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Gallagher Apollo 3000 Manual

Gallagher Apollo 3000 Manual

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Apollo 3000
Set-up, Installation & Parts Manual

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Summary of Contents for Gallagher Apollo 3000

  • Page 1 Apollo 3000 Set-up, Installation & Parts Manual...

  • Page 3: Safety Operation

    Caution Should the word “FLUId” appear in Display immediately implement part A & B of this section Refer page 06 of this Manual Apollo 3000 Set Up Procedure Std. Fuel paragraph 06 for details Caution This equipment contains components that can be damaged by Electrostatic Discharge.
  • Page 5 Fig 5 Vent Box Position & Sealing Page 26 Fig 6 Safety Hose Position Page 27 Apollo 3000 Hydraulic & Intrinsic Connections New Zealand Page 28 Apollo 3000 Hydraulic & Intrinsic Connections Australia. Page 29 Mains Wiring Connections AC Control & Power Supply...
  • Page 6 BP Apollo 3000 Dispenser Supply & Installation Procedure Stage 1 Under Ground Sump Enclosure Installation Components supplied by PEC to site. Components include; Sump Enclosure Box Assy with, Cable Duct, Delivery Ducts with Internal Delivery Pipe Assys. fitted. Bulkhead Seals (Pre fitted into Sump Enclosure) Sump Box Lid with Handles Sump Cover &...
  • Page 7 Stage 2 Vertical Delivery Pipe Assys Installation Procedure Components Supplied by PEC Front & Rear Vertical Pipe Assys Head Cabinet Assy. (Fitted with Grade ID Decals) Head Cabinet mtg. Brkts Flexible Safety Hose Assys External Hose Assy, fitted with Nozzles, Grade Covers & Gas Guards Nozzle Grade ID Decals Vent Box Assy Front &...
  • Page 8 • Stage 2 Vertical Delivery Pipe Assys & Modules Installation Procedure Continued • Drill pilot holes into Column through holes provided in horizontal fixing Brkts. (Min. 2 per Brkt. required) Uses 12 Gauge 32mm (12/24 x 23 Hex Hd. Buildx 500 Series or similar Screw. •...
  • Page 9 Installation Procedure (Start with Module C closest to Column) • (Ensure Product Position is Correct (Refer Pg. 27 NZ or 28 Aus.) Apollo 3000 Hydraulic & Intrinsic Connections • Connect Internal Delivery Hoses to Internal Delivery Pipe Assys (these exit into Sump from Ducts) (Refer Pg18) Inside Enclosure Layout •...
  • Page 10 Set addresses on AC Control PCB as shown in table below Note AC Control Boxes number from right to Left as viewed with Column on your left, refer Apollo 3000 Hydraulic & Intrinsic Connections layout Section Pg. 28 & 29 Box no.
  • Page 11 Apollo 3000 Set Up Procedure Standard Fuel continued Plug in Batteries Test Diagnostics (Refer Pg.08) Version VA 2.30P or Greater Software Version VA 2.30P has optional settings between Air Sense & Fluid Float Switch Operation. Explanation of operation: Air Sense Operation = No Link present or Link Cut @ position 10 @ Dip Switches positioned on Front Preset Display PCB Assy.
  • Page 12 Pump stack test 50* 70* This test cheeks the operation of the pump motors (internal or submersible). The motor can be switched on and off, as can the slow and fast flow rates. The flow rate is displayed in the Price per litre display. Pump motor Function number F1 &...
  • Page 13 Feed Line Detail Elbow B 22-22-12-12 3-4 CR 33 MS Note distance between test point seals on assy. shown above must be min possible . Inside distance between Bulkhead Seals in Hydraulic Enclosure is, 0.432m therefore feed line Tee termination arrangement must fit within this distance. Above view is as viewed from enclosure (sump) end away from Column (RH end ).
  • Page 14 Rear Grade ID 89717 Graphic Panel Rear 89716 Graphic Panel front (not 89937 Unleaded shown) 89922 Pre. Unleaded 89934 “Super” 89954 Ultmate Hi 89921 “Pre. Unleaded” 89952 “Ultmate Hi” NZ 89939 “BP Ultimate” or 89941 “Diesel” 89938 “:BP Ultimate” 89919 Low Sulp. Diesel 89940 “Diesel”...
