Fuel Dispensers Explained: Types, Components and Control Systems

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The fuel dispenser machine is used for dispensing and monitoring liquid fuels. Some of the common fuel types pumped using these devices include diesel, gasoline, oil, and kerosene. They can be used in a wide range of settings for dispensing fuel to vehicles, storage tanks, and portable containers. When you need fuel dispenser machines to support your fleet operations or fuel management system, it is important to know about the different options available and their components.

Types of modern fuel dispensers

When you need the right fuel dispenser, you should consider the different options. Fuel dispenser designs primarily depend on the fuel type that needs to be pumped. The fuel’s characteristics such as flammability, volatility, and boiling point are important factors that affect modern dispensers’ design and construction.

Modern fuel dispensers can be differentiated based on the following fuel types:

Petroleum fuels: This includes dispensers designed for fuels such as diesel, petrol (gasoline), and kerosene.
LPG & CNG: Liquefied petroleum gas (LPG) and compressed natural gas (CNG) are compressible types of fuels and require different types of fuel dispenser machine and components.
Alcohols: A different set of fuel dispensers are designed for dispensing alcohols such as ethanol, methanol, and butanol. They can be used as vehicle fuels as well as fuel additives along with petrol.
Specialized liquid fuels: Certain dispensers are designed for dispensing liquid ammonia, hydrogen, biodiesel, and synthetic fuels.

Fuel dispenser components

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Whether you choose a mechanical fuel dispenser or a modern unit, it will have many sections such as metering, hydraulic, and nozzle or hose. All these sections are made up of different components. For example, the hydraulic section comprises a rotary pump that draws fuel from the tank and a pilot valve that controls the fuel’s flow.

Hydraulic systems (pressure and suction types)

The hydraulic systems in fuel dispensers can use pressure and suction power for fuel movement from the storage tank to the nozzle. Both types of systems require pumps, pipes, and valves for efficient and safe fuel dispensing.

Pressure-type hydraulic systems

In these types of dispensers, the fuel is drawn by the pump before being pressurized. The role of the pump is to increase the fuel pressure and force it through the delivery lines and the dispensing nozzle. The pressure is required to ensure the fuel is delivered at the required rate to the vehicle’s fuel tank.

Suction-type hydraulic systems

In these types of systems, a suction pressure is created inside the fuel dispenser machine during the initial stage. This is usually achieved with the help of a positive displacement pump such as a piston or gear pump. The pump will produce a vacuum at the pump’s inlet. The vacuum generated is responsible for drawing fuel from the tank via the suction pipe and to the pump.

Electronic control units

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Another important component of the fuel dispenser, the electronics control unit comprises further parts. This includes:

Electronic assembly

The electronic assembly includes key electronic components including:

Power supply
Mainboard
Transformer
Display board
Relay
Keyboard
Display
Central control processing

A quality electronic assembly will have industrial-grade chips, a user-friendly interface, a waterproof keyboard, and anti-electromagnetic and anti-interference systems.

Pulse sensor

The pulse sensor features electrical conversion equipment for converting the flowmeter’s angular displacement into electrical pulse frequencies. In simple terms, its function is to convert the oil volume into the number of electrical pulses. This information is used by the main control board for calculating, storage, and display.

Display and interface options

When it comes to display and interface, the following fuel dispenser components are involved:

Fuel dispenser display

The fueling volume and other parameters are shown on the display with the help of a display board. Depending on the model, the dispenser can have a split-screen as well as a single-screen display. It can also support different backlights. An ideal display will have clear fonts, excellent durability, and it will be easy to install and maintain.

Dispenser keyboard

The keyboard works as the operations interface for the refueling operator. It assists with the following functions:

Refueling operations
Setting up system parameters
Checking system parameters
Stopping refueling operations

It allows you to preset the fuel volume and other parameters. Some models also let you set shortcut keys for functions such as refueling.

Security features and access control

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The two most commonly used ways to ensure secure access to a fuel dispenser machine include:

Passwords: The passwords can be set in digital form. The inputs can be made using the numeric keys. The system will generally display the symptoms as ‘*’ for security purposes.
Card authorization: Users can get access to fuel through a card. This will require logging in using an identification card.

Fuel dispensers: technical specifications comparison

Some of the key technical specifications of the fuel dispenser options discussed here are as follows:

Flow rate capabilities

Dimensions and installation requirements

Power supply specifications

Fuel dispenser control systems

Fuel dispenser control systems are mostly classified based on the method of operation and technologies they use to dispense and control the fuel’s flow. The most common types are as follows:

Manual control options

The key features of a manual control system in a mechanical fuel dispenser are as follows:

Manual control: Fuel dispensing is done and controlled manually by the operator.
Simple in design: These systems are typically older and feature mechanical parts such as levers, gears, and meters for measuring and dispensing fuel.
Functional limitations: It is rare for such control systems to have advanced features such as electronic displays and pre-set volume and other parameters.

Remote management features

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Modern dispensers feature control systems that allow remote management. This makes them perfect for applications and settings where there is a need for remote dispensing. An important feature of such systems is the integration of the fueling control panel. This includes combining features such as:

Dispenser or pump disconnects
Low voltage dispenser data disconnection
Dispenser hook isolation
Equipment power status monitoring
Remote power reset
Remote stop engagement

Virtual control solutions

Some fuel dispensers feature virtual control solutions that offer the following benefits:

Advanced control: Such systems rely on microprocessors, sensors, and other electronic components for controlling fuel dispensing with a high level of accuracy.
Automatic features: This can include automatic shutoff, electronic display of dispensed fuel volume, and pre-setting dispensing amounts.

Conclusion

Modern fuel dispenser units are available in a wide range of options, primarily depending on the fuel type involved. Different models are available to address the fuel dispensing needs in different types of settings.

Frequently Asked Questions

What are the main differences between mechanical and electronic fuel dispensers?
Mechanical and electronic fuel dispensers differ in terms of their functionality, control systems, and data management systems. A mechanical fuel dispenser has mechanical components and doesn’t have advanced features and integration systems available in electronic dispensers.

What are the maintenance requirements for modern fuel dispensers?
A modern fuel dispenser machine will require regular visual inspection, cleaning, inspection of display and interface, and replacement of damaged or worn-out nozzles and hoses.

Can fuel dispensers work with different types of fuel?
While some dispensers are designed to handle one type of fuel, others can handle different fuel types. Commonly, these devices handle diesel or gasoline.

How accurate are fuel dispenser measurements?
Fuel dispenser measurements are generally highly accurate. There are regulations and the need for periodic inspections in place to ensure an accurate amount of fuel gets dispensed.

What is the typical lifespan of a fuel dispenser?
A typical fuel dispenser can last from 15 to 20 years based on maintenance and upkeep.