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Gallagher PULSE Series Installation Manual

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PULSE Series
Installation, Commissioning & Servicing Manual
Part No. 2A01977
Revision 19

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Summary of Contents for Gallagher PULSE Series

  • Page 1 PULSE Series Installation, Commissioning & Servicing Manual Part No. 2A01977 Revision 19...
  • Page 2 Gallagher Fuel Systems Ltd. The information in this manual is subject to change without notice. Gallagher Fuel Systems Ltd has made every effort to verify the accuracy of this manual but does not make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current.

  • Page 3: Table Of Contents

    CONTENTS PART A: GENERAL 1 ABOUT THIS MANUAL ��������������������������������������������������������������������������������������������������������������������� 8 2 NOTATIONS �������������������������������������������������������������������������������������������������������������������������������������� 8 3 PICTOGRAMS ����������������������������������������������������������������������������������������������������������������������������������� 8 4 SAFETY WARNINGS & PRECAUTIONS ������������������������������������������������������������������������������������������ 9 Hazard Warnings ..........................9 Damage Warnings ......................... 10 Information Relating to DEF (Diesel Exhaust Fluid) ................ 10 Materials Not Recommended to be used with DEF .................
  • Page 4 9 ELECTRICAL ���������������������������������������������������������������������������������������������������������������������������������� 31 General ............................31 Mains ............................31 Comms ............................31 Forecourt Communications ......................33 Float Switch Installation ......................... 34 Installing the Head Lighting ......................35 Connecting the light cable for the Illuminated Spreader ..............38 PART C: COMMISSIONING 1 OVERVIEW ��������������������������������������������������������������������������������������������������������������������������������������...
  • Page 5 10 ELECTRICAL ���������������������������������������������������������������������������������������������������������������������������������� 69 10.1 Remounting a PULSE UI Battery Pack ................... 69 10.2 Simple Wiring Diagram ........................70 10.3 Junction Box Wiring Diagrams ....................... 71 11 SD CARD CONTENT ����������������������������������������������������������������������������������������������������������������������� 72 11.1 Process for Loading Firmware onto the SD Card ................72 11.2 Configuration Reinstall ........................
  • Page 6 16.4 Calibration ........................... 107 16.5 Flow Control - FLOWCTRL......................107 16.6 Grade Priority - MAPPING ......................107 16.7 Setting Hoses Active/Inactive - HOSE ..................107 17 RATIO ERROR ������������������������������������������������������������������������������������������������������������������������������ 107 18 ADDRESSING LPG METERS - VERSION 1�20 ��������������������������������������������������������������������������� 108 19 PULSE MEDIA ��������������������������������������������������������������������������������������������������������������������������������111 19.1 Operation .............................112 19.2...
  • Page 7 Figure 22� Location of Dipswitches �������������������������������������������������������������������������������������� 49 Figure 23� LPG Electrical Schematic ������������������������������������������������������������������������������������ 53 Figure 24� LPG Electrical Schematic Using Integrated Stack Controller ����������������������������� 53 Figure 25� Target Torques for Gasket Sealing ���������������������������������������������������������������������� 56 Figure 26� Elaflex ZVA Slimline 2 Nozzle ������������������������������������������������������������������������������ 57 Elaflex ZVA DEF Nozzle and Adapter59 Figure 27�...

  • Page 8: Part A: General

    A. General B. Installation C. Commissioning D. Servicing Included are models dispensing petrol, diesel, LPG and DEF (Diesel Exhaust Fluid). NOTATIONS Comms Communication Diesel Exhaust Fluid Gallagher Gallagher Fuel Systems Limited Intrinsically Safe Printed Circuit Board Steel Wire Armoured User Interface Vapour Recovery pump Three context sensitive meanings: (a) device used to pressurise or transport a liquid.

  • Page 9: Safety Warnings & Precautions

    The system must not be modified without consulting Gallagher.  Only use genuine spare parts. PULSE dispensers are supplied by Gallagher as a fully approved system. Genuine parts as specified in the original design are integral to the correct function and safety of the system. Gallagher cannot be held responsible for any consequences of using non-genuine parts and will not support under warranty any PULSE where substitution has occurred.

  • Page 10: Damage Warnings

     Installation must only be carried out by suitably qualified and competent personnel.  Initial electrical power-up and opening of fuel supply lines must only be carried out after inspection and approval by suitably qualified and competent personnel.  Dispensers contain hazardous liquid and vapour. The instructions in this manual must be followed.

  • Page 11: Materials Not Recommended To Be Used With Def

    4.4 Materials Not Recommended to be used with DEF Gallagher Fuel Systems have seen instances where severe corrosion has occurred on  components within the Tatsuno flow meter as a direct result of the use of copper, brass, bronze or other copper alloy components within the Diesel Exhaust Fluid delivery system.

  • Page 12: Fastening Of Panel Screws

    FASTENING OF PANEL SCREWS The following applies to panels that are fastened with M6 stainless steel button screws. These screws are torqued to 5-7Nm and have an application of Loctite 243 or Loctite 248 to prevent them from self-loosening. If panels are removed at install or for servicing, then the screws need to be retorqued to 5-7Nm and must have a new application of Loctite 243 or Loctite 248 applied.* The diagrams highlight the locations of all the relevant screws that these instructions apply to.

  • Page 13: General Shipping & Transportation Information

    If any is found it should be recorded at once on the delivery documentation and MUST be notified to Gallagher in writing (email or fax) within 3 working days; It is strongly recommended that photographs of damaged packaging and equipment be sent to Gallagher to assist the claim process;...

