applications

UPP's properties make it ideal for certain uses:

Chemical Resistance: Unlike steel, UPP won't corrode when exposed to ethanol, biodiesel, or DEF. This makes it perfect for alternative fuel applications where traditional materials would fail quickly.

Flexibility: While not as flexible as coiled piping, UPP can accommodate minor ground movement and thermal expansion without special fittings. This "semi-rigid" nature simplifies installation in areas with minimal but present ground movement.

Temperature Stability: UPP maintains its properties across a wide temperature range, important for vent lines that may experience temperature extremes.

Smooth Interior: The smooth bore reduces pressure drop and prevents buildup of deposits, particularly important in DEF systems where crystallization can be problematic.

Polyethylene vs. Fiberglass Sump Applications

The document shows different configurations for polyethylene and fiberglass sumps because these materials have different properties requiring specific connection methods:

Polyethylene Sumps: These require electrofusion entry boots that weld directly to the sump wall. This creates a permanent, leak-tight seal that becomes part of the sump structure. The advantage is reliability; the disadvantage is that repairs require cutting out and rewelding sections.

Fiberglass Sumps: Use mechanical entry boots with compression seals. These can be installed and removed without damaging the sump, making repairs and modifications easier. However, they require periodic inspection and retightening to maintain seal integrity.

Reducer Fittings and Transition Management

The various reducer fittings serve critical functions in system design. You'll encounter situations requiring transitions between pipe sizes, often when connecting new equipment to existing infrastructure. Understanding pressure drop across reducers, proper support requirements, and when to use concentric versus eccentric reducers will improve your installation quality.

The test ports integrated into many reducers allow pressure testing of individual sections without affecting the entire system. This capability is invaluable during troubleshooting - you can isolate problems to specific piping runs without extensive disassembly.

Termination Fittings and System Integration

Male and female termination fittings transition from electrofusion to threaded connections. Proper installation requires:

• Ensuring threads are clean and undamaged
• Using appropriate thread sealant (different for fuel versus vapor applications)
• Achieving proper engagement without over-tightening
• Supporting the fitting to prevent stress on the electrofusion joint

Practical Installation Scenarios

The page presents two common scenarios you'll encounter:

Scenario 1: UPP with Flexible Connector Riser: Used when codes require flexible connections at dispensers or when maximum vibration isolation is needed. The UPP provides the main run with a flexible connector making the final connection.

Scenario 2: UPP Direct Riser: Simpler and less expensive but provides less protection against movement and vibration. Appropriate for stable soil conditions and low-traffic areas.

Understanding when to use each configuration requires considering local codes, soil conditions, traffic patterns, and customer preferences. You'll develop this judgment through experience, but always err on the side of additional protection when uncertain.

Tank Sump Equipment and Configurations

Mastering Tank Sump Installations

Tank sumps are critical spaces where multiple systems converge - pumps, piping, electrical, and monitoring equipment all meet in these confined areas. Your ability to properly install, maintain, and troubleshoot tank sump equipment directly impacts site reliability and environmental compliance. This section covers the essential components and configurations you'll work with regularly.

Flexible Connector Applications in Tank Sumps

In tank sumps, flexible connectors serve specialized purposes beyond simple vibration isolation. The primary application connects the submersible pump manifold to the product piping. This connection experiences significant stress from hydraulic hammer (sudden pressure waves when pumps start/stop), thermal cycling, and minor tank settlement over time.

The configuration includes several important features:

• The 90-degree elbow integrated into the connector eliminates a potential leak point
• The male swivel on one end allows rotation during installation without twisting the hose
• The EZ FIT connection on the opposite end enables quick disconnection for pump service

When installing these connectors, maintain proper bend radius - over-bending reduces flow and accelerates wear. The minimum bend radius is typically 5 times the hose diameter, though manufacturer specifications may vary. Also ensure adequate clearance from sharp edges and hot surfaces (some pumps can run quite warm).

Ball Valve Placement and Function

Ball valves in tank sumps serve as isolation devices, allowing pump removal without draining the entire piping system. The brass ball valves are specifically designed for petroleum service with appropriate seals and pressure ratings.

Installation considerations include:

• Orientation: Install with handles accessible but protected from accidental operation
• Support: Properly support valves to prevent stress on connected piping
• Labeling: Clearly mark normal position (open/closed) and associated pump
• Exercise Schedule: Valves should be operated periodically to prevent seizing

You'll learn to recognize when ball valves need replacement - signs include handle resistance, visible corrosion, or leakage around the stem. Remember that a leaking ball valve in a tank sump can slowly fill the sump with product, creating both environmental and safety hazards.

Sensor Installation and Positioning

The sensor bracket systems represent best practices in leak detection sensor installation. Proper sensor positioning is crucial - too high and small leaks go undetected; too low and condensation causes false alarms.

Key installation principles:

• Mount sensors at the lowest point where liquids would naturally collect
• Ensure cables are properly secured to prevent tangling with other equipment
• Use appropriate sensors for the application (discriminating vs. non-discriminating)
• Test sensor operation before closing the sump

The discriminating sensors can distinguish between hydrocarbons and water, reducing false alarms from rainwater infiltration. These require proper calibration and periodic testing to maintain accuracy.

