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Important Safety Information

MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S

Start-Up and Service Manual · March 2019

Hazards and Actions

The following actions are recommended regarding these hazards:

• Do not go near a fuel spill or allow anyone else in the area.
• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not

remove AC power and do not always stop product flow.

• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow

open flames, smoking or power tools in the area.

• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.

WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.

Collision of a Vehicle with Unit

Fire at Island

Fuel Spill

!

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Summary of Contents for VaporTEK 110 V UL

Page 1: ...VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual MDE 5394B ...

Page 2: ...k MH8467 Transac System 1000 and PAM 1000 E105106 Dell DHM Minitower E165027 G SITE and Passport Systems National Conference of Weights and Measures NCWM Certificate of Conformance CoC Gilbarco pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program NTEP NCWM has issued the following CoC CoC Product Model CoC Product Model 02 019 Encore Nxx 02 036 Legacy Jxxx 02 020 E...

Page 3: ...nits as soon as they are received If any cartons are damaged or missing write a complete and detailed description of the damage or shortage on the face of the freight bill The carrier s agent must verify the inspection and sign the description Refuse only the damaged product not the entire shipment Gilbarco Veeder Root must be notified of any damages and or shortages within 30 days of receipt of t...

Page 4: ...nt purchase order Customer is responsible for all charges and freight associated with replacement order Customer Service will work with production facility to have the replacement product shipped as soon as possible If lost equipment is delivered at a later date and is not needed Gilbarco Veeder Root will allow a Return to Stock without a restocking fee Gilbarco Veeder Root will NOT be responsible...

Page 5: ...VaporTEK Pump Operation 3 3 System Calibration 3 4 Open loop vs Closed loop Flow Control 3 5 Changes in System Performance 3 5 VaporTEK 3 Controller Board 3 5 VaporTEK Controller Interfaces Connectors 3 6 VaporTEK System Configuration 3 8 4 VaporTEK Encore Wiring Diagrams 4 1 VaporTEK System for Collection Only 4 1 5 VaporTEK Calibration Start up Sequence 5 1 VaporTEK Start up Required Equipment 5...

Page 6: ...019 6 Troubleshooting and Analysis 6 1 Required Equipment 6 1 Troubleshooting Tools 6 1 VaporTEK Software 6 1 System Conditions That Can Be Ignored 6 12 System Conditions That Require Attention 6 13 Long term System Wear 6 13 Air Leaks 6 13 Nozzle side Leaks 6 13 Dispenser side Leaks 6 14 Troubleshooting Guide for VaporTEK Pump 6 15 Glossary Glossary 1 Index Index 1 ...

Page 7: ...g air actually a vapor air mixture and L being liquid or fuel The intent of the system is to collect the same amount of vapor as the fuel being dispensed However because the process for capturing vapor is subject to variation from many sources the regulatory bodies typically allow for some deviation from a one to one relationship between delivered fuel and recovered vapor The regulations for syste...

Page 8: ... Recovery System consists of the basic components shown in Figure 1 1 Figure 1 1 Basic Components of VaporTEK Vapor Recovery System Related Documents Document Number Title GOLDSM Library MDE 3804 Encore and Eclipse Start up Service Manual Encore and Eclipse MDE 3985 Encore Installation Manual Encore and Eclipse Encore and Eclipse Installers Footprints and Elevations VaporTEK 3 Controller VaporTEK ...

Page 9: ... Exhaust Fluid ECAL Electronic Calibration EPV Electronic Proportional Valve FC Function Code GOLD Gilbarco Online Documentation HV High Voltage LED Light Emitting Diode LPM Liters Per Minute NEC National Electrical Code NFPA National Fire Protection Association NPT National Pipe Thread OSHA Occupational Safety and Health Administration PCM Pulse Correction Module PCN Pump Control Node POS Point o...

Page 10: ...duction Purpose Page 1 4 MDE 5394B VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 This page is intentionally left blank ...

Page 11: ...e Center TAC at 1 800 743 7501 It is imperative to your safety and the safety of others to understand the procedures before beginning work Follow the Regulations Applicable information is available in National Fire Protection Association NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 70 National Electrical Code NEC Occupational Safety and Health Administration OSHA regu...

Page 12: ...emergency personnel Location of accident for example address front back of building and so on Nature of accident for example possible heart attack run over by car burns and so on Age of victim for example baby teenager middle age elderly Whether or not victim has received first aid for example stopped bleeding by pressure and so on Whether or not a victim has vomited for example if swallowed or in...