  • Page 14: Storage

    Weight Width Depth Height Weight Width Depth Height TYPE TYPE CX 8-Hose Pump(F) CS 2-Hose Pump(S) CX 6-Hose Pump(F) CS 4-Hose Dspnsr(S) CX 4-Hose Pump(F) CS 2-Hose Dspnsr(S) CX 8-Hose Dspnsr(F) CS 4-Hose Pump(F) CX 6-Hose Dspnsr(F) CS 2-Hose Pump(F) CX 4-Hose Dspnsr(F) CS 4-Hose Dspnsr(F) CS 4-Hose Pump(S)

  • Page 15: Pulse Technical Specifications

    PULSE TECHNICAL SPECIFICATIONS Suction System 1 pump and motor per product Dedicated meter for each product hose/nozzle Standard - suction head limit 4.0m (petrol @ 25°C @ sea-level) max, includes vertical lift and losses in supply pipe lines and fittings Standard - suction head limit 5.0m (diesel @ 25°C @ sea-level) max, includes vertical lift and losses in supply pipe lines and fittings Ultra - suction head limit 3.0m maxiumum effective suction head with the T140 only for Ultra/High Diesel flow Air Separation...

  • Page 16: Part B: Installation

    Installation - Section 9.5 Float Switch Installation) 2.2 Hydraulic Pre-Installation The footprint, anchor points and perimeter of the PULSE Series are contained in the document entitled “Gallagher PULSE Series - Footprint Information.” (Part No. 2A02068) To view this document access the following website and enter the name (eg footprint manual) in the search window.

  • Page 17: Figure 3� Anchor Point Locations

    2.3.1 Anchor Point Locations Ensure that all anchor points as shown below are fastened with a M12 bolt. Dispensers are to be installed on a flat surface to ensure that the anchor bolts can be secured sufficiently. L Series C Series Q Series Figure 3�...

  • Page 18: Electrical Requirements/Regulations

    2.4 Electrical Requirements/Regulations  All cabling must comply with all relevant National and Local Acts, Regulations and Standards, and must be installed by suitably qualified personnel. A constant and quality power source is required for all PULSE dispensers in accordance with local regulations. All wiring and installation work shall comply with AS/NZS 3000.

  • Page 19: Hydraulics

    SECTION. 3.4 Vapour Recovery Vapour Recovery (VR) components are common throughout the Gallagher PULSE range. Integral models are equipped with their own vapour recovery pump. This pump’s vapour line should be connected to underground vapour lines by means of a shear valve.

  • Page 20: Series Hose Installation (Hanging)

    C SERIES HOSE INSTALLATION (HANGING) The installation of the spreader and hoses must be carried out in a specific order of steps, namely: Remove the holsters. Fit the spreader on top of the lower assembly. iii. Fit the hoses. Refitting of holsters. Hoses SHOULD NOT be fitted to the spreader prior to placing it on top of the lower assembly.

  • Page 21: Fit The Hoses

    (c) Secure with nuts and washers. 4.3 Fit the Hoses Thread the hose down through the holes in the spreader base, connecting in the following order. 1 Brass hose end 2 Three bolt flange 3 Hanger point Bolt Flange 1 Brass Hose End After threading the hose down Connect the three bolt flange.

  • Page 22: Replace The Holsters

    Hanger Point Connect the hanger points. • The clamp attached to the hose hanger point will fit to the anchor points suspended from the spreader. Secure the clamp to the anchor points using the M5 Screw and nut inside the clamp. Repeat for all hoses. Anchor points underneath the The hose clamp attached to the C-Spreader...

  • Page 23: Series Hose Installation (Retractor)

    C SERIES HOSE INSTALLATION (RETRACTOR) This process requires the following steps: Removing the spreader panels. Preparing the cable from the spring reel to be connected to the hose. iii. Removing the holster panel to allow access to connect the hose. Connecting the hoses.

  • Page 24: Prepare Spring Reel Cable For Connection To Hose

    5.2 Prepare Spring Reel Cable for Connection to Hose hole locking pin Secure the spring reel while pulling the b While maintaining the tension on cable down, until the hole in the spring the reel, secure it by inserting the reel is visible next to the metallic support.

  • Page 25: Connect The Hoses

    5.4 Connect the Hoses Once the hose is threaded into the column it requires securing in 3 places. The brass end to the column; the hose flange to the base plate of the spreader; and the hose hanger point to the hose retractor. These connection points are described with matching numbers in the diagram below.

  • Page 26: Attach The Hose Clamp To The Hose And Retractor Cable

    5.5 Attach the Hose Clamp to the Hose and Retractor Cable Prepare the clamp by using single sided tape to retain the captivated nut in place. tape 1� 2� Place the clamp around the hose sleeve and fit the cable connector between the two sides of the clamp.

  • Page 27: Refit Panels

    5.6 Refit Panels The final step is to replace the spreader panels and reconnect the holster switch before replacing the holster panel. b Fasten the Phillips screws at the top Replace front and rear spreader and the bottom of the spreader panels. panels.

  • Page 28: Nozzle Switch Connection

    NOZZLE SWITCH CONNECTION Make sure that the switch connector is correctly plugged in with the hook fully engaged under the stop. A cable tie can be used to prevent movement causing the switch to disconnect. incorrect correct cable tied Figure 4� Correct Nozzle Switch Connection CORRECT FITTING OF HOSES TO HI-ARM As shown in the illustration below, a sufficient length of hose (arrowed) must be provided...

