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Start-up/Service Manual

1. D2 RX D10 TX ii amp ROVROH aoa Comm To Q Terminator ZLUHRU Status PC Serial Pon amp 5 1 OFF OK 9 A B C D E srqgwpoircH on 02 O r CN a ST CN 30 ST WO JO N CO Os pm po pes r r QO QO QO Q QO QO C C C C C QO QO ABCDE OFF ON Flash LON SERVICE System 5 p yu NoPower enum ON The nodehasno Heartbeat ids is status Codes valid LHXURQcode J we BOOT Routine is processing data Blinks twice a second O BOOT
2. MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 25 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Jump Jacks Jump Jack Purpose Status JP1 Reset CRIND Control Node only JP2 Coldstat notyetavallabl 4 0000000000 JP3 N A nofidlduse U 0000 JP4 JP5 Selects type of communication between PCN M00077A001 Totalizer Node and CCN e If JJ is installed on Pins 1 2 PCN and CCN communicate through 2 wire interface e If JJ
3. Manager s Name Date of Service Street Address Y OK or Service Performed O Broken Missing Etc City Explain All Items Marked O In Space Provided Phone Type of POS System Installed Passport G SITE TS 1000 Typeof Vapor Recovery System Installed Other POS System DOS PR A A Workstation 1 2 3 4 5 6 7 8 Workstation 1 Workstation 2 1 Clean Printer s Model Model 2 Remove Printer Paper Dust Serial Serial 3 Check Printer Operation 4 Check for Dedicated Isolated Circuit 5 Lubricate Cash Drawer Assembly per AGP spec Workstation 3 Workstation 4 6 Check Condition of Cables and Power Cords cuts frays bends Model Model 7 Check Condition of Plugs Serial Serial 8 Clean Keyboard Case G SITE amp TS 1000 9 Clean amp Dust Console amp Surrounding Area 10 Clean Card Reader with Cleaning Card Q12534 170 Workstation 5 Workstation 6 11 Check Hard Drive amp Note Bad Sectors G SITE only Model Model 12 Clean Floppy Drive with Q13476 101 see instructions Serial Serial 13 Check Presence amp Condition of R20391 01 FD Dust Cover 486 amp Pentium G SITE only 14 Vacuum not blow Power Supply Air Inlet amp Front Bezel Workstation 7 Workstation 8 15 Degauss Monitor Passport only
4. i PCB B 9 C P801 PPU Display Board Single or Dual P2115 CRIND Z180 Logic PB P2110 Em a Used IQOO 0X0 IOO s 1OOM Board Connections and Cables Connector Via Cable To Board At Connector P801 34 pin Mo1650A001 T17764 G3 4 CRIND Z180 Logic Board P264 6 pin M01621A001 Totalizer Interface PCA P1507 12 pin M01522A001 Single PPU Board P2201 2 pin M01525A001 Dual PPU PCA 804A 20 pin M01585A001 _MO1522A001 Single PPU Board P121 20pin M01525A001 Dual PPU PCA P2110 2 pin Currently not used P2115 3 pin M01650A001 Same as P801 above J2115 3 pin MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Displays Main PPU CRIND Electronic and Electrical Components Test Points Connector Pin Number Range Current P801 18 5 VDC 5 70 mA P801 20 0 VDC P2115 1to 3 9 4 VAC 1 10 2 2A JP1 Jump Jack Settings Side 1 A B Side 2 A B Master A B Reset Connector Pin Functions and Voltage P801 Pin Functions and Voltages
5. a oonnononnn o UUUUUUUU UUUUUUUU TOOT UUUUUUUU EL HL NR ol TMM ol TOTO TOOT TOOT nonnonnon o UTUUUUUUU DIRECT g CONNECT nn PARE nn h C B LON SER nnnnnnnr TUHUUUUUU BULL INA EHI zo Ee ETHERNET p 5 B DBG EN p p UIl5 UI gt F nu LON PRO o QO Depos STATUS 4ORDI 4c Q013 TERMI TUDTVTTTU LON TERM d det um IPS E n JP BRD ADDR TUONO ERIDORD DRACO o PIIO7 EXPANSION MEMORY 2W TX dCbDIO NEURON Cl3 0 Gilbarco Made in U S A SN TATA ATE THOT 695 Qjpnononconconcoononconsoono ETHERNET 2 P CONTROL NODE A TAA gt mtn o TOTO Cl6 r3 C18 c R20 ANAC TOOT TOOT DUUM THOTT IFSF AUXILIARY 1 0 UUUUUUUU WD ENABLE 7 JP7 28
6. 0 2002 6 43 M01753A001 CRIND Control Node 2 0 0 00 c eee 6 45 M01785A001 Door Node 2 0 0 eee 6 49 M01922A001 Pump Control Node 2 0 00 cee ee 6 53 M02044A001 Valve Converter PCA nananana 0 0 00 cee eee 6 56 M02097A001 Steering Valve Relay PCA 00005 6 57 M02335A001 Valve Converter PCA nananana aana aaaea anaana 6 58 T17764 G3 4 CRIND Z180 Logic Board n nnan aa anaana anaa 6 60 T19501 G2 Monochrome CPU PCA 0 000 eee 6 67 T20306 G1 CRIND Regulator PCA 0 0 cee eee 6 69 xoc SUPDIES mc 6 71 M00488AXXX Voltage Select Plug 0 0 0 6 72 M00050A001 Power Supply Board 18 VDC 6 73 M00053A002 Power Supply Board 24 VDC Ls 6 76 M00458A002 Encore 500 and Eclipse Power Supply 6 78 M01608A001 Encore 300 and Ultra Hi Power Supply 6 79 M02274A001 Universal Power Supply for Encore 300 Encore 500 arid ECIIDSO errad x cbr aw acr 6 80 M02774A001 Universal Power Supply 2 PCA for Encore 500 ANG ECUIDSCs ie cto be Rabe OL e atas da tn oma dura mec t td atis 6 82 Displays Main PPU CRIND seseeeel RR rns 6 85 About DISD SVS s 2 uci deca nant PS icles d ob dax eet Beier E rca dos 6 85 M01515A001 Main Display for Encore 300 6 86 M02652A003 and A004 PPU Single Display Module for Encore 300 6 89 M02652A007 and A008 PPU Dual Display Module for Encore 300 6 9
7. Pin Description Voltage Range 1 MAIN DATA A3 0to5V 2 MAIN DATA A2 0to5V 3 MAIN DATA A1 0to5V 4 MAIN DATA AO 0to5V 5 MAIN DATA B3 0to5V 6 MAIN DATA B2 0to5V 7 MAIN DATA B1 0to5V 8 MAIN DATA BO 0to5V 9 Not used 10 Not used 11 COM CONT 0to5V 12 Not used 13 CREDIT ST 0to5V 14 CASH ST 0to5V 15 DSEL1 0to5V 16 DSELO 0to5V 17 ST3 0to5V 18 5V 5V 19 ST2 0to5V 20 GND OV 21 ST1 0to5V 22 Not used 23 STO 0to5V 24 Not used 25 CASH DP 0to5V 26 MSTR RAM CLR 0V 27 VOLUME DP 0to5V 28 Not used 29 PPU DP 0to5V MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 87 Electronic and Electrical Components Page 6 88 Displays Main PPU CRIND Pin Description Voltage Range 30 Not used 31 MAIN ENABLE 0to5V 32 Not used 33 Not used 34 Not used P804A Pin Functions and Voltages Pin o CO NI O oa C N 10 P2110 Pin Functions and Voltages Description DO DATA D1 DATA DGTSEL1 D2 DATA DGTSELO D3 DATA ST CRDT ADD A2 ADD AO ADD A1 ADD A3 5V ST CASH OPCOMS GND OPCOM4 OPDP4 OPDP3 OPDP2 OPBP Voltage Range 0to5V 0to5V 0to5V 0to5V 0to5V 0to5V 0to5V 0to5V 0to5V 0to5V 0to5V 5V 0to5V 0to5V OV 0to5V 0to5V 0to5V 0to5V 0to5V Pin Description Voltage Range 1 9 4 VAC 9 4 VAC 10 2 9 4 VACRTN P2115 Pin Functions and Voltages Pin Description Voltage Range 1 9 4 VAC 9 4 VAC 10 2 Not used 3
8. Backplane C27 rc et ie Color Only P3116 Pump Control Page 6 24 i 125 pin N Node PC Serial Future P3112 Monochrome Interface Board ree Not MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Board Connections and Cables Connector Via Cable To Board At Connector P3101 5 pin M00497A002 SmartPad Side 2 12 pin P3102 5 pin M00497A002 SmartPad Side 1 12 pin P3103 34 pin M00716 A001 CRIND Auxiliary Board M00095A001 P3403 34 pin P3104 30 pin M00716A002 P3404 30 pin P3105 3 pin M00635A001 Terminal Block 2 in Power Supply CRIND Retrofits Only P3107 10 pin M00489A001 LON Header 1 10 pin P3108 10 pin LON Header 2 10 pin P3109 14 pin TI Gateway PCA J3110 P3110 14 pin M00515A001 TRIND Gateway PCA P250 P3111 10 pin M00719A001 Encore Serial Programming Port when available M00719A002 Eclipse P3112 20 pin M00545A001 M00095A001 CRIND Auxiliary I O Board P3301 P3113 125 pin M00101A001 CPCI Backplane Assembly In Design P3114 10 pin not used N A P3116 Serial Port on M00077A001 Totalizer Node Future P3118 2 pin M00491A001 M00056A001 Pump Node P1109 M01922A001 Pump Node Status LEDs Jump Jacks and Test Points Figure 6 11 CRIND Control Node Jump Jacks and Test Points TP1 TP2 TP3 TP4 JP3 JP4
9. BT1 P3107 LON Header 1 P3108 LON Lithium Battery 3 2V Q12674 01 nnnunnrnn UUUUJUUUU Header 2 lt F P3110 TRIND Not Used nunnnnrnr UTUUUUUUUTmUUuUUU E25 mU JUUUuUu P3118 Dispenser 2 Wire TOTO P3109 To Gateway PCA for TRIND nnnnnnrn UUUmUuu Gilbarco Made in U S A R26 UHUUTJUUUU aN P3113 CPCI nnnnnnnn nnnnnnrnrn UUUTJUUuUuU nnnnnnnrm HmuUuUuUuuuu c o co P3111 PC Serial LA Le
10. 0 0 0 eee 7 49 ADOUFE GDP 2 244 c bs aatia rb d aaa r a Goatees kOe 7 49 General GDP Service ProceduresS 0000 cee eee eee 7 50 DraIningtinG GDP a cs uio nee ne Behe ae ke ae a oe oe ea eal 7 50 Strainer Check Valve Service 0 c cc ees 7 52 Pressure Control Valve Service 0 eee 7 54 PUMP Device MIOLOF uas ae gor wae ERR RE CREER CR T eR Eae Sark a glk Ae aa ev Seed Roe ew pee reek RC es 7 56 Contents in this Sub section llle ees 7 56 About Electric Motor for Self Contained Pump Units 7 56 Belis ana PUNCYS uas tein veces etaed of mies Bed od eap a he tae 7 57 RIO VU OLS setter ct rach ee ors te alae po aes Ade ae are heh apna ace ek oth He MT IRE 7 58 VINO 56 82 Ue Ol hw eS Mein NS Sete ee a ee ae Retin Mees elas Sil eh Siew Ses Ba 7 59 Contents in this Sub section 0 0 ees 7 59 Check Valves at Manifold and Meter 0000 7 59 Bs 7 61 Proportional Control Valve 1 0 eee 7 63 Shear ValVes s s edades Ex Ea EJ ES eee Lede ee xS 7 66 Solenold ValV6S ss Uere one Hane Med Ow ee a as a ee einen eos Des 7 67 Steering Valves 1 cc eee eens 7 68 Vapor Valve Vapor Vac ise Ge Gia o oe oy Yo ao a d Be oen 7 68 Vapor Recovery Components saasaa aaeeea 7 69 Contents in this Sub section nannaa aaa eaa 7 69 VaporVac Assemblies 0 0 00 eee ees 7 69 Common Vapor Recovery Testing Procedures 7 70 Calibrating Vap
11. Lift up Access Cover Lift by Tab A Y i Aluminum Box Node housing extends past paper holder for Eclipse Figure 6 57 Printer LON Board Connections for Encore 500 and Eclipse Jump Jack OUT Side 1 IN Side 2 4l 24v Power Cable Connector IUUUUUUUUU LON Terminator T Printer Assembly Viewed From Underneath Bottom LON Header Cable Connector AT 5 UJUuUUUUUU Jump Jack Settings Jump Jack For This Side Jumper Setting Is JP 1 1 OUT 2 IN Page 6 108 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical Components Replacing CRIND Receipt Printer Paper It is important to keep the CRIND receipt printer supplied with paper If the CRIND printer is low on paper or out of paper the Cash Acceptor will not accept bills Note You may encounter different printers Follow the paper change instructions on the print
12. QUII RII IU X Too TOTO gt gt de E E q de E g g g E E g de E q g g E g g do E E q g oe g E g g g E d UUUUUUUU UUUUUUUU UUUUUUUU UUUUUUUU UUUUUUUU 30 nnnnnnnn 5 C29 ASSY M00056A00 REV Test Points Test Point Range TP 1 Battery 2 0 to 3 6 VDC TP 2 NV_VCC TP 3 14 to 22 8 VDC TP 4 4 75 to 5 25 VDC TP 5 3 0 to 3 6 VDC TP 6 GND Jump Jacks Jumper Description JP 1 NA JP 5 Coldstart if available see Service Tips on page 6 8 JP 6 Board Address IN suppresses minor nuisance error codes but still recorded in Event Logs JP 7 Watchdog Enable always IN JP 8 Disconnect Battery if IN NVRAM is NOT battery backed preserves power JP 9 Resets Processor short with power on if available Page 6 12 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M00059A00X Valve Driver PCA M00059A001 Board is standard for Encore 500 and Eclipse with digital valves M00059A002 is a fully loaded version for 4 Grade and steering valve equipped units multi hose blenders The board drives all valves and senses current through the valves for automatic configura
13. 5 seconds 1 15 seconds 30 seconds 45 seconds 60 seconds 75 seconds 90 seconds CO NI OM ony By WY N 120 seconds Page 5 20 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Function Code 13 Slowdown Ultra Hi units only Models NPO NP3 NP4 and NP5 Note This programming mode or Command Code 13 Function Code 4 can be used by Ultra Hi models The last Function Code programmed will be used by the unit regardless of the setting of the other code Program the point at which the dispenser goes into slowdown on all non blenders Not all software version offers all of the selections noted here Normally stations not offering prepays can be set at minimum times Higher values can be selected if preset targets are not hit consistently Select three preset sales minimums at the setting to allow the dispenser to learn the new value before drawing conclusions regarding a setting s ability to correct the preset problem For This Slowdown Press Configuration 070 gallons 265 liters 0 120 gallons 454 liters 170 gallons 643 liters 220 gallons 833 liters Default 270 gallons 1 02 liters 320 gallons 1 21 liters 370 gallons 1 40 liters 420 gallons 1 59 liters 470 gallons 1 78 liters O CO NI omy oy A N 520 gallons 1 97 liters Function Code 14 Push to Start for G6
14. Figure 1 4 Model Serial Number Example for Units Manufactured in January 2003 and Later Serial Number C GILBARCO Mfd By MUT ace ENCORE 388 REGISTER VEEDER ROOT Greensboro T Unit SERIAL 26514 Type m te EU LO A Date Code EC wa tage Voltage 115 UAV A Hertz 50 60 P CC NO 02 019 Amps 13 0 Model or use with equipment specified in installation Options Options ode instructions N Y F D C OF A 4986 CRIND 5 7 MONO Number POWER OPERATED DISPENSING DEVICE USER STRRT FOR FLAMMABLE LIQUIDS 34GL URPOR URC TOTRLIZER LISTED CRUTION H dof trical shack more than ene disconnect a may ee E energize ibe device TOR Servicing WARNING o not dj jsconnect connectors fuseholders lampholders etc e Suouii Js ali MB29898101 REUB Definitions of Fields Term Definition Model Number Contains Unit configuration information Options The Options is a list of customer driven options per unit Serial Number The Serial Number identifies the unit by customer Unit Type The Unit Type provides the type of unit for example Encore 500 or Eclipse MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 1 5 Read this First Model Information Model Codes Encore The Model Number provides information on the configuration and options of the unit In the example in Figure 1 3 on page 1 5 the model number NCO corresponds to an Encore Unit Type Pump and multi hose single grade unit wher
15. 2008 Calibration procedure requires that each parameter be entered before advancing to next procedure step If a parameter is not entered dispenser display will wait until parameter is entered Entries are not checked for errors and are thus accepted and used as entered by programmer Entry into meter calibration will default to Side 1 with no units programmed by default Page 5 72 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Layout and digit position is shown in the following diagram Figure 5 73 Layout and digit position Display qoom oan dean cms furo Com Can Can Can Pump man mand Size Size Size Side Code Code gt P U Units Meter Under Code Number Over For information on diagnosing calibration problems refer the Troubleshooting on page 8 28 section of this manual Pump software V 1 7 58 and higher for Encore 5XX and Eclipse contains enhancements to simplify the meter calibration verification and calibration process It is no longer necessary to run a separate verification process to determine if meter is properly calibrated and then run a separate calibration setting if so required With This Version Pump Software Refer To V1 7 58 or higher Enhanced Meter Calibration and Audit section on page 5 74 Prior to V1 7 58 Standard Meter Calibration Procedure Pre V1 7 58 software section on page 5 79 After co
16. The Monochrome LCD CRIND displays multiline prompts advertising messages and graphics no video on a monochrome LCD screen on the CRIND door The color display is a CRIND option that allows CRIND devices to display multiline prompts advertising messages graphics and videos on a full color screen on the CRIND door The cash acceptor option allows CRIND devices to accept cash payments in addition to credit and debit cards The External CRIND eCRIND adds card reader capabilities to a competitive pump The Card Reader reads the magnetic stripes on standard credit cards and debit cards Figure 8 15 Various CRIND Devices on Eclipse and Encore Units Reader MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Eclipse Customer Display Encore neypad Card Reader Cash Acceptor Scanner CRIND device printer z i Ld TRIND target Crind Device Printer Keypad Page 8 17 Theory of Operation and Troubleshooting Theory of Operation How a TRIND Device Works Overview The TRIND device is an option available as a retrofit kit or factory installed device The device is connected to the CRIND device via a Gateway or Serial Interface board In this application the TRIND device is a software slave to the CRIND and the associated Point Of sale POS Controller Host This means that a properly working TRIND system will look for and read tags but only when told to do so by the controller thr
17. Units take a long time to prime Units are noisy Use of a combined vacuum and pressure gauge eliminates the need to calibrate more than one gauge Figure 7 4 Typical Pressure Gauge Dial Typical Pressure Gauge Dial Face Ensure that you e Always use accurate calibrated gauges using gauge snubber or dampened gauge will help to prevent gauge damage and obtain more accurate readings Use gauges that have the appropriate scales for reading in pounds per square inch scale 0 100 PSI for pressure and 0 30 Hg inches of mercury for vacuum Pressure Measuring Locations on Unit For Dispensers Install the pressure gauge at any one of the following locations See Figure 7 5 on page 7 14 To Check Insert the Pressure Gauge in the Inlet pressure Shear valve test port Location A Internal pressure up to first valve Port on special modified filter cap Location B Discharge pressure Special Discharge fitting Location C MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 13 Hydraulic Mechanical Components Measuring Pressure and Vacuum Figure 7 5 Typical Pressure Gauge Installations Hydraulic Special Discharge Manifold AN T fitting E o3 Hia pan JEA d zx SETS rro 227 Special Filter Cap Test Port Location C Pressure Gauge in Discharge Fitting Location A Pressure Gauge in Shear Valve dispenser only Location B Pressure Gauge in Filter
18. Valves Hydraulic Mechanical Components Digital Valve Seepage SB1447 Current seals used in the digital valve are capable of handling very low temperatures However some sites have noted seepage at 15 degrees Fahrenheit or colder If sites with digital valves in your area have experienced extreme cold weather seepage at the valve seals the units can be fixed by using special seals and a new valve cover developed for extremely cold areas Depending upon fuels tolerances and other factors some valves will require this special kit It is generally only necessary to use the special kit where seepage is noted to occur when temperatures are extremely low approximately 15 degrees F or colder Monthly leak inspections of the dispenser hydraulics will detect any leaks that may develop The cold weather digital valve seal kit is K94444 05 The standard seal kit is K94444 03 The standard kit is considerably less costly than the 05 kit Also the standard kit is completely acceptable for even cold sites Hence use of the cold weather seal kits across the board is not recommended For additional information refer to MDE 4242 The Advantage Encore Eclipse Digital Valve Rebuild Kit Figure 7 39 Proper Diaphragm Fold Diaphragm Fold Path Proportional Control Valve The Gilbarco PCV uses an analog signal to control flow This feature provides smooth and quiet operation Coils and conduit are a combined unit and are easily replaced For deta
19. About Filters A noticeably slower flow rate very commonly indicates a dirty filter or clogged strainer Very slow flow rates also result from water alert filters if water is in the tank For efficient operation and long life of pumps and dispensers replace fuel filters and clean strainers regularly e After 50 000 gallons 189 000 liters or one month for new installations Every 300 000 gallons 1 134 000 liters or six months thereafter Notes 1 Harsh environments including old steel fuel storage tanks may require changing filters and cleaning strainers more frequently 2 Conversions from non alcohol to alcohol enhanced fuels will typically result in less frequent filter changes due to the cleaning effect of alcohol in the tanks and piping Page 7 22 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Filters and Strainers Hydraulic Mechanical Components Always use Gilbarco filters standard water alert and high capacity Filter Description Part Number Where Used Standard Standard 10 micron nominal Hydrosorb 2 R20039 Encore Eclipse flow Water Alert for gasoline diesel and other blend fuels Standard 10 micron nominal Alcohol H19736 10 Encore Eclipse Monitor for alcohol blend fuels High High capacity 30 micron nominal MO02264B001 Encore Ultra Hi capacity Particulate for all fuels 11 long Servicing Filters Before Removing Filters Read and follow all safety precautions as outlined in Read t
20. Pin 4 SmartPad RXD Pin 6 SmartPad TXD Printed Circuit Assemblies and Nodes MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes P290 Voice Output Module Electronic and Electrical Components Test Point Voltage Pin 1 GND Pin 2 VOM Data Pin 3 5 V Pin 4 VOM Clock Jump Jack Settings Setting Jump Jack Function Setting Function JP 1 In In Watch dog enable Out Watch dog disable JP2 Out Card Reader Inverts Active Low Clock Signals JP3 Out Card Reader Inverts Active Low Data Signals JP4 JP8 In Out CRIND Address See CRIND Logic Board Address Settings on page 6 66 JP9 Out Diagnostics IN Enters Diagnostic Mode At Power Up JP10 Out Hydraulic Test IN Enters Hydraulic Test At Power Up MOC only See Baud Rate Settings below JP11 Out Coldstart IN Performs Coldstart At Power Up In G CAT4 Always IN for G CAT 4 JP12 In IN Single line CRIND or CRIND with InfoScreen Out OUT CRIND with Monochrome LCD OUT lowers volume JP13 In Side 1 Master Slave Configuration MOC only IN Sets CRIND As Side 1 Master Out Side 2 JP13 has no affect for G CAT4 JP14 Out MOC Selects Generic or MOC IN Sets CRIND for generic TEC JP14 is not used with G CAT4 JP15 Out Download selection menu JP16 Out Spare MOC only JP17 Out Spare JP18 Out Spare JP19 IN BIOS selector IN Generic BIOS only JP20 Out Spare JP21 Out Spare MDE 3804B Encore a
21. To Board At Connector P552 12 pin M01668A002 harness T17764 G3 4 CRIND Z180 Logic Board Side 2 P251 12 pin P553 12 pin M01668A001 harness T17764 G3 4 CRIND Z180 Logic Board Side 1 P556 4 pin M01650A001 harness T17764 G3 4 CRIND Z180 Logic Board Side 1 J262 6 pin M01664A001 harness to field wiring P412 4 pin P557 4 pin P558 4 pin P559 15 pin M01662A001 M01608A00 Main Power Supply J606 6 pin P561 7 pin M01668A001 harness T17764 G3 4 CRIND Z180 Logic Board Side 1 harness P562 11 pin P563 5 pin Q13908 01 Monochrome Display Side 1 J5 2 pin P565 11 pin P566 5 pin Q13908 01 Monochrome Display Side 2 J5 2 pin P569 8 pin M01668A001 harness T17764 G3 4 CRIND Z180 Logic Board Side 1 P266 8 pin P570 8 pin M01668A002 harness T17764 G3 4 CRIND Z180 Logic Board Side 2 P571 11 pin M01668A001 harness T17764 G3 4 CRIND Z180 Logic Board Side 1 harness P564 7 pin M01668A002 harness T17764 G3 4 CRIND Z180 Logic Board Side 2 harness P572 11 pin M01668A002 harness T17764 G3 4 CRIND Z180 Logic Board Side 2 SK 6 pin M01663A001 T19501 G2 Monochrome CPU PCA P2014 2 pin Test Points Test Point Voltage TP1 5 V BATT TP2 59 V Single CRIND Display Voltage TP3 5 V TP4 5 V Unregulated TP5 2 5V TP6 DC GND TP7 24 V Page 6 70 MDE 3804B Encore and Eclipse Start up Service Manual Augu
22. mmn Wilh du mmm nnnnnnnn ELE LLL IL ZN ZI AMO LIO LOL IL Wii b r9 x roroi TITITITITUTITIT UTI P201 Hydraulic P202 Totalizer P206 Steering oe Interface Board P205 Hydraulic Interface board Valve Board Ire Data Interface Board P203 Managers K Note See the following tables for descriptions of callouts on this board Eypae Page 6 40 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components LED Indicators LED Indicates CR 1 On two wire loop reversed CR 2 Blinking transmitting data CR 3 On CPU is on CR 4 Blinking 2 receiving data from console Memory IC Description U4 Firmware location Board Connections and Cables Connector Via Cable To Board At Connector P135A B 12 pin M01650A001 T17764 G3 4 CRIND Z180 Logic Board P264 6 pin MIS M01621A001 Totalizer Interface PCA P1507 12 pin M01522A001 Single PPU Board P2201 2pin M01525A001 Dual PPUPCA P2201 2pin P201 20 pin H17995 G7 M01546A001 Hydraulic Interface PCA P101 20 pin P202 12 pin M01650A001 harness see above P203 10 pin P204 34 pin P206 10 pin Not used P402 2 PIN M01664A001 2 Wire from Field Wiring P1123 3 PIN M00150A001 E cal Security Switch P201 Connector Pin Functions and Voltages Pin Description I O Max Low Max High 1 SYS RESET O 0 10 VDC 4 50 VDC 2 VVac Error 0 80 VDC 2 00 VDC 3 TXB O 0 40
23. pressure Return pump handle to off position 8 Turn off power 9 Remove pressure gauges purge air and restore unit to original operation MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 15 Hydraulic Mechanical Components Measuring Pressure and Vacuum Analyzing Pressure Drop for Dispenser and Pumps Page 7 16 Pressure drop across components increases as total flow rate increases Total system pressure drop Product Lift from bottom of STP to dispenser base Pressure drop through external piping Pressure drop through dispenser including hose and nozzle Pressure drop through external piping segments will vary depending on size and types of piping used If total system pressure drop at total flow rate is less than STP pressure at that flow rate system will develop desired flow rate Figure 7 7 Graph for C Meter and 1 1 2 Inch Shear Valve 4 Ci 0 S 9 o A 10 15 20 25 30 35 40 GPM 0 19 38 57 76 95 114 132 151 LPM Flowrale mem Determining if Component is Faulty To determine 1f the component is faulty proceed as follows Always check replace filter and strainer before performing the test Determine dispenser pressure and flow rate at base of dispenser with nozzle wide open Note If the pressure at the base of the dispenser is substantially lower the dispenser is functioning correctly Compare observed flow rates to the actual inlet pressure for
24. u n Fe U6 gt en PUMP CONTROL NODE e jel lel fe e p o 1124 o down Test Points Test Point Value TP1 2 to 3 6 VDC TP2 2 to 3 6 VDC TP3 14 to 28 VDC TP4 4 75 to 5 25 VDC TP5 3 to 3 6 VDC TP6 common Where Used Battery Voltage Memory Voltage Lon Voltage Logic Voltage Logic Voltage For DC Voltage MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 55 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Jump Jacks Jumper Setting Function JP2 Out LON service see Note 2 JP3 Out Debug enabled see Note 2 JP4 Out LON programming see Note 1 JP5 Out Coldstart JP6 In Board address JP7 In Watchdog enabled JP8 Out Battery disconnect JP10 Out N A JP11 Out N A Notes 1 Used in manufacturing 2 Used in board repair M02044A001 Valve Converter PCA This board is 1n Encore 500 and the Eclipse series units with Proportional Flow Control Valves PFCV This board is the equivalent to the Encore 500 and Eclipse units with the digital valve driver board Service Tip Voltage to coils typically varies from 10 to 18 VDC during operation depending upon operating conditions Coil resistance is 40 to 45 ohms Figure 6 25 Valve Converter PCA M02044A
25. 1 of 3 1 blender only When Grade 6 3 1 blender programming has been enabled the G6 1 grade selection button must be pressed before fuel can be delivered for G6 To Program Zero PPU Pricing Press Configuration Disabled not installed 0 Enabled 1 Function Code 15 Zero PPU Pricing Allows fuel dispensing with a PPU of zero fleet operations only To Program Zero PPU Pricing Press Configuration Disabled Default 0 Enabled 1 Function Code 16 Beeper Time out Use with Function Code 12 to give an audible signal after pump time out After pump time out the beeper beeps for the programmed seconds then deactivates the dispensing unit with Error Code 29 Error Code 29 is dismissed by returning the nozzle to the nozzle boot Beeper Time out Press Configuration None Default 0 5 seconds 1 15 seconds 30 seconds 45 seconds or Bl O N 60 seconds MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 21 Pump Programming Encore 300 Programming and Data Access Instructions Beeper Time out Press Configuration 75 seconds 6 90 seconds 7 120 seconds 8 Function Code 17 Stop Control Deactivates one or both sides of a dispenser when optional Push To Stop Button is pressed To Program STOP Control Press Configuration For one side Default 0 For two sides 1 Function Code 18 Zero Previous Transaction Programs the dispenser to reset to zero the transaction displayed after e the pump h
26. 118015 VaporVac Valve Driver PCA 0 00 00 eee 6 117 118018 VaporVac Motor Drive PCA 0 000 6 119 T19401 VaporVac Controller PCA 0 0 0 cee 6 121 VaporVac Power Supplies llle 6 123 7 Hydraulic Mechanical Components 7 1 ADOT TIS SOCIO sun dr RECS IE beh Bur Bo oo SP A Oe Bo lad tomus uS Ae bei gra ur Be uei 7 1 Important Information about Releases slllusss 7 1 Topics in this Section aaa aaa 7 1 DECHON OVEWICW o5 dh dard Qe Quoc endete E 8 ee hese de o 7 1 How to Use this Section llle 7 2 Abbreviations and Acronyms llle 7 2 Terms Used in this Section llle 7 2 General Service Procedures a qudd Y Apu te ger eder ERO torret ud keen etees uos 7 3 About Servicing Hydraulic Components 000 ce eee 7 4 Servicing Seals O Rings and Gaskets lll 7 4 Pipes and Hydraulic Plumbing 0 00 cece eee eee 7 5 Torque SOCCIICALIONS 3 3 Borcher s eos US mr or ber a doe 7 5 Purging Air from the System sss ek eek e ER REGERE REG E REG ed Eus 7 7 Topics inthis SUD SCCHON i ass es ire oro edo Se wa daw SS Ab Den ee 7 7 About Purging System 0 0 eee eee 7 7 Purging Product Lines Dispenser 00000 e eee eee 7 7 Purging Pumps and Dispensers with fuel in product lines 7 9 WEaSULING row ales o3 aedes ad eae Moa dae pet bie PONI deat fien tact Dei ded way es des 7 11 Me
27. 3 pin T18162 VaporVac Power 3 pin Supply Assembly P1203 12 pin Encore T17928 G2 VaporVac Valves e Encore P1 on cable to M00845A001 Valve s J11 J12 cable at J P 1030 to J13 J21 J22 J23 M00830A001 cable at J Eclipse J13 J21 P2030 to P1 e Eclipse M00981A001 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 117 Electronic and Electrical Components VaporVac Electrical Components Page 6 118 Jump Jack Settings Multi hose Units Encore Series units only Diesel On Grade Unit Type If Applicable Side 1 Side 2 2 2 Grade 2 Hose MPD N A JP1A JP2A JP9A JP10A 1 JP2A JP10A 2 JP1A JP9A 3 3Grade 3HoseMPD NA JP1A JP2A JP3A JP9A JPIOA JPHA 1 JP2A JP3A JP10A JP11A 2 JP1A JP3A JP9A JP11A 3 JP1A JP2A JP9A JP10A 4 4Grade 4HoseMPD NA NA NA 1 JP1B JP2B JP3B JP9B JP10B JP11B 2 JP1A JP2B JP3B JP9A JP10B JP11B 3 JP1A JP2A JP3B JP9A JP10A JP11B 4 JP1A JP2A JP3A JP9A JP10A JP11A 8 3 Grade 3 Hose Blender NA JP1A JP2A JP3A JP9A JPIOA JPHA 10 3 Grade 3 Hose 1 Meter NA JP1A JP2A JP3A X JP9A JPIOA JPHA MPD Single Hose Units Encore and Eclipse Series units Unit Type Side 1 Side 2 1 1 Grade 1 Hose MPD JP1A JP9A 5 2 Grade 1 Hose MPD 6 3 Grade 1 Hose MPD 11 3 Grade 1 Hose 1 Meter MPD 12 2 Grade 1 Hose Blender 13 3 Grade 1 Hose Blender 14 4 Grade 1 Hose Blender 15 5 Grade 1 Hose Blender Single Hose
28. 5 40 5 41 5 42 5 45 5 46 5 40 5 53 5 56 5 58 5 59 5 60 5 63 5 68 5 70 5 71 5 75 5 76 5 77 5 78 5 79 5 80 5 83 5 86 5 87 5 88 5 90 5 92 5 95 5 97 5 98 5 99 5 100 5 101 5 102 5 103 5 105 5 107 5 108 5 114 5 115 5 118 5 120 5 121 5 122 Grades Recommended 4 23 Grounding 1 7 G SITE Programming Pumps Dispensers With 4 20 H Help Requesting Technical 1 2 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 High Low Grade Blend Ratio 4 22 Hoses Maintenance 3 2 Pressurization Option 4 19 IDs Programming Two Wire 4 20 Incremental Pump Preset 4 11 Inlet Pressure Testing on Dispensers 6 14 Inspecting Hoses 6 28 Pulleys 6 57 Inspection Preventive Maintenance 3 1 Internal Pressure Testing on Dispensers 6 14 IS Barriers Testing 6 46 J Jump Jack Settings T17764 Logic Board 5 66 T19501 Monochrome CPU Board 5 41 5 42 5 57 5 68 5 90 5 92 Junction Boxes Safety Information 1 7 K Keypad Dispenser Programming 4 1 L Lamps Testing 4 18 Last Transaction Displaying DLT see DLT Leaks Internal Testing 6 72 Preventing 3 2 Vapor Recovery Systems Testing 6 71 LED Indicators T17764 Logic Board 5 63 Lights see also Lamps Lock Out Tag Out Requirements 1 9 Low Flow Rates Causes 6 21 Low Grade Blend Ratio see High Low Grade Blend Ratio M M00044 Terminal Block Board 5 61 M00047 STP Driver Board 5 7 M00050 Power Supply Board 18 VDC 5 81
29. 5602 ATC node incorrect software version 5606 ATC node subscription failed 5609 ATC software not up to date Service Tips ATC will not function unless the fuel density is entered Encore 300 units with Proportional Flow Control Valves PFCV must be used with T20569 T2 ATC Interface Board The G2 version can spare G1 Problems with proper display of side 2 of the unit will occur if proper version board is not used MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 79 Hydraulic Mechanical Components ATC Components This page is intentionally left blank Page 7 80 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Theory of Operation and Troubleshooting 8 Theory of Operation and Troubleshooting About this Section Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section was last updated in August 2007 Topics in this Section Topic Page About this Section 6 1 Theory of Operation 8 2 Understanding Flow Rate 8 2 How a Standard Dispenser Works 8 4 How a Self Contained Pumping Unit Works 8 5 How a Master Satellite Ultra Hi Di
30. 7 Consider Consider length T distance between STP and diameter of hose L and units Master portion Satellite portion PUNY Eee BY IN Consider horsepower of STP motor Page 8 10 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting How VaporVac Vacuum Assist Vapor Recovery Works Note The numbers in Figure 6 11 correspond to the numbered steps below Figure 8 11 How VaporVac Vacuum Assist Vapor Recovery Works Vapor Pump And j Variable Dispenser Speed Schematic Motor Electronic Vapor Vapor Line F ump Controller Coaxial Hose Product Line vapor Eine Underground Storage Tank 1 The customer who is fueling places the VaporVac nozzle in the vehicle s fill pipe Vapors flow through holes in the nozzle spout 2 As the vehicle s fuel tank fills the VaporVac controller uses the pulser signals from the meters to track the real time flow rate 3 The variable speed VaporVac pump creates a vacuum which removes vapors from the vehicle tank at a speed proportional to the real time flow rate 4 The vapors return to the fuel storage tank through standard balance system underground vapor piping There is no need for any additional vapor processing MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 11 Theory of Operation and Troubleshooting Theory of Operation How Stage Two Balance Type Vapo
31. Model Model EN 16 Check UPS Battery Passport only Serial Serial DUMP DISP 2 amp CRIND PR A Dispenser 1 2 4 7 8 9 10 11 12 Pumps Pump 2 1 Check Hoses Type Type 2 Check Nozzles including Connection to Pumps Model Model Dispensers Retaining Springs amp Swivels Serial Serial 3 Check Breakaway Couplings 4 Check Condition of Hose Retrievers if used Pump 3 Pump 4 5 Check Lamps amp Lenses Type Type 6 Check for Exterior Damage Rust Model Model 7 Check Operation Clean Displays Serial Serial 8 Lubricate All Locks 9 Ensure Unit Is Bolted To Island Pump 5 Pump 6 10 Check Bezel amp PPU Gaskets Type Type 11 Check Shear Valve Operation Mounting amp Model Model Lube Serial Serial 12 Check Plumbing for Weeps Leaks 13 Check for Install Filter Instruction Tag and Pump 7 Pump 8 Install if Tag is Not Present see MDE 2215 Type Type 14 Check amp Lubricate All Linkages Model Model _ 15 Ensure Calibration Seals Are Intact Serial Serial 16 Check Junction Box Bolts Plugs 17 Check Pump Handle Switch Pump 9 Pump 10 18 Check Vapor Recovery Plumbing Type Type 19 Check Vapor Recovery Bellows Hoses for Model Model Holes Cuts Cracks Serial Serial 20 Verify that Vapor Recovery System Back Pressure and or Efficiency has been Tested per Pump 11 Pump 12 Regulatory Agencies Type Type 21 Check Belts On Pumps Model Model 22 Ensure Elec
32. Programming 4 24 Thermal Overload 6 56 Time Outs Beeper 4 17 Preselect 4 16 Pump 4 16 Totals Clearing Data Error 31 4 12 Displaying 4 19 4 25 Setting Input Mode CC 7 4 12 Totals Examples 4 5 Transactions Displaying Last DLT 4 25 Zeroing 4 18 Troubleshooting Blender Check Valves 6 60 Pressure Regulating Valves 6 60 Tube Fittings Torque Specifications 6 6 Two Wire Displaying Blank Option 4 16 Programming IDs 4 20 Selecting Mode of Operation 4 10 V Vacuum Assist Systems see Vapor Recovery Systems Pressure Testing 6 13 Vacuum Test Pressure 6 13 Values Programmable Pump Presets 4 18 see also Prices Valves Blender Check 6 60 6 67 Pressure Regulating 6 60 6 67 Repairing 6 61 Vapor Recovery Systems Testing Leaks Pressure Decay 6 71 Testing Performance 6 71 Testing Pressure Drops 6 70 Vapor Sense Option Programming 4 16 VaporVac Alarm 4 15 Verifying Blend Ratio 4 25 Volume Totals Displaying 4 12 4 19 4 25 Inputting 4 12 W Warranty Information 1 2 Wash Waxing Units 3 2 Z Zero PPU Pricing 4 17 Zero Previous Transaction 4 18 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Allen is a registered trademark of Industrial Fasteners Inc Blackmer is a registered trademark of Blackmer a Dover Resources Company Liquid Controls is a trademark of Liquid Controls Corp Phillips is a registered trademark of The Phillips Screw Co VEEDER ROOT Greensboro North Carolina 27420
33. R700 P2114 Door Sensor u30y38 aay Oo R68 R47 RBO RBI R76 O E O GN CD CO C D R270 R490 R190 R170 RI6D RISO R510 R660 R650 R640 R670 R54 P2101 PPU TX and RX to PPUs LEDs P2112 LON Header 2 P2109 LON Header 1 P2115 9 4 VAC Incandescent Backlight Status LEDs P2102 Card Track 2 3 Readers Reader Only LED Status Indication 1 LON Neuron Status ON or blinking indicates LON or Node problem 2 TX or PPU OUT indicates communication to PPU boards 3 RX or PPU IN indicates communication from PPU boards 4 OFF ON when the pump handle is active Test Points Test Point Range TP4 GRND TPS 475Vt0525VDC TP6 14Vto 28 VDC MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Board Connections and Cables Connector Via Cable To Board At Connector P2101 11 pin e M00509A001 or MO02652A00X PPU board one per P2201 MO00509A002 for grade Encore e M00509A0093 for Eclipse P2102 9 pin e M00501A001 Encore Card Reader e M00501A002 Eclipse P2103 5 pin not used P2104 4 pin e M00636A001 Encore Beeper refer to the Encore Series e M00495A001 Cable Block Diagram or the Eclipse MO00636A002 Eclipse X Series Cable Block Diagram P2106 12 pin MO1200A001 Soft Keys Keypad see Encore Cable Block Diagram M00284 P2107 15 pin M01202A001 Encor
34. The following manager functions are available when the unit is in normal operation Verifying Blend Ratios Changes to Blend Ratios and Configuration Changes To verify Blend Ratios Changes to Blend Ratios and Configuration Changes for blenders proceed as follows 1 Press ENTER on the Manager Keypad 2 The PPUs will display the blend ratios programmed Note The volume display will list the number of times that unit of volume configuration changes have been made The sale display will show the number of times blend ratios have been changed 3 Press CLEAR to exit Page 5 30 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Additional Manager Functions for Encore 300 Pump Programming Displaying Last Transaction DLT The last transaction displays for 15 minutes after AC power is lost Unit Totals Retrieval Convention Totals Examples For both TOTAL and VOL TOTAL keys press ENTER to toggle between grade and side selection Non Resettable Money and Volume Totals The dispenser maintains a set of non resettable totals for each dispensed fuel grade These totals reflect total money and volume since dispenser installation time Following are keypad and display examples for viewing dispenser non resettable money and volume totals Money and Volume Totals Use the TOTAL key to retrieve money totals for each fuel grade This and the VOL TOTAL key do not require a Security PIN Code Use the CLEAR key to exi
35. These units are available in the following formats e Standalone unit without a satellite e Master unit that combines a standalone unit with piping to direct flow to the satellite Master Satellite Combo combines a master and satellite combination within the same unit Note Actual flow rate depends on installation and accessories used Some local codes do not allow simultaneous operation of master and satellite Unit Descriptions Master Piping in the master is teed before the master s solenoid valve to send product to the satellite This arrangement allows for a higher flow rate in the master and satellite units when operating simultaneously IMPORTANT INFORMATION Refer to NFPA 30A local and state regulations to determine what type of operation is allowed in your area Satellite The satellite unit operates in conjunction with a master unit which meters the fuel It contains minimal electronics and hydraulics consisting of a shear valve solenoid valves hose and nozzle A combo unit 1s a master for a remote satellite unit and 1s a satellite for a remote master or another combo unit Figure 8 5 Various Encore Ultra Hi Configurations Single Satellite Single Mast le Master a Hose Casting a Hose Casting Breakaway Breakaway Breakaway Swivel Swivel L1 e AT E ee e MAT a CN Hose Casting S aiti ICO iii E LILID M4 Shear Valve eee a Valve Um Valve Fittings d ba Product Line Undergroun
36. and Eclipse Start up Service Manual August 2007 Page 7 3 Hydraulic Mechanical Components General Service Procedures About Servicing Hydraulic Components Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections Use OSHA Lock out and Tag out procedures Before Beginning Ensure that the unit is not pressurized with fuel For dispensers close and test shear valves Refer to Shear Valves on page 7 66 for details Isolate the unit at the distribution box Turn off power to the unit In case of dispensers remove power from involved STPs Use OSHA Lock out Tag out procedure at the station s breakers Open nozzle into approved container to bleed pressure Some residual pressure may remain Continue with required service procedures After Repairing Restore power to the unit In the distribution box place unit in normal operation Purge air and check for leaks after replacements or rebuilds Refer to Purging Air from the System on page 7 7 for details Verify proper unit operation Servicing Seals O Rings and Gaskets Page 7 4 Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections Use OSHA Lock out and Tag out procedures When opening or disassembling hydraulic components that have been in service for more than two years you should replace the disturbed seals Failure to replace degenerat
37. or Master Satellite setting this option to ON will cause all PPU displays to blink after pump handle is raised or in this case if nozzle is removed from an auto on pump handle Blinking stops when grade select button is pressed Default for this option is selection 1 This programming option affects all sides of dispenser all sides are programmed the same Figure 5 47 PPU Blinking Options Blinking PPU MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 51 Pump Programming Encore 5XX and Eclipse Programming Instructions 1 Press 4 then 3 then press ENTER to access this Command Code 2 Use the following table to select ON OFF Option Table below shows the available options for this Command Code Blinking Code Option State _ 1 Defaut On 2 E 3 Press ENTER Command Code 44 PPU Grade Mapping Command Code 44 is entered in Level 2 programming to map fuel grades to PPUs This allows programmer to change normal mapping of grades to PPU displays It does not change the grade to valve mapping This is used on single hose blenders and single hose MPDs Notes 1 Attempting to use this command on units other than single hose blenders and single hose MPDs will result in an error display condition as described in the section on Dispenser Programming 2 Setting jump jacks for the PPU boards can map the PPUs and grade to value If Reverse Side is set then side two will reverse order
38. side B CR40 side A CR41 side B CR 42 side A CR 43 side B Indicates ON normal operation Monitors T19401 VaporVac Controller PCA activation and fuel flow via pulser activity If LED is off and pulser activates check for problems in VaporVac controller M00080 VaporVac Isolation PCA or hydraulic interface boards or cabling ON normal operation Monitors T17942 VaporVac Pump Assemblies motor rotation If LED is off and fuel flowing check for problems in VaporVac pump motor VaporVac motor drive or VaporVac controller boards or cabling OFF normal operation Monitors errors in the system If LED is on check for problems in VaporVac pump motor VaporVac motor drive or VaporVac controller boards or cabling Brief flicker when motor changes speed normal operation Monitors excessive VaporVac motor current draw If LED is on check for problems in VaporVac pump motor VaporVac motor drive or VaporVac controller boards or cabling ON suspect unrestricted air purging Look for problems in VaporVac pump motor VaporVac motor drive or VaporVac controller boards or cabling MDE 3804B Encore and Eclipse Start up Service Manual August 2007 VaporVac Electrical Components Electronic and Electrical Components VaporVac Power Supplies The VaporVac power supply is part of the VaporVac electronics module and provides power to the VaporVac PCAs M01775A001 and A002 VaporVac Power Supply for Encore This power
39. to calibrate the cash acceptor If you do NOT have a calibration slip exit NOW using the Cancel key Enter Continue Cancel Exit If you select any interactive cash acceptor operation for the opposite side the side that 1s not being calibrated the following warning screen appears Cash Acceptor Cash Acceptor Enabled WARNING You will disrupt cash acceptor sales on the other side of this dispenser until it is restarted Enter Continue Cancel Exit 3 Press Enter to continue with the calibration and advance to the next screen OR Press Cancel to stop the calibration process and exit back to the Cash Acceptor main menu 4 If Enter was pressed the following screen appears Cash Acceptor Cash Acceptor Enabled Insert Calibration slip The two green arrow lights on the cash acceptor bezel will blink rapidly indicating that the device is in calibration mode and ready to accept a calibration card A reference slip of calibration paper approximately the size of United States paper currency is required to perform this operation Page 5 102 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 5 Insert the calibration slip The following screen appears Cash Acceptor Cash Acceptor Enabled Calibration in Progress Please Wait The cash acceptor calibrates itself to the content it received from th
40. 1 TP5 Jump Jack Notes JP1 and JP4 Normally out intended for future options JP4 LED 1 LON Service OFF OK ON Applicationless LED 4 OFF ON when the pump handle is active TP4 P2106 Soft Keys CAPACITOR DOOR NODE 2 o se uA Aot gt TIT Q ASSY MO1785A00 REY O J5 P PTPS R1 R690 iB LAE e710 P2113 Push to Start 12 oo D DIS d iS d LAVIS 01 wSng DAD 0130 Ovdia 1308 E f ao P2111 Pump Stop 5 OR28 Dii en R25 D P2108 Manager Keypad VdA3M 839YNYM al vH a a a ale e o EP ME o o o o a a o o z ro dg mal Ris RLS R540 210 alavaa uy P2102 Card Reader LL 34 CI0O CIIO 401 H Y LIII Go Oo UR pg oR DR cup cun DELL LN M Co LER P2107 Customer Keypad CN uU a 4 E 1 2 3 CARO READER P2115 TX and RX to PPUs 2 3Card Reader P2109 LON P2116 9 4 VAC Backlight Header 1 P2112 LON Header 2 Status LEDs LED Status Indication 1 LON Neuron Status ON or blinking indicates LON problem 2 TX or PPU OUT indicates communication to PPU boards 3 RX or PPU IN indicates communication from PPU boards 4 OFF ON when the pump handle is active MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 49 Electronic and Electrical Components Page 6 50 Printed Circuit Assemblies and Nodes Test Points Test Point Range TP4 GRND TP5 4 75 V to
41. 1000 Console PA0240 G SITE Monitor PA0303 ProBlender AU RAU TS 1000 Controller PA0241 G SITE Printer Citizen PA0308 Precision Blender AE RAE Distribution Box PA0242 02 038 C Meter T19976 02 024 Dispenser Standard AK RAK Micro T Console PA0250 02 039 Passport PA0324 Dispenser Low Profile AL RAL Meter EC Series PA024EC10 02 040 Ecometer T20453 Salesmaker ProBlender AB RAB 02 033 Meter C Series PA024XC10 99 165 Salesmaker Series 2 2H 4 4A AM MPD A3 Series AD RAD Patents Gilbarco Inc products are manufactured or sold under one or more of the following U S patents Dispensers 4 566 504 4 556 927 4 570 686 4 687 033 4 728 788 4 748 846 4 781 066 4 793 589 4 799 940 4 805 453 4 876 653 4 890 210 4 913 813 4 930 665 4 934 565 4 938 054 4 938 251 4 939 730 4 967 366 4 978 029 4 986 445 5 013 434 5 029 100 5 040 577 5 083 846 5 098 179 5 099 403 5 110 010 5 134 548 5 156 199 5 269 353 5 228 084 5 325 706 5 345 979 5 355 915 5 363 988 5 384 850 5 407 115 5 417 256 5 448 638 5 561 715 5 450 883 5 452 750 5 464 466 5 493 315 5 501 246 5 514 933 5 515 390 5 535 130 5 542 458 5 543 849 5 546 981 5 557 084 5 571 310 5 592 979 5 602 745 5 561 715 5 602 745 5 626 649 5 630 528 5 708 580 5 719 779 5 719 781 5 720 325 5 724 067 5 734 851 5 755 854 5 782 275 5 794 667 5 798 931 5 803 136 5 843 212 5 857 500 5 868 179 5 871 651 5 890 520 5 898 141 5 954 080 5 956 259 5 969 691 5 971 042 5 979 705 5 980 090 5 992 395 5 996 888 6 026 866 6 026 868 6 032 126 6 052
42. 5 VDC is present M02097A001 Steering Valve Relay PCA This board is on Encore 300 series units and used only with 6 hose blenders It accepts O to 14 VDC levels that control solid state relays These relays turn the steering valves on and off M01549 and M02097 are not interchangeable Figure 6 26 Steering Valve Relay Board M02097A001 P309C Fixed Blender P309D Fixed Blender P320 Hydraulic Manifold Manifold Interface ST Zu o E3 0 Gi Ilborco E E MO2097A001 MADE IN U S A 10l e so oo ooo of P203A O O P203A Hydraulic Interface MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 57 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Board Connections and Cables Connector Via Cable P203A 10 pin M01694A002 P309C 9 pin M01339A002 P309D 5 pin P320 4 pin R20593 G1 To Board At Connector M02335A001 Hydraulic Interface P306 M01339A002 Fixed Blender P701A P701B Manifold sides A and B M02335A001 Hydraulic Interface P310 M02335A001 Valve Converter PCA This board is used with the Encore 300 equipped with proportional valves Other parts to convert existing digital valve units to proportional valve units The board is the Proportional Control Flow Valve PFCV equivalent to the digital valve hydraulic interface board The function of this board is similar to the Advantage T20076 G3 Hydraulic Interface PCA Service Tip Voltage to coils typically
43. 6 69 About Nodes Encore 500 and Eclipse nodes communicate over a LON within the dispenser or pump The nodes receive power and data from the LON bus discrete cable All nodes except for the printer node have downloadable software The nodes appear to be connected serially but are actually a parallel circuit LON terminators must be located at the end of the LON run for the system to work correctly About PCAs Printed Circuit Assemblies PCA and Printed Circuit Boards PCB control the hydraulics monitor fuel delivery compute display and store transaction information interface with the Point of Sale POS device and support payment options The term PCA and PCB may be used interchangeably Encore 500 and Eclipse employ a LON and Nodes to provide various functional information that drive operations throughout the unit Nodes generally contains a processor MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 5 Electronic and Electrical Components Printed Circuit Assemblies and Nodes M00044A001 Terminal Block PCA Encore 500 Eclipse This board serves as the unit s field wiring terminal Field connection received at this board includes AC power hot neutral and ground This board was obsoleted by M02274 Power Supply Figure 6 1 Terminal Block Board M00044A001 Clean 120 VAC Currently used for Monochrome backlights Clean 120 VAC to Valve Driver Board M00059A001 CR 1 Green TERMINAL BOARD
44. 629 6 054 940 6 062 473 6 065 507 6 065 638 6 067 476 6 070 156 6 073 840 6 078 888 6 078 896 6 082 415 6 085 775 6 087 954 6 092 410 6 098 879 6 102 085 6 116 505 6 119 110 6 123 118 6 149 033 6 157 871 6 170 539 6 176 421 6 184 846 6 185 307 6 185 893 6 196 065 6 227 227 6 244 310 6 250 151 6 253 779 6 263 319 6 275 746 6 296 148 6 302 165 6 313 737 6 325 112 6 326 934 6 336 479 6 338 369 6 347 649 6 352 176 6 357 493 6 360 137 6 363 299 6 364 206 RE35 238 D262 971 D265 092 D306 719 D309 144 D316 471 D413 124 D413 311 D413 336 D413 337 D413 610 D413 901 D413 902 D414 192 D414 501 D414 778 D414 779 D414 780 D414 781 D414 782 D415 166 D415 167 D415 168 D415 169 D415 170 D415 171 D415 172 D415 501 D415 777 D416 915 D416 916 D417 226 D418 523 D420 684 D421 612 D422 285 D422 604 D426 555 D428 424 D428 897 D429 739 D429 740 D432 140 D432 548 D432 552 D433 032 D433 033 D433 034 D433 035 D433 036 D433 037 D433 685 D433 686 D435 051 D440 579 D443 624 Point of Sale Back Office Equipment 4 967 366 5 228 084 5 448 638 5 561 715 5 798 931 5 980 090 5 493 315 5 708 580 5 719 779 5 719 781 5 724 067 5 734 851 6 032 126 6 067 527 6 073 840 6 078 888 6 116 505 6 185 307 6 263 319 6 275 746 6 326 934 6 360 137 6 363 299 6 364 206 Additional U S and foreign patents pending Trademarks Non registered trademarks Registered trademarks C PAM G SITE Lite Surge Management System Dimension Series The Advantage Series Eclipse ECR Highline Tank Monitor Gilbar
45. 9 4 VACRTN 9 4 VAC 10 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Displays Main PPU CRIND Electronic and Electrical Components M02652A003 and A004 PPU Single Display Module for Encore 300 The single PPU display provides price per unit information to the customer on the Encore 300 and also reports grade selection and pump handle status A proximity switch acts as a grade select switch Module M02652A004 does not have the proximity switch Figure 6 41 PPU Module with Single Display for Encore 300 M00065A003 shown with proximity switch installed On board M01522A001 Proximity switch Q12514 10 Gilbarco MADE IN U S A This PCA M01522A001 is part of the display module assembly Not serviceable separately ASSY M01522400 REV Board Connections and Cables Note Board and connections per grade Connector Via Cable To Board At Connector P121 20 pin M01585A001 M01515A001 Main Display P804A 20 pin PCA P2201 2 pin M1586A001 or M01618A001 M01598A001 Pump P204 34 pin Controller PCA MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 89 Electronic and Electrical Components M02652A007 and A008 PPU Dual Display Module for Encore 300 Page 6 90 JP3 Jump Jack Settings Unit Type Standard MPD Single Hose MPD and Six hose Blenders Selectable Blenders Side 1 formerly A 2 formerly B 1 formerly A 2 formerly B Grade 1
46. A unit warm start also occurs after pressing F2 while in the programming mode Totals Money Totals Used to display money totals by side and grade This key does not require a Security PIN Code CLEAR key is used to exit money totals mode Vol Total Volume Totals Used to display volume totals by side and grade This key does not require a Security PIN Code CLEAR key is used to exit volume totals mode ENTER Value entry keys sends the entered value to pump Note If you do not press ENTER during programming that particular programming step will not be saved CLEAR CLEAR key Used to clear last keypad entry and exit money and volume total mode Display Conventions Page 5 4 Programming Convention The programming digit positions for main money and volume displays are shown in the Figure 5 2 on page 5 5 This applies even to cases where more than six display digits are available for display Information 1s displayed on all grade PPUs when necessary and restricted to digits 4 through 1 unless otherwise noted Note PPUs depending upon the vintage of the unit may not be found in the main display MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Pump Programming Figure 5 2 Programming Digit Positions for Main Money and Volume Displays Main Display V Grade Main Display o N Active Display Segment Main V Flashing Part of Display PU During pro
47. About Electric Motor for Self Contained Pump Units Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Figure 7 34 Motor for GDP pump Mounting Bolts g GDP Unit Thermal Overload Most motors have a thermal overload switch that opens the circuit automatically 1f the motor is drawing excessive current or overheats When the switch cools it activates and turns the motor back on Motors do not require a manual reset The 220 380 VAC motors do not have a thermal overload switch If overload shutoff occurs frequently e Check voltage switch for proper voltage selection 220 230 240 380 e Check for free pump and motor shaft rotation e Check pump bypass valve and relief pressure setting e Check belt tension e Check line voltage during operation with nozzle closed and then open Low or high voltages greater than 10 can cause overheating or premature failure Only use Gilbarco specified explosion proof motor for replacement NFPA requires explosion proof motors MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 56 Pump Device Motor Hydraulic Mechanical Components Belts and Pulleys Inspecting Pulleys and Belts Check every time you inspect or change belts Replace if these conditions exist Excessive wear in pulley grooves in pulleys or belts excessive pulley to shaft clearance or excessive b
48. Addresses can be set for up to 6 grades Jumper Grade 1 Grade 2 Grade 3 Grade 4 Grade 5 Grade 6 JO OUT IN OUT IN OUT IN J1 OUT OUT IN IN OUT OUT J2 OUT OUT OUT OUT IN IN MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 95 Electronic and Electrical Components Page 6 96 Board Connections and Cables Note Board and connections per grade Note M00497A001 used only when single hose MPD hose is on left grade 1 or grade select button is on far right Connector P2201 11 pin P2202 5 pin P2203 4 pin Via Cable e M00509A001 or M00509A002 Encore M00509A003 Eclipse Displays Main PPU CRIND To Board At Connector M00095A001 CRIND P2101 Auxiliary I O Board M01152A001 or in line with cable Pump Handle M00497A001 via J2202 P2202 See Note M00628A001 Grade Select Connector Pin Functions and Voltages P2201 Pin Description Input Output Voltage 1 AC IN 9 4 VAC 2 AC RET 9 GND OV 4 GND OV 5 PWR 5 V 5 V 5 6 CLK 0to5V 7 FEEDBACK 0to5V 8 SND REC 0to5V 9 PBP 0to5V 10 SER DATA 0to5V 11 RESET 0to5V P2202 Pin Description Input Output Voltage 1 PUMP HANDLE 0to5V 2 45 V 5 V 5 3 5 V 5 V 5 4 PUMP_HANDLE_LB 0to5V 5 GND 0V P2203 Pin Description Input Output Voltage 1 GRD SEL 0to5V 2 45 V 5 V 5 3 GRD_SEL_LB 0to5V 4 5 V 5 V 5 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 D
49. Cap port Measuring STP Pressure for Dispensers To measure STP pressure for dispensers proceed as follows 1 Turn off power to the STP 2 Verify if the pump on STP has been deactivated 3 Install the gauge at shear valve test port See Figure 7 5 Location A Note Ensure that you use eye protection 4 Activate nozzle Do not pump fuel 5 Read PSI on gauge Actual operating pressure depends on STP horsepower The following approximate pressures exist when not delivering fuel consult manufacturer for exact performance values 6 Refer to the following table for a representation of typical STP performance Values for STPs with additional or fewer stages will vary from those in the following table Page 7 14 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Measuring Pressure and Vacuum Hydraulic Mechanical Components Figure 7 6 Operating Pressure Chart Operating Pressure STP Horsepower Gasoline Diesel 34HP 30PS 88kgc 834PS 99kgom TH 2HP 80PS 91kgcm SS PSI 102kgem 2HP 41PS I 120kgcme 46PS 134kgom 3HP 84PSl 9ikgcm 35PS 102kgem 5HP 338PS tMikgem 43PS 126kgom For Self contained Pumps See Figure 7 5 on page 7 14 locations B and C nstall the pressure gauge to discharge side at a test port on special filter cap nstall pressure gauge downstream at nozzle or other locations as
50. Card Reader Menu Printer The Printer Menu allows you to perform certain configuration and diagnostics tasks on the printers From the Device Config menu press 6 The following screen appears Printer Menu 1 Print Test Side 1 2 Print Test Side 2 3 Set Country Code Cancel Exit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 109 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Print Test Sides From the main Printer Menu press 1 or 2 to cause a test receipt to print for that particular side and display the following screen Printer Menu Sending Printer Test Job Please Wait After 5 seconds the diagnostics session will return to the main Printer Menu and a sample receipt will be printed on the Side 1 or Side 2 printer Note Starting with CRIND Node software V02 1 60 the test receipt will include a sample UPC A barcode printed horizontally at the bottom of the test receipt If barcode scanner hardware is present this barcode should be scannable from the CRIND diagnostics session Refer to the Barcode Scanner Test Menu for a description of how the barcode should be scanned Set Country Code This function changes the printer s character set to better conform with those used in the individual countries listed at this screen 1 From the main Printer Menu press 3 The following screen appears Current Country Code USA 8 Spain Franc
51. Do not replace more than one pump or door node at a time or redundant data storage may be lost e Always replace incandescent lamps as a set MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 15 Electronic and Electrical Components EE TP4 P2113 N Start P211 y Call Button Manager Keypad P2107 Customer Keypad Page 6 16 Figure 6 8 Door Node M00062A001 JP5 IN Side 2 OUT Side 1 JP4 Normally OUT JP1 Normally OUT E 1 LON Service OFF OK ON Applicationless Printed Circuit Assemblies and Nodes Jump Jack Notes JP1 and JP4 for future options Pn 4 OFF ON when the pump handle is active refer to the Status LED table Norina Aly Layls p P2110 ES dO O08 O xD A 4 tl D 5M Lol2d Q0YdA3Y UgNOISI ps Ti p 5p5 UD 0EDI zu NN E ve s ASSY M00062400 p REV P2106 Soft C 05 o l D3 Ce CJ 430y3H N01 Des l B WERDEN m g zl o LEoS ppuout PPUIM Cloo Clio p CAPACITOR 6 6 LLLI Mais TT Do a wn ac Proximity Sensor not used P2104 CRIND Beeper R690 408835 4000 u3d338 Qhiad YOSNIS XOdd 05
52. Eclipse Start up Service Manual August 2007 ATC Components Hydraulic Mechanical Components Wiring from the ISD junction box terminates at the Tank Level Sensor TLS See Figure 7 48 for correct polarity connections Refer to ISD Vapor Flow Meter Installation Guide Veeder Root document number 577013 796 for additional information Note Correct polarity must be maintained to ensure proper equipment operation AN WARNING Wiring to this junction box must be intrinsically safe power from Veeder Root TLS 350 or Gilbarco EMC series tank gauge consoles and must be installed in accordance with Veeder Root installation document No 577013 796 Figure 7 48 ISD Flow Meter Junction Box Polarity Seal off Device p ISD junction box NOTE Maintain correct Intrinsically safe polarity wiring from Veeder From ISD Root TLS console Flow Meter Designates Connection 1 2 inch Rigid Conduit ATC Components Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Contents in this Sub section Topic Page Purpose Of The ATC Option 7 77 ATC Mapping 7 77 Programming ATC 7 78 Purpose Of The ATC Option ATC is an option that measures the temperature of the product being dispensed and compensates for the changes in product volume due to extreme changes in the ambient temperature Note ATC is used i
53. Encore Ji Om 1 p o L Bar Code Scanner How Automatic Temperature Compensation ATC Works The ATC option measures the temperature of the dispensed product and compensates for changes in product volume due to changes in fuel temperature to a standard defined temperature The ATC option uses the following components ATC Meter Cover contains the thermal test well and ATC probe senses fuel temperature T meter Module gathers and processes information from ATC probes Intrinsic Safety 1 S barrier provides power to T meter module provides data path from T meter module to ATC controller board ATC Controller Board replaces the valve driver board controls the fuel flow valves In an ATC equipped unit fuel temperature is monitored via a thermocouple probe commonly integral to the meter or optionally in close proximity This temperature is compared against a predetermined Standard temperature for the country or region involved The ATC equipment intercepts pulser signals prior to information being sent to the Pump Control Node or pump controller and adjusts the pulse count to reflect the pulse count that would have occurred if the fuel was metered at the Standard temperature If fuel being metered is hotter than the standard temperature pulse count is reduced If fuel being metered is colder than the Standard temperature pulse count is increased Adjustment changes as the fuel temperature into the
54. Enter 5 then 0 then ENTER to access this Command Code MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 57 Pump Programming Encore 5XX and Eclipse Programming Instructions 2 Use the following table to select option 1 2 Option Mapping 1 Default Normal 2 Valves Reversed 3 Press ENTER Command Code 51 Set Main Beeper Command Code 51 is entered in Level 2 programming to set beeper functionality The table below indicates beeper programming options If beeper option is set to ON the beeper will sound when pump handles are lifted when the dispenser is authorized and when any pump switches keypads are activated Default for this option is selection beeper ON Figure 5 56 Setting the Main Beeper Beeper Option 1 Enter 5 then 1 then ENTER to access this Command Code 2 Use the following table to select option 1 2 Option Code Beeper 1 Default ON 2 OFF 3 Press ENTER Command Code 52 Set VaporVac Alarm Command Code 52 is entered in Level 2 programming to set VaporVac alarm functionality The table below indicates alarm programming options If VaporVac alarm is set to ON the beeper will turn on at a VaporVac error and will not turn off until dispenser has been warm started Note In Mexico the VaporVac alarm must be set to ON Default for this option is selection VaporVac alarm ON Page 5 58 MDE 3804B Encore and Eclipse Start up Service Ma
55. First Level PIN Allows Site Manager to change site management level Level 1 PIN Code Entering new digits for new code changes display as digits are entered Display does not show actual PIN digit it only shows a 0 to signify that a number was entered Same PIN Code must be entered twice to be accepted First pass at entering PIN Code is signaled by a 1 displayed in Pass Code display Second pass is signaled by a 2 appearing in Pass Code display Acceptance of a PIN Code is signaled by a 3 appearing in Pass Code display A zero in Pass Code display indicates that the PIN Code was not accepted Layout and digit position shown below Figure 5 41 Changing the First Level PIN 1 Press 2 then 8 then press ENTER to access this Command Code Note Pass Code displays 1 for first pass 2 Enter PIN Code XXXX then press ENTER Note Pass Code displays 2 prompting a second pass 3 Enter PIN Code again then press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 47 Pump Programming Encore 5XX and Eclipse Programming Instructions Level Two Command Codes Set 2 wire ID Pump number Command Code 40 Command Code 40 is entered in Level 2 programming to set pump ID number Address range is 1 to 16 Pump side ID default values are Side 1 7 and Side 2 11 Layout and digit position meaning for this programming feature is shown below Figure 5 42 Setting Pump ID Numbe
56. M00696A001 Display Screen Softkeys MOOxxxxxxx Monochrome displays are used in the Encore 300 Encore 500 and Eclipse series units The Monochrome display assemblies built before July 14 2001 used replaceable fluorescent backlight bulbs to illuminate the display M01653A001 uses LEDs that are not replaceable Contrast adjustments are made using the CRIND Diagnostic card MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 99 Electronic and Electrical Components Page 6 100 CRIND Devices Figure 6 49 Monochrome Display Assembly MOxxxxxxx Bulb Ballast Fluorescent Bulb LCD Display Board Connections and Cables Connector Via Cable To Board At Connector J1 34 pin M01668A002 Monochrome PCA T1950 G2 P2015A for Side 1 P2015B for 2ide 2 J5 2 pin CRIND Regulator PCA T20304 P563 for Side 1 P566 for Side 2 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical Components M01653A001 Monochrome Display The Monochrome Display board displays multiline prompts advertising messages and static graphics on a monochrome LCD screen in Encore 300 Encore 500 and Eclipse series units Earlier version used replaceable fluorescent backlight bulbs to illuminate the display The LEDs in this assembly are not replaceable Contrast adjustments are made using the CRIND Diagnostic card Service Tips Rain shield inside the door is requ
57. Monochrome Interface Board is used in the Encore 500 and Eclipse equipped with first generation CCN MO00089A001 This interfaces displays signals from M00089A001 to side 1 and side 2 monochrome displays This board is not required with CRIND Node 2 Service Tip A fault in this board may affect one or both monochrome displays Figure 6 12 Monochrome Interface Board M00092A001 P3303 Side B Mono Module P3303 QO 19 OL AEs C13 C Cl4 Co LLLI TE LET TLTEII LLL LLL LE TL IT U6 U7 UU UU NUU L ASS S eL 16254 AN9 Idi 00v66000H ASSY ULT TL LED ETE LLLI LUE HE HEU LE LLLI FUE TT gt U U2 US WU UU LE LI OU OU IET U UU OU U 9330 C18 CPS 319 ceo Ld PEn oo ooo oo ooo oooo oo wero 2 0000000000000008 Lo nl P3302 Side A Mono Module had ua tn os eS e e D D D D D D D D D D e D D D DB B B B B D IOON 1708180 NIAI CE IKHOUHIONON Gilbarco Made in U S A QO P3301 CRIND Control Node Board Connections and Cables Connector P3301 20 pin P3302 34 pin P3303 34 pin Test Points Test Point TP1 GND TP2 14 V to 23 V Via Cable M00545A001 M00553A001 M00553A002 M00553A001 M00553A002 Encore Eclipse Encore Eclipse 0 00 Range To Board M00089A001 CRIND Control Node Monochrome Module Side 1 Monochrome Module Side 2 At Connector P3112 20 pin J1 34 pin J1 34 pin TP3 34 V to 36 V TP4 4 7