Page 13: ...wer These keys do not remove AC power and do not always stop product flow Take precautions to avoid igniting fuel Do not allow starting of vehicles in the area Do not allow open flames smoking or power tools in the area Do not expose yourself to hazardous conditions such as fire spilled fuel or exposed wiring Call emergency numbers WARNING Spilled fuels accidents involving pumps dispensers or unco...

Page 14: ...mportant Safety Information MDE 5394B VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 This page is intentionally left blank ...

Page 15: ...e with closed discharge shall not exceed 1600 mbar g at any speed The inlet outlet ports have standard National Pipe Thread NPT 3 8 inch female threads Technical Considerations Not for Field Representative s Use Use For use only in products where the acceptability of the combination is determined by Underwriters Laboratories UL LLC The following are the conditions of acceptability 1 When mounted i...

Page 16: ...cations Function Description Flow Medium Gasoline Vapor Mounting Four M6 X 1 Mounting Boss Either Side of Pump Motor Type Synchronous Brushless DC BLDC Motor Voltage Single 110 Voltage Alternate Current VAC 10 Frequency 50 60 Hz Watts 300 W Motor Speed 2500 rpm maximum Maximum Flow Rate Up to 120 LPM Noise Level 59 dB A Figure 3 1 VaporTEK Pump Specifications Flow Direction to UST Mounting Boss 4X...

Page 17: ...ction Pressure Figure 3 2 shows that the flow at 150 mbar suction pressure and the 100 mbar discharge pressure is approximately 95 LPM This is the design point of the system It defines the conditions under which the pump operates with the nozzle wide open and is illustrated by the small dot on the curve above During operation the inlet vacuum and to some extent the vapor flow is controlled by the ...

Page 18: ... The Pump Control Node PCN in the dispenser outputs pulses proportional to the flow 136 pulses 1 LPM These pulses are delivered to the Point of Sale POS system and the dispenser display and determine how much to charge the customer for the fuel dispensed These pulses are used by the VaporTEK system to set the vapor flow During the calibration process the VaporTEK Controller Board drives the pump a...

Page 19: ... the lifetime of the system Over time the seals on the pump piston wear the system develops slight leaks and restrictions and other long term effects cause the flow to change at every speed The flow can either rise or fall but it typically falls as the system ages Thus the vapor flow will begin to deviate from the fuel flow and the A L Ratio will go out of range initially only on occasion but even...

Page 20: ...onnector Description X1 L N PE Mains Electricity Connection 110 V AC X1 M1 M2 High Voltage HV Inputs X2 Motor Power U V W Connection X3 Motor Sensor Connection X4 RS 422 Connection to FB1 Handheld service terminal Performs system calibration and simulation X5 Programming connector for software updates and enhanced system debug setup X6 External Electronic Proportional Valve EPV Interface connectio...

Page 21: ...ler Board External EPV Connector Main Power Connector 15 V Motion Chip Power J1 J2 Jumper Setting RS 422 Serial J1 and J2 need to be placed to establish monitoring communication with re regulation using the X4 RS 422 interface High Voltage AC Main Power 110 V RS 422 Serial Port Conduit 5 V Board Logic Power External LED Connector Monitor Status LED Board Heartbeat LED V3 Motor Board To VaporTEK 3 ...

Page 22: ... following table lists the VaporTEK system configurations VaporTEK Configuration Encore 500 Only Input Type Mode of Operation Required Components Method of Operation Collection Only Liquid Pulse Signal Variable Speed VaporTEK 3 Controller VaporTEK 3 Controller receives liquid pulses from an active encoder or pulse interface from either side of the dispenser and calculates the fuel flow rate This f...

Page 23: ... VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 4 VaporTEK Encore Wiring Diagrams VaporTEK System for Collection Only Figure 4 1 VaporTEK System for Collection Only ...

Page 24: ...ms VaporTEK System for Collection Only Page 4 2 MDE 5394B VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 This page is intentionally left blank ...

Page 25: ...tion on page 5 5 Pulse rate setup with FB1 terminal refer to Pulse Rate Setup with FB1 Terminal on page 5 7 System integrity test refer to System Integrity Test on page 5 9 System calibration refer to System Calibration on page 5 10 VaporTEK Start up Required Equipment The following are the required equipment for the initial setup Description Part Number Burkert Flow Meter with Elaflex style Nozzl...