  • Page 15 Float Switch 89778 Float Swt Mtg 89749 Float Switch & Angle (only) Bracket Assembly...
  • Page 16 Head Cable Entry 89717 Graphic Rear 89715 Door 89716 Graphic Front FLP Gland 823450 89773 Cable Assy FLP Plug 44024 x 4 Dury Lock Nut 803220 x 9...
  • Page 17 Head Cabinet Rear Display 87276 Main Display. Refer Pg.?? 866570 Spacer (Typ.) for Cable Layout 803520 Nut (Typ) 87271 Price Display x 3 Clip 824080 89727 Switch Assy. 89755 Brkt only 87281 Preset Display .87711 Hinge Plate 88327 Hinge Screw M4 x 10 Csk. 89715 Door 825960 Lock 89713 Cam...
  • Page 18 Head Cabinet Inside View 87151 Pwr. Sup PCB Assy (not shown) 89752 Cover 862820 Terminal Strip (not shown) 83665 PCB Cover Mtg. (not shown) 83638 Mtg. Boss (not shown) + M3 x 8 Pan Hd. Screw 859570 Fluo. Light 859615 Batten Holder. 89719 Mtg.
  • Page 19 Head Cabinet Front Displays 87271 Price 87276 Main Display Display PCB PCB Assy. Assy. Refer Pg.?? for Cable Lay out 87281 Preset PCB Assy. 87195 Mem. Key Pad 89710 Head Cabinet Assy. 89711 Head Cab. Mtg. Brkts. x 2 not show...
  • Page 20 Head Cabinet Internal 824510 Cable Clip 88310 Cable Assy. (Logic Box – Processor) 40 Way Housing 861230 83210 Cable Assy Proc. - Power 83202 Cable Assy Pump Comms. 87380 Pro. Eprom. 87338 Tote Cable Assy. 881730 Label Intrinsic...
  • Page 21 Logic Box 878913 Logic Box Base. 89732 Logic Box Mtg. 87914 Logic Box Lid. 89737 Nozzle (not shown Cable Assy 87111 Logic 88310 Cable Assy PCB Assy...
  • Page 22 Inside Enclosure Layout Rerfer Pg. 27 & 28 For Hydraulic Layout Refer Pg.34- For Hose Specs. “B” “A” Link Cable @ 1.5m Link Cable @ 1.8m “C” Link Cable @ 1.2m 89772 Junction Box Assy. Refer Sump & Module Pg. 19 89733 Cable Assy.

  • Page 23: Rear Side

    Apollo Sump & Module Assy 3000 Front Side Module “A” Module “C” Module “B” Encoder Assy Module Mtg. Frame 89869 (5m) Assy 89942 Hinge Pin 89758 852530 Solenoid Valve ¾ “ AC Control Box Assy 89738 (5m) Column Manifold Delivery 89780 Pipe Module...
  • Page 24 Vertical Pipe / Vent Box Assy (Front Shown) 89711 Head Mtg Brkt 89825 Holster Panel Mtg. Brkt. 89947 Holster Panel 89826 Vertical Pipe Assy Front 89827 Vertical Pipe Assy Rear 89926 Top Cap 89925 Vent Body Front 89927 Vent Body Rear 89846 Safety Flex Hose Assy x 6 Internal Pipe Assys.
  • Page 25 Stage 1 Installation Procedure Sump Position Fig 1 Under Ground Front View Apollo Sump File @ gme d:/docum/pec/apollo2/fig 1.doc...
  • Page 26 Stage 1 Installation Procedure Sump/Column Position Fig 2...
  • Page 27 file gme c:/docum/pec/apollo2/fig-2-manual.doc Stage 1 Installation Service Area Spec. Fig 3...
  • Page 28 Stage 1 Installation Procedure Mounting Positions Fig 4...
  • Page 29 Stage 3 Vent Box Installation Vent Box Position & Sealing Spec. Fig 5...
  • Page 30 Stage 3 Vent Box Installation Safety Hose Position. Fig 6 Safety Hose Assy. 89846 Internal Pipe Assys. 89794 Upper Assy 89796 Middle Assy 89798 Lower Assy...
