Veeder-Root VaporTEK Installation, Setup And Troubleshooting Manual
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Veeder-Root VaporTEK Installation, Setup And Troubleshooting Manual

Veeder-Root VaporTEK Installation, Setup And Troubleshooting Manual

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Manual No: 577014-013
●
Revision: E
VaporTEK
Installation, Setup and Troubleshooting Manual

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Summary of Contents for Veeder-Root VaporTEK

  • Page 1 Manual No: 577014-013 ● Revision: E VaporTEK Installation, Setup and Troubleshooting Manual...
  • Page 2 Customer Service will work with production facility to have the replacement product shipped as soon as possible. If “lost” equipment is delivered at a later date and is not needed, Veeder-Root will allow a Return to Stock without a restocking fee.

  • Page 3: Table Of Contents

    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 ...........................
  • Page 4 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.

  • Page 5: Figure 1. Vaportek System Components

    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.

  • Page 6: 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;...

  • Page 7: Safety Warnings

    Introduction Safety Warnings ELECTRICITY TURN POWER OFF High voltage exists in, and is supplied to, the Live power to a device creates a potential shock device. A potential shock hazard exists. hazard. Turn Off power to the device and associ- ated accessories when servicing the unit.
  • Page 8 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.

  • Page 9: Vaportek Configurations

    Introduction VaporTEK Configurations 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). • VaporTEK Basic • VaporTEK Plus •...

  • Page 10: Vaportek Pump Certifications & Markings

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

  • Page 11: Material Compatibility With Constituents Of The Potentially Explosive Atmosphere

    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.

  • Page 12: Vaportek Controller Kit - P/N 900634-001

    Introduction VaporTEK Kits VaporTEK Controller Kit - P/N 900634-001 Quantity Description VaporTEK Controller, P/N 900628-001 Controller - Interface Mounting Bracket, P/N 900852-001 Controller - Cover, P/N 900850-001 Controller - Label High Voltage Warning, P/N 900853-001 Support Post, M4.0 X 6MM LG (Plastic), P/N 579081-001...
  • Page 13 Introduction VaporTEK Kits Quantity Description 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) –...

  • Page 14: Vaportek Interface Kit - P/N 900635-001

    RJ12 Cable – 3 FT Long, P/N 579084-001 18AWG, 2 Conductor Power Cable with Connector – 4 FT Long, P/N 900652-001 24AWG, 8 Conductor Signal Cables – 3 FT Long, P/N 900643-001 VaporTEK High Voltage Relay Kit - P/N 900664-001 Quantity Description High Voltage Relay...

  • Page 15: 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).

  • Page 16: Vaportek Controller

    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...

  • Page 17: Vaportek Controller

    Introduction VaporTEK Controller P M1 M2 Motor Jumper JP4 Sensor Connection RJ12 0 - 4 Connection Input 110-230 VAC (For Low Voltage Hook Signal Or Power Dispenser 230VAC Hook Signals Liquid Pulse Input) Figure 3. VaporTEK Controller...

  • Page 18: Vaportek Interface

    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.

  • Page 19: Vaportek Interface I/O

    VaporTEK Interface I/O I/O Interface Description Function Connection between laptop and Diagnose or setup VaporTEK Interface using laptop VaporTEK Interface RJ12 Connection between VaporTEK Inter- Transmits pulse rate or low voltage hook signal information to the face and VaporTEK Controller...
  • Page 20 Communication Both LEDs flash simultaneously when communicating properly. Any other status for Status 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 Run Status faster during an active fuel transaction.

  • Page 21: Vaportek Pump Configuration

    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. VaporTEK Mode of Required Method of Configuration Input Type...

  • Page 22: Installation

    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.

  • Page 23: Figure 6. Vaportek Pump Installation Orientations

    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...

  • Page 24: Vaportek Controller And Vaportek Interface

    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).

  • Page 25: Figure 9. Mount The Vaportek Interface To The Back Side Of The Support Backet

    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.

  • Page 26: Figure 10. Attach The Vaportek Controller Safety Cover

    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).

  • Page 27: Wiring Schematics

    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).

  • Page 28: Figure 11. Vaportek System - High Voltage Hook Signal Input

    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...

  • Page 30: Figure 13. Vaportek Interface - Low Voltage Nozzle Hook Signal Connections

    Nozzle Nozzle Nozzle Hook 1 Hook 2 Hook 3 Hook 4 24 VDC Power Supply Nozzle Nozzle Nozzle Nozzle Hook 1 Hook2 Hook 3 Hook 4 Dispenser Side A Figure 13. VaporTEK Interface - Low Voltage Nozzle Hook Signal Connections...