58. O ON AC present o Note Replaceable fuse POWER CLEAN POWER CLEAN VALVE BOARD is Type GDC 4A G in E pe acies idu Made in U S A Filter recognized 4 A ix Slow Blow AC 5x20mm If replaced the designated replacement must be used YIMOd ONIAIM 01314 L 1 VOLTAGE SELECTOR Voltage Select Plug Replaceable Line Plug In for replaceable Over Voltage Fuse See Note Protection Varistors See Note Board Connections and Cables Connector Via Cable To Board At Connector P1601 3 pin M00153A1001 Field Wiring Power Field wiring on terminal block P1607 None Plug In Voltage Program Plug 9 Pin e M00488A115 115 VAC e M00488A220 220 VAC e M00488A230 230 VAC e M00488A240 240 VAC P1614A 3 pin M00630A003 Encore Side 1 Backlight Ballast and Heater 3 pin series MO00630A004 Eclipse via J1614C to P1614C on M01103A001 cable P1614B 3 pin M00630A003 Encore Side 2 Backlight Ballast and Heater 3 pin series MO0630A004 Eclipse via J1614C to P1614C on M01103A001 cable P1615 3 pin M00625A001 to J1206 1 Transformer Card Reader Heater 1 N A P1206 connection to Sub Assembly M00293A001 2 P1206 3 pin M01006A001 cable 2 M00059A00X Steering Valve Driver PCA P1616 6 pin Multiple Colored Wires Primary on Power Supply P1631 6 pin None Plug In Varistor Assembly 6 pin Plug In M00487A115 115 Volt application e M00487A230 115 Volt application e M00487A231 115 Volt application Page 6
59. OFF TP4 35 V TP5 GND GND TP6 VCC 5 VDC T20306 G1 CRIND Regulator PCA The CRIND regulator supplies regulated voltages for CRIND devices and receives and transmits communication signals from and to the POS system Figure 6 30 CRIND Regulator Board T20306 G1 P556 Z180Logic P571 Z180Logic side 1 P561 Z180Logic Brd Side 1 side 1 P569 Z180Logic P562 Z180Logic Side 1 P566 Side 1 Monochrome Display Side 2 P562 LI P557 P558 P559 Main Power Supply TIPED TELCITEDERE YTETTNCTTT O mor ezi ES C853 SV dhs R52 1 8 L1 P553 Z180Logic Side 1 P552 Z180Logic Side 2 Hi Os eT eee Hef pno e 85 CO E Cory Hao FO L3 tu A Le P564 Z180Logic Side 2 P565 Z180Logic Side 2 P572 Z180Logic Side 2 P570 Z180Logic Side 2 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 4 assy a I20306 61 REV P556 P557 P558 RD RIC H CRs m H H H o H N O Qu SK2 TP1 TP3 TP5 TP6 TP2 TP7 TP4 Page 6 69 Electronic and Electrical Components Status LEDs LED CR7 CR9 CR13 CR25 CR26 CR27 CR28 Color Red Red Red Red Red Red Red Printed Circuit Assemblies and Nodes Function Two wire Receive Communication Two wire Reversed Two wire Transmit Communication 5 V Present 59 V Present 5 V Present 24 V Present Board Connections and Cables Connector Via Cable
60. Page 5 106 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming Cash Acceptor Cash Acceptor Enabled WARNING You will disrupt cash acceptor sales on the other side of this dispenser until it is restarted Enter Continue Cancel Exit To continue with the previously selected cash acceptor task press Enter To revert back to the Cash Acceptor main menu press Cancel 3 Press Cancel to exit back to the Cash Acceptor Test Switches Menu TRIND Device The TRIND Menu option allows the CRIND BIOS support for TRIND device hardware to be enabled or disabled 1 From the Device Config menu press 4 The following screen appears TRIND Menu TRIND Disabled Current status of TRIND device 1 Enable TRIND Enter Save Value and Exit Cancel Discard Change and Exit 2 Press 1 to toggle between disabling and enabling the TRIND device 3 Press Enter to save the current setting and return to the Device Config menu OR Press Cancel to discard the current setting and return to the Device Config menu Card Reader This menu allows a technician to review and manage the card reader statistics counts that have been collected since the last time the card reader statistics have been cleared Card reader counts are collected both during the course of normal transactions as well as during a diagnostics session Card read percentage
61. Phone 336 547 5000 http www gilbarco com Printed in the U S A MDE 3804B Encore and Eclipse Start up Service Manual August 2007 2007 Gilbarco Inc f Y GILBARCO 7300 West Friendly Avenue Post Office Box 22087 QS
62. Press ENTER Note Upon pressing ENTER the unit will perform a cold start On completion of reset process the pump will perform a normal lamp test and resume normal operation All Level 1 and 2 programmed data and the clock will be set to manufacturing default values Command Code 60 Set Clock and Calendar Settings for time and date programming may be completed from Manager Keypad or sent from console controller As a result dispenser always uses last settings made by either programmer or console controller Not setting the correct values may affect reports closing shifts and dispenser event logs Properly time stamped event logs are valuable in service situations There are two Function Codes applicable to Command Code 60 Function Code 1 for setting time and Function Code 2 for setting date Default selection upon entry into Command Code 60 is Function Code 1 for setting time MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 63 Pump Programming Encore 5XX and Eclipse Programming Instructions Layout and digit positions are show in the following diagram Figure 5 64 Layout and Digit Positions for Setting Clock and Calendar 6 0 Function J Code N Day Day Year Year 1 Enter 6 then 0 then press ENTER to access this Command Code 2 Set Dispenser Time Function Code 1 Dispenser time is set in 24 hour format Programmer enters time in terms of hours and minutes If no prior time pro
63. Programming Volume Allocation 2 Money PPU Decimal Total 4 Blanking Display Manually and 3 Volume Calculated PPU Decimal Point Selecting Money Volume Preset 4 Displayed PPU Decimal Point 1 Manual Blank Displays Conversion Factor 2 Five Button Preset 5 STP Preset 6 Clearing Memory for EC 31 and 35 only 6 Beeper ON OFF 7 Setting Totals Input Mode 7 Notusedin this version 8 Displaying Software Version Number 8 Two Wire Display Blank Option 9 Manual Display Blank Option 5 or 6 Digit Cash 10 Decimal Comma 11 Preselect Time out 12 Pump Time out 13 Slowdown Ultra High Only 14 Push to Start Blenders Only 15 Zero PPU Option 16 Beeper Time out 17 Stop Control 18 Zero Previous Transaction 19 Lamp Test 20 Programmable Pump Preset Value 21 PPU Blinking Option 22 Volume Decimal Point MPD Single Hose only 23 Program STP Control 24 Hose Pressurization Options Level Three Command Code refer to page 5 25 i 11 Not used 12 Programming Pumps 1 Two Wire ID 13 Changing PIN 2 Cash Credit at Pump 14 Not used 3 Side Exists 15 Various Time outs 4 PPU Options 16 Programming Blend Ratios 17 Entering Conversion Factors Performing Master Resets E Conversion Factor 2 Master Reset MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 9 Pump Programming Encore 300 Programming and Data Access Instructions Encore 300 Programming and Data Access Instructions This section contains inf
64. Q13245 01 orifice plug in the T19454 G1 nozzle testing tee GPM Vacuum Level Inches of Water 6 4 8 7 10 10 If the vacuum level cannot be adjusted to meet the above values the vapor pump motor 1s bad and must be replaced If the vacuum level can be adjusted to meet the specified levels one additional check must be performed Locate the current limit display LEDs CR40 and CR41 on the T19401 or T18021 Vapor Vac Controller board Set the flow rate selector on the pulse simulator box to 10 GPM Reauthorize the fueling position and place the pulse simulator box in the Run position Watch the LEDs as soon as the pulse simulator box has been switched to Run The LED for the side that you are monitoring should light and turn off quickly If the LED stays lit or flickers for more than 3 seconds the vapor pump motor is drawing too much current The slope trim pot R30 or R52 will have to be adjusted down counterclockwise until the LEDs turn on off quickly MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Vapor Recovery Components Hydraulic Mechanical Components Returning VaporVac Pump Motor Pumps with short or crushed wires cannot be rebuilt and in some cases even tested All motors returned for warranty credit must be of rebuildable condition with wire leads at least 26 inches long Spare part vapor pumps are packed in a reusable shipping container Use this box to return vapor pumps
65. Real time transaction Provides means to monitor ATC operation during a transaction Monitored data includes uncompensated volume compensated volume and product temperature for product selected Product selection will be accomplished by sensing the coincidence of grade authorization and pulser activity After product selection both money and volume displays are zeroed and product temperature will be displayed in PPU display During real time transaction mode money display on each side will show uncompensated volume for selected product Volume display on each side will display compensated volume for selected product Finally PPU display on each side will show current temperature in Celsius End of a transaction is determined when all grade authorization signals become inactive End of a transaction results in both money and volume displays being blanked with 8s shown in each PPU digit Function Code Keypad Programming in CC27 ENTER accepts default FC Select meter ENTER Select next meter ENTER Select FC 2 ENTER Select meter ENTER Select grade ENTER Select FC 3 ENTER Select meter ENTER Select next meter ENTER Select FC4 ENTER Select meter ENTER 1 Select next meter ENTER 1 Select FC5 ENTER Select meter ENTER Select next meter ENTER Select FC6 ENTER Select FC7 ENTER 12 ENTER avoid time out MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Pr
66. Safety Information 2 Important Safety Information This section introduces the hazards and safety precautions associated with installing inspecting maintaining or servicing this product Before performing any task on this product read this safety information and the applicable sections in this manual where additional hazards and safety precautions for your task will be found Fire explosion electrical shock or pressure release could occur and cause death or serious injury if these safe service procedures are not followed Preliminary Precautions You are working in a potentially dangerous environment of flammable fuels vapors and high voltage or pressures Only trained or authorized individuals knowledgeable in the related procedures should install inspect maintain or service this equipment Emergency Total Electrical Shut Off The first and most important information you must know is how to stop all fuel flow to the pump dispenser and island Locate the switch or circuit breakers that shut off all power to all fueling equipment dispensing devices and Submerged Turbine Pumps STPs N WARNING The EMERGENCY STOP ALL STOP and PUMP STOP buttons at the cashier s station WILL NOT shut off electrical power to the pump dispenser This means that even if you activate these stops fuel may continue to flow uncontrolled You must use the TOTAL ELECTRICAL SHUT OFF in the case of an emergency and not the console
67. Servicing Hydraulic Components on page 7 4 for additional information 5 WARNING You are working in a potentially dangerous environment of flammable fuels vapors and high voltage Fuel and its vapors may ignite leading to serious injury or death Fire explosion or electrical shock could result in severe injury or death if you do not follow safe procedures Surfaces of Eclipse Series units are non metallic In any situation where power is on and gasoline and its vapors are present or potentially present for example calibration do not attempt to use the Manager Keypad with electronics cabinet open When calibrating Eclipse series units run keypad cable over door and close door allowing keypad to be suspended on unit and accessed from outside for all procedures done with power applied or in presence of fuel or fuel vapor Some residual pressure may be present in unit after releasing pressure through the nozzle resulting in fuel spray Im Always wear proper eye protection when servicing the hydraulic system Take appropriate Steps to contain any spraying or draining fuel Static electricity may be present before or during dispensing of fuel A spark between container and nozzle may occur Fire or explosion may result causing serious injury or death Ground the nozzle and prover can to prevent static discharge Do not place prover cans on ungrounded surfaces such as plastic truck liners MDE 3804B Encore
68. The heading of the screen will depend on whether you selected Side 1 or Side 2 CRIND ID Side 1 Side 2 CRIND ID The current CRIND communication Range 1 32 99 disable address for Side 1 Side 2 Number Keys Direct Entry Clear Erase Entry Enter Save Value and Exit Cancel Discard Change and Exit 3 Press numeric keys to enter one or two digit CRIND ID Legal values for this field are 1 32 and 99 Setting the value at 99 configures the side not to answer polls on the CRIND communication loop This is useful for field troubleshooting and diagnostic purposes 4 Press Enter to save the edited CRIND ID and exit The CRIND ID menu appears OR Press Cancel to discard changes and exit CRIND IDs menu appears Page 5 96 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming CRIND Mode 1 From the CRIND Config menu press 2 The CRIND Mode menu appears CRIND Mode CRIND Mode Shows current setting For new 1 MOC installations and with existing 2 Generic CRIND nodes that have undergone purge or BIOS cold 3 MOC Kiosk start default will be Not 4 Generic Kiosk Configured 5 MOC Enhanced Kiosk Enter Save Value and Exit Cancel Discard Change and Exit 2 Press numeric key to change the current CRIND mode setting 1 causes the unit to operate in MOC CRIND The Advantage Series compatibility mode e 2 c
69. Two HEB PER P1501 m ins A T HE HH ee aati y Ex Ex yr Ea mw S ESTE nun 0 nnuno uu oo aa ou 7 Lew 3 les 73 Mer Mp1 621 A00 Gilbarco O REV One Product Page 6 44 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M01753A001 CRIND Control Node 2 The CRIND Control Node CCN is the primary CRIND device option processor on eCRIND equipped Encore 500 and Eclipse units This node receives information directly or indirectly from and or controls the card reader monochrome display printer barcode scanner cash acceptor beeper and CRIND related keypads It also interfaces with TRIND devices and supports USB communications The M01753A001 CCN is backward compatible with M00089A00X CCN It requires CNN BIOS version 2 1 80 or higher The M00089A00X is forward compatible with the M01753A001 CCN with the exception of enhanced durability improvements Service Tips Coldstarts are best done using the diagnostic card and the Clear Persistent Memory function e If the M01763A001 CCN is replaced with a M00089A00X CCN then a M00092A001 Monochrome Interface PCA and a M00545A001 interface cable will be required Figure 6 20 CRIND Control Node 2 Connectors M01753A001 BT1 Lithium Battery Q12674 01 P3114 Not Used peu reileyinad P3102 SmartPad zb eer NODE 2 P310 BOE OE 2 En E39 P310
70. VDC 4 75 VDC 4 RXDB 0 80 VDC 2 00 VDC 5 14 5 V See P201 Power Test Points on 6 42 6 14 5 V 7 14 5 V 8 DC GND 9 DC GND 10 DC GND 11 DC GND 12 DC GND 13 DC GND 14 DC GND 15 5 VDC O See P201 Power Test Points on 6 42 16 5 VDC O 17 DC GND MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 41 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Page 6 42 18 DC GND 19 45 VDC O See P201 Power Test Points on 6 42 20 5 VDC O P202 Connector Pin Functions and Voltages Pin Description I O Max Low Max High 1 ConnectA OV VCOA 2 STP 1 O 1 30 VDC 9 156 mA 3 STP 2 O 1 30 VDC 9 156 mA 4 STP 3 O 1 30 VDC 9 156 mA 5 14 5 V O See P201 Power Test Points on page 6 42 6 GND O 7 Connect B OV 4 50 VDC 20 uA 8 SPARE A O 1 30 VDC 156 mA 9 SPARE B O 1 30 VDC 9 156 mA 10 SPARE C O 1 30 VDC 9 156 mA 11 14 5 V O See P201 Power Test Points on page 6 42 12 GND O OV OV Jump Jack Settings Jump Jack Position Function JP1 IN Push to start activated OUT Lever on activated P201 Power Test Points Connector Pin I O Signal Name Tolerance Maximum Current P201 6 14 5 VDC 14 5 VDC 5 800 mA P201 12 GND Signal Return 0 VDC P201 16 O 5 VDC 5 VDC 5 125 mA MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M01621
71. Whether or not victim has received first aid for example stopped bleeding by pressure and so on Whether or not a victim has vomited for example if swallowed or inhaled something and so on LAX WARNING Dd Gasoline ingested may cause unconsciousness ar and burns to internal organs Do not induce vomiting Keep airway open Oxygen may be needed at scene Seek medical advice immediately AY WARNING p Gasoline inhaled may cause unconsciousness and burns to lips mouth and lungs Keep airway open Seek medical advice immediately AY WARNING m Gasoline spilled in eyes may cause burns to eye o tissue Irrigate eyes with water for approximately 15 minutes Seek medical advice immediately AY WARNING Gasoline spilled on skin may cause burns E Wash area thoroughly with clear water Seek medical advice immediately IMPORTANT Oxygen may be needed at scene if gasoline has been ingested or inhaled Seek medical advice immediately Lockout Tagout Lockout Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machine s or equipment or release of stored energy could cause injury to employees or personnel Lockout Tagout applies to all mechanical hydraulic chemical or other energy but does not cover electrical hazards Subpart S of 29 CFR Part 1910 Electrical Hazards 29 CFR Part 1910 333 contains specific Lockout Tagout provision for e
72. a zero PPU Default is DISABLED meaning that dispenser will not deliver fuel if any PPU is set to zero This Command Code is commonly used when a dispenser is not being used for retail sales Layout and meaning of each digit position for this programming feature is shown in the following diagram Figure 5 101 Setting Zero PPU Option 1 Onthe Manager Keypad press 9 then 4 then press ENTER Selection Option 1 Default Disabled 2 Enabled 2 Select Option 1 or 2 then press ENTER Page 5 92 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Additional Manager Functions for Encore 5XX Pump Programming Command Code 95 Reset Start Force Application Download Figure 5 102 Resetting Start Force Application Download 1 Onthe Manager Keypad press 9 then 4 then press ENTER Selection Option 1 Default Disabled 2 Enabled 2 Select Option 1 or 2 then press ENTER Additional Manager Functions for Encore 5XX Unit Totals Retrieval Convention Totals Examples For both TOTAL and VOL TOTAL keys press ENTER to toggle between grade and side selection Non Resettable Money and Volume Totals The dispenser maintains a set of non resettable totals for each dispensed fuel grade These totals reflect total money and volume since dispenser installation time Following are keypad and display examples for viewing dispenser non resettable money and volume totals Money and Volume Totals Use the TOTAL
73. accept credit or debit cards The CRIND device communicates with the site controller which in turn communicates with credit and or debit networks The CRIND device display prompts the customer through the transaction and depending on type may display promotional information The single line CRIND displays prompts and messages on a 14 segment 20 character display module Options to the CRIND include Cash Acceptor that allows the customer to pay for fuel by inserting cash into the acceptance slot and the Bar Code Reader option that allows customers to automatically authorize customer price discounts on CRIND device equipped units using a bar code tag The CRIND device printer prints customer receipts and in some cases promotional information Single line CRIND Display T20379 Figure 6 47 Single line CRIND Display T20379 Page 6 98 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical Components Board Connections and Cables Connector Via Cable To Board At Connector P851 40 pin M01668A004 CRIND Regulator PCA M02705 previously P252 T20306 P852 3 pin CRIND Logic Z180 PCA 117764 P558 Monochrome Display E300 and 500 The Monochrome Display screen displays multiline prompts advertising messages and static graphics on a monochrome LCD screen The outside view of the display is the same for Encore 300 Encore 500 and Eclipse Figure 6 48 Monochrome Glass with Softkeys
74. and TRIND at Pump Dispenser Pump Programming 3 The Cash Acceptor Reset Statistics screen displays after a few seconds Press Cancel to exit back to the Cash Acceptor main menu Show Device Details This screen allows you to query the firmware version s installed on each of the cash acceptor units in the system 1 From the Cash Acceptor main menu press 4 The following screen appears Cash Acceptor Cash Acceptor Enabled Side 1 Details Model 80 Firmware Version 36 Side 2 Details Model 80 Firmware Version 36 Cancel Exit 2 Press Cancel to exit back to the Cash Acceptor main menu Calibrate Cash Acceptors This function allows you to execute a calibration procedure on either side of the unit Note It is possible to calibrate the cash acceptor from the single side that started the diagnostics session 1 From the Cash Acceptor main menu press 5 The following screen appears Cash Acceptor Cash Acceptor Enabled 1 Calibrate Side 1 2 Calibrate Side 2 Cancel Exit 2 Tocalibrate Side 1 press 1 To calibrate Side 2 press 2 The following warning screen appears for the Side being calibrated MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 101 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Note Do not calibrate using currency Cash Acceptor Cash Acceptor Enabled WARNING You must insert a proper calibration slip on the next screen
75. are approximate and may vary depending on site conditions hardware used age of units and so on Flow rates for standard gallonage are based on 5 8 inch hoses 3 A inch swivels unleaded gas Flow rates for high gallonage are based on inch hoses and OPW7H nozzle Acceptable Ranges Standard Measure Full Flow All Nozzles Open Bypass Nozzles Closed Inlet Discharge Discharge Pump Vacuum Pressure Flow Rate Inlet Vacuum Pressure Configuration in Hg PSI GPM in Hg PSI One Pumping Unit per Hose Standard Flow 4 10 15 30 10 13 4 7 20 35 High Flow 6 12 25 40 18 24 5 8 28 45 One Pump Unit per two Hoses Standard Flow 4 10 20 35 17 20 4 7 22 38 Acceptable Ranges Metric Measure Full Flow All Nozzles Open Bypass Nozzles Closed Inlet Discharge Discharge Pump Vacuum Pressure Flow Rate Inlet Vacuum Pressure Configuration cm Hg Bar LPM cm Hg Bar One Pumping Unit per Hose Standard Flow 10 2 25 4 1 0 2 1 37 50 10 2 17 8 1 3 2 4 High Flow 15 2 30 5 1 7 2 8 68 90 12 7 20 3 1 9 3 1 One Pump Unit per Two Hoses Standard Flow 10 2 25 4 1 3 2 4 64 76 10 2 17 8 1 5 2 6 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 19 Hydraulic Mechanical Components Page 7 20 Measuring Vacuum Pump Probable Causes of Low Flow Rate for Pumps Use the following table to determine the causes of low flow rates Low Flow Rate Symptom Probable Causes The open nozzle vacuum reads high pressure r
76. available for the Eclipse model e Per product per side MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 19 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Figure 6 9 Totalizer Node PCA M00077A001 P1501 P1503 Grade 3 POl Grage P1504 Grade 4 P1505 Direct Connect P1502 Grade 2 P1506 LON Header 2 P5O4 P1503 A1502 P1501 a 4 4 4 1305 4 l Oy EIE L ogy OE OF 11 5V 14 5V TOTE GR4 TOTE GRS TOTE GR2 TOTE GRI DIRECT CONNECT sb Ic noonnnon GA CI LEE CL EL EL TL E m Um of E Ui Z CU UU AEN C5 RI L HEARTBEAT QF 10 LON HEADER 2 The NEURON OUT STATUS SIDE LON HEADER Made in U S A o Gilbarco D oo O O O O O O OD ODD TOTALIZER NODE gt C16ND M00077A00 u0g000 noo 05 04 03 ASSY JP2 Jump Jack is IN for Side 2 OUT for P1507 LON Header 1 Side 1 Board Connections Connector Via Cable to Board P1501 4 pin Electronic Totalizer Grade 1 P1502 4 pin Electronic Totalizer Grade 2 P1503 4 pin Electronic Totalizer Grade 3 P1504 4 pin Electronic Totalizer Grade 4 P1505 8 pin N A not for field use P1506 10 pin M00489 LON Header 2 P1507 10 pin LON Header 1 Page 6 20 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Test Points Test Point Range TP 1 17 5 to 28 V to GRND TP2 115Vtoi45VIo GRND TP83 475V10525VIo GRND d
77. densities MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 69 Pump Programming Encore 5XX and Eclipse Programming Instructions Deactivating VaporVac Pumps for Diesel Pumping in CC75 VaporVac motors do not need to run when dispensing diesel products Motors can be set not to run when diesel is pumped using this Command Code The default setting for Encore and Eclipse units with VaporVac is all products turn vapor motors on In order to dispense a product without turning on VaporVac motor for example diesel proceed as follows while in Command Code 75 1 Select meter see following illustration for meter locations Note Selecting a meter automatically sets the density for the corresponding meter on the opposite side for that product 2 Press ENTER 3 Select density Note Selecting 2 diesel will deactivate VaporVac pump for that meter Command Code 77 Change PIN Code PIN Codes are a security feature Changing PIN Codes from default can enhance station security Revised PIN Codes should be safely stored by the station and ASC such that they can be accessed as necessary They must not be misplaced or lost because a cold cold start is required to reset the code Or revert to V 1 3 74 or earlier software reload the latest version software and then reprogram Note PIN Code must be entered twice This Command Code allows the programmer to set new PIN Codes for entry into the four different prog
78. eee 7 27 Hoses and Flow Restrictors 0 000 eee 7 28 DICAKAWAYV Si sucus dele sane dee She Y tecla dar e eat on d eee dub nv t 7 29 Page iv MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Testing Hose and Hanging Hardware Continuity 7 31 Adjusting Nozzle Hook for Specific Nozzles 7 33 Seii ele e EE et Soe fe ac E ach gees tee veces back avg hts Sesh eae eA aoe Gea ange hoes Kus ers Bede oe ee ee 7 36 Topics in this Sub section 0 ccc eee 7 36 About Hydraulic Manifolds 0 0 0 ccc ee ees 7 37 Hydraulic Tree Assemblies 00000 cece ee eee 7 37 Steering Mantle dd 258 orte P ue E ot code e botes 7 38 Configuration Manifold 0 0 0 cee eee 7 40 UGG S 3 Sirah fare beara Ane Papen eo SR ae See cnc A ee a ee qd AE ane nedowaet vini od 7 43 Topics in this Sub section 0 000 cc eee 7 43 AbOUPMGIGIS uisu Seu e d ede mae dtu da boton bed a osx 7 43 CPG BP hon Eb Eo dui ideas e di ieu Muir EE 7 43 LC Meter Encore Ultra Hi 0 0 cc ee 7 45 xci ccce 7 46 TOPICS in this Sub section uma d Sew Sa Ec crap Bae 7 46 About PulSefs 5 ex obs ppc ed Nn ipis c PESE E peux Rm 6 Eh 7 46 Testing Pulsers and IS Barriers 2 0 00 cece eee 7 46 Pulser Drive Assembly 2 0 0 0 000 eee eee 7 47 PUMPING Device GDP s dace du na b Eee depo Bind de swe SOHO ab dx EE uA eee REGIS r3 d CU 7 49 Topics in this Sub section
79. hardware can be composed of other manufacturer s components Ensure that you follow manufacturer s recommendations MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 27 Hydraulic Mechanical Components Hanging Hardware Hoses and Flow Restrictors Page 7 28 Inspecting Hoses Check hoses regularly at least once a week for leaks and damage Inspect and replace hose assembly as needed The following conditions may indicate damage or an impending problem e Twisting and curling puts unusual stress on hose parts Repeated flexing of hose in the same spot can cut tear or split the hose cover e Flattened hoses cause restricted flow and cause hose reinforcement damage e A soft spot is a sign of internal damage to the hose reinforcement Reinforcement may appear through the cover Loose or cracked hose couplings can cause a fuel spill Hose bulges are a sign of pressurized gasoline pushing against the cover A full rupture could occur at any time Hose Retrieval Mechanisms Hose retrieval mechanisms must be operational or a trip hazard could exist Do not use hose longer than the recommended length without a hose retrieval system Replacing Hoses Do not use soft wall hoses They can cause the unit to register with nozzle closed when the nozzle hook is first raised Always use UL approved hoses designed for the fuel being dispensed Read and follow all safety precautions Follow OSHA Lock out and Tag out proced
80. hydraulic interface board through connector P262 except on generic systems Side 2 communicates to the dispenser through the side 1 logic board through P264 T17764 is a Z180 based microprocessor with input output I O ports I O ports connect to the card reader keypad display speaker printer controller board and regulator board The logic board controls CRIND two wire communications Jump jacks set the CRIND polling address and other options The CRIND logic board uses 5 VDC from the regulator board The logic board transfers 68 VDC from the regulator board to the CRIND display board The logic board has a built in lithium battery rated at 3 5 Volts and provides VRAM during loss of power This battery is not field replaceable CRIND BIOS on the logic board is in ROM at U7 This firmware contains software that defines pump control device control I O ports power up tests communications and diagnostics The site controller downloads customer specific applications such as display prompts and ISO tables to logic board RAM through the CRIND regulator board The G4 is for InfoScreen Monochrome only It is a simplified version of the G3 without the VF display interface components Service Tips MOC CRINDs do not require communication with the dispenser to download If CRIND cannot communicate to the dispenser the CRIND will stop at pump startup once download is complete If MOC CRIND is not communicating with the dispenser check th
81. is toggled Earlier versions of software allowed you to toggle the programming switch prior to entering the programming mode Now you must be in the programming mode prior to toggling the Weights and Measures switch See Important Information about Using V1 7 58 and Higher for Encore 5XX and Eclipse Dispensing Pump Software on page 5 7 for additional information To enter Level 3 programming levels with V 1 7 58 or higher software for programming purposes except those for calibration proceed as follows 1 Press F1 on the Manager Keypad 2 Toggle the Weights and Measures switch to enter the higher level programming 3 Enter Pin Code for higher level programming when required 4 When finished programming turn the Weights and Measures switch off 5 Press F2 to exit programming If the pump uses software prior to V1 7 58 You must toggle the Weights and Measures switch prior to entering the programming mode MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 65 Pump Programming Encore 5XX and Eclipse Programming Instructions Command Code 71 Set Volume Units Layout and meaning of each digit position for this programming feature is shown below Figure 5 66 Setting Volume Units 1 Enter 7 then 1 then press ENTER to access this Command Code 2 Select volume unit code 1 3 Volume Units Code Unit Type 1 Default U S Gallons 2 Liters 3 Imperial Gallons 3 Press ENTER Command Code 72
82. of side one entries onto side two Default setting is always one for one with Reverse Side setting disabled 0 Note This will also implicitly redirect totalizer addressing scheme to reflect PPU mapping Totalizer will be remapped to PPU to total flow from remapped grade Layout and meaning of each digit position for this programming feature 1s shown below Figure 5 48 PPU Grade Mapping Pump Reverse Side Side PPU PPU PPU PPU PPU 1 4 9 6 Example for keypad programming Note Due to complexity of grade select mapping following example is provided showing keypad sequence for re mapping default PPU mappings to Grade 2 mapped to PPU 1 and Grade I mapped to PPU 2 1 Press 4 then 4 then press ENTER to access this Command Code Page 5 52 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 2 Select side from the following table then press ENTER To Program Press Configuration Side 1 side with junction box 1 Side 2 2 3 Press ENTER again to disable Reverse Setting 4 Usethe following table to select Grade Mapping To Program Press Configuration Grade 1 mapped to PPU 2 1 Grade 2 mapped to PPU 1 2 5 Press ENTER Command Code 45 Set Lamp Test Time Command Code 45 is entered in Level 2 programming to set time duration of lamp test Lamp test time determines the amount of time allotted for the system to run a line le
83. off all power to STPs involved Start with the unit farthest from tank Use a UL approved sealant to connect a gasoline suitable conductive hose with a mechanical valve petcock to shear valve test port Leave valve closed Place end of hose into an approved container Restore power to STPs Activate STP for the line being purged Slowly open the mechanical valve until you obtain a slow constant stream of fuel Close the mechanical valve and the shear valve and remove power from STPs Remove hose from test port Reinstall and tighten plug removed earlier from test port Open shear valve and apply power Check for leaks MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 8 Purging Air from the System Hydraulic Mechanical Components Purging Pumps and Dispensers with fuel in product lines Using Nozzle to Purge Unit Use the following procedures for units that have had their product lines purged of air Encore 300 Encore 500 and Eclipse require different procedures to purge the units Begin purging by partially opening the nozzle until fuel is observed at nozzle after which you can open the nozzle further to finish purging For Blender nozzles select a blend grade Ensure that prices are set before you begin Refer to the following information for specific steps for your unit CAUTION Purging through a fully open nozzle on a unit with air in the product lines can damage the meter as a resul
84. on the option door Two way communication is indicated when the option door target graphic light comes on whether by car mount or hand held transponder signal Figure 8 16 Encore and Eclipse TRIND Target Graphic Location Eclipse Encore LL I 4 TRIND Target Graphic Page 8 18 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting How a Cash Acceptor Works 1 Insert a currency bill or quarters on some units The Cash Acceptor accepts bills face up or down and from either end depending upon the setup There will be a short delay while the system reads the bill Listen for the stacking of the bills e The system will register the Cash Acceptor total on the pump screen and on the printout at the pump 2 Repeat Step above with another bill or lift the nozzle 3 Select the fuel grade and begin pumping fuel or select car wash and follow prompts Once the fuel grade or car wash is selected the customer cannot put more money into the Cash Acceptor until the fueling transaction is complete Note The customer cannot pay for a completed sale at the Cash Acceptor Incomplete sales result in receipt that shows a refund due to the customer This refund is tendered by the cashier The printer must be operational and contain paper for the cash acceptor to work For more information on Cash Acceptors refer to MDE 3826 Cash Acceptor Mar
85. or board is found a cable problem could exist Use a test cable to temporarily replace each cable in the chain measuring ohms until the defective cable is found 4 If you find any faulty node board or cable replace it reconnect all cables properly and then check for a proper ohm reading again across pins 1 and 5 5 Replace the transformer if it was found defective MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 73 Electronic and Electrical Components Power Supplies Figure 6 32 Power Supply M00050A001 18 VDC Output to all Nodes LON Power ASSY M00050400 REV TO PUMP CRIND 12 54 23VDC O O Q 73 EN CN Ce jan el E e el E CCS CAN C e 14 VAC from transformer secondary 18V POWER SUPPLY cc LLI cc c LL i lt I cc FROM See table for description and function of LEDs CR 6 through CR 10 TO FILTER CAP Q Made in U S A T0 PRINTER PS Shut Down to 24 VDC Power Filter Capacitor Supply Board Note DC voltage measurements across these test points will indicate 1 2 the actual current 1 5 VDC 3 A 4 A is maximum Readings under 1 A are unreliable Status LEDs LED Color Function CR 6 Green Power IN CR 7 Green Power OUT CR 8 Red Power supply shut down CR 9 Red Fault CR 10 Red Overvoltage Page 6 74 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Power Supplies Electronic and Electrical Comp
86. other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section last updated August 2007 Topics in this Section Topic Page General Info About this Section 5 1 General Programming Information 5 2 Display Conventions 5 4 Locating Specific Programming Information 95 Firmware Software Versions 5 6 Programming Errors 5 6 Important Information about Using V1 7 58 and Higher for Encore 5XX and 5 7 Eclipse Dispensing Pump Software Encore 300 Encore 300 Programming Pump Dispenser 5 8 rogramming Encore 300 Programming Quick Reference 9 9 Pump Dispenser Encore 300 Programming and Data Access Instructions 5 10 e Level One Command Codes 5 10 e Level Two Command Codes 5 17 e Level Three Command Code 5 25 Programming Programming Encore 5XX and Eclipse Series Units 5 39 Eo d and Encore 5XX and Eclipse Programming Quick Reference 5 40 Eclipse Series Units Encore 5XX and Eclipse Programming Instructions 5 41 Level One Command Codes 5 41 Level Two Command Codes 5 48 Level Three Command Codes 5 65 Level Four Command Codes 5 88 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 1 Pump Programming About this Section Page Programming and Menu Tree 5 94 Diagnostics of MEE l CRIND and TR
87. page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out Tag out procedures Topics in this Sub section Topic Page About Calibrating Meters 7 21 About Calibrating VaporVac 7 21 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e j Wear eye protection N 4 Remove parts and fittings slowly Collect fuel in approved containers WA Clean up all spills promptly About Calibrating Meters Encore 300 units are shipped uncalibrated Encore 500 and Eclipse units shipped after December 1 2002 are shipped with initial factory calibration Note All meters including factory calibrated meters must still be checked for accuracy after purging air from system Before calibrating you must properly purge air from the system air in the system will affect calibration accuracy Refer to Purging Air from the System on page 7 7 for details After completing calibration the Weights and Measures switch must be sealed per local authority All replacement meters must be calibrated after installation and testing IMPORTANT INFORMATION All meters must be checked for accuracy after purging air from system in new or existing systems Air in the system will affect calibration accuracy Encore 300 NJO and NJ1 Six hose blends the Grade 1 switch when selected al
88. press ENTER to access this Command Code To Program Press Configuration Side 1 side with junction box 1 oide 2 2 Both Sides 3 Figure 5 38 Grade Selection 3 Select Grade then press ENTER Page 5 44 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 39 Setting Amount Allocation Allocation Amount 4 Set Allocation Amount in the Volume display then press ENTER Command Code 26 Not used Command Code 27 Review ATC Data Command Code 27 is entered in Level 2 programming to access Automatic Temperature Compensation ATC data Function Codes in this programming level provide read only access to ATC operating parameters No changes can be made to operating parameters at this level Default Function Code 1 provides for audit of last transaction data Notes 1 Attempting to use this Command Code when ATC is not installed will result in a display error as described in the Pump Programming section on page 5 1 of this manual Figure 5 40 Reviewing ATC Data Function Code 2 Complete ATC data will be shown in displays depending on specific Function Codes as described in sub sections that follow 1 Press 2 then 7 then ENTER to access this Command Code 2 Using the following table select Function Code number 1 8 then press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page
89. pump end first then to nozzle Always attach hose assembly by rotating hose and coupling Screw coupling in securely Do not over tighten Do not use zinc die cast couplings on standard hoses Use only chrome plated brass couplings Use an open end wrench to protect chrome finish 8 Check hose hanging hardware for continuity Refer to Testing Hose and Hanging Hardware Continuity on page 7 31 for details Replace components if necessary 9 Install padded or contoured plastic hose clamps and retractor cables properly In all instances do not install hose retractor clamps downstream of the breakaway 10 Restore power Open shear valve for dispensers 11 Check for leaks 12 Bleed system of air Refer to Purging Air from the System on page 7 7 for more information 13 Check for leaks again Breakaways Emergency breakaway couplings help protect against fuel spill fire hazard and equipment damage The breakaway valve stops flow during drive offs if the nozzle or hose loop catches on the vehicle Always use UL listed breakaways For proper operation of breakaways always bolt the dispenser pump securely to the island Refer to Gilbarco installation instructions for pumps and dispensers Some breakaway manufacturers require you test the dispenser pump for pull strength before installing the device Follow the manufacturer s instructions For overhead units install the spacer hose into the overhead outlet casting first followed by the
90. required Measuring Pressure Drop for Dispensers and Pumps Use the pressure drop test to check specific parts meters shear valves filters and so on An exceptionally high pressure drop for specific flow rates indicates that a part is clogged or defective To measure pressure drop for dispensers and pumps proceed as follows 1 Ensure that the pump handle is in the off position For dispensers close shear valve Place nozzle in an approved container Lift pump handle Squeeze nozzle to bleed pressure 2 Turn off power Multiple disconnects may be required 3 Install pressure gauges See Figure 7 5 on page 7 14 for locations Note Ensure that you use eye protection For dispensers install at shear valve test port or filter cap port and at the discharge special T fitting For pumps install pressure gauge at pumping unit discharge test port and the discharge special T fitting 4 Restore power to unit Open shear valve Lift pump handle Activate nozzle and pump fuel at full flow into an approved container 5 Measure flow rate and read PSI on both gauges Return pump handle to off position 6 Calculate pressure drop pressure drop is the difference between PSI readings See Figure 7 7 on page 7 16 for an example of desirable ranges 7 Ensure that the pump handle 1s in the off position If unit 1s a dispenser close the shear valve Place nozzle in an approved container Lift pump handle Squeeze nozzle and bleed
91. rs s MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Status LEDs Electronic and Electrical Components LED D1 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 Name HEART BEAT SMARTPAD A TX SMARTPAD A RX SMARTPAD B TX SMARTPAD B RX LON TERM1 LON TERM2 NEURON STAT POS 2W REV POS TX POS RX TRIND TX TRIND RX PC SER TX PC SER RX PCN 2W TX PCN 2W RX STATE A STATE B STATE C STATE D STATE E USB GOOD Status Indication Flashes steadily at rate of on for 1 second off for 1 second during normal operation Flashing begins 15 20 seconds after power up Blinking when sending data to Side 1 SmartPad or Krone pinpad via P3101 Blinking when receiving data from Side 1 SmartPad or Krone pinpad via P3101 Blinking when sending data to Side 2 SmartPad or Krone pinpad via P3102 Blinking when receiving data from Side 1 SmartPad or Krone pinpad via P3102 Off solid is normal condition On solid when LON cable connected to P3107 is not terminated Off solid is normal condition On solid when LON cable connected to P3108 is not terminated Off solid is normal condition On solid if Neuron is applicationless node must be returned Blinking at a rate of on for 1 second off for 1 second if Neuron in not configured node must be returned Short flashes every 1 5 seconds indicates PCN so
92. s ALL STOP and PUMP STOP or similar keys Total Electrical Shut Off Before Access Any procedure that requires access to electrical components or the electronics of the dispenser requires total electrical shut off of that unit Understand the function and location of this switch or circuit breaker before inspecting installing maintaining or servicing Gilbarco equipment Evacuating Barricading and Shutting Off Any procedure that requires access to the pump dispenser or STPs requires the following actions OSAGA e An evacuation of all unauthorized persons and vehicles from the work area e Use of safety tape cones or barricades at the affected unit s e A total electrical shut off of the affected unit s MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Read the Manual Read understand and follow this manual and any other labels or related materials supplied with this equipment If you do not understand a procedure call a Gilbarco Authorized Service Contractor or call the Gilbarco Support Center at 1 800 800 7498 It is imperative to your safety and the safety of others to understand the procedures before beginning Work Follow the Regulations Applicable information is available in National Fire Protection Association NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 70 National Electrical Code NEC Occupational Safety and Hazard Association OSHA regulations and fe
93. start up and commissioning of its pumps and dispensers installed in the United States This procedure ensures proper installation and warranty registration of the equipment It is also recommended that you follow this procedure outside the United States Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section was last updated in August 2007 Topics in this Section Topic Page Topics in this Section 3 1 Certificate of Conformance Numbers 3 1 Commissioning Instructions 3 2 Sample Install Start up and Commissioning Forms 3 3 Certificate of Conformance Numbers Certificate of Conformance CoC numbers are required during installation and start up of new sites You may be asked for these numbers by a Weights and Measures official Use the following table for reference Unit Name Gilbarco CoC Number Encore 02 019 Eclipse 02 020 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 3 1 Start up and Commissioning About this Section Commissioning Instructions Page 3 2 Most of the Encore and Eclipse Commissioning Form MDE 4228 is self explanatory Ensure that you read it entirely before commission
94. to Gilbarco The box has an insert that keeps the wires from being crushed by the casing of the vapor pump Put the vapor pump in this box immediately after removing it from the VaporVac system This will keep the wires from being damaged in transit to your shop Figure 7 45 Packaging VaporVac Motor for Return To return the VaporVac pump motor proceed as follows see Figure 7 45 1 The VaporVac motor box has an insert that is perforated at both ends Seat the insert into the box with the lower end curled 2 Set the removed motor into the box a The motor nipple should be at the end of the curl 3 Curlthe upper end of the insert b Lower the upper end down into the box 4 Insert the wire bundle in the upper curl c to prevent shipping damage Close and secure the box flaps ISD Vapor Flow Meter The Vapor Flow Meter junction box and plumbing is part of an In Station Diagnostic ISD system that measures the amount of vapor returning to the UST and determines whether the Vapor Recovery system is operating correctly Dispenser units are available as ISD ready as an option ISD ready dispensers include adaptive plumbing and a junction box See Figure 7 46 on page 7 76 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 75 Hydraulic Mechanical Components Vapor Recovery Components Page 7 76 Figure 7 46 ISD ready Dispenser Facing Side B of Dispenser Hydraulic Cabinet Area of Unit only v
95. un calibrated unit To purge an Encore 300 you will need to perform an electronic calibration procedure where the calibration factor will not be stored into memory Before proceeding with the steps below a system configuration Command Code 10 Function Code 1 must be entered if the unit is not a blender Also a Conversion factor Command Code 17 must be programmed into the unit or this procedure will not work Refer to MDE 4039 Encore 300 Programming Quick Reference Card shipped with all units for a summary of steps Open the side 1 CIM door side with serial plate by using the C751 key Flip up the Weights and Measures toggle switch located near the center of the cabinet Using the manager s keypad inside the cabinet press F1 and then Enter Press 90 for side 1 A or 91 for side 2 B and then Enter Press 5 then Enter Remove the nozzle and raise the pure product lever or select the pure product grade Purge air by dispensing 35 gallons for the new system where air has been previously purged up to the dispenser or 20 gallons when replacing an existing dispenser Upon completion of purging turn off the Weights and Measures switch Press F2 If you have more nozzles grades on that side or the other to purge repeat steps 3 through 9 Note The purged amount will not be reflected in the electronic totals MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Measuring Flow Rates Hydraulic Mechanical Com
96. varies from 10 to 18 VDC during operation depending upon operating conditions Coil resistance is 40 to 45 Ohms Figure 6 27 Steering Valve Relay Board M02335A001 P1200 P108 gan je imde J hs FORM vA m Pi 00 LONAC Pils 3 BBE B ni om o EDOR rmm VAPOR VAC E nup kc letra Ee Bs BEEEEB B PUMP CONTROLLER JP3 P1113 GRADE PULSER 383 GEE P1204B CR50 P306 P310 VALY SIP FEE STP uI ASSY M02335A00 REV EXE EE B Ea ir cn i c a A f BESTE SIE mar goes J a UE QDOUUOOUO0000 e eae E DE at f Zp E HEEEEEBEERES C dh des GRADE 3 PULSER GRADE 3 Er TE a GAA 2 P12024 wl RH mmm CR39 P1202B GRADE I CR43 PULSER P112 P1203B P1202A P1203A CR38 JP2 CR42 Note See the following tables for descriptions of callouts on this board Page 6 58 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Status LEDs Electronic and Electrical Components LED CR 37 CR 38 CR 39 CR 41 CR 42 CR 43 Status Indication On indicates current to P1204A On indicates current flow to the corresponding valve On indicates current to P1204B On indicates current flow to the corresponding valve Board Connections and Cables Connector Via Cable To Board At Connector P101 20 pin H17995 G7 VaporVac ATC option M01667A001 ATC option P104 10 pin M02971A001 Pump Controller PCA M01
97. voltage A Page 6 120 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 VaporVac Electrical Components T19401 VaporVac Controller PCA Electronic and Electrical Components Board controls the VaporVac system providing error checking for system status and controls It receives the following voltages e 5 VDC from the M00080 VaporVac Isolation PCA e 12 VDC from the T18018 VaporVac Motor Drive PCA Figure 6 68 VaporVac Controller Board CR40 CR42 CR45 CR41 Limit AY as m cy n s IOC A A O REGULATOR P1104 P1102 BAR CODE O Q dem Re H Proe 15959959 IN TERLOCK un mg 990000 amni om Se P1101 P1103 CR12 CR13 CR14 CR15 CR16 CR17 R52 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 R30 Calibrating Pots Page 6 121 Electronic and Electrical Components Page 6 122 VaporVac Electrical Components Board Connections and Cables Connector Via Cable To Board At Connector P1101 20 pin R19666 G1 T18015 VaporVac Valve P1201 Driver PCA P1102 34 pin R19667 G1 T18018 VaporVac Motor P1002 Drive PCA P1103 16 pin H19665 G1 M00080 VaporVac P1403 4 pin P1104 20 pin R17995 G4 ROUES P1404 P1106 R19699 G1 P1406 Jump Jack Settings JP 1 and JP 2 are always in the ON position LED Indicators LED CR12 ENABLED side A CR15 ENABLED side B CR13 ACTIVE side A CR16 ACTIVE side B CR14 ERROR side A CR17 ERROR
98. 0 M01785A001 Main Display for Encore 500 and Eclipse 6 92 M02652A001 and A002 PPU Single Display Module for Encore 500 ana EclBSez sedo cy ada irem aha ded ca gebe esaet ea eee ao eRe 6 93 M02652A005 and A006 PPU Dual Display Module for Encore 500 ANG ECOS MP 6 95 M02659A009 Satellite Indicator Display Module for Encore 300 GE SO Oko 6 dace tex en Bes tabu a Or qued vor aA a eae Redon uses 6 97 GRIND DS VIC Sse dado Eoi uu de dere Duce bd epi s inu dul am ated ed eb ane xd d E edm d d Eds 6 98 About CRIND Devices and Options 00000 eee 6 98 oingle line CRIND Display T20379 0 0 eee eee 6 98 Monochrome Display E300 and 500 00005 6 99 CRIND Device Card Reader anana cee ee eee 6 102 asd ACCENDO s vn team Sy dott reed ete r Ree eee nose uas 6 103 CRIND Printer Module 0 0 0 0 ce ee 6 106 Replacing CRIND Receipt Printer Paper 6 109 Cleaning Printer Instructions llle 6 110 Bar Code Sodio c ue tines ete On oe ea D etu teri Derbi 6 110 JUNCHOM BOXES 20 8 qom d et dede EHE Sa uer uat Nod Hon AUR a AER eee eS seme E prid 6 113 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page iii Encore Series Junction BOX a a 6 113 Eclipse Series Junction BOX 0 00 eee 6 114 VaporVac Electrical Components s 42d wed a PR ba aeo e psu ues 6 115 M00080 VaporVac Isolation PCA aana cee 6 116
99. 0 80 94 9 108 4 1 1 2 inch 150 180 203 244 NPT Flanged and Compression Tube Fittings Recommended Torque General Service Procedures Pipe in Ibs ft lbs 1 8 inch 40 45 z 1 16 inch 49 55 2 1 4 inch 58 65 i 5 16 inch 72 80 3 8 inch 9 10 1 2 inch 19 21 5 8 inch 26 29 3 4 inch 38 42 7 8 inch 49 54 Self Contained Pumping Units Recommended Torque Unit in Ibs Nm Pump head tightened in star pattern 200 23 Strainer Cover 150 17 Rear Cover 200 23 Meter Bolts Recommended Torque Bolt In Order in Ibs Kg meters 1 Cylinder cover gasket 130 10 1 50 0 12 2 Piston and connecting bar 95359 0 40 0 06 3 Shaft seal cap 25 t5 0 30 0 06 4 Lower bearing housing 75 t 10 0 90 0 12 5 Packing retainer 20 5 0 25 0 06 6 Body cover 130 10 1 50 0 12 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Purging Air from the System Hydraulic Mechanical Components Purging Air from the System Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About Purging System 7 7 Purging Product Lines Dispenser 7 7 Purging Pumps and Dispensers with fuel in product lines 7 9 WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fitt
100. 00 series units with a digital valve It interfaces with various devices such as pulsers valves VaporVac and STP relays to the pump or dispenser electronics This board provides a regulated 14 5 VDC for system operation contains solid state relays that control solenoid valves STP relays and a pulser signal interface This board also contains a buzzer and an interface to the VaporVac vapor recovery system The regulated 14 5 VDC has an under voltage lockout circuit that prevents regulated power supply circuits from starting until the unregulated DC input voltage reaches approximately 23 VDC This circuit also turns off regulated voltages when the unregulated DC input voltage drops to approximately 18 VDC Figure 6 14 Hydraulic Interface PCA M01546A001 P108 PB2 PAD P310 Line voltage P309B P307 24 VAC from Side 2 Grade2 Side 1 Grade 2 115 VAC and Neutral Grade 2 Valves Power Supply Pulsers Pulsers for Valves and STPs al ETE O P310 R44 CO R43 l S A ASSY M015464001 Cu Os O L O MADE IN P106 to Pump Controller JP3 JP2 PA3 Nees P101 to pump P105 to PUMP Enables Side 1 PA1 Side 2 Grade 3 Valves controller Controller Disables Grade 3 Side 1 Grade 3 P309A VaporVac for 1 Pulsers Grade 1 Pulsers JP1 For VaporVac Units Only Grade Pulsers Sets MPD and Blender IN Enabled PB1 OUT Disabled Side 2 Grade 1 Pulsers Grade 1 Valves MDE 3804B Encore and Eclipse Start up Service Manual August 20
101. 001 P1200 Main Transformer P1201 Pump Control Node PUMP CONTROL NOD CR39 usum ese ASSY M0O2044A00 CR43 P1204B i CR43 Grade 2 i B es Nol rdla Valve 22 A Ez El BO o P1202A Grade 1 AAA LIT m ura ura Jn XESLISEMS Vaven Grade 2 ZN aS B JE gd Bie Valve 12 jd AE E v s a EBB BEGE zz mannna P1202B SOU gs pom BGC BEN yy al adii Grade 1 algae fe eej vaso P1205A Dem s mn Grade 4 LL EI e Bi BERA BE aE hiin E igs L1ele _ P1203A Valve 14 Apes Ar B5BEEB GSE mele aa EISE Grade 3 PS un Valve 13 Pi TE STA J P1205B r gE gi 3 Grade 4 Valve 24 P1203B Grade 3 Valve 23 P1207 Steering Valve Page 6 56 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Board Connections and Cables P1200 Main Transformer P1201 26 pin Pump Control Node M04549A001 Valve Controller P1102 P1200A Grade MO02958A001 Valve 11 cableispatof P1202B8 Vave21 valve assembly P1200 Grade3 Valve 13 P1200B Valve 23 P120 Grade2 Valve 12 P1200B Valve 22 P1200 Grade4 Valve 14 P1200B Valve 24 P1207 10 pin Steering Valve M01694A001 M02097A001 P203A 10 pin Status LEDs LED Status Indication CR36 to CR43 On indicates current flow to the corresponding valve CR50 On indicates 24 VDC valve voltage is present CR51 On indicates
102. 07 Eclipse Series Junction Box Figure 6 64 Junction Box in Eclipse Dispenser Lower Inlet Support Rail Main Conduit Junction Box Page 6 114 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 VaporVac Electrical Components Electronic and Electrical Components VaporVac Electrical Components The following table lists the contents in this sub section Assembly Topic Page PCA M00080 VaporVac Isolation PCA 6 46 118015 VaporVac Valve Driver PCA 6 117 118018 VaporVac Motor Drive PCA 6 119 119401 VaporVac Controller PCA 6 121 Power Supply M01775A001 and A002 VaporVac Power Supply for 6 123 Encore 118162 VaporVac Power Supply for Eclipse 6 124 About VaporVac Electronic Components The fueling customer places the VaporVac nozzle in the vehicle s fill pipe The VaporVac Controller uses the pulse signals from the meters to track real time flow rates and determine the proper vacuum to remove vapors from the vehicle tank Vapors are returned to the site s fuel storage tank The Printed Circuit Assemblies PCAs power supply and card cage make up the VaporVac Electronics module The following table lists modules PCAs and power supply associated with each Model Voltage Module No PCA No Power Supply No Eclipse Encore 300 115 VAC 60 Hz without vapor M01776A004 T18018 G1 M01775A001 valves e 19401 G2 220 VAC 50 Hz w
103. 07 Page 6 31 Electronic and Electrical Components Page 6 32 Printed Circuit Assemblies and Nodes Board Connections and Cables Connector Via Cable To Board At Connector PA1 4 pin R20462 G4 Pulser Assembly T18350 G5 A1 P1 4 pin PA2 4 pin Pulser Assembly T18350 G5 A2 PA3 4 pin Pulser Assembly T18350 G5 A3 PB1 4 pin Pulser Assembly T18350 G5 B1 PB2 4 pin Pulser Assembly T18350 G5 B2 PB3 4 pin Pulser Assembly T18350 G5 B3 P101 20 pin H17995 G7 M01621A001 Totalizer Interface P201 20 pin P105 34 pin R19667 G1 i P205 34 pin P108 2 pin 2 wire 24 VAC M01608A00 Main Power Supply 2 wire P307 5 pin M01601A001 From Field Wiring STP1 2 3 P309A 9 pin M00454A001 Valves A1 B1 P309B 9 pin Valves A2 B2 N A for Dual P309C 9 pin Valves A3 B3 N A for Dual and Quad P310 4 pin 115 V Valve Feed M01608A00 Main Power Supply 4 wire Test Points AC Voltage Requirements Connector Pin Number Input Range Current AC Voltage Requirements P108 1 24 VAC Feed 24 VAC 5 0 750 A P108 2 24 VAC Return P101 16 5V 5 V 5 25 A P310 1 115 VAC 115 VAC 10 TOA P310 2 AC Neutral 0 VAC P310 4 STP Feed 98 to 240 VAC TOA DC Voltage Requirements P101 6 14 5 VDC 14 5 5 0 500 A P101 12 DC GND Jump Jack Settings Used only for units with VaporVac Jump Jack Function JP1 MPD Enables A2 and B2 VaporVac JP1 BLENDER Disables A2 and B2 VaporVac JP2 IN Enables disables for VaporVac 1 Grade Side 1 JP3 IN Enab
104. 1 3 ww Number of Calibrations Per Meter MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 33 Pump Programming Additional Manager Functions for Encore 300 Figure 5 32 Encore Eclipse Audit Trail Display Press Enter Fourth Time P Indicates Audit Trail Mode E ad Counts Blend Change Mode P 1110 Configuration Changes Gallon or Liter vol B lt 1014 1006 Number of Pulses Per Gallon or Liter Programming the ATC Option To program the ATC Option proceed as follows 1 Place the programming switch located on the ATC Controller board in the ON position 2 At power up e Programmed models will flash 104 and then normal information Non programmed models will flash 100 and requires the models to be programmed How To Program Each Fueling Position 1 Enter 100 2 Press ENTER Note If the program switch is OFF it will not work The money position will display 1 The money position shows which meter is selected Meter 1 through 8 The volume position will display 1 The volume position shows which fuel type has been selected Fuel Type 1 gasoline 2 diesel Page 5 54 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Additional Manager Functions for Encore 300 Pump Programming The PPU position will display 730 The PPU position shows which fuel density has been selected for the correspo
105. 1 Units Encore and Eclipse Series units Unit Type Side 1 Side 2 7 3 Grade 1 Hose 1 MPD Non Diesel 1 JP1A JP2A JP9A JP10A 16 2 Grade 1 Hose Blender 1 17 3 Grade 1 Hose Blender 1 Diesel EU OM 18 4 Grade 1 Hose Blender 1 19 5 Grade 1 Hose Blender 1 Encore Series units only Voltage Test Points Test Point Voltage P1202 Pin3 120 VAC Hot P1202 Pin 1 120 VAC Neutral MDE 3804B Encore and Eclipse Start up Service Manual August 2007 VaporVac Electrical Components Electronic and Electrical Components T18018 VaporVac Motor Drive PCA This board mounts in the electronics cabinet card cage on factory built units The motor drive board provides high current switching to drive the motors It receives the following voltages e 43 VDC and 25 2 VAC from the VaporVac power supply It supplies the following voltages e 12 VDC unregulated to P1005 e 12 VDC regulated to the T19401 VaporVac Controller PCA 6 2 VDC to the T17942 VaporVac Pump Assemblies for Hall effect sensors e 36 50 VDC unregulated to T17942 VaporVac Pump Assemblies Figure 6 67 VaporVac Motor Drive Board T18018 P1004 to Side 2 Motor P1004 MOTOR B P1001 from VaporVac Power Supply 950994 geere x m Y z l E made AE a renes o eon zs o PER Je 9 el picos GOO i GA eS NS i to Side 1 Motor chistes cos i K 9955 C X CJ risers BAR CODE i CR12 CR15 CR5 MDE 3804B Encore and Eclipse Start up Ser
106. 112 P115 Qty 4 8 pin P1101 10 pin P1102 26 pin P1103 P1104 P1105 5 pin P1106 Ethernet 1 34 pin P1108 34 pin P1109 2 wire P1110 26 pin P1111 10 pin P1123 3 pin P1124 Ethernet 2 16 pin Status LEDs Via Cable e M00453A001 Encore M01026A001 Eclipse M00635A001 M00549A001 M00489A001 LON Header 1 10 pin M00489A001 LON Header 2 10 pin M00635A001 M007124A001 M00713A001 M004914A001 M00549A002 Encore M01036A001 Eclipse M00719A001 M00150A001 Encore M00150A002 Eclipse Printed Circuit Assemblies and Nodes To Board Quad Pulser s M00786B001 STP Board m00047 M00059A00X Steering Valve Driver PCA LON system Side 1 LON system Side 2 M00050A001 Power Supply Board 18 VDC M00071A001 Pump Ethernet Board not yet available IFSF Interface Board Pump 2 Wire to Terminal Block in Power Supply Or e M00089A001 CRIND Control Node Or MOC special CRIND Control Node MO00089G001 See M00089A001 CRIND Control Node M00080 VaporVac Isolation PCB Serial Programming Port ECal Security Switch At Connector P1301 P1201 P1405 3 LED Name Status Indication D1 2W REV On solid if 2 wire loop is reversed D2 PC RX Blinking when receiving data from PC D3 PC TX Blinking when Transmitting data to PC D4 STATE A On solid when application is running properly D5 STATE B On solid when application is running properly D6
107. 118 PPU Board Communication Failure Major 5119 PPU Board Present but not configured for Minor 5120 PPU Board pump handle not connected Major 5121 PPU Board Grade select button not connected Major MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 25 Theory of Operation and Troubleshooting Error Codes 5126 5199 Code Description Level 5126 Key stuck on Manager Keypad Minor 5131 PPP keypad option set but Not present Super Major 5132 PPP keypad present but not configured for Minor 5133 Key stuck on PPP keypad Minor 5134 Call button option set but Not Present Super Major 5135 Call button present but not configured for Minor 5136 Call button stuck Major 5137 E Stop option set but not present Super Major 5138 E Stop button present but not configured for Minor 5139 E Stop button stuck Major 5140 Push to Start button option set but not present Super Major 5141 Push to Start button present but not configured for Minor 5142 Push to Start button stuck Major 5171 Power Fail Manager Keypad mode exited Undefined 5174 Totalizer node communication Failure Major 5175 Totalizer Node detected but not configured for Minor 5183 Totalizer present but no return pulse detected Major 5198 Measurement unit changed not programmed Undefined 5199 Measurement unit changed 500 pulses per gallon Undefined 5235 5241 Code Description Level 5235 Database corrupted Minor 5236 Database build proc
108. 2 N 0 oO A OJ N OI O1 BI WY P Displays Main PPU CRIND Jumper Setting A B AB AC BC ABC AB AC BC ABC AD BD ABD CD The Dual PPU display module M02652A007 and A008 is capable of supplying dual level price per unit information to the customer Grade selection and status is reported back to the CRIND device Jumpers are used to set the addresses A proximity switch that reports status of the pump handle is part of the M02652A007 module Module M02652A008 does not have the proximity switch Service Tip If one of the two backlight bulbs burns out it is a good idea to replace both bulbs on that board MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Displays Main PPU CRIND Electronic and Electrical Components Figure 6 42 PPU Module with Dual Display for Encore 300 M00065A007 shown with proximity switch installed Proximity switch Q12514 10 O This PCA M01525A001 is part ASSY MO1525A00 REV of the display module assembly Not serviceable separately Board Connections and Cables Note Board and connections per grade Connector Via Cable To Board At Connector P121 20 pin M01585A001 M01515A001 Main Display P804A 20 pin PCA P2201 2 pin M1586A001 or M01618A001 M01598A001 Pump P204 34 pin Controller PCA JP3 Jump Jack Settings Jump jack settings are the same for single and dual PPU displays Refer to JP3 Jump Jack Settings o
109. 30 Measurement unit volume changed To Imp Gallons Undefined 5031 Measurement unit volume changed Hawaiian Gallons Undefined 5041 Power Fail Power circuit register a power loss Undefined 5047 Reverse flow detect Medium 5048 No flow detect eMINOR Minor 5049 Unauthorized flow detected Medium 5050 Invalid Pulser Pulser Pattern does not fit profiled meter Medium 5066 STP 1 configured for but not connected Super Major 5067 STP 2 configured for but not connected Super Major 5068 STP 3 configured for but not connected Super Major 5069 STP 4 configured for but not connected Super Major 5070 Vapor Vacuum option set but VV board not present Super Major 5071 Vapor Vacuum option NOT set but VV board is present Minor 5072 Vapor Vacuum option set connected Super Major 5074 Vapor Vacuum motor not responding Medium 5079 Valve Not Configured for but is responding Minor 5081 Air sensor NOT connected but option is set Super Major 5091 ATC node Communication Failure ATC option set Super Major 5092 ATC node present but not configured for Minor 5098 T Meter Not Connected Super Major 5099 ATC number of probes exceeds number of meter Minor 9100 5121 Code Description 5100 ATC number of meters exceeds number of probes Medium 5101 No Pulse train detected from T Meters The T Meter is connected Super Major 5111 Door node Communication Failure Super Major 5115 Door node software download Flash Error Medium 5116 Door node software download incomplete Medium 5
110. 30 pin P2014 2 pin M01663A001 T20306 G1 CRIND Regulator PCA SK2 6 pin P2015A 34 pin M01668A001 Side 1 Q13908 01 Monochrome Graphic J1 34 pin Display P2015B 34 pin M01668A0002 Side 2 Jump Jack Settings Jump Jack Position Function JP 1 A ON Resets monochrome CPU B ON Disables watchdog OFF Enables watchdog JP2 OFF PPPRX JP3 OFF PPPTX LED Indicators LED Indicates CR2 1 Receiving data A side CR2 2 Receiving data B side CR2 3 Transmitting data A side CR2 4 Transmitting data B side CR3 Error code indicators CR4 Connectors P2013 interfaces the Monochrome Pins 1 2 4 and 5 connect to P268A of CRIND Logic board Pins 3 and 6 connect to P268B P2013 Monochrome Interface Pin Function Voltage Pin 1 CRIND Power disables monochrome communication circuits if VDC is not present Pin 2 CRIND A side RX Pin 3 CRIND B side RX Pin 4 CRIND GND Pin 5 CRIND A side TX Pin 6 CRIND B side TX P2014 Pin Function Voltage Pin 14 GND Pin 16 5 VDC supplied by the dispenser s regulator board MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Test Points Electronic and Electrical Components Test Point Voltage TP1 BATT 2 8 VDC or higher with power ON or OFF Power OFF to the monochrome CPU requires dispenser power to be removed and dispenser battery to be disabled TP2 VRAM 4 5 VDC with power ON 2 2 to 3 VDC with power