  • Page 31 A p o l l o 3 0 0 0 H y d r a u l i c & I n t r i n s i c C o n n e c t i o n s N e w Z e a l a n d G M E 0 8 / 0 2 / 0 0 U p d a t e d 0 9 / 0 3 / 0 1 F il e @ GME...
  • Page 32 G M E 0 1 / 1 1 / 0 0 A p o l l o 3 0 0 0 H y d r a u l i c & I n t r i n s i c C o n n e c t i o n s A u s t r a l i a U p d a t e d 2 7 / 1 1 / 0 0 - 2 1 / 0 8 / 0 1 - 2 7 / 0 2 / 0 2 F i l e @ G M E c : / m y d r a w d t / a p o l l o / l a y - 3 0 0 0 .
  • Page 33 Incoming Pump Comms. Mains & Switched Active Cabling Layout To PEC Main Processor PCB (Comms) Refer Pg 28 Head Cabinet * = FLP Gland Used Valve Wiring Option Layout shown below is used in conjunction only with new version Asco Valve PVG. Model (note: wiring also unsleeved on this version) A C Mains In Switched Active Out Sol_1...
  • Page 34 Control Logic Distribution PCB Assy 87110 N oz_F N o z3 N o z2 N oz_R N o z1 N /C A ir1 A C 3 A ir2 A C 2 A ir3 A C 1 U D D EN C_F3 F _ A EN C _F2 F _ B...
  • Page 35 Display Dip Switch Location Front Preset Display PCB Assy File: Display Dip Switch.doc Dip Sw. Dip Sw. 9= Open for Dollars per Litre (no Link) Linked = Cents per Litre Service Agents Pins Ver 2.30p > Air Sense Operation (No Link) Linked for Float Swt.
  • Page 36 Main Processor Board Information & Connections Part Number 87101 The main Processor Board controls all Pump operations, either alone or together with an input Processor Board The basic elements are : 80c31 or 80c32 Processor 64K external program Memory (Eprom) 32K Static Ram (Battery backed 2692 DUART Encoder Interface...
  • Page 37 Apollo 3000 Display Layout 89887 87333 87276 87271 x 3 87276 87271 x 3 07203 10 Way 10 Way 07203 87329 87333 87281 87281 89886 10 Way 10 Way To Processor PCB 89886 Apollo 3000 Rear Assy Apollo 3000 Front Assy...
  • Page 38 Issued 29/01/01 Update 15/05/01,30/09/04 File @ GME h:\mydrawdt\corel\draw\hose-3k.cdr 5/8” Hose Assy fitted with @ Nozzle ES-Break Hosetail - Swivel Nut 824170 3/4" BSP Male Hosetail 01805 Ferrule Swage 01804 Ferrule Swage 01804 5/8" Certified Rayon Braid Hose * Refer Options Below 819410 Anti Kink Cut A @ = 3.80...
  • Page 39 Errors This chapter contains the full list of error codes, in numerical order. Errors are normally indicated by the error code (number) being displayed. The error is displayed as ERRxx, where xx is the code number. Errors are also written to an error log. You can check logged errors using Function 02 as detailed in chapter 4.
  • Page 40 08..09 Not used Errors 08 and 09 are reserved. Fatal Errors (excluding fatal startup errors) Errors 10 through to 29 all cause the processor to stop. The errors are displayed but beeps are not sounded. The pump must be reset after one of these errors. 10..15 Pump Control State Errors (Pump A..F) This indicates an attempt to enter an undefined side control state on a particular pump number.
  • Page 41 This would be caused by either a fatal error in the input processor, or a physical loss of connection on the serial link between the two processor boards. Remote Parameters Failure Error 27 will be displayed if the pump is not within the diagnostics functions and the remote rx_param block that was sent from the input microprocessor is different to the set stored by the you.
  • Page 42 (Pump D2) The Grade 2 rear encoder inputs were out of sequence. Grade 3 Front encoder error (Pump E3) The Grade 3 front encoder inputs were out of sequence. Grade 3 Rear encoder error (Pump F3) The Grade 3 rear encoder inputs were out of sequence. Grade 1 Front encoder too fast (Pump A1) This error indicates an overflow of either encoder counts or encoder errors was detected for the Grade...
  • Page 43 One of these values is corrupt, and has not yet been set back to a valid value (using the appropriate diagnostic function). LPG Sensor failure The LPG sensor has stopped providing or is providing incorrect information, to the input processor. LPG system vapour present During an LPG delivery vapour was sensed in the system for more than one minute.
