Veeder-Root VaporTEK Installation, Setup And Troubleshooting Manual

Installation, Setup and Troubleshooting Manual

VaporTEK

Manual No: 577014-013 ● Revision: E

Notice

Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this publication.

Veeder-Root reserves the right to change system options or features, or the information contained in this publication.

This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication may be photocopied, modified or translated to another language without the prior written consent of Veeder-Root. Contact TLS Systems Technical Support for additional troubleshooting information at 800-323-1799.

DAMAGE CLAIMS / LOST EQUIPMENT

Thoroughly examine all components and units 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.

Veeder-Root must be notified of any damages and/or shortages within 30 days of receipt of the shipment, as stated in our Terms and Conditions.

VEEDER-ROOT’S PREFERRED CARRIER

1. Contact Veeder-Root Customer Service at 800-873-3313 with the specific part numbers and quantities that were missing or received damaged.

2. Fax signed Bill of Lading (BOL) to Veeder-Root Customer Service at 800-234-5350.

3. Veeder-Root will file the claim with the carrier and replace the damaged/missing product at no charge to the customer. Customer Service will work with production facility to have the replacement product shipped as soon as possible.

CUSTOMER’S PREFERRED CARRIER

1. It is the customer’s responsibility to file a claim with their carrier.

2. Customer may submit a replacement 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.

3. If “lost” equipment is delivered at a later date and is not needed, Veeder-Root will allow a Return to Stock without a restocking fee.

4. Veeder-Root will NOT be responsible for any compensation when a customer chooses their own carrier.

RETURN SHIPPING

For the parts return procedure, please follow the appropriate instructions in the "General Returned Goods Policy” pages in the "Policies and Literature" section of the Veeder-Root North American Environmental Products price list. Veeder-Root will not accept any return product without a Return Goods Authorization (RGA) number clearly printed on the outside of the package.

Introduction

Contractor Certification Requirements .................................................................................................2

Related Manuals .........................................................................................................................................2

Safety Precautions ....................................................................................................................................2

Safety Warnings .........................................................................................................................................3

VaporTEK Configurations ........................................................................................................................5

VaporTEK Pump Certifications & Markings .........................................................................................6

Safety Certification..........................................................................................................................6

Hazardous Area Installation Instructions ....................................................................................6

Equipment Marking .........................................................................................................................6

Material Compatibility With Constituents Of The Potentially Explosive Atmosphere ......7

TUV Certification..............................................................................................................................7

VaporTEK Kits .............................................................................................................................................7

VaporTEK Pump Kit - P/N 900612-001 ....................................................................................7

VaporTEK Controller Kit - P/N 900634-001.............................................................................8

VaporTEK Interface Kit - P/N 900635-001............................................................................ 10

VaporTEK High Voltage Relay Kit - P/N 900664-001......................................................... 10

VaporTEK Low Voltage Relay Kit - P/N 900665-001.......................................................... 10

VaporTEK Pump Characteristics ........................................................................................................ 11

VaporTEK Pump Specifications ................................................................................................ 11

VaporTEK Controller .............................................................................................................................. 12

VaporTEK Interface ................................................................................................................................ 14

VaporTEK Interface I/O ............................................................................................................... 15

VaporTEK Interface LEDs........................................................................................................... 15

VaporTEK LEDs ........................................................................................................................... 15

VaporTEK Pump Configuration ........................................................................................................... 17

Installation

VaporTEK Pump ...................................................................................................................................... 18

VaporTEK Controller and VaporTEK Interface ................................................................................. 20

Wiring Schematics

VaporTEK Wiring .................................................................................................................................... 23

Communication Setup - VaporTEK Interface

Setup with Laptop .................................................................................................................................. 32

VaporTEK Interface for Input Configuration ...................................................................................... 39

VaporTEK Calibration

Manual Calibration using the POT on the VaporTEK Controller board ..................................... 41

Dry Calibration - A/L Adjustment ........................................................................................................ 42

Equipment Required .................................................................................................................... 42

Initial Setup .................................................................................................................................... 42

Gas Meter Calibration ........................................................................................................................... 44

Pulse Rate Setup With FB1 Terminal ................................................................................................ 45

Pulse rate setup on VaporTEK Interface ................................................................................. 45

Pulse Rate Setup with FB1........................................................................................................ 45

Auto-Calibration using FB1 Terminal ................................................................................................. 46

Simulation with FB1 Terminal .............................................................................................................. 48

VaporTEK Pump Troubleshooting and Quick Help

Troubleshooting and Quick Help ........................................................................................................ 50

Appendix A: VaporTEK System Reference Wiring Diagrams

iii

Figures

Table of Contents

Figure 1. VaporTEK System Components .......................................................................................1

Figure 2. VaporTEK Pump Dimensions ......................................................................................... 11

Figure 3. VaporTEK Controller ......................................................................................................... 13

Figure 4. VaporTEK Interface ........................................................................................................... 14

Figure 5. VaporTEK Interface LEDs ................................................................................................15

Figure 6. VaporTEK Pump Installation Orientations ................................................................... 19

Figure 7. Mount The VaporTEK Controller To The Inside Of The Support Bracket................ 20

Figure 8. VaporTEK Motor/Sensor Connector’s Labeling And Poke Yoke ........................... 20

Figure 9. Mount The VaporTEK Interface To The Back Side Of The Support Backet .......... 21

Figure 10. Attach The VaporTEK Controller Safety Cover .......................................................... 22

Figure 11. VaporTEK System - High Voltage Hook Signal Input ............................................... 24

Figure 12. VaporTEK System - Liquid Pulse Signal and Low Voltage Hook Signal Input........ 25

Figure 13. VaporTEK Interface - Low Voltage Nozzle Hook Signal Connections .................. 26

Figure 14. VaporTEK Interface - Liquid Pulse Signal Connections ........................................... 27

Figure 15. VaporTEK System - Low Voltage Hook Signal With Relay Switches ................... 29

Figure 16. VaporTEK System - High Voltage Hook Signal With Relay Switches .................. 30

Figure 17. VaporTEK Low Voltage Relay Diagram ........................................................................ 31

Figure 18. VaporTEK High Voltage Relay Diagram ....................................................................... 31

Figure 19. Set Configuration Example .............................................................................................40

Figure 20. POT (Potentiometer) ........................................................................................................ 41

Figure 21. Calibration Setup .............................................................................................................. 43

Figure 22. Locate the Burkert Gas Meter Calibration Factor ..................................................... 45

Figure A-1. VaporTEK System Plus For Collection Only - Encore 500S Dispenser..................A-1

Figure A-2. VaporTEK System Plus For Collection Only - Encore 500S Dispenser ................A-2

Figure A-3. VaporTEK System Plus for collection only with 3 color LED -

Using 900855-001 Interface Board for Encore 500S Dispenser ........................A-3

Figure A-4. VaporTEK System Ultra for Collection only Using VRC 390/3 Board

for Encore 500S Dispenser ...........................................................................................A-4

Introduction

VaporTEK Controller

VaporTEK Interface

VaporTEK Pump

This manual contains installation and operation instructions for Veeder-Root’s VaporTEK. VaporTEK is a dispenser based, Stage II vapor recovery system that collects vapor during vehicle fueling and returns vapor to the underground storage tank (UST). Each VaporTEK system is designed to accommodate two active fueling points simultaneously.

VaporTEK System Components:

• VaporTEK Pump

• VaporTEK Controller

• VaporTEK Interface

Figure 1. VaporTEK System Components

Introduction Contractor Certification Requirements

Contractor Certification Requirements

Veeder-Root requires the following minimum training certifications for contractors who will install and setup the equipment discussed in this manual:

Installer Certification (Level 1): Contractors holding valid Installer Certification are approved to perform wiring and conduit routing; equipment mounting; probe, sensor and carbon canister vapor polisher installation; wireless equipment installation; tank and line preparation; and line leak detector installation.

Technician Certification (Level 2/3): Contractors holding valid Technician Certifications are approved to perform installation checkout, startup, programming and operations training, system tests, troubleshooting and servicing for all Veeder-Root Series Tank Monitoring Systems, including Line Leak Detection. In addition, Contractors with the following sub-certification designations are approved to perform installation checkout, startup, programming, system tests, troubleshooting, service techniques and operations training on the designated system.

• Wireless 2

• Tall Tank

VR Vapor Products Certification: Contractors holding a certification with the following designations are approved to perform installation checkout, startup, programming, system tests, troubleshooting, service techniques and operations training on the designated system.

• ISD – In Station Diagnostics

• PMC – Pressure Management Control

• CCVP - Veeder-Root Vapor Polisher

• Wireless – ISD/PMC Wireless

• A current Veeder-Root Technician Certification is a prerequisite for the VR Vapor Products course.

Warranty Registrations may only be submitted by selected Distributors.

Related Manuals

577014-018 Encore 500 Stage II Vapor Recovery Retrofit/Commissioning Installation and Start-Up Instructions

577013-988 MPV 10 Valve Installation and Maintenance Manual

577013-985 AVRN Vacuum Assist Nozzle Installation and Maintenance Manual

MDE-5064 Encore 500 VaporTEK Service and Troubleshooting Manual

Safety Precautions

The following safety symbols may be used throughout this manual to alert you to important safety hazards and precautions.