  • Page 29: Bennett Pump Unit

    BENNETT PUMP UNIT The Gallagher PULSE uses the Bennett T140 high fl ow pumping unit on commercial Ultra High Flow pump applications. In order to maintain Warranty and avoid premature pump failure, belt damage and fuses blowing, Service and Install Technicians must be aware of the following: The pump must NEVER be run dry for periods exceeding 5 minutes as the fuel is ...

  • Page 30: Pre-Installation Check Of Rotor Movement

    8.1 Pre-Installation Check of Rotor Movement A harsh knock in transit can affect clearance between the rotor, stator and rotor cover. Before the belt is installed, test clearance by turning the pulley wheel by hand. The wheel should move freely. If it is locked up, or excessive resistance is detected, carry out the realignment procedure below.

  • Page 31: Electrical

    Any procedure that requires access to electrical components of the electronics of a dispenser/pump requires total electrical isolation of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing or servicing Gallagher equipment. Before powering up check the tightness of all terminals and plugs. ...

  • Page 32: Mains Connections

    Mains Supply 230/240 VAC, 10A, 50Hz Mains Earth Neutral Live/Phase PE N L R1 R2 R3 R4 R5 R1,R2,R3 STP Control R4,R5 Relays (L) Dispenser Mains Supply 230/240 VAC, 16A, 50Hz Mains Earth Neutral Live/Phase PE N L Single Phase Pump Figure 8�...

  • Page 33: Forecourt Communications

    NOTE that the Gilbarco setting has an additional jumper which must be removed for  the PEC protocol.  The configuration file within the dispenser must match the protocol. Contact Gallagher if this requires changing. Protocol Pins Protocol Pins JUMPER JUMPER GILBARCO Figure 10�...

  • Page 34: Float Switch Installation

    9.5 Float Switch Installation The Float Switch bracket has a hole at one end and a slot at the other. The switch is installed in the round hole, not the slot, as indicated in Figure 11. Install the Float Switch in the round hole at the bottom end of the Float Switch bracket as indicated.

  • Page 35: Installing The Head Lighting

    9.6 Installing the Head Lighting This section describes the process of installing and connecting the Head Lighting Assembly (Part Number 2A100442) inside a PULSE Head with an Advert User Interface. The Head Lighting Assembly will be supplied as shown in the following figure. Lamp holder Lighting Assembly Cable Light Mounting Bracket...
  • Page 36 Procedure The following steps describe how to install the head lighting Dome nut Dome nut 1. At the rear of the head remove 2. Fit the light mounting bracket to the 2 the shield covering the gear studs in the middle of the head. Secure plate by first removing the with 2 M4 nuts.
  • Page 37 Live Live Neutral Neutral 4. Connect the Utilux Crimp Lugs to the terminal 5. Fit the light bulb to the lamp on the Motor Drive Board. Brown cable holder and conduct an electrical on the live terminal and blue cable on the safety test as required.

  • Page 38: Connecting The Light Cable For The Illuminated Spreader

    9.7 Connecting the light cable for the Illuminated Spreader The CX/CS illuminated spreader includes a light and cable bracketed to the top inside panel. Providing power for this light requires the installer to connect the light cable to a fixed mains output located inside the head.

  • Page 39: Part C: Commissioning

    PART C: COMMISSIONING  Gallagher dispensers are factory tested using ISOPAR test fluid. A quantity of this fluid may remain within the dispenser and may be released during commissioning. While this fluid is low in toxicity, it is recommended that the usual safety measures are followed including the use of PPE and washing after contact.

  • Page 40: Safety Inspection

    In the event that an error message is displayed, or if the dispenser does not start up, refer to Part D Servicing - Section 17 TROUBLESHOOTING. Contact the appropriate technical department or Gallagher Support. LPG TRADE MEASUREMENT VERIFICATION PROCESS Refer to Commissioning - Sections 7.6 (v1.11) and 7.7 (v1.20) LPG Trade Measurement Verification Process, for details regarding this procedure.

  • Page 41: Calibration

    CALIBRATION A Tatsuno Meter is used with petrol and diesel products. The DEF meter, although similar in appearance, is specially constructed for use with DEF. However the adjustment procedure is the same as for the petrol/diesel meter. Calibration adjustments affect the volume of fuel delivered per revolution of the flow meter, while the displayed volume always advances by exactly the same amount for each revolution.

  • Page 42: Lobe Meter (Ultra Diesel)

    6.2 Lobe Meter (Ultra Diesel) Due to the Lobe Meter having no mechanical adjustment in its design, the Ultra encoder incorporates a calibration facility which can compensate volume errors within a ±2% range, with a resolution of approximately ±0.1%. The encoder uses a “Hall Effect” device to detect the rotation of a magnet which is mounted at the end of a shaft within the meter body.

  • Page 43: Calibration Procedure For Blending Units

    Select the calibration vessel volume using SW2 DIP-switches 2, 3 & 4. Volume SW2.1 SW2.2 SW2.3 SW2.4 220 Litre 200 Litre 100 Litre Table 1 Encoder SW2 DIP-Switch settings Prepare for a test delivery by lifting the nozzle but do not commence delivering fuel.

  • Page 44: Lpg Section

    LPG SECTION This section describes the procedures required during commissioning specific to LPG such Fuel flow test. Trade Measurement test. It also provides a brief description of specific LPG components and characteristics including the following: Stack The LPG stack is always in the Product A position located as follows: L Series: closest to the hose column.