  • Page 44 The message received had a checksum error. Channel B Receiver Data Error This indicates that the polling message received from the Input Processor is an invalid type (or that the comms line has been corrupted, in which case a checksum error will probably also occur). Channel B Receiver Overflow Error The message received was too long for the buffer.
  • Page 45 PEC Fuel Pump Fluid/Float Switch operation. Apollo Dispensers Software required: LPG Apollo requires: Input Processor Assy = VI 1.21S (or >) This also allows for Single Temperature Probe operation. Dip Switch # 2 @ SW3 set “ON” Main Processor Assy = VA 2.30P (or >) Apollo Std Petrol/Diesel Dispensers requires: Main Processor Assy = VA 2.30P (or >)
  • Page 46 Apollo 2000 Set-up, Installation & Parts Manual...
  • Page 47 Caution Should the word “FLUId” appear in Display immediately implement part A & B of this section Refer page 06 of this Manual Apollo 3000 Set Up Procedure Std. Fuel paragraph 06 for details Caution This equipment contains components that can be damaged by Electrostatic Discharge.
  • Page 48 Apollo Manual Contents Page 1 Contents Page 2 -5 First & Second Stage Installation Specifications Page 6 Front Door Assy Lay out & Parts Descriptions Page 7 Rear Door Assy lay out & Parts Descriptions Page 8 Head Cabinet Assy Internal lay out & parts Descriptions Page 9 Sump &...
  • Page 49 BP Special Version Dispenser Supply & Installation Procedure Updated 24/06/98 / 21/07/98 / 30/04/99 05/05/99 File @ GME c:/pec/apollo/instal1.doc PEC will supply required Components to site. Components include; Sump Box with Delivery Ducts & Internal Delivery Pipe Assys fitted Sump Box Lid Bulkhead Seals Sump Box Lid with Handles Sump Cover &...
  • Page 50 Stage 1 - Installation Procedure continued • Install Main Feed Lines Into Sump (refer Pg. 16 NZ & Pg. 17 Aus.) for correct positioning etc. (Refer page 33 for Feed Line Details) • T connector terminated with ¾ Ball Valve & ¾ -3/4 BSP Elbow B22 22 12 12 •...
  • Page 51 Installation Procedure Modules & Delivery Pipe Assys Stage 2 - Components Supplied Front & Rear Vertical Pipe Assys Head Cabinet Assy Hydraulic Module Assy (Addresses pre-set) & with Data Cables fitted Flexible Safety Hose Assys x 6 Internal Supply Line Hose Assys x 2 Sets Internal Delivery Hose Assys x 3 •...
  • Page 52 Stage 2 - Installation Procedure Modules & Delivery Pipe Assys Continues (Start with Module A closest to Column) (Refer Pg. 16 or 17) • Install Module Assy. fit Hinge Pin lift module & Position Hold Up Brace (Refer pg. 9) •...
  • Page 53 Apollo Door Assy (Front) 89801 First issue 28.07.98 87333 Cable Assy x 2 Main Display Door Bezel 89770 87276 Face panel Front 89775 87271 Display x 3 Graphic Panel 89950 NZ Graphic Panel 89958 Aus. 87328 Cable Proc/Disp 825960 Lock 89750 Saddle mtg.
  • Page 54 Apollo Door /Head Assy 89802 (Rear View) First issue 29/07/98 Buzzer Cable Processor PCB 87727 Assy 87102 Power Cables 89726 Mtg Plate 87754 Modified Cable Assy Preset/Display 89725 Mini Spur Fastener 824810 Lock Latch Rear 89754 Cable Assy 87328 Cable Assy. x 2 07203 87254 Earth Bonding...
  • Page 55 Apollo Head Assy Internal First issued 29.07.98 Battery & Cable Assy 88230 Shown Unplugged Tote Assy 87287 Tote Cable Assy 87338 Tote Mtg. Brkt. 89751 FST Cable Rear 24984 Front Not Shown...