Page 26: ...ing side A show on the dispenser log file 6046 Shutdown warning side B show on the dispenser log file 6047 Vaporix board is detected but option is not set Vapor recovery units require two special programming steps First the PCN must be set up to provide output pulses to the VaporTEK interface using Command Code CC 91 Function Code FC 3 Then the fuel density must be set using CC 75 Accessing Dispen...

Page 27: ...g system is not installed 7 Press F1 The VaporVac is now set for vapor collection only Next the fuel density must be programmed 8 Press 75 Enter 9 Press 1 Enter for meter 1 volume blinks 10 Press 1 Enter for gas 11 Press 2 Enter for meter 2 right side cash blinks 12 Press 1 Enter for gas volume blinks 13 Press 5 Enter for meter 5 right side cash blinks 14 Press 1 Enter for gas volume blinks 15 Pre...

Page 28: ... operating correctly when it is calibrated If there are opportunities for air to enter the system leaks restrictions to flow blockages and improper electrical connections or faulty hardware the pump will not deliver the proper vapor flow A short test is performed before calibrating the system to verify its integrity The setup for system integrity test is shown in Figure 5 1 Figure 5 1 System Integ...

Page 29: ...meter encoder cable to FB1 terminal 4 Connect the hoses to gas meter 5 Ensure that the nozzle is shut off vapor valve closed to perform the leak test The following table lists the FB1 terminal key descriptions External Flow Meter Calibration External flow meter calibration must be completed before conducting a system calibration To calibrate the external flow meter proceed as follows 1 Press the S...

Page 30: ... Calib factor calibration factor on the gas meter see Figure 5 7 with the following display on the FB1 terminal see Figure 5 5 If the calibration factor already matches press ENTER If not press F2 to change the calibration factor Figure 5 5 Gas Meter Calibration Screen 4 5 Enter the Calib factor calibration factor shown on the gas meter and press Enter when the following screen opens for example 0...

Page 31: ...r is running the FB1 terminal will show the current petrol flow rate on the FB1 s display by using the FB1 Sub menu item Fuel flow 3 see step 4 on page 5 8 You need to use the procedure explained in Pulse Rate Setup with FB1 to verify the pulse rate is 136 pulses liter It cannot be set to any other number on an Encore dispenser The pulse rate adjustment can be set up either using the FB1 service t...

Page 32: ...en the screen shown in Figure 5 10 opens press 1 Figure 5 10 Pulse Rate Setup Screen 3 4 When the screen shown in Figure 5 11 opens press 4 Figure 5 11 Pulse Rate Setup Screen 4 5 When the screen shown in Figure 5 12 opens press F2 followed by the required number keys press the respective number keys to enter the pulse rate and press Enter Figure 5 12 Pulse Rate Setup Screen 5 6 Enter the pulse ra...

Page 33: ...roceed as follows 1 Press the Start button green button on the FB1 terminal until the following screen opens and then press 1 Figure 5 13 System Integrity Test Service Screen 2 When the screen shown in Figure 5 14 opens press 2 Figure 5 14 Identifying System Screen 3 When the screen shown in Figure 5 15 opens press 4 to start the simulation Figure 5 15 Simulation with FB1 Screen 4 Select the dispe...

Page 34: ...on test is performed To diagnose and resolve the issue refer to Troubleshooting and Analysis on page 6 1 System Calibration To calibrate the system proceed as follows 1 Verify that the power is available at the VaporTEK 3 Controller by confirming LED V1 and V6 red are ON and LED V3 green is flashing 2 Connect the FB1 terminal to the RS 422 connector on the VaporTEK 3 Controller Note Ensure that th...

Page 35: ...nual The following table lists the FB1 terminal key descriptions Figure 5 19 System Calibration Setup Diagram Ensure that the nozzle vapor valve is open and the external meter is connected see Figure 5 19 Key Description START Power ON the FB1 terminal ENTER Confirm selection SHIFT Cancel selection Connect vapor flow meter to barbed fitting on adapter AVRN Nozzle Hold open Clip Pin Vapor Collectio...

Page 36: ...ollows 1 Press the Start button until the screen shown in Figure 5 20 opens and then press 1 Figure 5 20 System Calibration Service Screen 2 Press 2 when the following screen opens see Figure 5 21 Figure 5 21 Identifying System Screen 3 Press 3 to start the Autocalib auto calibration when the following screen opens see Figure 5 22 Figure 5 22 Auto Calibration Using FB1 Screen 4 Select the dispense...