  • Page 45: Lpg Stack Components

    7.1 LPG Stack Components The image of the LPG Stack shown below is as viewed from the front where the filter housing is located. Front Hose Hydraulic Accumulator Front Hose 2 Stage Valve Hose Bleed Valves Rear Hose Hydraulic Accumulator Rear Hose 2 Stage Valve Excess Flow Valves...

  • Page 46: 4-Way Meter Feed Valve Settings

    7.2 4-Way Meter Feed Valve Settings The Meter Feed Valve can be adjusted to supply product to either front or rear meter, both, or none. Settings are shown below. Front Hose Rear Hose Front Hose Rear Hose Front and Rear Front Hose Rear Hose Front Hose...

  • Page 47: Lpg Stack Test - Version 1.11

    7.4 LPG Stack Test - Version 1.11 When installation is complete and fuel is available on site, perform a flow test for each LPG hose to clear out all air and vapour from the supply lines, meters, internal pipework and fittings and delivery hoses as follows: Couple the LPG nozzle to the return line fitting and open the ball valve.

  • Page 48: Lpg Stack Test - Version 1.20

    7.5 LPG Stack Test - Version 1.20 Enter Service Mode STK MENU Use the 2 & 8 keys to scroll through the list until STK MENU is displayed in the Dollars display. STK1 is shown in the Litres display STK1 Press 4 or 6 to select a different stack (if present) eg: STK2.

  • Page 49: Lpg Trade Measurement Verification Process - Version 1.11

    Figure 22� Location of Dipswitches The dipswitches must be in these positions. Do not move switches unless advised to by Gallagher technical staff. If moved,  essential settings will be lost needing specialist tools to reset.
  • Page 50 Press the 5 key. The following characters are displayed in the LPG price display confirming the key press. Press and hold to leave service mode. The dispenser will now be in verification mode for displaying both compensated and un-compensated delivery values. 10.

  • Page 51: Lpg Trade Measurement Verification Process - Version 1.20

    7.7 LPG Trade Measurement Verification Process - Version 1.20 Enter Service Mode Go to LPG MENU – press FILL. Go to LPG TEST - press 4 or 6 to select fuelpoint to be tested, press 5 to turn Test Mode to ON. Hold C to exit Service Mode and enter Test Mode.

  • Page 52: Lpg Meter Calibration - Version 1.20

    7.8 LPG Meter Calibration - Version 1.20 Make a delivery through the calibration meter and record the uncompensated value. If calibration is needed – follow these steps: Do not repower or perform any other delivery between calibration delivery and completing calibration process. Set security switch 1.

  • Page 53: Lpg Electrical Schematics

    7.9 LPG Electrical Schematics The following diagram indicates the interconnection between the various LPG components. Figure 22 is used where other products are present. Figure 23 would normally be used for a stand-alone LPG dispenser. REAR GEAR PLATE FRONT GEAR PLATE STACK BARRIER CORIOLIS...

  • Page 54: Part D: Servicing

    PART D: SERVICING DEPRESSURISATION WARNING Pumps or dispensers must first be depressurized before carrying out any hydraulic work on them. When carrying out this operation: Wear safety glasses and other appropriate safety gear. Isolate the dispenser from the feed line. With the nozzle triggers fully open and the nozzles placed in a container to capture any product, use the “Stack Test”...

  • Page 55: General Care And Maintenance

    GENERAL CARE AND MAINTENANCE Gallagher dispensers are designed to give many years of reliable service. However, a regular maintenance and servicing regime will maximise the life expectancy and reliability of your Gallagher dispenser. The following list is the minimum routine recommended by Gallagher for compliance with the terms of the product warranty.

  • Page 56: Target Torques For Gasket Sealing

    1.4 Target Torques for Gasket Sealing Tighten all fasteners diagonally, ensuring that the tightening load to each bolt is applied as uniformly as possible, in three or four stages up to the final torque value. 4G85424 Flange Gasket (T) Meter Torque = 11 Nm 4G82768 Meter Gasket Lobe Torque = 16.5 Nm...

  • Page 57: Nozzles

    (1). replacing strainer Replacement O-Rings (Part No. 4G00062) may be ordered from Gallagher. DELIVERY PRESSURE EXCEEDS 350kpa: Excessive pressure will result in tripping out the nozzle. Check and rectify.

  • Page 58: Elaflex Gg1Dn / Lpg

    2.2 Elaflex GG1DN / LPG Maintenance It is recommended that LPG nozzles be inspected every 6-12 months for any apparent physical damage to their components. • Inspect swivel nut/nose piece seals for damage (e.g. cuts or excessive wear). • Check that there is free rotation of swivel nut. •...

  • Page 59: Elaflex Def Nozzles

    2.3 Elaflex DEF Nozzles The PULSE series use Elaflex ZVA nozzles for the dispensing of DEF (Diesel Exhaust Fluid). Problem The nozzle will not operate or continually trips out. Remedies • Ensure the vehicle filler neck or test drum has the magnetic adapter fitted.

  • Page 60: Safety Breaks

    SAFETY BREAKS The PULSE Series dispenser range uses Elaflex Straight (SSB) safety breaks to protect the dispenser, the hose and the vehicle in the event of a drive-off. body SSB 16 break-away part hose assembly nozzle Figure 28� Elaflex SSB Safety Break SSBs may be used on 5/8”...

  • Page 61: Lpg Dry Breaks

    LPG DRY BREAKS Each LPG hose is fitted with a reusable dry break coupling designed to seal off the outflow of LPG in the event of a ring drive-off incident. During the reassembling procedure described below care must be taken to ensure the U-Bolt is not too tight to avoid deforming the break.