111. 44 PPU Grade Mapping 4 38 Command Code 45 Set Lamp Test Time 4 39 Command Code 46 Set Comma Decimal Point 4 40 Command Code 47 Set Reported Money Size 4 40 Command Code 48 Zero Previous Transaction 4 41 Command Code 49 STP Controls 4 42 Command Code 50 Map Valves and STPs 4 43 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Command Code 51 Set Main Beeper 4 44 Command Code 52 Set VaporVac Alarms 4 44 Command Code 53 Set Time Outs 4 45 Command Code 54 Set Slowdown Valve 4 47 Command Code 55 Set Hose Pressurization 4 47 Command Code 56 Set Stop Button Control 4 48 Command Code 57 Event Logs 4 49 Command Code 60 Set Clock and Calendar 4 49 Command Code 61 Two Wire Remapping Grade 4 51 Command Code 71 Set Volume Units 4 52 Command Code 72 Set Blend Ratios 4 52 Command Code 73 Set Display Money totals 4 53 Command Code 74 Set Display Volume Totals 4 54 Command Code 75 Set Fuel Density 4 55 Command Code 77 Change PIN Code 4 56 Command Code 78 Electronic Calibration 4 57 Command Code 80 Set Maximum Flow Rate 4 64 Command Code 90 Set Unit Type 4 65 Command Code 91 Select Installed Options 4 66 Command Code 93 Set Cash Credit at Dispenser 4 68 Command Code 94 Set Zero PPU Option 4 68 Command Code 95 Cold Start and Force Application Download 4 69 Command Codes Quick Reference 4 8 4 28 Index 1 Index Command Codes CC Programming PPU Mode 4 9 2 Settin
112. 4B Encore and Eclipse Start up Service Manual August 2007 3 1 3 1 3 1 3 1 3 1 3 2 3 3 4 4 4 1 4 1 4 1 4 1 4 1 4 1 4 2 4 4 5 1 5 1 5 1 5 1 5 2 5 4 9 5 5 6 5 6 Page i Important Information about Using V1 7 58 and Higher for Encore 5XX and Eclipse Dispensing Pump Software 0000 00 5 7 Encore 300 Programming Pump Dispenser llli 5 8 Contents in this Sub Section 0 0 0 0 es 5 8 Encore 300 Programming Quick Reference 0 cee eee n 5 9 Encore 300 Programming and Data Access Instructions 00 0000 eee eee 5 10 Level One Command Codes 0 00 cece eee eee 5 10 Level Two Command Codes 0 00 cece eee eee 5 17 Level Three Command Code 0 000 cece eee 5 25 Additional Manager Functions for Encore 300 0 ccc eee 5 30 Verifying Blend Ratios Changes to Blend Ratios and Configuration ChangeS lille 5 30 Displaying Last Transaction DLT 0 0000200 c eee 5 31 Unit Totals Retrieval Convention 0 0 000 cece eee 5 31 Displaying Pump Money and Volume Totals 5 31 Audit Trail Information llle 5 32 Programming the ATC OplIOLk 2 adm D tee Dod od neon 5 34 How to Access ATC Mode Information 005 5 35 Definition Function of ATC Codes lille 5 36 Programming Encore 5XX and Eclipse Series Units 0 00 0 es 5 39 Cont
113. 4B Encore and Eclipse Start up Service Manual August 2007 ATC Components Hydraulic Mechanical Components At Main At Volume At Grade 1 Function Code Description Display Display PPU Display 1 default Audit Last Transaction Gross volume Net volume Average temperature 2 Display Volume Correction Factor 27 2 Meter Number Volume correction factor 3 Display Fuel Density 27 3 e 730 Gas e 840 Diesel 4 Display Temperature 27 4 Current temperature 9 Display Gross Volume Totals 27 5 Gross volume Gross volume most least significant significant 6 Display Software Version 27 6 ATC version 7 Real time Transaction Mode Gross volume Net volume Current temperature Enabling ATC ATC is enabled at Level 4 at Command Code 91 Function Code 4 Selection Description 1 default Not Installed 2 Installed ATC Specific Error Codes Code Description 5091 ATC node communication failure 5092 ATC node present but not configured for ATC 5093 ATC node software download successful 5094 ATC node software download Authentication 5095 ATC node software download CRC error 5096 ATC node software download Flash error 5097 ATC node software download DownLoad Incomplete 5098 T Meter not connected 5099 ATC number of probes exceeds number of meters 5100 ATC number or meter exceeds number of probes 5101 No Pulse train detected from T Meters T Meter is connected 5600 Fuel Density note not programmed 5601 ATC temperature out of range
114. 5 uu s ur arp ew CRIND 2 P3106 Not Used wg c ue 1 n Wire dO 06 j E cdd P3117 ORs R36 rss SS R25 oO c R26 P3107 LON Bus P3108 LON Bus e R49 R50 P31 1 5 Oo O Laptop 6 EH REV P3110 TRIND F P3109 Not Used P3118 2 Wire ASSY M0175340 P3304 Not Used P3121 Not Used fer g z 2 ee EM SE foi m P3111 PC Serial is an P3121 mE Briss ges iere Ee a o Not Used P3116 Not Used 53405 Mono Interface P3303 Mono Interface MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 45 Electronic and Electrical Components Page 6 46 Printed Circuit Assemblies and Nodes Board Connections and Cables Connector P3101 5 pin P3102 5 pin P3105 3 pin P3107 10 pin P3108 10 pin P3110 14 pin P3111 10 pin P3115 4 pin P3117 4 pin P3118 2 pin P3302 34 pin P3203 34 pin Via Cable M00497 M02159A002 M00719A001 M02995A001 M00553A001 To Board SmartPad T20247 01 At Connector CRIND 2 wire P412 LON Bus TRIND Serial programming port to Laptop Pump Control Node P1109 2 pin Mono module J1 34 pin Figure 6 21 CRIND Control Node 2 LEDs Jump Jacks and Test Points 0 03 Lc C3855 OR54 ea 033 OR55 OR56 eos OR57 a ci im oF a c oa 59 Qa ae TP5 Duc Ba A IP6 0 ORS BE OR R37 R36 OR38 R39 R25 0 cR26 ERLO RAID y 1 molo S b R430 E Rao C b R450 P3117
115. 5 18 VUNREG 17 5 V to 28 V P2104 Pin Description Input Output Voltage 1 VCC 5 V 5 2 SPKRTN Open Collector to 0 V 3 SPKR_STAT Open to 0 V 4 GND 0V P2109 Pin Description Input Output Voltage 1 18 VUNREG 17 5 V to 28 V 2 GND OV 3 18 VUNREG 17 5 V to 28 V 4 GND OV 5 485B 7 V to 12 V Max 6 485A 7 V to 12 V Max 7 GND OV 8 18 VUNREG 17 5 V to 28 V 9 EXTRESET 0 V to 12 V 10 TERM RES FEEDTHRU P2112 Pin Description Input Output Voltage 1 18 VUNREG 17 5 V to 28 V 2 GND 0V 9 18 VUNREG 17 5 V to 28 V 4 GND 0V MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Pin olol NIOJ C Description 485B 485A GND 18 VUNREG EXTRESET TERM RES FEEDTHRU Description 9 4 VAC 9 4 VACRTN No connect M00077A001 Totalizer Node M00077A001 is a dedicated peripheral control node on the LON Bus for Encore 500 and Eclipse This node is used to control a maximum of four electro mechanical totalizers that may be found on one or both sides of the unit Totals are non changeable Electronic and Electrical Components Input Output Voltage 7 V to 12 V Max 7 V to 12 V Max OV 17 5 V to 28 V 0 V to 12 V Input Output Voltage 9 4 VAC 10 Totalizer operation can be programmed in select installed options Command Code 91 at Function Code 11 Totalizer can be configured as e Per inlet per unit only option
116. 5 25 VDC TP6 14 V to 23 VDC Board Connections and Cables Connector Via Cable To Board At Connector P2101 11 pin M00509A001 or M00077A001 Totalizer Node one per P2201 P2111 3 pin Push to Stop M00509A002 for Encore grade e M00509A0093 for Eclipse P2102 9 pin e M00501A001 Encore Card Reader 7 pin e M00501A002 Eclipse Card Reader Heater R20379 2 pin P2104 4 pin e M00636A001 Encore Speaker refer to the Encore Series e M00495A001 Cable Block Diagram or the Eclipse M00636A002 Eclipse Series Cable Block Diagram P2106 12 pin MO1200A001 Soft Keys Keypad see Encore Cable Block Diagram M00284 P2107 15 pin M01202A001 Encore Customer Keypad Options CRIND or Refer to the Encore M01202A002 Eclipse PPP Series Cable Block M01109 Misc Options Keypad Diagram or the M00141 CRIND Keypad Eclipse Series Cable Block Diagram P2108 14 pin M00515A001 Encore M00147 Manager Keypad Side 1 M00515A003 Eclipse only P2109 10 pin M00489 LON Bus 1 P2110 4 pin Call Button M01201A001 Encore M01109B001 Miscellaneous Options 12 pin M01215A001 Encore Keypad P2113 5 pin Push to Start P2112 10 pin M00489 LON Bus 2 P2114 4 pin N A Door sense P2115 9 pin M00614A004 Encore Power Supply 9 4 VAC PS2 M00614A002 Eclipse PS2 to PS3 on bulkhead connector P2116 3 pin M00614A005 to M00614A004 Main Power Supply J2115 MDE 3804B Encore and Eclipse Start up Service Manual August 200
117. 5 45 Pump Programming Encore 5XX and Eclipse Programming Instructions Table below shows Function Codes available and keypad programming for CC27 Function Code 1 Default Page 5 46 ATC Functions and Description Audit last transaction Provides display of uncompensated and compensated product volumes single meter in main money and volume displays respectively Average transaction temperature for the selected inlet is shown in PPU display for selected meter ATC data is reported after inlet selection has been entered in main volume display Note On blended product one would have to view both pure products and manually add them to create blended totals volume and sale Display Volume Correction Factor VCF Provides display of VCF for a selected product meter VCF is based on currently sensed meter temperature ATC data is reported after meter selection has been entered in main volume display Display fuel density Provides display of density for a selected meter Displayed density for a particular grade reflects density assignment made in Level 4 programming ATC data is reported after grade selection has been entered in main volume display Display temperature Provides display of the temperature in Celsius for a selected meter Display gross volume totals Provides display of gross volume totals for a selected meter Display software version Provides display of ATC neuron software version number
118. 5 V to 5 25 V Page 6 28 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M00122A001 LON to Serial Node LON Gateway The LON to Serial Node converts LON data to RS232 data on Encore 500 and Eclipse series units RS 232 serial data is a protocol that allows the LON to interface with serial devices such as scanners and cash acceptors This board is equipped with door indicator connections for security This board contains a replaceable battery that allows for monitoring of the door indicator connections even when power is disrupted WARNING There is a danger of explosion if battery is replaced incorrectly Replace with only the same or equivalent recommended type Dispose of used batteries according to the battery manufacturer s instructions Service Tips If the Neuron status LED is on or blinking then there is a problem with the LON Heartbeat LED should be blinking at a steady rate e Transmit and receive LEDs indicate communication on the RS 232 port Figure 6 13 LON to Serial Node P1508 TTL Serial P1510 Security Sensor P1509 RS 232 Serial P1513 Indicator Light BT1 Lithium Battery Q12674 01 TP8 TP10 SECURITY INDI ATOR 3 40 43 6V O H H E Y 22 8 TO 925 2 T TIT TUUTTUUT Gil barco a MADE IN U S A a TEETH dl U3 UU UU UU lt 1 ug e _ PI509 RS232 SERIAL 10 pe O m
119. 598A001 J106 P105 34 pin R19667 G1 Pump Controller PCA M01598A001 J205 P106 16 pin M01666A001 Vapor recovery controller T19401 G1 P108 2 pin Main Power Supply M042274 J108 P306 P307 5 pin field wiring Junction box P310 4 pin M01687A J310 or P604 P1112 8 pin Mo2651A001 Pulser T18350 G8 P1 P1113 8 pin M02651A001 Pulser T18350 G8 P1 P1114 8 pin M02651A001 Pulser T18350 G8 P1 P1200 3 pin Main Power Supply M042274 J108 P1202A 2 pin M02958A001 Valve B1 J1202A P1202B 2 pin M02958A001 Valve A1 J1202B P1203A 2 pin M02958A001 Valve A3 see Note 1 J1203A P1203B 2 pin M02958A001 Valve B3 see Note 1 J1203B P1204A 2 pin M02958A001 Valve A2 see Note 2 J1204A P1204B 2 pin M02958A001 Valve B2 see Note 2 J1204B P1208 Notes 1 Omit for Dual and Quad 2 Omit for Dual Jump Jacks Jump Jack Purpose Status JP1 For VaporVac only blender or MPD JP2 Side 1 Enables or disables VaporVac for the 1 Product In enabled out disabled JP3 Side 2 Enables or disables VaporVac for the 1 Product In enabled out disabled MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 59 Electronic and Electrical Components Printed Circuit Assemblies and Nodes T17764 G3 4 CRIND Z180 Logic Board Page 6 60 This board is used in the Encore series units Each dispenser can have up to two CRIND logic boards one per side Side 1 communicates directly with the dispenser controller board via the
120. 6 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Note If electronics are damaged due to power surge for example lightning the varistor should be replaced M00047A001 STP Driver PCA STP Driver Board receives line voltage from M00044A001 Terminal Block PCA Field Wiring It receives control signal from M00056A001 or M01922A001 Pump Nodes Totalizer Node and activates STP output signal relays Service Tip Use caution during service when positioning the metal shield over this and other components If the shield 1s not positioned correctly it can short on board components to ground and permanently damage the board Figure 6 2 STP Driver Board M00047A001 PISO PUMP CTRL REV Q e O m ns m o0 iy 2t gt v o ms A e a YG x Gilbarco Made in U S A P1303 WAGO Spring Loaded Terminal Board Connections and Cables Connector Via Cable To Board At Connector P1301 10 pin M00635A001 M01922A001 or M0056A001 Pump P1101 10 pin Node P1302 1 STP Control Out Field 1 Field Wiring Refer to 1 4 Outputs 2 Feed In e FE 340 Field Wiring Diagram 2 Terminal Block or for Encore Field Wiring e FE 341 Field Wiring Diagram for Eclipse 2 Field Wiring MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 7 Electronic and Electrical Compone
121. 62L3 Ce o UTTUUTUUT quo oe HEART BEAT s mcs 3 a i MMT RESET SERVICE ll REV JP2 JP3 dii se MUTT CR dC TP5 NEURONSTAIUS 14 TO 23V ASSY M00122A00 TP5 CR2 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 29 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Page 6 30 Board Connections and Cables Connector Via Cable To Board At Connector P1506 10 pin M00489 LON Header 2 P1507 10 pin LON Header 1 P1508 13 pin NA Cash Acceptor Interface 13 pin understand P4509 14pi NA RS232lte ace d4pin P1510 5 pin N A Not available VDC Bar code only e P3503B Side 2 P1513 4 pin N A Indicator Bar code only Test Points Test Point Range TP5 17 5 V to 28V TP6 4 75 V to 5 25 V TP7 GND TP8 3 0 to 3 6 V Battery TPQ 11 4 to 12 6 V TP10 22 8 to 25 2 V Status LEDs LED Status Indication CR 1 HEARTBEAT should blink at 1 per second CR2 LON Neuron Status ON or blinking indicates problem CR20 Serial TXD ON when transmitting CR21 Serial RXD ON when receiving Jump Jacks Jump Jack Purpose Status JP 1 Jumper for side 1 No jumper is side 1 JP2 Reset JP3 Not for field use MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M01546A001 Hydraulic Interface PCA This Hydraulic Interface board 1s used on Encore 3
122. 7 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Connector Pin Functions and Voltages P2101 Pin Description Input Output Voltage 1 9 4 VAC 9 4 VAC 10 2 9 4 VACRTN 3 GND 0 VDC 4 GND 0 VDC 5 DLT 5 VDC 4 7 V 10 6 PPUCLK 0 to 5V 7 PPUFBDATA 0 to 5V 8 PPUSND_REC 0 to 5V 9 PPUBP 0 to 5V 10 PPUSDATA 0 to 5V 11 PPUSYNC 0to5V P2102 Pin Description Input Output Voltage 1 VCC 5 V 5 2 CRRDT1 0to5V 3 CRRCL1 0to5V 4 CRRDT2 0to5V 5 CRRCL2 0to5V 6 CRCLD 0to5V 7 GND OV 8 CRSTAT Open to 0 V 9 GND OV P2103 Pin Description Input Output Voltage 1 VCC 5 V 5 2 GND OV 3 PRSENIN 0to5V 4 PRSENSTAT Open to 0 V 5 18 VUNREG 14V to 23V MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 51 Electronic and Electrical Components P2104 Printed Circuit Assemblies and Nodes Pin Ri wy N P2109 Pin OO CO NI oO oa BI wl NJ gt O P N pd n N gt I 5 O CO N oO oo A OJ N 0 P2115 Pin oO N Page 6 52 Description VCC SPKRTN SPKR_STAT GND Description 18 VUNREG GND 18 VUNREG GND 485B 485A GND 18 VUNREG EXTRESET TERM RES FEEDTHRU Description 18 VUNREG GND 18 VUNREG GND 485B 485A GND 18 VUNREG EXTRESET TERM RES FEEDTHRU Description 9 4 VAC 9 4 VACRTN No connect MDE 3804B Encore and Eclipse Start
123. 85A001 Fixed Blender Manifold J701 9 pin M00223B002 Side 1 coils P309D 9 pin Fixed Blender Manifold M00223A001 Side 2 coils P320 4 pin R20593 G1 M01546A001 Hydraulic Interface PCA Test Points Test Point Range Current Max P203A 7 14 VDC 0 50 VDC 70 mA P203A 8 P320 1 with respect to P320 2 115 VAC 596 600 mA MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 37 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Page 6 38 P203A Input Requirements Pin Signal Name On Off 1 SVA1 2 SVA2 9 SVA3 4 SVB1 10 mA of current flow 0 5 mA or less of current flow 5 SVB2 6 SVB3 7 8 14 V 9 10 GND P309C Output Requirements Pin Signal Name On Off 1 Steering Valve A1 Current flow 1 No current flow 2 2 3 Neutral 4 Steering Valve A2 Current flow 1 No current flow 2 5 6 Neutral 7 Steering Valve A3 Current flow 1 No current flow 2 8 9 Neutral Notes 1 Requires a 300 mA load to the appropriate neutral connection There should be current flow through the load and no more than a 1 4 Volt peak drop between P320 1 and the appropriate output 2 There should be 100 uA or less of current flow through the load P309D Output Requirements Pin Signal Name On Off 1 Steering Valve B1 Current flow 1 No current flow 2 2 3 Neutral 4 Steering Valve B2 Current flow 1 No current flow 2 5 6 Neutral 7 Steering Valve B3 Current flow 1 No curr
124. 96 Blackmer Global Dispenser Pump Service and Kit Manual MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 49 Hydraulic Mechanical Components Pumping Device GDP Figure 7 30 GDP Assembly Sump Vent or OIML Switch Port Sump Drain Plug Strainer Cover Pump Shaft Pressure Control valve Drain Plug OIML switch not required for US domestic units General GDP Service Procedures This service manual contains basic service procedures for the GDP unit For additional GDP service information refer to MDE 4096 Blackmer Global Dispenser Pump Operation Maintenance and Kit Installation Manual Draining the GDP Draining the GDP unit to some extent will be necessary when opening the unit for servicing the strainer or removing pressure valve Figure 7 31 Plug Locations Q Plug Left P d MN Side Casing Page 7 50 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Pumping Device GDP Hydraulic Mechanical Components The following procedure provides instructions on how to drain the bulk of the fluid from the pump Note Residual fluid may remain in the pump 1 Putapproved tray in place to catch fuel 2 Remove the plug on the upper face of head directly to the right of the strainer cover This port may be used to monitor vacuum see Figure 7 31 on page 7 50 3 Remove the plug on the lower right face of the head Fluid will be emptied by removing this plu
125. A001 Totalizer Interface PCA This board is the interface for the electromechanical totalizers Figure 6 18 Totalizer Interface Board M01621A001 P1503 Grade 3 Totalizer P1502 Grade 2 Totalizer P1501Grade 1 Totalizer ek LES s uu P1507 Pump u Controller Board P1506 Piso SIDE B dioi TOTAL IZER JP 3 Gilbarco O ASSY MO l621A00 Made in U S A REV JP4 P1505 JP3 P1504 Grade 1 Totalizer P1506 Grade 3 Totalizer Grade 2 Totalizer Board Connections and Cables Connector Via Cable To Board P1501 4 pin Totalizer cable Electronic Totalizer Side 1 Grade 1 P1502 4 pin Electronic Totalizer Side 1 Grade2 P1503 4 pin Electronic Totalizer Side 1 Grade3 P1504 4 pin Electronic Totalizer Side 2 Grade 1 P1505 4 pin Electronic Totalizer Side 2 Grade 2 P1506 4 pin Electronic Totalizer Side 2 Grade3 P1507 12 pin M01650A001 harness See M01621A001 Totalizer Interface PCA on page 6 43 Jump Jack Settings Jump Jack Position Function J1 Side A One Grade or Single Product J2 Side A One or Two Grades or Two Product J3 Side B One Grade or Single Product J4 Side B One or Two Grades or Two Product MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 43 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Figure 6 19 Jumper Setting Diagram for M01621A001 JUMPER Per Grade Grade Grade Three _
126. August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Pin To Pin Tables P251 Regulator Test Point Voltage Pin 1 5 V Pin 2 5V Pin 3 GND Pin 4 GND Pin 5 Key Pin 6 TXD G SITE Pin 7 RXD G SITE Pin 8 N C Pin 9 5 V Unregulated Pin 10 Cut Pin 11 58 V return Pin 12 58 V Test Point Voltage Pin 1 5 V Pin 6 Card inserted 5 VDC No card inserted 0 VDC Pin 7 GND P255 Speaker Signals Test Point Voltage Pin 1 Speaker Pin 2 Key Pin 3 N C Pin 4 Speaker P257 Thermal Printer Signals Test Point Voltage Pin 24 GND Pin 25 5 V P258 Thermal Printer Signals Test Point Voltage Pin 2 GND Pin 4 5 V MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 63 Electronic and Electrical Components Page 6 64 P262 Modular Two Wire A Test Point Voltage Pin 1 Pump data in Pin 2 Pump data out Pin 3 Key Pin 4 N C Pin 5 GND Pin 6 Side A select P268 Spare I O Test Point Voltage Pin 6 Cash acceptor door sensor Pin 14 GND Pin 17 5 VDC Pin 18 GND Pin 19 RXD InfoScreen Monochrome Monochrome Pin 22 GND Pin 29 InfoScreen identifier Pin 30 Monochrome identifier P269 Cash Acceptor Test Point Voltage Pin 1 5 V Pin 2 Data in Pin 3 GND Pin 5 Data out Pin 6 LRC removed signal Pin 9 5V Pin 10 GND P282 SmartPad Test Point Voltage Pin 1 5 V Pin 2 GND Pin 3 Button Press
127. C VUTC PPU Displays CT DLC DLC X3 Money Display N A BC BC Volume Display VUTC VUTC VUTC PPU Displays PPVUT CT CT X4 Money Display No Change BC BC Volume Display No Change VUTC VUTC PPU Displays No Change PPVUT PPVUT Legend BC Total times blends have been changed CT Total times associated meter calibrated DLC Days since last associated meter calibration PPVUT Pulses per VUT for associated meter VUTC Total time VUT changed VUT Volume Unit Type liters or US gallons Standard Meter Calibration Procedure Pre V1 7 58 software The calibration procedure assumes that either a 5 gallon or 20 liter prover can will be used If another size can is used you must change the default can size in Command Code 82 As the new can size will be stored in memory for future calibrations if the special can size 1s not likely to be used for the next calibration it is very important to reprogram the can size back to default after completing calibration It is also wise to verify the can size on the money display during calibration Error code 26 will not clear automatically after a unit has been first calibrated A warm start is now required This will be primarily noted after installing a new service board and calibrating or performing a true cold start drop back to V1 3 74 Pump Node software and then reload to the current version where re calibration is required When performing the combined verification test and re calibration electron
128. Cable Figure 6 37 Example of Encore 500 and Eclipse Configuration Power Supply 2 PCA M02774 Power Supply Chassis AC Distribution Cable Page 6 80 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Power Supplies Electronic and Electrical Components Figure 6 38 Universal Power Supply Back STP Board Location STP PCA See M00047A001 Board Connections and Cables Connector Model Via Cable To Board At Connector E500 J108 Not applicable to this configuration J302 M00614A00X Main Display M01785A001 J2115 J310 MO029544001 STPboard M00047A001 Terminal strip J605 N A Voltage plug M00488AXXX J1607 J606 Via attached cable Power Supply 2 M02774A001 P606 J607 P607 J1200 Via attached cable Valve Converter M02044A00X P1200 J1206 Not applicable to this configuration E300 J302 M01650A001 Main Display M01515A001 J2115 J605 N A Voltage plug M00488AXXX J1607 J108 Via attached cable Valve Converter M02335A00X P108 J310 Viaattachedcable STP board MO0047A001 Terminal strip J606 Not applicable to this configuration P606 J607 P607 J1200 Via attached cable Valve Converter M02335A00X P1200 J1206 Not applicable to this configuration Fuse Description Part Number Fuse 3AG Slo Blo 5 A Q10131 04 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 81 Electronic and Electrical Components Power Supplies M02774A001 Universal
129. Components Cash Acceptor The Cash Acceptor option for CRIND card readers accepts bills and extends pay at the pump convenience to cash customers Each bill inserted and accepted by the CRIND device is recorded in the CRIND log file The CRIND log file prints the bills accepted at the top of the receipt Cash Acceptor assembly part number M01271A002 is used in Encore 300 and MO01271A004 is used in Encore 500 and Eclipse In rare cases a customer may dispute the amount of money they inserted into the Cash Acceptor Use the G SITE system records to help settle the dispute or to get Cash Acceptor information beneficial to site management CAUTION Do not open the electronics cabinet to change paper to remove Cash Acceptor cassettes or to perform any other tasks while it is raining The moisture from the rain can damage the unit Service Tips e Technicians should always request the station manager to empty the cash acceptor cassette prior to servicing the mechanism e CRIND Diagnostics can be used to test cash acceptor performance and to determine statistical data Cash Acceptor Encore 300 Figure 6 52 Cash Acceptor Assembly M01271A002 LCR Removed Security Switch P193 Padlock Area Vault Door Bill Collector Passageway LEDs MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 103 CRIND Devices Electronic and Electrical Components Connections and Cables E300 Model Connector Via Ca
130. D 5 Usea7 mm nut driver or socket to remove the two upper Hex head screws 6 Use a 3 8 inch nut driver or socket to remove two nuts from lower carriage bolts 7 Remove nozzle hook and carriage bolts from the nozzle boot Save Hex head screws carriage bolts and nuts Page 7 34 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Hanging Hardware Hydraulic Mechanical Components Positioning Nozzle Hook for Specific Nozzles Determine the new nozzle hook position using the chart below as the guide to select new hole positions Refer to Figure 7 15 on page 7 34 to identify existing nozzle hook retaining screw and nut locations Identifying marks are located under right hand row of indented hole locations Nozzle Type Upper Hex Head Screw Location Lower Carriage Bolt and Nut Location Standard Factory Location All A D Non Vapor VaporVac OPW Husky Emco A D Wheaton VaporVac Catlow Richards B E Healy System C F Balance Husky Short A D Balance Husky Long Emco E Unmarked Use nozzle hook carriage Wheaton Long bolt holes as drill guide Balance OPW Long Bottom hole set G on Figure 7 15 Unmarked Used nozzle hook carriage on page 7 34 bolt holes as drill guide Drilling Holes To drill holes proceed as follows 1 Use 7 32 inch or 22 drill bit to drill new holes as needed 2 When locations E or G are used by the upper Hex head screws the lower carriage bolt and nut hole set a
131. ENTER Note Accepts set Preset Type Display toggles back to Function Code selection 9 Select Function Code 3 PPP Activation Press ENTER Select PPP ON or OFF then press ENTER Command Code 24 Set Operations Mode Command Code 24 is entered in Level 1 programming to set dispenser operating mode Operation mode setting determines how dispenser is controlled remotely or if 1t operates without external control Available choices for operation mode setting are shown below Figure 5 36 Setting Operations Mode Operation Mode 1 Press 2 then 4 then press ENTER to access this Command Code 2 Using the following table select Mode of Operation option Option Operation Mode 1 Default 2 Wire 2 Standalone 3 IFSF 3 Press ENTER to accept mode of operation MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 43 Pump Programming Encore 5XX and Eclipse Programming Instructions Command Code 25 Set Allocation Command Code 25 is entered in Level 1 programming to set side and grade allocation volumes Note Decimal point position may change in main volume display depending on its location from display decimal point programming Default allocation setting is none or all zeros 1 Press 2 then 5 then press ENTER to access this Command Code Note Layout and meaning of the digit position for this programming feature is shown below Figure 5 37 Layout and Digit Position 2 Select side then
132. ER to access this Command Code 2 Select side number 1 3 then press ENTER To Program Press Configuration Side 1 side with junction box 1 Side 2 2 Both sides 3 Select Grade 1 Select grade number 1 5 then press ENTER The following table contains the required grade numbers for each model Use the following table when programming grades Figure 5 24 Selecting the Grade Numbers Grade selection Q 1 g Q ZIN Percent Low Product NO N N For These Models Program These Grades Dual Grade 1 3 0 Grades 1 2 and 3 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 27 Pump Programming Encore 300 Programming and Data Access Instructions For These Models Program These Grades 540 Grades 1 2 3 4 and 5 3 1 Grades 1 2 3 and 6 Six Hose Fixed Blenders Grade 1 2 and 3 Note For three grades program as Grade 1 3 5 and 6 for an unblended hose certain modifications may allow Grades 1 2 3 and 6 2 Enter low product blend percentage then press ENTER The high product blend percentage calculates automatically 3 Repeat sequence for remaining grades and side if required Command Code 17 Performing Master Resets and Programming Conversion Factors Figure 5 25 Performing a Master Resets and programming conversion factors Function Code To perform a Master Reset and programming conversion factors proceed as follows 1 To perform a Master Reset press 1 then 7 and then pres
133. Eclipse Installation Checklist Form A Keep the copy of this form for your records and place the original in the unit The commissioning technician will use this form and MDE 4226 to complete commissioning Depending upon pre agreement with the installer calibration or VaporVac performance testing may be done by the installer IMPORTANT NOTE This checklist does not include all requirements for a complete start up of a pump dispenser Included however are certain checks for some of the more important items and items occasionally missed during start up The start up technician must read and completely follow the installation manual for the equipment and have a full knowledge of requirements of the station and units involved Incomplete forms may delay commissioning Start Up Checklist T Tissot encom RATNER 3 Uwmwmmeiessenmwemns My o pome O A RN EM V A S peoo a N O o pee M SI NN RN LT mcer FOS mach panels PPU To sme sake sene E O LX Bere mnissssperwameiee ten sempemae T S poeem T Verify meter calibration Recalibrate as necessary see INSTRUCTIONS above MEE CRIND only CRIND displays card readers cash acceptors scanners and printers pass diagnostic card testing o Ce Seperate M RR NN VaporVac units only VaporVac passes A L tests see INSTRUCTIONS above NENNEN ENLITIINIIIDIIIUIUII E RR RN TRIND only Proper response obtained with hand held and vehicular mount transponder testers depending upon unit e
134. Eclipse Model Serial Number Information Locations Left side tuxedo stripe called out as reference s TR Eclipse model viewed from Side 1 a Z For units manufactured in January 2003 and later the model serial number information is found on a label by opening the Oven Door and viewing the sheet metal of the main door behind it For units manufactured prior to January 2003 the model serial number information is located on right side tuxedo stripe when facing Side 1 Page l 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Model Information Read this First Model Serial Number Tag Formats Figure 1 3 Model Serial Number Example for Units Manufactured Prior to January 2003 Model Number Td Options VoporVac C Prox Sensar 5 7 Mono C wl Mfd By MARCONI PARENT SYSTEMS INC LL Balance Vapor Retriever 10 4 Soft Key Greensboro USA Model No NCO ATC Elec Teta 10 4 Touch Lever Activate Pump Stop C Ext Hose Reach Giilborco serial No N EN 005977 CRIND Teall amp intrem C PPP For use with equipment specified in installation inst Bar Cade Scan Cnpy Lgt Cnat Vaice Out Mod Pump Preset _ e Crind C IFSF Cash Acceptor _ Printer C Tring L L LI Push te Start Video Cnmera Cust Spec Spk L O L L Date Code Serial Number
135. Electronic and Electrical Components About this Section Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section was last updated in August 2007 Topics in this Section Topic Page About this Section 6 1 About Service Procedures 6 3 Printed Circuit Assemblies and Nodes 6 5 Power Supplies 6 71 Displays Main PPU CRIND 6 85 CRIND Devices 6 98 Junction Boxes 6 113 VaporVac Electrical Components 6 115 Section Overview This section provides information on the electronics and electrical components contained within the pumps and dispensers This information may consist of an illustration of the component functional description and where applicable data on connections test points and settings How to Use this Section Refer to Topics in this Section for a listing of topics contained in this section and its location Under each of the main topics is a table that lists individual components Use this table to find information on a specific component Additionally the index and table of contents can be used to locate information MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 1 Electroni
136. F1 to perform additional programming Press ENTER after making selection in all Levels Press F2 to exit programming Note Entry of Level 2 3 or 4 PIN Codes will also allow entry into Level 1 programming Layout and digit position meaning for programming features are shown below each Command Code Command Code 20 Set PPU Values Layout and digit position meaning for this programming feature is shown below Figure 5 33 Setting the PPU Values 2 0 Side Se Peu fee Pm 1 Press 2 then 0 then ENTER to access this Command Code 2 Select side then press ENTER To Program Press Configuration Side 1 side with junction box 1 Side 2 2 Both Sides 3 3 Select Price Level Cash Credit 4 Enter new PPU number Note Repeat for other Side Grade and Price Level MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 41 Pump Programming 2 Page 5 42 Encore 5XX and Eclipse Programming Instructions Command Code 22 Set Preset Types and Values Command Code 22 allows programming the keypad preset when set up in Level 4 configuration programming When values are programmed for the keypad preset buttons they set the same values for both sides of the dispenser AII fueling positions must have the same type of preset Figure 5 34 Setting the Preset Types and Values Press 2 then 2 then press ENTER to access this Command Code If NO KEYPAD PRESET was set in Level 4 configura
137. First Time Meter Calibration Procedure on page 5 75 and Combined Verification and Calibration Procedure on page 5 77 Page 5 74 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Set Up Calibration can be performed in Standalone mode or via console control operation If the unit volume type is programmed to gallons the prover can size will default to 5 gallons and if programmed to liters the default is 20 liters If a different size prover can is being used it can be programmed in CC82 This can size will be retained in memory If the Volume Unit Type VUT or blends are required to be programmed the programming mode is entered in the normal manner except that the calibration switch must be turned ON after entering the programming mode and turned OFF before exiting the programming mode to save the changes Special Considerations for V1 7 58 software Error Code 26 will not clear automatically after calibrating meter A warm start is now required e When performing the combined verification and calibration the electronic totals will be increased as during a normal sale When performing the first time calibration procedure the totals are not updated First Time Meter Calibration Procedure This calibration process is most commonly used for units not already calibrated Factory pre calibration must be verified 1 Move cover to expo
138. Function Code Descriptions for Command Code 53 Function Code 1 Set Beeper Time out Value Option determines amount of time beeper sounds after dispenser time out has occurred Allowed range for this time out is 0 to 999 seconds Default value is 0 or no beeper Beeper should sound once a second for the number of seconds programmed Function Code 2 Set Pre Select Time out Programming option will set pre select time out timer period allowed for cash credit or grade select buttons to be pressed before handle is raised for a non Nozzle activated unit Timer starts when dispenser is authorized and times until customer lifts pump handle Once pre select time out has occurred Cash Credit and or grade selected is lost and must be re selected by customer Pump does NOT change state when this time out occurs A zero value means there is no time out Pump Preset is also under control of pre select time out Allowed range for this timer is from 0 to 999 seconds Default value for this function is 15 seconds Function Code 3 Set Dispenser Time out Dispenser time out is measured from when pulses STOP flowing until handle is lowered to remind driver to remove the nozzle from tank If Beeper Time out is enabled and set to a value greater than 0 beeper should beep once a second until Beeper Time out timer runs down Default value for this function is O seconds no time out If fueling is resumed beeper will stop sounding and timer is reset Note If
139. Hi 1 5 VDC O 4 75 VDC 2 GND O 0 VDC 0 VDC 3 Pulser Data A1 1 00 VDC 3 50 VDC 4 Pulser Data A1 1 00 VDC 3 50 VDC PB1 Connector Pin Functions and Voltages Pin Description l O Max Lo Min Hi 1 5 VDC O 4 75 VDC 2 GND O 0 VDC 0 VDC 3 Pulser Data B1 1 00 VDC 3 50 VDC 4 Pulser Data B1 1 00 VDC 3 50 VDC PA2 Connector Pin Functions and Voltages Pin Description l O Max Lo Min Hi 1 5 VDC O 4 75 VDC 2 GND O 0 VDC 0 VDC 3 Pulser Data A2 1 00 VDC 3 50 VDC 4 Pulser Data A2 1 00 VDC 3 50 VDC PB2 Connector Pin Functions and Voltages Pin Description l O Max Lo Min Hi 1 5 VDC O 4 75 VDC 2 GND O 0 VDC 0 VDC 3 Pulser Data B2 1 00 VDC 3 50 VDC 4 Pulser Data B2 1 00 VDC 3 50 VDC PA3 Connector Pin Functions and Voltages Pin Description I O Max Lo Min Hi 1 5 VDC O 4 75 VDC 2 GND O 0 VDC 0 VDC 3 Pulser Data A3 1 00 VDC 3 50 VDC 4 Pulser Data A3 1 00 VDC 3 50 VDC PB3 Connector Pin Functions and Voltages Pin Description l O Max Lo Min Hi 1 5 VDC O 4 75 VDC 2 GND O 0 VDC 0 VDC 3 Pulser Data B3 1 00 VDC 3 50 VDC 4 Pulser Data B3 1 00 VDC 3 50 VDC MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 35 Electronic and Electrical Components Printed Circuit Assemblies and Nodes P309A Connector Pin Functions and Voltages Pin Description I O Max Lo Min Hi 1 Slowdown Valve A1 O 0 VAC 115 VAC 2 Main Valve A1 O 0 VAC 115 VAC 3 Slowdown Valve B1 O 0 VAC 115 VAC 4 Ma
140. IDs window select 2 CRIND ID Side 2 9 Inthe CRIND ID Side 2 window enter a value between 1 to 32 that corresponds to address of the fueling unit Press ENTER to have the value committed to memory and revert the CRIND device to the CRIND ID s window 10 Press CANCEL to return to the CRIND Config window 11 In the CRIND Config window select 2 CRIND Mode 12 In the CRIND Mode window if setup is for G SITES select 1 MOC If setup is not for G SITE that is third party POS select 2 Generic Press the ENTER to have the selected value committed to memory and revert the CRIND device to the CRIND Config window CRIND Configuration From the Main Menu press 1 The CRIND Config menu displays CRIND Confi 1 CRIND IDs 2 CRIND Mode 3 Generic BAUD Rate 4 Force BIOS Coldstart 5 Force App Coldstart Cancel Exit Note On most screens you can navigate to the previous screens by pressing Cancel MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 95 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser CRIND IDs This function allows you to choose the side of the dispenser for which IDs should be programmed 1 From the CRIND Config menu press 1 The following screen appears CRIND IDs 1 CRIND ID Side 1 2 CRIND ID Side 2 Cancel Exit 2 Press 1 to enter the CRIND ID Side 1 screen Press 2 to enter the CRIND ID Side 2 screen The following screen appears
141. IND Activating the Encore 5XX CRIND Device 5 95 at Pump Dispenser CRIND Configuration 5 95 Device Configuration 5 98 General Programming Information Terms Used in this Section Page 5 2 Term 6x6x4 Display Allocation ASC ATC Cold Start Cold Cold Start Command Code Command Level Dispenser Display blanking DLT EC Five Button Preset Firmware Function Code Grade LCD LSD Manager Keypad Money Display MSD Option Code PIN PPP PPU Display Definition Standard display unit for U S Market It is a six digit money six digit volume and a four digit PPU display Maximum amount of fuel that can be dispensed from a nozzle for a given transaction Authorized Service Contractor Automatic Temperature Compensation Clears pump and configuration data E300 procedure that performs a cold start plus clears certain information watch dog timer state and so on not cleared by a normal cold start Note Not commonly performed Listing under Command Level for setting software parameters A level of programming accessed by PIN s In this document dispenser is used interchangeably to describe a dispensing unit Function turns all displays ON or OFF on a side of the dispenser If the displays are blank then a transaction is not allowed Display Last Transaction Error Code a number that identifies an error condition reported by the software This is a keypad that contains five buttons using which
142. IeW ioio s dd eus D Rud dedo dated op dceciee edem ien dpi iie d D 6 1 How to Use this Section llle 6 1 Abbreviations and Acronyms llle 6 2 Terms Used in this Section llle 6 2 About Service PIOCCOUINES s oec tror del quet deoa dii Et Henkes V antur 6 3 Working on Electronic and Electrical Components 6 3 Printed Circuit Assemblies and Nodes lille 6 5 Abolt NOdSSu u s uber been aed owe laa a ibl oe rers ea e soe amu 6 5 ADOUUE OAS corea tente feb Gate lh ard peed dvtesuini aus d epee wie ina fiio Mela peat 6 5 M00044A001 Terminal Block PCA Encore 500 Eclipse 6 6 M00047A001 STP Driver PCA 2 2 ens 6 7 Page ii MDE 3804B Encore and Eclipse Start up Service Manual August 2007 M00056A001 Pump Control Node 1 0 00 eee eee 6 8 M00059A00X Valve Driver PCA 2 ee 6 13 M00062A001 Door Node 1 0 cc eee 6 15 M00077A001 Totalizer Node 2 0 eee 6 19 M00089A001 CRIND Control Node 1 0 0000 ee 6 23 M00092A001 Monochrome Interface PCA lusu 6 28 M00122A001 LON to Serial Node LON Gateway 6 29 M01546A001 Hydraulic Interface PCA ellen 6 31 M01549A001 Steering Valve Relay PCA 00005 6 37 M01564A001 Grade Select PCA 0 0 0 2 cee ee 6 39 M01598A001 Pump Controller PCA 00000 eee 6 40 M01621A001 Totalizer Interface PCA
143. Lamp Test Time 46 Set Comma Decimal Point 47 Set Reported Money Size 48 Zero Previous Transaction 49 STP Controls 1 Set STP Prestart 2 Set STP Control 51 Set Main Beeper 52 Set VaporVac Alarms 53 Set Time Outs 1 Set Beeper 2 Set Pre Select 3 Set Dispenser 4 Set Initial Dispenser 54 Set Slowdown Valve 55 Set Hose Pressurization 56 Set Stop Button Control 60 Set Clock and Calendar 62 Two Wire Remapping Grade Level Four Command Codes Starts on page 5 88 71 Set Volume Units 72 Set Blend Ratios 73 Set Display Money Totals 74 Set Display Volume Totals 75 Set Fuel Density 77 Change PIN Code 1 Level One 2 Level Two 3 Level Three 4 Level Four 78 Electronic Calibration 80 Set Maximum Flow Rate 82 Set Calibration Can Size 90 Set Unit Type 91 Select Installed Options 1 Preset Type 2 Push to Start 3 Set VaporVac 5 Set Push to Stop 6 Set ATC 11 Set Totalizer function 12 Set Nozzle activated Pump Handle 13 Set Meter Type 92 Set Side Exits 93 Set Cash Credit at Dispenser 94 Set Zero PPU Option 96 Feature Set MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Encore 5XX and Eclipse Programming Instructions Level One Command Codes Level 1 commands are those commands most commonly performed on site by station owner operator Programming Level Default PIN Code Command Code Range Level 1 2222 20 39 Press
144. M00053 Power Supply Board 24VDC 5 TT M00056 Pump Control Node 5 20 M00059 Valve Driver Board 5 13 M00065 PPU Board 5 20 M00071 Pump Ethernet Board 5 20 M00077 Electromechanical Totalizer Node 5 20 M00089 CRIND Control Node 5 23 M00122 LON to Serial Node LON Gateway 5 28 M00151 Power Supply Sub Assembly 18VDC 5 72 Maintenance Checklist MDE 2856 3 4 Preventive 3 1 Manager Keypad Key Definitions and Use 4 3 Manager Keypad Layout 4 3 Master Resets Performing 4 24 Material Safety Data Sheets MSDS 1 6 Maximum Limit on Fuel Volume Programming 4 10 MDE 2856 Preventive Maintenance Checklist 3 4 Memory Clearing For Modular Units CC 6 4 12 Meter Calibration 4 59 Meters Bolts Torque Specifications 6 7 Calibrating 4 25 Modes of Operation Selecting Programming For Modular Units CC 2 4 10 Money Totals 4 6 Displaying 4 12 Inputting 4 12 N NFPA Safety Information 1 6 Non Resettable Money And Volume Totals Examples 4 5 Nozzle Maintenance 3 2 O Operation Mode see Mode of Operation OSHA Lock Out Tag Out Safety Requirements 1 9 Overloads Thermal 6 56 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Index P Performance Testing Vapor Recovery Systems 6 71 Phone Numbers Important 1 2 Pin Code Entry 4 27 PIN Codes Programming Changing 4 22 Default 4 9 4 22 Pipe Plugs Torque Specifications 6 6 PPU Blinking Option 4 19 Programming Options 4 20 PPU Prices Programming CC 1 4 9 Ze
145. Manual August 2007 Page 5 87 Pump Programming Encore 5XX and Eclipse Programming Instructions Level Four Command Codes If using pump software V1 7 58 or Higher In this version of software the calibration mode is automatically entered when the Weights and Measures switch is toggled Earlier versions of software allowed you to toggle the programming switch prior to entering the programming mode Now you must be in the programming mode prior to toggling the Weights and Measures switch See Important Information about Using V1 7 58 and Higher for Encore 5XX and Eclipse Dispensing Pump Software on page 5 7 for additional information If the pump uses software prior to V1 7 58 You must toggle the Weights and Measures switch prior to entering the programming mode Level 4 provides configuration level commands that are performed by the factory to initialize dispenser and configure software to match dispenser hardware Under certain conditions an ASC may have to perform these commands to repair or convert a dispenser Note Improper dispenser configuration will result in display of applicable configuration error codes when pump is placed in normal operation Programming Level Security PIN Code Command Code Range Level 4 0128 90 109 Press ENTER after making selection in all Levels Press F1 to perform additional programming Press F2 to exit programming Command Code 90 Set Unit Type Function allows programmer to set unit
146. ONT OEE LL LOL O ALELA oojJP ADDR BT1 Lithium Battery 3 2V HEARTBEAT qORpDIA Y TRIER o TTT pu Bau 5 Bo nnnnnnmnrn UUUUUUUU nnnnnnnrn UUUUUUUU a cde EC26 C284 UUUUUUUU VAPORVAC ISOLATION H nnnnnnnr o C30 PULSER 3 PULSER P1112 Grade 1 Pulsers Both Sides P1113 Grade 2 Pulsers Both Sides MDE 3804B Encore and Eclipse Start up Service Manual August 2007 P1115 Grade 4 Pulsers Both Sides To VaporVac Electronics Page 6 9 Electronic and Electrical Components Board Connections and Cables Connector P1112 P1115 Qty 4 8 pin P1101 10 pin STP Control P1102 26 pin Valve Control P1103 LON Header 1 P1104 LON Header 2 P1105 5 pin 18 VDC from power supply P1106 34 pin Ethernet 1 P1107 Expansion Memory P1108 34 pin IFSF or Aux P1109 2 wire P1110 26 pin P1111 10 pin PC serial signals to Valve Driver PCA P1120 Direct Connect P1122 Debug P1123 3 pin E cal P1124 16pin Ethernet 2 Via Cable M00453A001 Encore quad M01026A001 Eclipse e 18350 G6 Encore requires V1 6 00 or late
147. P1110 26 pin M01036A001 Eclipse Node 1 P1406 4 pin R19669 G1 119401 VaporVac Controller P1106 Interlock PCA LED Indicators LED Status Indicates CR4 OFF Side 1 not authorized ON Side 1 authorized Blinking Side 1 dispensing fuel CR5 OFF Side 2 not authorized ON Side 2 authorized Blinking Side 1 dispensing fuel CR6 OFF no power to PCA ON power to PCA Page 6 116 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 VaporVac Electrical Components Electronic and Electrical Components T18015 VaporVac Valve Driver PCA When used in the Encore 300 Encore 500 and Eclipse this board receives 12 VDC signals from the T19401 VaporVac Controller PCA and switches 120 VAC to the T17909 Vapor Valves Service Tip Units manufactured after July 2002 do not use solenoid valves on this board Figure 6 66 VaporVac Valve Driver Board oide 2 Side 1 P1204 JP9 10 11 JP12 13 JP14 15 16 JP1 2 3 JP4 5 JP6 7 8 VAPOR E 5 ri wt QO m gt Yi ni lt x REV a BAR CODE Q PIZDE PIUS S0000357 P1203 Board Connections and Cables Multi Hose 1 Units Encore Series units only MADE IN U S A Unit Type Side 1 Side 2 9 3 Grade 3 Hose Blender 1 Non Diesel 1 N A N A Diesel 1 JP1A JP2A JP3A JP9A JP10A JP11A Connector Via Cable To Board At Connector P1201 20 pin R19666 G1 T19401 VaporVac P1101 20 pin Controller PCA P1202
148. Page 5 99 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser 1 From the Cash Acceptor main menu press 2 The following screen appears Cash Acceptor Statistics for Side 1 Insertions 000005 Rejects 000000 Escrows 000000 Jams 000000 Enter Next Screen Cancel Exit 2 Press Enter to toggle between Side 1 and Side 2 counter screens The first screen displays the statistics for Side 1 and the second screen displays the statistics for Side 2 3 Press Cancel to exit back to the Cash Acceptor main menu Reset Statistics Counters This function allows you to reset cash acceptor event statistics for each side of the unit This function should be used after correcting a cash acceptor problem so that future statistics will reflect the repaired cash acceptor state Statistics will also be cleared each time persistent storage is cleared purged via the Persistent Storage Menu 1 From the Cash Acceptor main menu press 3 The following screen appears Cash Acceptor Cash Acceptor Enabled 1 Reset Statistics Side 1 2 Reset Statistics Side 2 Cancel Exit 2 To reset statistics for Side 1 press 1 To reset statistics for Side 2 press 2 The following screen appears to confirm that the statistics have been reset Cash Acceptor Cash Acceptor Enabled Statistics Reset Page 5 100 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND
149. Power Supply 2 PCA for Encore 500 and Eclipse Figure 6 39 Universal Power Supply PCA M02774A001 Pump CRIND Control Node Connector P3502B to dde P607 to Main Power Supply Printer Bar Code Reader Monochrome Side 2 Transformer Connectors P607 P606 24 VDC Connectors P3502B P3503B P3502A P3503A O ahs 4i ASSY WO2774A00 BEY P60 a lo APF db m pply P606 Pins P3502A to Printer Bar Code Reader Monochrome Side 1 Green LEDs CR17 Notes CR18 1 P606 pins 1 and 2 are for 8 VAC pins 3 and 4 are for Test Points 34 5 VAC TP1 22 8 to 25 2 V 2 P607 pins 1 and 3 are for TP2 GND 18 VAC TP3 17 5 to 28 V Board Connections and Cables Connector Via Cable To Board At Connector P606 6 pin From Transformer Main Power Supply M02946A001 J606 P607 3 pin J607 P1402 5 pin M00635 M01922 P1105 P3502A B 2 pin M00517A B Printer Barcode Reader Monochrome CN1 Status LEDs LED Status Indication CR17 18 VDC CR18 24 VDC Test Points Test Point Range TP1 24 VDC TP2 GND DC TP3 18 VDC Page 6 82 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Power Supplies Electronic and Electrical Components Troubleshooting Node Resistance Measurement Preparation Node What to Do Before Measuring Resistance Between Pins 1 and 5 Pump Temporarily disconnect the LON cables to Pump Node CRIND device Temporarily disconnect Monochrome Interface Board Last Node in C
150. Press Configuration Cash price levels 1 Credit price levels 2 5 Enter new PPU Start with MSD for example 1 259 press 1 2 5 9 Press ENTER 6 Repeat steps 2 through 6 to program all sides grades and price levels Command Code 2 Program Two Wire Standalone Choose mode of operation two wire for console control or standalone for non console control for your pump dispenser Figure 5 5 Program Two Wire Standalone 1 Press 2 then ENTER on Manager Keypad to access this Command Code 2 Select Mode then press ENTER To Select Mode Press Configuration Standalone without console control 0 Two wire operation with console control 1 Note This is the default MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 11 Pump Programming Encore 300 Programming and Data Access Instructions Command Code 3 Programming Volume Allocation Set a maximum limit on fuel volume pumped per customer Figure 5 6 Programming Volume Allocation 1 Press 3 then ENTER on Manager Keypad to access this Command Code 2 Select Side then press ENTER To Select Press Configuration Side 1 side with junction box 1 Side 2 2 Both sides 3 3 Select Grade then press ENTER Note The number of grades vary for each model Figure 5 7 Grade Selection Screen 4 Enter volume allocation amount Start with MSD For example to enter 500 gallons press 5 then 0 The default is 000 0 no allocation limit You cannot en
151. Pressure Performance of Vapor Recovery Systems of Dispensing Facilities San Diego County Pressure Decay Leak Test Procedure For Phase and II Vapor Recovery APCD TP 91 1 Installations TNRCOC TXP 102 1 Determination of Static Pressure Performance Pressure Decay of Vapor Recovery Systems at Gasoline Dispensing Facilities Bay Area AQMD ST 30 Static Pressure Integrity Test For Underground Storage Tanks Testing Performance Vacuum Assist Systems Read and follow all safety precautions as outlined in the Read This First section and in this and related sections of this manual This test verifies that the system 1s working in a manner similar to which it was certified by CARB There are two basic performance tests for vacuum assist vapor recovery system Test 1 is the A L or V L test This test simultaneously measures the volume of air being collected by a vapor recovery nozzle and the volume of fuel being dispensed by that nozzle Test 2 the vacuum test was developed by Gilbarco It measures vacuum generated at the nozzle by drawing air through a controlled orifice MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Vapor Recovery Components Hydraulic Mechanical Components Known Test Procedures Description CARB TP 201 5 Determination by Volume Meter of Air to Liquid Volume Ration of Vapor Recovery Systems of Dispensing Facilities Gilbarco MDE 3022 Operating Instructions for Field Performance Test Kit K94123
152. Pump Control Node 2 Certain features such as USB may be lost Some nodes list TP3 voltage as 14 22 VDC but 14 28 VDC is also acceptable Pump software must be loaded through the CRIND node or a temporary bridge pump node The pump nodes contain two software types Pump MIP and Pump Node software The pump 2 wire transmit TX LED may flash under certain circumstances when the pump node is not transmitting MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Figure 6 3 Pump Control Node 1 PCA P1104 LON P1111 PC header 2 Serial P1102 Valve Control RC SERIA L P1103 LON Header 1 VALVE CONTROL EADER P1101 STP Control Electronic and Electrical Components from Power Supply STP CONTROL 1 QV POWER P1109 2 Wire P1105 18 VDC ON 2 Wire Reversed PUMP WIRE nunnnnnrn o TUUUUUUIU nnnnnnnn TUUUUUUU P1106 Ethernet 1 Not Used nnnunnnnnn o MANANNAN nnn nnnm o TITIO P1107 Expansion memory ETHERNEW I AAA o TOT Not Used PIIO7 EXPANSION MEMORY gp 9909000000500 BoB ooo oo P1124 Ethernet 2 Not Used noononnn UUUUUUUU nnnnnnnn o UUUUUUUU P1108 IFSF or Aux Not Us
153. Routine detected a failure of its own hash The node has valid value E LED flashes on and off LHXURGoode but no J Q 0 BOOT Routine has detected that a loader is not SSOLFDWLRQSRGH present and is waiting for a download D LED fidshesscon dndoff LHXURQDSSOLFDWLRQ J BOOT Routine is downloading the LOADER program KDVORMHWEHHOQ C LED flashes on and off NVAQFKURQL HGZLWK O BOOT detected an error condition in the LOADER 3XPSDSSOLFDWLRQ hash value D and E LEDs flash on and off e LOADER routine processing data OFF The node has both e o w Oo LOADER has detected that an APPLICATION is not application and network present and is waiting for a download D LED configuration flashes on and off DQGKDVEHHQ e o LOADER routine is downloading an APPLICATION C LED flashes on and off WOFKUROLIHGZLWK 5 LOADER has detected a failure in the APPLICATION 2XPSDSSOLFDWLRQ HASH value and is waiting for a download D and E LEDs flash on and off e 0 Normal Operation MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 11 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Test Points and Jump Jacks Figure 6 5 Pump Control Node Jump Jack PC SERIAL EADER STP CONTROL 18V POWER PUMP 2 WIRE
154. Run Diagnostics Side 2 Cancel Exit 2 To start diagnostic tests for Side 1 press 1 To start diagnostic tests for Side 2 press 2 A message Please Wait 1s displayed and then the following screen appears Cash Acceptor Cash Acceptor Enabled To allow bill stack testing you must remove the station s cassette and attach test cassette Enter Continue Cancel Exit Notes 1 If the CRIND BIOS detects a pair of Cassette Removed Cassette Replaced events as having occurred some time earlier in the current diagnostics session this screen will not appear 2 If you select any interactive cash acceptor operation for the opposite side the side that is not being calibrated the following warning screen appears Cash Acceptor Cash Acceptor Enabled WARNING You will disrupt cash acceptor sales on the other side of this dispenser until it is restarted Enter Continue Cancel Exit 3 If you are troubleshooting a potentially defective casette remove the station cassette and replace it with another similar cassette for testing purposes Page 5 104 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 4 Press Enter to display the Cash Acceptor Insert Bill screen Cash Acceptor Cash Acceptor Enabled Insert Bill Cancel Exit 5 Insert a bill into the cash acceptor on the side selected in th
155. STATE C Blinking if PCN is unable to communicate with door nodes D7 STATE D On solid when handle on Side 1 is raised D8 STATE E On solid when handle on Side 2 is raised D9 2W RX Blinking when receiving data from POS or CRIND D10 NEU 2W TX e Off when current is present On solid if no current is present e Blinking when transmitting to POS or CRIND MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components LED Name D11 NEU STAT D12 LON TERM1 D13 LON TERM2 D14 HEART BEAT Status Indication Off solid is normal condition On solid if Neuron is applicationless node must be returned Blinking at a rate of on for 1 second off for 1 second if Neuron in not configured node must be returned Short flashes every 1 5 seconds indicates PCN software is not running This is normal during PCN software upgrade and during the first 15 20 seconds of startup Off solid is normal condition On solid when LON cable connected to P1103 is not terminated Off solid is normal condition On solid when LON cable connected to P1104 is not terminated Flashes steadily at rate of on one half second off one half second during normal operation Flashing begins 15 20 seconds after power up Test Points and Jump Jacks Figure 6 24 Test Points and Jump Jack Locations zz
156. SY M00053A00 JT zc E Q4 Gilbarco Made in U S A TO FILTER CAP MADE IN USA 14 VAC from Transformer Secondary Filter Capacitor Note Replaceable Fuses are Gilbarco Part Q12682 07 2 5A Slow Blow LED CR3 GREEN CR7 GREEN CR8 GREEN e Power Supply shutdown check CR8 on M00050A001 Power Supply Board 18 VDC OR Status Indication ON good 24 VDC available See Note ON good 24 VDC output to connectors P3502B and P3503B for Side 2 Printers and or Cash Acceptors See Note ON good 24 VDC output to connectors P3502A and P3503A for Side 1 Printers and or Cash Acceptors See Note Note If CR3 is ON and CH7 and CR8 are both OFF one of two conditions exist Both replaceable fuses are blown unlikely MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Power Supplies Electronic and Electrical Components Test Points Test Point Range TP 1 22 5 V to 25 5 VDC TP2 GRND Reading across TP 3 and TP4 14 V to 25 VAC Board Connections and Cables Connector Via Cable To Board P3501 4 pin M00486A001 M00050A001 Power Supply Board 18 VDC P3502A 2 pin 1 M00517A001 Encore or 1 Printer Controller Side 1 M00517A006 Eclipse 2 Monochrome Fan 2 M00822B002 P3502B 2 pin 1 M00517A001 Encore or 1 Printer Controller Side 2 M00517A006 Eclipse 2 Monochrome Fan 2 M00822B002 P3503A 2 pin M00721A001 Side 1 M00122A001 LON to Serial Node LON Ga
157. Scanner Settings 3 Send POS Seitings to Scanner Cancel Exit Reset to Factory Defaults This function resets the scanner to its default settings Any required POS specific settings must be re applied Resetting scanners affects both sides automatically 1 From the Barcode Scanner setup menu press 1 The following warning screen displays to remind the technician that all scanner settings will be reset if he she proceeds Barcode Scanner Scanner Enabled WARNING This action will reset scanner setup to factory defaults All POS specific changes must be reapplied Enter Continue Cancel Exit Page 5 112 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 2 Press Enter to advance the session to begin the process of resetting the scanners to their default settings All scanner settings will be reset OR Press Cancel to exit back to the Barcode Scanner setup menu without resetting the scanners to their default settings If Enter is pressed the following screen displays for Side 1 and then for Side 2 Barcode Scanner Scanner Enabled Resetting scanners to Factory defaults Programming Side X Please Wait The scanners are currently being sent configuration commands that will reset them to their default operating parameters 3 When the reset operations are complete the following screen appears Barc
158. Set Blend Ratios Set blend ratios allows programmer to program all blend ratios for all grades that can be blended according to dispenser type Only blend programming for grades that can be blended is allowed Thus non blended grades are treated as pure 10046 products Valid entries for percent figures are from 0 to 100 Entries above 100 will result in a programming error condition as described in the pump programming section Default value is 120 Note There is no default value for blend ratios and as a result programmable ratios must be programmed before the dispenser will operate Un programmed blend ratios will appear as flashing 888 for each product Layout and digit positions are shown in the following diagram Page 5 66 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 67 Setting Blend Ratios Percent Percent Percent Low Low Low Product Product Product 1 Enter 7 then 2 then press ENTER to access this Command Code 2 Select Grade 1 to 6 Grade Selection Low Product Blend Percentage 1 6 0 to 100 3 Select percent low product 0 100 9c 4 Press ENTER Note No Default MUST be programmed Command Code 73 Set Display Money Totals Allows programmer to read and set money totals Initially displays will show zeros in all locations Note This function can only be performed at first initialization of dispen
159. T OUT IN IN N 30 OUT IN N N IN 30 IN OUT IN N IN 31 IN N N N IN 31 OUT IN N N N 32 OUT OUT OUT OUT OUT 32 N N N N N Page 6 66 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components 119501 G2 Monochrome CPU PCA This board is used on CRIND devices with monochrome LCDs in the Encore 300 series units It stores all graphics and fonts to be displayed Graphics and fonts are downloaded from the G SITE system after a coldstart 1s performed It then sends the graphics and fonts images to the LCD display Service Tip This board functions similar to the G1 used in some early and recent Advantage units but has a different mounting hole pattern Figure 6 29 Monochrome CPU Board T19501 Side 1 RX Side 2 RX CR2 Side 1 TX COCOA CACACAGN OOC X uoc Side 2 TX U S A ASSY 119501 G We ar mm oie MoM DDD e 3spc poto EDT LO LLLI 3 259ooooos e LUTTER B Bis Ti b P2013 CRIND P2015B Monochrome Z180 Logic PCA Display Side 2 P2015A Monochrome P2014 CRIND Display Side 1 Regulator PCA MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 67 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Page 6 68 Board Connections and Cables Connector Via Cable To Board At Connector P2013 10 pin M01650A001 harness T17764 G3 4 CRIND Z180 Logic J268A to Side 1 30 pin Board J268B to Side 2
160. Temperature Control GDP Global Dispenser Pump Blackmer unit ISD In Store Diagnostics PCV Proportional Control Valve STP Submerged Turbine Pump TLS Tank Level Sensor UST Underground Storage Tank Terms Used in this Section Page 7 2 Term Definition Dispenser Fixture from which product is supplied under pressure from STP or aboveground pump Dispensing Device Refers to both Dispenser and Pump Metric Fasteners Fastener design is based on millimeter measuring system Pump Unit contains motor and pumping device to draw product from storage tank also known as a self contained unit SAE Fasteners Fastener design is based on inch measuring system MDE 3804B Encore and Eclipse Start up Service Manual August 2007 General Service Procedures Hydraulic Mechanical Components General Service Procedures Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Working on Hydraulic Components Dispensing devices pressurize fuels from the Underground Storage Tank UST by way of Submerged Turbine Pump STPs for dispensers or by pressurizing fuel within the unit in the case of self contained pumps A potential hazard of fluid spray or leaks exists when working on the hydraulic system especially if under pressure Ensure that proper procedures are followed and necessary precautions taken Refer to About
161. V to 28 V 2 GND OV 3 18 VUNREG 17 5 V to 28 V 4 GND OV 5 485B 7 V to 12 V Max 6 485A 7 V to 12 V Max 7 GND OV 8 18 VUNREG 17 5 V to 28 V 9 EXTRESET OVto 412 V 10 TERM RES FEEDTHRU P1507 Pin Description Input Output Voltage 1 18 VUNREG 17 5 V to 28 V 2 GND 0V 3 18 VUNREG 17 5 V to 28 V 4 GND OV 5 485B 7 V to 12 V Max 6 485A 7 V to 12 V Max 7 GND OV 8 18 VUNREG 17 5 V to 28 V 9 EXTRESET 0 V to 12 V 10 TERM RES FEEDTHRU MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M00089A001 CRIND Control Node 1 First Generation CRIND Control Node CCN M00089A001 found in the Encore 500 and Eclipse communicates through the LON Major Oil Company MOC applications access this node by communicating through the two wire It controls the card reader monochrome display printer bar code scanner cash acceptor TRIND beeper and associated keypads The lithium battery on this node maintains CRIND application software and CRIND Control Node programming M00089A001 is replaced by M01753A001 CRIND Control Node 2 CCN 1 is interchangeable with CCN 2 however certain features such as USB support will be lost Additionally the CCN 2 does not use a Monochrome Interface board WARNING same or equivalent recommended type Dispose of used batteries according to the There is a danger of explosion if battery
162. VDC 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC 4 50 VDC 20 pA 3 50 VDC 4 50 VDC 20 pA 4 50 VDC 20 pA 3 50 VDC 4 50 VDC 20 pA 3 50 VDC 4 50 VDC 20 pA 3 50 VDC 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 pA 3 50 VDC 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 pA 3 50 VDC 3 50 VDC 3 50 VDC 3 50 VDC Page 6 33 Electronic and Electrical Components Page 6 34 P106 Connector Pin Functions and Voltages Pin 1 OO CO N oO oa AJ OJ Io 10 Description Pulse B Pulse B1 Connect Connect GND GND Pulse A1 Pulse A VVac A4 VVac B3 VVac B2 VVac B1 VVac A2 VVac A3 VVac A4 VVac A1 l O O O OLO O O O O O O OOo OC O Max Lo 0 10 VDC Q 20 uA 0 10 VDC Q 20 uA Feed through to pin 4 Feed through to pin 3 0 VDC GND 0 10 VDC 20 uA 0 10 VDC Q 20 uA GND 0 10 VDC Q 20 uA 0 10 VDC Q 20 uA 0 10 VDC 20 uA 0 10 VDC Q 20 uA 0 10 VDC 20 uA GND 0 10 VDC Q 20 uA MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Min Hi 4 50 VDC 20 pA 4 50 VDC 20 pA 0 VDC 4 50 VDC 20 uA 4 50 VDC 20 uA 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 pA 4 50 VDC 20 uA Printed Circuit Assemblies and Nodes Electronic and Electrical Components PA1 Connector Pin Functions and Voltages Pin Description l O Max Lo Min
163. Warranty Policy Technical Literature Parts Manuals and other documents MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Call the following phone numbers Gilbarco Training Department at 336 547 5743 Gilbarco Technical Support at 1 800 743 7501 Gilbarco Tele Support at 1 800 800 7498 Contact your local Gilbarco distributor for assistance Gilbarco Literature Department at 336 547 5661 Page 1 3 Read this First Model Information Where to Find Model Information on Unit Model Information Depending on the date of manufacture Encore and Eclipse series units will have the model serial number information located in different areas of the unit The following information describes where to find the model serial numbers examples of the format and the coding pertaining to model and date numbers Encore Figure 1 1 Encore Model Serial Number Information Locations Encore Model viewed from Side 1 E For units manufactured in January 2003 and later the model serial number information is found on a label by opening the CIM door and viewing the sheet metal of the main door behind it SIM DOON For units manufactured prior to January 2003 the model serial number information is a plate on the bottom rail of Side 1 Eclipse Figure 1 2
164. Wash unit Inspect all areas of pump dispenser for damage or sharp edges Replace any missing warning labels Inspect for leaks and damage Inspect hose covering for weakness splits cuts bulges flattened spots wet spots soft spots and reinforcement showing Look for holes and cuts in vapor recovery hoses See Hoses and Flow Restrictors on page 6 28 Check for frayed or broken cables and cables wrapped around hoses See Testing Hose and Hanging Hardware Continuity on page 6 31 Check if retractors are operating properly Inspect all hoses nozzles swivels couplings casting and so on Repair immediately if leak is found Inspect for leaks missing parts and damage Inspect vapor recovery boots bellows for proper seal and damage Inspect VaporVac nozzle spouts for blockage loose spouts and damage that is dents See Adjusting Nozzle Hook for Specific Nozzles on page 6 33 Inspect for secure connection to hose and for any leaks or wet spots See Breakaways on page 6 29 Note Some manufacturer s breakaways are resettable and others require replacement after a drive off Refer manufacturer s documentation for information Inspect all hydraulic connections and seals including meters valves and so on Repair immediately if wetness or dripping fuel is found Some staining of parts around seals is normal Monitor these places more closely See Servicing Filters on page 6 23 for detailed instructions Follow al