Entry Boot Configurations for Different Piping Types

The distinction between rigid and flexible piping entry methods is crucial for maintaining sump integrity:

Rigid Entry Boots (REB series): Used with APT rigid piping, these boots require precise alignment during installation. The boot must be perpendicular to the sump wall to prevent stress on the piping. Installation involves:

1. Core drilling the proper size hole
2. Cleaning and preparing the surface
3. Installing the boot with appropriate sealant
4. Allowing proper cure time before loading

Flexible Entry Boots (FEB series): Accommodate movement and misalignment better than rigid boots. These are preferred when:

• Piping alignment is challenging
• Ground movement is expected
• Retrofitting existing installations

Conduit Entry Considerations

Electrical conduit entries require special attention to maintain explosion-proof ratings. Every conduit entering a tank sump must be properly sealed to prevent vapor migration. You'll learn about:

• Sealing fittings and their proper installation
• Maintaining area classification boundaries
• Proper grounding and bonding through seals
• When to use rigid versus flexible conduit

Practical Sump Layouts

Organizing equipment within the confined space of a tank sump requires planning. Consider:

• Accessibility: Frequently serviced components should be easily reached
• Segregation: Keep electrical components away from potential fuel sources
• Drainage: Maintain slopes toward the sump sensor location
• Future Expansion: Leave space for additional sensors or equipment

You'll develop preferred layouts through experience, but always prioritize safety and maintenance access over installation convenience.

DEF System Specialized Components

Understanding DEF System Requirements

Diesel Exhaust Fluid (DEF) systems require specialized knowledge because DEF has unique properties that affect every aspect of system design. DEF is a 32.5% urea solution that freezes at 12°F and is highly corrosive to standard materials. As regulations require DEF at more sites, your expertise in these systems becomes increasingly valuable.

Material Compatibility Critical Factors

Every component in contact with DEF must be specifically designed for this service. Standard carbon steel, brass, and even some stainless steels will corrode rapidly when exposed to DEF. Approved materials include:

Stainless Steel: 304 and 316 stainless are standard, with 316 preferred for long-term exposure. All fittings use stainless construction.

Specialized Plastics: The piping systems use specially formulated polyethylene that won't degrade when exposed to DEF. Standard polyethylene will become brittle and fail.

Seals and Gaskets: Only EPDM, FKM (Viton), and certain other elastomers are compatible. Standard Buna-N seals will fail quickly.

During installation, you must verify every component's DEF compatibility - using even one incorrect fitting can contaminate an entire tank of DEF, resulting in expensive disposal and potential vehicle damage.

Recirculation System Design and Operation

The recirculation system prevents DEF from freezing in cold climates. The design uses several innovative features:

Temperature Monitoring: The temperature sensor installs in a specially designed tee assembly that ensures accurate temperature reading. The sensor must be positioned where DEF flow is guaranteed - stagnant areas give false readings.

Automated Control: The EVO system with conditions software monitors temperature and automatically activates recirculation when DEF approaches freezing. The system also includes time-based circulation to prevent stratification even when temperatures are above freezing.

Three-Phase Pump: The variable-length STP provides the circulation flow. Three-phase power is required for the reverse rotation needed in some configurations. You'll learn to verify proper rotation direction during commissioning.

Check Valve Integration: The check valve prevents reverse flow when the pump stops, maintaining prime and preventing air entrainment.

Dispenser Sump Tee Assembly

The recirculation tee assembly in the dispenser sump is a critical component that's often misunderstood. This assembly:

• Combines discharge and return flows
• Provides temperature sensor mounting
• Maintains proper flow patterns for accurate temperature reading
• Includes air release provisions to prevent vapor lock

Installation requires careful attention to flow direction - reversing the connections will cause poor circulation and inaccurate temperature readings. The close nipples must be stainless steel and properly sealed to prevent leaks that could contaminate the DEF.

Tank Top Configurations

DEF tank top equipment differs from standard fuel systems:

Separate Vent Lines: DEF tanks require dedicated venting separate from fuel tanks. The 2-inch single wall vent line is adequate for most applications since DEF has low vapor pressure.

Fill Considerations: The 3-inch double wall fill line provides freeze protection and containment. Some installations include heat tracing in extreme climates.

Overfill Protection: Standard overfill valves aren't DEF compatible - ensure you're using appropriate models with stainless internals and compatible seals.

Hanging Hardware and Dispensing Equipment

DEF dispensing equipment includes unique features to prevent contamination:

Mis-filling Prevention: The DURADEF nozzle includes a magnetic sensor that only allows dispensing into DEF tanks with corresponding receivers. This prevents expensive mistakes where DEF is accidentally dispensed into diesel fuel tanks.

Stainless Construction: All nozzles, breakaways, and swivels must be stainless steel for DEF-specific applications.

Dedicated Hoses: DEF hoses use specialized materials and shouldn't be interchanged with fuel hoses. The BSPP (British Standard Pipe Parallel) threads are common in DEF equipment due to European origin of many components.