  • Page 62: Hoses

    HOSES Hoses should be checked regularly for signs of wear and tear or damage (e.g. abrasions, bulges, distortion, etc.) and any hoses showing such signs should be replaced. Also replace any hose which can no longer be adjusted not to touch the ground when the nozzle is holstered correctly.

  • Page 63: Shortening Hoses

    5.1 Shortening Hoses Minor hose elongation will occur on all hoses. Gallagher supply hoses at a standard length that maintains clearance from touching the ground, even after elongation. In some instances however, certain fuel compositions will result in hose elongation that brings the hose close to, or even touching the ground.

  • Page 64: Asco 24V Proportional Valve

    ASCO 24V PROPORTIONAL VALVE Disassembly Pay attention to exploded views provided for identification of parts. Remove retaining clip, coil and spring washer from solenoid base sub-assembly. When metal retaining clip disengages, it can spring upwards.  Unscrew the solenoid base sub-assembly. Remove core assembly, core spring, guide core assembly, spring piston and bonnet gasket.

  • Page 65: Maintaining The Spring Reel Tension (L Series)

    MAINTAINING THE SPRING REEL TENSION (L SERIES) The following describes the procedure for tensioning the spring reel with the use of a locking pin which is inserted through holes drilled in each side of the spring reel (1) WARNING: Extreme care must be taken to avoid ...

  • Page 66: Replacing The Pump Unit / Air Separator Strainers

     These instructions apply only to a Tatsuno pump. Information relating to a Bennett pump may be found at: https://fuelsystems.gallagher.com/media/1675/bennett_pump_manual.pdf The Pump Unit/Air Separator contains two separate strainers - Inlet and Outlet. 8.1 To Replace the Inlet Strainer: locate the strainer at the back of the pump unit. Unscrew the bolts from the strainer cover.

  • Page 67: To Replace The Outlet Strainer

    8.2 To Replace the Outlet Strainer: locate the outlet strainer at the front of the pump unit. unscrew the bolts from the strainer cover. pulling out the strainer will release the float which will obstruct the replacement strainer when inserted. with a thin piece of wire hold back the float to allow the replacement strainer to enter the chamber.

  • Page 68: Def Filter Cartridge Replacement

    DEF FILTER CARTRIDGE REPLACEMENT It is recommended that goggles and gloves are worn when dealing with fluids  under pressure. The filter cartridge should be changed when: • there is a noticeable reduction in fluid flow. • the delivery system reaches the maximum recommended differential pressure. Procedure head Shut off pressure to the dispenser.

  • Page 69: Electrical

    Understand the function and location of this switch or circuit breaker before inspecting, installing or servicing Gallagher equipment. 10.1 Remounting a PULSE UI Battery Pack On occasion the PULSE Battery BUP 4 x AA Pack Assembly, mounted on the inside of the dispenser head cabinet door panel, may come loose and hang on the red and black wires from the BUP board.

  • Page 70: Simple Wiring Diagram

    10.2 Simple Wiring Diagram The PULSE Electronic Set Modules are interconnected for communication purposes and power supply. The following figure shows the connections between the different modules present in the standard PULSE assembly. Ethernet Head Rear Column Head Front Local Bus Central Stack Holster...

  • Page 71: Junction Box Wiring Diagrams

    10.3 Junction Box Wiring Diagrams As shown in Figure 34 the mains power supply connector block varies between a dispenser, and a single phase pump. POS cabling is connected into a common connector block as shown in Figure 37. Mains Supply 230/240 VAC, 10A, 50Hz Mains Earth Neutral...

  • Page 72: Sd Card Content

    Keyboard map KB_map 11.1 Process for Loading Firmware onto the SD Card The latest firmware release is available from Gallagher Technical Support or from the Fuel Systems website: https://fuelsystems.gallagher.com/support The latest firmware release must be installed during the commissioning of a new dispenser.

  • Page 73: Obtaining Dispenser Logs

    11.3 Obtaining Dispenser Logs Agents may be required to obtain dispenser logs which are used to assist in the diagnosing of dispenser issues or to locate details of specific sales or other events. Safely remove the SD card. Place the SD card in a computer. Copy the entire contents.

  • Page 74: Firmware - Firmw

    Version 1.11 12.4 Firmware - FIRMW The following actions are possible regarding the firmware: viewing of the installed firmware version number(s). upgrading firmware. rollback to previously installed firmware, provided that the previous version is still available on the module.  Note that the rollback option is not available on a Central Controller.

  • Page 75: Setting Vr Active - Vrctrl

    Version 1.11 12.5 Setting VR Active - VRCTRL For non-VR sites VR Control can be set as either ACTIVE or OFF. For VR equipped sites VR Control must be set to ACTIVE. VR Control can be set to OFF to disable alarms and forced shutdown.

  • Page 76: Setting A Password - Cgpwd

    Both the Service Agent password (Level 2) and the Manager password (Level 1) can be altered. Once set, if the password is forgotten, Gallagher will only be able to reset to default when provided with the serial number of the Central Controller.

  • Page 77: Errors - Errors

    The errors are displayed for each fuelpoint. A PULSE dispenser logs all errors to the SD Card (even those that have been cleared) in a form that is not easily read. Gallagher Technical Support can interpret dispenser logs and provide a more detailed description of errors.

  • Page 78: Setting Hoses Active/Inactive - Hose

    Version 1.11 12.9 Setting Hoses Active/Inactive - HOSE Newly delivered dispenser’s have hoses set as active before leaving the factory. To set hoses active/inactive enter the service mode. Scroll to the screen shown where H1 indicates the hose number followed by 1 for active or 0 for inactive. Pressing the 6 key will move between hoses and pressing 5 will toggle between active and inactive.