165. abel usually indicates acceptable range that is 4 8 5 2 VDC e LED Status Code Where applicable refer to LED Status description that is included with other board information MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Printed Circuit Assemblies and Nodes Components in this Sub Section Part Number and Description Model Page M00044A001 Terminal Block PCA Encore 500 Eclipse Encore 500 and Eclipse 6 6 MO0047A001 STP Driver PCA s s Ss 6 7 M00056A001 Pump Control Node 1 6 8 MOO059A00X Valve Driver PCA ss s 6 13 M00062A001 Door Node 1 6 15 M00077A001 Totalizer Node 6 19 M00089A001 CRIND Control Node 1 6 23 M00092A001 Monochrome Interface PCA 6 28 M00122A001 LON to Serial Node LON Gateway 6 29 MO1546A001 Hydraulic Interface PCA Encore300 631 M01549A001 Steering Valve Relay PCA 637 MO1564A001 Grade SelectPCA ss s S 6 39 MO1598A001 Pump Controller PCA sts 6 40 MO1621A001 Totalizer Interface PCA 6 43 M01753A001 CRIND Control Node 2 Encore 500 and Eclipse 6 45 M01785A001 Door Node 2 6 49 M01922A001 Pump Control Node 2 6 53 MO2044A001 Valve Converter PCA 6 56 M02097A001 Steering Valve Relay PCA Encore300 657 M02335A001 Valve Converter PCA 6 58 T17764 G3 4 CRIND Z180 Logic Board 6 60 T19501 G2 Monochrome CPU PCA 6 67 T20306 G1 CRIND Regulator PCA
166. acked keypads will not adhere to Eclipse unit surfaces as they will to others In any situation where power is on and gasoline and its vapors are present or potentially present for example calibration do not X attempt to use Manager Keypad with electronics cabinet open Se e When calibrating Eclipse units run keypad cable over door and close door allowing keypad to be suspended on unit and accessed from outside for all procedures done with power applied or where there is a possibility of fuel or fuel vapor presence All meters must be calibrated before the dispenser functions If unit is a blender where the percentage for low grade product is not 0 or 100 for high grade product you must temporarily set the blend to 10046 for the low grade product meter or 046 for high grade product meter If all meters are not calibrated dispenser will display Not Calibrated error code when the dispenser is placed in normal mode CAUTION Before you proceed read and understand Purging Air from the System on page 7 7 in the Hydraulic Components section of this manual Operating unit with air in the system can cause damage to meter from overspeed The unit must be properly configured to CC71 before calibration After completing calibration the Weights and Measures switch must be sealed per local authority All replacement meters must be calibrated after installation and testing Figure 5 72 Manager Keypad 6000
167. afe practice which may result in property or equipment damage Working With Fuels and Electrical Energy Prevent Explosions and Fires Fuels and their vapors will explode or burn if ignited Spilled or leaking fuels cause vapors Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island Page 2 1 Important Safety Information No Open Fire S Open flames from matches lighters welding torches or other sources can ignite fuels and their vapors No Sparks No Smoking Sparks from starting vehicles starting or using power tools burning cigarettes cigars or pipes can also ignite fuels and their vapors Static electricity including an electrostatic charge on your body can cause a spark sufficient to ignite fuel vapors Every time you get out of a vehicle touch the metal of your vehicle to discharge any electrostatic charge before you approach the dispenser island Working Alone It is highly recommended that someone who is capable of rendering first aid be present during servicing Familiarize yourself with Cardiopulmonary Resuscitation CPR methods if you work with or around high voltages This information is available from the American Red Cross Always advise the station personnel about where you will be working and caution them not to activate power while you are working on the equipment Use the OSHA Lockout Tagout procedures If you are not familiar with this requirem
168. age 6 39 Electronic and Electrical Components Printed Circuit Assemblies and Nodes M01598A001 Pump Controller PCA Pump Controller Board on the Encore 300 processes data pulses from pulser assemblies level changes from pump handles and two wire serial data Also provides necessary outputs to control the transaction and price posting displays solenoid valves STPs motors and converts 14 VDC to 5 VDC The function of this board is similar to the Advantage T20011 G1 Pump Controller Board however the firmware on this board is not compatible with the Encore 300 IMPORTANT INFORMATION This board runs at approximately 50 faster clock speed than an Optimized Advantage Pump Controller Board Figure 6 17 Pump Controller Board M01598A001 P1123 E cal P135B Side 2 Handle P135A Side 1 Handle Security Switch and Grade Select Mea Side GEG Switch P139B Grade Select P139B Grade Select Interface board P204 Main Display Board Interface Board REV Q Qo Qo 28 UN ZUM UM ANI EIE O 000 gt 275 z 9 Lum amis uw oa es ua U ASSY MO1598A001 Cos CORA RATO Co 4 ci CI R7 CI R42 ID C36 ane ien seid zUUs 3UBUZ MADE IN U S e Q al o x 5 n _ _ t Doon S DOMINIO Moon CREDE p Cee fee as oe H mMm T TET TT TT TT LE ETT T T TT IT ET ET ET ET TT TT T IEEE ET ET TT TT LT LE TIT IT ET ET ET IT IT LT LI TIT TT EE ET TT ET E OT T TET IT ET ET ET TT TT DT LI p 0z
169. ailure Excessive tightening may fracture component during installation or assembly or tape Do not excessively torque fittings Refer to Torque Specifications on page 7 5 for details Always check for leaks after service Torque Specifications Ensure that you follow these recommendations when working with fasteners on pumps and dispensers Never use a metric fastener in place of an SAE or non metric fastener or an SAE fastener in place of a metric fastener This may lead to damage to the device Always use same grade or higher materials for load bearing devices for example for lifting brackets and bolts else there is a possibility of failure Note Use of Universal Bolt and Fastener Kits that contain commonly replaced bolts during service is recommended The following tables provide general torque guidelines for plated steel screws and bolts pipe plugs and tube fittings Screws and Bolts Plated Recommended Torque Thread in Ibs Nm M4 10 12 e130 M5 25 35 2 8 4 0 M6 36 40 4 1 4 5 M8 120 140 13 6 15 8 M10 150 170 16 9 19 2 Pipe and Tube Fittings Recommended Torque Thread in Ibs Nm 1 8inch NPT 10 12 13 6 16 3 1 4 inch NPT 22 25 29 8 33 9 3 8 inch NPT 30 35 40 7 47 5 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 5 Hydraulic Mechanical Components Page 7 6 Recommended Torque Thread in Ibs Nm 1 2 inch NPT 35 40 47 5 54 2 3 4 inch NPT 45 55 61 0 74 5 1 inch NPT 7
170. aintenance action taken at the site How to Use this Section Discuss the suggested maintenance items listed in the Suggested Maintenance Chart on page 4 2 with the station owner Review the Sample Maintenance Checklist on page 4 4 to familiarize yourself with preventive maintenance tasks that you may have to perform at the site Topics in this Section Topic Page Preventive Maintenance Checklists 4 2 Suggested Maintenance Chart 4 2 Sample Maintenance Checklist 4 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 4 1 Preventive Maintenance and Inspection Preventive Maintenance Checklists Preventive Maintenance Checklists Suggested Maintenance Chart See specific item in the component section for more detailed information Discuss this information with the station owner Remind the owner about the importance of preventive maintenance and inspections Page 4 2 IMPORTANT INFORMATION Check maintenance instructions for third party component manufacturers hoses nozzles shear valves and so on for their maintenance recommendations Comply to whatever recommendation is more stringent relative to inspection frequency and ensure inspection routines include their requirements as well Item Inspection Procedure Frequency General inspection Hoses Hose retrievers Leaks external Nozzles and boot areas Breakaways Leaks Internal Filter change and strainer cleaning
171. ak test prior to opening the dispenser valves Maximum allowed lamp test time is 9 seconds minimum is 0 seconds and default test time is 3 seconds Basic test sequence 1s all 8s blanks Os transaction PPU Figure 5 49 Setting Lamp Test Time 1 Press 4 then 5 then press ENTER to access this Command Code 2 Select Lamp Test time 0 9 seconds 3 Press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 53 Pump Programming Page 5 54 Encore 5XX and Eclipse Programming Instructions Command Code 46 Set Comma Decimal Point Command Code 46 is entered in Level 2 programming to select comma or decimal point display at main transaction and PPU displays Figure 5 50 Setting Comma Decimal Point Symbol Selection Press 4 then 5 then press ENTER to access this Command Code Select the symbol option 1 2 from the following table Symbol Options Symbol 1 Default Decimal Point 2 Comma Press ENTER Command Code 47 Set Reported Money Size Command Code 47 is entered in Level 2 programming to set method by which transaction money amount is returned to console over 2 wire communication loop This Command Code is for third party international consoles supporting six digits Selection 1 is default and returns money in the following format with an implied decimal point as shown XXX XXY For programming option 1 least significant digit shown as Y in the above example is not used and sh
172. alibration problems MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 45 Hydraulic Mechanical Components Pulsers Pulsers Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About Pulsers 7 46 Testing Pulsers and IS Barriers 7 46 Pulser Drive Assembly 7 47 About Pulsers Pulsers convert meter rotation to pulses per gallon or liter for use in some units by the controller board You can program the unit to scale pulses for specific applications For example standard gallonage units use 1000 pulses per gallon Refer to Pump Programming on page 5 1 of this manual for other conversion factors Earlier Encore 500 units used a pulser M00453A001 which was replaced with an Encore 300 style pulser T18350 G6 in September 2002 The M00453A001 pulser will continue to be available as a replacement part The minimum version of Pump Control Node PCN software required to support the T18350 G6 pulser is V1 6 00 The Eclipse will continue to use the M00453A001 pulser Ultra Hi units use the T18350 G6 pulser Figure 7 27 Pulser Assemblies M00453A001 Pulser 118350 G6 Pulser Testing Pulsers and IS Barriers Voltage is limited to 12 VDC in the pulser An IS Intrinsic Safety Barrier is used to limit current Test the pulser by subs
173. amming Barcode Scanner Test Failure Screen The following screen appears when the barcode scanner interactive test operation times out after waiting 60 seconds for valid barcode data The screen lets the technician know that the scanner laser should be off and the scan session has been stopped Barcode Scanner Scanner Enabled Test scan failed Enter Continue Cancel Exit e Press Enter to return to the Barcode Scanner test menu Press Cancel to return to the Barcode Scanner main menu Keypad The keypad menu displays a unique code in real time for each key that is pressed 1 From the Device Config menu press 8 The following screen appears Keypad Menu Key Pressed Cancel Exit 2 Pressakey on the keypad to display the value of that key Keypad Menu Key Pressed Example 1 displays when 1 is pressed on keypad Cancel Exit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 119 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser The Cancel key differs from other keys in that it displays Cancel exiting and then the screen exits back to the Device Config menu The F4 key differs from other keys in that it displays F4 and then the screen exits back to the Device Config menu Page 5 120 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Electronic and Electrical Components 6
174. and A006 PPU Dual Display Module for 6 95 Encore 500 and Eclipse CRIND Encore 300 Single line CRIND Display T20379 6 98 Encore 300 and 500 Monochrome Display E300 and 500 5 99 About Displays The main display provides the customer with information about total cost and total volume of fuel dispensed PPU displays provide price per unit information to the customer The following table shows which PPUs also have reed switch Q11075 31 attached PPU Assembly Number Encore Model PPU Display Type Reed Switch M02652A009 Ultra Hi Single None M02652A008 300 Dual None M02652A007 300 Dual Yes M02652A006 500 Dual None M02652A005 500 Dual Yes M02652A004 300 Single None M02652A003 300 Single Yes M02652A002 500 Single None M02652A001 500 Single Yes MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 85 Electronic and Electrical Components Displays Main PPU CRIND M01515A001 Main Display for Encore 300 Page 6 86 This board is used in Encore 300 units to display the pump transaction information Service Tip If one of the backlight bulbs burns out and the unit has been in service for quite some time it is recommended that all backlight bulbs be replaced as others are also probably near the end of their service life Figure 6 40 Main Display for Encore 300 FRONT VIEW Main Displays BACK VIEW P804A CRIND Z180 Logic
175. and so on Recent US Weights and Measures requirements require that configuration 1 and later firmware versions not be programmed differently To Set Hose Pressurization Option Press Configuration Off Default 0 On up to 10 minutes 1 On up to 30 minutes 2 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 23 Pump Programming Page 5 24 Encore 300 Programming and Data Access Instructions Command Code 12 Programming Pump Dispenser ID and Certain Configurations Program the pump as follows Each fueling position side must be programmed Figure 5 18 Programming Pump Dispenser ID Press 1 2 then ENTER to access this Command Code Select Side then press ENTER To Select Press Configuration Side 1 A side with junction box 1 Side 2 B 2 Enter a Function Code number 1 5 then press ENTER Figure 5 19 Entering Function Code numbers Function Code Configuration Code Option Enter a Configuration Code Option then press ENTER Choose another Function Code number or press F2 to exit Function Code 1 Two wire ID Do not use the same ID address number for units or unit sides on the same data loop Side 1 always defaults to 7 Side 2 always defaults to 11 To assign a number 1 16 press that number on the keypad and press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pum
176. andle is activated raised and unit is authorized no fuel is dispensed the handle 1s deactivated lowered Normally the previous sale would be shown You must use Configuration Code for New Jersey installs To Zero Previous Transactions Press Configuration After lamp test Default 0 Before lamp test 1 Function Code 19 Lamp Test Leak Detector Test Setup Sets in seconds the amount of time the display shows all 8 s during the reset cycle at the beginning of a transaction This time is typically set to allow for the STP mechanical leak detectors to run a complete test For electronic line leak detectors normally this is set to OFF However follow the recommendations of line leak detector manufacturer to set time not an actual test of lamps To Perform Press Configuration Not used 0 One second lamp test Two second lamp test Three second lamp test Default Four second lamp test Five second lamp test Six second lamp test Seven second lamp test Eight second lamp test OO CO NI oO a BY Wy Iv Nine second lamp test Function Code 20 Programmable Pump Preset Value Normally set to 0 Program to 1 for use with 6 digit cash programming To Set Programmable Pump Preset Value Press Configuration X1 Default 0 X10 1 Page 5 22 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Fu
177. apor return associated parts are shown for clarity Vapor Return Line from Vacuum Motor Outlet Assist or Hose Manifold Balanced ISD Junction box Y ISD Vapor Pipe Assembly temporary piping removed when installing the ISD meter Bottom Rail of Dispenser ISD ready dispensers are integrated with the ISD system by replacing the ISD vapor pipe assembly with an ISD vapor flow meter assembly See Figure 7 47 Figure 7 47 ISD ready Dispenser with Vapor Flow Meter Installed Facing Side B Hydraulic cabinet area of unit only vapor return associated parts shown for clarity Vapor Return Line from Vacuum Motor Outlet Assist or Hose Manifold Balanced ISD Vapor Flow Meter Assembly Mating Fittings Contractor Supplied Seal off 1 NPT Nipple Contractor supplied 3 4 NPT Nipple awn H Conduit to TLS Console Contractor Supplied P Vapor Return to Tank The vapor flow meter is in line and near the vapor return shear valve in the hydraulic area of the dispensing unit Ensure that there are no liquid flow traps For more information on liquid traps refer to MDE 3985 Encore Installation Manual Wiring for the ISD vapor flow meter must be intrinsically safe and run in a separate conduit Conduit must be potted where it enters and leaves any designated hazardous zones Potting requirements for hazardous zones must be followed so that fuel vapors do not migrate to other areas MDE 3804B Encore and
178. asuring Pressure and Vacuum 0 eee 7 12 Topics in this Sub section 3 nos de us eor et e dose dg dx 7 13 Using Pressure Gauge llllllllll ees 7 13 Pressure Measuring Locations on Unit 022005 7 13 Measuring Pressure Drop for Dispensers and Pumps 7 15 Analyzing Pressure Drop for Dispenser and Pumps 7 16 Measuring Vacuum Pump avkcu scien Opel Rabon ded Ce be Oddo a dolci a 8 ne Ge ood 7 17 Topics in this Sub section llle 7 17 About Vacuum Readings 0 00 cee eee eee 7 17 Measuring Dry Vacuum for Pump 00000 eee eee eee 7 18 Measuring Wet Vacuum and Pressure for Pump 7 19 amp leczuo MCCC T TP 7 21 Topics in this Sub section llle 7 21 About Calibrating Meters llle 7 21 About Calibrating VaporVac llle 7 21 Fllters and Strainers s oseni iot e deiode Uo ed deor e e dioderdirdode ea abd d Gta estet degit git 7 22 Topics in this Sub section llli 7 22 ADONE eut soonest a dax d dace Baek eat ad cs 7 22 oervielhda dilielS 4 225 3 oed ad m cox ES DR Ar tUpaie s 7 23 PDO UT MAI ONS a once aniar uae ovr dying as p BP Aveeno ee du eee 7 25 Servicing Strainers eens 7 25 Handing Marwa Gd he ct cec doy Sa toco e Ste ee Mew ile 1 SI dra Tits d on MM os dtu V oh dso veel hr ne Da 7 27 Topics in this Sub section 1 0 eee 7 27 About Hanging Hardware 0 ccc ee ee
179. auses the unit to operate in Generic CRIND The Advantage Series compatibility mode e 3 causes the unit to operate in MOC Kiosk mode and will automatically set the other Side s CRIND ID to 99 e 4 causes the unit to operate in Generic Kiosk mode and will automatically set the other Side s CRIND ID to 99 3 Press Enter to save changes and exit The CRIND Config menu appears OR Press Cancel to discard changes and exit The CRIND Config menu appears Generic BAUD Rate This option is currently disabled Pressing 3 from the CRIND Config menu causes the Unsupported Feature screen to display Force BIOS Cold Start This option is currently disabled Pressing 4 from the CRIND Config menu causes the Unsupported Feature screen to display Force App Cold Start This option is currently disabled Pressing 5 from the CRIND Config menu causes the Unsupported Feature screen to display MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 97 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Device Configuration From the Main Menu press 2 The Device Config menu appears Device Config Display Settings Audio Setting Cash Acceptor TRIND Card Reader Printer Barcode Scanner Keypad CONOORWDND Display Settings This function allows you to select a display side for contrast adjustment If the contrast setting for one side has been set to a value tha
180. ay slowly remove three Hex bolts from diaphragm assembly and remove Do not remove pan head bolts that require special tools Wear eye protection Save bolts Note The internal parts of the PCV are not serviceable 5 Remove existing O Rings and discard 6 Install new O Rings see Figure 7 41 Use Gilbarco kit K96621 0X Page 7 64 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Valves Hydraulic Mechanical Components Replacing Proportional Control Valve Parts To replace the proportional control valve parts proceed as follows 1 Reverse disassembly procedure to install the valve 2 Torque the three Hex bolts to 100 inch pounds 3 Test for proper operation and leaks after installing valve Figure 7 41 Proportional Control Valve Assembly Proportional Control Valve Coil Stem Service Tips Ensure that the coil 1s installed properly Do not pry on coils No flow or other valve problems may be caused by a bad valve coil valve adaptor or pump control node board Do not rebuild or replace the valve without checking these first MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 65 Hydraulic Mechanical Components Valves Shear Valves Page 7 66 Shear valves have a section of the valve that 1s designed to break from a sufficient impact to the unit Shear valves cut off the flow of fuel from product piping if impact or fire causes shear valve linkage to trip Single poppe
181. be effective if a STOP button has been selected as INSTALLED in the Level 4 programming mode Option 1 means that each STOP button will only stop its own side Selection two means that either STOP button will stop both sides of dispenser Default 1s selection 1 for one side only Figure 5 62 Setting Button Control Options Button Control Option 1 Press 5 then 6 then press ENTER to access this Command Code Page 5 62 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 2 Use the following table to select Option Option Button Control 1 Default Stop one side only 2 Stop both sides 3 Press ENTER Command Code 59 System Cold Start Allows programmer to clear all pump controller application memory and start again All Level and Level 2 Command Codes are reset to their default Manufacturing values This Command Code is not required to upgrade software It is to be used only in the event that all other attempts to correct a dispenser problem do not work This action does not disturb metrological data storage or force a download Layout and digit position meaning for this programming feature is shown below Figure 5 63 Setting the System Cold Start 1 Press 5 then 9 then press ENTER to access this Command Code 2 Usethe following table to select the Reset option 0 Normal Default 1 Cold Start allow master reset 3
182. bic inch If the calibrator fails to stop flow within this limit then the calibration process must be repeated Figure 5 76 2 Un calibrated pulses This example shows 2 Un calibrated pulses 5 Lower the handle or replace the nozzle and the volume display changes to the programmed prover can value This meter 1s now calibrated and the volume display shows the amount corresponding with the prover can size Figure 5 77 Meter Calibration 6 Ifother meters must be re calibrated repeat steps 2 through 5 for each meter It is not necessary to re enter prover can size and VUT information after each meter calibration This allows calibration of both sides of the unit without returning to the Manager Keypad Page 5 76 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 7 After all the meters are calibrated flip the Weights and Measures switch to the OFF position When the switch is placed in the OFF position the new calibration values are first saved to redundant data storage The Money display shows PPPPPP and the volume display shows and then returns the unit to normal operation Figure 5 78 Flipping the Switch 8 Install seal wire and apply seal as determined by the governing authority Combined Verification and Calibration Procedure This alternate approach is for all units previously calibrated at some point in ti
183. ble To Board E300 P193 2 pin MO22114A001 CRIND Logic PCA T17764 G3 G4 P1 30 pin M02154A001 to MO22114A001 J115 2 pin M02160A002 to Monochrome PCA T19501 G2 M01650A001 PWR 3 pin M022369A002 Power Supply M02274A001 Line Filter 2 pin M022369A002to Cable M02211A001 At Connector P269 10 pin P192 2 pin Cash A B 3 pin P1991 4 pin M02154A004 Cash Acceptor Encore 500 Figure 6 53 Cash Acceptor Assembly M01271A001 LON to Serial Node LCR Removed Security Switch P193 Mo0122A001 Refer to M00122A001 LON to Serial Node LON Gateway on page 6 29 Assembly Vault Door Bill Collector Passageway LEDs Page 6 104 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical Components Cash Acceptor Eclipse Figure 6 54 Cash Acceptor Assembly M01403A001 Padlock Assembly LON to Serial Node MO00122A001 Vault Door Hefer to M00122A001 LON to Serial Node LON Gateway on page 6 29 Bill Collector Chute Support Passageway LEDg Connections and Cables E500 and Eclipse Circuit Board Model Connector Via Cable To Board At Connector E500 Eclipse J1 80 pin M02154A001 to Serial to LON Node M00122A001 P1508 13 pin MO2153A001 J115 2 pin M02160A001 to P1510 5 pin M02152A001 J193 2 pin M02152A001 P193 2 pin Line Filter M02154A001 to P1508 13 pin MO2153A001 PWR 3 pin M02367A002 Power sup
184. breakaway and the hose When used a hose retention coupling must never be installed between the breakaway and the nozzle When installing breakaways always use wrench on breakaway Hex or wrench flats only Always use pipe sealant for connections except on O Ring fittings Never use Teflon tape Some breakaways are reusable Follow breakaway s manufacturer instructions on inspection and reuse Periodically and after a drive off check breakaway hoses and couplings for hose continuity Refer to Testing Hose and Hanging Hardware Continuity on page 7 31 for details MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 29 Hydraulic Mechanical Components Hanging Hardware 10 Page 7 30 Reinstalling or Replacing Breakaways Figure 7 13 Typical Breakaway To reinstall or replace breakaways proceed as follows Close and test shear valve Units may require multiple shear valve closures Also refer to manufacturers instructions Turn off power to the unit and associated STPs Use OSHA Lock out and Tag out procedures Drain nozzle and hose into an approved container Clean up any spills promptly Be prepared for any residual pressure that may still exist in the hanging hardware Note Ensure that you use eye protection Check for damage to nozzle especially the spout and threads Perform a hose continuity test Refer to Testing Hose and Hanging Hardware Continuity on page 7 31 for details In
185. c and Electrical Components About this Section Abbreviations and Acronyms Term Description CRIND Card Reader in Dispenser LON Local Operating Network MIP Microprocessor Interface Program MOC Major Oil Company PCA Printed Circuit Assembly PCB Printed Circuit Board POS Point of Sale USB Universal Serial Bus Terms Used in this Section Term Definition LON Local Operating Network This is a hardware and software system devised by the Echelon company for coordinating distributed control systems from something as small as a copying machine to large building utility systems such as Elevators Fire Alarms and so on All reference to LON in this manual refers to systems inside the dispenser electronics PCA Printed Circuit Assembly This is a dedicated component designed for specific function with limited or non existent intelligence or processing power Refer to Printed Circuit Assemblies and Nodes on page 6 5 for comparison This term may be used interchangeably with PCB PCB Printed Circuit Board This is a dedicated component designed for specific function with limited or non existent intelligence or processing power Refer to Printed Circuit Assemblies and Nodes on page 6 5 for comparison This term can be used interchangeably with PCA MIP Microprocessor Interface Program Allows all of the nodes to communicate together Neuron A low level processor found on all nodes Its primary function is handling commun
186. ccess this Command Code 2 Program assign new PIN Code 3 Press ENTER to accept new PIN Code Change PIN Codes Function Codes 1 4 PIN Code levels correspond to Function Codes in Command Code 77 Thus Function Code 1 for Level 1 2 for Level 2 and so on Note that all PIN Code assignments work the same Keypad Programming New PIN Code e Select Level 1 4 for code change Notes 1 If Level I no selection necessary Level I is Default e ENTER accept level PIN Code for change Enter PIN Code ENTER complete first pass pass number now shows 2 e Re enter PIN code e ENTER complete second pass 2 If pass number display shows value of O it indicates that first and second PIN Code entries did not agree Press FI to start PIN Code entry sequence from the beginning If the new code is entered correctly twice pass number display will display a value of 3 to indicate acceptance of new PIN Code MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 71 Pump Programming Encore 5XX and Eclipse Programming Instructions Electronic Calibration AN WARNING You are working in a potentially dangerous environment of flammable fuels vapors and high voltage CN Fuel and its vapors may ignite leading to serious injury or death Fire explosion or electrical e shock could result in severe injury or death if you do not follow safe procedures Surfaces of Eclipse Series units are non metallic Magnetic b
187. ceptor is too screen CRIND Printer Module unstable to continue operation CRIND Devices Corrective Action Ensure that the cassette Is properly installed Ensure that all locks are installed REMOVE INSTALL latch must be turned completely to the INSTALL position and not beyond on the LRC Ensure that the CRIND receipt printer has paper Ensure that the cassette Is properly installed Ensure that all locks are installed REMOVE INSTALL Latch must be turned completely to the INSTALL position and not beyond on the LRC Remove any bill pieces in the Cash Acceptor If none of the above work try a different cassette spare or from another unit If this is a recurring problem Verify all Cash Acceptor switches are correctly set Cash Acceptor requires calibration Power fail the dispenser The CRIND printer and the Printer Node in Encore 500 and Eclipse series units is an assembly module with the node portion being connected to the LON bus The printer node provides power to the thermal printer contained inside the unit and is designed to move information from the LON to the printer and control the printer There 1s one jumper on the printer node to determine side 1 or 2 The Encore 500 and Eclipse printer module assembly are interchangeable by relocating the printer node enclosure The Encore 300 has a printer interface board attached to the printer interface mechanism similar to the Encore 500 and Ec
188. co Transac TRIND EMC MultiLine TCR InfoScreen Trimline Passport Additional U S and foreign trademarks G CAT Optimum Series Ultra Hi Legacy Vapor Vac CRIND pending Gilbert PAM 1000 ValueLine Making Things Better G SITE Performer Other brand or product names shown may be G Poll Interface PAM MPD Transac System 1000 InfoScreene trademarks or registered trademarks of their SmartPad SMART Connect Encore respective holders This document is subject to change without notice For information regarding Gilbarco Inc Literature call 336 547 5661 E mail literature gilbarco com Internet http www gilbarco com 2007 Gilbarco Inc All Rights Reserved Quad EUM EQUIPMENT IN S ITUTE Table of Contents 1 Read this First Introduction Model Information Important Information about Releases 00002000 aite PME TOPICS MANS SOCIO eso a eter Eos hora radon osos Se hr eee Related Documents aaa Who Should Use this Manual lene Service PIOEIODO o dea rete ae ERR AGREE o RR tree ees Where to Find Model Information on Unit lees Model Serial Number Tag Formats llllllllssnn Model 4508068 isa dog ded ache t a eher dod RC RR Rol wh as Dale CodeS sacs deudor u edv botes ip etn Jn Eti pate upper A Rh 2 Important Safety Information 3 Start up and Com
189. core 5XX and Eclipse Programming Instructions Figure 5 79 Meter Calibration and Verification 4 No other transaction can be active on the other side of the unit during this procedure The unit will not go into calibration mode if more than one pump handle is activated Note The CRIND may reboot during this procedure 5 This meter is now calibrated Note Electronic and electromechanical totals are updated when this method is used Audit Trail Feature While in the calibration mode of operation pressing ENTER on the Manager Keypad the specified number of times as listed in the following steps will display data described in the Audit Table Descriptions on page 5 79 1 To access the audit feature place the unit in normal mode of operation press ENTER on the Manager Keypad as shown here 4 times for a blender e 3 times for a non blender 2 The displays now show information conforming to the audit trail for the associated meter Refer to Audit Table Descriptions on page 5 79 3 Press CLEAR on the Manager Keypad to return to normal operation Page 5 78 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Audit Table Descriptions Pump Programming Press ENTER Unit Type 1 7 Unit Type 8 9 Unit Type 12 19 X1 Money Display N A BC BC Volume Display VUTC VUTC VUTC PPU Displays DLC Blend Ratio Blend Ratio X2 Money Display N A BC BC Volume Display VUTC VUT
190. corresponding pump bore as shown see Figure 7 32 on page 7 52 Press assembly squarely over receiving cylindrical surface until O Ring sits firmly over the surface and holds the assembly in position 5 Insert new or cleaned strainer 17 into bore over check valve assembly 6 Clean debris from strainer cover O Ring groove and install O Ring 18 If O Ring does not stay in place use a small amount of all purpose grease to hold the O Ring in the groove 7 Install strainer cover 19 with screws 21 Hand tighten alternating between each screw to keep the cover parallel to the casing face Torque the screws to 150 Ibs in 17 Nm Do NOT overtighten Overtightening may cause damage to screw or casing 8 Replace the plug 11 in the hole located to the right of the strainer cover MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 53 Hydraulic Mechanical Components Pumping Device GDP Pressure Control Valve Service Pressure Control Valve Removal Figure 7 33 Pressure Control Valve e LZ JL A y Valve Cover 13 d IO S snap NN D me Ring 15 ee EN KS Z SD Y Valve 10 v l s Retainer MV Spring 12 Cover O ring 14 CAUTION Excessive wear on the Pressure Control Valve PCV can cause improper pump performance including flow loss or excessive or low discharge pressure To remove the PCV proceed as follows Note The numbers within parenthesis in the procedural steps bel
191. ction Topic Page About Meters 7 43 C Meter 7 43 LC Meter Encore Ultra Hi 7 45 ISD Vapor Flow Meter see Vapor Recovery section 7 75 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing hoses Fire and explosion could result in severe injury or death Wear eye protection Remove hoses and nozzles slowly Collect fuel in approved containers Clean up all spills promptly About Meters Gilbarco C meters are used on standard Encore units refer to C Meter for more information For Encore Ultra Hi units refer to LC Meter Encore Ultra Hi on page 7 45 Gilbarco does not recommend a major field overhaul of the meter Suggested repairs are related to fixing external leaks The only serviceable parts on the meter are gaskets and seals Most repairs require removing the meter from the unit Automatic Temperature Compensation ATC equipped C meters have a special cover to accommodate probe end and test wells Model and Date Codes Model number is stamped on each meter see Figure 7 25 on page 7 44 Refer to Model Configurations for a breakdown of this designation C Meter The C Meter is a positive displacement piston meter where fluid is pushed into a cylinder which causes the opposing piston to push a similar cylinder of fluid out The piston connecting rod converts the piston movement into rotation of the pulser shaft The C meter has a flow path that dischar
192. curity PIN Code is entered all configuration Level 3 Level 2 and Level 1 Command Codes are allowed N WARNING Surfaces of Eclipse Series units are non metallic Magnetic backed keypads will not adhere to Eclipse unit surfaces as they will to others In any situation where power is on and gasoline and its vapors are present or potentially present for example calibration 22 do not attempt to use the Manager Keypad with electronics cabinet open Fuel and its vapors may ignite leading to serious injury or death For Eclipse units run keypad cable over door and close door allowing keypad to be suspended on unit and accessed from outside for all procedures performed with power applied or where there is a possibility of fuel or fuel vapor being present MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 3 Pump Programming About this Section Manager Keypad Layout Figure 5 1 Manager Keypad Layout Manager Keypad Key Definitions and Use Key s Definition Use 0 9 Numeric Values F1 Function 1 Used to start dispenser programming and sequence among programming and Function Codes In general pressing F1 will take user back to a previous programming function selection Pressing F1 from the normal dispenser state will always initiate programming mode Note Displays are always activated during programming mode F2 Function 2 Used to exit programming mode and return to normal mode
193. d where required and checked for coninaiy 7 nitancored othe sland perinstllaioninsutions O 8 Napor recovery piping has no waps orsagsindapemersump ge HE XE Correct nozzles piping and brand panels used for each grade VAG NN 10 All code regulatory agency or customer specified safety warning signs 1306 Nor de have been installed 0 Hose lengths beyond standard lengths are not being used without spegaWgiflevaM No more than 6 inches of hose is touching the ground with uS nozzle in nozzle boot for vacuum assisted vapor recovery hoses Vap UN OS S CCP a s dm MR RR RN NN 12 Fumear omieswingsarwaveorpumpsaxhwig ng NNilemes 000000 LL a3 Encore only Piping has been secured to the lower pipgesbratg amp e Installation instructions 1 2 J 4 5 7 10 11 12 13 14 Individual Pump Dispenser Electrical Related Units without factory installed or factory kit junction boxes only Conduit into electronic cabinet is potted per installation instructions and no unfilled openings exist between the electronics cabinet and the lower piping area All wiring to dispenser is stranded copper of gauge and insulation type specified in installation instructions 7 Ground wires properly connected at pump dispenser Contractor supplied conduit and junction box approved for hazardous locations involved and properly sized for wiring and number of connections per codes All junction box covers replaced and all bolts use
194. d Eclipse Start up Service Manual August 2007 Model Information Read this First Eclipse The model number provides information on the configuration and options of the unit For units with totalizers installed in tuxedo stripe see Figure 1 2 on page 1 4 for stripe location totalizer will always be on left tuxedo stripe when facing Side 1 Note If unit does not have a totalizer do not assume side location by unused knockouts in tuxedo stripe All tuxedo stripes have totalizers knockouts whether a totalizer can be installed or not Model Unit Type Grade Hoses EGO Dispenser Single Hose 3 Grade 2 Hose ELO Blender Dispenser X41 241 Grade 4 Hose EL 1 3 1 Grade 4 Hose EL2 4 1 Grade 4 Hose EL3 5 1 Grade 4 Hose ENO Blender Dispenser X 0 2 0 Grade 2 Hose EN1 3 0 Grade 2 Hose EN2 4 0 Grade 2 Hose EN3 5 0 Grade 2 Hose Date Codes The date code provides the month and year of manufacture In the example in Figure 1 3 on page 1 5 an Encore unit stamped BK was built in February 2001 Use the chart below as reference to determine date codes A January J September B February K October C March L November D Apri M December uem Nem T 26 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 1 7 Read this First Model Information This page is intentionally left blank Page 1 8 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Important
195. d Storage Tank 8 Page 6 6 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting Types of Operation Simultaneous Operation Allows customer to fuel saddle tank vehicle with master and satellite unit at same time Note Some regulatory agencies require a physical barrier to prevent access to another fueling vehicle if simultaneous operation is possible Independent Operation Allows customer to fuel a saddle tank vehicle only one side at a time Master and Remote Satellite Piping A Master and remote satellite system is shown in Figure 8 6 Note The numbers in Figure 8 6 correspond to the numbered steps below Figure 8 6 Master Remote Satellite Fuel Flow Schematic REMOTE SATELLITE MASTER 8 Pulser y CER S o Two Stage Valve Sd 9 7 l Liquid Controlg Mater Check Valve Shear Flow from STP Operation Product passes through a shear valve and enters the dispenser Product flows through a check valve and strainer Product flows through a Liquid Controls meter Metered product passes through a single stage shutoff valve and slowdown valve in parallel or in more recent units a two stage valve and or through piping to the satellite Product flows through the remote satellite through a shear valve and through solenoid valves and then to the nozzle Fuel is discharged through the nozzle MDE 3804B Encore and Ec
196. d and tightened and all openings are plugged NENNEN 10 All speaker intercom and other Class 2 wiring is located in separate conduit and junction box from power wiring o Station Electrical Check this section only once per site New site wiring to pumps dispensers was Megger tested Old site wiring was continuity and short tested with a digital meter 6 Alipumpiispenser wiring properly spaced and isolated rom wiring to electrically noisy devices as per the installation manual L3 Em Required Signature Installer Name Print Tech No if applicable Duc NOTE This is a two part form Place the top copy original in the pump dispenser away from wiring and circuit boards and keep the bottom copy for your records An incomplete or missing form may delay commissioning of the unit site and may void warranty MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 3 3 Start up and Commissioning Sample Install Start up and Commissioning Forms Figure 3 2 Sample Start up Checklist MDE 4227 f GILBARCO 7 VEEDER ROOT MDE 4227B Encore Eclipse Start Up Checklist Form B May 2006 Site and Start Up Technician Information SITE INFORMATION START UP TECHNICIAN INFORMATION Unit Serial Number Company Name Site Name Number Company Address City State Zip City State Zip INSTRUCTIONS Before powering the unit the start up technician ASC should verify that the unit has been inspected per MDE 4226 Encore
197. d if an unusual prover can size is required If changing the Volume Unit type enter the programming mode in the usual manner except that the Weights and Measures calibration switch must be turned ON before entering CC82 and switched OFF before exiting this programming mode to make the changes effective If Volume Unit Is Set To Prove Can Size Defaults To US gallons or Imperial gallons 5 gallons Liters 20 liters Figure 5 93 Setting Prover Can Size 1 The following example shows Command Code 82 and unit side 1 Page 5 86 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 94 Command Code 82 and Unit Side 1 2 Insert prover can size The default value is 0 It is necessary to enter a volume from 1 to 999 to proceed to the next step In this example the prover can size is 20 US gallons Current volume unit is selected in CC71 and reported in the Unit code field shown as 1 in the following example Figure 5 95 Inserting Prover Can Size This reference table shows the volume units and their codes Prover Can Volume Units Unit Codes No Units Programmed Defaut 0 U S Gallons 1 Liters 2 Imperial Gallons B 3 Press ENTER to accept the default or press 2 to select for side 2 Then insert the calibration side Default value is 1 as shown below MDE 3804B Encore and Eclipse Start up Service
198. d save the original for your records Keep the original of this commissioning form and Form A and Form B in your records for three years The commissioner will discuss results of all the checklists with the station manager supervisor IMPORTANT NOTE The commissioning ASC should verify that the units have been inspected per the Installation Checklist Form A and the Start Up Checklist Form B Failure complete all forms may delay commissioning completion and may affect warranty In case all forms are not complete or available the commissioner must explain the options for completing commissioning to the station owner COMMISSIONING The commissioner should have all of the required forms and signatures ready and call 1 888 800 7498 to report commissioning Log the SR at the top right of form Do not mail commissioning form Information is taken over the phone Model Serial Numbers POS Type amp Name gt gt o Check if Received Biodiesel Blend Ratio Programming or E85 Model Number Serial Number Pmp Disp CRINDe Door Node Low High Product Product of Low Product EINEN SEN MRNNNEK Customer representative s signature indicates blend ratios listed L are same as those provided to the ASC Door Node information is applicable only for Encore 500 and Eclipse units Individual Unit Inspections Item Procedure Installation and start up checklists have been completed and results reviewed with station manager supervisor 3 Un
199. d side and allows the technician to present barcodes to be read Barcode Scanner Scanner Enabled Present test barcode in front of scanner This test will time out in 60 seconds Cancel Abort If the diagnostics session is currently running on the opposite side and this 1s the first time scanners have been tested in this session the following warning screen will appear This is a one time warning message displayed to alert the technician that interactive barcode testing will disrupt transactions on the opposite side Barcode Scanner Scanner Enabled WARNING You will prevent barcode scanner use during sales on the other side of dispenser until it is restarted Enter Continue Cancel Exit e Press Enter to advance to the next screen Press Cancel to exit back to the Barcode Scanner test menu 3 Present a readable barcode in a format currently enabled on the scanner The following screen appears Barcode Scanner Scanner Enabled scan Data 012345678905 Scan data and code type format in Code Type UPC EAN which data was encoded is read from barcode and displayed on screen Enter Continue Cancel Exit 4 To return to the Barcode Scanner interactive test screen press Enter OR To exit to the initial Barcode Scanner test menu press Cancel Page 5 118 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Progr
200. der when a meter check valve is bad Error code 5047 will occur if reverse flow is detected For service the pulser can be used with T18350 G6 pulsers in the same unit as long as pulsers are replaced as pairs The T18350 G6 pulsers are still being used for the Encore 300 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Pumping Device GDP Hydraulic Mechanical Components Pumping Device GDP Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About the GDP 7 49 General GDP Service Procedures 7 50 Draining the GDP 7 50 Strainer Check Valve Service foe Pressure Control Valve Service 7 54 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly About the GDP Self contained Encore pumps use the Blackmer Global Dispenser Pump GDP Service on the pump should be performed in the shop and not attempted in the field The case is made of aluminum and sealing surfaces may be damaged while working on an inappropriate surface For additional information about the GDP unit refer to MDE 40
201. deral state and local codes All these regulations must be followed Failure to install inspect maintain or service this equipment in accordance with these codes regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment Replacement Parts Use only genuine Gilbarco replacement parts and retrofit kits on your pump dispenser Using parts other than genuine Gilbarco replacement parts could create a safety hazard and violate local regulations Safety Symbols and Warning Words This section provides important information about warning symbols and boxes Alert Symbol A This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazards Obey safety directives that follow this symbol to avoid possible injury or death Signal Words These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards The precautions below must be followed to prevent death injury or damage to the equipment DANGER Alerts you to a hazard or unsafe practice which will result in death or serious injury WARNING Alerts you to a hazard or unsafe practice that could result in death or serious injury CAUTION with Alert symbol Designates a hazard or unsafe practice which may result in minor injury CAUTION without Alert symbol Designates a hazard or uns
202. e equipment Required Signature Start Up Technician Name Print Tech No if applicable NOTE This is a two part form Place the top original copy in the pump dispenser away from wiring and circuit boards and keep the bottom copy for your records An incomplete or missing form may delay commissioning of the unit site and may void warranty Trademarks CRINDS Eclipse Encore TRIND and VaporVac are registered trademarks of Gilbarco Inc Page 3 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Sample Install Start up and Commissioning Forms Start up and Commissioning Figure 3 3 Sample Commissioning Checklist MDE 4228 uu fA GILBARCO MDE 4228J Encore Eclipse Commissioning Checklist 2 VEEDER ROOT Form C October 2006 E n i Commissioning SR Site Information SITE INFORMATION Site Name Number Street Phone Number City State Zip INSTRUCTIONS This form is to be completed by the commissioner The commissioner is defined as a person with the appropriate Gilbarco training usually an Authorized Service Contractor ASC necessary to complete the commissioning process and train station personnel MDE 4226 Encore Eclipse Installation Checklist Form A and MDE 4227 Encore Eclipse Start Up Checklist Form B are prerequisites to this form The commissioner should retrieve the original and a copy of Form A and Form B from the dispensers pumps Give the copy to the station representative an
203. e sensitive electronic components Follow all precautions and recommendations OWS Preparing for Service Barricade area that you will be working in e Remove all power to unit when servicing electronic components Remove power from involved devices STPs and so on Multiple disconnects may be required e Use extreme caution during any observation or testing procedure that requires power to be applied to the unit Follow Electrostatic Discharge ESD procedures to prevent damage to electronic components or ignition of flammable fuels or vapors Preventing Electrostatic Discharge Wrist strap IC extractor Printed Circuit Assemblies PCAs and Integrated Circuits ICs are sensitive to electrostatic discharge caused by static electricity Electrostatic discharge can damage electronic parts When removing PCAs or handling sensitive parts Touch an unpainted metal surface to discharge any static electricity buildup Use a wrist strap connected to a grounded metal frame or chassis Place removed PCAs or ICs on a grounded antistatic mat e Use an IC extractor tool to remove ICs Place PCAs you plan to return for credit or repair in antistatic bags MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 3 Electronic and Electrical Components About Service Procedures Page 6 4 Hazardous Materials Some materials present inside electronic enclosures may present a health hazard if not handled co
204. e 9 Japan Germany 10 Norway England 11 Denmark 2 Denmark 12 Spain 2 Sweden 13 Latin America Italy 14 Japan 2 nter Code Current Country Code Selection 2 Press numeric keys to enter a one or two digit country code The default setting is 1 USA Values range from 01 14 Page 5 110 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 3 Press Enter to commit the code entered into persistent storage on the CRIND node If you enter a number incorrectly and wish to delete it press Clear Note If the setting you enter is out of range Value Out of Range will be displayed in this field for a few seconds and then the field will return to previous setting OR Press Cancel to exit back to the main Printer Menu Barcode Scanner The barcode scanner menu allows you to configure and test barcode scanner operations 1 From the Device Config menu press 7 The following screen appears Barcode Scanner Scanners Enabled Indicates status of barcode scanner 1 Disable Scanners This status applies to both sides of 2 Show Device Details the unit when it is configured for 3 Setup Scanners dual sided CRIND operation 4 Test Scanners Enter Save Value and Exit Cancel Discard Change and Exit 2 Use numeric keys to select option from the menu 3 Press Enter to save the changes and exit back to the Devic
205. e Cash Acceptor Diagnostics menu to initiate diagnostics tests The following screen appears Cash Acceptor Cash Acceptor Enabled Status Line displays the current state of the cash acceptor being tested Possible values for this line Bil Escrowed X Bill Escrowed X bill is currently held in escrow position awaiting command bill has been read Clear Refund Bill Bill Escrowed Bookmark Unknown unknown or invalid bill type is read or Enter Stack Bill device is rejecting a bill that is currently Cancel Refund Bill if present and Exit left in the bezel awaiting removal 6 Press one of the following keys Clear instructs cash acceptor to return the bill in escrow Enter instructs cash acceptor to stack the escrowed bill in the test cassette Note This option is only available if the CRIND BIOS previously detected a cassette swap Cancel instructs cash acceptor to return the bill in escrow You are asked to replace the station s cassette and then must press Enter The Cash Acceptor Run Diagnostics screen appears 7 When ready to exit screen press Cancel The following screen appears Cash Acceptor Cash Acceptor Enabled Please replace the station s cassette Enter Continue You must press Cancel to exit this screen MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 105 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser 8 Remove
206. e Config menu 4 Press Cancel to disregard any changes and exit to the Device Config menu Enable Disable Scanners From the Barcode Scanner menu press 1 to toggle between disabling and enabling the scanner Show Device Details 1 From the Barcode Scanner menu press 2 to display firmware information about Side 1 and Side 2 scanners Barcode Scanner Scanner Enabled Side 1 Details Firmware Version NBRWCAAH Side 2 Details Firmware Version NBRWCAAD Cancel Exit 2 Press Cancel to return to the Barcode Scanner menu MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 111 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Setup Scanner Use this function to adjust the barcode scanner settings From the Barcode Scanner menu press 3 If this is the first time entering the barcode setup screen the following warning screen appears Barcode Scanner Scanner Enabled WARNING The following actions could disrupt scanner use by customers on the other side of this dispenser Ensure that the other side is not in use before continuing Enter Continue Cancel Exit To continue to the barcode scanner setup menu press Enter To exit to the Barcode Scanner menu press Cancel If this is not the first time entering the barcode setup screen the barcode setup menu appears Barcode Scanner Scanner Enabled 1 Reset to Factory Defaults 2 View Change POS
207. e Customer Keypad Options CRIND or Refer to MDE 3804B M01202A002 Eclipse PPP Wiring and M01109 Misc Options Keypad Configuration Manual e M00141 CRIND Keypad P2108 14 pin M00515A001 Encore M00147 Manager Keypad Side 1 M00515A003 Eclipse only P2109 10 pin M00489 M02235 LON Bus 1 P2110 4 pin M01201A001 Encore M01109B001 Miscellaneous Options 12 pin Call Button M01215A001 Encore P2111 3 pin Push to Stop P2113 5 pin Push to Start P2112 10 pin M00489 M02235 LON Bus 2 P2114 4 pin N A Door sense P2115 3 pin M0061 4A004 Encore Power Supply 9 4 VAC PS2 M00614A002 Eclipse PS2 to PS3 on bulkhead connector Connector Pin Functions and Voltages P2101 Pin Description Input Output Voltage 1 9 4 VAC 9 4 VAC 10 2 9 4 VACRTN 9 GND 0 VDC 4 GND 0 VDC 5 DLT 5 VDC 4 7 V 10 with the power on 6 PPUCLK 0to5V 7 PPUFBDATA 0to5V 8 PPUSND REC 0to5V 9 PPUBP 0to5V 10 PPUSDATA 0to5V 11 PPUSYNC 0to5V MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 17 Electronic and Electrical Components Page 6 18 Printed Circuit Assemblies and Nodes P2102 Pin Description Input Output Voltage 1 VCC 5 V 5 2 CRRDT1 0to5V 3 CRRCL1 0to5V 4 CRRDT2 0to5V 5 CRRCL2 0to5V 6 CRCLD 0to5V 7 GND OV 8 CRSTAT Open to 0 V 9 GND OV P2103 Pin Description Input Output Voltage 1 VCC 5 V 5 2 GND OV 3 PRSENIN 0to5V 4 PRSENSTAT Open to 0 V
208. e LEDs on the Hydraulic Interface board During loss of communication with the dispenser the Pump In and Pump Out LEDs on the CRIND logic boards may still flash due to communication between the Side 1 and Side 2 logic boards MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes T17764 G3 G4 Boards Figure 6 28 Z180 Logic Board G3 G4 P253 Customer Keypad P252 CRIND P280 Not Used display Single Line Components in dotted box are on G3 board only or TY Be JP17 JP18 P281 not used P258 Gateway or Bar Code Scanner Battery JP19 P266 CRIND Regulator U7 Firmware P264 Grade Select g m n CR29 lk CR28 W x e EPEBEGEGEIEDEL RES z 3 Ell L d El E dE 3 JPi6 p id JP14 JP6 Jp2 JP11 JP7 JP10 JP8 ae JP9 JP4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Electronic and Electrical Components P282 SmartPad P254 Card Reader P255 CRIND Regulator JP12 CR22 CR23 CR11 Not On G4 Board CR25 CR24 P269 Cash Acceptor P290 Not Used P268 Monochrome PCA P257 CRIND Printer P262 CRIND Regulator Page 6 61 Electronic and Electrical Components Board Connections and Cables Printed Circuit Assemblies and Nodes Connector Via Cable To Board At Connector P251 12 pin M01668A002 harness T20306 G1 CRIND Regulator PCA P552 12 pin P253 17 p
209. e calibration slip The following screen displays once the cash acceptor has completed calibration The operator s result is displayed Cash Acceptor Cash Acceptor Enabled Calibration result Results of calibration display here e Succeeded if calibration completed properly Failed if calibration did not complete properly Enter Continue 6 Press Enter to return to the Cash Acceptor calibration menu Test Cash Acceptors This function allows you to execute specific diagnostic tests on the cash acceptor The following functions can be performed nserting a bill and reading escrowing the bill if not rejected by the cash acceptor e Returning a bill from the escrow position Returning a bill from the escrow position and exiting Diagnostics Mode e Stacking a bill from the escrow position if a Test Cassette has been installed Note A second Test Cassette is necessary to stack bills during diagnostics mode The CRIND BIOS must see a set of cassette removed replaced events to allow bill stack testing Otherwise the stack bill option will not be provided from the Cash Acceptor Interactive Diagnostics Menu MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 103 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser 1 From the Cash Acceptor main menu press 6 The following screen appears Cash Acceptor Cash Acceptor Enabled 1 Run Diagnostics Side 1 2
210. e document Refer to the Gilbarco Online document resource GOLD for the latest update This section was last updated in August 2007 Topics in this Section Topic Page About this Section 7 1 General Service Procedures 7 3 Purging Air from the System 7 7 Measuring Flow Rates 7 11 Measuring Pressure and Vacuum 7 12 Measuring Vacuum Pump 7 17 Calibration 7 21 Filters and Strainers 7 22 Hanging Hardware 7 27 Manifolds 7 36 Meters 7 43 Pulsers 7 46 Pumping Device GDP 7 49 Pump Device Motor 7 56 Totalizers 7 58 Valves 7 99 Vapor Recovery Components 7 69 ATC Components 7 77 Section Overview This section supplies information on the hydraulic systems and fuel handling mechanical components contained within the Encore and Eclipse units This information includes specific safety information typical measuring procedures information on related components and common service procedures MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 1 Hydraulic Mechanical Components About this Section How to Use this Section Refer to the Topics in this Section on page 7 1 for a listing of topics contained in this section with its location At those locations are tables that list individual components Use this list to find information on a specific component Additionally the index and table of contents can be used to locate information Abbreviations and Acronyms Term Description ATC Automatic
211. e in the following table N represents an Encore unit first column of data C multi hose pump second column of data O represents 1 grade third column of data Refer to the following table to determine the model code on a Gilbarco pump or dispenser N X X Encore A Multi Hose Dispenser 0 1 Grade 1 2 Grade 2 3 Grade 3 4 Grade C Multi Hose Pump 0 1 Grade 1 2 Grade 2 3 Grade 3 4 Grade G Single Hose 0 3 Grade Dispenser 1 3 Grade 1 Dispenser 2 3 Grade Pump 3 3 Grade Pump 1 4 2 Grade Single Hose MPD 5 2 Grade Single Hose Pump J Multi Hose Blender 0 3 Grade Blender Dispenser 1 3 Grade Blender Pump 2 4 Grade Blender 1 Dispenser 3 4 Grade Blender 1 Pump L X 1 Blender 0 2 1 Grade Blender Dispenser 1 3 1 Grade Blender Dispenser 2 4 1 Grade Blender Dispenser 4 2 1 Grade Blender Pump 5 3 1 Grade Blender Pump 6 4 1 Grade Blender Pump N X 0 Blender 1 3 0 Grade Blender Dispenser 2 4 0 Grade Blender Dispenser 3 5 0 Grade Blender Dispenser 5 3 0 Grade Blender Pump 6 4 0 Grade Blender Pump 7 5 0 Grade Blender Pump P High Flow 1 Grade 3 Ultra Hi Master 4 Ultra Hi Combo 5 Ultra Hi Satellite 6 Ultra Hi Master Single Sided Dual Product 8 Ultra Hi Satellite Single Sided Dual Product R Special 0 No Hydraulics 1 Robot 2 Simulator 3 Pumpless Pump 4 No Electronics Page 1 6 MDE 3804B Encore an
212. e pressure if valve does not open easily Refer to shear valve manufacturer s instructions for proper tools and procedures Figure 7 42 Typical Shear Valve Linkage Open Closed Shear Valve Shear Valve MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Valves Hydraulic Mechanical Components Inspecting Shear Valves AN WARNING Always confirm proper operation of shear valve prior to performing hydraulic service that requires shear valve to be closed In some instances a shear valve may outwardly appear closed but could actually be open To inspect shear valves proceed as follows 1 Authorize hose at console as required 2 Lift operating handle 3 Place discharge nozzle in approved container 4 Squeeze nozzle operating lever If flow continues after several seconds valve 1s defective 5 Repair or replace valve 6 After testing place a few drops of SAE 10W motor oil or equivalent on valve body shaft Open and close valve by hand several times Place valve back in service Solenoid Valves Solenoid valves use a solenoid coil to open or close a valve Valves of this type are either fully open or closed Servicing is relatively simple consisting mainly of replacing the coil the valve body or the board supplying voltage to the valve Solenoid valves are usually associated with e VaporVac valves e Steering valves e Ultra Hi valves Rebuilding or Replacing Labor cost for your area may determine you
213. e vapor recovery system proceed as follows 1 Place the dispenser in standalone mode 2 Install a new or known good nozzle on the hose position in question 3 Install the nozzle testing tee from the K94123 Field Performance Test Kit by following the instructions in MDE 3022 Field Performance Test Kit K94123 for VaporVac Ensure that you use the 05 or 07 no flow insert in the testing tee 4 Hook up the pulse simulator box by following previous instructions in this manual MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 73 Hydraulic Mechanical Components Vapor Recovery Components 10 11 12 13 14 15 Page 7 74 Select the flow rate on the pulse simulator box that is closest to the actual dispenser site flow rate If the actual flow rate 1s not known set the pulse simulator box to 8 GPM Raise the nozzle hook to authorize the dispenser and then turn the pulse simulator box to the Run position Do not engage squeeze the nozzle lever Measure the vacuum level after 3 gallons have registered on the volume display of the dispenser Adjust the vacuum level by turning the slope trim pots R30 and R52 on the T18021 or 119401 VaporVac Controller board Turn Trim Pot Screw Clockwise increases vacuum level Counter Clockwise Decreases vacuum level The vacuum level should be adjusted as specified in the following chart The vacuum levels in this chart are only valid when using the
214. eads low and closed nozzle pressure is normal The open nozzle vacuum reads low or normal pressure reads high and closed nozzle pressure is normal The open nozzle vacuum reads low and pressure reads low closed nozzle vacuum reads low and closed nozzle pressure reads normal Surging or hesitation occurs Motor stalls or burns out Check valve sticking closed or partially closed Pumping unit strainer dirty Supply line obstructed or restricted Spring loaded check valve in supply line Storage tank air vent plugged Undersized supply line for unit Tank too far or too deep no further than 50 away and 10 deep Vapor lock Hose crushed Nozzle defective Meter binding Discharge piping obstructed Filter dirty Bypass valve defective or sticking Regulator or check relief valve defective or sticking Solenoid valve defective Belt slipping Pump operating below specified rpm rate Pumping unit parts worn Sump float valve malfunctioning Leak in supply line between tank and pump Relief valve stuck open Supply line check valve defective Leak in supply line that traps air High spots in supply line Relief valve sticking Motor defective Low voltage or defective wiring Debris in pump Broken pump elements MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Calibration Hydraulic Mechanical Components Calibration Read and follow all safety precautions as outlined in Read this First on
215. earing play e Cracks and so on Frayed belts or excessively worn belts Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Use OSHA Tag out and Lock out procedures AN WARNING iy Belts and pulleys can pinch fingers and hands d Injuries may result Avoid placing fingers or hands between belts and pulley P Never turn power on to fit belt on pulley Setting Belt Tension Tighter belt tensions can cause both pump and motor bearing wear and premature failures Loose belts result in low flow or pulley belt failures or noise Use the following rating 45 55 Ibs 200 240 Newtons Do not run motor to install belt Belt will be tight during assembly This is normal Some belts have arrows marked on them showing direction of rotation When replacing belts ensure that the arrow points in the direction of rotation Figure 7 35 Motor and Pump Pulley Assembly Motor and Drive Pulley Assembly Mounting Bolts GDP Unit Pump Cartridge Drive Pulley Adjuster Pulley Assembly Check Pulley Alignment MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 57 Hydraulic Mechanical Components Totalizers Totalizers Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Figure 7 36 El
216. ecovery Works 8 12 How a Digital Valve Works 0 0 00 ee eee 8 13 How a Proportional Control Valve PCV Works 8 14 How the Electronics Works for the Encore 300 8 16 CRIND Device 0 0 ce ee eens 8 17 How a TRIND Device Works 0 00 0 cc ee 8 18 How a Cash Acceptor Works 0000 cece eee eee 8 19 Howa Scanner WORKS 553 43 129 oo deine ea ded ey pened QUEUE Peleas 8 19 How Automatic Temperature Compensation ATC Works 8 20 UCET ete ae eel data dc E eae aay ae EE ged Mean tee ana Se 8 21 Encore 300 Error CodeS 2 0 A ee eee 8 21 Encore 500 and Eclipse Error Codes 0 00000 liuius 8 23 OT ERES 8 28 Common Failure Modes with Solutions llis 8 28 EECH T art mb etd eR de br ET Eee turo deiade AE te dx s qa 8 28 Hydraulic CGompofnenis 53 xar obc edes E Pda ce Bede cbe ds 8 29 Software Firmware 0 0 cc ers 8 29 Error Code Explanations 0 00 eee eee 8 30 Index 1 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Introduction Read this First Read this First Introduction Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of t
217. ectronic Totalizer Assembly Service Tips Encore and Eclipse totalizers can be set to operate per product inlet per unit or per side Programming of jump jacks is required to set functionality e Certain problems can be indicated by error codes Page 7 58 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Valves Hydraulic Mechanical Components Valves Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Contents in this Sub section Topic Page Check Valves at Manifold and Meter 7 58 Digital Valve T6 Proportional Control Valve 768 Shear Valves 7 66 Solenoid Valves 7 67 Steering Valves 7 68 Vapor Valve Vapor Vac 7 68 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly Flow control valves regulate the flow rate and blend ratio 1f applicable The Encore and Eclipse models may be outfitted with digital valves or PCVs These valves and manifolds are not interchangeable and must be used with specific components such as air gap plates manifold and electronics The proportional flow contr
