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CONTENTS

1 APOLLO 3000L INSTALLATION ......................................................... 7

1.1 Underground Sump Enclosure Installation. ................................. 7

1.2 Vertical Delivery Pipe Assembly Installation ................................11

1.3 Module Installation .................................................................... 18

1.4 Apollo 3000L Electronics Installation ......................................... 21

2 APOLLO 3000L VR2 COMPONENTS INSTALLATION ....................... 25

2.1 Installation Procedure Overview ................................................ 25

2.2 Hydraulic Installation ................................................................. 28

2.3 Vapour Sensor Assembly .......................................................... 30

2.4 Connecting to the Underground Return Pipework ...................... 34

2.5 Electrical Installation ................................................................. 35

3 APOLLO 3000L COMMISSIONING .................................................... 37

3.1 Safety Inspection ...................................................................... 37

3.2 Dispenser Configuration and Setup ........................................... 37

3.3 Tatsuno Meter Calibration ......................................................... 47

2A03229 APOLLO 3000L Installation and Commissioning Manual Issue 1

Содержание APOLLO 3000L

Страница 1: ...Part No 2A03229 Issue 1 APOLLO 3000L Installation and Commissioning Manual...

Страница 2: ...stralia and AS NZS 3008 2 for New Zealand When terminating external cables in the FDS crimp joints should be used and should comply with AS NZS 3000 If the FDS is to be installed at a Marina then all...

Страница 3: ...000L VR2 COMPONENTS INSTALLATION 25 2 1 Installation Procedure Overview 25 2 2 Hydraulic Installation 28 2 3 Vapour Sensor Assembly 30 2 4 Connecting to the Underground Return Pipework 34 2 5 Electric...

Страница 4: ...lo 3000L Electronic Set 21 Figure 20 Setting of Protocol Jumpers for PEC and Gilbarco Protocols 22 Figure 21 Comms Connections 22 Figure 22 Motor Drive Module Connection Guide 23 Figure 23 Solenoid Va...

Страница 5: ...tection technique for the safe operation of electronic equipment in explosive atmospheres The theory behind intrinsic safety is to ensure that the available electrical and thermal energy in the system...

Страница 6: ...ic hazard and suitable precautions should be taken at all times to prevent ingestion inhalation and contact with skin and eyes y y Only use genuine spare parts Genuine parts as specified in the origin...

Страница 7: ...ied by Gallagher Sump box enclosure assembly with cable duct pipe ducts and internal delivery pipes fitted Bulkhead seals pre fitted into sump enclosure Sump box lid Sump cover and sub frame 1 APOLLO...

Страница 8: ...m column the distance between the end of the protruding delivery ducts and the external side of the column should be 50mm D Check the end face of the enclosure is 300mm E out from the column Note Ensu...

Страница 9: ...cal feed line assembly It considers the use of a Tee connector terminated with a ball valve and a BSP Elbow These components are not supplied by Gallagher Fuel Systems Note Inside distance between bul...

Страница 10: ...he sump using timber or similar to prevent walls collapsing inwards during backfilling Re check seals and sump position Backfill to cover feed lines and secure sump enclosure position Backfill and com...

Страница 11: ...assemblies External hose assembly fitted with nozzles grade covers and splash guards Vent box assembly front and rear with their respective top caps Serial name plate to be adhered to top left hand c...

Страница 12: ...sump at right hand side of column and mark it as a datum point on the face of the column It must be established as an initial point to start measuring the positions of components and mounting bracket...

Страница 13: ...until the top face of the third horizontal bracket from the top aligns with the lower mark at 1405 4mm on the column and or the top face of the second horizontal bracket aligns with the upper mark on...

Страница 14: ...Figure 9 Delivery Pipes Assembly Part Numbers 2A03229 APOLLO 3000L Installation and Commissioning Manual Issue 1 14 APOLLO 3000L INSTALLATION...

Страница 15: ...bly The cut out section in the lower head mounting bracket must be located over the fixing bracket Secure the head into position with clamps Drill pilot holes into the column through the holes in the...

Страница 16: ...e using 50mm wide aluminium tape to provide a vapour seal Also tape the top of the vent box to the column refer to Figure 11 Using a Bostik Matrix 600 or 700FC polyurethane sealant seal all joints and...

Страница 17: ...rear side of the dispenser Figure 12 Safety Hose Position Install external hoses after the external cladding has been fitted Refer to Section 2 for instructions on the installation of coaxial hoses T...

Страница 18: ...tallation The following components are supplied by Gallagher Meter module assemblies Module hinge pins Product feed line hose assemblies x 3 product feed line to modules Product delivery hose assembli...

Страница 19: ...possible Verify that float is free to move upwards without obstruction Using the cable clips route the float switch cable through the cable duct out of the sump to the Multiplexer board located under...

Страница 20: ...alve cables inside the Ex e enclosure according to the wiring guide decal located inside the enclosure cover Figure 18 Wiring Guide Decal Attach the Ex e enclosure to the sump box using the supplied m...

Страница 21: ...Interface Barrier Multiplexer 1 4 Apollo 3000L Electronics Installation As shown in the image below most of the electronic set modules are mounted to the gear plate inside the head cabinet except for...