EXPLOSIVE

Fuels and their vapors are extremely explosive if ignited.

FLAMMABLE

Fuels and their vapors are extremely flammable.

Introduction Safety Warnings

OFF

ELECTRICITY

High voltage exists in, and is supplied to, the device. A potential shock hazard exists.

NO OPEN FLAMES

Open flames from matches, lighters, welding torches, etc. can ignite fuels and their vapors.

NO VEHICLES

Moving vehicles in the area during service can create a potential for personal injury to you or others. Sparks from starting vehicles can ignite fuels and their vapors.

CLEAN WORK AREA

Dispose of fuel soaked materials properly and not into trash barrels that may be used by customers.

WAR N ING

Heed the adjacent instructions to avoid damage to equipment, property, environment or personal injury.

TURN POWER OFF

Live power to a device creates a potential shock hazard. Turn Off power to the device and associated accessories when servicing the unit.

NO SMOKING

Sparks and embers from burning cigarettes or pipes can ignite fuels and their vapors.

USE SAFETY BARRICADES

Unauthorized people or vehicles in the work area are dangerous. Always use safety cones or barricades, safety tape, and your vehicle to block the work area.

INJURY TO EYES AND SKIN

Unauthorized people or vehicles in the work area are dangerous. Always use safety cones or barricades, safety tape, and your vehicle to block the work area.

READ ALL RELATED MANUALS

Knowledge of all related procedures before you begin work is important. Read and understand all manuals thoroughly. If you do not understand a procedure, ask someone who does

Safety Warnings

WARNING

This product is to be installed and operated in the highly combustible environment of a gasoline dispenser where flammable liquids and explosive vapors may be present.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PR ECAUTION S COU LD CAUS E DAMAG E TO PR OPE RTY, ENVIRON M E NT, RESULTING IN SERIOUS INJURY OR DEATH.

The following hazards exist:

1. Electrical shock resulting in serious injury or death may result if power is on during installation and the device is improperly installed.

2. Product leakage could cause severe environmental damage or explosion resulting in death, serious personal injury, property loss and equipment damage.

Observe the following precautions:

1. Read and follow all instructions in this manual, including all safety warnings before installing this equipment.

2. Before installing this device, turn Off, tag/lock out power to the affected dispenser, including submersible pumps.

3. Evacuate of all unauthorized persons and vehicles from the work area.

4. To protect yourself and others from being struck by vehicles, block off your work area with cones, safety tape or barricades during installation or service.

5. Do not operate this equipment in hazardous locations with any securing screws or covers removed. Comply with all applicable codes including: the National Electrical Code; federal, state, and local codes; and other applicable safety codes.

Introduction Safety Warnings

Veeder-Root maintains a continuous process of product development and therefore product specifications may not be as described in this manual. Please contact the Veeder-Root office nearest you, or visit our website at www.veeder.com for information on new or updated products. Changes affecting products or procedures described in this manual will be reported in subsequent revisions.

Veeder-Root has taken every care in the compilation of this manual; however, it is the installers’ responsibility to take every precaution to safeguard themselves and others. Every person working with Veeder-Root equipment is expected to take every safety precaution possible and to have read this manual.

Deviation from the specifications contained in this manual can result in rework, delays in system installation and additional installation charges.

Contractors are advised to contact their nearest Veeder-Root office where local conditions may preclude using the specifications contained in this manual.

Introduction VaporTEK Configurations

● ● ● ●

● ●

●

VaporTEK UltraVaporTEK Basic VaporTEK Plus VaporTEK Enhanced

●

VaporTEK Pump

VDI 4205 21

BlmSchV 21st BlmSchV 21st BlmSchV

A/L Performance

GOOD BETTER BEST

VaporTEK Controller

VaporTEK Interface

MPV 10

Electronic Proportional Valve

Pulse signal required

Compatible with VDI 4205 A/L monitoring

A/L performance thru entire flow range w/1 fueling point

A/L performance with simultaneous fueling

*Site uptime

Energy efficiency

TUV certificates

VRC390/3 Controller Board

*Installation errors due to system complexity, nuisance A/L monitoring alarms, contractor visits for periodic adjustmen

ts.

●●● ●●

●●

● ●●

●●● ●● ●●● ●●

●●● ●●

●●●

●●●●

●●● ●●●●

●●●●

●●●●●●

●●

VaporTEK Configurations

VaporTEK is available in four different configurations depending on required A/L (air to liquid) performance, compatibility with localized A/L monitoring requirements and performance A/L thresholds (see table below).

• Vap orTE K B a sic

• Vap orTE K Plus

• VaporTEK Enhanced

• Vap orTE K Ultra

Introduction VaporTEK Pump Certifications & Markings

VaporTEK Pump Certifications & Markings

Safety Certification

Product ATEX IECEx

VaporTEK Pump

VaporTEK Controller N/A N/A

VRP2 Pump CML 18ATEX1245X N/A

VRM2 Motor CML 18ATEX1244X IECEx CML 18.0116X

ML 18ATEX6243X N/A

Certificates can be obtained upon request. The IECEx certificates can be obtained Online at:

http://iecex.iec.ch/

Hazardous Area Installation Instructions

1. VaporTEK Pump may be used with flammable gases and vapors with apparatus group II and temperature class T3.

VaporTEK Pump is certified for maximum operating ambient temperature of +55°C.

3. The VaporTEK Pump is equipped with a temperature cut-off switch for thermal protection.

4. The VaporTEK Pump assembly certificate number has an “X” suffix, indicating that special condit safe use

application:

ions are for

When the vapor recovery pump is used as a flame arrester in vapor recovery pipes and a separate flame arrester is not fitted, the following maximum hose and pipe lengths are permitted between the filler nozzle an the vacuum pump accordi

ng to EN13463-1 standard:

• Vapor recovery hose with an inside diameter < 10mm in the coaxial hose < 6m, or,

• Coaxial hose < 6m with an outside diameter < 38mm and fitted together with a downstream pipeline DN 15

(G 1/2) <

3m.

In addition, the tanks mentioned in Test Reports PTB Ex 05-45017 and PTB Ex 05-45027 may be installed in the DN 15 (G 1/2) pipeline at a distance of between 0.3m and 2.5m in front of the VRP2 vapor recovery pump. The pipeline between hose and tank shall have a minimum length of 0.5m.

The ambient temperature and the temperature of the fuel vapor/air mixture taken in shall remain within the temperature range -20°C to +55°C at the intake end.

Flame paths shall not be repaired or reworked.

Equipment Marking

Product ATEX/IECEx

VaporTEK Pump

Ex db IIA T3 Ga/Gb

e II 1/2 G c d Ta=55°C

Introduction VaporTEK Kits

Material Compatibility With Constituents Of The Potentially Explosive Atmosphere

The VaporTEK Pump is suitable for temporary exposure to petrol and associated vapors, ethanol blended fuels, diesel, biodiesels, LPG and associated vapors, water with minimal salt content, mild cleaning agents, AdBlue anticipated vehicle exhaust emissions, and small traces of engine oil or other lubricants which could be transferred by hand contact. The pumping unit is suitable for permanent internal exposure to vapors of petrol, ethanol blended fuels and temporary exposure to liquid fuel.

The equipment is not suitable for use where external surfaces may come into regular exposure to substances which are incompatible with any of the following materials:

• Aluminium and aluminium alloys, brass alloys, zinc plated steel, carbon/alloy steel, nitrile rubber.