Troubleshooting DEF Systems

Common DEF system problems you'll encounter:

• Crystallization: DEF leaves white crystals when it evaporates. These can clog valves and sensors
• Contamination: Even trace amounts of petroleum products can ruin DEF
• Freezing: Despite recirculation systems, exposed components may still freeze
• Corrosion: Improper materials cause rapid failure

Developing expertise in DEF systems sets you apart as these installations become more common and existing systems require maintenance.

Wire Management Systems

CableTight System Overview

Wire management might seem mundane compared to pumps and piping, but proper electrical installation is crucial for safe, reliable operation. The CableTight system provides organized, code-compliant routing for power and control wiring in hazardous locations. Your understanding of these systems affects both safety and troubleshooting efficiency.

Understanding Hazardous Area Classifications

Fuel dispensing facilities are classified as hazardous locations under the National Electrical Code (NEC). You'll work primarily with:

Class I, Division 1: Areas where flammable vapors are normally present (inside dispenser cabinets, sumps)

Class I, Division 2: Areas where vapors may occasionally be present (areas around dispensers)

These classifications determine required equipment ratings and installation methods. Using incorrect components or methods in hazardous areas can cause explosions - there's zero tolerance for mistakes here.

Rigid Conduit Systems and Applications

The coated rigid metal conduit provides mechanical protection and corrosion resistance. The polyethylene coating prevents the galvanic corrosion that destroyed older steel conduit systems. Key installation points:

Bending Requirements: The 90-degree bends must maintain minimum radius to prevent coating damage and allow wire pulling. You'll learn to use hydraulic benders for accurate, smooth bends.

Support Spacing: Conduit requires support every 10 feet and within 3 feet of boxes and fittings. Improper support leads to sagging and stress on connections.

Grounding Continuity: Despite the coating, conduit must maintain electrical continuity for grounding. Special grounding bushings pierce the coating to ensure proper bonding.

Entry Seal Systems

Entry seals where conduit enters sumps serve multiple functions:

• Prevent vapor migration between areas
• Maintain sump integrity against liquid infiltration
• Provide strain relief for conductors
• Maintain explosion-proof ratings

The distinction between polyethylene and fiberglass entry seals relates to sump material - using the wrong type compromises the seal. Installation requires:

1. Proper hole sizing (too large weakens the seal)
2. Appropriate sealant application
3. Correct tightening sequence
4. Cure time before wire pulling

Flexible Conduit Applications

Flexible conduit serves specific purposes:

• Connections to vibrating equipment (pumps, dispensers)
• Transitions between rigid sections with relative movement
• Temporary installations during construction

However, flexible conduit has limitations - maximum 6-foot lengths in hazardous locations, requires separate grounding conductor, and must be properly supported to prevent sagging.

Seal-Off Requirements

Seal-offs are critical safety devices preventing vapor propagation. Required locations include:

• Within 18 inches of leaving Class I, Division 1 areas
• Where conduit enters enclosures containing switches or circuit breakers
• At area classification boundaries

Proper seal-off installation involves:

1. Installing the fitting at the correct location
2. Pulling wires before sealing
3. Packing fiber correctly (25% fill minimum)
4. Mixing and pouring compound properly
5. Allowing complete cure before energizing

You'll learn to identify when existing seal-offs have failed (cracked compound, missing fiber) and how to properly repair them without complete replacement.

Practical Layout Considerations

Typical conduit routing from sumps to electrical panels follows these key principles:

• Minimize bends (each 90-degree bend makes wire pulling harder)
• Plan for future expansion (install larger conduit than immediately needed)
• Separate power and control wiring when possible
• Maintain accessibility for maintenance

Turbine Pump Interface Systems

Understanding Modern Pump Control Systems

The integration between submersible turbine pumps (STPs) and electronic monitoring systems represents one of the most important advances in fueling system technology. This integration, called Turbine Pump Interface (TPI), transforms simple pumps into intelligent systems that self-monitor, self-protect, and optimize performance.

Submersible Turbine Pump Fundamentals

Modern STPs are sophisticated machines far removed from simple centrifugal pumps. The models available include:

Advanced Protection Package: Special coatings and materials resist corrosion from ethanol and other aggressive fuels. This includes e-coating of housings, stainless steel fasteners, and special seal materials.

Intake Filter Screens: Protect pump internals from debris. You'll learn proper cleaning intervals and replacement indicators (pressure differential, flow reduction).

Variable Length Options: Accommodate different tank depths without field modifications. Understanding how to specify correct length based on tank diameter and burial depth is crucial.

Integrated Check Valves: Prevent product backflow and maintain prime. Some models include "soft-start" check valves that reduce hydraulic hammer.

Controller Selection and Capabilities

The choice between MagVFC variable speed and Guardian fixed speed controllers depends on site requirements:

Variable Speed (MagVFC) Advantages:

• Soft start reduces electrical demand and mechanical stress
• Flow rate adjusts to match dispenser demand
• Energy savings through optimized pump speed
• Extended pump life from reduced wear

Fixed Speed (Guardian) Applications:

• Simpler installation and troubleshooting
• Lower initial cost
• Adequate for sites with consistent flow demands
• Easier integration with older dispensers

You'll learn to size controllers based on pump horsepower, electrical service, and number of dispensers served. Understanding phase rotation, overload protection, and control circuit integration is essential.