  • Page 79: Pos/Standalone - Pos

    Version 1.11 12.12 POS/Standalone - POS Allows the POS/Standalone setting to be changed at the dispenser (via the User Interface). Set for each Fuel Point (FP).  For Standalone mode the dispenser must first be isolated from the Forecourt Controller. The display shows POS in the Dollars display followed by the Fuel Point number and a 0 or 1 in the Litres display.

  • Page 80: Hydraulic Stack Test - Stack

    Version 1.11 12.14 Hydraulic Stack Test - STACK A stack test should be performed for each dispenser to ensure that the fuel supply is flowing freely. This will also flush the delivery pipes and hoses as well as prime the system.

  • Page 81: Checking Input Status

    Version 1.11 Key Points The motor must be on and the valves open to set flow rates. Press 5 to store the current setting for fast flow. The number in the top row of the price window (A or B) is the valve percentage.

  • Page 82: View/Set Date & Time

    Press 2 to move to TIME and set in the same manner.  Gallagher advise the checking of the date and time when obtaining dispenser logs. Should either be incorrect, make a note to be included with the logs. This will assist in finding the events being investigated.

  • Page 83: Manager & View Totes Modes - All Versions

    Version 1.11 & 1.20 MANAGER & VIEW TOTES MODES - ALL VERSIONS 13.1 Manager Mode Manager mode is provided to allow site owners/managers to view and set a limited number of functions. The available functions are: Set SD Card Active/Locked View Firmware versions Set VR Control Active/Off View Errors...

  • Page 84: Service Mode Functions

    Version 1.20 SERVICE MODE FUNCTIONS This section describes the Service Mode 1.20, including new features and changes to the existing functions. 14.1 Summary of New Key Features and Functions The following information summarises the new key features and functions added to the new service mode.

  • Page 85: Entering Service Mode

    Version 1.20 14.2 Entering Service Mode Service Mode is accessed by holding down the F key for three seconds. The word FILL is displayed in the Preset window and then disappears. Enter the Service Mode password and press F to confirm or to clear and retry.

  • Page 86: Sd Card Setting - Sdcard

    Version 1.20 15.1 SD Card Setting - SDCARD SD CARD ACTIVE The SD Card can be set to ACTIVE or LOCKED by pressing the 5 key.  Only remove an SD Card when in the LOCKED mode. SD CARD LOCKED 15.2 Stack Menu - STK MENU The stack menu allows the completion of a hydraulic stack test.
  • Page 87 Version 1.20 15.2.2 Adjusting Proportional Valves There are two valve setting modes in stack test, slow flow and fast flow. The 0 key is used to access the slow flow settings. The 5 key is used to access the fast flow settings.

  • Page 88: Setting Pump Numbers - Fp Id

    Version 1.20 15.2.4 Checking Input Status When in Stack Menu press the 2 or 8 key to scroll to the input menu item which displays the available stack input groups for the selected stack. The digits in each group relate to the following inputs: INPUTS 1 - 10 Lifting each nozzle opens the switch indicated by a 1 on the...

  • Page 89: Point Of Sale Menu - Pos

    Version 1.20 15.4 Point of Sale Menu - POS The POS Menu has four options - ENABLED, PROTOCOL, 5/6 DIGIT, and COMMSLOG - allowing all POS related changes to occur whether or not MENU the POS connection is enabled. Press F to enter POS Menu. Press 2 (or 8) to scroll through the four options.

  • Page 90: Grade Priority - Mapping

    Version 1.20 15.4.3 5/6 Digit Mode - 5/6DIGIT When set to 6 Digit mode, a dispenser will allow sales up to a maximum of $9990.00 and preset up to $9990.00. The 5 Digit mode allows sales up to a maximum of $990.00 and preset up to $990.00.

  • Page 91: Setting Hoses Active/Inactive - Hose

    Version 1.20 15.6 Setting Hoses Active/Inactive - HOSE This function allows the hoses to be set to active (ON) or inactive (OFF). HOSE H1 ON  Newly delivered dispensers have hoses set as active before leaving the factory. The Dollars display shows HOSE and the Litres display shows H(X) ON (or OFF), where (X) represents the hose number.

  • Page 92: Lpg Menu

    Version 1.20 15.8 LPG Menu The LPG Menu has five options - MTR SECU, TEST, XS FLOW, MTR CAL, and MTR SIDE. Each option allows the following functions. 1 MTR SECU - Check the security setting of each LPG meter. LPG MENU 2 TEST - Enables testing pump accuracy against the test meter.
  • Page 93 Version 1.20 15.8.3 Safety feature supplementing excess flow rate - XS FLOW The XS FLOW supplements the physical excess flow valve safety feature. Where an excess flow rate situation occurs the dispenser will cycle the delivery speed down or terminate the delivery to prevent the physical excess flow valve from activating unnecessarily.

  • Page 94: Errors - Errors

    The errors are displayed for each fuelpoint. A PULSE dispenser logs all errors to the SD Card (even those that have been cleared) in a form that is not easily read. Gallagher Technical Support can interpret dispenser logs and provide a more detailed description of errors.

  • Page 95: Pulse Counted Error Codes

    Version 1.20 15.10 PULSE Counted Error Codes Name Brief Meaning Type Troubleshooting FLUID The float switch has been Hard Check sump for fluid. Check fluid activated switch operation and connections Lost connection with POS Soft Check POS/Forecourt controller during delivery loop connection and operation STACK Stack failed to start delivery...