TUV Certification

Product Test Standard

VaporTEK Basic VDI 4205 A/L 13.1 Goodyear Flex Steel Veeder-Root AVRN

VDI 4205 85-13.2 Goodyear Flex Steel Veeder-Root AVRN

VaporTEK Plus

VaporTEK Enhanced VDI 4205 85.13.3 Goodyear Flex Steel Veeder-Root AVRN

VaporTEK Ultra VDI 4205 85.13.4 Goodyear Flex Steel Veeder-Root AVRN

VDI 4205 85-2.172

EN 16321-1 VR2-1509/1-112EU

TUV Certificate

Number Hose Nozzle

ELAFLEX Conti ELAFLEX Slimline 2

VaporTEK Kits

VaporTEK Pump Kit - P/N 900612-001

Quantity Description

1 VaporTEK DATASHEET, P/N 576047-180

VaporTEK PUMP, P/N 900621-001

Introduction VaporTEK Kits

VaporTEK Controller Kit - P/N 900634-001

Quantity Description

1 Controller - Interface Mounting Bracket, P/N 900852-001

1 Controller - Cover, P/N 900850-001

VaporTEK Controller, P/N 900628-001

1 Controller - Label High Voltage Warning, P/N 900853-001

4 Support Post, M4.0 X 6MM LG (Plastic), P/N 579081-001

3 Hex Nut, M6 X 1, Steel, P/N 579082-001

Introduction VaporTEK Kits

Quantity Description

3 Socket Head Cap Screw M6X1 X 20MM LG, P/N 579281-001

M3.5 x 12 mm, Lockwasher M3, PH. Screw (Bracket ground), P/N 579158-001

18AWG, 3 Conductor Power Cable with Connector – 3 FT Long, P/N 900651-001

18AWG, 2 Conductor Hook Signal Cable (110-230V) – 4 FT Long, P/N 900644-001

18AWG, 1 Conductor Wire – 4 FT Long (For Grounding To Dispenser), P/N 616343-024

Introduction VaporTEK Kits

VaporTEK Interface Kit - P/N 900635-001

Quantity Description

4 Support Post, M3.5 X 4MM LG (Plastic), P/N 579080-001

1 RJ12 Cable – 3 FT Long, P/N 579084-001

1 24AWG, 8 Conductor Signal Cables – 3 FT Long, P/N 900643-001

VaporTEK Interface, P/N 900630-001

18AWG, 2 Conductor Power Cable with Connector – 4 FT Long, P/N 900652-001

VaporTEK High Voltage Relay Kit - P/N 900664-001

Quantity Description

High Voltage Relay

VaporTEK Low Voltage Relay Kit - P/N 900665-001

Quantity Description

Low Voltage Relay

Introduction VaporTEK Pump Characteristics

VaporTEK Pump Characteristics

1. The VaporTEK Pump is driven by the VaporTEK Controller.

2. The VaporTEK Pump has integrated flame arrestors at the inlet and outlet ports that prevent flame transmission.

3. The inlet/outlet ports have standard G ¼” female threads (ISO – 228-1).

Warning! DO NOT remove the flame arrestors. DO NOT install piping which can stress the pump housing.

4. Vapor flow is from the nozzle through the vapor pump to the UST (See Figure 2 for flow direction).

5. The following conditions must apply according to EN13463-1 for the maximum pipe and hose lengths between the nozzle and the VaporTEK Pump.

a. An inner diameter b. Coaxial hose of length

W = 140 mm

Outlet Port G 1/4”

Flame Arrester (1)

≤10mm in the coaxial hose of length ≤6m, OR

≤ 6m with an outer diameter ≤38mm together with a DN15 pipe (G ½”), length ≤ 3m.

65 mm

Sensor Cable

M22 x 1.5,6g Hex Cable Retainer (2)

Flame

rresters (2)

Inlet Ports G 1/4” (2)

VaporTEK Pump Specifications

Function Description

Flow medium Gasoline vapor Flame Arrestors Type: Ex IIA; Inlet & Outlet Ports Mounting Four M6 X 1 Mounting Boss (Either side of the pump) Motor Type Synchronous BLDC (Brushless DC) Motor Voltage (Single Phase) 230 VAC (±10%) Frequency 50/60 Hz Amps 1.2 A

Motor Cable

65 mm

Flow Direction to UST

Figure 2. VaporTEK Pump Dimensions

L = 245 mm

Mounting Boss (4) Both Sides (M6 x 1)

H = 235 mm

Introduction VaporTEK Controller

Function Description

Motor Speed 2500 rpm max. Maximum flow rate Up to 120 lpm Noise Level 59 dB (A)

VaporTEK Controller

The VaporTEK Controller board is shown in Figure 3. Mode selections for the VaporTEK Controller board require a jumper in the JP4 position(s) shown below:

Mode Selection Jumpers in JP4

Configuration Type VaporTEK Controller Input Type

Vap orTEK Basic VaporTEK Enhanced VaporTEK Ultra

Vap orTEK Plus Pu lse Si gnal YesNoNoNoNo

High Voltage Hook Signal No

Low Voltage Hook Signal YesNoNoNoNo

0 1 2 3 4

Ye s Ye s N o N o

Introduction VaporTEK Controller

Jumper JP4

0 - 4

Sensor

Connection

Motor

Connection

Input

Power

230VAC

110-230 VAC

Dispenser

Hook Signals

RJ12

(For Low Voltage

Hook Signal Or

Liquid Pulse Input)

NE P M1 M2

POT

Figure 3. VaporTEK Controller

Introduction VaporTEK Interface

VaporTEK Interface

The VaporTEK Interface is a dual-sided board which provides an electrical interface between the fuel dispenser and the VaporTEK Controller. The VaporTEK Interface has four input channels per side which can be configured as pulse train, low voltage nozzle hook signals (0-24V) and diesel disable inputs.

For the pulse input configuration, a fuel flow rate higher than 6 liter/min is required for the VaporTEK Controller to start the VaporTEK pump.

The VaporTEK Interface board is shown in Figure 4.

Encoder Power Outputs

Power Supply Ratings

Voltage: 8 to 24VDC Current: 20mA@24V

24 VDC

Power Supply

Voltage: +5VDC

Current: 10mA@20°C)

+++

+ + – –

SIDE B - 4 channels (P1B to P4B) Liquid Pulses or 0-24VDC Hook Signals

USB Connector

Encoder Power Outputs

Voltage: +5VDC

Current: 10mA@20°C)

RS-422

Connector

RJ-12

Connector

+++

SIDE A - 4 channels (P1A to P4A) Liquid Pulses or 0-24VDC Hook Signals

Figure 4. VaporTEK Interface

Introduction VaporTEK Interface

V15 LED Input 1B V11 LED Input 2B

V20 LED Input 3B V19 LED Input 4B

RS-422 Connector

USB

Connector

RJ-12 Connector

V9 Run LED

V4 Power LED

V8 Error LED

VEEDER-ROOT

VaporTEK interface

V17 LED Input 1A V24 LED Input 2A V23 LED Input 3A V14 LED Input 4A

V13 Rx LED V12 Tx LED V10 Flash LED

J1 Flash Jumper

VaporTEK Interface I/O

I/O Interface Description Function

USB Connection between laptop and

Diagnose or setup VaporTEK Interface using laptop

VaporTEK Interface

RJ12 Connection between VaporTEK Inter-

face and VaporTEK Controller

Transmits pulse rate or low voltage hook signal information to the VaporTEK Controller

RS422 Connection to FB1 Terminal Used to perform system calibration with hand held FB1 Terminal

VaporTEK Interface LEDs

Figure 5. VaporTEK Interface LEDs

Vap orTE K LEDs

LED Function Description

V4 Power Status Illuminates when the internal 24V power is present.

Side A Input Status V17 V24 V23 V14

P1A

P2A

P3A

P4A

Illuminate when input voltage is between 4V- 24VDC, Off when input voltage is less than 4VDC

Introduction VaporTEK Interface

LED Function Description

Side B Input Status V15 V11 V20 V19

P1B

P2B

P3B

P4B

Illuminate when input voltage is between 4V- 24VDC, Off when input voltage is less than 4VDC

V12 V13

V9 Run Status

Communication

Status

Both LEDs flash simultaneously when communicating properly. Any other status for the LED means communication to the VaporTEK Controller has been interrupted.

LED flashes with “1sec On-Off cycle” when there is no transaction. It starts flashing faster during an active fuel transaction. (Flow rate > 6 l/min).

V8 Error Status Normal operation is OFF. When it flashes, a communication error has occurred.

V10 Programming LED Engineering use only.

J1 Flash Jumper Engineering use only.

Introduction VaporTEK Pump Configuration

VaporTEK Pump Configuration

The VaporTEK Pump can be configured to operate in either a 2-Speed or a Variable-speed mode depending on the configuration type and available dispenser inputs/signals.

Vap orT E K

Configuration

Basic,

Enhanced, and

Ultra

Input Type

High Voltage Hook Signal (110-230VAC)

High Voltage Hook Signal (220/240VAC)

Low Voltage Hook Signal

(0-24VDC)

Mode of

Operation

Two Speed VaporTEK Controller

Two Speed

Required

Components

VaporTEK Controller, Switch Relay

VaporTEK Controller, VaporTEK Interface

Method of Operation

The VaporTEK Controller receives nozzle hook signals from either side of the dispenser.

With one fueling point active, the pump operates in low speed. With two fueling points active, the pump operates in high speed.

In this configuration a high voltage hook signal from either side of the dispenser operates a relay switch which in turn control’s the high voltage input to the Vapor TEK Controller.

Note: One relay switch is required for each gasoline nozzle in the dispenser.

With one fueling point active, the pump operates in low speed. With two fueling points active, the pump operates in high speed. This configuration is typically used for Multi Product dispensers with high voltage hook signals and more than one nozzle grade per side

The VaporTEK Interface receives low voltage hook signals from either side of dispenser and transmits this signal to the VaporTEK Controller.

With one fueling point active, the pump operates in low speed. With two fueling points active, the pump operates in high speed.

Refer to VaporTEK Wiring section to set up low voltage liquid pulse inputs.

Plus

Low Voltage Hook Signal

(0-24VDC)

Liquid Pulse Signal

Two Speed

Variable Speed

VaporTEK Controller, Switch Relay

VaporTEK Controller, VaporTEK Interface

In this configuration a low voltage hook signal from either side of the dispenser operates a relay switch which in turn controls the high voltage input to the VaporTEK Controller.

Note: One relay switch is required for each gasoline nozzle in the dispenser.

VaporTEK Interface receives liquid pulses from an active encoder (from either side of the dispenser) and calculates the petrol flow rate. This flow rate value is then transmitted to the VaporTEK Controller to determine the pump speed.