Leak Detection Integration

The system incorporates multiple leak detection methods:

Statistical Continuous Automatic Leak Detection (SCALD): Allows 0.2 gph leak detection without shutting down tanks. The system learns normal usage patterns and identifies anomalies indicating leaks. You'll understand how to set up SCALD, interpret results, and distinguish between actual leaks and false positives from temperature changes or equipment issues.

Electronic Line Leak Detection: Monitors up to three pressure lines simultaneously. The system performs:

• 3 gph catastrophic leak detection within seconds
• 0.2 gph precision tests during quiet periods
• Continuous pressure monitoring for anomalies

Installation requires proper transducer placement, calibration for line volume, and integration with the ATG. You'll learn to troubleshoot common issues like trapped air, thermal expansion false alarms, and sensor drift.

Probe and Sensor Systems

Inventory Probes: Magnetostrictive probes provide accurate level measurement to 0.001 inches. Probe selection depends on tank diameter, with models available from 29 inches for 2-foot diameter tanks to 221 inches for 18-foot diameter tanks. Installation requires:

• Proper probe positioning (avoiding tank internals)
• Float kit selection based on product type
• Calibration to tank chart
• Water float adjustment for accurate water detection

Float Kit Options: Different products require specific floats:

• Gasoline floats have specific gravity around 0.73
• Diesel floats accommodate specific gravity around 0.85
• Phase separation floats detect ethanol/water phase separation
• Density floats measure product density for inventory reconciliation

Communication Protocols

Modern TPI systems communicate using various protocols:

• Serial RS-485 for probe communications
• Discrete I/O for pump control
• Modbus for integration with point-of-sale systems
• Ethernet for remote monitoring

Understanding these protocols helps troubleshoot communication issues and integrate new equipment with existing systems.

Practical Troubleshooting Scenarios

Common TPI issues you'll encounter:

• Pump Won't Start: Check controller status, verify ATG permissions, test control circuits
• Erratic Flow: Look for partially clogged filters, check valve problems, VFD parameter issues
• Communication Errors: Verify wiring continuity, check termination resistors, confirm addresses
• False Leak Alarms: Investigate thermal expansion, trapped air, sensor calibration

Corrosion Control Systems

Comprehensive Corrosion Prevention Strategy

Corrosion is the silent destroyer of fueling systems, causing failures that lead to environmental releases, equipment damage, and costly repairs. The Corrosion Control system takes a proactive approach, addressing corrosion before it causes problems. Your understanding of these systems helps customers avoid catastrophic failures and regulatory violations.

Understanding Corrosion Mechanisms

Corrosion in fueling systems occurs through several mechanisms:

Microbiologically Influenced Corrosion (MIC): Bacteria feeding on fuel and water create acidic byproducts that attack steel. Common in diesel tanks with water bottoms.

Galvanic Corrosion: Dissimilar metals in contact create electrical cells that accelerate corrosion. Often seen where copper grounds contact steel tanks.

Atmospheric Corrosion: Humidity in vapor spaces condenses, creating ideal corrosion conditions. Particularly problematic in partially filled tanks.

Chemical Corrosion: Ethanol and biodiesel can be aggressive to certain materials, while DEF is highly corrosive to standard steels.

Water Separator Technology

The Corrosion Control Water Separator actively removes water from diesel tanks:

Operating Principle: The separator uses coalescing media to combine small water droplets into larger ones that settle out. A pump then removes accumulated water.

Automated Operation: The EVO controller activates the separator based on:

• Scheduled run times (typically daily)
• Water level detection
• Manual activation for testing

Installation Considerations:

• Position at tank's lowest point for optimal water collection
• Ensure adequate pump capacity for tank size
• Provide proper disposal path for removed water
• Install bypass piping for maintenance

You'll learn to adjust separation efficiency, troubleshoot pump issues, and properly dispose of contaminated water according to regulations.

Desiccant Pack Systems

The Desiccant Pack and sensor work together to control humidity:

Desiccant Function: Silica gel or molecular sieve materials absorb water vapor from sump atmosphere. As humidity drops, condensation potential decreases dramatically.

Sensor Integration: The sensor monitors desiccant condition, alerting when replacement is needed. This prevents the common problem of forgotten, saturated desiccants that no longer protect equipment.

Installation Best Practices:

• Mount packs at highest sump point (water vapor rises)
• Ensure adequate air circulation around packs
• Replace all packs simultaneously for consistent protection
• Document replacement dates for maintenance records

Corrosion Detection Sensors

The Corrosion Detection Sensor provides early warning of corrosive conditions:

Detection Method: Sacrificial metal coupons corrode at known rates in corrosive atmospheres. The sensor monitors coupon thickness, calculating corrosion rate.

Placement Strategy: Install in tank ullage space where vapor accumulates. Multiple sensors may be needed in compartmented tanks.

Response Actions: When corrosion is detected:

1. Investigate water sources
2. Check vapor recovery system operation
3. Verify tank venting adequacy
4. Consider installing additional protection

Advanced Protection Submersible Pumps

STPs with Advanced Protection feature:

• E-coating on all external surfaces
• Stainless steel hardware throughout
• Special seal materials resistant to ethanol
• Upgraded bearing materials for longer life

These pumps cost more initially but last significantly longer in corrosive environments. You'll learn to identify when standard pumps are adequate versus when Advanced Protection is necessary.