  • Page 56: Front Side

    Apollo Sump & Module Assy Front Side Module “B” Module “A” Module “C” Module Mtg. Frame Encoder Assy 89811 (3.7m) Assy 89942 852530 Solenoid Valve AC Control Box Assy ¾ “ Hinge Pin 89813 (3.7m) 89758 Column Power J/Box Assy 89812 89780 Manifold Delivery `Meter Delivery...
  • Page 57 Inside Sump Flex Conduit & Gland 50mm & 40mm Dia. Float Switch & Mtg. Brkt. Assy 89729 89760 Internal Pipe Assys. Idle @ Hoz. Connector Box Upper, Middle & Lower Normal Closed Mtg. Brkt 890430 Trunking Refer Sump & Module open Slot 25/25 89812 2 @ 0.9m...
  • Page 58 Mk 11 Inside Enclosure Delivery Hose Lengths 89742 A/F&R = ¾ Hose @ 0.9m - ¾ Swivel Nut 19243/12/12/AU - F/Swivel 90 Elbow 1B243-12-12 89743 B/F&R = ¾ Hose @ 1.39m - ¾ Swivel Nut 19243/12/12/AU - F/Swivel 90 Elbow 1B243-12-12 89744 C/F&R = ¾...
  • Page 59 Nozzle Holster & Delivery Pipe Assy 83780 Nozzle Holster Assy 1000 x 6 89947 Holster Mtg. Panel 89764 Holster Panel Mtg. Brkt. Not Shown 87315 Nozzle Switch Cable Assy. x 6 89790 Vertical Pipe Assy Front 89791 Vertical Pipe Assy Rear 89740 Safety flex Hose...
  • Page 60 Apollo Set Up Procedure Standard Fuel 1. Set Up Addresses Dip Switches Set addresses on AC Control PCB as shown in table below Note AC Control Boxes number from Left to right as viewed with Column on your left, refer Apollo Hydraulic &...
  • Page 61 Set Product Price Product A = Enter 31-Fill-$ amount(eg 0.86)-Fill Product B = Enter 51-Fill-$ amount-Fill Product C = Enter 71-Fill-$ amount-Fill Note To test Comms. And Console control is working correctly, enter a non real price for each product and then switch unit over to Console control price should then change as set on console.
  • Page 62 Pump stack test 50* 70* This test cheeks the operation of the pump motors (internal or submersible). The motor can be switched on and off, as can the slow and fast flow rates. The flow rate is displayed in the Price per litre display. Pump motor Function number F1 &...
  • Page 63 A p o l l o H y d r a u l i c & I n t r i n s i c C o n n e c t i o n s N e w Z e a l a n d G M E 0 5 / 0 6 / 9 8 u p d a t e 6 / 8 / 9 , 1 5 / 0 9 / 9 8 , 0 5 / 0 5 / 9 9 , 1 0 / 0 2 / 0 0 , 2 5 / 0 3 / 0 1...
  • Page 64 G M E 0 5 / 0 6 / 9 8 A p o l l o H y d r a u l i c & I n t r i n s i c C o n n e c t i o n s A u s t r a l i a u p d a t e 6 / 8 / 9 8 , 1 5 / 0 9 / 9 8 , 0 5 / 0 5 / 9 9 , 1 0 / 0 2 / 0 0 , 2 5 / 0 3 / 0 1 F ile @ G ME...
  • Page 65 Errors This chapter contains the full list of error codes, in numerical order. Errors are normally indicated by the error code (number) being displayed. The error is displayed as ERRxx, where xx is the code number. Errors are also written to an error log. You can check logged errors using Function 02 as detailed in chapter 4.
  • Page 66 Non Volatile Setup Error 05 is a check of the non volatile variables. These are the set up variables which must remain unchanged during a power failure. They remain constant unless changed by a diagnostic function. They are checked (against their backup variables) both at startup (all non-vol variables checked) and dynamically (one byte checked each call from main loop).
  • Page 67 Fatal Errors (excluding fatal startup errors) Errors 10 through to 29 all cause the processor to stop. The errors are displayed but beeps are not sounded. The pump must be reset after one of these errors. 10..15 Pump Control State Errors (Pump A..F) This indicates an attempt to enter an undefined side control state on a particular pump number.
  • Page 68 Solenoid Control Error This indicates that an attempt was made to open or close a solenoid valve when it was already in that state (according to the software). It will also occur (except in diagnostic mode) if an attempt is made to turn on a solenoid valve when the corresponding motor is not on.