Refer to VaporTEK Wiring section to set up pulse rate inputs.

Installation

OFF

VaporTEK Pump

Before installing this device, turn off, tag/lock out power to the dispenser.

1. Remove the dispenser’s hydraulic cabinet sheet metal doors to access the dispenser hydraulics area.

2. Find a suitable location to install the VaporTEK Pump.

3. Ensure correct orientation of the pump, suction ports and discharge ports prior to installing in the dispenser. See Figure 6 for allowable VaporTEK Pump orientations (red arrows indicate direction of flow). Also ensure the electrical cables of the VaporTEK Pump’s location will reach the VaporTEK Controller installed in the electronic cabinet of the dispenser (Unclassified Area).

4. After identifying the desired pump orientation, secure the VaporTEK Pump onto the dispenser support structure. Excessive vibration may require additional support and vibration mounts to secure the VaporTEK Pump.

5. Route the two cables (Motor and Signal) from the VaporTEK Pump into the dispenser’s electronic cabinet. Tie wrap the cables neatly and securely against fixed support members away from moving parts.

6. Reinstall and secure the lower hydraulic doors.

Installation VaporTEK Pump

Preferred Pump Installation

Orientation

Fins Down

Acceptable Pump Installations

Orientation

Fins Up Motor Facing

Incorrect Pump Installation

Motor On Top Motor Down

Figure 6. VaporTEK Pump Installation Orientations

Installation VaporTEK Controller and VaporTEK Interface

OFF

VaporTEK Controller and VaporTEK Interface

Before installing this device, turn off, tag/lock out power to the dispenser until all steps in this section are complete.

The VaporTEK Controller and VaporTEK Interface must be installed in the non-hazardous location of the dispenser (unclassified area), and protected from weather.

1. Mount the VaporTEK Controller board to the sheet metal bracket 900852-001 with the 4 stand offs (579081-

001) from the kit (Figure 7).

Figure 7. Mount The VaporTEK Controller To The Inside Of The Support Bracket

Figure 8. VaporTEK Motor/Sensor Connector’s Labeling And Poke Yoke

Installation VaporTEK Controller and VaporTEK Interface

2. Mount the VaporTEK Interface board to the new sheet metal bracket 900852-001 with the 4 stand offs (579080-001) from the kit (Figure 9).

Figure 9. Mount The VaporTEK Interface To The Back Side Of The Support Backet

3. Attach VaporTEK Controller/Interface sheet metal bracket 900852-001 to the dispenser with M6 socket head bolt and M6 nut (Figure 9).

4. Plug the VaporTEK motor and sensor connectors to the VaporTEK Controller board (Figure 7).

5. Attach the motor ground wire to the sheet metal bracket with M3 screw (579158-001) included in the kit (Figure 7).

6. Plug the RJ12 cable socket to the VaporTEK Controller (Figure 7).

7. Attach the 900651-001 input power cables to the VaporTEK Controller (Black: phase; White: Neutral; GreenYellow: Ground) and attach the Green-Yellow ground wire with the ring terminal to the sheet metal bracket with M3 screw (579158-001). The other end of the cable should be connected to the 230V power source (Figure 7).

8. Plug the 24V cable with connector to the VaporTEK Interface board (Figure 9).

9. Plug the Pulse Side B cables with connector to the VaporTEK Interface (Figure 9).

10. Plug the Pulse Side A cables with connector to the VaporTEK Interface (Figure 9).

11. Plug the RJ12 cable socket to the VaporTEK Interface (Figure 9).

Installation VaporTEK Controller and VaporTEK Interface

12. Attach the cover 900851-001 included in the kit (Figure 10.).

Figure 10. Attach The VaporTEK Controller Safety Cover

13. Use M6X12 socket head screw (579281-001) & M6 nut (579082-001) to attach the cover to the bracket (Figure 10).

14. Paste the High Voltage warning label 900853-001, included in the kit (Figure 10).

15. if the controller bracket mounting base plate is not grounded, connect the 18AWG, 1-conductor cable (616343-024) from the VaporTEK Controller kit as the ground wire between the mounting bracket and the dispenser frame (use ground screw and nut included in the kit).

Wiring Schematics

VaporTEK Wiring

1. Depending on the configuration used to actuate the pump, follow steps 2, 3, 4, 5 or 6.

2. VaporTEK with High Voltage Hook Signal (see Figure 11)

a. Refer to the dispenser manufacturer’s manual, to determine where to tap into the 110-230 VAC hook

signal. Using the 18AWG, 2 conductor cable included in the VaporTEK Controller Kit, connect the hook signal from Side A to M1 on the VaporTEK Controller and connect the hook signal from Side B to M2.

b. Set two jumpers in positions 1 and 2 on JP4 (see Figure 11).

3. VaporTEK with Low Voltage Hoo k Signal - Requires VaporTEK Interface Kit (see Figure 12)

a. Refer to the dispenser manufacturer’s manual, to determine the dispenser type (Blended or Multi product),

the number of available nozzle hooks and where to tap into the hook signals (0-24VDC).

b. The VaporTEK Interface can be connected to a maximum of four nozzle hooks per side.

c. Connect the available nozzle hook signal inputs to the VaporTEK Interface using 24AWG, 8 conductor

signal cables included in the Kit. (Note: 2 conductors used per hook signal input, see wiring diagram in Figure 13.)

d. Set one jumper in position 0 on JP4 (see Figure 12).

4. VaporTEK with Pulse Signal - Requires VaporTEK Interface Kit (see Figure 12).

a. Refer to the dispenser manufacturer’s manual, to determine the dispenser type (Blended or Multi product),

the number for available pulse signals and where to tap into the pulse signals.

b. The VaporTEK Interface can be connected to a maximum of 4 pulse signals per side.

c. Connect the pulse signal inputs to the VaporTEK Interface using the 24AWG, 8 conductor signal cables

included in the Kit. (Note: 2 conductors used per pulse signal input, see wiring diagram in Figure 14.)

d. Set one jumper in position 0 on JP4 (see Figure 12).

Wiring Schematics VaporTEK Wiring

3 1 2 4

G 1 2 3 4

Set JP4

1 and 2

Sensor

Cable

Motor Cable

MAIN POWER

Phase - 230 VAC

VaporTEK

Pump

DISPENSER SIDE 2

High Voltage Hook signal

(110 - 230 VAC)

PE N L M1 M2

VaporTEK Controller

DISPENSER SIDE 1

High Voltage Hook signal

(110 - 230 VAC)

Attach the motor ground wire ring terminal to the sheet metal bracket with M3 screw from the kit.

POT

RJ-12

LEGEND:

PE - Protected Earth N - Neutral L - Main Phase 230 VAC JP4 - Jumpers (0 - 4) POT - Potentiometer (speed/gain control) M1 - Side 1 High Voltage hook signal M2 - Side 2 High Voltage hook signal

Figure 11. VaporTEK System - High Voltage Hook Signal Input

Motor

Cable

3 1 2 4

G 1 2 3 4

Attach the motor ground

wire ring terminal to the

sheet metal bracket with

Sensor

M3 screw from the kit.

Set JP4 to 0

Cable

Pump

VaporTEK

MAIN POWER

RJ12 Cable

Phase - 230 VAC

PE N L M1 M2

VaporTEK Controller

Terminal

FB1 Service

—

F10

PgDn

PgUp

START

INS

F6F1F8

•

END

Home

SHIFT SPACE ENTER

Dispenser

Power Supply

24 - 28V

Figure 12. VaporTEK System - Liquid Pulse Signal and Low Voltage Hook Signal Input

(0 - 24 VDC)

Pulse or LV Hook

Signal Inputs Side 2

(0 - 24 VDC)

Signal Inputs Side 1

Pulse or Low Voltage Hook

Wiring Schematics VaporTEK Wiring

USB Cable

GND

+24 V

VaporTEK Interface

Wiring Schematics VaporTEK Wiring

Dispenser Side B

24 VDC

Power Supply

+ +

Gnd Gnd

Nozzle

Hook 1

GND

Nozzle

Hook 2

GND

Nozzle

Hook 3

GND

Nozzle

Hook 4

GND

+ GND + GND + GND + GND

Nozzle

Hook 1

Nozzle Hook2

Nozzle

Hook 3

Nozzle

Hook 4

Dispenser Side A

Figure 13. VaporTEK Interface - Low Voltage Nozzle Hook Signal Connections

Wiring Schematics VaporTEK Wiring

Dispenser Side B

Pulse 1 Gnd Pulse 2 Gnd Pulse 3 Gnd Pulse 4 Gnd

24 VDC

Power Supply

+ +

Gnd Gnd

Pulse 1 Gnd Pulse 2 Gnd Pulse 3 Gnd Pulse 4 Gnd

Dispenser Side A

Figure 14. VaporTE K Interface - Liquid Pulse Signal Connections

Wiring Schematics VaporTEK Wiring

5. VaporTEK with Low Voltage hook signal with relay switches (see Figure 15)

a. Refer to the dispenser manufacturer’s manual to determine the dispenser type (Blended or Multi product),

the number of available nozzle hooks and where to tap into the hook signal (Verify the low voltage hook signal voltage rating is 3-32 VDC).

b. Using the 18AWG, 2 conductor cable from the kit, connect each nozzle hook signal on Side A of the

dispenser to one relay circuit.

c. A High Voltage source (110-230VAC) is connected to the M1 on the VaporTEK Controller through all the

relay circuits on Side A (See Figure 17 for low voltage relay wiring diagrams).

d. Make similar connections on Side B and connect to M2 on the VaporTEK Controller.

e. Set two jumpers in positions 1 and 2 on JP4 (see Figure 15).