System Integration and Monitoring

The Multiplexing Sensor Hub enables retrofit installation without new conduit:

• Connects multiple sensors using single cable
• Reduces installation cost and time
• Provides addressing for sensor identification
• Enables phased implementation of protection

The EVO ATG centralizes monitoring:

• Displays all sensor status on single screen
• Logs historical data for trend analysis
• Generates alerts for out-of-range conditions
• Enables remote monitoring via web interface

Cost Justification and ROI

Help customers understand corrosion control value:

• Prevented tank replacement: $50,000-$100,000
• Avoided environmental cleanup: $100,000-$1,000,000+
• Reduced pump replacement frequency: $5,000-$10,000 per pump
• Minimized emergency repairs and downtime

Document existing corrosion during site surveys, photograph problem areas, and maintain records showing system effectiveness.

Generator Backup Systems

Emergency Power System Integration

Generator backup systems ensure sites remain operational during power outages, critical for emergency services, hospitals, and strategic locations. These systems are complex, involving fuel supply, return lines, day tanks, controls, and safety systems. Your expertise in generator systems adds significant value to your service capabilities.

Day Tank System Design

The aboveground day tank serves as a buffer between the main underground tank and generator:

Capacity Sizing: Day tanks typically hold 4-24 hours of generator runtime at full load. Factors include:

• Generator fuel consumption rate
• Required runtime during extended outages
• Available space for tank placement
• Local fire code restrictions on aboveground storage

Double Wall Construction: Required for environmental protection, the interstitial space includes:

• Leak detection sensors
• Visual inspection ports
• Pressure/vacuum monitoring in some designs

Level Control: Multiple level switches control operation:

• Low level: Starts supply pump from main tank
• High level: Stops supply pump
• Low-low level: Generator shutdown to prevent damage
• High-high level: Alarm condition preventing overflow

Supply and Return Piping

The system uses separate supply and return lines, each serving specific functions:

Supply Line Components:

• Foot valve maintains prime in supply line
• Submersible pump provides fuel transfer
• Electronic line leak detection monitors line integrity
• Check valves prevent backflow during pump shutdown

Return Line Function: Diesel generators return excess fuel to maintain injector cooling. This return fuel is significantly heated, requiring:

• Proper sizing to handle return flow without restriction
• Thermal expansion compensation
• Mixing provisions in day tank to prevent hot spots

Control System Integration

The generator control system coordinates multiple components:

Emergency Alarm System: Provides local and remote annunciation of:

• Tank overfill conditions
• Leak detection alarms
• Power failure notifications
• Generator run status

Submersible Pump Guardian Controller: Manages pump operation based on:

• Day tank level signals
• Leak detection inputs
• Manual override commands
• Power availability

EVO with Generator Package: Provides:

• Inventory management for main and day tanks
• Leak detection for all tanks and lines
• Historical runtime logging
• Predictive maintenance alerts

Transition Sump Configurations

The grade level transition sump manages the underground-to-aboveground transition:

Critical Functions:

• Secondary containment for piping connections
• Access point for valve operations
• Mounting location for control equipment
• Separation point for supply/return lines

Installation Requirements:

• Proper drainage to prevent water accumulation
• Adequate space for maintenance access
• Protection from vehicle traffic
• Compliance with setback requirements

Safety Systems and Code Compliance

Generator installations must meet multiple code requirements:

Emergency Venting: The emergency vent prevents tank rupture during fire exposure. Sizing depends on tank surface area and must comply with NFPA 30 requirements.

Overfill Prevention: The OPV valve prevents tank overflow during filling. Generator day tanks require special consideration since they're filled automatically rather than by delivery truck.

Anti-Siphon Protection: Ball valves and solenoid valves prevent fuel siphoning if lines are damaged. Some jurisdictions require fusible link valves that close automatically during fires.

Maintenance and Testing Protocols

Generator systems require regular maintenance:

Weekly Testing: Run generator under load, verify automatic transfer, check fuel levels

Monthly Inspection: Test leak detection, verify control operations, inspect piping

Annual Maintenance: Clean day tank, replace filters, calibrate sensors, test emergency systems

You'll learn to develop maintenance schedules, perform load bank testing, and troubleshoot common problems like air entrainment, control conflicts, and sensor failures.

Common Installation Challenges

Typical issues you'll encounter:

• Coordinating multiple trades (electrical, mechanical, controls)
• Managing long lead times for generator equipment
• Ensuring proper system commissioning
• Training facility personnel on operation
• Maintaining compliance with evolving codes

Understanding these challenges helps you plan installations, set customer expectations, and avoid costly delays.

Vent Line Systems

Comprehensive Venting System Design

Vent lines are often treated as afterthoughts, but they're critical for safe tank operation. Improper venting can cause catastrophic tank failure, vapor releases, or operational problems. Your expertise in vent system design and installation prevents these issues while ensuring code compliance.