Page 37: ...e O rings are not missing After the system calibration is completed the calibration result needs to be verified using dry simulation 7 Press Shift to go back to the previous screen Follow the procedure on system integrity test steps 3 through 5 on page 5 8 The FB1 terminal starts the simulation and displays the results as shown in Figure 5 26 Refer to the following notes for information regarding ...

Page 38: ...1 terminal 4 Connect the hoses to gas meter 5 Remove the nozzle from the dispenser holder and secure the A L nozzle adapter to the spout of OPW nozzle as appropriate The A L nozzle adapter O rings prevent air leakage into the nozzle s vapor collection holes see Figure 5 19 on page 5 11 After ensuring the nozzle shutoff port is not covered by the adapter body tighten the two knurled end rings to se...

Page 39: ...rTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 10 Compare the fuel and vapor total results of transaction Calculate the A L Ratio as follows A L Vapor FB1 Total Fuel Volume Dispenser Display x 100 Figure 5 29 Calculating A L Ratio ...

Page 40: ...p on VaporTEK 3 Controller using FB1 Terminal to meet the regulations Figure 5 30 A L Rate Adjustment 12 Press F2 and adjust the Gas Rate A L Ratio according to the wet test result Set the offset parameter to zero and confirm these modification by pressing ENTER 13 Evaluate the A L Ratio on further two wet transactions One at max performance point high nozzle clip at roughly 38 LPM and another tra...

Page 41: ...orrect adapter can be used for system calibration 579290 001 Troubleshooting Tools The following tool is available for advanced troubleshooting and analysis VaporTEK Programming software refer to VaporTEK Software VaporTEK Software By connecting a laptop with a terminal emulator HyperTerminal or equivalent to the computer on the VaporTEK PROGRAM Connector a site technician can access all the setup...

Page 42: ...tart Up and Service Manual March 2019 Figure 6 1 Programming VaporTEK Software Note All necessary setup parameters like pulse ratio and K Factor can be set by using a FB1 Service Terminal S N 0000586 DA TE 49 2016 RoHS Compliant F1 L N PE M1 M2 V6 V3 V8 V1 X8 J1 J2 X1 X4 BR1 IC5 UNSAFE AREA Safe Area Safe Area Service USB Service and FlashAdapter Motor Sensor Conduit ...

Page 43: ...anual March 2019 To program the VaporTEK software proceed as follows 1 On your laptop open a terminal emulator such as HyperTerminal can be downloaded from the Internet Once the HyperTerminal menu screen opens click File in the menu bar and select New Connection Figure 6 2 Connection Description 2 In the Connection Description dialog box Name field enter VaporTEK Click OK see Figure 6 2 ...

Page 44: ...2019 3 Select the appropriate Communication COM port on your laptop COM X in Figure 6 3 To verify COM port go to Control Panel System Device Manager and select ports Check to see which COM port says USB 2 0 Click OK Figure 6 3 Selecting Appropriate COM 4 In the COM Properties dialog box COM X in Figure 6 4 set the port setting fields as shown in Figure 6 4 and click OK Figure 6 4 Port Setting Fiel...

Page 45: ... then click the Settings tab to open the dialog box shown in Figure 6 5 Ensure that all settings match the example shown in Figure 6 5 Figure 6 5 VaporTEK Interface Properties 6 Click File in the HyperTerminal window and select Properties then click the Settings tab to open the dialog box shown in Figure 6 6 Ensure that all settings match the example shown in Figure 6 6 7 Click ASCII Setup button ...

Page 46: ... Service Manual March 2019 8 Click OK to return to the main terminal window of HyperTerminal and click to connect 9 Switch on the main power or type m on the laptop to active the display screen The screen in Figure 6 7 opens after power up Figure 6 7 VaporTEK Main Display Screen 10 Type m on your keyboard to display the implemented main menu Figure 6 8 VaporTEK Main Menu Screen ...

Page 47: ... set configuration The Set Configuration submenu shows how the motor speed value can be assigned to HV Signals M1 and M2 Inputs This menu requires this safety code 33154 Once the HV Input M1 or M2 becomes active the motor runs with the setup speed If both HV Signals become active the motor runs with the speed that is the sum of the single speed values of M1 and M2 If the result of speed value is h...

Page 48: ...as an undefined malfunction This menu requires safety code as 33154 The factory defaults are M1 and M2 H V Inputs are set default 1200 rpm The Pulse Ratio is set to 136 p l The A L Ratio is set to 100 Figure 6 11 Setting Factory Defaults 14 Press 4 to enter the Debug Mode This submenu shows all debug mode options Press f to toggle between fuel flow debug mode ON and OFF If the debug mode is ON the...

