Gallagher Apollo 3000, Manual

Page 1: ...Apollo 3000 Set up Installation Parts Manual...

Page 2: ......

Page 3: ...er without a full service inspection If there is a fire or injury call Emergency Services Caution Should the word FLUId appear in Display immediately implement part A B of this section Refer page 06 o...

Page 4: ......

Page 5: ...n Page 23 Fig 3 Service Area Page 24 Fig 4 Mounting Positions Page 25 Fig 5 Vent Box Position Sealing Page 26 Fig 6 Safety Hose Position Page 27 Apollo 3000 Hydraulic Intrinsic Connections New Zealand...

Page 6: ...s to stop any foreign matter entering Install Main Product Feed Lines Into Sump refer Apollo Hydraulic Intrinsic Connections Pg 27 NZ Pg 28 Aus for correct positioning etc Refer page 09 for Feed Line...

Page 7: ...ed on Column could be advantageous as they could then both serve as a double checks Note Marks should be made Horizontally as they will later be used to align Vertical Pipe Holster Assy Mtg Brkts etc...

Page 8: ...wn fig 5 Ensuring base edge contacts against Forecourt Place Top Cap into gap of Vent Box as shown in Fig 5 Ensure Cap is fitting correctly into recess Cut a 70 mm long section of 50 mm wide Aluminium...

Page 9: ...is free to travel upwards without obstructions etc Using a Draw Cord Pull Encoder Float Switch AC Signal Cables through Cable Duct Also feed Steel Wire Amour Cable up Cable Duct Plug Cables into Logic...

Page 10: ...follows Hose F1 Enter 22 Fill 1 Fill Hose R1 Enter 23 Fill 1 Fill Hose F2 Enter 42 Fill 1 Fill Hose R2 Enter 43 Fill 1 Fill Hose F3 Enter 62 Fill 1 Fill Hose R3 Enter 63 Fill 1 Fill 5 Check Pricing D...

Page 11: ...r a Float Switch which is positioned within under ground Sump Enclosure to detect the presents of Fluid which then shuts Dispenser down Reset required If Dispenser is in idle stage eg Non Delivery Flo...

Page 12: ...ed Note Encoder errors can be any number but must not change eg change indicates error Diagnostic Testing of Motor Valve Operation This function can be used to turn Motor Final main stages of Solenoid...

Page 13: ...32m therefore feed line Tee termination arrangement must fit within this distance Above view is as viewed from enclosure sump end away from Column RH end Tee Shut off Valve hang down towards floor of...

Page 14: ...y B Mid 3 25m x 2 89885 Hose Assy A Long 3 4m x 2 89938 BP Ultimate or 89940 Diesel or 89918 Low Sulp Diesel 89947 Hol Panel 89825 Holster Panel Mtg Brkt Not Shown 83780 Holster Assy 83694 Holster onl...

Page 15: ...11 Float Switch 89778 Float Swt Mtg Angle only 89749 Float Switch Bracket Assembly...

Page 16: ...12 Head Cable Entry FLP Gland 823450 FLP Plug 44024 x 4 Dury Lock Nut 803220 x 9 89773 Cable Assy 89717 Graphic Rear or 89716 Graphic Front 89715 Door...

Page 17: ...3520 Nut Typ 87276 Main Display Refer Pg for Cable Layout 87271 Price Display x 3 Clip 824080 89727 Switch Assy 89755 Brkt only 87281 Preset Display 87711 Hinge Plate 88327 Hinge Screw M4 x 10 Csk Hd...

Page 18: ...trip not shown 83665 PCB Cover Mtg not shown 83638 Mtg Boss not shown M3 x 8 Pan Hd Screw 859570 Fluo Light 859615 Batten Holder 89719 Mtg Brkt 867105 Light Cable 1m 89779 FST Mtg Brkt 800620 Screw M4...

Page 19: ...Cabinet Front Displays 87281 Preset PCB Assy 87271 Price Display PCB Assy 87276 Main Display PCB Assy Refer Pg for Cable Lay out 87195 Mem Key Pad 89710 Head Cabinet Assy 89711 Head Cab Mtg Brkts x 2...

Page 20: ...abinet Internal 88310 Cable Assy Logic Box Processor 40 Way Housing 861230 83210 Cable Assy Proc Power 83202 Cable Assy Pump Comms 87380 Pro Eprom 881730 Label Intrinsic 87338 Tote Cable Assy 824510 C...

Page 21: ...17 Logic Box 87111 Logic PCB Assy 88310 Cable Assy 878913 Logic Box Base 87914 Logic Box Lid not shown 89732 Logic Box Mtg 89737 Nozzle Cable Assy...