6. VaporTEK with High Voltage hook signal with relay switches (see Figure 16)

a. Refer to the dispenser manufacturer’s manual to determine the dispenser type (Blended or Multi-product),

the number of available nozzle hooks and where to tap them (Verify the hook signal voltage rating is 220/ 240 VAC).

b. Using the 18AWG, 2 conductor cable from the kit, connect each nozzle hook signal on Side A of the

dispenser to one high voltage relay circuit.

c. A High Voltage source (110-230VAC) is connected to the M1 on the VaporTEK Controller through all the

relay circuits on Side A (See Figure 18 for high voltage relay wiring diagrams).

d. Make similar connections on Side B and connect to M2 on the VaporTEK Controller.

e. Set two jumpers in positions 1 and 2 on JP4 (see Figure 16).

DISPENSER - SIDE A

VaporTEK

Neutral

110 - 230 VAC

Switched 2

110 - 230 VAC

+5VDC

Ground

PPU3

Power

110-230VAC

Low Voltage

Relay

Reed Contact

Switch 1

Reed Contact

Switch 2

Reed Contact

Switch 3

Distribution

Cable

Set JP4

1 and 2

POT

RJ-12

VaporTEK

Pump

L (Phase 230 VAC)

PE N L M1 M2

VaporTEK Controller

LEGEND:

PE - Protected Earth

N - Neutral

L - Main Phase 230 VAC

JP4 - Jumpers (0 - 4)

POT - Potentiometer (speed/gain control)

M1 - Side 1 High Voltage Hook Signal

M2 - Side 2 High Voltage Hook Signal

Grade 1

Low Voltage

Relay

Grade 2

Low Voltage

Relay

Grade 3

See Figure 16 for

low voltage relay

wiring diagrams

DISPENSER SIDE 2

High Voltage Hook Signal

(110 - 230 VAC)

Note: wiring similar

to side A.

PPU1 PPU2

3 1 2 4

G 1 2 3 4

Sensor

Cable

Motor

Cable

Attach the motor ground

wire ring terminal to the

sheet metal bracket with

M3 screw from the kit.

Figure 15. VaporTEK System - Low Voltage Hook Signal With Relay Switches

Wiring Schematics VaporTEK Wiring

DISPENSER - SIDE A

VaporTEK

Neutral

110 - 230 VAC

Switched 2

110 - 230 VAC

Line

Neutral

PPU3

Power

110-230VAC

Reed Contact

Switch 1

Reed Contact

Switch 2

Reed Contact

Switch 3

Distribution

Cable

Set JP4

1 and 2

VaporTEK

Pump

DISPENSER SIDE 2

High Voltage Hook Signal

(110 - 230 VAC)

L (Phase 230VAC)

PE N L M1 M2

VaporTEK Controller

LEGEND:

PE - Protected Earth

N - Neutral

L - Main Phase 230 VAC

JP4 - Jumpers (0 - 4)

POT - Potentiometer(speed/gain control)

M1 - Side 1 High Voltage Hook Signal

M2 - Side 2 High Voltage Hook Signal

POT

RJ-12

High Voltage

Relay

High Voltage

Relay

High Voltage

Relay

Grade 1 Grade 2

Grade 3

See Figure 17 for

High voltage relay

wiring diagrams

Note: wiring similar

to side A.

PPU2PPU1

3 1 2 4

G 1 2 3 4

Sensor

Cable

Motor

Cable

Attach the motor ground

wire ring terminal to the

sheet metal bracket with

M3 screw from the kit.

Figure 16. VaporTEK System - High Voltage Hook Signal With Relay Switches

Wiring Schematics VaporTEK Wiring

110 - 230 VAC

to VaporTEK

Controller

110 - 230 VAC

Power Mains

3 - 32 VDC

VaporTEK Low

Voltage Relay

Output

Gnd

013-26.eps

Low Voltage Nozzle Hook Signal Input

110 - 230 VAC

to VaporTEK

Controller

110 - 230 VAC

Power Mains

Neutral Line

013-27.eps

VaporTEK High

Voltage Relay

High Voltage Nozzle Hook Signal Input

Figure 17. VaporTEK Low Voltage Relay Diagram

Figure 18. VaporTEK High Voltage Relay Diagram

Communication Setup - VaporTEK Interface

Connection Description

OK Cancel

? X

New Connection

Name:

Enter a name and choose an icon for the connection:

VaporTEK Interface

Icon:

Setup with Laptop

Connect your laptop to the VaporTEK Interface using a USB cable (see Figure 12).

1. On your laptop, go to Start / All Programs / Accessories / Communications / HyperTerminal.

Note: “HyperTerminal” is an inbuilt program for Windows XP and earlier operating systems. It is not readily available on Windows 7 and needs to be downloaded from the internet. Also, a non-commercial program like “M16 –Terminal” can be downloaded and used instead of HyperTerminal.

Once the Hyperterminal menu screen appears, click on File in the menu bar and select New Connection.

2. In the Connection Description dialog box Name field, enter VaporTEK Interface. Click OK (see example below).

Communication Setup - VaporTEK Interface Setup with Laptop

VaporTEK Interface

Connect using:

Detect Carrier Loss

Connect To

Enter details for the phone number that you want to dial:

Enter the area code without the long-distance prefix.

Country/region:

Area code:

Phone number:

Use country/region code and area code Redial on busy

Configure...

OK Cancel

COM X

? X

Enter details for the phone number that you want to dial:

Enter the area code without the long-distance prefix.

Country/region:

Area code:

Phone number:

Use country/region code and area code Redial on busy

Port Settings

COM X Properties

Restore Defaults

OK Cancel

Flow control

Stop bits

Parity

Data bits

Bits per second

None

9600

? X

Apply

3. Select the appropriate COM port on your laptop (COM X in example below). 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.

4. In the COM Properties dialog box (COM X in the example below, set the all of the port setting fields as shown and click OK.

Communication Setup - VaporTEK Interface Setup with Laptop

ASCII Sending

ASCII Setup

OK Cancel

? X

ASCII Receiving

Send line ends with line feeds

Echo type characters locally

Line delay: milliseconds.

100

Character delay: milliseconds.

Append line feeds to incoming line ends

Force incoming data to 7-bit ASCII

Wrap lines that exceed terminal width

5. Click File in the HyperTerminal window and select Properties, then click the Settings tab to open the dialog box shown below. Double check and make sure all settings match the example below.

VaporTEK Interface Properties

SettingsConnect To

Function, arrow, and ctrl keys act as

Terminal keys

•

Backspace key sends

Crtl+H Del Crtl+H, Space, Crtl+H

•

Emulation:

Auto detect

Telnet terminal ID:

Backscroll buffer lines:

Play sound when connecting or disconnecting Allow remote host initiated file transfers Exit program upon disconnecting

Windows keys

Terminal Setup...

ANSI

500

OK Cancel

? X

Colors...

ASCII Setup...Input Translation...

6. Click the ASCII Setup button to and set the properties shown below:

7. C l i c k OK to return to the main window of HyperTerminal.

Communication Setup - VaporTEK Interface Setup with Laptop

New Connection Hyperterminal

File Edit View Call Transfer Help

Print echoCaptureNUMCAPSSCROLL9600-8-N-1Auto detectConnected 0:02:44

************************ * VaporTEK Interface * * Init-Software * * SW 1.03 (MUX) * * Chip Version M16C26A * * Device No: 000000003 * * * ************************

VaporTEK-Potentiometer is in use!

Pulse rate [Imp/l] = 136 Pulse Prescaler = 1 Pulse Prescaler x Pulse rate = 136 pulses/l

Run Status:

----------Status 1 Idle Status 2 Idle

8. On power up the current settings display:

9. Type m on your keyboard to display the following menu:

New Connection Hyperterminal

File Edit View Call Transfer Help

************************************ * VaporTEK Interface * * Init-Software * * SW 1.03 (MUX) * * Chip Version M16C26A * * Device No: 000000003 * * * ************************ ************************ * MAIN MENU * ************************

1. Show Config

2. Set Config

3. Set Factory Defaults

4. Debug Fuel Flow and Com_RJ12

5. Show Calibration Table

6. A/L - Ratio

7. Pulse - Ratio

8. Reregulation Factors

9. MUXI - Function Test h. Show Hot Keys

Please select:_

Print echoCaptureNUMCAPSSCROLL9600-8-N-1Auto detectConnected 0:02:44

Communication Setup - VaporTEK Interface Setup with Laptop

1. Show Config

--------------****** Inputs ****** Side A Side B 1 Pulse Input 1 2 Pulse Input 2 3 Pulse Input 3 4 Pulse Input 4

VaporTEK-Potentiometer is in use!