  • Page 69 Single Pump Number Fatal Errors Errors 30 through to 59 do not cause a complete system crash, as they relate to a single pump number only. They cause the related pump to stop delivery, and its displays to flash. This continues until the nozzle is replaced and any nozzle on that pump number is removed again.
  • Page 70 Grade 1 Front encoder error (Pump A1) Grade 1 front encoder inputs out of sequence for more than 1 count in 512 (0.19% minimum error rate). This could be due to the encoder missing a count, the rotation being backwards, etc. Grade 1 Rear encoder error (Pump B1) The Grade 1 rear encoder inputs were out of sequence.
  • Page 71 Grade 3 Rear encoder too fast (Pump F3) There was an overflow of either encoder counts or encoder errors detected for the Grade 3 rear encoder. Grade 1 Front encoder run on (Pump A1) Flow did not stop (the encoder was still rotating) at the end of a Grade 1 front hose delivery (i.e. after the "get dribble"...
  • Page 72 Non Fatal System Errors Errors 60 through to 89 do not cause any loss of system functionality. They are logged only (for service use). Comms Channel A errors Channel A Receiver Parity Error This indicates a parity error was detected in one or more of the received message bytes. Channel A Receiver Framing Error Character was received for which no stop bit was detected.
  • Page 73 Comms Channel B errors Channel B Receiver Parity Error Error 70 indicates a parity error was detected in one or more of the received message bytes. Channel B Receiver Framing Error A character was received for which no stop bit was detected. Channel B Receiver Break Error A steady low (space) signal has appeared at a receiver, indicating a break condition at the transmitting end.
  • Page 74 General log only system errors Errors 80 through 89 are general system errors. They are logged only; they do not cause the system to crash. Grade 1 Front Preset Overrun This indicates that the delivery on the Grade 1 Front hose did not stop at the preset or allocation limit.
  • Page 75 Main Processor Board Information & Connections Part Number 87101 The main Processor Board controls all Pump operations, either alone or together with an input Processor Board The basic elements are : 80c31 or 80c32 Processor 64K external program Memory (Eprom) 32K Static Ram (Battery backed 2692 DUART Encoder Interface...
  • Page 76 Display Dip Switch Location Front Preset Display PCB Assy Dip Sw. Dip Sw. 9= Open for Dollars per Litre (no Link) Linked = Cents per Litre Service Agents Pins Ver 2.30p > Air Sense Operation (No Link) Linked for Float Swt. Operation...
  • Page 77 Incoming Pump Comms. Mains & Switched Active Cabling Layout To PEC Main Processor PCB (Comms) Refer Pg 28 Head Cabinet * = FLP Gland Used Valve Wiring Option Layout shown below is used in conjunction only with new version Asco Valve PVG. Model (note: wiring also unsleeved on this version) A C Mains In Switched Active Out Sol_1...
  • Page 78 Control Logic Distribution PCB Assy 87110 Noz_F N oz3 N oz2 Noz_R N oz1 N /C A ir1 A C 3 A ir2 A C 2 A ir3 A C 1 U D D ENC_F3 F_ A ENC_F2 F_ B ENC_F1 R _A ENC_R3...
  • Page 79 Feed Line Detail Elbow B 22-22-12-12 Note distance between test point seals on assy. shown above must be min possible . Inside distance between Bulkhead Seals in Hydraulic Enclosure is, 0.432m therefore feed line Tee termination arrangement must fit within this distance. Above view is as viewed from enclosure (sump) end away from Column (RH end ).
  • Page 80 GME 15/09/98 Up date 27/03/01 File @ GME c:/ mydrawdt/apollo/lay-out.idw Pg. hose spec (Pg 3) External Hose Assy Specifications Above Bry Break Note 1 per each external hose: 5/8 ID Hose @ 250 mm 7/8 SAE Sw/Nut (824170)- 3/4 BSPP Fittings Hose Assy "A"...
  • Page 81 89725 87333 87271 x 3 87271 x 3 87276 87276 07203 16 Way 07203 87333 87329 To Processor PCB To Processor PCB 87328 87328 Apollo Front Door Assy Apollo Rear Door Assy Inside View Inside View 16/04/99 File @ GME c:/mydrawdt/draw/apollo/display.idw...