Page 22: ...side Enclosure Layout Rerfer Pg 27 28 For Hydraulic Layout Refer Pg 34 For Hose Specs 89772 Junction Box Assy Refer Sump Module Pg 19 C Link Cable 1 2m B Link Cable 1 5m A Link Cable 1 8m 89733 Cable...

Page 23: ...Assys are as follows A 89794 Internal Pipe Assy Upper B 89796 Internal Pipe Assy Middle C 89798 Internal Pipe Assy Lower Note These Pipe Assys run up inside Ducting to connect to Vertical Pipe Assys...

Page 24: ...t 89827 Vertical Pipe Assy Rear 89711 Head Mtg Brkt 89947 Holster Panel 89825 Holster Panel Mtg Brkt 89925 Vent Body Front 89927 Vent Body Rear 89926 Top Cap 89846 Safety Flex Hose Assy x 6 Internal P...

Page 25: ...21 Stage 1 Installation Procedure Sump Position Fig 1 Under Ground Front View Apollo Sump File gme d docum pec apollo2 fig 1 doc...

Page 26: ...22 Stage 1 Installation Procedure Sump Column Position Fig 2...

Page 27: ...23 file gme c docum pec apollo2 fig 2 manual doc Stage 1 Installation Service Area Spec Fig 3...

Page 28: ...24 Stage 1 Installation Procedure Mounting Positions Fig 4...

Page 29: ...25 Stage 3 Vent Box Installation Vent Box Position Sealing Spec Fig 5...

Page 30: ...26 Stage 3 Vent Box Installation Safety Hose Position Fig 6 Safety Hose Assy 89846 x 6 Internal Pipe Assys 89794 Upper Assy 89796 Middle Assy 89798 Lower Assy...

Page 31: ..._ to Exit Pipes _ B AC Control Address 1 Dip Switch 1 Off 2 4 On AC Control Address 2 Dip Switch 2 Off 1 3 4 On AC Control Address 3 Dip Switch 1 2 Off 3 4 On Connection Pipes _ Pre Unleaded Address...

Page 32: ...Dip Switch 1 Off 2 4 On AC Control Address 2 Dip Switch 2 Off 1 3 4 On AC Control Address 3 Dip Switch 1 2 Off 3 4 On Connection Pipes _ Super LRP Address 3 Func 62 63 F3 R3 C Func 71 Diesel or BP Ult...

Page 33: ...er Switched Active 7 Core Steel Wire Armor Cable FST FLP Junction Box FLP Barrier Gland FLP Gland Used Updated 06 05 99 26 11 99 16 02 00 29 01 01 19 02 01 23 03 01 Head Cabinet Mains Switched Active...

Page 34: ...Air2 Air3 Noz1 UDD F_A F_B R_A R_B GND N C AC3 AC2 AC1 ENC_F3 ENC_F2 ENC_F1 ENC_R3 ENC_R2 ENC_R1 R E A R R E A R A C C T R L E N C O D E R S A IR N O Z Z LE S W F R O N T F R O N T 87110v1 R 1 R 1 R 2...

Page 35: ...isplay PCB Assy File Display Dip Switch doc 3 on 3 2 4 6 5 7 8 Dip Sw SW2 7 8 on Dip Sw SW3 9 10 9 Open for Dollars per Litre no Link Linked Cents per Litre Ver 2 30p Air Sense Operation No Link Linke...

Page 36: ...r together with an input Processor Board The basic elements are 80c31 or 80c32 Processor 64K external program Memory Eprom 32K Static Ram Battery backed 2692 DUART Encoder Interface Power Control Disp...

Page 37: ...81 To Processor PCB 89886 10 Way 10 Way 89887 07203 07203 Apollo 3000 Rear Assy Inside View 87271 x 3 87276 Inside View 87333 87329 87281 87333 89886 To Processor PCB Apollo 3000 Front Assy 87271 x 3...

Page 38: ...BSPP 01805 3 4 BSP Female 01803 Fittings Assy PEC Pt 89884 Hose Assy C 5 8 ID Hose 3 025 m 3 4 BSPP 01805 3 4 BSP Female 01803 Fittings Assy PEC Pt 89883 Product Delivery Hose Assy 3 4 ID Hose 3 4 Fem...

Page 39: ...s may occur either at startup or dynamically during operation In either case the processor is halted if an error is found 04 External RAM Error This is a walking bit test of the XRAM This test is perf...

Page 40: ...ase it is probable that the encoder is going too fast such that the incoming encoder counts which are accumulated under interrupt control are not being consumed quickly enough by the maths routines to...

Page 41: ...ut processor This error is fatal only to the pump numbers associated with the LPG grade Note Errors 32 37 apply to units fitted with software version lower than va 2 30p only Units fitted with Softwar...