2. Set Config

--------------****** Inputs ****** Side A Side B 1 Pulse Input 1 2 Pulse Input 2 3 Pulse Input 3 4 Pulse Input 4

VaporTEK-Potentiometer is in use!

Input 1 what type?(1-Pulse,2-Nozzle):1 Input 2 what type?(1-Pulse,2-Nozzle):1 Input 3 what type?(1-Pulse,2-Nozzle, 3-D_Disable):2 Input 4 what type?(1-Pulse,2-Nozzle, 3-D_Disable):3

you’ve set Input(s) as a Nozzle Input what logic do you need H or L active? (0=l, 1=H):1

Please select the VaporTEK Control Mode (0 = Potentiometer, 1 - Auto Calibration Tables):1

Config has been stored successfully

****** Inputs ****** Side A Side B 1 Pulse Input 1 2 Pulse Input 2 3 Nozzle Input 38l/min(H) 3 4 Diesel disable Input(H) 4

Auto Calibration Tables are in use!

10. Show Config: Press 1 Shows the input configuration currently set.

11. Set Configuration: Press 2

a. Choose “Input Type”: Press 1 for “Pulse”, Press 2 for “Nozzle” or Press 3 to select “Diesel Disable” on

Inputs 3 & 4.

b. Select “Nozzle Logic” in case a nozzle input has been chosen: Press 0 for “L – Low”, Press 1 for “H –

High”.

c. Choose “Control Mode”: Press 0 for “Potentiometer” - The A/L Ratio is controlled adjusting the Pot

setting on the VaporTEK Controller or Press 1 for “Auto Calibration tables” - The A/L Ratio is controlled by the auto calibration tables in the VaporTEK Interface.

The control mode will be set automatically to ‘Auto Calibration Table’ mode when the auto calibration has been accomplished. Please consider that the auto calibration needs to be accomplished for each side separately.

Communication Setup - VaporTEK Interface Setup with Laptop

4. Debug Com_RJ12

-----------------Press ‘f’ to toggle to real time fuel flow Press ‘d’ to debug RJ12 Com Port Messages Press ‘t’ to toggle between flow and speed messages

5. Calibration Table

--------------------

MP Flow A Flow B Speed [No] [l/min] [l/min] [rpm]

-------------------------- 0 0 0 0 1 4 4 80 2 8 8 160 3 12 12 240 4 16 16 320 5 20 20 400 6 24 24 480 7 28 28 560 8 32 32 640 9 36 36 720 10 40 40 800 11 44 44 880 12 48 48 960 13 52 52 1040 14 56 56 1120 15 60 60 1200

12. Set Factory Defaults: Press 3

This function sets all configuration parameter into default conditions.

• All inputs are pulse inputs

• The Pulse Ratio is set to 136p/l

• The A/L - Ratio is set to 100% and the Speed offset is set to 0

• The control mode is set to Potentiometer

1. Set Factory defaults

-----------------------Are you sure? [Y.N]:N!

13. Debug Fuel Flow and Com_RJ12: Press 4

This sub-menu allows a debug mode selection. If fuel flow debug mode is selected the screen will show the fuel flow rate when a transaction is running. Pressing f again will disable the flow debug mode. During flow debug mode no other mode can be activated.

Press d to activate Com port message prints to the VaporTEK – Controller. This feature is useful to analyze the quality of communication between VaporTEK – Interface and VaporTEK – Controller. To toggle between speed and flow message press t. Both messages should be supported by the VaporTEK – Controller.

14. Show Calibration Table: Press 5

Displays factory set calibration table when connected for the first time; thereafter shows the latest calibrated table.

Communication Setup - VaporTEK Interface Setup with Laptop

6. A/L - Ratio

-----------------Recover-Ratio Speed-Offset 104% 1

do you want to change it [Y/N]? Y Recover Ratio = 104 new Ratio = 100 Speed Offset = 1 new Offset = 0

Data have been written successfully

Recover-Ratio Speed-Offset 100% 0

7. Pulse - Ratio

-----------------Pulse rate [Imp/l] = 100 Pulse Prescaler = 1 Pulse Prescaler x Pulse rate = 100 pulse/1

do you want to change these [Y/N]? Y

Input Pulse Ratio [pulse/l] (10 - 250):132 Neuer Impulsvorteiler(1...10):1

Data have been written successfully

Pulse rate [Imp/l] = 132 Pulse Prescaler = 1 Pulse Prescaler x Pulse rate = 132 pulse/1

8. Show Reregulation faxtors

---------------------------side A = 100 side B = 100

do you want to change these [Y/N]? N

15. A/L – Ratio: Press 6 Sub item 6 can be used to modify the A/L – Ratio. Set A/L – Ratio according to value which is mentioned on the certificate. NOTE: Set Speed Offset to "0”.

16. Pulse – Ratio: Press 7 This sub items allows a modification of Pulse Ratio. The pulse ratio defines the fuel flow rate which has to match the dispenser flow rate. Refer to the dispenser manufacturer’s manual to input the correct pulse ratio.

17. Reregulation factors: Press 8 Use item 8 to review the reregulation factors those will be controlled by the intelligent reregulation of monitoring. The permitted reregulation range is (85 – 125)%. A factor value of 100 represents 100%.

18. Function Test - menu option 9 Do not select - the function test requires special testing equipment and is for factory use only.

19. Show Hot Keys: Press h This item shows all other available hot keys.

Communication Setup - VaporTEK Interface VaporTEK Interface for Input Configuration

**** Hot-Keys ****

---------------------------‘m’ show the Main Menu ‘h’ show this Help Menu ‘f’ toggle ON/OFF real time fuel Flow ‘d’ debug ON/OFF RJ12 Com Port messages ‘t’ toggle between flow/speed messages

VaporTEK Interface for Input Configuration

The VaporTEK Interface has four inputs per side and each of them can be configured separately. This configuration setup applies to both sides of the dispenser. For instance if the Input 1 is configured as a pulse input, then Input 1 side A and B are set to the same input configuration.

It is recommended that you determine the current configuration before making changes. As explained in the previous section, type m in the HyperTerminal to retrieve the VaporTEK Interface Menu.

Press 1 “Show Config” to determine the current configuration. If this setup doesn’t match the system application, change the configuration by pressing 2 “Set Config” (see Figure 19).

When in the Set Config screen, all four Inputs can be configured as either Pulse or Nozzle by pressing 1 or 2 respectively. Inputs 3 and 4 can also be configured as Diesel Disable by pressing 3 (see Figure 19).

1. Pulse Input: VaporTEK pump starts only with fuel flow (>6 liters/min) Liquid pulses from an active encoder calculates the petrol flow rate. This flow rate value is then transmitted to the VaporTEK Controller to operate the pump. NOTE: Set any unused inputs as “pulse input” to avoid malfunction on these inputs.

2. Nozzle Input: VaporTEK pump starts when nozzle hook signal is energized. In order to setup the correct nozzle logic when nozzle is removed from the cradle, the logic signal needs to be identified as either high (H) or low (L) as shown in the table below.

Remove The Nozzle And Measure Its Status

Voltage, Or Check Its VaporTEK Interface

Nozzle Status Voltage

(Logic Signal)

Nozzle Status LED

VaporTEK Interface

Nozzle Status LEDs:

V17, V24, V23, V14,

V15, V11, V20 and

V19 (see Figure 5)

Nozzle

Input

Selection Remarks

> 4VDC ON H The active nozzle Logic = High (H)

< 1VDC OFF L The active nozzle Logic = Low (L)

Note: An open input is always on low (L) state.

3. Diesel disable Input: VaporTEK pump will never start. This option suppresses the diesel signal. When a pulse train output from the encoder sends all gasoline grade and diesel signals, the diesel nozzle hook signals are connected to the VaporTEK Interface and set to “Diesel Disable”. In this configuration when diesel hook is activated, all generated flow rate will be ignored. If this input becomes active (H or L), the VaporTEK Interface will ignore the incoming pulse train and any active nozzle inputs for the dedicated side.

Communication Setup - VaporTEK Interface VaporTEK Interface for Input Configuration

2. Set Config

--------------****** Inputs ****** Side A Side B 1 Pulse Input 1 2 Pulse Input 2 3 Pulse Input 3 4 Pulse Input 4

VaporTEK-Potentiometer is in use!

Input 1 what type?(1-Pulse,2-Nozzle):1 Input 2 what type?(1-Pulse,2-Nozzle):1 Input 3 what type?(1-Pulse,2-Nozzle, 3-D_Disable):2 Input 4 what type?(1-Pulse,2-Nozzle, 3-D_Disable):3

you’ve set Input(s) as a Nozzle Input what logic do you need H or L active? (0=l, 1=H):1

Please select the VaporTEK Control Mode (0 = Potentiometer, 1 - Auto Calibration Tables):1

Config has been stored successfully

****** Inputs ****** Side A Side B 1 Pulse Input 1 2 Pulse Input 2 3 Nozzle Input 38l/min(H) 3 4 Diesel disable Input(H) 4

Auto Calibration Tables are in use!