  • Page 96: Timeout Menu - Timeout

    Version 1.20 15.11 Timeout Menu - TIMEOUT This function allows changing the value of the three different TIMEOUT timeouts: BEEPER, NOFLOW and WAITFLW. MENU Press F to enter the Timeout Menu. Press 2 (or 8) to scroll through the three options. 15.11.1 Beeper Timeout - BEEPER The timeout beeper will activate when a nozzle has not been returned BEEPER...

  • Page 97: Start-Up Delay - Startdel

    Version 1.20 15.12 Start-Up Delay - STARTDEL This function sets the delay before deliveries can start. Start-up delay is set to 0.0 by default. The delay should be entered in tenth of a second increments with a maximum setting of 30.0 seconds The Dollars display shows STARTDEL and the Litres display STARTDEL shows FP(X), where (X) represents the fuelpoint number.

  • Page 98: View/Set Time - Time

    The Dollars display shows DATE (without the asterisk) to indicate that the UI is back in ‘view’ mode.  Gallagher advise the checking of the date and time when obtaining dispenser logs. Should either be incorrect, make a note to be included with the logs. This will assist in finding the events under investigation.

  • Page 99: Setting A Password - Passwd

     Once set, if the password is forgotten, Gallagher will only be able to reset to default when provided with the serial number of the Central Controller. While it is the responsibility of the site to manage passwords, Gallagher Technical Support have a mechanism for recording alternate passwords if they are informed of the changes.

  • Page 100: Totes

    Version 1.20 15.18 Totes This menu item allows you to save current tote values from the Central TOTES Controller to the Stack Controller and restore tote values from the SAVE Stack Controller back to the Central Controller. This can be used when swapping the Central Controller board out to avoid losing the current tote values.

  • Page 101: Operating System Menu - Os

    Version 1.20 15.21 Operating System Menu - OS The OS Menu has five options: OS VER, NETWORK, CLOUDID, LANCHECK, INTERNET and SYSLOGS MENU Press F to enter the OS Menu. Press 2 or 8 to scroll through the five options. Press to return to the main menu.

  • Page 102: Firmware - Firmware

    Version 1.20 15.21.6 SYSLOGS SYSLOGS Creates SYSLOGS when F is pressed. CREATE Press the F button to start creation of the logs. The operator will see SYSLOGS “CREATING” and when it is finished SYSLOGS “OK”. Press to return to the main menu. Before removing the SD Card SYSLOGS from the pump either lock it or power down the unit.
  • Page 103 Version 1.20 15.22.1 Upgrading the Firmware To upgrade firmware, a new firmware file must be present in the FIRMWARE firmware folder on the SD Card. UPDATE? To update firmware, scroll to the module to be updated and press 5 . The Litres display shows UPDATE?.

  • Page 104: Hydraulic Stack Test (Blending)

    HYDRAULIC STACK TEST (BLENDING) NOTE: The layout of the hoses during a stack test differ from the physical layout on the dispenser. Valves according to Stack Test display. Motors Valve 2 Grade 98 Out Valve 98 91 Dsl Valve 1 Grade 98 Base Valve Valve 4 Grade 91 Out Valve M 000 Valves...
  • Page 105 Grade 91 The flow rate for Grade 91 can be tested by using Base Valve 5 and Out Valve 4. Motor 1 M100 V 0++000 Valves Valves Non-Return Valves Valve % Base Valves Flow Rate Motors With a normal delivery, the Base Valve will be open to 100% and the Out Valve will adjust the flow rate to meet the target flow defined in the Flow Control settings.

  • Page 106: Testing The Non-Return Valves (Circled In Diagrams)

    16.2 Testing the Non-return Valves (circled in diagrams) Grade 98 To test the non-return valve for Grade 98, turn on Motor 1 and open Out Valve 4 and Base Valve 1. Verify that no flow is coming out of the Grade 91 nozzle. Motor 1 M100 V 0++000...

  • Page 107: Calibration

    Version 1.20 16.4 Calibration The procedure for calibrating the various grades is as follows: Grade 1 Normal procedure. Grade 2 No calibration is possible.* Grade 3 Normal procedure. Grade 4 Diesel Normal procedure. *If Grade 2 is out of acceptable tolerance, recalibrate Grades 1 and 3. 16.5 Flow Control - FLOWCTRL FLOWCTRL All target flow rates can be adjusted.

  • Page 108: Addressing Lpg Meters - Version 1�20

    Version 1.20 ADDRESSING LPG METERS - VERSION 1�20 Only possible with Firmware version 1.20 or later. New LPG meters are not rear or front specific and require their address to be configured. To configure the LPG meter addresses (one meter at a time): Leave pump ON.
  • Page 109 Version 1.20 When reset is complete, set factory reset switch (dip 3) to OFF and leave security switch OFF (dip 1). When a meter is reset, the pump display may show LPG COMMS ERROR, which can be cleared by lifting any hose on that side. Enter service mode.
  • Page 110 11. Unplug the newly addressed LPG meter inside the head. 12. Repeat from step 2 for any remaining LPG meters to be addressed, only plugging in the meter currently being addressed. 13. Once all meters have been addressed, unplug all LPG meters inside the head, then plug them all back in.

  • Page 111: Pulse Media

    PULSE MEDIA PULSE Media is a multimedia solution integrated into the pump. It has the ability to display video on an LCD screen with audio and wireless internet connectivity. All components are located inside the rear side of the head. Figure 40�...