  • Page 31: Figure 14. Vaportek Interface - Liquid Pulse Signal Connections

    Pulse 1 Gnd Pulse 2 Gnd Pulse 3 Gnd Pulse 4 Gnd 24 VDC Power Supply Pulse 1 Gnd Pulse 2 Gnd Pulse 3 Gnd Pulse 4 Gnd Dispenser Side A Figure 14. VaporTEK Interface - Liquid Pulse Signal Connections...
  • Page 32 Using the 18AWG, 2 conductor cable from the kit, connect each nozzle hook signal on Side A of the dispenser to one relay circuit. 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).

  • Page 35: Figure 17. Vaportek Low Voltage Relay Diagram

    Output Signal Input Voltage Relay 110 - 230 VAC 3 - 32 VDC Power Mains 013-26.eps Figure 17. VaporTEK Low Voltage Relay Diagram 110 - 230 VAC VaporTEK High to VaporTEK Voltage Relay Controller 110 - 230 VAC Power Mains...

  • Page 36: Communication Setup - Vaportek Interface

    “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).
  • Page 37 Communication Setup - VaporTEK Interface Setup with Laptop 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...
  • Page 38 Communication Setup - VaporTEK Interface Setup with Laptop 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.
  • Page 39 Communication Setup - VaporTEK Interface Setup with Laptop 8. On power up the current settings display: New Connection Hyperterminal File Edit View Call Transfer Help ************************ * VaporTEK Interface Init-Software * SW 1.03 (MUX) * Chip Version M16C26A * * Device No: 000000003 *...
  • Page 40 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.
  • Page 41 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.
  • Page 42 Communication Setup - VaporTEK Interface Setup with Laptop 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”.

  • Page 43: Vaportek Interface For Input Configuration

    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.

  • Page 44: Figure 19. Set Configuration Example

    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...

  • Page 45: Vaportek Calibration

    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).

  • Page 46: Dry Calibration - A/L Adjustment

    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.

  • Page 47: Figure 21. Calibration Setup

    VaporTEK Calibration Dry Calibration - A/L Adjustment RS-422 Connector START Home PgUp PgDn — • SHIFT SPACE ENTER AVRN Nozzle Connect vapor flow meter to barbed fitting on adapter Nozzle hold-open clip Tighten Vapor collection holes rings (2) O-rings (2) Nozzle shutoff port (don’t cover)

  • Page 48: Gas Meter Calibration

    VaporTEK Calibration Gas Meter Calibration 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 –...

  • Page 49: 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.

  • Page 50: Auto-Calibration Using Fb1 Terminal

    VaporTEK Calibration Auto-Calibration using FB1 Terminal Service Parameter Autocalib Simulation 4. When the display below appears, press the keys shown: 10 Errors Production Fuel Flow Impulse 5. When the display below appears, if necessary to change the pulse rate, press the keys shown:...
  • Page 51 VaporTEK Calibration Auto-Calibration using FB1 Terminal Service Parameter Autocalib Simulation 4. At the display below, select the dispenser side (1 or 2) that you want to calibrate: Select Side Side 1 Side 2 5. Set the A/L Ratio rate: **Adjustment**...

  • Page 52: Simulation With Fb1 Terminal

    Max 35 l/min Free Input 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.
  • Page 53 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.

  • Page 54: Vaportek Pump Troubleshooting And Quick Help

    Verify power circuit breaker is switched on. No power to VaporTEK Controller Restore input power. Verify input voltage rating. F1 fuse blown out on the VaporTEK Controller Replace Controller if F1 fuse blown out. Verify the V4 light is illuminated. If not, check No Power to VaporTEK Interface wire schematic per Figure 12.

  • Page 55: Figure A-1. Vaportek System Plus For Collection Only - Encore 500S Dispenser

    Sensor Cable Motor Cable CAUTION: Motor and Sensor cable connectors are keyed to avoid interchangeability. Cross VAPORTEK PUMP connection may damage the VaporTEK Controller and the pump. (900621-001) Figure A-1. VaporTEK System Plus For Collection Only - Encore 500S Dispenser...
  • Page 56 Gilbarco, Inc. 135W...
  • Page 59 For technical support, sales or other assistance, please visit: www.veeder.com...

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