Figure 19. Set Configuration Example

VaporTEK Calibration

Note: Refer to dispenser manufacturer’s manual for VaporTEK system commissioning before conducting the A/L calibration procedure.

Manual Calibration using the POT on the VaporTEK Controller board

The flow rate of VaporTEK pump can be adjusted by changing the position of the POT setting in the VaporTEK Controller. The flow rate will increase as the POT is rotated CW from 1 to 8 (see Figure 20).

To adjust the POT (potentiometer) on the VaporTEK Controller use a non-conductive mini-screwdriver until the desired flow rate is achieved. Note: changing the pot position impacts both low and high speeds.

Warning! Use a non-conductive screwdriver while setting the POT.

Figure 20. POT (Potentiometer)

VaporTEK Calibration Dry Calibration - A/L Adjustment

Dry Calibration - A/L Adjustment

A/L adjustment using dry calibration can be performed only with the VaporTEK Plus or VaporTEK Ultra configurations.

Equipment Required

FB1 hand held terminal with 15-pin to RS422 cable

•

• Gas meter

• A/L nozzle adapter (varies by nozzle manufacturer)

• Hoses

Initial Setup

1. Verify power is available at the VaporTEK Interface by confirming V4 LED is RED (see Figure 5).

2. Connect the FB1 Terminal to the RS422 connector on the VaporTEK Interface (see Figure 21).

3. Connect the gas meter encoder cable to the FB1 Terminal.

4. Connect the hoses to the gas meter.

5. Remove the nozzle from the dispenser holder and secure the A/L nozzle adapter to the spout of either the ARVN or Elaflex nozzle as appropriate. The A/L adapter o-rings prevent air leakage into the nozzle’s vapor collection holes (see nozzle close up detail in Figure 21). After ensuring the nozzle shutoff port is not covered by the adapter body, tighten the two knurled end rings to secure the adapter to the nozzle.

6. See manufacturer’s nozzle manual on method to open the nozzle vapor valve for dry calibration.

7. FB1 Terminal key description:.

START Power ON the FB1 Terminal

ENTER Confirm selection

SHIFT Cancel selection

VaporTEK Calibration Dry Calibration - A/L Adjustment

(

)

(

)

(

)

Dir

Connect vapor flow meter to barbed fitting on adapter

AVRN Nozzle

Vapor collection holes

Nozzle hold-open clip

Nozzle shutoff port (don’t cover)

Tighten rings (2)

O-rings (2)

RS-422

Connector

Elaflex Nozzle

Air

flow

Gas Meter

Home

END

•

SHIFT SPACE ENTER

INS0—

PgDn

4 5

PgUp

9 8

F9F4F10

F7F2

START

Figure 21. Calibration Setup

VaporTEK Calibration Gas Meter Calibration

* Gasmeter** Calib. factor Cur : 05 New : 07

ENTER

Gas Meter Calibration

Gas meter calibration must be completed before conducting simulation.

1. Press the Start button until below screen appears. Press the keys as shown:

*** SERVICE *** SAL – pump (1) S&B – pump (2) GIL – pump (3)

2. When the display below appears, press the keys shown:

*** SERVICE *** Gas measuring (1)

SYS–Identify (2) EC2000 (3)

3. When display below appears, press the key shown:

VAPOR CONTROLLER * Gas measuring * Tot : 000,0 liter

Cur : 000,0 l/min

4. Match the calibration factor on the gas meter (see Figure 15) with the following display on the FB1 Terminal. If the calibration factor already matches, press ENTER. If not, press F2 to change the calibration factor.

* Gasmeter** Calib. factor Cur : 05

Change with F2

5. When display below appears, input the calibration factor shown on the gas meter (example: 07 is now the New factor) and press ENTER.

Refer to the Burkert Gas meter product manual for the calibration factor. It is typically marked “K-Factor” (see Figure 22).

VaporTEK Calibration Pulse Rate Setup With FB1 Terminal

Kal Faktor 7

Figure 22. Locate the Burkert Gas Meter Calibration Factor

Pulse Rate Setup With FB1 Terminal

Pulse rate setup on VaporTEK Interface

The VaporTEK Interface receives pulses from an active encoder and calculates the current flow rate by using of the adjusted pulse rate - Range: 50 to 200 Pulses/liter (1 US Gallon = 3.785 liters). For example, the pulse rate for a VaporTEK Interface should be set to 136 pulses/litre for Gilbarco Encore 500S.

If the dispenser is running, the FB1 Terminal will show the current petrol flow rate on the FB1’s display by using the FB1 - Sub menu item “Petrol flow (3)” (see step 4 below).

The pulse rate adjustment can be setup either using the service terminal FB1 connected to the VaporTEK Interface, or a Laptop connected to the VaporTEK Interface.

Pulse Rate Setup with FB1

1. Switch on the FB1. Press the Start button until below screen displays, then press the keys shown:

*** SERVICE *** SAL – pump (1) S&B – pump (2) GIL – pump (3)

2. When the display below appears, press the keys shown:

*** SERVICE *** Gas measuring (1)

SYS–Identify (2) EC2000 (3)

3. When the display below appears, press the keys shown:

VaporTEK Calibration Auto-Calibration using FB1 Terminal

Press number keys to enter desired pulse rate, e.g., 136

*** SERVICE *** SAL – pump (1) S&B – pump (2) GIL – pump (3)

*** SERVICE *** Gas measuring (1) SYS–Identify (2) EC2000 (3)

Service (1) Parameter (2) Autocalib (3) Simulation (4)

4. When the display below appears, press the keys shown:

10 Errors (1) Production (2) Fuel Flow (3) Impulse (4)

5. When the display below appears, if necessary to change the pulse rate, press the keys shown:

VAPOR CONTROLLER Pulse assignment Cur: 050 Change with F2

6. Enter Pulse Rate 136 for Encore 500S/500/300 dispensers.

Auto-Calibration using FB1 Terminal

1. Press the Start button until below screen appears. Press the keys as shown:

2. When the display below appears, press the keys shown:

ENTER

3. When the display below appears, press the keys shown to start the auto-calibration:

VaporTEK Calibration Auto-Calibration using FB1 Terminal

Service (1) Parameter (2) Autocalib (3) Simulation (4)

Select Side Side 1 (1) Side 2 (2)

**Adjustment** Rate 100 % Offset 001 Change with F2

Auto Calibration Side: 1 Test point: 15 Vap: 048.00 l/min

VAPOR CONTROLLER Rate 99.5 % Set 40.0 l/min Cur 39.8 l/min

4. At the display below, select the dispenser side (1 or 2) that you want to calibrate:

1 2

5. Set the A/L Ratio rate:

6. Wait while the auto-calibration is calibrating through 15 points:

The auto calibration procedure will complete at test point 1.

After the auto-calibration has been accomplished the result of calibration needs to be verified using dry simulation. Follow the steps 1- 6 of the Simulation section and verify the A/L – Ratio which is shown as “Rate”:

The Rate as displayed on the FB1 Terminal shall be within the legislated range established by local regulation.

VaporTEK Calibration Simulation with FB1 Terminal

Service (1) Parameter (2) Autocalib (3) Simulation (4)

Simulation Max 40 l/min (1) Max 35 l/min (2) Free Input (3)

Simulation with FB1 Terminal

1. Press the START green button on the FB1 Terminal until the below screen appears. Press the keys as shown:

*** SERVICE *** SAL – pump (1) S&B – pump (2) GIL – pump (3)

2. When the display below appears, press the keys shown:

*** SERVICE *** Gas measuring (1)

SYS–Identify (2) EC2000 (3)

3. When the display below appears, press the keys shown to start the simulation:

4. At the display below, select the dispenser side (1 or 2) that you want to simulate:

5. At the display below, select the simulation rate of petrol you want to check by pressing the keys shown:

When the flow rate input is provided through the FB1 Terminal the VaporTEK pump will start if greater than 6 liters/minute. The flow rate achieved by the VaporTEK Pump will be displayed in the FB1 Terminal.

6. The FB1 Terminal will start the simulation and display the results as in the example below:

Select Side Side 1 (1) Side 2 (2)

1 2

2 3

VaporTEK Calibration Simulation with FB1 Terminal

VAPOR CONTROLLER Rate 99.5 % Set 40.0 l/min Cur 39.8 l/min

Where:

- Rate is the ratio of current vapor flow (Cur) divided by the simulated petrol flow (Set).

- Set is the simulated petrol flow established in Step 5 above. NOTE: Set value must be greater than 6 lpm to

start the VaporTEK Pump.

- Cur is the vapor or air flow measured by the gas meter.

Adjust the POT until the Rate as displayed on the FB1 Terminal is within the legislated range established by local regulation (see Figure 20).

VaporTEK Pump Troubleshooting and Quick Help

Troubleshooting and Quick Help

Problem Cause Corrective Procedure

Electrical system fuse or circuit breaker tripped Replace fuse or reset the breaker

No power to VaporTEK Controller

F1 fuse blown out on the VaporTEK Controller Replace Controller if F1 fuse blown out.

Verify power circuit breaker is switched on. Restore input power. Verify input voltage rating.