Vent Line Hydraulics and Sizing

Understanding vent line hydraulics is fundamental:

Flow Requirements: Vents must handle:

• Incoming air during product dispensing
• Outgoing vapor during filling
• Thermal expansion/contraction breathing
• Emergency venting during fire exposure

Pressure Drop Calculations: Every component adds resistance:

• Straight pipe: Minimal resistance
• Elbows: Equivalent to 10-30 feet of straight pipe
• Tees: Similar to elbows depending on flow path
• P/V vents: Must crack at specified pressure

Undersized venting causes vacuum during dispensing (potentially collapsing tanks) or pressure during filling (potentially rupturing tanks). You'll learn to calculate required vent capacity and verify adequate sizing.

UPP Vent Line Installation

UPP makes excellent vent piping due to its properties:

Corrosion Resistance: Won't rust from condensation like steel

Smooth Interior: Reduces pressure drop and prevents condensate buildup

Electrofusion Joints: Create permanent, leak-free connections

Semi-Rigid Nature: Maintains slope without excessive supports

Installation best practices:

• Maintain consistent upward slope (minimum 1/8" per foot)
• Avoid low points where condensate can collect
• Install drip legs where direction changes are necessary
• Ensure proper support spacing to prevent sagging

Defender Series P/V Vent Technology

The Defender Series pressure/vacuum vents with in-line vaults represent current best practices:

Dual Function Operation:

• Vacuum relief: Opens when tank pressure drops below -8 inches water column
• Pressure relief: Opens when pressure exceeds +3 inches water column
• Normal breathing: Remains closed to minimize vapor emissions

In-Line Vault Benefits:

• Grade-level access for maintenance
• Protection from weather and vandalism
• Easy screen cleaning without tank-top access
• Visual inspection capability

Installation Requirements:

• Proper vault depth (frost line consideration)
• Adequate drainage around vault
• Correct orientation for water drainage
• Appropriate distance from buildings/property lines

Vent Stack Configurations

Two primary configurations are available:

End-of-Line Installation: P/V vent mounts directly on vent stack

• Simpler installation
• Lower cost
• Traditional appearance
• Requires tank-top access for maintenance

In-Line Installation: Vault-mounted P/V vent with separate stack

• Grade-level maintenance
• Better protection from elements
• Higher initial cost
• Requires careful vault placement

Manifolded Vent Systems

Multiple tanks can share common vent piping with proper design:

Advantages:

• Fewer penetrations through pavement
• Reduced installation cost
• Simplified vapor recovery connections

Critical Requirements:

• Individual tank isolation capability
• Proper sizing for combined flow
• Flame arrestor protection
• Prevention of product migration between tanks

You'll learn to design manifolded systems that meet code requirements while maintaining operational flexibility.

Emergency Venting Requirements

Emergency vents provide rapid pressure relief during fire exposure:

Sizing Criteria: Based on wetted area calculations per NFPA 30

Installation Location: At highest point of tank

Operating Pressure: Must open before tank design pressure

Maintenance: Regular inspection for corrosion, obstruction, proper operation

Tools and Equipment

Proper tools are essential for quality vent line installation:

Electrofusion Welder: Automated welding ensures consistent joints

Pipe Scrapers: Remove oxidation for proper fusion

Pipe Cutters: Create square, clean cuts

Clamps: Hold components during welding

Testing Equipment: Verify vent operation and pressure drop

Maintaining and calibrating these tools ensures consistent installation quality.

Common Venting Problems

Issues you'll diagnose and correct:

• Blocked Vents: Insect nests, ice, debris
• Incorrect Slope: Causing condensate accumulation
• Undersized Piping: Leading to operational problems
• Failed P/V Vents: Stuck open (vapor release) or closed (pressure/vacuum damage)
• Code Violations: Improper materials, locations, or installation methods

Understanding these problems helps you perform thorough inspections and preventive maintenance.

Above-Grade Systems Introduction

Moving From Underground to Customer-Facing Equipment

So far, your training has covered everything below the concrete - tanks, piping, pumps, and all the equipment customers never see. Now we're moving to above-grade systems: the dispensers, payment terminals, and hanging hardware where customers actually interact with the fuel system. Think of it this way: below-grade keeps fuel safe and contained; above-grade delivers it to customers and keeps them coming back.

Both matter equally. A leaking underground pipe creates environmental problems, but a broken dispenser creates immediate customer frustration and lost sales. You'll need to understand both worlds to be effective in the field.

What You'll Work With Above Grade

Fuel Dispensers: These are the units customers interact with. Modern dispensers aren't just "gas pumps" - they're specialized computers managing fuel delivery, payment processing, display screens, and constant self-monitoring. You'll install, maintain, troubleshoot, and repair these units regularly.

Hanging Hardware: The nozzles, hoses, breakaways, and swivels that actually deliver fuel. Each part has specific purposes and common failure points you'll learn to recognize.

Payment and Media Systems: Everything from card readers to video screens. These systems tie into networks you can't see, which makes troubleshooting interesting - sometimes the problem isn't where it appears to be.

Integration Points: How dispensers connect to underground equipment, store computers, payment processors, and inventory systems. Understanding these connections helps you solve problems faster.