Страница 22: ...Fit the comms cables mains cable relay cables and 18 core cable into the head cabinet using appropriate glands Before connecting the comms cables to the Comms Connector Block ensure the POS protocol...

Страница 23: ...tion Guide The solenoid valve cables have to be connected to the AC Solenoid Drive module according to the connection guide located inside the head cabinet see Figure 23 Each valve cable has a number...

Страница 24: ...nnect the cables according to the following diagram Figure 24 Multiplexer Module Connection Guide Check all hydraulic and electrical connections Fit the protective covers once the commissioning proces...

Страница 25: ...uirements have been met the procedure will typically be Installation of the coaxial adaptors including manifold and vapour return pipes between the delivery pipes and hoses Installation of the vapour...

Страница 26: ...om the non VR2 version in the following key areas Extra electronic components inside the Head Cabinet VR2 nozzles VR2 coaxial hoses and adaptors with supplementary brackets Vapour return hoses and sen...

Страница 27: ...the central portion while fuel flows through the outer section The vapour is directed to the vapour return hoses by coaxial adaptors situated at the junction of the delivery pipes and hose assemblies...

Страница 28: ...ter brackets with covers that enclose the coaxial adaptors Each splitter bracket is fixed to the soffit panel using three capscrews and a backing plate The splitter bracket is used as a template for d...

Страница 29: ...e coaxial adaptors Note The right illustration in Figure 30 shows that the diesel hose or E85 connects directly to the delivery pipe A plastic grommet strip is fitted to prevent damage to the hose Fig...

Страница 30: ...ensor and feed the gooseneck through the hole in the bracket B to the left and A to the right 4 Prior to tightening the bottom clamp fit the rear part of the top clamp into position 5 Ensure there is...

Страница 31: ...Upper Manifold Hoses 1 Place a jubilee clip over the end of each vapour hose which is attached to the end of each vapour pipe that comes down from the upper manifolds 2 Fit each hose over the brass fi...

Страница 32: ...strain is placed on the sensors 2 Secure the jubilee clips 3 Cover the join with 15cm of self vulcanising tape stretching it to approximately two thirds its width as it is applied 4 Adjust the length...

Страница 33: ...of head cabinet assembly bracket vapour flow sensor cable logic cable connection for ball valve or similar vapour flow sensor proportional valve cable proportional valve lower manifold flametrap The c...

Страница 34: ...s recommends that the vapour return lines be connected via a ball valve or other suitable isolating device as shown in the illustration below This may require removal of the existing connection to fac...

Страница 35: ...ble is described in Section 1 4 Although the following VR cables should be connected prior to despatch this section can be used as a reference point in the event that some cable may need re connecting...

Страница 36: ...iring of the Fafnir Vapour Sensor Cables Both front A and rear B cables have to be wired into the Phoenix Connectors as shown in the figure below Figure 36 Phoenix Connector for Vapour Sensor Cables O...

Страница 37: ...fuel and electrical supply are turned on for the first time the installation must be inspected and approved for safety by suitably qualified personnel Items that must be checked during safety test in...

Страница 38: ...ken out of Service Mode the second UI will immediately enter Service Mode 3 2 2 Service Mode Function Screens In Service Mode the 2 and 8 keys initially serve as direction keys and are used to navigat...

Страница 39: ...n installed the display will appear not to change other than the ID in the Price window Upgrading the Firmware To upgrade firmware a new firmware file must be present in the firmware folder on the SD...

Страница 40: ...8 to access the CGFPID FP1 Fuel Point 1 screen CGFPID Change Fuel Point ID Press the F key Enter the desired number for example 7 Then press the F key Once allocated scroll using keys 4 or 6 to access...

Страница 41: ...llagher Technical Support can interpret dispenser logs and provide a more detailed description of errors In Service Mode scroll to ERRORS FP1 Press 5 view the current error status of the fuelpoint ALL...

Страница 42: ...e number followed by 1 for active or 0 for inactive Pressing the 6 key will move between hoses and pressing 5 will toggle between active and inactive Hoses are set as active inactive at the local fuel...

Страница 43: ...only be set in Standalone Mode When the fuel point is POS enabled the grade price cannot be changed at the dispenser User Interface This function allows the grade price to be changed at the dispenser...

Страница 44: ...ollars display now shows GRADE1 and the Litres display shows a row of four digits indicating the state of motors and valves 0 Off 1 On Open Motor and valves can be toggled between On Off or Open Shut...

Страница 45: ...h which is indicated by a 1 on the associated digit INPUT 3 1 6 Supplementary Inputs For use with features such as highflow switches or float switches INPUT 4 VR Switches Inputs For use when VR2 equip...

Страница 46: ...isk to indicate that the UI is back in view date mode Press 6 to move to TIME and set in the same manner Gallagher advise the checking of the date and time when obtaining dispenser logs Should either...

Страница 47: ...nt Wheel A single pitch turn one hole to the next varies the flow by 0 04 approx 0 2ml per revolution The meter can be adjusted up to a maximum of 0 64 3 2ml per revolution After calibration the meter...

Страница 48: ......

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