Pump Fails To Start

No Power to VaporTEK Interface

wire schematic per Figure 12. Restore input power. Verify input voltage rating.

Verify the V4 light is illuminated. If not, check

F1 fuse (T250mA) blown out on the VaporTEK Interface

Replace F1 fuse rated for 250V/250mA.

Incorrect wiring will damage both VaporTEK

Pump and the Controller. Check cable connecVaporTEK Pump and VaporTEK Controller wired incorrectly

tions. Verify the cables are connected per the

appropriate schematic in the Equipment Wiring

Schematics Section. Replace both VaporTEK

Pump and Controller if wired incorrectly.

Verify wiring connection per the appropriate VaporTEK Interface inputs wired incorrectly

schematic in the Equipment Wiring Schematics

Section.

No hook signal input

Verify wiring and hook signal input voltage rat-

ing.

Check pulse input wiring on VaporTEK InterNo input fuel pulses

face. Also verify input LED's (Refer VaporTEK

Interface LED section).

RJ 12 cable missing or incorrectly connected between VaporTEK interface and Controller

No Communication between VaporTEK Interface and Controller

Refer to the equipment wiring schematic and

connect RJ 12 cable.

Verify if LED V12 and V13 are flashing simulta-

neously. Defective RJ12 Cable. Replace RJ12

cable.

Pot setting too low Increase pot setting.

Pump Fails To

Start

Flow Rate below 6 lpm Increase fuel flow rate beyond 6 lpm

VaporTEK Interface inputs configured incorrectly

Blocked outlet/discharge

Configure inputs correctly. Refer to the

VaporTEK Interface setup.

Clean outlet/discharge line. Replace flame

arrestors if clogged.

VaporTEK Controller requires high voltage hook Low Voltage hook signal wired directly to VaporTEK Controller

signals (110-220 VAC). Add VaporTEK Inter-

face or Switch Relays as discussed

in“VaporTEK Pump Configuration” on page 17.

Temperature in the hydraulics area of the dispenser is below the VaporTEK pump’s rating and is creating too much starting torque friction.

Install appropriate heater as defined by the dis-

penser manufacturer.

Ambient temperature above rated temperature Pump Thermal protector Trips

of the product. Verify proper ventilation for the

VaporTEK Pump. Wait a couple of minutes

before starting the pump again.

Defective VaporTEK Controller or, if equipped, VaporTEK Interface Board

Replace VaporTEK Controller or VaporTEK

Interface Board.

Appendix A: VaporTEK System Reference Wiring Diagrams

0 1 2 3 4

MODE

JP4

COMMS

JP1

POT

ENPM1M2

JP6

+14 - 28V POWER

P1105

VAPORVAC ISOLATION

RJ12 Cable

(579084-001)

VAPORTEK INTERFACE BOARD

(900630-001)

PUMP CONTROL NODE

VAPORTEK PUMP

(900621-001)

VAPORTEK CONTROLLER BOARD

(900628-001)

6-Conductor Cable

(M12970A001)

Motor CableSensor Cable

G12 3 4

P1B

P2B

GND

P1A

P2A

GND

421 3

Mode jumper

(0 position)

P1110

SIDE B

SIDE A

ORANGE

GREEN

YELLOW

RED

BLACK

BROWN

Attach the ground terminal to the corner of the controller board’s mounting bracket .

FB1

Terminal

LAPTOP

USB 2.0 A-Male, to B-Male Cable

15 pin Serial RS-422 Cable

CAUTION: Motor and Sensor cable connectors are keyed to avoid interchangeability. Cross connection may damage the VaporTEK Controller and the pump.

F7F2

F9F4F10

Home

4 5

END

INS0—

•

SHIFT SPACE ENTER

START

PgUp9

PgDn

Figure A-1. VaporTEK System Plus For Collection Only - Encore 500S Dispenser

A-1

Gilbarco, Inc. 24V 135W

TB3

Check Fuses on Fuse Module before replacing

Power Supply

This cover MUST

be replaced upon

completion of

servicing

HIGH

VOLTAGE

WARNING

TB3

VAPORTEK INTERFACE BOARD

(900630-001)

VAPORTEK CONTROLLER BOARD

(900628-001)

VALVE BOARD

POWER SUPPLY

Ground wire

connect to

“C” channel

P1200A

J1200

Ground wire

connect to

Controller

bracket using

M3 screw

2-Conductor Cable

(P/N M12083A002)

2-Conductor Cable

(P/N M05547A006)

2-Conductor Cable

(P/N M13884A001)

+24

GND

01234

MODE

JP4

COMMS

JP1

POT

PNL M1M2

JP6

BLACK

RED

WHITE

BLACK

GREEN/YELLOW

PNL

VAP OR VA C

CASH (A)

TRIND

SMRT

CASH (B)

Orange

Connector

3-Conductor Cable

(900651-001)

AC Power

Distribution Cable

(P/N M04406A001)

P1201

P1200

P1207

STEERING VALVE

P1300

J1300

J1200A

A-2

Figure A-2. VaporTEK System Plus For Collection Only - Encore 500S Dispenser

Appendix A: VaporTEK System Reference Wiring Diagrams

A-3

01234

MODE

JP4

COMMS

JP1

POT

JP6

VAPORTEK PUMP

(900621-001)

VAPORTEK CONTROLLER BOARD

(900628-001)

Motor CableSensor Cable

G12 3 4

421 3

Set J4-0

Attach the ground terminal

to the corner of the controller

board’s mounting bracket .

CAUTION:

Motor and Sensor cable connectors are

keyed to avoid interchangeability. Cross

connection may damage the VaporTEK

Controller and the pump.

NEPM1 M2

MAIN

230VAC

M12970A001

900857-001

3-Color LED Functions

Dispenser Panel

Failure Status and LED Color

3-Color LED V1

(900856-001)

3-Color LED V2

(900856-001)

VEEDER-ROOT VaporTEK

Interface with LED

(900855-001)

0 Green idle

0 green (ﬂashing) busy

> 9 Red idle

> 9 Red (ﬂashing) busy

1 - 9 Orange idle

1 - 9 Green / Orange (ﬂashing) busy

impact the front panel led color.

- Each failure during an acve transacon will increase an internal error counter and will be

Error counter Front panel LED Color Run Status

- Failure status and Led color

Each acve transacon without communicaon error between VaporTEK – Interface and

VaporTEK – Controller will reset the error counter.

Remark: An acve transacon is a transacon with a fuel ﬂow rate higher than 6l/min.

Figure A-3. VaporTEK System Plus for collection only with 3 color LED - using 900855-001 Interface Board for Encore 500S Dispenser

Appendix A: VaporTEK System Reference Wiring Diagrams

L1 N

230VAC

MAIN

01234

MODE

JP4

COMMS

JP1

POT

JP6

VAPORTEK PUMP

(900621-001)

VAPORTEK CONTROLLER BOARD

(900628-001)

Motor CableSensor Cable

G12 3 4

421 3

Set J4-1

Set J4-2

Attach the ground terminal

to the corner of the controller

board’s mounting bracket .

CAUTION:

Motor and Sensor cable connectors are

keyed to avoid interchangeability. Cross

connection may damage the VaporTEK

Controller and the pump.

NE P M1 M2

Controlled in two speed mode over

high voltage hook signal

CABLE TYPE M12970A001

CABLE TYPE

M12970A001

A-4

Figure A-4. VaporTEK System Ultra for Collection only Using VRC 390/3 Board for Encore 500S Dispenser

Appendix A: VaporTEK System Reference Wiring Diagrams

For technical support, sales or

other assistance, please visit:

www.veeder.com

Veeder-Root VaporTEK Installation, Setup And Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Figures

Introduction

Contractor Certification Requirements

Related Manuals

Safety Precautions

Safety Warnings

VaporTEK Configurations

VaporTEK Pump Certifications & Markings

Safety Certification

Hazardous Area Installation Instructions

Equipment Marking

VaporTEK Kits

VaporTEK Pump Kit - P/N 900612-001

VaporTEK Controller Kit - P/N 900634-001

VaporTEK Interface Kit - P/N 900635-001

VaporTEK High Voltage Relay Kit - P/N 900664-001

VaporTEK Low Voltage Relay Kit - P/N 900665-001

VaporTEK Pump Characteristics

VaporTEK Pump Specifications

VaporTEK Controller

VaporTEK Interface

VaporTEK Interface I/O

VaporTEK Interface LEDs

Vap orTE K LEDs

VaporTEK Pump Configuration

Installation

VaporTEK Pump

VaporTEK Controller and VaporTEK Interface

Wiring Schematics

VaporTEK Wiring

Communication Setup - VaporTEK Interface

Setup with Laptop

VaporTEK Interface for Input Configuration

VaporTEK Calibration

Manual Calibration using the POT on the VaporTEK Controller board

Dry Calibration - A/L Adjustment

Equipment Required

Initial Setup

Gas Meter Calibration

Pulse Rate Setup With FB1 Terminal

Pulse rate setup on VaporTEK Interface

Pulse Rate Setup with FB1

Auto-Calibration using FB1 Terminal

Simulation with FB1 Terminal

VaporTEK Pump Troubleshooting and Quick Help

Troubleshooting and Quick Help