Why This Matters to Your Work

Here's a surprising fact: 60% of convenience store customers never walk inside. They pay at the pump and drive away. That means the dispenser is often the only contact between business and customer. A clean, working, easy-to-use dispenser keeps customers coming back. A dirty, confusing, or broken one sends them to the competitor down the street.

Your job maintaining these systems directly affects whether sites make money or lose customers. That makes you valuable - sites depend on you keeping their primary customer touchpoint operational.

Wayne Ovation 2 Dispenser Overview

Why We're Focusing on the Ovation 2

At Southern Tank Testers and STT Services, you'll work on dispensers from various manufacturers. Wayne offers many different dispenser models, and other brands are represented in the field as well. Each has its own design philosophy, features, and quirks. However, the Wayne Ovation 2 is by far the most common new dispenser you'll encounter in the field, particularly in retail fueling applications. For this training, we're using it as our primary example because understanding this platform thoroughly gives you a solid foundation that translates to other models.

The principles you learn here - how fuel flows, how payment systems integrate, how components are organized - apply across all modern dispensers. Once you master the Ovation 2, you'll find that working on other dispenser types becomes much easier because you understand the underlying concepts. Think of this as learning one language really well - it makes picking up related languages much simpler.

Understanding the Ovation 2

Wayne has built fuel dispensers for over 120 years, and the Ovation 2 represents their current thinking on what makes a good dispenser. Understanding how it works - and why it's designed the way it is - makes your job easier when you encounter this model at customer sites.

Five Key Design Features

Wayne built the Ovation 2 around five main ideas. Understanding these helps you explain features to customers and make smart recommendations during installations.

Durability: Built to Last in Harsh Conditions

Dispensers live outside 24/7 in extreme conditions - from Minnesota blizzards to Arizona summers, plus constant sun exposure, humidity, and the occasional careless driver. The Ovation 2 handles this through:

• All-metal columns (no plastic that cracks or fades)
• Tempered glass on areas people touch frequently
• Stainless steel options for coastal or industrial environments
• Sealed compartments keeping moisture out of electronics

When you survey a site, you'll look at local weather, traffic patterns, and environmental factors to recommend the right durability options.

Visibility: Making Sites Stand Out

The Ovation 2 has 25% more space for branding than older Wayne dispensers. This matters because dispensers are often the first thing customers notice about a site - before the building, before the staff. Features include:

• Customizable color combinations on the main panel
• Side panels visible from the road
• Illuminated top section with brand graphics
• Multiple screen sizes for displaying content

You'll work with customers on graphics, coordinate with sign shops, and make sure everything looks consistent across the forecourt.

Serviceability: Easy to Maintain and Update

The Ovation 2 is designed to make your job easier:

• Simplest paper change on any dispenser (literally 30 seconds, no tools)
• One-step calibration process
• Modular parts you can swap instead of repairing
• Upgradeable payment systems without replacing the whole unit
• Organized internal layout with color-coded wiring
• Hinged doors (no bolts to lose or strip)

You'll practice these maintenance tasks until they become second nature. Your speed directly affects customer satisfaction and your own productivity.

Capability: Handles Different Fuels and Technologies

The Ovation 2 works with various setups:

• Different meter types for different flow needs
• Multiple fuel options (regular gasoline, ethanol blends, biodiesel)
• Various payment types (swipe cards, chip cards, tap-to-pay, fleet cards)
• Screen options from basic displays to large touchscreens
• Different vapor recovery systems depending on local requirements

Understanding options helps you recommend the right configuration for each site's needs.

Usability: Easy for Customers to Use

The Ovation 2 is the only fully ADA-compliant dispenser available, meaning it works for customers with disabilities. It also guides all users through fueling with clear steps:

• Logical flow: swipe card → authorize → select grade → pump fuel → get receipt
• Buttons recessed to prevent accidental presses
• Displays readable even in bright sunlight
• Multiple languages available
• Design works for wheelchair users

When customers say "the pump doesn't work," sometimes they mean "I couldn't figure out how to use it." Good usability reduces these calls.

Standard vs. LX Models

The Ovation 2 comes in two main versions:

Standard Ovation 2: Core features for typical sites. Includes basic payment, standard displays, essential functions.

Ovation 2 LX: Premium version with extras:

• Curved lower door (looks better, more durable)
• LED lighting on transaction flow indicators
• Enhanced button lighting
• Larger 10.4" screen included
• Better speakers for media
• Advanced connectivity built-in

Understanding the difference helps you recommend the right model. Don't oversell features customers won't use, but don't undersell when they need the capability.

How Fuel Flows Through the Dispenser

Understanding the Basic Flow Path

Before you can troubleshoot a dispenser, you need to understand how fuel moves through it. Think of the dispenser as a gatekeeper and measurer - it controls when fuel flows and precisely measures how much goes to each customer.

Remote Dispenser Setup (Most Common)

The underground pump does all the work pushing fuel. The dispenser just controls, measures, and directs it:

1. Fuel enters through the shear valve (safety device at bottom)
2. Passes through an inlet check valve (prevents backflow)
3. Goes through product selector valves (directs the right fuel)
4. Flows through the meter (measures volume precisely)
5. Exits through an outlet check valve (maintains pressure)
6. Goes through the hose and nozzle to the customer's vehicle

Each component has a specific job. When something goes wrong, understanding this flow helps you isolate the problem.