218. ed nnnnnnnrn o UTUUUUUU IFSF AUXILIARYN 0 nnnnnnnrm TUUUUUUU O nnnnnnnn o UUUUUUUU C29 TOTO rw TIOIODOODOO TUTTO o TOTO TTT TTT nnnnnnnn o UUUUUUUU ASSY M00056A00 REV P1114 Grade 3 Pulsers Both Sides a o PI 109 LI nnnnnnnn UUUUUUUU C TOTO DOR DI PRO TITIO TATA o DIRECT CONNECT 8 JP5 and cc6 JP6 AAAA See hdd Service i ci Tips e COLDSTART a JP5 Made in U S A P CONTROL NODE oO Cl 6 r3 C18 C4 R20 T TUI o TIT noononon UUUUUUUU TOLL AA UUUUUUUU OPD ERMI qOpDI20O ATUS 4OP E LON TERM 4013 LONI NANO LAAN COUNT MANU C
219. ed and product is mapped Super Major 24 Volume unit type not set Major 26 Pump not calibrated Major 27 Two Wire ID changed side A Undefined 28 Two Wire ID changed side B Undefined 29 Valve Not Open Medium 30 Catastrophic error has occurred on the VaporVac Super Major 33 E stop button activated or VaporVac fail one side Medium 35 Configuration data error Medium 37 Pin code 1 changed Undefined 38 Pin code 2 changed Undefined 39 Cash Credit option changed Undefined 41 Side exists option changed Undefined 42 PPU option changed Undefined 44 PPU Board pump handle on at power up Medium MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 23 Theory of Operation and Troubleshooting Error Codes 4000 4999 Code Description Level 4307 Blends not programmed Super Major 4311 Blender Lo Octane Product Low Flow Minor 4312 Blender Hi Octane Product Low Flow Minor 4313 Blender Lo Octane Product No Flow Minor 4314 Blender Hi Octane Product No Flow Minor 4315 Blender Hi Octane Product contaminated by Lo Octane Minor 4316 Blender Lo Octane Product contaminated by Hi Octane Minor 4320 Valve configured for but not responding Super Major 4321 Valve stuck Super Major 4322 Valve board not responding Super Major 5000 5025 Code Description Level 5000 Meter 0 calibration changed Undefined 5001 Meter 1 calibration changed Undefined 5002 Meter 2 calibration changed Undefined 5003 Meter 3 calibration changed Unde
220. ed or old seals could result 1n subsequent leakage Note Use of Universal Seal Kits that contain proportional quantities of material types commonly replaced during service is recommended Inspect leaking seals for excessive swelling hardening softening and other degradation Clean and inspect sealing surfaces before replacing installing seals O Rings or gaskets Note Always use Gilbarco approved O Rings and gaskets Replace parts as needed Use a small amount of silicone grease to retain O Ring seals in position during assembly and to improve durability of dynamic seals MDE 3804B Encore and Eclipse Start up Service Manual August 2007 General Service Procedures Hydraulic Mechanical Components Pipes and Hydraulic Plumbing Read and follow all safety precautions as outlined in the Read this First on page 1 1 in this section and related sections of this manual Use OSHA Tag out and Lock out procedures To work on piping proceed as follows Only use UL approved pipe sealants suitable for the fuels involved for pipe threads as required Follow sealant manufacturer recommendations for use Note Avoid any sealants that will become hard over time Do not tighten or disturb joints where sealant has set Always clean and inspect pipe threads before applying sealant Do not apply sealant to dirty oily or wetted threads Do not apply sealant to the first two threads Do not use Teflon tape fragments will cause pump f
221. eering 6 Hose Fixed Blender Test Points Via Cable M00549A001 At Connector P1102 26 pin To Board M01922A001 or M00056A001 Pump Node Slowdown Valve and Main Valve 11 21 Slowdown Valve and Main Valve 13 4 23 Slowdown Valve and Main Valve 12 4 22 Slowdown Valve and Main Valve 14 24 M00044A001 Terminal Block PCA P1615 3 M00223B002 Steering Valve coils J701 Reference Figure 6 7 for location of test points all relays K1 K18 are installed The A001 board does not provide G4 and steering valve control As a result not all test points shown in Figure 6 7 are applicable Figure 6 7 Test Points on A002 Version HVXX or SVXX Legend H High S Slow V Valve First digit Side 1 A 2 B Second digit Grade 1 2 3 or 4 Digital Control Valve oe T ERING NEUT MV22 n MVI 2 Ds LAC VOLTAGE E Units Only iis in ee Pn 1 8 FERIA eoe CRED EGRNEE HERIYNEE GRADE Digital Control Valve Digital Control Valve Mv21 Sv21 MvII SVII O O GRADE nos aves Mos s 0 GRADES 7o 93 Neutral Steering Valve Side 2 Grade 3 STR5 Steering Valve Side 2 Grade 2 Page 6 14 MV24 Steering Valve Side 2 Grade 1 S
222. egulatory agencies 1 For above ground tanks a pressure regulator valve model 52 is used at the base of the unit Occasionally shear valves are used for this as well as other applications 2 Fuelenters through the pump inlet pipe passing through a strainer or strainer check valve located in the pumping unit 3 Maximum pressure is regulated by the bypass valve which recirculates fuel within the pumping unit 4 The pump has an air separation system built within the pumping unit 5 The sump separates air from the fuel prevents air return to the pump when sump fuel level is low and prevents air from passing through the nozzle and being metered when the underground tank is dry 6 Airseparated fuel flows back to the pump 7 Air free fuel flows out of the pump discharge line through a filter 8 Fuel then flows through the digital or proportional valve MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 5 Theory of Operation and Troubleshooting Theory of Operation 9 Fuel flows through a regulating check relief valve This valve keeps the meter full of fuel and helps relieve excessive pressure that could damage parts 10 The meter measures fuel flow 11 Fuelis discharged through the nozzle How a Master Satellite Ultra Hi Dispenser Works These models are for applications requiring higher flow rates A master meters product and controls the satellite This configuration can deliver up to 60 GPM
223. em The lithium battery on this board maintains level 1 and level 2 programming Figure 6 23 Pump Control Node 2 PCA P1120 Direct Connect P1104 LON Header 2 P1102 Valve Control P1111 PC Serial P1123 E cal P1122 Debug P1103 LON Header 1 PC SERIAL P CONTROL 14 AG pe MER PUNE vs E PIII VALVE CONTROL P1102 CRA E B cred E LJ e 4 e e e o wm R18 AE mE B LON PROGRAM 8 9 P4 PLD DB i e 5 P10 LON s DBG u JP borco MADE IN U S A PUMP CONTROL NODE 2 0727727727727 DECEDRUET EE IO Len LosLn LIL Of 4 C146 Co L1 mS c O C4 R62 C1 CX37 p42 ae R630 ocs 32 Wo Mel R69C3 CES R76 3987973 Tm TT Je p WD ENABLE es JPT B BAIT DISC p bd JP8 eee nO no fft ne wh eO eoo no no fh O00 10 0000 0000 B R810 CIR83 o R82C3 Cores 5 25V0C REV PULSER 3 PULSER PULSER 4 P1115 Grade 4 Pulsers P113 Grade 2 Pulsers P1112 Grade 1 Pulsers P1108 IFSF Auxiliary I O P1114 Grade 3 Pulsers MDE 3804B Encore and Eclipse Start up Service Manual August 2007 P1101 STP Control P1105 14 28V Power oo oF oo PIIIO VAPORVAC ISOLATION A cio N o R 0 R I O OR R250 CAR 6 TP1 to TP8 P1109 Pump 2 Wire D1 ON 2 Wire Reversed Status LEDs BT1 Lithium Battery 3 2V Q12674 01 P1110 VaporVac Isolation Page 6 53 Electronic and Electrical Components Board Connections and Cables Connector P
224. en e Discharge pilot valve opens energized This allows fuel to flow at about 1 2 GPM low flow when the nozzle opens Full flow The inlet pilot valve closes energized The discharge pilot valve opens energized Pressure in the control chamber drops Diaphragm piston assembly forced upwards by pressure in flow chamber Fuel flows at rate set by software and nozzle opening MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 13 Theory of Operation and Troubleshooting Theory of Operation Mode Operation Regulate The inlet pilot valve closes energized The discharge pilot valve is closed The discharge pilot valve is opened variably based upon software to accommodate blend ratios Control chamber pressure maintained at constant level Discharge flow for the involved valve continues or adjusts at a rate determined by software Power fail Inlet pilot valve opens Discharge pilot valve closes Diaphragm piston assembly seats closing main valve Equal pressure in two chambers holds the diaphragm against main valve seat No fuel flows How a Proportional Control Valve PCV Works The Proportional Control Valve PCV Figure 8 14 utilizes an analog signal to control flow while providing smooth and quiet operation Opening the pilot orifice causes pressure above the diaphragm to decrease so that the diaphragm lifts off the main valve seat This opens the main orifice until the valve is de e
225. ended to avoid damage to dispenser and to improve appearance Testing Hose and Hanging Hardware Continuity Perform an electrical continuity check when installing hoses after a drive off and for periodic preventive maintenance The STP check valve or pump regulating valve must maintain operating pressure to perform this test The following procedure tests the continuity of the hanging hardware that is hose nozzle swivel breakaway and hose casting AN WARNING Hanging hardware without the proper electrical continuity rating presents a risk of igniting fuel vapors Injuries or death may result if hose continuity is not maintained Use approved procedures to test for hanging hardware continuity Refer to PEI RP400 02 in addition to equipment and component manufacturer s instructions for additional information MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 31 Hydraulic Mechanical Components Hanging Hardware AN WARNING You are working in a potentially dangerous environment of flammable fuels vapors Fuel and its vapors may ignite leading to serious injury or death Fire explosion or electrical shock could result in severe injury or death if you do not follow safe procedures Ensure that you correct any safety hazards and barricade the area Follow manufacturer s instructions for the safe use operation and maintenance of the testing equipment Use only a low voltage digital ohmmeter D
226. ent refer to this information in the service manual and OSHA documentation Working With Electricity Safely Ensure that you use safe and established practices in working with electrical devices Poorly wired devices may cause a fire explosion or electrical shock Ensure that grounding connections are properly made Take care that sealing devices and compounds are in place Ensure that you do not to pinch wires when replacing covers Follow OSHA Lockout Tagout requirements Station employees and service contractors need to understand and comply with this program completely to ensure safety while the equipment is down Hazardous Materials Some materials present inside electronic enclosures may present a health hazard if not handled correctly Ensure that you clean hands after handling equipment Do not place any equipment in the mouth AX WARNING The pump dispenser contains a chemical known to the State of California to cause cancer A WARNING The pump dispenser contains a chemical known to the State of California to cause birth defects or other reproductive harm Page 2 2 In an Emergency Inform Emergency Personnel Compile the following information and inform emergency personnel Location of accident for example address front back of building and so on Nature of accident for example possible heart attack run over by car burns and so on Age of victim for example baby teenager middle age elderly
227. ent flow 2 8 9 Neutral Notes 1 Requires a 300 mA load to the appropriate neutral connection There should be current flow through the load and no more than a 1 4 Volt peak drop between P320 1 and the appropriate output 2 There should be 100 uA or less of current flow through the load MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M01564A001 Grade Select PCA Grade Select printed circuit board is used on the Encore 300 for grade select and pump preset option for units with 4 5 or 6 grade select options Figure 6 16 Grade Select Board M01564A001 If Programmable Pump Preset is installed connectors are installed here instead of P139A and P139B on M01598A001 Pump Controller PCA P135 Payment Select Switch ASSY M015644001 REV To Grade 4 5 and 6 Select Buttons on Side 2 M To Grade 4 5 and 6 Select Buttons on Side 1 Gilbarco Made in U S A P239B to CRIND P139C To Pump P239A To CRIND Keypad Side 2 Controller Keypad Side 1 Board Connections and Cables Connectorf Via Cable To Board AtConnectorff P135 12 pin M01695A001 Payment Select Membrane P136 4 pin Switches T19370 P139C 16 pin M01693A001 Pump Controller PCA P139A B 8 pin P239A 8 pin M01686A001 CRIND Keypad M00141B002 P902 Side 1 or 2 P239B 8 pin 12 pin MDE 3804B Encore and Eclipse Start up Service Manual August 2007 P
228. ents Vapor Recovery Components Contents in this Sub section Topic Page VaporVac Assemblies 7 69 Common Vapor Recovery Testing Procedures 7 70 Calibrating VaporVac 7 73 Returning VaporVac Pump Motor 7 75 ISD Vapor Flow Meter 7 75 Read and follow all safety precautions as outlined in Read this First on page 1 1 and related sections of this manual Consult your local regulatory agency for the proper test procedure AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly VaporVac Assemblies R19663 G1 and T17942 These assemblies mount in the upper piping housing of the unit on field retrofit units and in the hydraulics cabinet on factory built VaporVac units Retrofit units use R19663 G1 with attached connector Factory built units use T17942 The VaporVac motor driver board provides 36 50 VDC to operate the motor and 6 2 VDC for the sensors Figure 7 44 VaporVac Pump Motor Assembly 50000352 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 69 Hydraulic Mechanical Components Vapor Recovery Components Load Table Unit Load Singl sided 3A 120VAC Dual sided 5 A 120 VAC Wiring Wire Label Min Wire Number REF Color Lengt
229. ents in this Sub Section 0 0 0 00 cc ees 5 39 Software VersionS a na naaa aoaaa a ee eee 5 39 PIN Code BU oe orna ode Sor ed pde oa c hee UE sa too ci ea da ee di 5 39 Encore 5XX and Eclipse Programming Quick Reference llle 5 40 Encore 5XX and Eclipse Programming Instructions llle 5 41 Level One Command Codes 0000 cee eee 5 41 Level Two Command Codes 0 000 eee eee eee 5 48 Level Three Command Codes 00 eee eee eee 5 65 Enhanced Meter Calibration and Audit 0005 5 74 Standard Meter Calibration Procedure Pre V1 7 58 software 5 79 Level Four Command Codes 000 cece eee eee eae 5 88 Additional Manager Functions for Encore 5XX 1 eee ee 5 93 Unit Totals Retrieval Convention 0 000 cece eee eee 5 93 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser 5 94 AIMENT CT T eee a Ree Rhee Se ee Be 5 94 Activating the Encore 5XX CRIND Device 005 5 95 GRIND GOnDIOUFATIOEL s sorri men rar tx arare ton aen ee ar andy Boal gra a 5 95 Device Configuration llle 5 98 6 Electronic and Electrical Components 6 1 ADOUE TUS SECON ers coria n dat ea oh PCR Gema M mE ne Sache Eee A maio did aca een eee ee UE oe 6 1 Important Information about Releases sellus 6 1 Topics in this Section lt 3d aun ore ap CP E aa SUR tae se a dua eee Bes 6 1 Seclion OVerv
230. er Replacing the CRIND Receipt Printer Paper To replace the CRIND receipt printer paper proceed as follows 1 Remove paper roll core 2 Raise roller access cover and actuate printhead release lever 3 Remove paper from cutter and chute 4 Feed new paper into paper inlet until paper appears between roller bars 5 Align and feed paper through printer rollers until paper protrudes slightly past end of chute 6 Lower printhead release lever 7 Fully close roller access cover 8 Confirm proper installation by printing test receipts Note Certain models will automatically print a test receipt Otherwise use the diagnostic card to print a test receipt Figure 6 58 CRIND Device Receipt Printer Recommended Suppliers Supplier Part Number Fujitsu FTP 202PE011 64M NCR SLW690 Wallace 1146 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 109 Electronic and Electrical Components CRIND Devices Cleaning Printer Instructions Use printer cleaning cards Q13400 periodically to clean the printer Gilbarco recommends cleaning the printer every three months Cleaning the printer will eliminate most printing quality problems such as light or faint printing To clean the printer proceed as follows 1 Raise roller access cover and activate printhead release lever 2 Remove paper from printer 3 Insert a printer cleaning card Q13400 into the printer inlet and into the rollers 4 Close printhead release l
231. ess started Minor 5239 Database init forced Minor 5240 Database wrong read Minor 5240 Database read failed Minor 5240 Database wrong write Minor 5241 Database write failed Minor Page 8 26 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Error Codes Theory of Operation and Troubleshooting 5378 5647 Code Description Level 5378 Customer interface door node configuration not received Major 5413 PPU Option pump handle not connected correctly Medium 5600 Fuel density not programmed Super Major 5601 ATC temperature out of range Medium 5602 ATC node incorrect software version Minor 5603 Door node incorrect software version Minor 5604 Totalizer node incorrect software version Minor 5605 MIP node incorrect software version Minor 5606 ATC node subscription failed Super Major 5607 Door node subscription failed Super Major 5608 Totalizer node subscription failed Super Major 5612 TW converter error Minor 5613 Pump updated with data from door node storage Minor 5614 Door node A updated with data from pump node Minor 5616 Pump and door node storage match Minor 5647 Printer node current software version Undefined MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 27 Theory of Operation and Troubleshooting Troubleshooting Troubleshooting Common Failure Modes with Solutions This section presents some common failure issues in the field that can best be solved by performing the
232. ever 5 Manually advance the cleaning card through the roller bars by moving the gears on the side 6 Replace the paper roll and re install receipt paper as described in Replacing CRIND Receipt Printer Paper on page 6 109 Bar Code Scanner When interfaced with a POS system the Bar Code Scanner option allows customers to automatically authorize customer price discounts on CRIND device equipped units using a bar code tag Encore 300 uses existing T17764 XX CRIND Z 180 Logic Board For Encore 500 and Eclipse units the Scanner is controlled by a LON serial node per unit side The Encore 500 and Eclipse Bar Code Scanners use CRIND Basic Input Output System BIOS software version 2 0 30 or greater in order to operate properly The Encore 300 scanners require CRIND BIOS software version 60 7 20 or greater for generic dispensers and version 25 2 40 or greater for Major Oil Companies MOC A WARNING Laser light used in this product and may present an eye hazard during service Direct viewing of laser light may damage eyesight Avoid long term viewing of direct laser light Page 6 110 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical Components Figure 6 59 Bar Code Scanner Assembly M00969A001 Scanner Engine Interface Board M01323A001 Connector P1521 Figure 6 60 Advantage E300 Block Diagram TRIND Scanner Card Cage Card Read LEDs Scanner Interface B
233. f GILBARCO QA VEEDER ROOT Encore and Eclipse Start up Service Manual MDE 3804B Computer Programs and Documentation All Gilbarco Inc and or Veeder Root Company computer programs including software on diskettes and within memory chips and documentation are copyrighted by and shall remain the property of Gilbarco Inc and or Veeder Root Company Such computer programs and documents may also contain trade secret information The duplication disclosure modification or unauthorized use of computer programs or documentation is strictly prohibited unless otherwise licensed by Gilbarco Inc and or Veeder Root Company Federal Communications Commission FCC Warnin This equipment has been tested and found to comply with the Irmits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense Changes or modifications not expressly approved by the manufacturer could void the user s authority to operate this equipment A
234. fault XXX XXX 1 Press Function Code 2 then press ENTER 2 Select Position Parameter Option 1 4 3 Press ENTER to save setting Page 5 50 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Function Code 3 Set PPU Decimal Point Position for Calculations Canada Only The table below indicates locations where PPU calculation decimal point can be located Default PPU decimal point for calculations is position 4 1 Press Function Code 3 then press ENTER to access this Command Code 2 Select Position Parameter Option 1 4 then press ENTER Position Option Decimal Point Positions 1 XXXX 2 XXX X 3 XX XX 4 Default X XXX Function Code 4 Set PPU Decimal Point Position for Display The table below indicates where PPU display decimal point can be positioned Default PPU decimal point for display is position chosen in section 6 4 3 4 1 Press Function Code 4 then press ENTER to access this Command Code 2 Select Position Parameter Option 1 4 from the following table then press ENTER Position Option Decimal Point Positions 1 XXXX 2 XXX X 3 XX XX 4 Default X XXX Command Code 43 PPU Blinking options Command Code 43 is entered in Level 2 programming to set PPU blinking functionality This allows programmer to set PPU displays for blinking on and off under certain conditions On a single hose blender MPD
235. fers to pouring fuel into the piping to create liquid traps in any low points Balance vapor recovery systems are tested from the nozzle to the UST Vacuum assist systems such as VaporVac are tested from the riser at the base of the dispenser to the UST The allowable pressure drop for balance vapor recovery systems is listed in the actual test procedure The allowable pressure drop for vacuum assist systems is listed in the CARB Executive Orders Known Test Procedures Description CARB TP 201 4 Determination of Dynamic Pressure Performance of Vapor Recovery Systems of Dispensing Facilities San Diego County Pressure Drop vs Flow Liquid Blockage Test Procedure For Phase II Balance APCD TP 91 2 System Installations TNRCC TXP 103 1 Determination of Dynamic Pressure Performance Dynamic Back Pressure of Vapor Recovery Systems at Gasoline Dispensing Facilities Bay Area AQMD ST 27 Gasoline Dispensing Facility Dynamic Back Pressure Testing Leaks Pressure Decay Static Pressure This test evaluates the integrity of the vapor seals of the vapor recovery system components and connections and determines if there are any leaks The entire vapor recovery system is pressurized with nitrogen to a specified amount The pressure is then monitored over a specified period of time The maximum amount of pressure loss or decay is based upon the ullage or vapor space in the UST Known Test Procedures Description CARB TP 201 3 Determination of Static
236. fined 5004 Meter 4 calibration changed Undefined 5005 Meter 5 calibration changed Undefined 5006 Meter 6 calibration changed Undefined 5007 Meter 7 calibration changed Undefined 5008 Blend ratio changed for product 1 Undefined 5009 Blend ratio changed for product 2 Undefined 5010 Blend ratio changed for product 3 Undefined 5011 Blend ratio changed for product 4 Undefined 5012 Blend ratio changed for product 5 Undefined 5013 Blend ratio changed for product 6 Undefined 5014 Blend ratio changed for product 7 Undefined 5015 Blend ratio changed for product 8 Undefined 5016 Flow Control Setting changed per product 1 Undefined 5017 Flow Control Setting changed per product 2 Undefined 5018 Flow Control Setting changed per product 3 Undefined 5019 Flow Control Setting changed per product 4 Undefined 5020 Flow Control Setting changed per product 5 Undefined 5021 Flow Control Setting changed per product 6 Undefined 5022 Flow Control Setting changed per product 7 Undefined 5023 Flow Control Setting changed per product 8 Undefined 5024 ATC enabled Undefined 5025 ATC disabled Undefined Page 6 24 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Error Codes Theory of Operation and Troubleshooting 5026 5099 Code Description 5026 ATC base value changed Undefined 5027 Sealable switches have been accessed Undefined 5028 Measurement unit volume changed To Liters Undefined 5029 Measurement unit volume changed To Gallons Undefined 50
237. flow and stop at the preset amount Customer lowers pump handle The pump controller signals the hydraulic interface to remove power from the valves and STP or self contained pump motor to stop product flow The pump controller loads delivery amount into memory and sends this information to the console via the hydraulic interface and two wire circuit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation CRIND Device Theory of Operation and Troubleshooting The Card Reader In Dispenser CRIND device is a customer activated point of sale terminal located at the dispenser that accepts cash credit cards and debit cards It allows customers to activate the dispenser without help from station attendants It communicates with the site controller G SITE or Passport for MOC CRIND devices or third party controller for generic CRIND devices The site controller communicates with credit debit networks The CRIND device contains the following assemblies Keypad Customer display single line monochrome or color Receipt printer Magnetic stripe card reader Printed circuit boards Cash acceptor optional TRIND device optional Scanner optional Cold weather option kits Information in this section applies to CRIND devices in all Gilbarco dispensers unless otherwise noted The single line CRIND displays prompts and messages on a 14 segment 20 character single line display on the CRIND door
238. fluid level by removing the plug located at the right of the strainer cover and rotating the pump shaft counterclockwise approximately ten turns Note Removing the plug allows air to enter Remove the three strainer cover screws see Figure 7 32 Remove the strainer cover Inspect cover O Ring 18 for damage If damaged discard O Ring and replace with new O Ring Carefully pull out strainer 17 Keep strainer in a horizontal position to avoid contaminating pump with strainer debris It may be necessary to use a small tool to gently hook the inside of the metal strainer end cap If equipped remove the inlet check valve assembly 16 Inspect for cracked or otherwise damaged O Rings Replace if damaged Lift dome strainer 25 out from the bore located behind the check valve assembly Inspect strainer for damage Clean and replace if necessary MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Pumping Device GDP Hydraulic Mechanical Components Strainer Check Valve Installation To install the strainer check valve proceed as follows Note The numbers within parenthesis in the procedural steps below refer to the numbers in Figure 7 32 on page 7 52 1 Ifequipped with check valve option insert dome strainer 25 into bore 2 Clean debris from check valve especially at the O Ring seats 3 Lubricate O Ring before installing check valve assembly 4 Insert check valve assembly 16 or strainer support 30 into
239. for VaporVac Bay Area AQMD ST 39 Gasoline Dispensing Facilities Air Vapor to Liquid Volume Ratio San Diego County Vapor to Liquid Ratio at Gasoline Dispensing Facilities Using Vacuum Assist APCD TP 95 2 Systems Testing for Internal Leaks Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Consult your local regulatory agency for the proper test procedure Use this procedure to quickly test for leaks of fuel into the vapor area Use this procedure for service periodic tests and regulatory agencies To test the tank for internal leaks proceed as follows 1 Raise the nozzle hook dispenser handle to authorize the dispensers but do not dispense fuel 2 Observe the gallonage readout on the main display 3 Ifa slow and continual readout is noted while the nozzle is closed a leak may exist at the inner vapor hose or seals Calibrating VaporVac Before calibration ensure that the following has occurred e Visually inspect for leaks loose pipe connections and so on Use the K94123 Field Performance Test Kit to test the system e Verify that all hanging hardware for example hose nozzle and breakaway is in good working condition Calibrate the vapor recovery system if e A new vapor pump has been installed e The vacuum level is out of the acceptable range from testing with the field performance test kit and the pulse simulator box To calibrate th
240. ftware is not running This is normal during PCN software upgrade and during the first 15 20 seconds of startup Off solid is normal condition ON solid if 2 wire loop is reversed Blinking when sending data to the POS via P3105 Off when current is present but communications are idle On solid if no current is present e Blinking when receiving data from POS via P3110 Blinking when sending data to TRIND system via P3110 Blinking when receiving data from TRIND system via P3110 Blinking when sending data to service laptop via P3111 Blinking when receiving data from service laptop via P3111 Blinking when sending data to the pump via P3118 Off when current is present but communications are idle On solid if no current present e Blinking when receiving data from pump via P3118 Currently not used Currently not used Currently not used Currently not used Off solid is normal condition e On solid if CRIND MIP version is older than V02 0 00 of if Neuron is not communicating with the CPU Usually means MIP must be upgraded but sometime infers board failure On solid if USB link is established MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 47 Electronic and Electrical Components Page 6 48 Test Points Printed Circuit Assemblies and Nodes Test Point Value Where Used TP1 3 15 to 3 45 VDC Memory voltage TP2 47510525VDC Logic voltage TP3 35 VDC Display voltage TP4 Common fo
241. g Fluid must be properly contained during draining procedure 4 Pump contains up to 0 5 liters of fluid Do NOT use this port to monitor system pressure 5 If sump drainage is desired the plug near the mounting hole on the left side of the pump casing may be removed 6 Manually turn the pump pulley counterclockwise to aid in fluid removal 7 Properly dispose of all fluid drained from pump 8 After pump is drained replace all plugs using a non hardening pipe sealant suitable for type fluids being used Note Do NOT use teflon tape MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 51 Hydraulic Mechanical Components Pumping Device GDP Strainer Check Valve Service Page 7 52 Strainer Check Valve Removal Check valves if equipped should be replaced only if the pump is experiencing frequent loss of prime indicating that the check valve is not functioning Check valve should be installed when tank check valve is not available Always use strainers with or without check valves Strainer must be kept clean to ensure proper operation and pump life Figure 7 32 Strainer Check Valve Optional Dome Strainer 25 Optional Check Valve TON Screws 21 Strainer Support OF Strainer 17 Strainer Cover 19 O Ring 18 To remove the strainer check valve proceed as follows Note The numbers within parenthesis in the procedural steps below refer to the numbers in Figure 7 32 above Lower pump
242. g Gilbarco documentation Document Number Title GOLD Library MDE 2183 Warranty Form Domestic Warranty and Owner s Manuals MDE 2540 The Advantage Legacy and MPD Series Owner s Manual Advantage and Legacy Models MDE 2755 Gilbarco STP Control and Dispenser Isolation Relay Box Encore and Eclipse PA0287 The Advantage and Legacy Models MDE 3026 Standardized Service Coding Terminology Gilbarco Forms MDE 3802 Encore and Eclipse Site Preparation Site Preparation MDE 3860 Encore and Eclipse Programming Quick Reference Card Encore and Eclipse MDE 3985 Encore Installation Manual Encore and Eclipse MDE 3986 Eclipse Installation Manual Encore and Eclipse MDE 4226 Encore and Eclipse Installation Checklist Encore and Eclipse MDE 4227 Encore and Eclipse Start up Checklist Encore and Eclipse MDE 4228 Encore and Eclipse Commissioning Checklist Encore and Eclipse P 1362 Gilbarco Literature Guide Find a Document PT 1936 Encore Series Pump and Dispenser Illustrated Parts Encore and Eclipse Manual Parts Manual PT 1937 Encore and Eclipse Recommended Spare Parts Encore and Eclipse Parts Manual PT 1938 Eclipse Illustrated Parts Manual Encore and Eclipse Parts Manual HP100 90 PEI Recommended Practices for Underground Liquid N A Storage Systems Note In addition to these documents Gilbarco Product Service Bulletins PSBs and the monthly newsletter ASC Update are excellent sources of service information Page 1 2 MDE 3804B Encore and Eclipse S
243. g Mode of Operation 4 10 4 Blanking The Display Manually 4 11 6 Clearing Memory 4 12 7 Setting Totals Input Mode 4 12 9 Servicing the Battery 4 13 10 Configuring The System 4 14 4 19 12 Programming Pumps 4 20 13 Changing PIN Code 4 22 16 Programming Blend Ratios 4 22 17 Entering Conversion Factors Master Resets 4 23 19 Selecting Meter for Calibration 4 25 Command Code 59 System Cold Start 4 49 Compression Tube Fittings Torque Specifications 6 6 Configuration Data Error 35 Clearing 4 12 Configuring The System 4 14 4 19 Connectors Logic Boards 5 66 Conversion Factors Programming 4 24 Cut off Switch 1 7 Cylinder Covers Meter Bolts Torque Requirements 6 7 D Data Loop 4 20 see also Two Wire ID Decimal Points Setting Displays Calculated PPUs 4 15 Displayed PPU 4 15 Money 4 15 Decimal Comma Displays 4 16 Default PIN Codes 4 22 Discharge Pressure Testing on Dispensers 6 14 Display Conventions 4 5 Displaying Blend Ratios 4 25 Last Transaction DLT 4 25 Pump Totals 4 25 Volume Totals 4 19 Index 2 Displays Blanking Manually CC 4 For Modular Units 4 11 Calculated PPU Decimal Points 4 15 Decimals or Commas 4 16 Displayed PPU Decimal Points 4 15 Money Decimal Points 4 15 DLT Display Last Transaction 4 25 Doors Locks Maintenance 3 3 Draining Filters 6 24 Safety Information 1 7 Driver Boards T18015 VaporVac Valve 5 115 5 116 Drops In Pressure 6 15 Dynamic Back Press
244. ges product from the center chamber on the bottom of the meter This configuration reduces water and contaminants from building up in the meter thus resulting in longer meter life MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 43 Hydraulic Mechanical Components Meters Page 7 44 The C meter is electronically calibrated C meters for the Encore 300 are not shipped calibrated from factory and precise calibration must be performed at start up Encore 500 and Eclipse units built after December 2002 are shipped with initial factory calibration An error message is displayed if calibration at start up is not completed Meter calibration must always be verified at start up Figure 7 25 C Meter Date and Model Code Location Model Number Date Code Service Tips Purge air from the system before performing calibration Air in the system will affect accuracy of the calibration Refer to Purging Air from the System on page 7 7 for details Place the approved pan under the meter during repair to collect residual fuel Replacing the top quad ring requires use of a special tool that is included with the replacement seal kit This tool protects the new seal during installation over the drive pin cross hole in the shaft Usually it is not cost effective to rebuild a meter If the meter exhibits problems install a new meter Remove and replace the meter using metric tools Inspect all gaskets during off
245. gramming Command Code is always shown left justified in the main money display starting at digit position 6 Other display information is dependent upon specific programming Command Codes and Function Codes within the Command Code The flashing field on the LCD display is shown in large bold italic font example 2 Programming parameters are shown in LCD displays as soon as parameter selection key is pressed Selected parameters continue flashing until either ENTER or F2 is pressed Parameters are entered into the memory only after ENTER is pressed Locating Specific Programming Information Specific programming information related to product series begins on the following pages For Information on Go to Page Encore 300 Series Encore 300 Programming Pump Dispenser 5 8 Encore 5XX and Eclipse Series Programming Encore 5XX and Eclipse Series Units 5 39 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 5 Pump Programming About this Section Firmware Software Versions Encore 300 Firmware Versions Unit Type With Digital Valves With Proportional Valves MPD Dual Quad V20 X X V10 X X Single Hose MPD V22 X X V12 X X Single Blender V25 X X V15 X X Multi 6 Blender V27 X X V17 X X ATC Option ATC Controller V30 X X V30 X X Encore 5XX Firmware Versions Unit Type Version All V1 8 00 Programming Errors Page 5 6 If data entered Command Code Function Code Parameter is invalid data field w
246. gramming has been done time will default to 1200 Table below shows the display assignments for setting the time Main Volume Display HHMM 3 Set Dispenser Date Function Code 2 Date is programmed by entering month day and year in that order If no prior date has been programmed default date will be shown as 010100 January 1 2000 Table below shows the display assignments for setting the time Main Volume Display MMDDYY Command Code 62 2 Wire Remapping Grade Command Code 62 is used to remap grades of a blender 3 0 configuration onto 2 Wire protocol Configuration switches grades 2 and 3 of a 3 0 blender to 3 and 5 respectively Feature is set when dispenser is connected to POS system requiring different grade configuration Layout and digit position meaning for this programming feature is shown below Page 5 64 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 65 2 Wire Remapping Grade Grade Mapping 1 Enter 6 then 2 then press ENTER to access this Command Code 2 Use the following table to select grade mapping options Selection 340 Blender Grade Mapping 1 Default 2 Wire 1 2 3 2 Other POS System 1 3 5 3 Press ENTER Level Three Command Codes If using pump software V1 7 58 or Higher In this version of software the calibration mode is automatically entered when the Weights and Measures switch
247. gure 7 20 Configuration Manifold Location Configuration is stamped on casting OPEN configuration shown CLOSED and BLEND versions are also available MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 41 Hydraulic Mechanical Components Manifolds The following cutaways show the features of each type of configuration manifold Figure 7 22 Open Configuration Manifold Cutaway Outlet casting when used connects to this outlet on manifold The opening in the manifold allows fuel from all pipes to be channeled into one hose casting outlet Figure 7 23 Closed Configuration Manifold Cutaway Outlet casting when ax used connects to this outlet on manifold The closed off area in the manifold will not allow fuel from all pipes to be channeled into a single hose casting outlet Figure 7 24 Blend Configuration Manifold Cutaway Bores from this flange end are closed off from the other bores QT shown in this cutaway Outlet casting connection point The blend manifold allows fuel from two pipes to blend and be delivered to outlet casting Page 7 42 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Meters Hydraulic Mechanical Components Meters Read and follow all safety precautions as outlined in the Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub se
248. h Gauge Description 1 CHL Green 30 22 Hall Effect sensor 2 BHL Gray 30 22 Hall Effect sensor 3 AHL Yellow 30 22 Hall Effect sensor 4 PHL Orange 30 22 Hall Effect sensor 5 GHL Black 30 22 Hall Effect sensor 6 A WYE Blue 30 18 Power motor 7 B WYE White 30 18 Power motor 8 C WYE Brown 30 18 Power motor Vapor Valve Vapor valves mount in the upper piping housing assembly They are single stage solenoid valves that isolate all hoses not in use The VaporVac valve driver board supplies 120 VAC for operation Refer to Vapor Valve Vapor Vac on page 7 68 for additional information Common Vapor Recovery Testing Procedures This section contains tests that are frequently used for vapor recovery systems Ensure that you consult your local regulatory agency before performing any test on your vapor recovery system There may be three or four different procedures that exist for each test Only your local regulatory agency can inform you of their version provide you with a copy of the test procedure and provide you with the correct method of reporting test results Testing Air to Liquid A L Volume with a Pulse Simulator Box Note This test is not for certification Required materials e A L Test Kit K94255 Five gallon or larger prover can for changing failed nozzles e Standard and Phillips screwdriver e Allen wrench set e New spare nozzles to replace any that might fail e T19343 G1 Pulse simulator Page 7 70 MDE 3804B Enc
249. h installed PPU BOARD ASSY M00065 A00 REY Gilbarco MADE IN U S A LLL EE TETELE TL T LETLEE TEL TL TET Connector UU UU LU UU LU LU LET Proximity switch didi Q12514 10 PUMP HAN mcd e x UE TA l DOOR NODE LAMP PPU INTFC POWER This PCA M0065A001 is part of the display module assembly Not serviceable separately PPU Address Jumpers Addresses can be set for up to 6 grades Jumper Gradei Grade2 Grade3 Grade4 Grade5 Grade6 JO OUT IN OUT IN OUT IN J1 OUT OUT IN IN OUT OUT J2 OUT OUT OUT OUT IN IN MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 95 Electronic and Electrical Components Page 6 94 Board Connections and Cables Note Board and connections per grade Displays Main PPU CRIND Connector Via Cable To Board At Connector P2201 11 pin e M00509A001 or M00509A002 e M00095A001 CRIND P2101 Encore Auxiliary I O Board e M00509A003 Eclipse e M01785A001 Door P2202 5 pin M01152A001 or in line with cable Node 2 e M000062A001 Door Node 1 Pump Handle M00497A001 via J2202 P2202 See Note P2203 4 pin M00628A001 Note M00497A001 used only when single hose MPD hose is on left grade 1 or grade select button is on far right Grade Select Connector Pin Functions and Voltages P2201 Pin Description Input Output Voltage 1 AC IN 9 4 VAC 2 AC RET 3 GND OV 4 GND OV 5 PWR 5 V 5 V 5 6 CLK 0to5V 7 FEEDBACK 0t
250. hain Temporarily disconnect its LON cable and temporarily move the LON terminator to the node immediately upstream Others Temporarily bypass them with a LON jumper cable LON Power Problem A LON power problem can appear as pump power cycling off and on every 2 or 3 seconds or as the pump logic boards having no power Refer to the following If Then table If Then Pump power 1 Shut off power to the dispenser cycles off and on 2 Disconnect 5 pin P1402 connector to the pump or CRIND node every 2 to 3 3 Reapply power to dispenser If the power cycling stops the pump or CRIND node may seconds be defective If the cable goes to a car wash kiosk pin 3 on the cable might need to be omitted Note The cable to a car wash kiosk should have a 002 suffix all other CRIND cables should have a 001 suffix Pump logic 1 Disconnect 3 pin P607 connector from M02774 board boards haveno 2 Measure AC voltage between pins 1 and 3 on the cable connector If voltage across power CH17 is pins 1 and 3 is in 17 VAC and 35 VAC range the M02774 board may be defective If not lit voltage across pins 1 and 3 is not in 17 VAC and 35 VAC range the transformer on the M02274 power supply assembly may be defective 3 Disconnect 5 pin P1402 connector from M02774 board 4 Measure resistance across pins 1 and 5 on the cable connector If 800 ohms or more reconnect the cable to P1402 and power up the dispenser This procedure is over If under 800
251. he PPU in dollars but display the decimal point in cents for example for Canada You must program Function Code 3 before Function Code 4 if the displayed decimal point is different from the calculation decimal point For This Displayed PPU Decimal Point Press Configuration TEE LLLLLLLLLLLLLLLLLLOOCSSN XXXX 1 XXX X 2 XX XX 3 X XXX Default 4 Function Code 5 STP Prestart Use this function to program the STP to turn on after pump handle activation Turn this function ON for mechanical line leak detectors or OFF for most electrical line leak detectors To Program the STP Press Configuration ff 0 O On Default with pump handle activation 1 Function Code 6 Beeper and VaporVac Alarm Option Use this function to program the beeper to sound when you lift pump handles authorize the dispenser or press keypad switches The VaporVac alarm beeps until warm start occurs To Program the Beeper And the VaporVac Alarm Press Configuration _ Off Defa Of OQ On Off 1 Off On 2 On On 3 VaporVac alarm must be set to ON for units in Mexico MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 19 Pump Programming Encore 300 Programming and Data Access Instructions Function Code 7 Vapor Sense Option Automatically set to ON for units with VaporVac option To Program the Vapor Sense Option Press Configuration Off Default 0 On 1 Function Code 8 Two wire Display Blank O
252. he document Refer to the Gilbarco Online document resource GOLD for the latest update This section was last updated in August 2007 Purpose Sections of this manual combine to provide start up and service information for Encore and Eclipse series units This manual is a general service guide and not a replacement for Gilbarco certified training Certified training includes instructions regarding safety procedures use of test equipment and common tools wiring requirements and electrical service procedures This section contains a general introduction section service protocol safety and model number information Chapters in this manual cover the following topics Section Page Read this First 1 1 Important Safety Information 2 1 Start up and Commissioning 3 1 Preventive Maintenance and Inspection 4 1 Pump Programming S Electronic and Electrical Components 6 1 Hydraulic Mechanical Components 7 1 Theory of Operation and Troubleshooting 8 1 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 1 1 Read this First Introduction Topics in this Section Topic Page Introduction 1 1 Model Information 0 44 ModelCodes 1t 6 Ce Date Codes 0000000000000 dE Related Documents The following documents may be helpful when servicing Gilbarco equipment Refer to P 1362 for a complete list of available documents Contact the Literature Department 336 547 5661 for information regardin
253. his First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Before removing the filters proceed as follows 1 Close shear valve dispensers only Check operation of valve May require multiple shear valve closures For pumps turn off all power to the pump 2 Bleed pressure dispensers only Lift operating handle and authorize unit Place nozzle in approved container Close nozzle Turn off operating handle 3 Turn off associated STP circuit breakers dispensers only May require multiple STP disconnects 4 Turn off dispenser circuit breaker Turn off all power to the unit Removing Filters AN WARNING Servicing filters without properly turning off power and ensuring that the appropriate valves are closed may result in fuel discharge or spray Any involved STPs with power still applied can be energized from another unit resulting in fuel pressure in the product lines for the unit you are working on Pumping units with power applied could also be accidently energized You may not be able to retighten filter to stop fuel flow Fire and explosion could result in severe injury or death Ensure that you e Wear eye protection e Test and close the involved shear valves e Remove power to pump dispensers and any involved STPs e Remove parts slowly Collect fuel in approved containers Clean up all spills promptly MDE 3804B Encore and Eclipse Sta
254. ic and electro mechanical totals will increase as during a normal sale Note Use this calibration procedure for units with pump software prior to version V1 7 58 1 Prior to entering Command Code 78 the Weights and Measures switch must be turned ON See Figure 5 74 on page 5 74 2 On the Manager Keypad Figure 5 72 on page 5 72 press 1 3 Press 0128 then ENTER 4 Press 78 then ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 79 Pump Programming Encore 5XX and Eclipse Programming Instructions The following example shows Command Code 78 and unit side 1 Figure 5 80 Command Code 78 and Unit Side 1 5 Insert prover can size The default value is 0 It is necessary to enter a volume from 1 to 999 to proceed on to the next step In this example the prover can size 1s 20 US gallons Current volume unit is selected in CC71 and reported in the Unit Code field shown as 1 in the following example Figure 5 81 Current Volume Unit Reported in the Unit Code Field This reference table show the volume units and their codes Prover Can Volume Units Unit Codes No Units Programmed Default 0 U S Gallons 1 Liters 2 Imperial Gallons 3 Page 5 80 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 6 Press ENTER to accept the default or press 2 to select for side 2 Then insert the calibration side Defa
255. ication between higher level processors The CRIND device and pump nodes contain this kind of higher level processors Nodes Nodes contain intelligence a processor or neuron and connect to one or more peripheral boards Nodes communicate with each other over the LON See Note below RX Receiving data TX Transmitting data Watchdog Monitors and resets processor in the event of a system hang up Note In and out LON cable connection on nodes are not critical as there is no specific in or out Where a side s identity is critical the node involved will have an identifying jump jack so that the system can determine if it is related to side 1 or side 2 Page 6 2 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About Service Procedures Electronic and Electrical Components About Service Procedures AN WARNING You are performing inspections and maintenance in a potentially dangerous environment of flammable fuels vapors and high voltage Fire explosion or electrical shock could result in severe injury or death if you do not follow safe procedures Read and follow all safety precautions Working on Electronic and Electrical Components Explosive vapors or liquids may be present in and around fuel dispensing equipment that can be ignited by electrical arcs or static electricity discharges A potential shock hazard exists when working with this equipment Additionally static electricity discharges can damag
256. ice valve 6 Remove existing O Ring and discard 7 Remove spring from center of diaphragm piston assembly Spring is snapped onto center stem of diaphragm piston assembly 8 Remove diaphragm retainer ring 9 Retainer ring is not threaded it is pressed in place Removal may require use of channel lock pliers and a screwdriver to pry retainer ring loose Use tools carefully to avoid damage to digital valve body 10 Grasp outer edge of plastic piston cup with needle nose pliers and pull to remove diaphragm piston assembly Note Suction within digital valve body may cause resistance during removal Replacing Digital Valve Parts Follow kit instructions to install new parts Reverse disassembly procedure to reinstall existing parts Test for proper operation and leaks after rebuilding the valve Service Tips When servicing the diaphragm assembly ensure that diaphragm is positioned correctly on piston If necessary gently roll diaphragm over to follow path shown in Figure 7 39 Diaphragm may have unfolded during shipping Ensure that all parts are clean Introduction of contamination can cause faulty operation or premature failure of the valve Replace all parts as provided when rebuilding the valve as some parts have design enhancements Retainer ring is not threaded it is pressed in place Use tools carefully to avoid damage to digital valve body Page 7 62 MDE 3804B Encore and Eclipse Start up Service Manual August 2007
257. iled information on how the proportional control valve works refer to Theory of Operation and Troubleshooting on page 8 1 Some Potential Problems Excessive noise Error codes Leads external and bypass Preset overrun or underrun No flow or low flow Flow hesitation MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 63 Hydraulic Mechanical Components Valves Figure 7 40 Proportional Control Valve Assembly Manifold Coil Wires and Connector Proportional Control Valve i ZA a POV Coil and Conduit Assembly Mounting Bolts x3 Coil Retention Nut Service Steps Replacing Proportional Control Valve Assembly Determine 1f problem is with coil or valve assembly Only valve assembly service requires opening the fuel system The instructions below pertain to valve replacement This is usually done to solve problems with valve noise internal leaks bypass and flow problems Note Other components can cause similar symptoms To replace the proportional control valve assembly proceed as follows 1 Using approved containers absorbent materials and practices prepare for any residual fuel and pressure that may be in valve 2 For dispensers close the shear valves involved and verify proper operation 3 Remove power from the unit and any associated STPs at circuit breakers Follow OSHA Lock out and Tag out procedures 4 While being careful of any residual pressure and fuel spr
258. ill go blank for 2 seconds and a double beep will sound After 2 seconds Error Code 20 will be displayed General Programming Operation On pressing F1 dispenser will go offline and all main display LCDs will blank out and money display will show 8888 To begin programming you will need to enter a four digit Security PIN Code for the required security level As each digit of Security PIN Code is entered a dash will be displayed on main money display for that digit Once all security digits are entered press and release ENTER If Security PIN Code is accepted main money display will change to flashing 0000 Else money display will show flashing 8888 to indicate an invalid Security PIN Code Note To begin programming you must enter the four digit Security PIN Code If a valid Security PIN Code is entered user may then enter Command Code and proceed with dispenser programming as described in the sections that follow If an invalid Security PIN Code is entered user simply re keys the code and presses ENTER again Else user may press F2 to exit programming mode Upon valid Security PIN Code entry display will show 0000 until first digit of a Command Code is entered Upon entry of first digit display will blank out showing entered digit as flashing and left justified to position 6 As each new digit 1s entered digits flash and follow in positions 5 4 and so on When a complete Command Code is entered it will flash until ENTER is pres
259. in M01555A001 Softkeys Customer Keypad 12 pin P254 9 pin Card Reader 7 pin P255 4 pin M01668A002 harness T20306 G1 CRIND Regulator PCA J255 4 pin P257 30 pin M01668A001 Side 1 Printer Controller CN2 30 pin M01668A002 Side 2 P258 7 pin M01804A001 Side 2 CRIND Logic Board P258 7 pin TRIND Gateway Board J250 14 pin P262 6 pin M01650A001 harness 120306 G1 CRIND Regulator PCA cable harness Side 1 only P264 6 pin M01650A001 harness Encore 300 Electronics cable harness M01522A001 Single PPU Board M01621A001 Totalizer Interface PCA P266 8 pin M01668A001 Side 1 T20306 G1 CRIND Regulator PCA P569 8 pin Side 1 P268 30 pin M01668A002 Side 2 M01650A001 119501 G2 Monochrome CPU PCA Note Connectors not shown are not used at this time LED Indicators P570 8 pin B Side P2013 10 pin LED Status Indicates CHR11 On Indicates display circuit failure replace logic board Off 2 Normal operation CR22 Blinking 2 Receiving data from CPIB pump CR23 Blinking Sending data to CPIB pump CR24 Fast flash Receiving data from Cash Acceptor CR25 Fast flash 2 Sending data to Cash Acceptor CR28 Blinking Receiving data from CRIND InfoScreen or Monochrome CR29 Blinking Transmitting data to CRIND InfoScreen or Monochrome Test Points Test Points Voltages TP1 VRAM 3 to 3 5 VDC Power Off 5 VDC Power On Pa ABV Ts OGND Page 6 62 MDE 3804B Encore and Eclipse Start up Service Manual
260. in Valve B1 O 0 VAC 115 VAC 6 AC Neutral O 0 VAC 7 AC Neutral O 0 VAC 8 AC Neutral O 0 VAC 9 AC Neutral O 0 VAC P309B Connector Pin Functions and Voltages Pin Description l O Max Lo Min Hi 1 Slowdown Valve A2 O 0 VAC 115 VAC 2 Main Valve A2 O 0 VAC 115 VAC 3 Slowdown Valve B2 O 0 VAC 115 VAC 4 Main Valve B2 O 0 VAC 115 VAC 6 AC Neutral O 0 VAC 7 AC Neutral O 0 VAC 8 AC Neutral O 0 VAC 9 AC Neutral O 0 VAC Page 6 36 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M01549A001 Steering Valve Relay PCA This board is used only with 6 hose blenders on the Encore 300 It accepts 0 to 14 VDC levels that control solid state relays These relays turn the steering valves on and off Units manufactured after June 2002 will use M02097A001 M01549 and M02097 are electronically the same but are not interchangeable because of connector differences Figure 6 15 Steering Valve Relay Board M01549A001 P309C to Steering Valve coils Side 1 P P205A Md i nnnnanannnnsnj 1O F A A U g Y Y SET OOVEPSION ASSY P320 To Hydraulic Interface Board Board Connections and Cables P203A to Hydraulic Interface Board Y S N NI 3O0VA 1UODJON P309D To Steering Valve Coils Side 2 Connector Via Cable To Board At Connector P203A 10 pin M01694A001 M01546A001 Hydraulic Interface P206 10 pin PCA P309C 9 pin M016
261. ing manifold are three steering valves These valves ensure that only the selected hose is activated The valve is activated by the unit s electronics to open the appropriate chamber to direct the fuel Fuel enters steering manifold through the Low and High product lines Eclipse series units are not configured as a multi hose blender and therefore do not require a steering manifold Refer to Solenoid Valves on page 7 67 for more information Page 7 36 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Manifolds Hydraulic Mechanical Components Figure 7 18 Steering Valve Manifold in Multi hose Blender Steering Manifold M00223AXXX Steering Manifold M00223AXXX Figure 7 19 Steering Manifold Components Steering Manifold M00223AXXX Solenoid Coil MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 39 Hydraulic Mechanical Components Manifolds Service Tips The main problems that you will notice with the steering valve manifold are leaks at the connection points and valve seals coil related problems and no flow with certain products Ensure that filters and stainers are in place Non use of filters and strainers can cause this and other valves to fail For additional information on seal problems refer to Servicing Seals O Rings and Gaskets on page 7 4 Configuration Manifold The configuration manifold channels fuel to the proper hose o
262. ing the site paying particular attention to instructions and notes Additional information is supplied to further define some areas and to explain how the Installation Checklist MDE 4226 Figure 3 1 on page 3 3 the Start up Checklist MDE 4227 Figure 3 2 on page 3 4 and the Commissioning Checklist MDE 4228 Figure 3 3 on page 3 5 are related The commissioning ASC should have previously read and understood the latest versions of MDE 3804 Encore and Eclipse Service manual MDE 3985 Encore Installation Manual MDE 3986 Eclipse Installation Manual and MDE 3802 the Encore and Eclipse Site Preparation Manual prior to performing any commissioning The commissioning ASC should read and be very familiar with the required checks and instructions as outlined under MDE 4226 Form A Installation Checklist and MDE 4227 Form B Start up Checklist It will be necessary for the commissioner to clearly explain to the station manager or representative the nature of problems uncovered in the checklists and the implications of not correcting them In MDE 4228 Encore Eclipse Commissioning Checklist under Model Serial Numbers there are check boxes for the commissioner to record whether he she has obtained Form A and Form B for each unit being commissioned The checklists are to be left in the electronics cabinet of each individual dispenser by the installing contractor and the start up ASC The commissioner should obtain these forms and keep a copy of each as ou
263. ings Fire and explosion could result in severe injury or death Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers Clean up all spills promptly About Vacuum Readings Use vacuum readings to determine if the unit has the ability to move product from the storage tank to the pump Inability to pull a vacuum may also indicate that air 1s entering the system Use vacuum gauges that read in inches of mercury scale 0 30 Hg Figure 7 8 Vacuum Gauge Typical Vacuum Gauge Dial MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 17 Hydraulic Mechanical Components Measuring Vacuum Pump Measuring Dry Vacuum for Pump Page 7 16 Use this test to determine priming ability of a self contained pumping unit only run test if priming problems exist Ensure that you follow all safety precautions Figure 7 9 Vacuum Gauge Port on GDP Vacuum Test Port 1 Blackmer GDP Unit E e y Vacuum Gauge and f Extenuation Pipe E To measure dry vacuum for the pump proceed as follows Remove power from the unit Multiple disconnects may be required Use OSHA Lock out and Tag out procedures Drain Blackmer Global Dispenser Pump GDP unit of all fuel Use an approved container Refer to Draining the GDP on page 7 50 for details Clean up any spills promptly Plug the pumping unit inlet Use a flat rubber disc between the union halves or use a pi
264. ings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly About Purging System Properly purging air from the hydraulic system is an important service step Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and in related sections Use OSHA Lock out and Tag out procedures Failure to properly purge air from the system can damage components and result in inaccurate calibration and fuel delivery Purge air from the system for new installations or whenever fluid containing parts of the hydraulic system are serviced Purging Product Lines Dispenser In any situation where air may have accumulated or been introduced into the product lines of the dispensers it must be purged before purging the dispenser Using the appropriate connections and with a hose connected to the shear valve test port purge the product lines until a steady stream of fuel is observed Check for leaks as you move toward the tank Close shear valve test port with the appropriate plug and move on to purging air from the unit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 7 Hydraulic Mechanical Components Purging Air from the System 10 11 Figure 7 1 Typical Shear Valve and Test Port Test Port To purge product lines proceed as follows Turn
265. ins 3 and 4 of P1403 are presently not used In future 24 V board M00053 may be powered through these pins instead of through a dedicated transformer secondary MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 75 Electronic and Electrical Components Power Supplies M00053A002 Power Supply Board 24 VDC F1 Replaceable fuse for P3502B and P3503B connector circuits See Note at the bottom right corner TP1 TP2 Page 6 76 On the Encore 500 and Eclipse series units there are two 24 VDC power circuits on this board capable of supplying power to printers barcode scanners and or cash acceptors LEDs are present on the board to indicate output for each side of this board Board will shut down with a power fault from the 18 VDC power supply board M00050A001 This board has been obsoleted by the M02274A001 Power Supply These parts are not interchangeable Figure 6 33 Power Supply Board M00053A002 Shut Down from 18 VDC Power Supply Board M00050A001 TP3 Fi 24V AOWER SUPPLY rd FROM 24V CAP MEER GND CI TP4 nN lt CR 7 Green LED 24 VDC for all Printers Cash Acceptors CR 3 Green LED CR 8 Green LED F2 replaceable fuse for P3502A and P3503A connector circuits See Note at bottom right IDE Hic T ES CA un oO x co L 24v A SIDE c aA o c eM ce kee lt O e oO a Pi ma lt Ny cS u ND n al m m5 Status LEDs AS
266. ion OFF Else calibration mode cannot be exited Command Code 80 Set Maximum Flow Rate Option allows user to select maximum flow rate allowed per Grade If flow rate value entered is larger than hydraulics maximum capable flow rate maximum hydraulic flow rate will flow Default value flow rate is 10 Gallons Per Minute GPM per Grade for US and 40 Liters Per Minute LPM per Grade for Europe This function only works properly with proportional flow control valves It does not work properly with digital valves The table below shows available options for this Function Code Selection Option 1or2 Side 1 6 Grade 01 98 Flow units per minute grade MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 85 Pump Programming Encore 5XX and Eclipse Programming Instructions Layout and meaning of each digit position for this programming feature is shown below Figure 5 92 Layout and Digit Position for the Programming Feature 1 Onthe Manager Keypad press 8 then 0 then ENTER 2 Select Side 1 or 2 then press ENTER 3 Select Grade 1 to 6 then press ENTER 4 Select Flow Rate 01 to 98 Default 2 10 then press ENTER Command Code 82 Setting Prover Can Size Command Code 82 is used with pump software version V1 7 58 and higher Prover can size is set to default to a preset number based on the type of volume units entered Refer to the following table for those defaults Command Code 82 is use
267. ion and Troubleshooting Flow Rate Restrictors Each site s configuration has a number of restrictors that may affect flow rate Figure 8 2 shows a typical site and its possible restrictors Figure 8 2 Possible Flow Rate Restrictors Single Satellite N N Casting Ne Y Ee Shear Valve Fittings 7 N Ec ee NI ge de LLL Product Line Single Mast le Master E 1 E al Hose Casting A f 7 Breakaway ENG d a Underground Storage Tank Eo Gud Combo ea Hose uu Swivel ES 7 i a A gi Valve The following table identifies the possible restrictions in Figure 8 2 that may affect the site s flow rate Possible Restrictions Reason for Restriction Hose casting Breakaway Nozzle Swivel Hose Shear valve Dispenser model Fittings Pipes STP Check valves Underground tank Other flow considerations Optional in line flow restrictors to limit maximum flow rate MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Size and type of hose casting Type and number of breakaways Type of nozzle Type of swivel Size and length of hose Size and type of shear valve Type of dispenser that is High vs Ultra Hi vs Super Hi master satellite combo pump vs dispenser and so on Number of fittings Size and length of pipe run Horsepower and output of STP Number of valves Burial depth Number of units dispensi
268. ion obtained should be recorded on a data sheet The selected flow rate setting from the pulse simulator box 6 8 or 10 GPM e The actual liquid volume registered The final value on the mechanical totalizer or frequency counter for the air volume meter Calculate the A L value for the fueling position that was tested Refer to CARB Executive Order G 70 150 AD for the VaporVac system Verify that the dispenser flow rate and A L value are within the acceptable limits specified If the A L values are within the acceptable limits the vapor recovery system is operating properly and testing should be concluded for that hose position If the A L values are not within the acceptable limits it will be necessary to troubleshoot and possibly calibrate the system MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 71 Hydraulic Mechanical Components Vapor Recovery Components Page 7 72 Testing Pressure Drops Dynamic Back Pressure This test measures the pressure drop or resistance in the vapor recovery piping from the dispenser to the UST Nitrogen is forced through the vapor recovery piping at various flow rates while the back pressure or resistance is measured with pressure gauges There are two basic versions of this test Version 1 is called the dry test Dry refers to testing the piping as is and assumes there is no fuel in the piping to create a liquid trap Version 2 is called the wet test Wet re
269. ioning ASC Name ASC Tech Number Signature NOTE This is a two part form Top original Keep for your records Second sheet Give to station manager MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 3 5 Start up and Commissioning Sample Install Start up and Commissioning Forms This page is intentionally left blank Page 3 6 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Preventive Maintenance and Inspection 4 Preventive Maintenance and Inspection About this Section Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section was last updated in August 2007 Purpose This section provides information on preventive maintenance and associated inspections Section Overview Preventive maintenance is essential to prevent unexpected downtime of units The Suggested Maintenance Chart on page 4 2 provides maintenance recommendations The Sample Maintenance Checklist on page 4 4 shows a sample of MDE 2856 Site Survey Preventive Maintenance Checklist a valuable tool for recording site configuration information and tracking preventive m
270. ions Note Refer to MDE 2540 The Advantage Legacy and MPD Series Owners Manual for determining software versions P Indicates Audit Trail Mode Blend Changes from eo Dispenser P 101010 Blend Chan ged from Console voat 0101016 lt 1 28 PPU Display Shows the Current Price Figure 5 28 Advantage Audit Trail Display Newer SW Versions Note Refer to MDE 2540 The Advantage Legacy and MPD Series Owners Manual for determining software versions Counts Blend Change Mode PI 01010151 Vol I0l0l2l6 44 Total Blend Changes ag Configuration Changes PPU Displays Low Grade Page 5 32 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Additional Manager Functions for Encore 300 Pump Programming Figure 5 29 Encore Eclipse Audit Trail Display Press Enter First Time P Indicates Audit Trail Mode Counts Blend Change p Mode P 10 vol 3 straton changes 10075 so 25 0 Low Grade Figure 5 30 Encore Eclipse Audit Trail Display Press Enter Second Time P Indicates Audit Trail Mode Y Counts Blend Change P lo Configuration Changes vol 1 13 Sucre Number of Days Since Last Calibration Figure 5 31 Encore Eclipse Audit Trail Display Press Enter Third Time P Indicates Audit Trail Mode i Counts Blend Change Mode P 0 Configuration Changes Gallon or vol 11