Page 42: ...ere was an overflow of either encoder counts or encoder errors detected for the Grade 3 rear encoder 50 Grade 1 Front encoder run on Pump A1 Flow did not stop the encoder was still rotating at the end...

Page 43: ...een added to a console which is not yet supported or the comms line has been corrupted in which case a checksum error will probably also occur 66 Channel A Receiver Overflow Error The message received...

Page 44: ...ation limit When this happens the cutover point at which slow flow is entered automatically adjusts to compensate Note the difference from the encoder run on error encoder run on is a continued flow a...

Page 45: ...immediately with Displays stationary displaying delivery values point when delivery stopped Again Dispenser will start to Beep if Nozzles not returned within a Minute period Once Nozzle is returned Di...

Page 46: ...Apollo 2000 Set up Installation Parts Manual...

Page 47: ...er without a full service inspection If there is a fire or injury call Emergency Services Caution Should the word FLUId appear in Display immediately implement part A B of this section Refer page 06 o...

Page 48: ...aulic Intrinsic Connection Lay out Diagram Australia Page 18 Quick Set Up Test Record Page 19 28 Error Codes Page29 Main Processor lay out Circuit Page 30 PCB Dip Switch Position Page 31 Wiring Connec...

Page 49: ...nto Sump Box Cable Feed Flexible Conducts 40 50 mm Dia with Fittings Stage 1 Installation Procedure Install Sump Box into position below ground level as shown Centralise Sump with Box end Face to Colu...

Page 50: ...Column Forecourt Surface as per Pg 2 Secure Delivery Ducts Main Feed Lines into proposed Position Temporarily pack internal side walls of Sump using timber or similar to eliminate walls collapsing inw...

Page 51: ...position Vertical Pipe Assys on Column Permanently attach Vertical Delivery Pipe Assys to Column with Bandit Strapping See Fig for position Options Drill Screw Brackets to Column or use threaded draw...

Page 52: ...secure surplus cable Plug Cables into Logic PCB see Drawing Pg 32 Cables are Marked Fit Steel Wire Armoured Cable Mains Feed Line to Head Cabinet Gland FLP connect as per Drawing Pg 31 inspection req...

Page 53: ...splay 87281 then to top of the bottom Price Display 87271 Cable 87333 goes from bottom of Price Display 87271 to top of Price Display above it repeats 87271 Display x 3 Door Bezel 89770 825960 Lock 87...

Page 54: ...r of top Price Display 87271 then to left hand connector of Preset Display 87281 as viewed Cables 87333 goes from top connector of bottom Price Display 87271 to bottom connector of Price Display above...

Page 55: ...8 Apollo Head Assy Internal First issued 29 07 98 Tote Assy 87287 Tote Cable Assy 87338 Tote Mtg Brkt 89751 FST Cable Rear 24984 Front Not Shown Battery Cable Assy 88230 Shown Unplugged...

Page 56: ...dule Hose 1 1 m x 2 Mk 11 B Hose 1 39 m x 2 C Module Hose 1 46 m x 2 Mk 11 C Hose 1 67 m x 2 AC Control Box Assy 89813 3 7m Module Mtg Frame Assy 89942 Hinge Pin 89758 Encoder Assy 89811 3 7m 852530 S...

Page 57: ...fications for these can be obtained on request Refer Page for Mk11 Version Refer Sump Module 89812 Pg 9 89760 Connector Box Mtg Brkt Float Switch Mtg Brkt Assy 89729 Idle Hoz Normal Closed Internal Pi...

Page 58: ...w 1B243 12 12 89744 C F R Hose 1 67m Swivel Nut 19243 12 12 AU F Swivel 90 Elbow 1B243 12 12 Internal Supply Hose Lengths 89748 Hose 1 05m Swivel Nut 19243 12 12 AU x3 Pipe Assys are as follows A 8979...

Page 59: ...olster Mtg Panel 83780 Nozzle Holster Assy 1000 x 6 87315 Nozzle Switch Cable Assy x 6 89740 Safety flex Hose Assy x 6 89764 Holster Panel Mtg Brkt Not Shown 89790 Vertical Pipe Assy Front 89791 Verti...

Page 60: ...ersion VA 2 21 listen for single beep pause single followed by six short beeps Displays should show as follows FRONT Pn A REAR Pn b Fn _ _ Fn _ _ Note if you get FUEL OFF then toggle Managers Switch t...

Page 61: ...ber Comms Connection To connect to Console unit has to be numbered both front rear To number Front Enter 20 Fill display PF 00 Enter display PF number entered enter Fill To number Rear Enter 21 Fill d...

Page 62: ...ived Note Encoder errors can be any number but must not change eg change indicates error Diagnostic Testing of Motor Valve Operation This function can be used to turn Motor Final main stages of Soleno...