  • Page 112: Operation

    19.1 Operation The system works as a standard windows PC, therefore all configurations including WiFi connections should be made accordingly. A Windows keyboard and mouse may be connected via the two USB ports. By default the system is set to boot directly into the media player. The desktop may be accessed using the key combination windows+D as shown below.

  • Page 113: Adjusting The Volume

    19.3 Adjusting the Volume The volume can be adjusted on the amplifier using the volume knob (arrowed). Figure 44� Volume Knob 19.4 Electrical Protection The media system is protected by a 5A standard small (20x5mm) fuse located in the Mains Connector Block (arrowed).

  • Page 114: Troubleshooting

    TROUBLESHOOTING 20.1 Dispenser Will Not Deliver Fuel Fault Action (a) No screens (no pixels lit). y Ensure dispenser is powered (any LED lit indicates presence of power). y Check Central Controller LEDs are correctly lit. No LEDs indicate Central Controller fuse may be blown. y Check Local Bus to displays are correctly connected.
  • Page 115 Fault Action (f) Screen displays. Indicates stack events outside normal parameters. May be a one-off event requiring no STACK action. Cleared by nozzle lift and logged within ERROR the dispenser. Repeated Stack Errors can indicate hydraulic issues with valve function, leaks and nozzle func- tion.

  • Page 116: Dispenser Will Deliver Fuel

    20.2 Dispenser Will Deliver Fuel Fault Action (a) Continual clicking of nozzle. y Ensure pressure and flow rate meets pump specifications, i.e. <40 L/min and <350 kPa. y DEF: Check for blocked airway (see Servicing - Section 2.3 Elaflex DEF Nozzles). y Check nozzle tip for damage to airway.

  • Page 117: Quick Reference Guide - Version 1�11

    Version 1.11 QUICK REFERENCE GUIDE - VERSION 1�11 Entering Service Mode Stack Test Hold FILL 3 seconds Scroll to STACK 1000 Enter Password FILL (* displayed) Press 4 or 6 to scroll to other stacks where present 2 – 8 scroll between options Press FILL to enter Stack Mode 4 –...

  • Page 118: Quick Reference Guide - Version 1�20

    Version 1.20 QUICK REFERENCE GUIDE - VERSION 1�20 Entering Service Mode Set Time/Date Hold FILL 3 seconds, enter Password, Scroll to Time or Date press FILL again Press FILL, enter complete time/date Use 2 and 8 to scroll between items Use 4 and 6 to scroll between options Setting Flow Control Pressing 5 changes setting, turns on/off...

  • Page 119: Appendix - Blending Information

    APPENDIX - BLENDING INFORMATION 23.1 Flow The diagram below demonstrates the hydraulic flow of the blending dispenser. Although both the component fuels and the blended fuel can be any octane, this diagram refers to 91 and 98 as the component fuels. The blended grade is referred to as 95. Upon nozzle lift, the blended grade 95 draws the correct ratio of each component fuel (91 and 98) from their respective submersible pumps.

  • Page 120: Layout

    23.2 Layout The diagram below shows the hydraulic components and layout. The large numbers indicate the location of the solenoid valves. These valve numbers, described below, are referred to throughout the document. The valve numbers are the same for front and rear. Location of Front Multiplexer Blending Manifold...

  • Page 121: Blending Manifold

    23.3 Blending Manifold The blending manifold has 3 proportional valves attached with two non return valves. The two “component” fuels are fed into the manifold and channelled proportionally into the centre of the manifold to make the blended fuel. seal non-return valve blending manifold solenoid valves...

  • Page 122: Multiplexers

    rear front Figure 50� Head Contents Valve 5 91 Feed Valve 4 91 Delivery Note: Feed and Delivery Valve 6 Diesel Feed relate to in and out of the Valve 3 95 Delivery Blending Manifold Valve 1 98 Feed Valve 2 98 Delivery P28 P27 P25 P24 P23 P22 Figure 51�...

  • Page 123: Appendix - Dispenser Control Systems

    APPENDIX - DISPENSER CONTROL SYSTEMS SD CARD SD CARD SD CARD Figure 53� Central Controller PULSE Installation, Commissioning and Servicing Manual - Revision 19...
  • Page 124 Figure 54� DC Power Supply PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 125: Figure 55� 3-Board Stack Controller

    Figure 55� 3-Board Stack Controller PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 126: Figure 56� Dc Integrated Stack Control - 1

    Figure 56� DC Integrated Stack Control - 1 PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 127: Figure 57� Dc Integrated Stack Control - 2

    Figure 57� DC Integrated Stack Control - 2 PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 128: Figure 58� Ac Integrated Stack Control

    Figure 58� AC Integrated Stack Control PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 129: Figure 59� 1 Or 2 User Interface Modules

    Figure 59� 1 or 2 User Interface Modules PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 130: Figure 60� 3 Or 4 User Interface Modules

    Figure 60� 3 or 4 User Interface Modules PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 131: Figure 61� Multiplexer Board Detail

    Figure 61� Multiplexer Board Detail PULSE Installation, Commissioning and Servicing Manual - Revision 19...

  • Page 132: Figure 62� Vr2 Subsystem Detail

    YELLOW GREEN BROWN WHITE Figure 62� VR2 Subsystem Detail PULSE Installation, Commissioning and Servicing Manual - Revision 19...
  • Page 133 L E N Figure 63� LPG Additions PULSE Installation, Commissioning and Servicing Manual - Revision 19...
  • Page 134 Figure 64� Mains Entry Box PULSE Installation, Commissioning and Servicing Manual - Revision 19...
  • Page 135 PULSE Installation, Commissioning and Servicing Manual - Revision 19...

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