271. ions 6 7 Sensing Vapor Programming 4 16 Service Procedures Testing Pressures 6 13 Servicing The Battery CC 9 4 13 Set Dispenser Date Function Code 2 4 50 Set Dispenser Time Function Code 1 4 50 Side Exists Programming 4 20 Signalling Pump Time Outs 4 17 Single Dual Pulsers Programming 4 17 Single Sided Units Programming 4 20 Six Digit Cash Programming 4 18 Slowdown Programming 4 17 Software Versions 4 27 Spare Parts 1 2 Split Island Operation 4 20 Standalone Mode of Operation Selecting 4 10 Index 4 Static Pressure Testing 6 71 Stop Control Programming 4 18 STP Pressure Testing Dispensers 6 14 Pumps 6 13 STPs Activating on Transactions 4 19 Activation 4 15 Prestarts 4 15 Safety Information 1 7 Switches Grade Select 4 11 System Configuring 4 14 4 19 T T18015 VaporVac Valve Driver Board 5 115 5 116 T19501 Monochrome CPU Board 5 56 5 68 Tag Out Requirements see OSHA Lock Out Tag Out Safety Requirements Technical Assistance Requesting 1 2 Telephone Numbers Important 1 2 Tension Pump Belts 6 57 Test Points T19501 5 69 Testing Air to Liquid A L Volume 6 69 Discharge Pressure 6 14 Dynamic Back Pressure 6 70 For Leaks 3 2 6 71 6 72 Inlet Pressure 6 14 Internal Pressure 6 14 IS Barriers 6 46 Lamps 4 18 Pressure Decay 6 71 Pressure Drops 6 15 6 70 Pressures 6 13 6 14 Pulsers 6 46 Self Contained Pumps 6 15 Vapor Recovery System Performance 6 71 The Advantage Series Conversion Factors
272. ired for assembly Do not remove the plastic shield over the display Order Display Module M02636A001 for service Figure 6 50 Monochrome Display Assembly M01653A001 Display Module M02636A001 Encore 300 Jump Jac Video Jump Jack J5 2 pin Backlight Power J1 34 pin Board Connections and Cables Connector Via Cable To Board At Connector J1 84 pin M00553A001 CRIND Control Node M01753A001 P1302 for Side 1 P1303 for Side 2 J5 2 pin R02778 G1 to 24 V Power Supply PCA M02774A001 P3502A M00517A005 Jump Jacks Jumper Setting Function J3 A Normal image J3 B Image rotated 180 degrees inverted Connector Pin Functions and Voltages J1 34 pin Data Interface pin assignment not available J5 2 pin Pin Description Input Output Voltage 1 Backlight power 24 V Regulated 2 Ground Backlight power supply MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 101 Electronic and Electrical Components CRIND Devices CRIND Device Card Reader Page 6 102 Production of the Single Head Card Reader was discontinued in January 2002 Use kit M02139K00X to replace Refer to PI 1936 Encore Illustrated Parts Manual The Dual Head Card Reader option provides two magnetic heads located at the top of the card reader and directly opposite each other This provides the capability for reading the card from either side as long as the magnetic strip is facing up Enc
273. is her signature MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Sample Install Start up and Commissioning Forms Start up and Commissioning Sample Install Start up and Commissioning Forms Figure 3 1 Sample Installation Checklist MDE 4226 f GILBARCO aA VEEDER ROOT MDE 4226B Encore Eclipse Installation Checklist Form A May 2006 Site and Installer Information SITE INFORMATION INSTALLER INFORMATION Site Name Number Company Address City State Zip City State Zip INSTRUCTIONS Complete this checklist for each pump dispenser Information regarding Station Electrical need only be completed on one pump dispenser form After completing the form leave the original in the pump dispenser cabinet away from wiring or circuit boards Keep the copy for your records IMPORTANT NOTE This checklist does not include all requirements for a safe or proper installation of a pump dispenser Included however are certain checks for some of the more important items and items occasionally missed during installation The installer must read and completely follow the installation manual for equipment installation Individual Pump Dispenser Hydraulic Mechanical Related Where required shear valves nsalledpermanufacrrinsiuatios EUN N NE Ex 1771 77007 C RR RR 5 Hose breakaways installed per code and manufacturerrecommendatons O OOOO 6 Allhanging hardware is UL or equivalent d CARB certifie
274. is installed on Pins 2 3 PCN and CCN communicate via PC serial interface not available at this time JP6 Not populated also part of PCN to CCN serial interface f JJ is installed on Pins 1 2 pump is set for 2 wire or PC serial without a Clear to send handshaking capability e If JJ is installed on Pins 2 3 PC serial communications is set to use the Clear to send handshaking signal Test Points Test Point Range Where Used TP1 3 15 to 3 45 V Memory Voltage TP2 4 75 to 5 25 V Logic Voltage TP3 3 0 to 3 6 V Battery Battery TP4 GND Common for DC Voltage TP5 17 5 to 28 V LON Voltage TP6 2 0 to 3 6 V RAM Voltage Page 6 26 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes LEDs LED COLOR Electronic and Electrical Components Status Indication RED D1 YELLOW YELLOW D10 D11 D12 D13 D14 D15 D16 D17 Heartbeat should blink at 1 per second TX SmartPad Side 1 RX SmartPad Side 1 TX SmartPad Side 2 RX SmartPad Side 2 LON 1 Terminator LON 2 Terminator LON Neuron Service ON or blinking indicates problem POS 2 Wire reversed if ON POS 2 Wire TX TRIND RX TRIND TX PC Serial RX PC Serial TX Pump 2 Wire RX Pump 2 Wire MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 27 Electronic and Electrical Components Printed Circuit Assemblies and Nodes M00092A001 Monochrome Interface PCA M00092A001
275. is replaced incorrectly Replace with only the battery manufacturer s instructions Service Tips The Coldstart jumper does work for this board A true Coldstart can be done using the diagnostic card and accessing the Clean Persistent Memory function e This board must be used with a Monochrome Interface board CRIND MIP software must be loaded through the pump node The CRIND node uses three types of software CRIND MIP CRIND Node and CRIND application from Point of Sale POS software MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 23 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Figure 6 10 CRIND Control Node M00089A001 P3103 Auxiliary for IFSF and Ethernet Not Used P3104 Auxiliary Touchscreen P3101 SmartPad Side 2 P3106 18V LON P3102 SmartPad Side 1 P3105 CRIND POS 2 Wire P3105 lana cri D9 a UWJuUJguuu Power nnnnnnnn mumUuUuuuu
276. isplays Main PPU CRIND Electronic and Electrical Components M02659A009 Satellite Indicator Display Module for Encore 300 and 500 The satellite indicator display module is mounted in the Encore Ultra Hi Master or master side of a satellite master combo unit on Encore 300 Ultra Hi and Encore 500 Ultra Hi units This display indicates that the nozzle boot handle has been lifted on the satellite unit that 1s connected by product piping and wiring with that master Figure 6 46 Satellite Indicator Display M02652A009 CR1 to CR8 are Display LEDs Board Connections and Cables Connector Via Cable To Board At Connector P121 2 pin M02371A001 Transformer sub assembly M02370A001 JSEC MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 97 Electronic and Electrical Components CRIND Devices CRIND Devices The following table lists the content in this sub section Topic Page About CRIND Devices and Options 6 98 Single ine CRIND Display T20379 698 Monochrome Display E300and500 1 1 699 CRIND Device Card Reader 6402 Cash Acceptor 6 103 CRIND Printer Module 6406 Bar Code Scanner 6 110 About CRIND Devices and Options The Card Reader In Dispenser CRIND device is a customer activated POS device located at or near the dispenser The CRIND device allows customers to activate dispensers and pay for fuel and merchandise without help from the station attendants The CRIND device can be set up to
277. it position for this programming feature is shown below Figure 5 69 Volume Totals Display a NIZ 7 Pump Grade Side Selection et Volume Volume Volume Volume Volume EM O bep b 1 Enter 7 then 4 then press ENTER to access this Command Code 2 Select Side 1 2 and then press ENTER 3 Select grade 1 6 up to 8 for blenders and then press ENTER 4 Setor Display Total 5 Press ENTER Page 5 68 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Command Code 75 Set Fuel Density ATC and VaporVac Only Allows programmer to set density of fuel to be dispensed under ATC Values can be set to 730 for gasoline and 840 for diesel fuel Only the number of meters that exist sensed by dispenser controller software are shown Once in this mode meters can be cycled by repeatedly pressing ENTER Layout and meaning of each digit position for this programming feature is shown below Figure 5 70 Setting the Fuel Density 7 5 Pump Meter Side v _ N _ V Code PRU o mmm 1 Enter 7 then 5 then press ENTER to access this Command Code 2 Select side 1 2 then press ENTER to accept side 3 Select meter the press ENTER to accept meter 4 Select density 1 or 2 Density Codes Fuel Density 1 gasoline Default 730 2 diesel 840 5 Press ENTER to accept density The table below shows the allowed fuel
278. ithout vapor M01776A006 M01775A002 valves Encore 500 115 VAC 60Hz without vapor M01776A003 M00080A001 M01775A001 valves e 18018 G1 220 VAC 50 Hz without vapor M01776A005 T19401 2 M01775A002 valves MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 115 Electronic and Electrical Components VaporVac Electrical Components M00080 VaporVac Isolation PCA The VaporVac Isolation Printed Circuit Board is used to interface the VaporVac system with the pump node Figure 6 65 VaporVac Isolation Board Gilbarco Made in U S A F1 2 A Fuse Q13173 108 R amp 1 C rm 9 Jump Jack JP1 All Units NOON de DUTT e Vv CoO c200 R64 C220 R54 L1 LE TET TET TT UOTE P1403 VAPORVAC POWER PUMP CONTROL NODE RIAL INTERLOCK UNREG P O CR4 Side 1 P1405 P1402 P1406 P1401 CRe GRS Side2 Active Power Active Board Connections and Cables Connector Via Cable To Board At Connector P1401 4 pin R19672 G1 118018 VaporVac Motor P1005 4 pin Drive PCA P1403 4 pin R19665 G1 T19401 VaporVac Controller P1103 Interface P1404 20 pin R17995 G4 em P1104 20 pin P1405 26 pin M00549A002 Encore MO00056A001 Pump Control
279. its without factory installed or factory kit junction boxes only Conduits iptoWlectroNysCabinet are potted and no unfilled openings exist between the electronics cabinet and the lower piping area a m En v 4 Minimum wire gauges meet Gilbarco field wiring diagram specificatio Aken dispenser entry Po All wiring is stranded gas and oil resistant per installation insguctAN KtNernet and DSL cables meet requirements per installation instructions o DW EM Units with junction boxes have all junction box covers and all bolts installed EE Encore 500 Eclipse only Check software versions and record versions above If not latest production released versions install download from laptop BEEN computer and generate a separate SR by calling Gilbarco Call Center 1 888 800 7498 Station Requirements including training for station manager supervisor S E O O O O ES LC iti M ee E Reviewed for Encore 500 Eclipse V 1 8 00 and later software units security procedures for station approval of programming access by service technicians Po NENNEN 2 NENNEN B KEEN Advised station manager that nondefault PIN access codes are to be installed as part of commissioning to enhance security after explaining security benefits and that lost code additional service labor will not be covered by warranty If station refuses to allow nondefault PIN codes to be used do not modify codes and do not check box to right will not invalidate wa
280. k 1 Good Reads count of card insertions with good track 1 data Track 1 Bad Reads count of card insertions with bad track 1 data Track 2 Good Reads count of card insertions with good track 2 data Track 2 Bad Reads count of card insertions with bad track 2 data Track 3 Good Reads count of card insertions with good track 3 data Track 3 Bad Reads count of card insertions with bad track 3 data Total Reads count of all card insertions with at least some valid data on at least one track Total Reads Without Data count of card insertions with no valid data present 2 Press Enter to toggle between Side 1 and Side 2 card reader counts screens 3 Press Cancel to exit back to the Card Reader Menu Page 5 108 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming Reset Card Counts This function allows the technician to reset card reader counts independently for each side of the unit 1 From the Card Reader Menu press 2 The following screen appears Card Reader 1 Reset Counts Side 1 2 Reset Counts Side 2 Cancel Exit 2 To reset the card reader counts for Side 1 press 1 To reset the card reader counts for Side 2 press 2 The following screen appears Card Reader Card counts reset This screen appears for several seconds then the Card Reader reset menu displays 3 Press Cancel to return to the
281. key to retrieve money totals for each fuel grade This and the VOL TOTAL key do not require a Security PIN Code Use the CLEAR key to exit money totals mode The 1 shown in the leftmost display indicates that this total is a non resettable money total The VOL TOTAL displays the volume for the grade selected Volume for both sides of the unit can be viewed Use the CLEAR key to exit the volume total mode This convention comes from the Advantage series product line and is maintained here for ASC and site manager familiarity MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 93 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Menu Tree The following diagram shows the options that are available from the Main Menu Main Menu 1 CRIND Config 2 Device Config 3 Networking Config 4 Totals Reports 5 Data Storage CRIND Confi 1 CRIND IDs 2 CRIND Mode 3 Generic BAUD Rate 4 Force BIOS Cold Start 5 Force App Cold Start Device Config Display Settings Audio Setting Cash Acceptor TRIND Card Reader Printer Barcode Scanner Keypad Oo 0o0 amp onNv Data Storage 1 Flash File system 2 Persistent Storage Feature supported for Kiosk only at this time Page 5 94 MDE 3804B Encore and CRIND IDs 1 CRIND ID Side 1 2 CRIND ID Side 2 CRIND M
282. l as the nozzle opening state One pilot controls fuel flow into and out of the control chamber thereby raising or lowering pressure in relation to the flow chamber The other pilot valve bypasses flow through the valve during slow flow times such as during the pulser test and just before hitting a preset target The valve 1s biased via a spring to maintain a back pressure of 2 5 PSI When control chamber pressure is equal to or higher than flow chamber pressure the valve closes and fuel flow stops When control chamber pressure is lower than flow chamber pressure the valve opens Figure 8 13 Digital Valve Components zc Control chamber Electromagnetic 3 a CSS Discharge pilot valve S 7 gt actuation coils Diaphragm Discharge pilot Inlet pilot valve Inlet pilot valve valve Fuel from manifold Fuel port to inlet LA A LA pilot valve Ce 77 Valve open Inlet pre re Fuel to meter t pressu Valve closed Piston Flow chamber The following table describes how the valve operates in various modes Mode Operation Valve at rest The inlet pilot valve is open maintaining pressure in control chamber unpowered The discharge pilot valve is closed preventing loss of pressure in control chamber Diaphragm piston assembly is seated closing main valve Equal pressure in the two chambers holds the diaphragm against main valve seat No fuel flows when the nozzle opens Slow flow Inlet pilot valve is op
283. l for binding MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 47 Hydraulic Mechanical Components Pulsers Page 7 48 Service Tips During shipment T18350 G6 pulsers are restrained by a tie wrap and should be removed during installation If a tie wrap 1s discovered on the pulser during service it should be removed A tie wrap left in place can result in binding of the pulser shaft Inconsistent communication with the M00453A001 pulser will usually indicate a defective pulser if the unit had been programmed and calibrated properly Event Logs can be used to pinpoint a specific pulser while troubleshooting pulser errors such as 20 5047 5049 and 5050 Pulsers locations are designated by ePulserX Refer to the following table to determine the location of the pulser Pulser Name Signifies This Side Of Unit At This Product Pulser ePulser1 1 1 ePulser2 1 2 ePulser3 1 3 ePulser4 1 4 ePulser5 2 1 ePulser6 2 2 ePulser7 2 3 ePulser8 2 4 Pulser Fail SB1470 Error code 20 pulser fail has been enhanced to further aid troubleshooting The software has been modified to display only the pulsers affected by the error code in the PPU displays The error code can now also be cleared by just lowering the pump handle Previously error code 20 would display in all PPU displays and a warmstart was required to clear the error code Pulser Rotation Error SB1451 The M04012B001 pulser currently learns its correct
284. l safety precautions Frequency of filter changes will depend on fuel and installation cleanliness Corroded tanks poor quality fuel and initial conversion to alcohol enhanced fuels may require more frequent filter changes and strainer cleanings Refer to MDE 3893 Encore and Eclipse Owners manual for detailed instructions and MDE 4516 Encore S Series Owner s Manual Once a week or upon complaint Once a week or after drive offs Once a month or upon complaint or drive off occurrence One month or 50 000 gallons after new installs Every 300 000 gallons or six months thereafter Once a month or as needed MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Preventive Maintenance Checklists Preventive Maintenance and Inspection Item Wax units Stainless steel sheathing and lower doors Door locks Meters Nozzles hooks shafts Pumps pulleys belts and belt tension Shear valves CRIND Card Reader CRIND Printer Display Backlight bulbs and Eclipse ad panel bulbs Displays Underground piping for sites using VaporVac system Inspection Procedure Refer to MDE 3893 Encore and Eclipse Owners manual for detailed instructions and MDE 4516 Encore S Series Owner s Manual For stains on stainless steel use a cleaner specifically formulated for cleaning stainless steel Gilbarco recommends Barkeepers Friend Ensure to thoroughly rinse off the cleaner Do not spray water c
285. l speed discharge pressure must NOT exceed 50 PSI 3 5 Bar with any discharge restriction fully open to fully close discharge If the pressure exceeds 50 PSI 3 5 Bar see Figure 7 33 on page 7 54 Pressure Control Valve Adjustment PCVs must be set to the desired single hose operation pressure A retaining ring must be in place at all times during pressure control valve adjustment A WARNING Not using a retaining ring can release hazardous pressure that can cause personal injury or property damage Always ensure that the retaining ring is in place before adjusting the PCV Take appropriate safety precautions If not personal injury or property damage may occur To set the PCV operation pressure proceed as follows 1 To increase the pressure setting turn the PCV cover 13 inward or clockwise using a 16 mm socket wrench See Figure 7 33 on page 7 54 2 To decrease the pressure setting turn the PCV cover 13 outward or counterclockwise using a 16 mm socket wrench MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 55 Hydraulic Mechanical Components Pump Device Motor Pump Device Motor Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Contents in this Sub section Topic Page About Electric Motor for Self Contained Pump Units 7 56 Belts and Pulleys 7 57
286. laced incorrectly or damaged Excessive buzzing Error codes Leaks internal bypass and external Coil activation handle switch if bracket is not used Preset overrun underrun No or low flow Very cold weather leaks solved by using a special valve kit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 61 Hydraulic Mechanical Components Valves Service Steps Disassembling Digital Valve Determine if problem is with coil or valve assembly Only valve assembly service requires opening the fuel system The instructions below pertain to diaphragm replacement This is usually done to solve problems with valve noise internal leaks bypass and flow problems Depending upon labor rates in your area it may be less expensive to replace as opposed to rebuilding the valve Note Other components can cause similar symptoms To disassemble the digital valve proceed as follows 1 Using approved containers absorbent materials and practices prepare for any residual fuel and pressure that may be in valve 2 Close shear valves involved and verify proper operation dispensers only 3 Remove power from the unit and any associated STPs at circuit breakers Follow OSHA Lock out and Tag out procedures 4 While being careful of any residual pressure and fuel spray slowly remove three Hex bolts from diaphragm assembly cover and remove cover Wear eye protection Save cover and bolts 5 Use Gilbarco kit K96621 to serv
287. le hook to accommodate various manufacturer s manuals Notify site personnel and secure the work area Isolate dispensing unit from point of sale or pump controller and close shear valves Follow all safety precautions Tools Required to Modify Nozzle Boot e Drill e 7 32 or 22 drill bit e 1 4 inch square tip driver e 7 mm metric Hex nut driver or socket e 3 8 inch nut driver or socket VAN WARNING AC or battery powered drills must not be used at the dispensing unit There exists a danger of explosion or fire due to the presence of hazardous vapors MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 33 Hydraulic Mechanical Components Hanging Hardware Removing Existing Nozzle Boot To remove the existing nozzle boot proceed as follows 1 Remove nozzle s from nozzle boot s and place on ground 2 Loosen two nozzle boot mounting screws and remove boot from dispenser by pulling it towards you see Figure 7 15 using 1 4 inch square tip driver Save nozzle boot mounting screws to be reused Figure 7 15 Nozzle Boot Mounting Screws Save Standard Nozzle Hook Location A and D are Nozzle Boot Identifying Marks 3 Place nozzle boot face down on the soft cloth to protect the nozzle boot face 4 See Figure 7 15 to identify existing nozzle hook retaining screw and nut locations Identifying marks are located under right hand row of indented hole locations Standard nozzle hook locations are A and
288. leaner directly at or into card readers cash acceptors or printer chutes Lubricate with a good grade of lock oil Check calibration and calibrate if needed See About Calibrating Meters on page 6 21 Check operation Clean and lubricate with silicone grease if necessary Inspect belts for fraying cracks Inspect pulleys for excessive wear in grooves and excessive bearing play There should be no more than one inch of play on either side of the belt See Belts and Pulleys on page 6 57 Check valve operation and lubricate See Shear Valves on page 6 66 Clean card reader using cleaner card Q11482 Clean print head using Q13400 printer cleaning card Inspect for bad bulbs and replace as necessary Inspect and repair as required Perform a static pressure decay test See page 6 70 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Frequency Once a month in harsh environments or every six months Once every three months once a month in harsh environments Every six months Once a week or upon complaint Every three months or upon complaint Once a month Once a week or upon complaint Once a year Page 4 3 Preventive Maintenance and Inspection Sample Maintenance Checklist Q GILBARCO VEEDER ROOT Customer s Name Store Sample Maintenance Checklist SITE INSPECTION PREVENTIVE MAINTENANCE CHECKLIST
289. lectrical hazards MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Important Safety Information Hazards and Actions Spilled fuels accidents involving pumps dispensers or uncontrolled fuel flow create a serious hazard Fire or explosion may result causing serious injury or death Follow established emergency procedures The following actions are recommended regarding these hazards Pa Q e ae o e Collision of a Vehicle with Unit Fire at Island Fuel Spill Do not go near a fuel spill or allow anyone else in the area Use station EMERGENCY CUTOFF immediately Turn off all system circuit breakers to the island s Do not use console E STOP ALL STOP and PUMP STOP to shut off power These keys do not remove AC power and do not always stop product flow Take precautions to avoid igniting fuel Do not allow starting of vehicles in the area Do not allow open flames smoking or power tools in the area Do not expose yourself to hazardous conditions such as fire spilled fuel or exposed wiring Call emergency numbers MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 2 3 Important Safety Information This page is intentionally left blank Page 2 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Start up and Commissioning 3 Start up and Commissioning About this Section Gilbarco requires
290. les disables for VaporVac 1 Grade Side 2 For units with VaporVac only P105 Connector Pin Functions and Voltages Pin Description O Max Lo Min Hi 1 Slowdown Valve A1 1 00 VDC 3 50 VDC 2 Main Valve B3 1 00 VDC 3 50 VDC 3 Slowdown Valve A2 1 00 VDC 3 50 VDC MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Pin o o NI OJ o gt MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Description Main Valve B2 Slowdown Valve A3 Main Valve B1 Slowdown Valve B3 Main Valve A2 Slowdown Valve B2 Main Valve A3 Slowdown Valve B1 Pump Handle B2 Pump Handle B3 Pulser Data A3 Pump Handle B1 Pulser Data A3 Pulser Data A2 Pump Handle A3 Pulser Data A2 Pump Handle A2 Pulser Data A1 Pump Handle A1 Pulser Data A1 Pulser Data B2 Pulser Data B2 Beeper A Pulser Data B1 Pulser Data B3 Pulser Data B1 Pulser Data B3 STP 1 Main Valve A1 STP2 STP3 I O OO O O OLO O O Electronic and Electrical Components Max Lo 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC 0 10 VDC 20 uA 1 00 VDC 0 10 VDC 20 uA 0 10 VDC 20 pA 1 00 VDC 0 10 VDC 20 uA 1 00 VDC 0 10 VDC 20 uA 1 00 VDC 0 10 VDC 20 uA 0 10 VDC 20 pA 0 10 VDC 20 uA 1 00 VDC 0 10 VDC 20 uA 0 10 VDC 20 uA 0 10 VDC 20 pA 0 10 VDC 20 pA 1 00 VDC 1 00 VDC 1 00 VDC 1 00 VDC Min Hi 3 50
291. lied junction box on Side 1 The stub up for this box is located on Side 2 of the unit Junction boxes must be secured to the dispenser s frame Junction box retrofit kits are typically installed when existing station wiring is adapted to an Encore unit Refer to MDE 4084 Junction Box Retrofit Kit Installation Manual for more information Check conduit routing through the air gap for compliance no unsealed holes are allowed in the air gap plates Refer to MDE 3985 Encore Installation Manual and MDE 3986 Eclipse Installation Manual for specific information on junction boxes Encore Series Junction Box Figure 6 62 Junction Box in Encore Dispenser Gap Plate Main Conduit Lower Air Gap Plate Junction Box MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 113 Electronic and Electrical Components Junction Boxes Figure 6 63 Junction Box in Encore pump Lower Air Gap Plate SEN NK dl Lower Inlet Support Rail not visible in this view y a L 6 SN i Aft d Ca MU Ae A wn IK A e D CY A cn Al i manaj 4 i mann 1 maan A I L Wy Y I A N Y W b Eri iy MAN A Iia zu Junction Box S00015
292. lipse Start up Service Manual August 2007 Page 5 115 Pump Programming 6 7 Page 5 116 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Barcode Scanner Scanner Enabled 1 Code 128 Enabled 2 UCC EAN 128 Enabled 3 Interleaved 2 of 5 Enabled 0 Next Screen Page 3 3 Enter Save Values and Exit Cancel Discard Changes and Exit To configure the settings proceed as follows Press 1 to enable disable the ability for a Code 128 EAN 13 barcode format to be detected and reported by the scanner Press 2 to enable disable the ability for a UCC EAN 128 Code 39 barcode format to be detected and reported by the scanner Press 3 to enable disable the ability for a Interleaved 2 of 5 Code 128 barcode format to be detected and reported by the scanner Press 0 to proceed to the next screen The following screen appears Barcode Scanner Scanner Enabled 1 UCC EAN 128 Enabled 2 Interleaved 2 of 5 Enabled 0 Next Screen Page 4 4 Enter Save Values and Exit Cancel Discard Changes and Exit Use the following instructions to configure the settings Press 1 to enable disable the ability for an UCC EAN 128 barcode format to be detected and reported by the scanner Press 2 to enable disable the ability for Interleaved 2 of 5 barcode formats to be detected and reported by the scanner To save changes and exit press Enter To exit without saving changes press Cancel Send POS Settings to Scanner Use
293. lipse Start up Service Manual August 2007 Page 8 7 Theory of Operation and Troubleshooting Theory of Operation How Truck Stops are Configured Figure 8 7 Figure 8 8 on page 9 Figure 8 9 on page 9 and Figure 8 10 on page 10 show sample master satellite combo configurations for use at truck stops Figure 8 7 Truck Stop Configuration Single Master with Remote Satellite Single Single Satellite master u 1 EI vi E uw E E E E ut length and diameter of hose Consider Consider distance between STP and units Fuel Type A Consider horsepower of STP motor Page 8 8 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting Figure 8 8 Truck Stop Configuration Dual Master Single Satellite Single Satellite Dual Master Consider distance between STP and units length and diameter of hose Fuel Type A Consider horsepower of STP motor Figure 8 9 Truck Stop Configuration Dual Satellite Single Dual Single Satellite Satellite Satellite Consider Consider distance between STP and units length and diameter of hose Fuel Type A Fuel Type A Consider horsepower of STP motor MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 9 Theory of Operation and Troubleshooting Theory of Operation Figure 8 10 Truck Stop Configuration Combo Single Single Satellite Master
294. lipse The Encore 300 printer is not interchangeable with the Encore 500 and Eclipse printer Page 6 106 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical Components Service Tips Printer and circuit boards are only replaceable as a unit Paper size and type are critical for proper printer operation Paper that does not conform may shorten printer life and cause service problems such as jams and poor print quality See the following table for recommended suppliers Use Printer Cleaning Card part number Q13400 when print quality 1s poor Intermittent cable connections can cause printer problems Ensure that cable connections are secure and tight The anti static brush bristles under the roller access cover must touch the paper lightly to prevent paper jams Paper jams may occur if the roller access cover is not closed completely Printer chute kits are available for printers manufactured prior to March 2003 that have jamming problems Figure 6 55 CRIND Printer Assembly Module Encore 300 Node Housing in Encore Position n Roller Access Cover Date Code 1 Label S Lift up Access Cover Lift by Tab housing Near Flush at Paper Holder for Encore MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 107 Electronic and Electrical Components CRIND Devices Figure 6 56 CRIND Printer Assembly Module Eclipse
295. lled by a Wayne Nucleus or NCR POS MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 29 Theory of Operation and Troubleshooting Troubleshooting Error Code Explanations Page 6 30 31 and 35 for Encore 300 SB1478 Error Code 31 Totals Data Error Error Code 35 Configuration Data Error Error code 31 and 35 cannot be removed by a warm start or a cold start master reset Troubleshoot the error in the following order Record all totals Perform Command Code 6 Function Code 1 through Manager Keypad Note A Command Code 6 works only if error code 31 or 35 occurs Re program the unit re enter previous totals Check for loose cables Investigate other problem possibilities if error code 31 or 35 reappears again later Error code 31 or 35 can be caused by various problems noise a bad controller board loose cables bad controller board battery and so on Always perform Command Code 6 first before warm starting cold starting or replacing any parts Refer to Command Code 6 Clearing Memory on page 5 14 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Index Index A A L Air to Liquid Volume Testing 6 69 Activating STPs 4 15 4 19 Addresses External CRIND 5 67 Addresses see IDs Air to Liquid A L Volume Testing With Pulse Simulator Box 6 69 Alarm VaporVac 4 15 ALL STOP Button 1 7 Allocation Limit Programming CC 3 4 10 Annunciator see Beepe
296. m About this Section Sample Install Start up and issioning Important Information about Releases 00000 eee Topics In this SecllOfi o n 2hcehecc dete ee heen eee oes Certificate of Conformance Numbers 000 0c eee eens Commissioning InstructionS 0 0 0 ccc eee Commissioning FONTS 24 5 0 3 a nies diodes baler odes eti we A 4 Preventive Maintenance and Inspection About this Section Important Information about Releases llis PUIDOSC 1d pd drop do E rd eos 78 Ucet M EAS SO ue Ma dodo eee dee qi Section OVEIVIEW oIa i em 3 ea ui D Rh eR ea E VP E Howto Usethis SECON usse kn abd es Rr ae A ROCCO EUER TOPICS IN INIS SCCUON cea adc oa sada od eee ah at at aor c ACA cee Preventive Maintenance Checklists l eee ee eee eee eee ee eee ee eens Suggested Maintenance Chart 0 0 00 eee Sample Maintenance Checklist 0 0 nannan anaana ee eee eee ee eens 5 Pump Programming About this Section Important Information about Releases 0002005 TODICSHMINIS SECUON sa pretio de van ee eds iom E TETUR aan ace rn General Programming Information l l eee eee Display Conventions 3 3 x plbqe E OI Gee S EQ Peu p dent Locating Specific Programming Information Firmware Software Versions 0 0 00 cee eee eee eee Programming EMOS Seca tere ab cem Dedi cence Gt etic A gn Roel es MDE 380
297. m the M02774 board to the affected device If you find a bad connection fix the problem If you are still not able to locate the source of the problem verify the voltages with respect to ground TP2 at test points TP1 and TP3 Note The 24 VDC power connection is made on any of P3502A P3502B P3503A and or P3503B CR18 is not lit Either the M02774 board is bad or the transformer part of the M02274 power supply assembly feeding the 24 VDC section of the M02774 board is bad Measure AC voltage across pins 3 and 4 on connector P606 The voltage should be in the 30 VAC to 40 VAC range If not in that range suspect the transformer If in that range suspect the M02774 board MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Displays Main PPU CRIND Electronic and Electrical Components Displays Main PPU CRIND The components in this sub section is grouped first by type model and then description Display Type Model Description Page Main and PPU Encore 300 M01515A001 Main Display for Encore 300 6 86 M02652A003 and A004 PPU Single Display Module for 6 89 Encore 300 M02652A007 and A008 PPU Dual Display Module for 6 90 Encore 300 Encore 300 and M02659A009 Satellite Indicator Display Module for Encore 6 97 Encore 500 300 and 500 Encore 500 and M01785A001 Main Display for Encore 500 and Eclipse 6 92 Eclipse M02652A001 and A002 PPU Single Display Module for 6 93 Encore 500 and Eclipse M02652A005
298. me Prior to this enhancement the technician had to run a verification test to determine if re calibration was required and run through the calibration process if the meter needed re calibration If the technician or Weights and Measures official is checking calibration then 5 gallons 20 liters are dispensed into the prover can stopping at the zero mark on the can Compare the prover can size and the displayed amount and use the appropriate set of instructions Main Display and Prover Can Match If the pump displays the amount in the can plus or minus one cubic inch then that meter is within tolerance and you can move to the next meter Main Display and Prover Can do not Acceptably Match 1 STOP Do not lower the pump handle or replace the nozzle at this time but continue on to the following procedures 2 Cut the seal wire on the calibration switch and switch to the ON position wait for confirmation 2 beeps and then switch back to the OFF position and wait for confirmation 2 beeps 3 After lowering the pump handle or replacing the nozzle the money display will flash PPPPPP and the volume display will show the volume in the prover can for 2 seconds before saving the new calibration value in storage Note The display then returns to the transaction value that was displayed before the calibration procedure was performed MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 77 Pump Programming En
299. meter changes Refer to MDE 3139 Automatic Temperature Compensation ATC Troubleshooting Information in The Advantage and Legacy library on GOLD Page 6 20 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Error Codes Theory of Operation and Troubleshooting Error Codes Encore 300 Error Codes 20 44 Code Description 20 Pulser Fail 21 Non existent memory 22 Not used 23 Grade assignment changed 24 Conversion Factor Changed Not programmed 25 Two Wire Stand Alone changed 26 No conversion factor table 27 Side A Two Wire ID changed 28 Side B Two Wire ID changed 29 Pump Time Out error 30 VaporVac fail both sides or Vapor Sense 31 Totals data error 32 Pulser count error 33 VaporVac fail both or Push To Start button activated 34 Battery charge low 35 Configuration data error 36 Unit type configuration code changed 37 PIN Code 1 changed 38 PIN Code 2 changed 39 Cash Credit Option changed 40 Master Reset jumper in place 41 Side Exists option changed 42 PPU Option changed 43 Not used 44 Pump handle on at power up MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 21 Theory of Operation and Troubleshooting Page 6 22 4301 4329 Blend Error Codes Code Description 4301 Communication Time Out 4302 Blend Controller busy 4303 Communication limit 4304 Communication limit 4305 Received Data Error 4306 Received Block Error 4307 Blends not
300. meters in a fuel dispenser Software Basic unit component operational instructions downloaded from a laptop or other source and stored within the dispenser Side 1 Indicates the electrical access side of the dispenser The Manager Keypad is accessed from Side 1 of the dispenser Volume Display A six digit display that during normal operation shows the total volume of product dispensed VUT Volume Unit Type Liters or US gallons Warm Start Accomplished by powering down the dispenser and repowering and exiting programming modes Resets the unit processors Programming Mode Dispenser programming mode can only be entered when both sides of dispenser are in an idle mode Nozzles must be in nozzle boots and no grade select buttons can be pressed Dispenser programming results in unit being placed offline with regard to external communications To start programming the dispenser press F1 on the Manager Keypad The following sub sections describe general dispenser operation while in the programming mode Programming Levels There are three basic programming levels associated with the Encore 300 and four programming levels with Encore 5XX units and Eclipse For Encore 5XX entry into a security level allows use of all the programming features within that security level and below For Encore 300 entry into a security level allows use of all of the programming features within that security level and not below Thus if the configuration Level 4 Se
301. mpleting calibration the Weights and Measures switch must be sealed per local authority All replacement meters must be calibrated after installation and testing Install the updated software to take advantage of the enhancements MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 73 Pump Programming Encore 5XX and Eclipse Programming Instructions Figure 5 74 Weights and Measures Switch E Cal switch ae ON P With switch moved to the left LT m Off position this cover can slide Note Secure seal wire tightly to B down and two holes at top line prohibit tampering up Insert seal wire through these holes and apply seal Seal and Seal Wire pply Cover Enhanced Meter Calibration and Audit Pump software V 1 7 58 for Encore 5XX and Eclipse with C meters contains enhancements to simplify C meter calibration and provides the capability for Weights and Measures audit trail It is no longer necessary to run a separate verification process to determine if meter was previously calibrated and then run a calibration process if so required IMPORTANT INFORMATION To ensure accuracy for pump software V1 7 58 and higher it is Very Important that the filling of the prover be accurate and within 1 cubic inch of the zero reading If the calibrator fails to stop flow within this limit then the calibration process must be repeated For more information refer
302. n Canada only ATC Mapping ATC temperature probes are mapped to meters in the Encore hydraulics as shown in the following diagram and table MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 77 Figure 7 49 Meter Mapping Diagram Hydraulic Mechanical Components MANIFOLD 4 PULSER o METER 8 METER 4 o PULSER PULSER O METER 7 METER 3 o PULSER ATC Components MANIFOLD 2 PULSER 6 METER 6 METER 2 PULSER PULSER o METER 5 METER 1 o PULSER SERIAL PLATE Product Inlet Side 1 Meter No Side 2 Meter No 1 W 1 2 2 X 5 6 3 Y 4 3 4 Z 8 7 Blend Product W and X 1 and 5 2 and 6 Programming ATC ATC programming is accomplished through dispenser programming command codes The following instructions are intended as an overview of ATC programming Refer to Pump Programming on page 5 1 Accessing Command Codes Press F1 then enter the 4 digit security code for the level of the command code that is be accessed Four zeros will flash on the display Enter the appropriate command code then press ENTER on the Manager Keypad ATC Review Mode Command code 27 provides read only access to ATC operating parameters Function code 1 default provides for audit of last transaction data Additional ATC data will be displayed depending on the function code selected See the following table for ATC Function Codes and descriptions Page 7 78 MDE 380
303. n page 6 90 for settings MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 91 Electronic and Electrical Components Displays Main PPU CRIND M01785A001 Main Display for Encore 500 and Eclipse Page 6 92 The main display is part of the Door Node 2 PCA on Encore 500 and Eclipse series units Refer to M01785A001 Door Node 2 on page 6 49 for information on connectors status LEDs and test points Figure 6 43 Main Display Door Node 2 for Encore 500 and Eclipse FRONT VIEW Main Displays ull 2 as J EE mmm B ie g P Bu s eo a e H s s H E a 3 Eg googescoE aZ222z2e2 Ins MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Displays Main PPU CRIND Electronic and Electrical Components M02652A001 and A002 PPU Single Display Module for Encore 500 and Eclipse The single PPU display provides price per unit information to the customer and also reports grade selection and pump handle status information back to the pump node A proximity switch that reports status of the pump handle is part of the M02652A001 module Module M02652A002 does not have the proximity switch The PPU displayed and the STPs activated will be determined by setting the jump jacks Service Tip It is recommended that you replace bulbs in pairs Figure 6 44 PPU Module with Single Display for Encore 500 and Eclipse M02652001 shown proximity Test Point 5V Ground switc
304. nction Code 21 PPU Blinking Option Program the PPU displays in the price bar to blink under certain conditions To Set PPU Blinking Press Configuration Off 0 On Default 1 Function Code 22 Volume Display Decimal Point Use this function to program the decimal point out of the main volume display When programmed to 1 the decimal point is not shown on the display Function Code 22 is not approved by U S Weights and Measures To Set Volume Display Press Configuration XXX XXX Default 0 XXXX XX Export Only r Note If set to 1 decimal point will not show The decimal point shown in the table is for reference only Function Code 23 Program STP Control Use this function to activate all STPs on all transactions regardless of which grade is selected Use this Code for Encore MPD single hose units only NGO NG2 NG4 or NG5 To Set STP Control Press Configuration Off Default 0 On 1 Function Code 24 Hose Pressurization Option Use this function to pressurize the hose during lamp tests of the first transaction after a power up or the first transaction after a period of inactivity Note This function should not be used to correct situations with leaky check valves nozzles or vapor recovery hoses This programming feature can be useful to correct minor leaks from the meter back towards the tank which cause calibration issues fuel delivery indication when the fueling position is activated with the nozzle is closed
305. nd Eclipse Start up Service Manual August 2007 Page 6 65 Electronic and Electrical Components Printed Circuit Assemblies and Nodes CRIND Logic Board Address Settings MOC and Generic CRINDand Generic CRIND Table 2 G CAT 4 Addresses Table 1 Address JP8 JP7 JPG JP5 JP4 Address JP8 JP7 JPG JP5 JP4 1 N OUT OUT OUT OUT 1 OUT OUT OUT OUT OUT 2 QUT IN OUT OUT OUT 2 IN OUT OUT OUT OUT 3 N IN OUT OUT OUT 3 OUT IN OUT OUT OUT 4 OUT OUT IN OUT OUT 4 IN IN OUT OUT OUT 5 IN OUT IN OUT OUT 5 OUT OUT IN OUT OUT 6 OUT IN IN OUT OUT 6 IN OUT IN OUT OUT 7 IN IN IN OUT OUT 7 OUT IN IN OUT OUT 8 OUT OUT OUT IN OUT 8 IN IN IN OUT OUT 9 IN OUT OUT IN OUT 9 OUT OUT OUT IN OUT 10 OUT IN OUT IN OUT 10 IN OUT OUT IN OUT 3 IN N OUT IN OUT 1 OUT IN OUT IN OUT 12 OUT OUT IN N OUT 12 N N OUT IN OUT 13 IN OUT IN IN OUT 13 OUT OUT IN IN OUT 14 OUT IN N N OUT 14 IN OUT IN IN OUT 15 IN IN N N OUT 15 OUT IN N N OUT 16 OUT OUT OUT OUT IN 16 IN IN N IN OUT 17 IN OUT OUT OUT IN 17 OUT OUT OUT OUT IN 18 OUT IN OUT OUT IN 18 IN OUT OUT OUT IN 19 IN IN OUT OUT IN 19 OUT IN OUT OUT IN 20 OUT OUT IN OUT IN 20 IN IN OUT OUT IN 21 IN OUT N OUT IN 21 OUT OUT IN OUT IN 22 OUT IN IN OUT IN 22 IN OUT N OUT IN 23 IN IN N OUT IN 23 OUT IN IN OUT IN 24 OUT OUT OUT IN IN 24 IN IN N OUT IN 25 IN OUT OUT IN N 25 OUT OUT OUT IN IN 26 OUT IN OUT IN N 26 IN OUT OUT IN N 27 IN N OUT IN NN 27 OUT IN OUT IN N 28 OUT OUT IN IN N 28 IN IN OUT IN NN 29 IN OUT IN N IN 29 OU
306. nding meter Fuel Density gasoline 730 diesel 840 Note The default value for Fuel Density is 750 Money Position Main Display Current Meter Information Volume Position Fuel Type PPU Position Fuel Density The software will sequence through each meter position for you to assign the fuel type desired 3 Press ENTER after selecting the fuel type 4 Sequence through each meter position and verify desired fuel type by pressing ENTER 5 Place the programming switch on the ATC controller board in the OFF position 6 Press F2 to exit ATC programming mode 7 Weights and Measures auditor will put a seal on the programming switch 8 Close electronics door as described in MDE 2531 Pump and Dispenser Start up Service manual How to Access ATC Mode Information View Last Transaction 1 Enter 3 digit keypad code reference definitions below EU 2 Press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 55 Pump Programming Additional Manager Functions for Encore 300 3 Press 1 for Meter Position One information 4 Press ENTER 5 Record the information 6 Continue to press each position number for corresponding position information 7 Press ENTER 8 Press F2 to exit ATC Mode Wait for one minute Time out if F2 is non functional Definition Function of ATC Codes 100 Programming Code For instructions on programming ATC option see Pr
307. nergized When controlled by the Gilbarco electronics in a closed loop system proportional flow control is obtained by controlling the plunger position Coils and conduit are a combined unit and the diaphragm is easily replaced The PCV can be programmed for flow control for blenders not for Encore 300 units Figure 8 14 Proportional Control Valve Assembly and Manifold manifold coil wires and connector diaphragm assembly T PCV coil and conduit assembly mounting bolts 3 coil retention nut 1 Alow voltage signal 1s sent to the valve coil The valve opens a slight amount to create during the pulser test 2 Once the pulser has been verified as good then a higher voltage is sent to the valve to accomplish the following Wide open if not a blender or limited by a programmable flow rate e Partially open to maintain a blend ratio in conjunction with a parallel valve or if programmable flow control is present Page 6 14 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting 3 Forablender or a pre programmed maximum flow rate the valve will be open or closed based upon a revised signal from the electronics to maintain the blend ratio and or maximum flow during delivery 4 For preset sale near the end of that sale the valve signal is reduced to create slow flow and to allow the valve to close on target The following table describes how
308. nfiguration P3503B MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Power Supplies Electronic and Electrical Components M01608A001 Encore 300 and Ultra Hi Power Supply M01608A001 Main Power Supply Assembly This power supply is obsolete and is replaced by M02274 Figure 6 35 Power Supply for Encore 300 To J108 To J604 To J302 Board Connections and Cables Connector P601 J604 J108 J302 J606 Via Cable M01591A001 M1650A001 to M01515A001 M01662A001 To Board A2 A10 A13 field connection wires Valve and STP feed 24 VAC Feed 9 4 VAC Backlight voltage CRIND Regulator board T20306 G1 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 At Connector J401 3 pin P604 P108 J2115 P559 Page 6 79 Electronic and Electrical Components Power Supplies M02274A001 Universal Power Supply for Encore 300 Encore 500 and Eclipse The main assembly provides power to Encore 300 Encore Ultra Hi Encore 500 and Eclipse This assembly was included in production units beginning December 5 2002 Encore 500 and Eclipse units have an additional board attached to the main assembly to provide 18 and 24 volts An STP board is also included in units that are dispensers Service Tip This power supply can substitute for older power supplies using a M00016K003 kit Figure 6 36 Example of Encore 300 Configuration Power Supply Chassis AC Distribution
309. ng per STP The programmable maximum flow rates affecting valve operation available with certain models Page 8 3 Theory of Operation and Troubleshooting Theory of Operation How a Standard Dispenser Works Note The numbers in Figure 6 3 correspond to the numbered steps below Figure 8 3 How a Standard Dispenser Works Flow roms TF Flow trams TP Flow tram STF Product 1 Product 1 Product 1 Note Shear valves are not normally used with pumps but may be required by some regulatory agencies 1 Fuel passes through a shear valve and enters the dispenser 2 Fuelflows through a strainer and filter 3 Filtered fuel passes through a digital or proportional control valve 4 Fuelflows through a meter check valve and the meter measures fuel flow 5 Fuel is discharged through the nozzle n the case of blenders two meters supply fuel to a single hose casting where fuel is combined prior to the hose Directional valves are used in six hose blenders to send the correct product for delivery to the hose Page 8 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting How a Self Contained Pumping Unit Works The numbers in Figure 8 4 correspond to the numbered steps below Figure 8 4 How a Self contained Pumping Unit Works Flow hom STP Flow from s TF Product 1 Produc 1 Note Shear valves are not normally used with pumps but may be required by some r
310. nlet chamber and above the diaphragm holds the diaphragm against main valve seat No fuel flows MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 15 Theory of Operation and Troubleshooting Theory of Operation How the Electronics Works for the Encore 300 1 2 10 11 12 13 14 Page 8 16 Customer raises pump handle Signal travels to the pump controller board through the hydraulic interface board The pump controller sends signals to the displays for reset and price display The pump controller via the hydraulic interface signals the console for authorization The pump controller signals the hydraulic interface to activate the STP for dispensers or self contained pump motor for pumps Attendant authorizes sale at console Console sends preset sale data 1f applicable to the pump controller via the hydraulic interface Customer begins fueling which initiates valve slow flow The pump controller receives pulses through the hydraulic interface from the pulser The meter turns with fuel flow which rotates the pulser shaft After ten pulses the pump controller signals the hydraulic interface to initiate full flow in the valves During delivery the pump controller receives volume pulses and translates them into cost information This information is sent to the displays and the console For a preset delivery the pump controller signals the hydraulic interface to slow the product
311. ntainer Stop fuel flow Clean up any spills promptly 2 To calculate gallons liters per minute multiply volume amount by four For example 5 gallons x 4 20 gallons per minute MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 11 Hydraulic Mechanical Components Measuring Pressure and Vacuum Figure 7 3 Dispensing into Prover Can Ground Wire and Clips Prover Can AM Measuring Pressure and Vacuum Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Use OSHA Lock out and Tag out procedures AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts Fire and explosion could result in sever injury or death e Wear eye protection e Test and close the involved shear valves e Turn off power to unit e Remove parts slowly Collect fuel in approved containers e Clean up all spills promptly Page 7 12 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Measuring Pressure and Vacuum Hydraulic Mechanical Components Topics in this Sub section Topic Page Using Pressure Gauge 7 13 Pressure Measuring Locations on Unit 7 13 Measuring Pressure Drop for Dispensers and Pumps 7 15 Using Pressure Gauge Use pressure gauges and vacuum gauges to test pumps and dispensers when Flow rates are too low e Motors fail prematurely or stall
312. nts Printed Circuit Assemblies and Nodes Test Points Test Point Range TP 1 5 VDC TP 2 DC GRND TP 3 STP Feed Voltage M00056A001 Pump Control Node 1 The main purpose of the first generation pump control node 1s to provide control for fueling This board drives the LON stores the operating system configuration programming and one complete set of totals and operational logs The Pump Control Node connects directly to the LON Valve Driver Board Pulsers the STP driver board the POS two wire PC serial port VaporVac and also connects to the Weights and Measures E cal switch For non eCRIND units the Pump Control Node provides the main processing power for system The lithium battery on this board maintains Level 1 and Level 2 programming Page 6 8 Service Tips The coldstart jumpers only reset the processor of Level 1 and Level 2 programming To completely reset the board cold coldstart it is necessary to load V 1 3 74 software and then load the latest version of software Cold Coldstart clears all programming the clock totals calibration and resets the processor Software version V 1 5 40 or later provides redundant storage of programming information Two door nodes and one pump node are required to maintain redundancy storage Never replace two of these boards at the same time or redundant storage may be lost The LON circuit must have a terminator at the last node Pump Control Node 1 is interchangeable with
313. nual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 57 Setting VaporVac Alarm VaporVac Alarm 1 Enter 5 then 2 then press ENTER to access this Command Code 2 Use the following table to select option Option Code VaporVac Alarm 1 Default ON 2 OFF 3 Press ENTER Command Code 53 Set Time outs Command Code 53 is entered in Level 2 programming to set dispenser time out options Function Codes 1 through 3 are selected to set various dispenser time outs Sub sections that follow describe each time out programming option Entry into Command Code 53 will select Function Code 1 by default Layout and digit position meaning for this programming feature is shown below Figure 5 58 Setting Time outs Function Code Value Value Value 1 Press 5 then 3 then press ENTER to access this Command Code 2 Use the following table to select 1 3 the Function Code Note Refer to the Function Code Descriptions Function Code Descriptions for Command Code 53 for more information MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 59 Pump Programming Page 5 60 Encore 5XX and Eclipse Programming Instructions Function Code Option Time out Option 1 Default Set Beeper Time out 2 Set Pre select Time out in seconds 3 Set Dispenser Time out in seconds Figure 5 59 Function Code Settings Function Code Function Code Settings Press ENTER
314. o not test continuity if there is spilled fuel leaking components or fuel vapors present in the area Be familiar with hazardous zones requirements Do not turn tester on until after connections are made Turn tester off before disconnecting test clips To test the hose and hanging hardware continuity proceed as follows 1 Ensure that there is no liquid fuel or flammable vapors present Clean up as necessary 2 Liftthe nozzle hook and authorize the unit to pressurize hose 3 Lower the nozzle hook Figure 7 14 Testing Hanging Hardware Continuity Outlet Castin x Digital Ohm Meter BEEN E Note Use only a low voltage digital ur ohmmeter to perform this test Do not use a Megger tester Breakaway r in A maintain at least 18 inches above the Nozzle A ground and away form Swivel unit during test hose Dispensing Unit A Page 7 32 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Hanging Hardware Hydraulic Mechanical Components 4 With meter off connect one probe to the nozzle spout the other probe to fuel outlet fitting at outlet casting or other component grounded with the unit s frame see Figure 7 14 on page 7 32 Probe contact surface must be clean and free from fuel or other contamination Use test leads at least 3 feet long 1 meter equipped with insulated clips Typical meter test clips are not suited for direct attachment to hanging hardware Use approp
315. o5V 8 SND REC 0to5V 9 PBP 0to5V 10 SER DATA 0to5V 11 RESET 0to5V P2202 Pin Description Input Output Voltage 1 PUMP HANDLE 0to5V 2 5 V 5 V 5 3 5 V 5 V 5 4 PUMP_HANDLE_LB 0to5V 5 GND OV P2203 Pin Description Input Output Voltage 1 GRD_SEL 0 to 5V 2 5 V 5 V 5 3 GRD_SEL_LB 0to5V 4 5 V 5 V 5 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Displays Main PPU CRIND Electronic and Electrical Components M02652A005 and A006 PPU Dual Display Module for Encore 500 and Eclipse The Dual PPU display module M02652A005 and A006 is capable of supplying dual level price per unit information to the customer Grade selection and status 1s reported back to M00095A001 CRIND Auxiliary I O Board Jumpers are used to set the addresses A proximity switch that reports status of the pump handle is part of the M02652A005 module Module M02652A006 does not have the proximity switch Service Tip If one of the two backlight bulbs burns out it is a good idea to replace both bulbs on that board Figure 6 45 PPU Module with Dual Display for Encore 500 MO00065A005 shown proximity switch installed Point 5V O nO a eee Gilbarco MADE IN U S A BE NOE Sonnets Proximity switch S ease Q12514 10 pras E JESEN Q nz rm lt DOOR NODE LAMP PPU INTFC POWER This PCA M01303A001 is part of the display module assembly Not serviceable separately PPU Address Jumpers
316. oard Scanner M01304A001 M01989 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 111 Electronic and Electrical Components CRIND Devices Figure 6 61 E500 Eclipse E500S Block diagram Card Reader LEDs M01369 From 24v P1512 Scanner Interface Scanner Board M01304A001 M01323 M00122 Board Connections and Cables Connector Via Cable To Board At Connector P1521 14 pin P01378A001 Serial to LON Node M00122A001 P1509 14 pin Jump Jack Settings Jump Jack JP1 Turns scan laser on for testing normally not installed Page 6 112 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Junction Boxes Electronic and Electrical Components Junction Boxes The following table lists the contents in this sub section Topic Page Encore Series Junction Box 6 113 Eclipse Series Junction Box 6 114 About Junction Boxes For Encore units conduits may run into the electronics cabinet without the use of a junction box Depending on configuration the Encore Series dispenser units may ship without a junction box or field conduit Some retrofit units will require a junction box due to limited wire length available from sub up conduit in this case the installer would have installed a junction box to splice wires Junction boxes when installed are Class 1 Division 1 explosion proof The junction box is mounted on Side 1 of unit Eclipse dispensers contain a factory supp
317. ode 1 MOC 2 Generic 3 MOC KIOSK 4 Generic KIOSK 5 MOC Enhanced KIOSK Monochrome Contrast 1 Adjust Contrast Side 1 2 Adjust Contrast Side 2 Cash Acceptor 1 Enable Cash Acceptors Show Statistics Reset Statistics Counters Show Device Details Calibrate Cash Acceptors Test Cash Acceptors Check Cassette Door Switches TRIND Menu 1 Enable TRIND Card Reader Menu 1 Show Counts 2 Reset Counts Printer Menu 1 Print Test Side 1 2 Print Test Side 2 3 Set Country Code Barcode Scanner 1 Enable Scanners 2 Scanner Setup 3 Test Scanners Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming Activating the Encore 5XX CRIND Device Perform the following steps to activate the CRIND device Refer to MDE 2562 CRIND Service Manual for details on enabling the CRIND device 1 Restore power to the fueling units 2 Initiate CRIND BIOS Diagnostics using Diagnostic Card Q12534 170 3 Inthe Diagnostic Startup Menu window select 1 Main Menu 4 In Main Menu window select 1 CRIND Config 5 Inthe CRIND Config window select 1 CRIND IDs 6 In the CRIND IDs window select 1 CRIND ID Side 1 7 Inthe CRIND ID Side 1 window enter a value between 1 to 32 that corresponds to address of the fueling unit Press ENTER to have the value committed to memory and revert the CRIND device to the CRIND ID s window 8 In the CRIND
318. ode Scanner Scanner Enabled scanners reset to factory defaults Enter Continue 4 Press Enter to return to the Barcode Scanner setup menu View Change POS Scanner Settings This function allows you to enable or disable codes and each of the supported barcode formats Configuration changes will not be automatically sent to the scanner the application software POS establishes the formats that are supported Once configuration is complete all settings must be sent to the scanner at the same time using the Send POS Settings to Scanner function MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 113 Pump Programming Page 5 114 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser 1 From the Barcode Scanner setup menu press 2 The following screen appears Barcode Scanner Scanner Enabled 1 AIM Code Disabled 2 Laser Scanning Mode Raster 0 Next Screen Page 1 4 Enter Save Values and Exit Cancel Discard Changes and Exit Barcode Scanner Scanner Enabled 1 AIM Code Disabled 2 UPCA Enabled 3 UPCE Enabled 0 Next Screen Page 1 3 Enter Save Values and Exit Cancel Discard Changes and Exit 2 Toconfigure the settings proceed as follows Press 1 to enable disable the ability for an AIM Code to be pre pended to the data reported by the device each time a barcode is scanned Press 2 to enable disable the ability for an UPCA barcode format to be detected and
319. ogramming Instructions Pump Programming Function Function Code Keypad Code ATC Functions and Description Programming in CC27 8 Engineering audit e Select FC8 Engineering audit mode is intended for use by Gilbarco e ENTER Engineering personnel to judge performance of ATC system Select grade Mode provides information on t meter operation and temperature e ENTER data conversion Typically customer or ASC will not need to e Select next grade access this mode e ENTERS Money display shows probe width and volume display shows temperature in Celsius Values are updated continuously Notes 1 Display indicates 0 for a negative temperature value and is blank for a positive value Current PPU display cannot display a character 2 When ENTER is pressed display will blank money and volume displays of both sides and show 8s in the PPUs When fuel flow is detected display will show real time uncompensated volume in money display compensated volume in volume display and temperature in PPU displays When the transaction is complete display will retain transaction data for 1 minute and then revert back to blank money and volume displays with 8s shown in PPUs One minute time out can be avoided by pressing ENTER 3 Indicates a negative temperature value and is blank for a positive value Money display shows probe width and volume display shows temperature in Celsius Values are updated continuously Command Code 28 Change
320. ogramming the ATC Option on page 5 34 200 Inspection Mode Access this mode to obtain a precise reading of ATC system operation during an actual transaction This is the most accurate means of checking ATC system accuracy because temperature readings are displayed during transaction Pure product only Program a blender for 100 otherwise the PPU display shows error code 105 product error Money display shows uncompensated volume e Volume display shows compensated volume e PPU display shows real time temperature in Celsius 300 View Last Transaction Access this mode after a transaction This mode can be used as a basic check to ensure that the ATC system is operating properly Temperature displayed in this mode is an average during the last transaction Do not use this mode to verify the accuracy of the ATC system Page 5 36 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Additional Manager Functions for Encore 300 Pump Programming There are no blender restrictions e Money display shows uncompensated volume e Volume display shows compensated volume e PPU display shows average temperature in Celsius 301 Display Volume Correction Factor VCF e Money display shows product number e PPU display shows volume correction factor 302 Display Density PPU display shows selected meter s programmed density information 303 Display Temperature PPU display shows selected meter s current product tempe
321. ohms proceed to next step 5 To find bad node or board temporarily disconnect each node board one at a time and measure the resistance across pins 1 and 5 on the cable If 800 ohms or more with board disconnected replace the disconnected node board If under 800 ohms and each node board has been temporarily disconnected proceed to next step Note Components using 18 V include all nodes and the monochrome board The pump node receives 18 V from a direct plug in while all other nodes receive 18 V over the LON cable If no bad board or node is found a cable problem could exist Use a test cable to temporarily replace each cable in the chain measuring ohms 800 or more until defective cable is found If no defective cable is found escalate the problem through normal channels If defective cable is found proceed to next step 6 Replace defective cable 7 Reconnect all nodes boards and cables 8 Power up dispenser MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 83 Electronic and Electrical Components Power Supplies Page 6 84 24 VDC Problem If one or more 24 VDC devices in the dispenser fails to operate examine CR18 on M02774 and perform the action in the following If Then table Note Examples of 24 VDC devices are the CRIND printer the monochrome display backlight and the LED board for the bar code scanner If Then CR18 is lit If you still have problems trace out the connections fro
322. ol valve can be programmed for flow control for blenders Non use of filters and strainers can cause premature valve failures Check Valves at Manifold and Meter Meter pressure check valves help keep the meter full of fuel They also help relieve excessive pressure due to thermal expansion that could damage parts or make nozzles difficult to open For blending they also prevent crossover flow from tank to tank The check valves are located in the meter intake port MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 59 Hydraulic Mechanical Components Valves Page 7 60 Figure 7 37 Check to Meter Orientation Check Valve Some Potential Problems Damage to hydraulic parts can occur from thermal expansion or driving over a hose if valve is inoperative If valve sticks open a sale may register when you first turn the nozzle hook ON with nozzle closed Also check STP check valve for problems e Blend error codes indicating product contamination e Stuck valve causing reduced flow rates e Leaks Calibration problems Service Steps Check valves are not rebuildable replace any defective check valves Wear eye protection for this process Close and test shear valves for dispensers Remove power to unit and involved STPs Use OSHA Lock out Tag out procedure Open nozzle into approved container to bleed pressure Some residual pressure may remain Use Gilbarco repair kit to replace check valve Inspec