Product Configurations

Non-Blending (Up to 3 Products):

Simplest setup. Customer presses a button, one valve opens, fuel flows through one meter. Three separate products, no mixing. Easy to maintain but limits product choices.

Standard Blending (Up to 5 Products from 3 Base Fuels):

Uses 2-3 base fuels to create 5 product options. For example:

• Base fuels: Regular (87 octane), Premium (93 octane)
• Blended product: Midgrade (89 octane) - about 60% Regular + 40% Premium

The dispenser mixes fuels automatically in precise ratios. More options for customers, but requires careful calibration to ensure correct mixing.

Dual Hose (E85 Flex Fuel):

Two separate hoses - one for gasoline, one for E85 (high ethanol blend). Used where customers need both options. Requires special materials since ethanol is harder on equipment than regular gasoline.

Meters: The Heart of Accurate Delivery

The meter measures how much fuel flows. Two main types:

Wayne iMeter:

• Uses rotating precision parts to measure volume
• Works accurately with all fuel types
• Standard choice for most sites
• Reliable and cost-effective

Wayne Xflo:

• High-speed meter for fast filling
• Important for truck stops or fleet facilities
• Maintains accuracy even at high flow rates
• Costs more but necessary for some applications

Choosing the wrong meter causes problems - iMeters wear out fast in high-flow situations, while Xflo meters may not read accurately at very slow flows.

Valves and Their Jobs

Several valves control the flow:

Inlet Check Valve: Stops fuel from draining back to the tank when the pump stops. If this fails, you get slow starts and air in the lines.

Product Selector Valves: Direct which fuel flows (Regular, Plus, or Premium). Failure here delivers wrong fuel or blocks flow entirely.

Outlet Check Valve: Keeps pressure in the hose for quick starts. When it fails, you get vapor lock in hot weather or slow, spitting starts.

Blending Valves: Control fuel mixing ratios for midgrade products. These need periodic checking to ensure correct octane delivery.

You'll learn to test each valve, recognize failure symptoms, and replace them when needed.

Payment Systems and Customer Screens

Modern Payment Processing

Payment systems have gotten complicated. What used to be a simple credit card swipe now involves encryption, chip readers, contactless payments, mobile wallets, and fraud prevention. The Ovation 2 handles this through a system called iX Pay.

iX Pay: Modular Payment Platform

Think of iX Pay as a foundation that accepts different payment devices. Benefits:

• Upgrade payment hardware without replacing the entire dispenser
• Add new payment types through software updates
• Single platform works with multiple payment methods
• Enhanced security and fraud prevention

Payment Device Options You'll Encounter

iX Pay EPP (Basic Encrypted Pin Pad):

• Keypad for entering PINs
• Magnetic stripe card reader
• Small display for prompts
• Encrypts data immediately at swipe

This is the baseline - works with credit cards and debit cards requiring PINs.

iX Pay Hybrid Chip Card Reader:

• Reads chip cards (customer inserts instead of swipes)
• Falls back to magnetic stripe if card has no chip
• Often includes tap-to-pay capability
• More secure, becoming the standard

Important: The hardware alone isn't enough. The store's computer system must support chip cards or they won't work.

Wayne TAP Contactless Reader:

• Accepts tap-to-pay cards
• Works with phone payment apps (Apple Pay, Google Pay, etc.)
• Requires the iX Pay secure system
• Fast transactions (customers prefer it)

When Payments Go Wrong

Understanding the payment flow helps troubleshoot:

1. Customer presents card
2. Dispenser reads and encrypts data
3. Sends to store computer
4. Store contacts payment network
5. Approval comes back
6. Fuel turns on

Problems can happen at any step:

• Card read errors: Dirty reader, damaged card, wrong insertion
• Communication problems: Connection between dispenser and store computer
• Authorization declines: Customer's bank or card issue, not your equipment
• Timeout errors: Slow networks or overwhelmed systems

You'll learn systematic testing to find where in the chain things break.

Display Screens and Customer Interface

Three main screen options:

5.7" Monochrome: Basic black and white display. Shows transaction info but no graphics or videos. Cheap but limited.

5.7" Color: Same size, but color makes it easier to read and enables simple graphics. Better customer experience for small cost increase.

10.4" VGA Touchscreen: Large color screen enabling:

• Video advertisements
• Interactive applications
• Clear transaction guidance
• Rich media content

This is standard on LX models. Sites wanting to engage customers beyond basic fueling benefit from the larger screen.

Why Media Matters

Remember: 60% of customers never go inside. The dispenser is their only contact with your store. Screens let you:

• Advertise in-store products
• Promote limited-time offers
• Run loyalty programs
• Upsell premium fuel or car washes
• Provide entertainment (news, weather, sports)

Media requires additional infrastructure (in-dispenser computers, site server, content system). You'll learn to install and maintain these systems as more sites adopt them.

Accessibility Features

The Ovation 2 works for all customers:

• Height and reach requirements for wheelchair users
• High-contrast displays for vision impairment
• Tactile buttons in consistent locations
• Audio feedback options
• Clear, logical layout

Understanding accessibility helps verify installations meet legal requirements and serve everyone effectively.