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.
©Veeder-Root 2018. All rights reserved
.
Table of Contents
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
iv
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
1
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.
2
Introduction Safety Warnings
OFF
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.
3
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.
4
Introduction VaporTEK Configurations
● ● ● ●
● ●
●
●
●
●
●
●
●
●
●
●
●
VaporTEK UltraVaporTEK Basic VaporTEK Plus VaporTEK Enhanced
●
VaporTEK Pump
VDI 4205 21
st
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
5
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
C
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.
2.
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.
d
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
6
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
1 VaporTEK DATASHEET, P/N 576047-180
VaporTEK PUMP, P/N 900621-001
7
Introduction VaporTEK Kits
VaporTEK Controller Kit - P/N 900634-001
Quantity Description
1
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
8
Introduction VaporTEK Kits
Quantity Description
3 Socket Head Cap Screw M6X1 X 20MM LG, P/N 579281-001
2
1
1
1
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
9
Introduction VaporTEK Kits
VaporTEK Interface Kit - P/N 900635-001
Quantity Description
1
4 Support Post, M3.5 X 4MM LG (Plastic), P/N 579080-001
1 RJ12 Cable – 3 FT Long, P/N 579084-001
1
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
1
High Voltage Relay
VaporTEK Low Voltage Relay Kit - P/N 900665-001
Quantity Description
1
Low Voltage Relay
10
Introduction VaporTEK Pump Characteristics
A
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
11
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 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
12
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
13
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.
X4
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
X2
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
14
Loading...