323. ommand Code E5XX Command Code Programming Level Code Range Range Level 1 2222 1 9 20 39 Level 2 1503 10 12 40 69 Level 3 1309 13 17 70 89 Level 4 0128 N A 90 109 Only on Encore 5XX and Eclipse Sub sections that follow describe programming commands for each programming level Important Information about Using V1 7 58 and Higher for Encore 5XX and Eclipse Dispensing Pump Software As the calibration mode is automatically entered when the Weights and Measures switch is toggled for these versions of software to program Level 3 and 4 commands 70 and higher a different approach must be used Earlier it was possible to toggle the Weights and Measures switch prior to entering the programming mode Now you must be in Level 3 or 4 prior to toggling the switch Follow instructions provided at the beginning of Level 3 and Level 4 programming for this version of software The calibration procedure assumes that either a 5 gallon or 20 liter prover can will be used If another size can is used you must change the default can size in Command Code 82 As the new can size will be stored in memory for future calibrations if the special can size 1s not likely to be used for the next calibration it is very important to reprogram the can size back to default after completing the calibration It is also wise to verify the can size on the money display during calibration MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 7 P
324. on Code then press ENTER Page 5 90 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Command Code 92 Set Side Exists Option allows setting up for single sided operation Default is for both sided operation Layout and meaning of each digit position for this programming feature is shown below Figure 5 99 Setting Up for Single Sided Operation Option 1 Default 1 Onthe Manager Keypad press 9 then 2 then ENTER Option Sides Active 1 Default Both Sides 2 Side 1 Only 9 Side 2 Only 2 Select Function Code 1 to 3 then press ENTER Command Code 93 Set Cash Credit at Dispenser Command Code 93 allows programmer to enable cash credit for each side of dispenser Layout and meaning of each digit position for this programming feature is shown below Figure 5 100 Setting Cash Credit at Dispenser Option 1 Default 1 On the Manager Keypad press 9 then 3 then ENTER 2 Select Side 1 or 2 then press ENTER Option Sides Active 1 Default No Cash Credit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 91 Pump Programming Encore 5XX and Eclipse Programming Instructions Option Sides Active 2 Side 1 Only 3 Side 2 Only 4 Both Sides 3 Select Option Code 1 to 4 then press ENTER Command Code 94 Set Zero PPU Option When this option is enabled the dispenser is allowed to dispense fuel with
325. on in all Levels Press F2 to exit programming Note Use of a higher level Encore 5XX Eclipse PIN Code will allow access to lower level programming codes as well for example keying the Level 5 PIN Code will allow access to Level I 2 and 3 programming but not Level 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 39 Pump Programming Encore 5XX and Eclipse Programming Quick Reference Encore 5XX and Eclipse Programming Quick Reference Command Codes and Function Codes Quick Reference Chart The following chart shows level Command Codes and Function Codes where applicable Refer to the following pages for more detail Level One Command Codes Starts on page 5 41 20 Set PPU Values 21 Not applicable 22 Set Preset Types and Values 1 Set Preset Type L 2 Set Preset Amounts 3 Set PPU ON OFF 24 Set Operations Mode 1 Two Wire 2 Standalone 25 Set Allocation 27 Review ATC 2 Display Volume Correction Factor 3 Display Fuel Density 4 Display Temperature 5 Gross Volume Totals 6 Software Version 7 Real Time Transaction 8 Engineering Audit 28 Change First Level PIN Level Three Command Codes Starts on page 5 65 Level Two Command Codes Starts on page 5 48 40 Set Two Wire ID pump number 41 Set PPU Options 42 Set Decimal Point Options 1 Main Display Money 2 Main Display Volume 3 PPU for Calculations 4 PPU for Display 43 PPU Blinking Options 44 PPU Grade Mapping 45 Set
326. on of the cash acceptors From the Device Config menu press 3 The following screen appears Cash Acceptor Cash Acceptor Enabled Indicates status of cash acceptor Since cash acceptor support is Disable Gash Acceptors enabled for both sides of the unit at Show Statistics once this status reflects both sides Reset Statistics Counters of the unit Show Device Details Calibrate Cash Acceptors Test Cash Acceptors Check Cassette Door Switches Enable Disable Cash Acceptors From the Cash Acceptor main menu press 1 to toggle between enabling and disabling the cash acceptors Once the cash acceptors are enabled the cash acceptor software is started when a function such as the Show Statistics option is chosen that requires the software to be running The following screen will display the first time you attempt to access a cash acceptor function in diagnostics mode Cash Acceptor Cash Acceptor Enabled Cash Acceptor Software Ready Enter Continue Press Enter to continue to the screen option you selected Show Statistics This function allows you to view the cash acceptor events statistics for each side of the unit for troubleshooting purposes Cash acceptor statistics are collected for all cash acceptor activity regardless of whether the cash acceptor events occur in the course of normal transactions or during a diagnostics session MDE 3804B Encore and Eclipse Start up Service Manual August 2007
327. onents Test Points Test Point Range TP 1 System current draw See Note TP2 DC GRND TES 12 5 V to 28 VDC Note Calculate system current draw as follows Current 2X indicated voltage Circuit cannot indicate provide reading lower than 0 5 V Board Connections and Cables Connector Via Cable To Board at Connector P1401 2 pin white wire 14 V Secondary on Power Supply N A P1402 5 pin M00635A001 18 V to M00077A001 Totalizer P1105 Node P1403 4 pin M00486A001 M00053A002 Power Supply Board P3501 24 VDC Printer Option P1404 2 pin M00484A001 Filter Capacitor 2 pin Connector Pin Functions and Voltages P1401 Pin Description Voltage Range 1 Power In 12 24 VAC as measured to P1401 2 2 Power In 12 24 VAC as measured to P1401 1 P1402 Pin Description Voltage Range 1 System Ground Reference OV to System DC Ground 2 System Ground Reference OV to System DC Ground 3 Power Power Fail Output 0 4 V Power Fail 4 V Power Good Measured through external 10K pull up 4 System DC Power 22 V DC nominal 17 5 VDC to 28 VDC operational 5 System DC Power 22 V DC nominal 17 5 VDC to 28 VDC operational P1403 Pin Description Voltage Range 1 Supply Shutdown 0 4 V Shutdown 4 0 V Active 2 System Ground Reference OV 3 4 Not Used P1404 Pin Description Voltage Range 1 System Ground Reference OV 2 18 V Filter Capacitor 18 VDC nominal 15 VDC to 28 VDC operational Note P
328. options are not installed Entry into Command Code 91 will default to Function Code 1 The dispenser will generate an event log for improperly configured options Layout and meaning of each digit position for this programming feature is shown below Figure 5 97 Selecting the Installed Options 1 On the Manager Keypad press 9 then 1 then ENTER 2 Select Function Code 1 to 21 then press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Function Code 1 Default Page 5 89 Pump Programming Function Code and Option Selection Table Function Code Dispenser Option Description 1 Default Preset Type 2 Push to Start 3 VaporVac 4 Master Satellite 5 Push to Stop Button 6 ATC 11 Totalizer Function 12 Nozzle Activated Pump Handle 13 Meter Type Figure 5 98 Selecting the Option Code Encore 5XX and Eclipse Programming Instructions Option Selections 1 No Keypad Default 2 5 Button Preset 3 Incremental Preset 4 Programmable Pump Preset 1 Not Installed 2 Installed 1 Not Installed Default 2 Installed 1 Not Installed Default 2 Installed 1 Not Installed Default 2 Installed 1 Not Installed Default 2 Installed 1 Not Installed Default 2 Installed one per meter side 3 Installed one per inlet unit 1 Not Installed Default 2 Installed 1 C Meter Default 2 LC Meter 3 Select Opti
329. orVac 1 eee eens 7 73 Returning VaporVac Pump Motor 000 cee eee eee 7 75 ISD Vapor Flow Meter 0 0 0 cc eee 7 75 ALG COMPONCHIS ss PCI dace sta waned Se bua cane d a a tee eet thea eee 7 77 Contents in this Sub section 0 0 eee 7 77 Purpose Of TheATG ODOM 242 0934 oo Pea emt ot Reate 7 77 ATO MapDDIFIQ 2 eek denk epo ri we Ee oo ee he CORR doa oe de dns 7 77 PrOgrammMmmGAlG s twee eae io Ma Rs qu A ee i hd ee hae 7 78 8 Theory of Operation and Troubleshooting 8 1 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page v About this Section Theory of Operation Error Codes Troubleshooting Index Page vi ru eeu eg ee aoa glee oe ee 8 1 Important Information about Releases 2000000 8 1 TOPICS I this SECON up mcs eite pos ono Oed eoe ed wor ieee ros 8 1 Section Overview llle 8 2 How to Jse his SCHON si Deco e er 20 Up ore redes od bee rus 8 2 Terms Used in this Section 2 0 ee eee 8 2 rM PEE 8 2 Understanding Flow Rate 0 ce eee 8 2 How a Standard Dispenser Works 000 cece eee eee 8 4 How a Self Contained Pumping Unit Works 0005 8 5 How a Master Satellite Ultra Hi Dispenser Works 8 6 How Truck Stops are Configured 0 0 00 cee eee 8 8 How VaporVac Vacuum Assist Vapor Recovery Works 8 11 How Stage Two Balance Type Vapor R
330. ore and Eclipse Start up Service Manual August 2007 Vapor Recovery Components Hydraulic Mechanical Components 10 11 12 13 14 To test the air to liquid volume with a pulse simulator box proceed as follows Place the dispenser in standalone mode Install the nozzle testing tee from the K94255 A L Test Kit Ensure that you use the 05 or 07 no flow insert in the testing tee If air volume meter has a mechanical totalizer record initial value If air volume meter has electronic output reset the frequency counter to zero Note Be aware that testing meter can measure a light breeze since there is a very low pressure drop through the meters Protect testing meter from wind Ensure that the nozzle hook is in the OFF position and the pulse simulator box is set to Halt Unplug the pulser from the cable assembly for the hose position to be tested Plug the pulse simulator box connector into the cable assembly Select the flow rate on the pulse simulator box that is closest to the actual dispenser site flow rate If the actual flow rate is not known set the pulse simulator box to 8 GPM Raise the nozzle hook to authorize the dispenser and then turn the pulse simulator box to the Run position Do not engage squeeze the nozzle lever Switch the pulse simulator box from the run position to the halt position when the volume display on the dispenser indicates 4 5 0 3 gallons The following informat
331. ore 300 models that contain a CRIND logic board will require an upgrade to the CRIND BIOS when switching from single to dual head card reader Contact the Gilbarco Call Center at 1 800 800 7498 for details of the version of CRIND BIOS needed to support the Dual Head Card Reader Service Tips Card readers must be cleaned periodically weekly or as needed using a Cleaning Card G11482 A dirty reader can result in reading problems Always attempt to clean reader before deciding to replace it CRIND diagnostics can be used to test card reader performance and determine statistical data useful in card reader service Figure 6 51 Dual Head CRIND Card Reader To CRIND Logic PCA E300 To Door Node E500 Eclipse To Ground Card Slot Board Connections and Cables Model Connector Via Cable To Board At Connector E300 7 pin M01555A001 Door Node M00062A001 P254 9 pin CR 6 pin M02134A001 GND ring terminal E500 Eclipse 7 pin M00501A001 Door Node P2102 9pin GND ring terminal Cleaning Card Reader Instructions Use a Gilbarco Cleaning Card Q11482 to clean the card reader frequently Gilbarco recommends cleaning the card reader weekly with a new cleaning card Also use a cleaning card to clean the card reader if cards are not being read in normal operation Re order cleaning cards from your Gilbarco distributor MDE 3804B Encore and Eclipse Start up Service Manual August 2007 CRIND Devices Electronic and Electrical
332. orm a Totals Memory Clear Record all totals before reset After performing a totals memory clear a master reset Command Code 17 Function Code 2 should also be completed Note A totals memory clear works only if Error Code 31 Totals Data Error or 35 Configuration Data Error occurs Figure 5 10 Clearing Memory 1 Press 6 then ENTER to access this Command Code 2 Press 1 then ENTER System performs power up reset and continues in normal operation You must reprogram the unit Page 5 14 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Command Code 7 Setting Totals Input Mode Money total appears when Totals Input Mode is entered Press VOL TOTAL to enter volume totals Press TOTAL to change back to money total Figure 5 11 Setting Totals Input Mode Command Code 7 is active only after clearing memory see Command Code 6 Clearing Memory on page 5 14 performing a master reset or during an install 1 Press 7 then ENTER on Manager Keypad to access this Command Code 2 Select side then press ENTER To Select Press Configuration Side A side with junction box 1 Side B 2 3 Select grade then press ENTER Note For Blenders grade 7 high product and grade 8 low product 4 Enter total starting with MSD Press ENTER 5 Repeat Steps to 4 for each side and grade 6 Press VOL TOTAL on Manager Keypad and repeat ste
333. ormation and steps to program the Encore 300 dispenser pump Certain programming levels will also allow you to view dispenser pump data Note For a simplified listing of functions and settings refer to MDE 4039 Encore 300 Programming Quick Reference Guide Level One Command Codes To access Level One Command Codes proceed as follows 1 Press F1 on Manager Keypad 2 Enter your PIN default 2222 To access a different Level One Command Code from any Command Code proceed as follows 1 Press F1 on Manager Keypad 2 Enter the Command Code number to access 3 Press ENTER Command Code 1 Programming PPU Mode Program the Price Per Unit PPU for each side grade and price level cash credit Figure 5 4 Programming PPU Mode 1 Press 1 then press ENTER on Manager Keypad to access this Command Code 2 Select Side then press ENTER To Select Side Press Configuration Side 1 side with junction box 1 Side 2 2 Both sides 3 Page 5 10 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming 3 Select grade then press ENTER Price level number flashes Note The number of hoses grades vary for each model Dispenser Type Grade Numbers MPD 1 2 3 MPD 4 Not available Quad 1 2 Dual 1 6 Blender 1 2 3 3 0 blender 1 2 3 5 0 blender 1 2 3 4 5 3 1 blender 1 2 3 6 4 Select Price Level then press ENTER The PPU flashes To Select
334. ough the CRIND application The TRIND system uses an electronic system located in the pump or register to talk with a miniature radio like device a tag Together these electronic devices provide cashless access to gasoline food and merchandise by charging purchases to a credit card check card or other account you already have The TRIND system operates on a dedicated tag identification code Your credit card or check card account numbers are not typically used with the tag signal system which protects your account from unauthorized use TRIND utilizes radio frequency RF waves to communicate with a customer s transponder For car tag systems transmitters located on overhead assemblies transmit radio waves that serve as a wake up call As a car mounted transponder enters the transmitter s effective read zone the transponder is activated The transponder then transmits a code which is received by the TRIND antennas mounted overhead or on the option doors For hand held tag systems the transmitter is located behind the target graphic See Figure 8 16 This transmitted code is communicated from the TRIND to the CRIND unit and from there to the POS The POS system communicates with a host to obtain authorization Car mounted transponders are activated when they are within 6 feet of the front of the dispenser perpendicular to front of dispenser Hand held transponders usually on a key chain function when pointed at a target graphic
335. ould be discarded All known consoles in the USA use this default Option 2 means that all six digits of money display are returned with an implied decimal point as selected for money display In this case all six digits of money reported over the 2 wire communications loop are meaningful MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 51 Setting the Reported Money Size Selection 1 Press 4 then 7 then press ENTER to access this Command Code 2 Select the Digit Selection Option 1 2 from the following table Digit Selection Option Return Digits 1 Default Return 5 Digits 2 Return All 6 Digits 3 Press ENTER Command Code 48 Zero Previous Transaction Command Code 48 is entered in Level 2 programming to determine when dispenser displays will be zeroed out and previous transaction cleared internally Default is option 1 after lamp test Option 2 before lamp test results in the dispenser being reset to zero the transaction displayed after e The pump handle is activated raised and unit is authorized No fuel is dispensed The handle is deactivated lowered Note Option 2 is required in New Jersey and is generally known as the New Jersey Display Option Figure 5 52 Zero Previous Transaction Lamp Test 1 Press 4 then 8 then press ENTER to access this Command Code MDE 3804B Encore and Eclipse Start up Ser
336. ousing Clean the strainer cap seal ring and strainer body Inspect cap seal ring for damage hardening or distortion Replace as needed Coat O Ring with a thin film of oil before replacing cap Refer to Servicing Seals O Rings and Gaskets on page 7 4 for details Replace the cap turning clockwise and tighten securely Purge air after service Refer to Purging Air from the System on page 7 7 for details Check for leaks after assembling and purging air from the system Hanging Hardware Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About Hanging Hardware 7 27 Hoses and Flow Restrictors 7 28 Breakaways 7 29 Testing Hose and Hanging Hardware Continuity 7 31 Adjusting Nozzle Hook for Specific Nozzles 7 33 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death Wear eye protection Remove parts and fittings slowly Collect fuel in approved containers Clean up all spills promptly About Hanging Hardware Hanging hardware are the components that attach to the outlet casting This includes hose nozzles swivels spacer hose and breakaways Hanging hardware is tested for leaks and electrical continuity Hanging
337. ow refer to the numbers in Figure 7 33 above CAUTION Adjusting valve pressure beyond factory specifications to increase flow rates can result in premature motor failure or pump wear not covered by warranty 1 Drain the pump following the procedure outlined under Draining the GDP on page 7 50 2 Remove the snap ring 15 Refer to Figure 7 33 above 3 Using a 16 mm socket wrench turn the valve cover 13 outward or counterclockwise until completely removed 4 Remove the spring 12 and valve 10 5 If valve did not come out with the spring use needle nose pliers to remove it from the bore Page 7 54 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Pumping Device GDP Hydraulic Mechanical Components Pressure Control Valve Installation To install PCV proceed as follows Note The numbers within parenthesis in the procedural steps below refer to the numbers in Figure 7 33 on page 7 54 IMPORTANT INFORMATION Modification of pressure control valve or failure to correctly install all components of the pressure control valve will void any regulating agency recognition applicable to this pump 1 Inspect valve 10 for damage or excessive wear Replace if necessary 2 Install PCV in reverse order of removal see Figure 7 33 on page 7 54 3 Apply a light coating of grease on the cover O Ring 14 to help keep the O Ring from being damaged during installation 4 When pump is operating at ful
338. p Programming Function Code 2 Cash Credit at Pump When programmed to Yes the customer must select Cash or Credit at the unit This Function Code should always be set at 0 for the Encore 300 Function Code 3 Side Exists Use this option to disable unused side of single sided units only To Program Press Configuration Does not exist 0 Exists Default 1 Function Code 4 PPU Options This option is used mainly with single level CRIND units and split island operation If the unit has single level PPU displays with switches M02652A003 or without switches M02652A004 The PPU will display the price regardless of the level sent from the console or CRIND If the unit has dual level PPU displays with switches M02652A003 or without switches M02265A008 The Level 2 bottom display is used for single level price posting when top display is covered To Program Press Configuration Level 1 price bar displays level sent by console or CRIND card reader 0 Normal Default 1 Level 2 price bar Level 1 prices Level 1 Level 2 prices 2 Level 2 price bar displays level sent by console or CRIND card reader V70 6 and 3 higher Function Code 5 Not available 1n this version of software Level Three Command Code To access Level Three Command Codes 1 Press F1 on Manager Keypad enter the Level 3 PIN Code then press ENTER Figure 5 20 Accessing Level Three Command Codes on Manager Keypad MDE 3804B Encore and Ecli
339. parately Voltage select plugs may also be reused from other power supplies or terminal block PCAs as long as they are configured correctly Use the following table to determine the correct voltage select plug Figure 6 31 Voltage Select Plug M00488AXXX M00488A115 Configuration Side View View at Bottom Voltage Plug Designation For This Voltage Use This Plug 115 M00488A115 220 M00488A220 230 M00488A230 Jumper Configuration This Plug With This Voltage configuration This Terminal Connects To This Terminal M00488A115 115 1 3 5 6 8 2 M00488A220 220 1 7 5 2 M00488A230 230 1 4 5 2 Page 6 72 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Power Supplies Electronic and Electrical Components M00050A001 Power Supply Board 18 VDC M00050A001 Board supplies 18 VDC power to LON system on Encore 500 and Eclipse series units and has LEDs for Power and Fault It is used in M00458A002 now obsolete power supply assembly In addition to rectifying the transformer secondary it has a connection for a large filter capacitor and has over and under voltage detection It also provides an advance power fail detection has over current sensing and auto power down timing The M00050A001 board is capable of shutting down electronics This board along with the M00458A002 assembly has been replaced by M02274A001 These boards are not interchangeable Troubleshooting Power Supply The following procedu
340. pe plug in the lower half of the inlet union Check pump to motor belt tension Refer to Setting Belt Tension on page 7 57 for details Restore power and turn the unit on Read vacuum gauge Newly installed units should read 8 inches Hg mercury or above Older units about 1 000 hours of service should read approximately 4 inches Hg After testing is complete turn off power at circuit breaker Remove any barriers to fuel and install any plugs removed earlier Restore power and check for leaks MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Measuring Vacuum Pump Hydraulic Mechanical Components Measuring Wet Vacuum and Pressure for Pump This test should be performed when flow output is low or you are experiencing repetitive pump failures Ensure that you follow all safety precautions 1 Turn off power to the unit 2 Check pump to motor belt tension Refer to Setting Belt Tension on page 7 57 for details 3 Install pressure and vacuum gages 4 Restore power and operate the unit with both pressure and vacuum gauges attached Use an approved container to collect fuel Clean up any spills promptly 5 Record discharge pressure with nozzle open and nozzle closed 6 Record vacuum pressure with nozzle open and nozzle closed 7 Record flow rate with nozzle open 8 Compare readings with values in the following Acceptable Range Tables Acceptable Range Tables The values listed in the following tables
341. ply terminal block Cash A B 3 pin Cash Acceptor Troubleshooting Use the following table to troubleshoot Cash Acceptor problems If you cannot resolve the problem contact your local service provider Problem Possible Cause Corrective Action Unit is not getting power no LEDS lit inside passageway at door Unit is in calibration mode Cash Acceptor does not operate or stack bills when power is applied Cash Acceptor does not give credit or register accepted bills The Cash Acceptor is in test pulse mode e The Cash Acceptor is defective MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Check AC power to Cash Acceptor Verify all Cash Acceptor switches are off Take Cash Acceptor out of test mode Replace Cash Acceptor Page 6 105 Electronic and Electrical Components Problem Cash Acceptor won t pull in a bill motor does not start Cash Acceptor has excessive number of bill jams Cash Acceptor rejects all bills Possible Cause The cassette is not installed The cassette is installed incorrectly The Cash Acceptor is defective The CRIND receipt printer is low on paper or out of paper The cassette is installed incorrectly There are bill pieces in the Cash Acceptor The Cash Acceptor has had a failure of one or more components The Cash Acceptor is not properly programmed General Fault displays on G SITE The Cash Ac
342. ponents Measuring Flow Rates Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections Use OSHA Lock out and Tag out procedures AN WARNING Static electricity may be present before or during dispensing of fuel A spark between container and nozzle may occur Fire or explosion may result causing serious injury or death Ground nozzle to proven can to prevent static discharge Place prover can directly on ground and not on any insulated surface Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly Dispense fuel into a container and ensure that proper equipment and procedures are being used to eliminate the hazard of fuel vapors igniting as a result of static discharge or other sources Touch nozzle to prover can or use a grounding clip while dispensing fuel Return dispensed fuel to the proper storage tank Use the appropriately sized prover can e For standard flow units use at least a 5 gallon prover can e For high gallonage units use at least a 25 gallon prover can e Start with displays reading O zero To measure flow rates proceed as follows 1 Dispense fuel for 15 seconds 1 4 of a minute into an approved co
343. pprovals Gilbarco is an ISO 9001 2000 registered company Underwriters Laboratories New York City Fire Department NYFD California Air Resources Board CARB UL File Products listed with U L NYFD C of A Product Executive Order Product MH1941 All Gilbarco pumps and dispensers that bear 4805 The Advantage Series and G 70 52 Balance Vapor Recovery the U L listing mark Legacy Series G 70 150 AB VaporVac MH8467 Transac System 1000 and PAM 1000 4986 Encore and Eclipse E105106 Dell DHM Minitower E165027 G SITE and Passport Systems National Conference of Weights and Measures NCWM Certificate of Conformance CoC Gilbarco pumps and dispensers are evaluated by the National Conference of Weights and Measures NCWM under the National Type Evaluation Program NTEP NCWM has issued the following Certificates of Compliance COC CoC Product Model CoC Product Model CoC Product Model 02 019 Encore Nxx 02 026 H111B Series AC RAC 02 034 External Mount CRIND CECXXXXXXX 02 020 Eclipse Exx MPD 1 Series 02 035 Dimension Dxx T 12C Console PA0188 RAO188 Fixed Blender E aes 02 036 Legacy Ixxx 02 021 RAG T 12C Console PA0203 RA0203 Dispenser Low Profile AR RAR G SITE Printer Epson PA0307 02 022 T 12G Console PA0180 RAO180 02 028 Indoor Card Q11640 G SITE Distribution Box PA0306 T 15 Console PA0189 Outdoor Card Q11891 02 037 G SITE Keyboard PA0304 02 023 T 15 Controller C2 PA0211 G SITE Mini Tower PA0301 T 15 Controller PA0190 TS
344. programmed 4308 No blend table 4311 Lo Product Low Flow 4312 Hi Product Low Flow 4313 Lo Product No Flow 4314 Hi Product No Flow 4315 Hi Product Contaminated by Lo 4316 Lo Product Contaminated by Hi 4317 Lo Product Surge 4318 Hi Product Surge 4319 Undefined Surge 4320 Valve configured for but not responding 4321 Valve stuck 4322 Valve board not detected 4323 Pulser Fail 4324 Invalid Command Software 4325 Maximum Pulse Lag exceeded 4326 Lost Communications 4327 Software Stack error 4328 BPC Slow in Removing Pulses 4329 Leaky Valve Error Codes MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Error Codes Encore 500 and Eclipse Error Codes Theory of Operation and Troubleshooting Error Codes El E8 are displayed in Main Money display or PPU XXXX display Error codes 11 5614 that appear on the main display when an error occurs are useful in diagnosing problems with the pump dispenser E1 E8 Code Description Level E 1 Database Corrupted Super Major E 2 Flash Corrupted Super Major E3 LON configuration error Super Major E4 One or more tasks not started Super Major ES Cold Start was forced Super Major E 6 Redundant data storage error Super Major E 8 Data base changed set as default the new values Super Major 0 50 Code Description Level 11 2 wire communications lost disconnected Minor 20 Pulser connected and product is not mapped Super Major 20 Pulser disconnect
345. ps 3 to 5 for volume totals MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 15 Pump Programming Encore 300 Programming and Data Access Instructions Command Code 8 Displaying Software Version Display software version installed in dispenser Version number appears on volume display Figure 5 12 Displaying Software Version Software Option Code 1 Press 8 then ENTER to access this Command Code 2 Select software option To Select Press Configuration Pump Controller 1 Hydraulic Interface 2 Customer Programmable Preset 3 3 Software version is displayed in the Volume Display Figure 5 13 Volume Display Software Option Code Page 5 16 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Level Two Command Codes Do not allow station owners to program these Service Command Codes Before programming make a note of your unit s model number and software version See Command Code 8 Displaying Software Version on page 5 16 Note ASCs are required to use this programming information during the start up procedure To access Level Two Command Codes 1 Press F1 on Manager Keypad enter the Level 1 PIN Code then press ENTER Figure 5 14 Level 1 PIN Code on Manager Keypad 2 Entera Level 2 Command Code 10 12 then press ENTER A decimal point appears in the money display and a 2 appears in the vol
346. pse Start up Service Manual August 2007 Page 5 25 Pump Programming Encore 300 Programming and Data Access Instructions Command Code 13 Changing PIN Code Use the following procedure to change PIN Code for added security Current PIN Code must be accessed before it can be changed Revised PIN Codes enhance unit security They must be securely stored by the station and the ASC Note Do not allow station owners to program these Service Command Codes To access Level 3 Command Codes proceed as follows 1 Press F1 on Manager Keypad then enter the Level 1 PIN 2 Entera Level 2 Command Code 10 12 then press ENTER 3 Enter the Level 2 PIN Code Default 1503 then press ENTER 4 Enter a Level 3 Command Code 13 or higher then press ENTER 5 Enter the Level 3 PIN Code Default 1309 then press ENTER CAUTION Carefully monitor keystroke activity for these steps If you enter an incorrect PIN number different than intended a cold start reprogramming and re calibration of the unit will be required Figure 5 21 Accessing Manager Keypad Page 5 26 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Command Code 14 Do not use Command Code 15 Do not use Command Code 16 Programming Blend Ratios Blenders Only Figure 5 23 Programming Blend Ratios Percent Low Product 1 For Blenders only press 1 then 6 then ENT
347. ption Use this function to blank the displays and disable the dispenser using the console You must perform a 980 00 preset post pay at the console to blank the displays and a 981 00 preset post pay to turn them back on Also see Command Code 4 Function Code 1 on page 5 13 for details on how to manually blank out displays at the dispenser pump Note Dispenser backlights remain on after digits are blanked out Pumps and dispensers cannot be used when displays are blanked since handles and grade select button are disabled To Program The Two Wire Blank Option Press Configuration Off Default 0 On 1 Function Code 9 5 or 6 Digit Cash Use this function to program five or six digits of cash You must program control console cash register to same mode for proper operation To Program The Digits of Cash Press Configuration 5 Digits of cash Default 0 6 Digits of cash 1 Function Code 10 Decimal Comma Use this function to set commas instead of decimals for all displays To Program The Decimal Comma Press Configuration Decimal Default 0 Comma 1 Function Code 12 Pump Time out Pump Time out sets the maximum continuous amount of time after starting the fueling that a customer can halt fuel delivery before the sale is terminated This function can be used as a security feature to monitor tampering with the unit Setting to too small a time leads to customer inconvenience For This Time Out Press Configuration None Default 0
348. qPA QGRN Electronic and Electrical Components Status LEDs LED Status Indication CR2 LON Neuron Status ON or blinking indicates problem CR9 HEARTBEAT should blink at 1 per second Currently blinks every 5 seconds In future all Heartbeats should be consistent with each other Connector Pin Functions and Voltages P1501 Pin Description Input Output Voltage 1 TOTE RETURN 0 V to open collector 2 TOTE DETECT 1 0to 45V 3 5 V 5 V 5 4 TOTE_FEED1 13 V 10 P1502 Pin Description Input Output Voltage 1 TOTE RETURN2 0 V to open collector 2 TOTE DETECT2 0to 45V 3 5 V 5 V 5 4 TOTE FEED2 13 V 10 P1503 Pin Description Input Output Voltage 1 TOTE RETURNS 0 V to open collector 2 TOTE DETECTS3 0to 45V 3 5 V 5 V 5 4 TOTE_FEED3 13 V 10 P1504 Pin Description Input Output Voltage 1 TOTE RETURNA4 0 V to open collector 2 TOTE_DETECT4 0to 45V 3 5 V 5 V 5 4 TOTE_FEED4 13 V 10 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 21 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Page 6 22 P1505 Pin Description Input Output Voltage 1 CPO Selectable Hysteresis 2 CP1 Selectable Hysteresis 3 CP2 0 to 5 V 4 CP3 0to 45V 5 RX DISABLE 0to 5 V 6 GND OV 7 No connect 8 BOARD_RESET 0 to 0 7 V P1506 Pin Description Input Output Voltage 1 18 VUNREG 17 5
349. r Pump Pump ID Pump ID Sid 17 1 Press 4 then 0 then press ENTER to access this Command Code 2 Select side then press ENTER To Program Press Configuration Side 1 side with junction box 1 Side 2 2 Figure 5 43 Pump ID Number 3 Enter Address 1 16 then press ENTER Command Code 41 Set PPU Options Dispenser contains two sets of PPU prices Level 1 and Level 2 PPU price levels can be displayed at dispenser on either single or dual PPU display devices per fuel grade Programming options provided with this Command Code determine which PPU display device s the PPU values appear on order in which they appear and where the displayed value comes from Default for this option is selection 1 Layout and meaning of each digit position for this programming feature is shown below Page 5 48 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 44 Layout of Digit Position for Programming Feature 1 Press 4 then 1 then press ENTER to access this Command Code 2 Select side then press ENTER To Program Press Configuration Side 1 side with junction box 1 Side 2 2 Figure 5 45 Layout of Digit Position for Programming Feature 3 Select Level Code 1 4 then press ENTER Level Code L1 Display L2 Display 1 Default From POS N A 2 L1 L2 3 L2 L1 4 N A From POS Command Code 42 Set Decimal Poin
350. r Assistance Requesting Technical 1 2 ATC Programming 4 25 B Batteries Servicing Mode CC 9 4 13 Testing 3 2 Batteries Logic Board 5 61 Baud Rates Supporting G CAT4 5 61 Beeper Pump Handle 4 15 Time Outs 4 17 VaporVac Alarm 4 15 see also Speaker Belts On Pumps 6 57 Blank Options Programming Two Wire Display 4 16 Blend Ratios Displaying 4 25 Programming CC 16 4 22 Blender Check Valves 6 60 6 67 Blinking PPUs Programming 4 19 Bolts Torque Specifications 6 6 Breakaways Maintenance 3 2 Safety Information 1 9 Buttons see Switches C Calculating Flow Rates 6 12 Pressure Drops 6 16 Calibrating Selecting Meter 4 25 Cash Acceptor Logic Board Requirements 5 61 Cash Display 5 or 6 Digits 4 16 Cash Credit Pricing 4 9 4 20 Cash Volume Totals Displaying 4 25 Changing PIN Code CC 13 4 22 Checklists Preventive Maintenance MDE 2856 3 4 Cleaning Pumps Dispensers 3 2 Clearing Memory For Modular Units CC 6 4 12 see also Resets Coldstart see Master Reset Comma Decimal Displays 4 16 Command Code 20 Set PPU 4 29 Command Code 22 Set Preset Types and Values 4 29 Command Code 24 Set Operations Mode 4 31 Command Code 25 Set Allocation 4 31 Command Code 27 Review ATC 4 32 Command Code 28 Change First Level PIN 4 34 Command Code 41 Set PPU Options 4 35 Command Code 42 Set Decimal Point Options 4 36 Command Code 42 Function Codes 4 36 Command Code 43 PPU Blinking options 4 38 Command Code
351. r DC voltage TP5 141028VDC LONvolage i TP6 21036VDC RAMvollapg gt TP7 21036VDC Battery voltage Jump Jacks Jumper Setting Function JP1 Out Reset see Note 1 JP2 Out Coldstart JP3 Out Service see Note 2 JP4 Out LON Programming see Note 1 JP7 Out Battery disconnect Notes 1 Used in manufacturing 2 Used in board repair MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M01785A001 Door Node 2 Door Node 2 is used on Encore 500 and Eclipse series units This node displays transaction information to the customer and serves as on I O gathering point by interfacing peripherals to the LON bus These peripherals include the card reader customer keypad and CRIND beeper The door node collects pump handle and grade data maintains a backup of the pumps data and communicates to the PPU display boards for that side The M01785 Door Node 2 is backward compatible with M00062A00X Door Node requires door node LON version 1 0 37 or higher The M00062A00X door node is forward compatible with M01785A001 with the exception that certain enhanced reliability components will not be available Service Tip Do not disrupt the download process when loading door node MIP software or the node will require repair at the factory Figure 6 22 Door Node 2 for Encore 500 and Eclipse TP6 JP5 IN Side 2 OUT Side
352. r Recovery Works Page 8 12 Note The numbers in Figure 8 12 correspond to the numbered steps below Figure 8 12 How Stage Two Balance Type Vapor Recovery Works Hose Casting A Venturi y TT Suction EM uct Coaxial Hose ube i j The fueling customer places the nozzle in the vehicle s fill pipe and compresses the nozzle bellows to form a pressure tight seal A slight pressure develops in the car tank during fueling which forces vapor back to the dispenser through the nozzle Balance systems use coaxial hoses to remove vapors Fuel flows through the inner hose and vapor flows through the outer hose A venturi pump in the hose removes liquid via a suction tube from the outer hose As system pressure balances the vapors flow from the vehicle fuel tank through the bellows nozzle outer hose dispenser vapor piping and underground piping to the underground storage tank MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operation and Troubleshooting How a Digital Valve Works The Gilbarco Digital Valve Figure 8 13 consists of an aluminum main valve casting a diaphragm piston assembly and two pilot control valves with electromagnetic actuation coils The diaphragm piston assembly divides the main valve casting into flow control and inlet chambers Fluid pressure in the control chamber is determined by inlet pressure and the pilot valves as wel
353. r is inactive large temperature differences between tank and ambient temperature and other unusual conditions that may affect calibration Three options exist for programming for current versions of software and firmware this feature is automatically enacted and cannot be programmed e Option off default Unit is inactive for 10 minutes Unit is inactive for 30 minutes The option should not be used as a fix for defective leaking check valves vapor hoses or nozzles which can affect calibration or sale indications with the nozzle closed after the unit has dispensed fuel Refer to MDE 3860 Programming Quick Reference Card for information regarding calibration Software Firmware Preset Overruns Encore 300 SB1465 The information in this Service Bulletin applies to Encore 300 Single Hose Selectable Blenders with Proportional Flow Control Valves manufactured after 4 26 03 V 15 0 95 Encore 300 software has been released K93734 701 to production and fixes the following issues Preset over runs and Error Code 46 e Fixes problem with Hose Pressurization not working on side B e Changes CC24 FC 1 to 10 minutes If you are having any E300 Models NL 1 3 3 or NN 1 6 4 experiencing Preset overruns or displaying Error Code 46 upgrade the software to v15 0 95 K93734 701 Once the software has been installed re program the dispenser as needed In addition V15 0 91 is required for any units having preset issues that are contro
354. r service philosophy High labor costs favor replacement Difficult removal from unit favors partial rebuild in unit Gilbarco recommends the following services for average or lower than average labor costs For Valves Recommended Service Less than two years old Use a repair kit replace spring diaphragm and O Rings More than two years old or high usage Replace the valve To rebuild or replace solenoid valves proceed as follows 1 Close and test shear valves for dispensers 2 Remove power to unit For dispensers remove any involved STPs Use OSHA Lock out Tag out procedure 3 Open nozzle into approved container to bleed pressure Some residual pressure may remain MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 67 Hydraulic Mechanical Components Valves 4 Check disconnected valve coils for continuity if bad replace coil 5 Replace valves if defective Use UL approved sealant as required for fuels when replacing valves Do not use teflon tape teflon tape debris may cause the valve to malfunction Clean valve area Do not introduce contamination into valve or piping Install valves with flow arrow pointing in the proper direction Service Tips If no magnetic field or power exists the likely problem is Problem with power from the valve driver board A cable problem If power exists the problem may reside in Coil e Valve body Steering Valves Steering valves are used on multi ho
355. r software M00635A001 M00549A001 M02235 LON Header 1 10 pin M02235 LON Header 2 10 pin M00635A001 not used not used not used M00491A001 M00549A002 Encore M01036A001 Eclipse M00719A001 not used not used M00150A001 Encore M00150A002 Eclipse not used Printed Circuit Assemblies and Nodes To Board Pulser s STP Board M00047 MO00059A00X Steering Valve Driver PCA LON system Side 1 LON system Side 2 M00050A001 Power Supply Board 18 VDC Pump 2 Wire To Terminal Block in Power Supply Stand alone or generic CRIND OR e M00089A001 CRIND Control Node MOC CRIND ny OR e MOC special CRIND Control Node M00089G001 See M00089A001 CRIND Control Node M00080 VaporVac Isolation PCB Serial Programming Port E cal Security Switch At Connector P1301 P1201 P1402 P1405 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components Status LEDs Figure 6 4 Pump Control Node LCD Nomenclature _ ON 2wie 2 2 Reversed
356. ramming levels When accessed all codes are shown as Entering new digits for new codes changes the display as they are entered Display does not show actual PIN digit but shows a 0 to denote that a number was entered Same PIN Code must be entered twice for it to be allowed First pass at entering a PIN Code is signaled by a 1 displayed in the Pass Code display Second pass is signaled by a 2 appearing in the Pass Code display Acceptance of a PIN Code is signaled by a 3 appearing in the Pass Code display A zero in the Pass Code display indicates the PIN Code was not accepted Four Function Codes are provided for changing each programming level PIN Code All Function Code PIN Code change operations have identical procedures Default selection upon entry into Command Code 77 is for Function Code 1 change level one PIN Code Layout and meaning of each digit position for this programming feature is shown below Page 5 70 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 71 Changing the PIN Code 7N N 7 7 Function Pass Code Number eeu fe Table below shows the Function Codes available for this Command Code Function Code Option 1 Default Change PIN Code Level 1 2 Change PIN Code Level 2 3 Change PIN Code Level 3 4 Change PIN Code Level 4 1 Enter 7 then 7 then press ENTER to a
357. rature 304 Display Gross Volume Totals Volume and PPU displays shows a ten digit number representing the selected meter s cumulative uncompensated volume total for a pure product 500 Software Version Main display shows software version number 600 Troubleshoot Probe Access this mode to troubleshoot probes There should be a small change in readings every second if T Meter and controller board are working properly Each probe can be checked by entering meter number Money display pulse width in terms of counts e Volume display probe resistance in ohms e PPU display shows the temperature of probe in Celsius 601 Probe History Use this mode to display probe history since ATC was installed This 1s useful for troubleshooting intermittent probes or probe connections Access each probe by entering meter number Money display shows probe number entered e Volume display shows total number of probe range errors logged e PPU display shows total number of missing probe pulse errors MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 37 Pump Programming Page 5 38 Additional Manager Functions for Encore 300 Error Codes Error Error Code Description Programming Error 100 All fuel types not programmed Rom Checksum 101 Controller ROM checksum error Ram Error 102 Controller RAM write read error T Meter Dead 103 Not receiving any T meter pulses T Meter Sync 104 Receiving T meter pulses but with e
358. re should be used for diagnosing 18 V Power Supply Problems M00050 18 V Power supply board Revision G and later incorporate a very quick protective circuit to prevent the transformer fuse from blowing With G boards cycling power will allow the system to supply power again providing that an overcurrent condition does not occur 1 With power on measure AC voltage from the transformer to the M00050 board Voltage should read 12 to 25 VAC if the system is good 2 Ifthe system has a fault very low voltage you will need to check the transformer and perform the following steps With power off you can remove the transformer connector to the M00050 Supply board and check resistance across the wires from the transformer Resistance should be very low 5 ohms or less if good f very high the transformer is bad open Do not replace any transformer until you find the reason for its failure or the new transformer may also fail 3 With power off at the M00050 board remove the 5 pin cable to the pump node e Measure ohms across pins 1 and 5 If ok you will see 800 ohms or more depending upon the number of options in the system If bad resistance will be very low and there is likely a fault with one of the nodes boards using 18 V To find the bad node or board you will need to temporarily disconnect the node board from the 18 V supply and determine if the ohm reading returns to 800 or more e Although unlikely to occur if no bad node
359. re unmarked Temporarily mount the nozzle hook with the upper Hex head screws in location E or G as determined by chart then use the nozzle hook carriage bolt holes as a drilling guide for the unmarked hole set 3 Once holes are drilled remove nozzle hook and clean up debris around hole set Assemble Nozzle Hook to Nozzle Boot To assemble the nozzle hook to the nozzle boot proceed as follows 1 Locate nozzle boot on dispenser and insert nozzle hook and carriage bolts into nozzle boot Attach using Hex head screws carriage bolts and nuts 2 Use a 3 8 inch nut driver or socket to tighten the two nuts onto lower carriage bolts 3 Usea7 mm nut driver or socket to attach the two upper Hex head screws 4 See Figure 7 15 on page 7 34 to identify existing nozzle hook retaining screw and nut locations identifying marks are located under right hand row of indented hole locations Standard nozzle hook locations are A and D MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 35 Hydraulic Mechanical Components Manifolds Dispenser Nozzle Boot Installation To install the nozzle boot proceed as follows 1 Position nozzle boot over correct positioning holes for nozzle type 2 Using the two existing screws attach the nozzle boot to the dispenser 3 Hold nozzle boot upright and insert nozzle over nozzle hook and into boot Wiggle boot to verify if the nozzle does not slip out of position 4 Power the unit and
360. rect offset If Reading On Prover Can Is An Indicated By a Reading Enter This On Keypad Overflow above 0 plus 0 Underflow below 0 minus 9 Figure 5 90 Underflow Overflow Designation Field Value shown in example is the value entered if equipped with software version 1 5 40 or later Page 5 84 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 14 Press ENTER On pressing ENTER the volume that should be in the can 1s shown on the display Compare this reading to the actual volume in the prover can Note If figures do not match then a number was entered incorrectly or the wrong offset code was used 0 004 gallon I cubic inch Figure 5 91 Can Volume Shown in the Display 15 Accepting rejecting the indicated amount To reject the displayed amount press CLEAR The selection field will then move back to the Volume field and allow re entry of the overflow underflow amount To accept the displayed amount press ENTER again The selection field then moves back to the side selection in the main money display 16 The dispenser now calculates the calibration factor based on the internal pulse count of the dispenser test volume and overflow underflow amount The meter is now calibrated F1 allows additional programming or F2 may be used to exit programming F1 and F2 will operate only if the security switch has been set to the secure posit
361. reported by the scanner toggling between Raster and Cyclonic laser scanning modes Press 3 to enable disable the ability for an UPCE barcode format to be detected and reported by the scanner MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 3 Press 0 to proceed to the next screen The following screen appears Barcode Scanner Scanner Enabled 1 UPCA Enabled 2 UPCE Enabled 3 EAN8 Enabled 0 Next Screen Page 2 4 Enter Save Values and Exit Cancel Discard Changes and Exit Barcode Scanner Scanner Enabled 1 EAN8 Enabled 2 EAN13 Enabled 3 Code 39 Enabled 0 Next Screen Page 2 3 Enter Save Values and Exit Cancel Discard Changes and Exit 4 To configure the settings proceed as follows e Press 1 to enable disable the ability for an EAN8 UPCA barcode format to be detected and reported by the scanner Press 2 to enable disable the ability for an EAN13 UPCE barcode format to be detected and reported by the scanner Press 3 to enable disable the ability for a Code 39 EANS barcode format to be detected and reported by the scanner 5 Press 0 to proceed to the next screen The following screen appears Barcode Scanner Scanner Enabled 1 EAN 13 Enabled 2 Code 39 Enabled 3 Code 128 Enabled 0 Next Screen Page 3 4 Enter Save Values and Exit Cancel Discard Changes and Exit MDE 3804B Encore and Ec
362. riate clamping device to ensure good contact Keep the nozzle at least 18 inches above the ground and 18 inches away from the dispenser during test e Wear insulating gloves if hanging hardware component is handheld during test or use an insulated device to support nozzle Refer to PEI RP400 02 for additional information 5 Testing continuity Turn meter on to conduct test Measure resistance while flexing and moving hose and nozzle into various positions that could be reasonably expected during fueling e Keep good electrical contact between probes and contact locations 6 Iftest reading complies with UL330 which states that resistance should not exceed 70 000 ohms per foot 233 000 ohms per meter the hanging hardware has passed the continuity test If test readings exceed 70 000 ohms per foot Perform continuity test between junction box and hose discharge casting on pump or dispenser This helps verify dispenser continuity and adequacy of test point locations f no problem exists here then isolate defective part by performing continuity tests between and across hose nozzle swivel breakaway and hose casting Replace part if resistance exceeds manufacturer s recommended maximum limit Do not use components if test reading shows an open circuit no resistance or other defect Adjusting Nozzle Hook for Specific Nozzles The following instructions are intended to adjust the position of the Gilbarco Encore dispensing unit nozz
363. rior to completion of the calibration procedure will result in lost calibration Note If a blender is being calibrated where either a pure low or pure high grade does not exist it will be necessary to change a blend ratio in Command Code 16 temporarily to create the missing pure high or pure low grade Revert the temporary grade back to actual once for the missing pure grade to be calibrated 7 Lower the pump handle or return nozzle to boot nozzle activated lever 8 Enter the offset number of cubic inches or centiliters away from zero and press ENTER 9 Enter 0 if the offset is above 0 zero or 9 if the offset is below 0 zero Press ENTER 10 The volume display will flash the adjusted volume for example 5 008 gallons is slightly less than 2 cubic inches on the prover scale You now have the option of pressing CLEAR to return to step 9 to re enter the offset data Note One cubic inch is 0045 gallon 11 Press ENTER to return to main display to enter new prover can size side or grade The volume display will display the adjusted volume amount for example 5 008 should equal plus 2 cubic inches on the prover can scale 12 When calibration is complete turn off Weights and Measures switch to exit programming mode Note Programming will be lost if Weights and Measures switch is turned off prior to the completion of calibration programming 13 Press F2 to return the unit to service Additional Manager Functions for Encore 300
364. ro Pricing 4 17 Preactivation STPs Programming 4 15 Preselect Time Outs 4 16 Presets Programming Five Button 4 11 Programmable Pump Values 4 18 Type 4 11 Pressure STP 6 14 Testing 6 13 Pressure Drops Testing Dispensers 6 15 Vapor Recovery Systems 6 70 6 71 Pressure Regulating Valves 6 60 6 67 Pressurization Hose Option 4 19 Prestart STP 4 15 Preventive Maintenance 3 1 Previous Transaction Zeroing 4 18 Prices Cash Credit 4 20 PPU Prices 4 9 Zero PPU 4 17 Problems see Assistance see Testing see Troubleshooting Product Blend Ratios Programming 4 22 Programmable Pump Preset Values 4 18 Programming Errors 4 4 Programming Levels 4 2 Programming Quick Reference 4 27 Pulleys 6 57 Pulse Simulator Box Testing Air to Liquid A L Volume 6 69 Pulsers Setting Single Dual 4 17 Testing 6 46 Index 3 Index Pump Handle Programming Beeper 4 15 Pump Tests Self Contained Units 6 15 Pump Timeouts 4 16 Pump Totals Displaying 4 25 Pumps Self Contained Torque Specifications 6 7 Purpose of This Document 4 3 4 57 Push To Stop Programming 4 18 H Ratios Blend Programming 4 22 Verifying 4 25 Replacing Gasoline Filters 6 28 Hoses 6 29 Parts 1 2 Requesting Technical Assistance 1 2 Resets Master 4 24 Restrictors Flow 7 3 S Safety Information 1 4 1 10 Screws and Bolts Torque Specifications 6 6 Select Options G6 4 17 Self Contained Pumps Testing Pressure 6 15 Self Contained Pumps Torque Specificat
365. rogramming has just been done If this is done the calibration steps will appear to function and display properly but actually will not Always start with pressing F1 and use appropriate PIN Codes to go directly into calibration mode IMPORTANT INFORMATION If ATC is installed product must be dispensed to exactly 20 liters in a 20 liter test can with no offset entered Failure to do this will result in significant measurement errors in the net volume in the normal operating mode 200 and 300 modes 1 Turnon to right the Weights and Measures switch See Figure 5 74 Weights and Measures Switch on page 74 2 On the Manager Keypad press F1 3 Enter Command Code 19 and press ENTER 4 You will be prompted to enter the prover can size in the measuring units for example gallons liters and so on that is programmed in Command Code 17 After entering prover can size press ENTER 5 Remove nozzle and select grade or lift lever Note Only pure product can be calibrated MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 29 Pump Programming Additional Manager Functions for Encore 300 6 Forunits without Automatic Temperature Compensation ATC dispense product into the prover can as close to zero volume as possible and hang up nozzle For units with ATC dispense exactly 20 liters into the calibration can The Volume display will show the number of uncalibrated pulses Any re activation of the handle switch p
366. rotational direction by monitoring the first 20 pulses every time the dispenser 1s powered up Should the pulser replace an existing pulser and it turn or be turned in the wrong direction for the first 20 pulses or more after power up of a unit it will establish that rotational direction as being correct The subsequent delivery will result in an error code 5047 To avoid this do not assemble or rotate a live pulser in the wrong direction just after replacement or power up If the pulser 1s inadvertently rotated incorrectly you can simply correct the condition by powering the unit down and back up and ensuring that the pulser turns in the proper direction for the first 20 pulses Software changes are being investigated to prevent this minor potential problem eliminate the need to learn rotational direction and you will be notified of any new software release Pulser Interchangeability SB1451 The M04012B001 pulser is backward compatible with the old pulser and vice versa However certain important error code information will not be provided if the new design is replaced with the old Therefore new pulsers should always be used to service new pulsers except in a case of an emergency situation where it is not available The pulser is similar in internal design to those used for Eclipse units but 1s not interchangeable with Eclipse pulsers As the pulser is of quadrature design it can used to reliably detect reverse flow such as for a blen
367. rranty CRIND device only Provided USB Printer Maintenance Cards to Manager CRIND device only Reviewed Paper Jam Removal Procedures specific paper requirements and how to order and replace CRIND paper 1 Reviewed periodic maintenance inspections leaks rust hanging hardware belts etc and recommended frequency see Owner s Manual EN Station manager supervisor was given an Owner s Manual MDE 3893 MDE 4516 and received explanation of information in the manual Lm Station manager supervisor received information about non compliance when all forms were not completed or problems were discovered Required Signatures Station Manager Information station manager must check one of the following and sign I have been advised that all dispensers have I have been advised that either some equipment inspections have not been completed or problems requiring correction were found been inspected per the checklists and no during inspections Should the equipment not have been properly installed it may be subject to one or more of the following A problems were found needing correction problems functions improperly fails prematurely creates a safety hazard not covered by warranty I have further been given information regarding inspections or corrections required I have also been advised on how to correct these situations and provide results to the commissioning ASC to ensure warranty coverage Station Manager Name print Signature Commiss
368. rrectly Ensure that you clean your hands after handling equipment Do not place any equipment in mouth A WARNING This area contains a chemical known to the State of California to cause cancer A WARNING This area contains a chemical known to the State of California to cause birth defects or other reproductive harm Laser Light Energy Scanners emit laser light that can damage eyesight when viewed directly A WARNING Laser light is used in this product and may present an eye hazard during service Direct viewing of laser light may damage eyesight Avoid long term viewing of direct laser light Replaceable Batteries Some printed circuit boards contain replaceable batteries Ensure that you insert batteries correctly WARNING There is a danger of explosion if battery is replaced incorrectly Replace with only the same or equivalent recommended type Dispose of used batteries according to the battery manufacturer s instructions Replacing Fuses CAUTION Using an incorrectly sized fuse may cause equipment damage To ensure good equipment protection and maintain safe operation always use the correct replacement fuse Helpful Service Information For Printed Circuit Assemblies PCAs Printed Circuit Boards PCBs and Nodes where applicable e Cable connectors are labeled with the destination of the cable Test Points are clearly labeled and recessed to facilitate use of meter probes Test point l
369. rrors Product Error 105 Multiple product selected Ramp Range Error 106 Gilbarco use only Range Error For Probe 107 Probe out of range Missing Error 108 Probe information missing Pulser Error 109 Pulser fail Reset JJ Error 110 Reset jump jack is installed Ram Corrupted 111 RAM data corrupted No Input Timer 112 No timer A interrupts occurring No Output Timer 113 No timer B interrupts occurring Power Fail Error 114 Power fail signal stuck Recursion Error 115 Read T meter interrupt recursion Note Refer to MDE 2531 Pump and Dispenser Start up Service manual for additional troubleshooting information if needed MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming Encore 5XX and Eclipse Series Units Pump Programming Programming Encore 5XX and Eclipse Series Units Contents in this Sub Section Description Page Software Versions 5 39 PIN Code Entry 5 39 Encore 5XX and Eclipse Programming Quick Reference 5 40 Level One Command Codes 5 41 Level Two Command Codes 5 48 Level Three Command Codes 5 65 Level Four Command Codes 5 88 Software Versions Software versions can be obtained by using the Laptop Tool for a complete listing or Power up for a partial display PIN Code Entry Programming Level Default PIN Code Command Code Range Level 1 2222 20 39 Level 2 1503 40 69 Level 3 1309 70 89 Level 4 0128 90 109 e Press F1 to perform additional programming Press ENTER after making selecti
370. rt up Service Manual August 2007 Filters and Strainers Hydraulic Mechanical Components 4 Attach filter to hydraulic manifold and turn clockwise until the gasket touches the base Then hand tighten an additional 1 2 turn 5 Restore power 6 Open shear valve on dispensers 7 Lift nozzle hook and authorize pump 8 Check for leaks 9 Bleed air by dispensing 10 gallons 40 liters into an approved container for each hose involved 10 Check for leaks again Service Tips e Hand tighten filter only Do not use filter wrench to tighten A light coating of oil on the gasket helps seal to seat properly and allows for easier release at time of removal About Strainers Strainers are installed between the manifold and filter to trap larger particles leaving fine filtering to be done by the filter element The strainer helps to prolong filter life by preventing premature filter clogging Always re install or replace strainer Servicing Strainers Cleaning Replacing Standard and High Flow Filter Strainers Figure 7 11 Filter and Strainer Assembly bl A Manifold 44 Strainer Kab tab down FUEL FILTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 25 Hydraulic Mechanical Components Filters and Strainers Page 7 26 To clean replace a standard and high flow filter strainer proceed as follows Remove strainer located between filter and filter base Use needle nose pliers to remove s
371. rt up Service Manual August 2007 Page 7 23 Hydraulic Mechanical Components Filters and Strainers AN WARNING OS Residual pressure and entrapped fuel may still be present and may spray when OS removing parts DA Fire and explosion could result in severe injury or death ol Ensure that you follow all safety instructions and are prepared for any residual A fuel pressure Use an approved container to collect residual fuel Use gasoline fuel approved absorbent materials to mop up spilled fuel Use Gilbarco fuel collectors if applicable To remove the filter proceed as follows 1 Remove the filter slowly by turning it counterclockwise 2 Drain the removed filter into an approved container and dispose of properly do not dispose of filters and fuel soaked absorbent materials in trash cans Follow local state and national code requirements for disposal Use of fuel catch cup or pan is recommended 3 Remove the strainer and clean Refer to Servicing Strainers on page 7 25 for details Installing New Filters To install a new filter proceed as follows 1 Read and follow instructions printed on the new filter Figure 7 10 Coating Filter Gasket Manifold Apply Oil to Gasket Strainer Filter and Gillbarco Gasket S0000280 FUEL FILTER 2 Install the strainer properly 3 Coat the new filter gasket with a thin film of clean oil as shown in Figure 7 10 Page 7 24 MDE 3804B Encore and Eclipse Sta
372. s User Guide for Managers and Cashiers Using G SITE Systems located in the CRIND and TRIND library on GOLD How a Scanner Works When interfaced with a POS system the Bar Code Scanner option allows customers to scan the bar coded loyalty card on Card Reader In Dispenser CRIND device equipped units G SITE systems require that the Automatic Identification Manufacturers AIM code be enabled for proper operation CRIND device scanner diagnostics can be used to enable and disable the AIM code as necessary Refer to Passport documentation for information particular to that system The scanner mechanism uses a low power laser directed downward that reads bar codes that are presented directly below the scanner window The bar codes are interpreted by the scanner components and information is sent through the CRIND to the POS for processing The POS system responds to the information by sending special commands to the CRIND for authorizing specialized loyalty card discounts and so on In Encore 500 and Eclipse units the scanner is controlled by a Local Area Network LAN Serial Node per unit Service Tip The Encore 500 and Eclipse Bar Code Scanner require CRIND BIOS software version 200 30 or greater in order to operate properly MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 19 Theory of Operation and Troubleshooting Theory of Operation Figure 8 17 Encore and Eclipse Bar Code Scanner Location Eclipse
373. s ENTER Function Code 1 Master Reset To Program Press Configuration N A 0 Master reset 1 2 Enter Function Code 1 then press ENTER If you select Function Code 2 and press ENTER then select 1 and press ENTER the unit will perform a master reset If you select 1 and press ENTER it returns to the normal operation See Function Code 1 Master Reset above 3 Enter the configuration change Function Code 2 then press ENTER Page 5 28 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Function Code 2 Conversion Factor Note Units will not operate without a conversion factor programmed To Program Press Configuration No conversion factor Default 0 U S gallons 1 Imperial gallons 2 Liters 3 1 012 pulses per gallon 4 4 Select conversion factor and then press ENTER Command Code 18 Do not use Command Code 19 Encore 300 Electronic Calibration Procedure Ensure that you follow the order of the steps listed below Failure to follow the steps in the order given will result in calibration not being properly completed Electronic calibration must always be manually verified before returning the dispenser to service Additional calibration information can be found in the Pump Programming section on page 5 lof this manual IMPORTANT INFORMATION Never enter into Command Code 19 directly from any other Command Code if p
374. s are not properly lit on the 18 Volts power supply inspect the M00050 18 Volts supply board for its revision level If you have revision F G or H you may need to clip R9 off the 18 Volts board to correct a false over current shutdown problem To determine if a false over current is involved with these revision boards you should perform the following test You will be checking both channels of the 18 Volts power supply board Power down the unit Disconnect one LON cable from the Pump Node Power up and check the two green LEDs on the M00050 18 Volts power supply board If the two green LEDs are ON the other channel is good f both channels and if the 18 Volts power supply board pass the test then a false over current fault is likely occurring and you should clip off R9 to solve the problem Page 6 268 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Troubleshooting Theory of Operation and Troubleshooting Hydraulic Components Meter Jump SB1470 Hose pressurization feature CC 55 enacted Previous software programming codes anticipated release of the feature but it was never made functional Hose pressurization is potentially useful for the following conditions Extremely cold temperatures resulting in sale indication when the nozzle hook is activated but the nozzle is closed commonly called meter jump Infrequent intermittent problems with check valves significant temperature changes while dispense