Page 49: ...rmation are shown on the terminal screen Motor activation using M1 and M2 HV inputs do not support this debug mode Use s mode to obtain the speed and power information Press s in order to show the power consumption data of the motor Figure 6 13 Terminal Screen 15 Press 5 to show the calibration table The factory set calibration table is displayed when connected for the first time thereafter the ta...

Page 50: ... be used to modify the A L Ratio Set A L Ratio according to the value that is mentioned on the certificate as K Factor 110 Note Set Speed Offset to 0 Figure 6 15 A L Ratio 17 Press 7 to display Pulse Ratio setup This subitem allows a modification of Pulse Ratio The pulse ratio defines the fuel flow rate which must match the dispenser flow rate Refer to the dispenser manufacturer s manual to input ...

Page 51: ...ose will be controlled by the intelligent reregulation of monitoring and impact the vapor performance per side The permitted reregulation range is 85 125 A factor value of 100 represents 100 Figure 6 17 Reregulation Setup 19 Press 9 for Function Test Do not select this function because the test procedure requires special function test equipment and is intended to be used on the factory line end te...

Page 52: ...pen routinely but should not cause the A L Ratio to deviate by more than a few percent and should not occur for ten consecutive transactions This is one reason the regulations are written to allow for the A L Ratio to deviate by more than 5 at 38 LPM or 10 on half performance point Minor Variations in Pump Performance The relationship between pump speed and vapor flow will change as the pump wears...

Page 53: ... of the pump changes due to wear recalibration will bring the pump flow back to the acceptable level That is the pump will need to be run at a higher speed to deliver the same flow that it previously delivered at a slower speed The calibration routine described in External Flow Meter Calibration on page 5 5 will drive the pump to run faster than it had when it was previously calibrated and the sys...

Page 54: ...about the same However if an air leak develops on the opposite side where no transaction is running then the system will draw air from the leaking point which reduces the vapor performance on the active fueling point A test with max simulation value of 99 LPM will show a maximal vapor performance but if this performance is lower than expected then the leakage point needs to be detected before a va...

Page 55: ... LPM Increase fuel flow rate beyond 6 LPM Blocked Vapor Pumping Unit Remove the motor from the pumping unit and let it run If the pumping unit is clogged try to release the clog or replace the pumping unit Temperature in the dispenser electronic cabinet is lower than the rating Install appropriate heater as defined by the dispenser manufacturer Temperature in the hydraulics area of the dispenser i...

Page 56: ...roubleshooting Guide for VaporTEK Pump Page 6 16 MDE 5394B VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 This page is intentionally left blank ...

Page 57: ...e nozzle is opened for the fuel Vapor Recovery Systems Uses a vapor pump for the suction of vapor Vaporix Pulse Correction Module PCM Control module for pulse controlled Vapor Recovery Systems which can correct physically caused drift effects of the vapor recovery rate for example through temperature variations or swelling hoses and seals It extends and improves the function of pulse controlled Va...

Page 58: ...Glossary Glossary 2 MDE 5394B VaporTEK VaporTEK 3 Controller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 This page is intentionally left blank ...

Page 59: ...A L Ratio 1 1 AVRN 5 11 B BLDC 3 2 Burkert Gas Meter 5 6 C Calibration factor 5 6 E Eclipse 1 2 Encore 1 2 Encore 500 S 5 7 F F1 5 2 FB1 Terminal 5 7 FB1 terminal 5 9 5 11 5 13 Flow Meter 5 1 H HyperTerminal 6 1 M M13351A001 5 1 6 1 M13353A001 5 1 6 1 O O rings 5 13 P P1109 5 2 S Stage II 1 1 System Integrity Test 5 1 U UST 1 1 V vapor air mixture 1 1 VAPORIX Pulse Rate 5 1 VaporTEK 5 1 VaporTEK I...

Page 60: ...ntroller Board 110 V UL Vapor Recovery Collection System for Encore 500 S Start Up and Service Manual March 2019 UL is a registered trademark of Underwriters Laboratories Inc VaporVac is a registered trademark of Gilbarco Inc VaporTEK is a trademark of Veeder Root Company Veeder Root is a registered trademark of Veeder Root Company Windows XP is a registered trademark of Microsoft Corporation ...

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