Page 63: ...ess 1 Dip Switch 1 Off 2 4 On AC Control Address 2 Dip Switch 2 Off 1 3 4 On AC Control Address 3 Dip Switch 1 2 Off 3 4 On Connection Pipes _ Unl 91 Address 3 Func 62 63 F3 R3 C Func 71 Diesel Addres...

Page 64: ...ontrol Address 1 Dip Switch 1 Off 2 4 On AC Control Address 2 Dip Switch 2 Off 1 3 4 On AC Control Address 3 Dip Switch 1 2 Off 3 4 On Connection Pipes _ Reg Unleaded Address 3 Func 62 63 F3 R3 C Func...

Page 65: ...be reset Power down and wait for 5 seconds before switching on the pump 00 Start up log This is not really an error it contains the number of startups 01 Processor Error This is a sequential IRAM add...

Page 66: ...livery related variables These variables are overwritten with each new delivery but in case of power loss must be present between deliveries Unlike the non vol variables during deliveries these are co...

Page 67: ...requires range checking 19 Dollar Maths Error At the end of a delivery the delivery dollar calculations are performed ie price per litre multiplied by litres equals dollars Error 19 indicates an erro...

Page 68: ...ing any comms response from it This would be caused by either a fatal error in the input processor or a physical loss of connection on the serial link between the two processor boards 26 Main to Input...

Page 69: ...only to the pump numbers associated with the LPG grade Note Errors 32 37 apply to units fitted with software version lower than va 2 30p only Units fitted with Software va 2 30p greater Float Switches...

Page 70: ...of sequence 43 Grade 3 Rear encoder error Pump F3 The Grade 3 rear encoder inputs were out of sequence 44 Grade 1 Front encoder too fast Pump A1 This error indicates an overflow of either encoder coun...

Page 71: ...ng at the end of a Grade 2 rear hose delivery 54 Grade 3 Front encoder run on Pump E3 Flow did not stop the encoder was still rotating at the end of a Grade 3 front hose delivery 55 Grade 3 Rear encod...

Page 72: ...indicates the message received had a checksum error 65 Channel A Receiver Data Error Error 65 indicates the polling message received from the Console is an invalid type i e a new feature has been adde...

Page 73: ...or 75 Channel B Receiver Data Error This indicates that the polling message received from the Input Processor is an invalid type or that the comms line has been corrupted in which case a checksum erro...

Page 74: ...imit 82 Grade 2 Front Preset Overrun This overrun error indicates that the delivery on the Grade 2 Front hose did not stop at the preset or allocation limit 83 Grade 2 Rear Preset Overrun Error 83 ind...

Page 75: ...r together with an input Processor Board The basic elements are 80c31 or 80c32 Processor 64K external program Memory Eprom 32K Static Ram Battery backed 2692 DUART Encoder Interface Power Control Disp...

Page 76: ...Front Preset Display PCB Assy 3 on 3 2 4 6 5 7 8 Dip Sw SW2 7 8 on Dip Sw SW3 9 10 9 Open for Dollars per Litre no Link Linked Cents per Litre Ver 2 30p Air Sense Operation No Link Linked for Float Sw...

Page 77: ...er Switched Active 7 Core Steel Wire Armor Cable FST FLP Junction Box FLP Barrier Gland FLP Gland Used Updated 06 05 99 26 11 99 16 02 00 29 01 01 19 02 01 23 03 01 Head Cabinet Mains Switched Active...

Page 78: ...Air2 Air3 Noz1 UDD F_A F_B R_A R_B GND N C AC3 AC2 AC1 ENC_F3 ENC_F2 ENC_F1 ENC_R3 ENC_R2 ENC_R1 R E A R R E A R A C C T R L E N C O D E R S A IR N O Z Z LE S W F R O N T F R O N T 87110v1 R 1 R 1 R 2...

Page 79: ...is 0 432m therefore feed line Tee termination arrangement must fit within this distance Above view is as viewed from enclosure sump end away from Column RH end Tee Shut off Valve hang down towards fl...

Page 80: ...ssy C 5 8 ID Hose 3 5 m 3 4 BSPP 01805 3 4 BSP Female 01803 Fittings Product Feed Hose Assy 3 4 ID Hose 1 05 m 3 4 BSP Female Sw Nut both ends 3 per unit Feed Line to Modules Product Delivery Hose Ass...

Page 81: ...Way 89725 10 16 07203 07203 Apollo Rear Door Assy 87333 87329 87333 87328 To Processor PCB Apollo Front Door Assy Inside View Inside View File GME c mydrawdt draw apollo display idw 16 04 99 87271 x 3...