375. s can be derived from these numbers to analyze whether this card reader is working acceptably or requires cleaning or repair Compare results to other units and similar stations Note A 100 reading will never occur as not all cards will be inserted properly or it may be a wrong or defective card MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 107 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser From the Device Config menu press 5 The following screen appears Card Reader Menu 1 Show Card Counts 2 Reset Card Counts Cancel Exit Show Card Counts When this screen 1s displayed you will not be able to exit diagnostics mode by using the Gilbarco CRIND diagnostics card This feature allows you to use the diagnostics card on this screen to interactively test the card reader without inadvertently exiting the configuration interface session 1 From the Card Reader Menu press 1 The Card Reader Counts screen displays for Side 1 Card Reader Side 1 Track 1 Track2 Track 3 Good Reads 13 13 0 Bad Reads 0 0 Total Reads Total Reads Without Data Enter Next Screen Cancel Exit Note ISO magstripe cards support up to three tracks sets of data storage The data follows a certain format and contains a checksum to guarantee against data corruption on the track The screen reports the current totals for each of the supported card reader statistics Trac
376. s shown in the following table Prover Can Volume Units Difference Volume Units Liters Millimeters US gallons Cubic Inches Imperial gallons Page 5 82 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Figure 5 86 The Display Field is the Volume Field IMPORTANT INFORMATION The procedures in Step 14 pertain to dispensers that have software version 1 5 40 or later The procedures in Step 15 pertain to dispensers that have software version prior to 1 5 40 10 If the dispenser has software version 1 5 40 or later In this example 12 is the number of cubic inches read as over from the prover can Enter 12 on the keypad to show up in the display as shown Figure 5 87 Entering on the Keypad 11 If the dispenser software version is prior to 1 5 40 In this example all zeros are flashing in the volume field MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 83 Pump Programming Encore 5XX and Eclipse Programming Instructions Figure 5 88 Zero Flashing in the Volume Field 12 Enter the offset number number of cubic inches or centimeters away from zero Figure 5 89 Entering the Offset Number 13 Press ENTER Upon entering the overflow or underflow amount the selection field will move to the underflow overflow designation field as shown in the following example Use the following table to select the cor
377. s where seepage is noted to occur when temperatures are extremely low approximately 15 degrees F or colder Monthly leak inspections of the dispenser hydraulics will catch any leaks that should develop The cold weather meter seal kit is K35222 01 The standard seal kit is K35222 The standard kit is considerably less costly than the 01 kit Also the standard kit is completely acceptable for even very cold sites Hence use of cold weather seal kits across the board 1s not recommended One Kit services ten meters LC Meter Encore Ultra Hi LC meters are used in Encore Ultra Hi Master or Ultra Hi Combo series units Figure 7 26 LC Meter and Pulser Assembly Meter Discharge Service Tips e Remove and replace meter using metric tools Place approved pan under meter during repair to collect residual fuel Inspect all gaskets during off unit repairs Replace as needed Some meter bolts are difficult to access A 13 mm universal socket will make installation and removal easier For calibration problems refer to About Calibrating Meters on page 7 21 Non use of filters and strainers can significantly reduce meter life Meter failure may be indicated by a significant change in calibration from high to low flow rates excessive calibration spread or meter stall at low flow Note Other problems may also cause the same symptoms Calibration problems are not always caused by meters dispenser check valves and leaking nozzles may also cause c
378. se blenders These valves are part of the steering valve manifold and are used to direct fuel flow to the proper hose The valves ensure that only the proper hose is activated Refer to Steering Manifold on page 7 38 for information on Steering Valves Vapor Valve Vapor Vac Page 7 66 Vapor valves mount in the upper piping housing assembly Refer to Vapor Recovery Components on page 7 69 for additional Vapor Vac Information Vapor valves that do not operate properly can cause loss of vapor recovery system efficiency or premature nozzle cut off especially in Balanced Vapor Recovery systems They are single stage solenoid valves that isolate all hoses not in use Figure 7 43 Vapor Valve T17909 S0000356 Note New units do not use vapor valves They require a particular type of nozzle which is different from units containing vapor valves Ensure that you use the correct nozzle type refer to manufacturer s instructions for the application or clean air regulations may not be met Service Tip Under normal operating conditions vapor valves make a clicking sound when flow begins However a defective valve can make the VaporVac pump motor noisier during operation If the vacuum pump becomes noisier only when a certain hose on a certain side is being used suspect the valve associated with that hose MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Vapor Recovery Components Hydraulic Mechanical Compon
379. se the Weights and Measures switch See Figure 5 74 on page 74 Flip the switch to ON turning on the main display on both sides of the unit The PPU shows the number of days that have lapsed since the last calibration If this meter has not been verified or calibrated before factory pre calibration is not counted the PPU displays flashing 8s Figure 5 75 PPU Display 2 Setting the prover can size and VUT The three Most Significant Digits MSDs of the money display contains the prover can size which is 5 gallons in this case The Least Significant Digit LSD of the money display shows the volume unit type l U S Gallons and 2 Liters Option 1 is shown in this case If the VUT or blends have not been programmed the PPUs will flash 26 for No VUT and or 4307 tor No Blends MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 75 Pump Programming Encore 5XX and Eclipse Programming Instructions If the prover can size is not as shown refer to CC82 instructions You must turn off the Weights and Measures calibration switch before changing CC82 can sizing 3 Remove nozzle and select pure product grade by raising the pump handle or removing the nozzle and pushing the grade select button of the meter to be calibrated Note All PPUs except for the one associated with the meter being calibrated will be blank 4 Dispense fuel into the appropriate prover can ensuring that you stop within 1 cu
380. sed MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Pump Programming Once a programming Command Code is activated the default or first selectable entry for that mode will be shown as flashing Defaults and further keypad entries will show as flashing digits and will update display as they are keyed in This action continues until ENTER is pressed Once you press ENTER the next programming field will start flashing indicating an operator action is required This keypad display functionality will continue until you exit the programming mode Notes 1 It is important to note that each programming level utilizes a Security PIN Code as shown in the following table Function Codes within a Command Code begin at 1 2 Entering the highest level Security PIN Code for Encore 5XX and Eclipse series units will grant you access to all lower level Security PIN Codes Entry into a Command Code will present data as the default value or last programmed values for that Command Code Only one Command Code and Function Code Parameter may be programmed changed at a time The following table shows currently allocated Security and Command Codes that have been assigned for use in Encore and Eclipse These PIN Codes can be programmer modified as described later Note For maximum station security Gilbarco recommends default Security PIN Codes be reprogrammed to the non default Codes Default Security PIN E300 C
381. ser and before total flow exceeds 250 volume units Once totals of a grade reach 250 volume units they cannot be reset Only grades used in dispenser will accept money totals Note that position of decimal point in totals values will depend on prior programmed location of decimal point in dispenser display Layout and meaning of each digit position for this programming feature is shown below Layout and digit positions are shown in the following diagram Figure 5 68 Money Totals Display Grade Selection hi MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 67 Pump Programming Encore 5XX and Eclipse Programming Instructions 1 Enter 7 then 3 then press ENTER to access this Command Code 2 Select Side 1 or 2 then press ENTER 3 Select Grade 1 to 6 then press ENTER 4 Setor Display Money Total 5 Press ENTER Command Code 74 Set Display Volume Totals Allows programmer to read and set volume totals Initially for a new pump controller board displays will show zeros in all locations Notes 1 Function can only be performed at first initialization of dispenser and before total flow exceeds 250 volume units Once totals of a grade reach 250 volume units they cannot be reset Only grades used in dispenser will accept volume totals 2 Position of decimal point in totals values will depend on prior programmed location of decimal point in dispenser display Layout and meaning of each dig
382. spect unit for structural meter and piping damage Repair or replace damaged components as necessary Note Meters piping and connections may leak after a drive off Replace breakaway if it is not the reusable type Check for damage to breakaway valve and seals before reassembly Follow manufacturer s instructions Follow manufacturer s instructions for cleaning and lubricating seals and valve ends Follow manufacturer s instructions for recoupling MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Hanging Hardware Hydraulic Mechanical Components 11 Restore power and open shear valves 12 Authorize nozzle and check for leaks in hose and plumbing area especially the meter and filter 13 Purge system of air Refer to Purging Air from the System on page 7 7 for more information 14 Check for leaks again Ensure that you check meter and internal piping if a drive off was involved Service Tips Do not reuse a separated breakaway if any part appears damaged e Some manufacturers require lubrication of breakaways every six months Others require only periodic visual inspections Follow their recommendations nspect breakaways for leaks at least once a week f breakaway separates without a drive off occurring do not reuse e Consult manufacturer for the maximum number of times you can reset a breakaway Some breakaways are not resettable A protective sleeve supplied by manufacturer is recomm
383. spenser Works 8 6 How Truck Stops are Configured 8 8 How VaporVac Vacuum Assist Vapor Recovery Works 8 11 How Stage Two Balance Type Vapor Recovery Works 8 12 How a Digital Valve Works 8 13 How a Proportional Control Valve PCV Works 8 14 How the Electronics Works for the Encore 300 8 16 CRIND Device 8 17 How a TRIND Device Works 8 18 How a Cash Acceptor Works 8 19 e How a Scanner Works 8 19 How Automatic Temperature Compensation ATC Works 8 20 Error Codes 8 23 e Encore 300 Error Codes 8 21 Encore 500 and Eclipse Error Codes 8 23 Troubleshooting 8 28 Error Code Explanations 8 30 Hydraulic Components 8 29 Hydraulic Components 8 29 Error Code Explanations 8 30 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 8 1 Theory of Operation and Troubleshooting Theory of Operation Section Overview This section provides the theory of operation and troubleshooting tables to help diagnose problems with individual components and systems Observation error code recording and measurement taking are used where applicable to find the symptom and a possible remedy How to Use this Section Use the Topics in this Section on page 8 1 to locate the appropriate topic Review the information in Theory of Operation on page 8 2 to familiarize yourself with how the system works Cable block diagrams in Electronic and Electrical Components on page 6 1 and Hydraulic Mechanical Componen
384. st Note This flow will appear on the customer displays This option is used in cold climates where fuel in hose may have contracted after a period of inactivity This could cause what is commonly referred to as meter jump at the beginning of a transaction Default value is selection 1 OPTION OFF This function will pressurize hose during lamp test of first transaction after a power up or during lamp test of first transaction after a period of inactivity defined by programming option code Note Fuel passing through meter during hose pressurization will not be registered on displays nor counted toward the sale prior to start of delivery IMPORTANT INFORMATION Command Code 55 is not intended as a fix for defective equipment such as a leaky meter meter check valve nozzle or vapor recovery hoses Always fix problems first MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 61 Pump Programming Encore 5XX and Eclipse Programming Instructions Figure 5 61 Setting Hose Pressurization 1 Enter 5 then 5 then press ENTER to access this Command Code 2 Use the following table to select option 1 3 Option Hose Option 1 Default Option OFF 2 Unit has sat inactive for 10 minutes 3 Unit has sat inactive for 30 minutes 3 Press ENTER Command Code 56 Set Stop Button Control Command Code 56 is entered in Level 2 programming to set stop button control Programming is allowed but will only
385. st 2007 Power Supplies Electronic and Electrical Components Power Supplies The following table lists the contents in this sub section Topic Model Page MO00488AXXX Voltage Select Plug Encore 300 Encore 500 and 6 72 Eclipse M00050A001 Power Supply Board 18 VDC Encore 500 and Eclipse 6 73 M00053A002 Power Supply Board 24 VDC 6 76 M00458A002 Encore 500 and Eclipse Power Supply 6 78 M01608A001 Encore 300 and Ultra Hi Power Supply Encore 300 and Ultra Hi 6 79 M02274A001 Universal Power Supply for Encore 300 Encore 500 Encore 500 and 6 80 Encore 500 and Eclipse Eclipse M02774A001 Universal Power Supply 2 PCA for Encore Encore 500 and Eclipse 6 82 500 and Eclipse For VaporVac power supplies refer to VaporVac Electrical Components on page 6 115 About Power Supplies The function of the power supply is to provide clean voltage at the correct values required by the electronics Replacing Fuses CAUTION Using an incorrectly sized fuse may cause equipment damage To ensure good equipment protection and maintain safe operation always use the correct replacement fuse MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 71 Electronic and Electrical Components Power Supplies M00488AXXX Voltage Select Plug The Encore 300 Encore 500 and Eclipse main power supplies use a voltage select plug to determine power supply AC voltage input Voltage select plugs are not included and must be ordered se
386. steps included for the observed problem This information and similar for other significant and common problems is published at the Technical Resource Page TRP under http www gilbarco com interactive login cfm You must be a certified technician with pre approved access through your company Gatekeeper to access this information It is strongly suggested that you monitor the TRP frequently for similar useful information Electrical Blank Monochrome Display SB745 If the monochrome displays are blank on the Encore 300 the F1 fuse 8 5 Volts may also be blown on the CRIND Regulator Board or for the Encore 500 Eclipse the overload LED CR 10 on the 18 Volts DC Power Supply is on The first thing that needs to be checked is the C45 capacitor on the back of the monochrome display C45 may show signs of being burnt Use an ohmmeter to determine if the reading across the capacitor is zero to a few ohms If so the capacitor is bad approximately 4 5K ohms or higher is a good reading If C45 is bad the monochrome display and F1 fuse Q12682 06 will need to be replaced on the Encore 300 For the Encore 500 Eclipse the monochrome display will need to be replaced Current production units use Q13908 05 monochrome displays that do not have a C45 capacitor Power Supply M00050 Shutting Down SB910 The in rush current for a E500 Eclipse at power up may create a false over current fault that will shutdown the dispenser If a unit shuts down and LED
387. supply is part of the VaporVac electronics module Figure 6 69 VaporVac Power Supply M01775A001 Connections and Cables Connector Via Cable To Board At Connector J1001 9 pin Power supply lead VaporVac Motor Drive PCA T18018 G1 P1001 9 pin P404 3 pin M02710A002 Main power supply J404 3 pin Fuse Part Description F1 Fuse 250 VAC SLO BLO 7A MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 123 Electronic and Electrical Components VaporVac Electrical Components T18162 VaporVac Power Supply for Eclipse Figure 6 70 VaporVac Power Supply T18162 G3 Fuse 250 VAC SLO BLO 7A gt a lt x a Z Q o uJ uo Connections and Cables Connector Via Cable To Board At Connector J1001 9 pin Power supply lead VaporVac Motor Drive PCA T18018 G1 P1001 9 pin J1202 3 pin VaporVac Valve Driver PCA T18015 P1202 3 pin P404 3 pin M02948A001 Main power supply J404 3 pin Fuse Part Description F1 Fuse 250 VAC SLO BLO 7A Page 6 124 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Hydraulic Mechanical Components 7 Hydraulic Mechanical Components About this Section Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of th
388. t Options Command Code 42 is entered in Level 2 programming to assign decimal point locations Function Codes 1 through 4 are selected to set location of money and volume decimal points for display and calculation purposes Entry into Command Code 42 will select Function Code 1 by default Layout and meaning of each digit position for this programming feature is shown below MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 49 Pump Programming Encore 5XX and Eclipse Programming Instructions Figure 5 46 Set Decimal Point Options 1 Press 4 then 2 then press ENTER to access this Command Code 2 Select Function Code 1 4 from the following table then press ENTER Function Code 1 Set Money Decimal Point Position for Display The table below indicates locations where main money display decimal point can be positioned via Command Code 42 Function Code 1 Position Parameter Options Decimal Point Positions 1 XXXXXX 2 XXXXX X 3 Default XXXX XX 4 XXX XXX 1 Press Function Code 1 then press ENTER Note Accepts default Function Code Main Money Display 2 Select Position Parameter Option 1 4 then press ENTER Function Code 2 Set Volume Decimal Point Position for Display The table below indicates locations where main money display decimal point can be positioned via Command Code 42 Function Code 2 Position Option Decimal Point Positions 1 XXXXXX 2 XXXXX X 3 XXXX XX 4 De
389. t metallic seat of valve body for damage or uneven seating surface Clean contamination from valve body interior when servicing Torque bolts properly Refer to Torque Specifications on page 7 5 Follow the steps in After Repairing on page 7 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Valves Digital Valve Hydraulic Mechanical Components The digital valve consists of a casting a diaphragm piston assembly and two pilot control valves with electromagnetic actuation coils Fuel flow is controlled by signals actuating the coils that open and close the pilot control valves The digital valve allows for precise control of fuel blends by regulating the movement in small increments of a diaphragm piston assembly The opening closing of the pilot control valves are continuously monitored and adjusted to maintain blend ratios For non blenders the valve operates at only slow and fast flow For more detailed information on how the digital valve works refer to Theory of Operation and Troubleshooting on page 8 1 Note Digital valves cannot be used for programmable flow control Figure 7 38 Digital Valve Assembly Digital Valve Body Diaphragm Piston Assembly y AP Piston Assembly Valve Stems M LZ Y Center Stem Digital Diaphragm Valve Body Retainer Ring Spring Some Potential Problems Coils improperly installed upside down can result in improper valve operation Retaining hardware p
390. t money totals mode The 1 shown in the leftmost display indicates that this total is a non resettable money total The VOL TOTAL displays the volume for the grade selected Volume for both sides of the unit can be viewed Use the CLEAR key to exit the volume total mode This convention comes from the Advantage series product line and is maintained here for ASC and site manager familiarity Displaying Pump Money and Volume Totals 1 To view Side 1 Totals proceed as follows Press TOTAL on Manager Keypad Combined cash and credit total will appear for Grade 1 Side 1 Select grade s using keypad Read totals for each grade selected The number of hose s erades s vary for each model Note For Blenders grade 7 high product and grade 8 low product To view side 2 money totals press ENTER Press VOL TOTAL Volume total appears for the grade selected Select grade s using keypad Read volume totals for each grade selected To view Side 2 Totals press ENTER Select Side 2 Repeat To view Side 1 steps on next page for Side 2 Press CLEAR to exit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 31 Pump Programming Additional Manager Functions for Encore 300 Audit Trail Information Figure 5 26 Advantage Dispenser Audit Trail Display Newer no main PPU display Counts Blend Change Mode PPU Displays Low Grade Figure 5 27 Advantage Audit Trail Display Older SW Vers
391. t of overspeed Note Damage resulting from overspeed is not covered by warranty Amount to Purge at Nozzle Use the table below to determine how much fuel to dispense when purging unit through the nozzle For Pump This Amount Start ups installing new systems 35 gallons 130 liters per hose System with fully purged product lines 25 gallons 130 liters per hose Major services changing meters pumping units and so on 25 gallons 90 liters per hose Minor services changing filters strainers and so on 10 gallons 40 liters per hose Encore 500 and Eclipse Units manufactured after December 1 2002 require no special programming to purge units Prior to this date use Encore 300 procedures To purge the dispenser proceed as follows 1 Lift nozzle handle for hose being purged 2 Place nozzle in approved container see Figure 7 2 on page 7 10 3 Slowly open nozzle until a constant stream of fuel is observed You may now open the nozzle wider to dispense the proper amount MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 9 Hydraulic Mechanical Components Purging Air from the System Page 7 10 10 Figure 7 2 Dispensing into Prover Can Purge Nozzle Ground Wire and Clips a Prover Can Return the nozzle to the nozzle boot Empty approved container into appropriate product tank Encore 300 Units The Encore 300 will display error code 26 if you attempt to purge air from an
392. t renders the display temporarily unusable you can adjust contrast from the opposite side of the unit 1 From the Device Config menu press 1 The following screen appears Monochrome Contrast 1 Adjust Contrast Side 1 2 Adjust Contrast Side 2 Cancel Exit 2 To display the settings for Side 1 press 1 To display the settings for Side 2 press 2 A screen displays the contrast settings for the side that was selected Contrast Side1 Side 2 Contrast Range 1 99 Number Keys Direct Entry Clear Erase Entry Up gt Enter Apply Entry Cancel Exit Down gt 3 Use numeric keys to enter a one or two digit contrast setting Press the Up or Down function keys 1f applicable to increase or decrease the contrast setting 4 Press Enter to apply the change made to the contrast setting and view the display with the new setting immediately Page 5 98 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 5 Press Cancel to exit the screen and return to the Monochrome Contrast menu If the contrast setting 1s currently blank the display will continue to show the last valid contrast setting that was entered Audio Setting This option is currently available for kiosk only Press 2 from the Device Config menu to access this feature Cash Acceptor The Cash Acceptor menu allows the user to configure and test operati
393. t shear valves only stop fuel at the product piping Double poppet shear valves also stop fuel from draining out of dispenser CAUTION Improper wrench technique may damage the shear valve and lead to leaks Excessive force applied to shear valve during fitting and tightening may damage or weaken shear section of valve Always use two wrenches one wrench to hold valve above the shear line and the other to apply force to fitting UL requires all dispensers to use shear valves Follow these recommendations when installing or servicing shear valves Ensure free movement of linkage Lubricate valve linkage per manufacturer s instructions Follow manufacturer s recommendations first when installing valves Shear section of valves must be flush with top of islands Do not mount valve upside down Anchor shear valves rigidly Rigid cross member and mountings are important devices for proper operation of the system Inspect valves every six months Ensure that valve linkage is free and clear from any obstructions conduit piping and so on Lubricate the linkage with SAE 10W motor oil Gilbarco highly recommends use of double poppet shear valve instead of single poppet when replacing valves Use of double poppet shear valves may require some internal plumbing changes for older units Double poppet shear valves prevent fuel from draining from a unit that has been knocked off the island Do not use pliers to open or close shear valves Reduc
394. tart OFF 2 Prestart ON 2 Press ENTER Function Code 2 Set STP Control Option determines how STPs will be controlled during a fueling operation Option 1 is default and results in only the STP s necessary for fueling operation to be turned on Option 2 turns on all STPs anytime there is a fueling operation Option 3 turns on only the STP s required for fueling operation until backward pulses are sensed from a meter not used for the fueling operation At that time the STP associated with the backward turning meter is turned on for the duration of the fueling operation 1 Using the following table select option 1 3 2 Press ENTER Option STP Option 1 Default Turn on ONLY selected STP Default _ 2 TunonALLSTPs 3 Automatic Mode Command Code 50 Map Valves and STPs Command Code 50 provides ability to reverse order of mapped valves and STPs This option is useful in case the site or an individual dispenser was plumbed backwards It does not move the association between PPU display position and grade Use of this code is not recommended for correcting plumbing errors Pump node replacement will set this parameter to default Valves and STPs will than be improperly programmed Default for this option is selection 1 NORMAL Note This Command Code will result in an error display as described in Dispenser Programming if attempted on a multi hose MPD dispenser Figure 5 55 Mapping Values and STPs Valve Mapping 1
395. tart up Service Manual August 2007 Introduction Who Should Use this Manual Read this First This manual 1s intended for Gilbarco Authorized Service Contractors ASCs who have been trained and certified on completion of Gilbarco certified Training Courses These ASCs should be aware of basic troubleshooting techniques such as reading a volt ohm meter reading pressure and so on and understand the differences in Gilbarco products options and functionality If you have not been through Gilbarco training contact the Gilbarco Training Department Service Protocol Requesting Further Technical Assistance A Service Technician requesting technical assistance should do the following 1 Beatthe site 2 Have the following available when placing the call Unit model and serial number e Site name and telephone number Your technician number Problem description and history All required recommended spare parts e Manuals available for reference 3 Call the Technical Support department 1 800 743 7501 Refer to the Customer Service Report CSR number if previously assigned Using Replacement Parts Use only genuine Gilbarco replacement parts Use of other parts will void warranty and could affect unit conformance to various national local or state codes Whom to Contact at Gilbarco For this type of information Schedule Training Technical Assistance Warranty Service and information Explanation of Gilbarco s
396. teering Valve Side 1 Grade 1 MV14 Steering Valve Side 1 Grade 2 SV24 Steering Valve Side 1 Grade 3 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Printed Circuit Assemblies and Nodes Electronic and Electrical Components M00062A001 Door Node 1 The first generation Door Node M00062A001 is for use with Encore 500 and Eclipse with Steering Valves only This node provides an interface for inputs and outputs from the customer and acts as the interface to many of the devices that are found on the door The door node also provides sales totals to the customer There are two generations of door nodes which are interchangeable The first generation node shown in Figure 6 8 on 6 16 has more connectors and some additional components not seen on the second generation node There is no loss in features in the second generation node The door node is part of the LON system and many devices normally found on the door will connect to the node and pass information on via the LON Devices directly or indirectly connected to the Door Node are e Push to Start Call and Pump Stop Buttons e Customer CRIND keypad e Manager Keypad Side 1 only ndirectly handle switches and grade select switches through PPU Board e Soft Keys Monochrome and Color eCRIND Beeper Speaker Door Sensor security Service Tips For software version V1 5 40 or later Pump Node software the door node provides redundant data storage
397. ter the hundredths digit Page 5 12 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Figure 5 8 Volume Allocation Display 5 Press ENTER Side number flashes 6 Repeat steps to 5 to program all sides grades and price levels Blanking Display Manually and Selecting Five Button Money Cash Volume Preset Command Code 4 This manual blank function is typically used for standalone units to blank out the displays when the station is closed but the power is not removed from the dispenser pump Figure 5 9 Blanking Display Function Code 1 Press 4 then ENTER on Manager Keypad to access this Command Code 2 Select Function Code or 2 then press ENTER Function Code 1 Manual Blank Displays To Select This Option Press Configuration Displays OFF 0 Displays on Default 1 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 13 Pump Programming Encore 300 Programming and Data Access Instructions Function Code 2 Five Button Preset Press To Select This Option Configuration No Five Button Preset Default 0 Money Preset 1 Volume Preset 2 Incremental Presets 3 f Programmable Pump Preset is present unit cannot be programmed to Five Button Operation Note Command Code 10 Function Code 8 on page 5 20 can also be used to blank out displays from the console Command Code 6 Clearing Memory Perf
398. teway P3503B 2 pin M00721A002 Side 2 M00122A001 LON to Serial Node LON Gateway P3504 2 pin M00484A001 Filter Capacitor P3505 3 pin Blue wire 14 V secondary on Power Supply Optional MDE 3804B Encore and Eclipse Start up Service Manual August 2007 At Connector P1403 4 pin 2 pin 2 pin P1512 2 pin P1512 2 pin 2 pin Page 6 77 Power Supplies Electronic and Electrical Components M00458A002 Encore 500 and Eclipse Power Supply Page 6 78 M00458A002 Power Supply Assembly This power supply is no longer available and has been replaced by M02274 It is shown here for reference only Refer to MDE 4133 Power Supply Kit M00016K003 Installation Manual for replacement instructions Figure 6 34 Encore Power Supply M00458A00X 18 VDC Regulator PCA M000050A001 9 4 VAC Transformer Connection 24 VDC Regulator PCA Transformer Sub assembly M00151A00X A 0 fq if j f im lf FL D ff 2 Wire Red yellow or blue data wires attach here P3502B P3503B D gt A s ps 7 zi f Lx P3502A O Q Field wiring to STP board inside here P3503A M000053A002 Connections and Cables Power Supply connections At Connector Connector Via Cable To Board P1402 M00635A003 Pump Control Node M01922 P1105 P3502A M00715A005 Printer M00317A001 CN1 P3502B P3503A Not used in this co
399. the customer can enter a pre determined value and or increment or decrement the selected sale or volume value prior to fueling Basic unit component operational instructions contained and sold on a hardware electronic chip One or more procedures within a Command Code Indicates the fuel grade available at the nozzle In case of blender dispensers a grade is created by blending products Liquid Crystal Display Least Significant Digit A device where programming and access of other unit information such as totals can be accessed A six digit display that during normal operation shows the total value of the fuel dispensed Most Significant Digit A choice that is available upon entering a Function Code Personal Identification Number is a Security PIN Code used to access the programming Programmable Pump Preset This option is used to set up specific volume of fuel or dollar amounts to be dispensed using specific key pad buttons Display that contains the Price Per Unit PPU of the associated grade MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Pump Programming Term Definition Product Indicates the base fuel grade available in the storage tank Not to be confused with Grade However in a non blending environment a grade is the same as a product Prover can A calibrated can used by Weights and Measures officials and calibrating technicians to accurately check or calibrate
400. the dispenser model being checked If the flow rate is low for the pressure it 1s likely that the dispenser or hanging hardware problem exists If readings are close to the specification it 1s likely that the dispenser is OK and it is a system problem Use this table to evaluate the probable cause of dispenser low flow rate Low Flow Rate Symptom Probable Causes Observed pressure drop is more that a few PSI higher Flow restriction Observed and expected pressure drop is close to Hanging hardware specification MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Measuring Vacuum Pump Hydraulic Mechanical Components Reaching Desired Flow Rates Listed below are a few methods for meeting desired flow rate Correct replace faulty component Use larger STP or manifolded STP Use larger inlet piping to the pump dispenser Use less restrictive hoses and nozzles e Reduce maximum lift of product from tank Use a higher capacity pump or dispenser model Measuring Vacuum Pump Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections Use OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About Vacuum Readings 7 17 Measuring Dry Vacuum for Pump 7 18 Measuring Wet Vacuum and Pressure for Pump 7 19 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fitt
401. the test cassette and return the station s cassette This operation should be performed by the manager so that the vault can be locked when the station cassette 1s restored 9 Press Cancel to return to the Cash Acceptor Diagnostics Menu Check Cassette Door Switches This function allows you to select which side of the unit should be used for switch testing It is possible to check switches on either side regardless of which side started the diagnostics session Use this function to test the operation of the three switches that govern cash acceptor operation e Cassette switch changes state whenever cash acceptor cassette is removed or replaced Vault switch changes state whenever the cash acceptor vault is opened or closed Door switch changes state whenever the main Encore CIM door or Eclipse oven door is opened or closed 1 From the Cash Acceptor main menu press 7 The following screen appears Cash Acceptor Cash Acceptor Enabled 1 Check Switches Side 1 2 Check Switches Side 2 Cancel Exit 2 To start the switch testing procedure for Side 1 press 1 To start the switch testing procedure for Side 2 press 2 The following screen appears Cash Acceptor Cash Acceptor Enabled Cassette Switch Closed Vault Switch Open Door Switch Open Cancel Exit If you select any interactive cash acceptor operation for the opposite side the side that is not being tested the following warning screen appears
402. the valve operates in various modes Mode Valve at Rest Unpowered Slow Flow Full Flow Regulate Power Fail Solenoid is de energized Operation Supply pressure is allowed above the diaphragm through the eyelet bleed hole The plunger is pressed against the pilot orifice by a spring maintaining pressure above the diaphragm Slightly greater or equal pressure in the inlet chamber and above the diaphragm holds the diaphragm against main valve seat No fuel flows The solenoid is energized such that the plunger raises slightly above the pilot orifice Flow occurs through the eyelet bleed hole and through the pilot orifice Pressure above the diaphragm is still high enough to keep the diaphragm against the main seat The solenoid is energized and the plunger raises further above the pilot orifice Flow increases though the pilot orifice decreasing pressure above the diaphragm The diaphragm is forced upwards by pressure in the inlet chamber Fuel flows through the main valve seat and main orifice Flow rate is set by software by raising or lowering plunger slightly The dispenser electronics adjust the solenoid signal to the plunger to maintain any programmed maximum flow rate or to maintain a blend ratio Discharge flow continues at rate determined by software Plunger is pressed against the pilot orifice by a spring Pressure increases above diaphragm pushing diaphragm against main valve seat Equal pressure in the i
403. this function to send the changes you made to the scanner settings to the scanner device MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Programming and Diagnostics of CRIND and TRIND at Pump Dispenser Pump Programming 1 From the Barcode Scanner setup menu press 3 The following screen appears Barcode Scanner Scanner Enabled Sending POS settings to scanners Programming Side 1 Programming scanners affects both Please Wait sides automatically Once the Side 1 programming is finished Side 2 programming will begin When programming is complete the following screen appears to notify the technician that all settings from the four page Barcode Scanner settings menu have been applied Barcode Scanner Scanner Enabled POS Settings applied Enter Continue 2 Press Enter to return to the Barcode Scanner setup menu Test Scanners This function enables the technician to run interactive scanner tests on either side of the unit 1 From the Barcode Scanner setup menu press 4 The following screen appears Barcode Scanner Scanner Enabled 1 Test Scanner Side 1 2 Test Scanner Side 2 Cancel Exit MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 117 Pump Programming Programming and Diagnostics of CRIND and TRIND at Pump Dispenser 2 Press 1 or 2 to display the Barcode Scanner interactive test screen This screen enables the barcode scanner for the selecte
404. this is a nozzle activated Option 91 Function 12 unit this value is ignored and treated as if value was set to 0 NOZZLE ACTIVATED PUMPS AUTO ON SHOULD NOT ALLOW PRE SELECTION OF GRADE CASH CREDIT or PUSH TO START Pump Preset can still be pre selected MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming Command Code 54 Set Slowdown Valve Command Code 54 is entered in Level 2 programming to determine when dispenser goes into slowdown mode prior to reaching transaction preset value Programmer enters slowdown value using digit keys Slowdown value is in terms of a percentage of pulses per unit volume with a default value of 20 pulses unit Range of values is O to 99 percent A value of 0 means no slowdown Layout and meaning of each digit position for this programming feature is shown below This parameter is set to reduce preset problems with missed targets Experimentation is typically required to find a suitable value It is typically used when multiple units are experiencing preset problems Figure 5 60 Setting Slowdown Valve 1 Enter 5 then 4 then press ENTER to access this Command Code 2 Select percentage 0 99 3 Press ENTER Command Code 55 Set Hose Pressurization Command Code 55 is entered in Level 2 programming to pressurize hose before dispensing by not registering flow up to 20 pulses or 1 second whichever comes fir
405. tion and error code generation It receives its signal from the pump node and filtered AC power from M00044A001 Terminal Block PCA It is not used with Proportional Flow Control Valves PFCV Figure 6 6 Steering Valve Driver Board M0059A00X P1201 Pump Test Point GRND P1206 Line Voltage SOHO OO Test Point 5V O dd 3 2 DRM PUMP GONTROL NODE REY OO OQ ie Q T lo LJ sol 2 H H N B ede 5 ab Z m PTH z Gilbarco ue ak xc Made in U S A VALVE BD JERE SVI OSTRO R 5 Q 9 SA 2 9 MA 7 9 5 pn SV2 1 je NEUT Mv22 sve Mvi SVI STR5 T SV24 MvI amp SVI4 Mv23 Sv23 MVIS SVI3 M 1 MV Oo O O Oo O O O O o O Oo Oo o GRADE 2 STEERING GRADE amp STEERING GRADE 3 GRADE l z m o e gt lu EN Y AC VOLTAGE p FOR 2 z nul P1204 P1207 P1205 Grade 4 Grade 2 Steering Steering MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 6 13 Electronic and Electrical Components Printed Circuit Assemblies and Nodes Board Connections and Cables Connector P1201 26 pin Pump Control Node P1202 9 pin Dedicated Cables Grade 1 M00454A002 l Encore Mud e M00724A001 Grade 3 l Eclipse P1204 9 pin Grade 2 P1205 9 pin Grade 4 Steering P1206 3 pin M00625A001 Inline connection J1206 to P1206 on cable M01006A001 on Eclipse only M01339A001 P1207 5 pin St
406. tion then a programming error display will result as described in the Dispenser programming section Table below shows programming options for preset operations Preset Mode Function Code Preset Type 1 5 Button Preset 1 Set Preset Type 1 Money 2 Incremental Preset 2 Set Preset Amounts 2 Volume 3 PPP 3 Set PPP ON OFF 1 ON 0 OFF Default amounts for presets are 1 2 5 and 10 for both money and volume units Figure 5 35 Setting Money and Volume units Preset Mode Function Code Type Button Select Function Code 1 Set Preset Type Press ENTER Note Display toggles to the Function Code selection MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 3 Display indicates preset option set up in Lever 4 Programming Press ENTER to select Preset Type 4 Select Function Code 2 Volume Preset Type Press ENTER to accept Volume Preset Type Note Accepts set Preset Type Display toggles back to Function Code selection 5 Select Function Code 2 Set Preset Amounts Note Main money display shows button field active and main volume display shows current amount associated with button Begin Preset Amounts entry 6 Select appropriate Preset button then press ENTER 7 Key in Preset Amounts Press ENTER Note Accepts preset amount and toggles back to button selection 8 Select Function Code Set Preset Types and Value press
407. titution Unplug pulser and plug a known good one in e Rotate pulser and watch displays for count Page 7 46 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Pulsers Hydraulic Mechanical Components Test the IS barrier by substitution or disconnect it and check it with an ohmmeter Measure 10 000 ohms or 20 from gray to gray yellow to yellow brown to brown and orange to orange e Always read a low resistance from the green wire to the case Measure between each wire Meter should indicate an open Figure 7 28 Pulser and l S Barrier Test Points 150 VDC With Plug Disconnected 12 VDC With Plug Connected 5 VDC for Optimum Series only with Plug Connected Point B Gray or White 150 VDC Pulser Return Pulser Feed Yellow Pulser Data Brown Ground Pulser Data Chassis Ground 75 VDC 5 VDC for Optimum only Orange or Red Yellow or Blue Brown or Black To C D Module I S Barrier All measurements are made to point A or B at the respective I S Barrier Pulser Drive Assembly Figure 7 29 Pulser Drive Assembly Retaining Clip Upper Plate Retaining Clip Lower Plate Lower Plate Pivot CD Drive Collar U 0002031 Special Note for Canadian Installations An O Ring is used on the shaft in Canadian installations If squealing is noted lubricate with silicone grease When replacing a meter align lower drive collar to meter shaft to reduce the potentia
408. tlined on the individual forms with the MDE 4228 Commissioning Checklist Form C for the site The signed forms should be retained by the commissioning ASC for a minimum of three 3 years The commissioning ASC is not responsible for completing Form A and Form B for each commissioned unit nor does the commissioning fee paid by Gilbarco Veeder Root cover such effort Should Form A or Form B not be complete or missing for each unit the commissioner must notify the station manager or representative of the need to have the checklists completed and sent to the commissioner to ensure warranty coverage and proper and safe operation of the equipment Note Unit problems created by improper installation or start up are not covered by warranty Upon receipt of the forms the commissioner will retain the completed form with his commissioning records for the site The ASC must carry Form A and Form B in case it is not present in the dispensers Gilbarco Veeder Root may request a copy of Form A Form B or Form C during commissioning call in should a unit be reported as not passing inspection or not having been inspected per Form A or Form B Under Required Signatures the station manager or representative must read and check either box A or B and then sign Form C When box B is appropriate the commissioner should ensure that all details as covered under box B have been explained to the station manager or representative prior to requesting h
409. trainer while being careful not to damage strainer Clean strainer with a soft brush and alcohol If strainer is permanently clogged or damaged replace strainer Dispose of rejected strainer properly Install cleaned or new strainer back into bore with tabs facing toward the filter cartridge Note Failure to use a strainer will void the meter and valve warranty Cleaning Replacing Ultra Hi Inlet Strainer Figure 7 12 Ultra Hi Dispenser Strainer Assembly Strainer Cap O Ring Strainer Strainer Inlet Body To clean replace an Ultra Hi inlet strainer proceed as follows Close shear valve Inspect operation of valve Refer to Shear Valves on page 7 66 for details Bleed pressure Lift operating handle and authorize unit Place nozzle in approved container e Open nozzle to reduce system pressure Close nozzle Turn off operating handle Turn off involved STP circuit breakers Turn off dispenser circuit breakers Clean area around strainer cap Remove strainer cap by slowly turning it counterclockwise Watch for residual pressure causing spray Clean up spills promptly Remove strainer and inspect for clogging Clean with a soft brush and alcohol or replace if needed Note Do not tap the strainer on a hard surface to dislodge particles MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Hanging Hardware 10 11 12 Hydraulic Mechanical Components Insert the strainer in h
410. trical Panel Circuits Are Clearly Serial Serial Marked 23 Ensure Free Access To Emergency Cut off Switch 24 Check CRIND for Correct Installation amp Type of Paper 25 Check Operation Clean Card Reader use Q11482 Cleaning Card see MDE 3562 26 Check Operation Clean Keypad 27 Perform CRIND Diagnostics see MDE 3562 28 Verify that Safety Information is Intact Legible Notify Dealer Only perform this task if a new pump or dispenser has been installed or if an existing pump or dispenser was removed and replaced Note any problems w equipment I certify that all inspections and maintenance items have been performed and problems noted and explained to the Station Manager INCIDENT Date Station Manager Date ASC ASC Name Tech Name Tech MDE 2856H 09 2002 Gilbarco Inc E White Contractor Copy B Yellow Customer Copy Mail to Maintenance Supervisor Weekly B Pink Site Copy B Golden Rod Mail to Gilbarco Inc F 53 Page 4 4 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 About this Section Pump Programming 5 Pump Programming About this Section This section provides instructions for programming Encore and Eclipse Series Dispenser pump functions from the Manager Keypad using only the Manager Keypad and the main transaction and grade PPU LCDs for displaying programming information Important Information about Releases Sections of this manual may be released independently of each
411. ts on page 7 1 may also be helpful in analyzing problems Go to the appropriate sub section to finalize the search Use the applicable table or chart to find a symptom and determine a remedy Terms Used in this Section Term Definition PCB Printed Circuit Board PCB is a dedicated component designed for a specific function with limited or non existent intelligence or processing power See Printed Circuit Assemblies and Nodes on page 6 5 for comparison PCV The Proportional Control Valve PCV controls product blending as well as programmable maximum flow rates This valve opens and closes by direction of electronic programming Product flow determines the proper opening ratio of each PCV valve to maintain the required blend Theory of Operation Understanding Flow Rate Page 6 2 Flow rate is the number of gallons dispensed per minute GPM In the United States flow rate for gasoline dispensing devices is limited to 10 GPM Flow rate may be affected by restrictions such as distance to the output damage and leaks in the line These restrictions may reduce the flow rate Example Figure 8 1 The left container has minimal restrictions therefore a greater flow rate The right container has many restrictions therefore a lower flow rate Figure 8 1 Flow Rate Examples Restricted Flow Unrestricted Flow 50001127 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Theory of Operation Theory of Operat
412. type for dispenser Figure 5 96 Setting Unit Type Unit Type Default 1 You must perform a cold cold start before changing selection in CC90 or the unit type may not be properly set regardless of what is indicated during programming Unit type assignment is based on a numeric code as shown in the following table Page 5 88 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Unit Type Assignment Table Option Unit Type 1 Default 1 Grade 1 Hose MPD 2 2 Grade 2 Hose MPD 3 3 Grade 3 Hose MPD 4 4 Grade 4 Hose MPD 5 2 Grade 1 Hose MPD 6 3 Grade 1 Hose MPD 7 3 Grade 1 Hose 1 MPD 8 3 Grade 3 Hose Blender 9 3 Grade 3 Hose Blender 1 10 3 Grade 3 Hose 1 Meter MPD 1 On the Manager Keypad press 9 then 0 then ENTER Option 2 Select Unit Type 1 to 21 then press ENTER Pump Programming Unit Type 3 Grade 1 Hose 1 Meter MPD 2 Grade 1 Hose Blender 3 Grade 1 Hose Blender 4 Grade 1 Hose Blender 5 Grade 1 Hose Blender 2 Grade 1 Hose Blender 1 3 Grade 1 Hose Blender 1 4 Grade 1 Hose Blender 1 5 Grade 1 Hose Blender 1 Super High Command Code 91 Select Installed Options Note Self Configuring Allows the factory and under certain circumstances a field programmer to install optional equipment in dispenser Function Codes under this command are used to enable disable dispenser options By default all
413. ult value 1s 1 as shown below Figure 5 82 Inserting the Calibration Side To Select This Side Complete This Action 1 Side A Press ENTER default setting 2 Side B Press 2 on Manager Keypad then press ENTER 7 Activate the fueling position The volume display shows all dashes to indicate that the pump is ready to start dispensing fuel Figure 5 83 Volume Display Showing Dashes 8 Fill the prover can to within 1 cubic inch of the 0 mark Return the pump handle to the OFF position when done Note For blenders calibration can be performed only on pure product grades ratio 100 or O percent A double beep sound will signal an incorrect grade selection During the fuel dispensing process real time raw pulses are shown in the Volume display area See the following example Figure 5 84 on page 5 82 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 81 Pump Programming Encore 5XX and Eclipse Programming Instructions Figure 5 84 Real time Raw Pulses Shown in the Volume Display Final raw pulses are shown until ENTER is pressed Pressing any other key will signal error by sounding a double beep If an error occurs during this phase it will be accompanied by E on the volume display Figure 5 85 Error Shown on Volume Display 9 The display field is the Volume field Enter the overflow or underflow value from reading the scale on the prover can Unit volume is expressed difference a
414. ume display Figure 5 15 Money Display 3 Enter your Level 2 PIN Code Default 1503 then press ENTER MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 5 17 Pump Programming Encore 300 Programming and Data Access Instructions Figure 5 16 Level 2 PIN Code Command Code 10 Configuring the System Note Settings affect both fueling positions Figure 5 17 Configuring the System Function Code 1 Press 1 then 0 then ENTER on Manager Keypad to access this Command Code 2 Entera Function Code number 1 to 24 then press ENTER 3 Enter a Configuration Code then press ENTER 4 Choose another Function Code number or press F2 to exit Function Code 1 Unit Type It is recommended to leave these settings at the system defaults For This Unit Type Press Configuration 1 Product 1 2 Products 2 3 Products 3 Page 5 18 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming and Data Access Instructions Pump Programming Function Code 2 Money Decimal Point For This Money Decimal Point Press Configuration XXXXX 1 XXXX X 2 XXX XX Default 3 XXX XXX 4 Function Code 3 Calculation PPU Decimal Point U S Weights and Measures requires Configuration Code 4 For This Calculation PPU Decimal Point Press Configuration XXXXX 1 XXX X 2 XX XX 3 X XXX Default 4 Function Code 4 Displayed PPU Decimal Point Use this Function Code when you calculate t
415. ump Programming Encore 300 Programming Pump Dispenser Error Code 26 will not clear automatically after a unit has been first calibrated A warm start is now required This will be primarily noted after installing a new service board and calibrating or performing a true cold start drop back to V1 3 74 Pump Node software and then reload to the current version where re calibration is required When performing the combined verification test and re calibration electronic and electro mechanical totals will increase as during a normal sale Encore 300 Programming Pump Dispenser Contents in this Sub Section Description Page Encore 300 Programming Pump Dispenser 5 8 Encore 300 Programming Quick Reference 5 9 Encore 300 Programming and Data Access Instructions 5 10 e Level One Command Codes 5 10 e Level Two Command Codes 5 17 e Level Three Command Code 5 25 Additional Manager Functions for Encore 300 9 30 Page 5 8 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 300 Programming Quick Reference Pump Programming Encore 300 Programming Quick Reference Command Codes and Function Codes Quick Reference Chart The following chart shows Command Codes and Function Codes for different levels Refer to the following pages for more details Level One Command Codes refer to page 5 10 Level Two Command Codes refer to 5 17 1 Programming PPU Mode 10 Configuring The System 2 Setting Mode of Operation 1 Unit Type 3
416. unit repairs Replace as needed Some meter bolts are difficult to access A 13 mm universal socket will make installation and removal easier For calibration problems refer to Calibration on page 7 21 After a drive off inspect the meter for leaks Non use of filters and strainers can significantly reduce meter life Abnormally low pressure and flow rates can cause meter to stall Meter failure may be indicated by a significant change in calibration from high to low flow rates excessive calibration spread or meter stall at low flow Note Other problems may also cause the same symptoms Calibration problems are not always caused by a bad meter Meter check valves leaking nozzles binding pulsers defective pistons or internally leaking vapor recovery hoses can also result in calibration problems MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Meters Hydraulic Mechanical Components C Meter Seepage SB1441 Current seals used in the C and C meter are capable of handling very low temperatures However some sites have noted seepage at 15 degrees Fahrenheit or colder If sites with C or C meters in your area have experienced extreme cold weather seepage at the shaft seals the units may be fixed by using special seals developed for extremely cold areas Depending upon fuels meter tolerances and other factors some meters will require special seals It is generally only necessary to use the special seal
417. up Service Manual August 2007 Input Output Voltage 5 V 5 Open Collector to 0 V Open to 0 V 0V Input Output Voltage 14 V to 23 V OV 14 V to 23 V OV 7 V to 12 V Max 7 V to 12 V Max OV 14 V to 23 V 0 V to 12 V Input Output Voltage 14 V to 23 V OV 14 V to 23 V OV 7 V to 12 V Max 7 V to 12 V Max OV 14 V to 23 V 0 V to 12 V Input Output Voltage 9 4 VAC 10 Printed Circuit Assemblies and Nodes M01922A001 Pump Control Node 2 Electronic and Electrical Components The Pump Control Node PCN is used on the Encore 500 and Eclipse series units to control fueling operations It performs all totals calculations processes handle switch information and pulser input and stores Weights and Measures data The PCN interfaces directly with the Vapor Vac Controller STP Control Board and Valve Driver Board The PCN interfaces with the Door Node CRIND Control Node CCN and the Automatic Temperature Compensation ATC Node via the LON It uses the ATC Node to supply information to adjust the metered volume to a predetermined standard temperature The M01922A001 PCN is backward compatible with M0056A00X PCN It requires PCN software version 1 6 00 or higher The M0056A00X node is forward compatible with M01922A001 but certain enhancements such as USB support and durability improvements will be lost For non eCRIND units the Pump Control Node provides the main processing power for syst
418. ure Testing 6 70 E Electrical Service 1 7 Electrostatic Discharge Preventing 5 3 Emergency In Case Of 1 7 Phone Numbers 1 10 Procedures 1 7 see also Safety Information Emergency Breakaway Couplings see Breakaways Error Codes Clearing 4 12 E STOP Emergency Button 1 7 External CRIND Setting Addresses on T17764 Logic Board 5 67 F Field Wiring Safety Information 1 7 Filters Changing 6 28 Gasoline 6 28 Maintenance 3 2 Safety Information 1 8 Firmware T17764 Logic Board 5 61 First Aid 1 9 see also Safety Information Five or Six Digits Cash Display 4 16 Five Button Presets 4 11 Flanged Tube Fittings Torque Specifications 6 6 Fleet Operations Setting Zero PPU 4 17 Flow Rates Calculating 6 12 Causes of Low 6 21 Forms Preventive Maintenance MDE 2856 3 4 Function Code 1 Set Beeper Timeout Value 4 46 Set Money Decimal Point Position For Display 4 36 Set STP Prestart 4 42 Function Code 2 Set Pre Select Timeout 4 46 Set STP Control 4 43 Set Volume Decimal Point Position For Display 4 37 Function Code 3 Set PPU Decimal Point Position For Calculations 4 37 Function Code 4 Set PPU Decimal Point Position For Display 4 37 G6 Select Option 4 17 Gaskets Safety Information 1 7 Gasoline Safety Statements 1 10 Gasoline Filters 6 28 G CAT4 Logic Board Requirements 5 61 General Programming Operation 4 4 Glossary 5 6 5 7 5 10 5 13 5 16 5 17 5 20 5 21 5 24 5 26 5 27 5 29 5 31 5 36 5 38
419. ures AN WARNING Residual pressure and entrapped fuel may still be present and may spray when removing hoses Fire and explosion could result in severe injury or death e Wear eye protection e Remove hoses and nozzles slowly Collect fuel in approved containers e Clean up all spills promptly To replace the hose proceed as follows On dispensers close the shear valve Check for proper shear valve operation Units may require multiple shear valve closures Turn off power to the unit and associated STPs Multiple STP disconnects may be required Use OSHA Lock out and Tag out procedures Drain nozzle and hose into approved container Remove nozzle first then hose Install swivel couplings and breakaways to unit as needed MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Hanging Hardware Hydraulic Mechanical Components 6 Use UL approved pipe sealant on hose coupling threads Follow these recommendations Do not use Teflon tape Teflon tape on these components can cause damage during assembly or installation and defeat the conductive property of the handing hardware and cause nozzles to malfunction Do not apply sealant to first two threads of hose coupling Do not use sealant on O Ring seals a light coating of oil or silicone grease 1s advised For co axial and tri axial vapor recovery hoses inspect and lubricate all O Ring seals with silicone grease to aid assembly 7 Install hose assembly to
420. utlet and is incorporated into the fuel discharge assembly mounted in the upper housing of Encore series units manufactured as of March 2002 This manifold is not incorporated into Encore six hose blenders and Eclipse series units This configuration manifold is of open closed or blend design and allows unit conversions from single hose blenders to standard units and vice versa without major rework Refer to the following description any conversion kit instructions and Figure 7 22 on page 7 42 Open Manifold The passages in this manifold allows fuel from all fuel discharge pipes to be channeled to one hose outlet The open configured manifold is primarily used for single hose MPD Closed Manifold The passages in the closed manifold channel fuel from the discharge piping to be separated and directed to separate outlets The closed manifold design is used primarily on multi hose units Blend Manifold The blend manifold allows two different grades of fuel to mix just prior to being discharged to the outlet casting Note The Blend Manifold is used primarily on blender units Model Configuration Manufactured Encore All except 6 Hose Prior to March 2002 Blender All except 6 Hose March 2002 and after Blender 6 Hose Blender N A Eclipse Any unit N A Configuration manifold not applicable to these units Page 7 40 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Manifolds Hydraulic Mechanical Components Fi
421. verify proper operation Nozzle Boot Spring Repair SB1483 Encore lift to start fipper nozzle boots are being replaced to correct a broken spring condition If the failure is just the spring replace only the spring M00349B003 Manifolds Read and follow all safety precautions as outlined in the Read this First on page 1 1 in this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About Hydraulic Manifolds 7 37 Hydraulic Tree Assemblies 7 37 Steering Manifold 7 38 Configuration Manifold 7 40 AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly Page 7 36 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Manifolds Hydraulic Mechanical Components About Hydraulic Manifolds The hydraulic manifold is a fluid input chamber where fluid is distributed into one or two outlets The manifolds included in this section are Hydraulic Tree Assembly e Steering Manifold e Configuration Manifold Note Do not over torque inlet piping into hydraulic manifold Hydraulic Tree Assemblies The Encore manifold meters valves and filter make up the hydraulic tree There are two
422. versions that are distinguished by different valves and manifolds For units with digital valves refer to Manifold M00159 With Digital Valves on page 7 37 and for units with proportional valves refer to Manifold M02656 with Proportional Control Valves on page 7 38 Manifold M00159 With Digital Valves Figure 7 16 Hydraulic Tree With Digital Valve Digital Valve Manifold M00159 anor Check Valve 7 d Filter Contains Gasket Filter Pd C Meter Inlet Pipe MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 37 Hydraulic Mechanical Components Manifolds Manifold M02656 with Proportional Control Valves Figure 7 17 Hydraulic Tree with PCV Inlet Pipe Filter Catch Cup Proportional Control Valve PCV Service Tips To avoid damage to the hydraulic manifold always keep the inlet piping support U bolt in place When replacing inlet union nipple loosen the U bolt only enough to allow nipple to turn with wrench Do not pull the wrench and pipe up and toward you while turning Upon completion of service U bolts must be tight and in place to ensure proper operation of shear valve during impact When replacing filters refer to Filters and Strainers on page 7 22 Steering Manifold The Encore series steering manifold and valves are located in the upper housing of six hose Encore blenders multi hose to direct the fuel to the proper hose Attached to the steer
423. vice Manual August 2007 Page 5 55 Pump Programming Encore 5XX and Eclipse Programming Instructions 2 Using the following table select 1 2 for the Lamp Test Option Option Setting 1 Default After Lamp Test 2 Before Lamp Test 3 Press ENTER Command Code 49 STP Controls Command Code 49 programming is used to set when the STPs will turn on which STPs will be activated and where the STP relay signal originates Sub sections that follow describe each Function Code programming option Layout and meaning of each digit position for this programming feature is shown below Figure 5 53 STP Controls 1 Press 4 then 9 then press ENTER to access this Command Code 2 Select the Function Code 1 3 See the following listing 3 Then select the appropriate Option Code Figure 5 54 Selecting the Option Code Option Code Po Function Code 1 Set STP Prestart STP pre start should be programmed depending on type of leak detection implemented in dispenser Pre start should be set to ON for mechanical line leak detectors and OFF for electrical line leak detectors Default for this option is selection 1 PRESTART OFF PRESTART ON turns the STPs on when the handle switch 1s activated Page 5 56 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Encore 5XX and Eclipse Programming Instructions Pump Programming 1 Using the following table select option 1 2 Option Function 1 Default Pres
424. vice Manual August 2007 Page 6 119 Electronic and Electrical Components VaporVac Electrical Components Board Connections and Cables Connector Via Cable To Board At Connector P1001 9 pin T18162 VaporVac Power Supply Assembly P1002 34 pin R19667 G1 T19401 VaporVac Controller PCA P1102 34 pin P1003 12 pin Encore M00845A001 to 117942 VaporVac Pump Assemblies e Encore J3003 M00830A001 at J2003 Motor Side 1 Eclipse J11 P2003 to J3003 Eclipse M00980A001 P1004 12 pin Encore M00845A001 to T17942 VaporVac Pump Assemblies e Encore J3004 M00830A001 at J2004 Motor Side 2 Eclipse J21 P2004 to J3004 Eclipse M00980A001 P1005 4 pin R19672 G1 M00080 VaporVac Isolation PCA P1401 4 pin LED Indicators ED Indicates CR12 Faut A ON vacuum pump motors are off and fuel is not flowing If LED is on or flickering with CR15 FaultB aa look for problems in VaporVac pump motor motor drive board or related CR5 DC OK ON normal operation 12 VDC for VaporVac controller board If LED is off look for problems in VaporVac motor drive board controller board or power supply rm Voltage Test Points Test Point Voltage P1001 pins 3and6 43 VDC P1001 pins 8and9 43 VDC return P1001 pins 1 and2 25 2 VAC P1001 pin 4 GND P1001 pin 7 0 VAC P1005 pin1 12 VDC unregulated out _ Fuses Fuse Rating Fl 2A 250 VAC Slo Blo 12 VDC F2 2A 250 VAC Slo Blo 12 VDC F3 15A 32 VAC for motor
425. ways calibrates the w product meter regardless of how the blend ratios are set for Grade 1 Grade 2 and Grade 3 switches always calibrate the x product regardless of how the blend ratios are set Other blended models rely on the programmed blend ratios to determine which meter is calibrated For details on calibrating meters refer to Pump Programming section on page 5 1 of this manual About Calibrating VaporVac For details see Calibrating VaporVac on page 7 73 MDE 3804B Encore and Eclipse Start up Service Manual August 2007 Page 7 21 Hydraulic Mechanical Components Filters and Strainers Filters and Strainers Read and follow all safety precautions as outlined in Read this First on page 1 1 this section and related sections of this manual Follow OSHA Lock out and Tag out procedures Topics in this Sub section Topic Page About Filters 7 22 Servicing Filters 7 23 About Strainers 7 25 Servicing Strainers 7 25 Note To prevent fueling problems with vehicles and to minimize dispenser down time due to damage to valves and motor never operate a unit without the use of a filter or strainer AN WARNING Residual pressure and entrapped fuel may still be present and may drain or spray when removing parts and fittings Fire and explosion could result in severe injury or death e Wear eye protection e Remove parts and fittings slowly Collect fuel in approved containers e Clean up all spills promptly

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