Gallagher APOLLO 3000L Guide

Part No. 2A03229
Issue 1
APOLLO 3000L
Installation and Commissioning Manual

Gallagher Fuel Systems Ltd
2 Station Rd
PO Box 308
Marton 4741
New Zealand
Phone: [phone]
Fax: [phone]
Emails: [e-mail]
[e-mail]
Web: http://fuelsystems.gallagher.co
When contacting Gallagher Fuel Systems Ltd always quote the serial number on the
product’s nameplate which can be found affixed to the column beneath the User Interface.
How to Contact Gallagher
The Wiring Regulations
All wiring and installation work shall comply with AS/NZS 3000
Each Fuel Delivery System (FDS) should be protected by a 16 amp circuit breaker that is
capable of being locked off.
When designing the site, cable selections should comply with AS/NZS 3008.1 for Australia
and AS/NZS 3008.2 for New Zealand.
When terminating external cables in the FDS crimp joints should be used and should
comply with AS/NZS 3000.
If the FDS is to be installed at a Marina then all wiring shall be performed in compliance
with AS/NZS 3004
Document History
Issue Date Comments Author(s)
1. Nov 2014 Inial Release E. Schaub
2.
3.
Copyright © Gallagher Fuel Systems Ltd 2014
All rights reserved. This manual may not be copied or reproduced in part or whole by any means
without the prior written consent of Gallagher Fuel Systems Ltd.
The information in this manual is subject to change without notice. Gallagher Fuel Systems Ltd has
made every effort to verify the accuracy of this manual but does not make any other representation,
warranty or guarantee that the information is accurate, correct, reliable or current.
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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CONTENTS
1 APOLLO 3000L INSTALLATION ......................................................... 7
1.1 Underground Sump Enclosure Installation. ................................. 7
1.2 Vertical Delivery Pipe Assembly Installation................................11
1.3 Module Installation.................................................................... 18
1.4 Apollo 3000L Electronics Installation......................................... 21
2 APOLLO 3000L VR2 COMPONENTS INSTALLATION....................... 25
2.1 Installation Procedure Overview................................................ 25
2.2 Hydraulic Installation................................................................. 28
2.3 Vapour Sensor Assembly .......................................................... 30
2.4 Connecting to the Underground Return Pipework ...................... 34
2.5 Electrical Installation................................................................. 35
3 APOLLO 3000L COMMISSIONING.................................................... 37
3.1 Safety Inspection...................................................................... 37
3.2 Dispenser Configuration and Setup........................................... 37
3.3 Tatsuno Meter Calibration ......................................................... 47
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2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

LIST OF FIGURES
Figure 1. Apollo 3000L Components .........................................................................................7
Figure 2. Underground Sump Enclosure Components...............................................................7
Figure 3. Apollo Underground Sump Front View........................................................................8
Figure 4. Main Product Feed Line Configuration .......................................................................9
Figure 5. Typical Feed Line Assembly.......................................................................................9
Figure 6. Apollo Sump/Column Position Top View...................................................................10
Figure 7. Vertical Delivery Pipes Assembly Components......................................................... 11
Figure 8. Vertical Delivery Pipes Assembly Mounting Positions...............................................12
Figure 9. Delivery Pipes Assembly Part Numbers....................................................................14
Figure 10. Head Cabinet Mounting Brackets.............................................................................15
Figure 11. Vent Box Position and Sealing Specifications...........................................................16
Figure 12. Safety Hose Position................................................................................................17
Figure 13. External Hose Positions...........................................................................................17
Figure 14. Apollo Sump and Modules Assembly........................................................................ 18
Figure 15. Product Delivery Hoses Connection.........................................................................19
Figure 16. Float Switch Assembly Installation............................................................................19
Figure 17. Solenoid Valves Cable Distribution...........................................................................20
Figure 18. Wiring Guide Decal..................................................................................................20
Figure 19. Apollo 3000L Electronic Set .....................................................................................21
Figure 20. Setting of Protocol Jumpers for PEC and Gilbarco Protocols....................................22
Figure 21. Comms Connections................................................................................................22
Figure 22. Motor Drive Module Connection Guide.....................................................................23
Figure 23. Solenoid Valves Connection Guide...........................................................................23
Figure 24. Multiplexer Module Connection Guide......................................................................24
Figure 25. Internal Comparison of Apollo 3000L Standard and VR2 ..........................................26
Figure 26. VR2 Nozzles............................................................................................................27
Figure 27. Coaxial Adaptor........................................................................................................27
Figure 28. Coaxial Adaptors and Splitter Bracket ...................................................................... 28
Figure 29. Fitting of Bracket and Backing Plate to Soffit Panel.................................................. 28
Figure 30. Soffit Panel, Splitter Bracket and Hoses in Place......................................................29
Figure 31. Splitter Bracket Cover in Place.................................................................................29
Figure 32. Complete Vapour Sensor Assembly..........................................................................33
Figure 33. Example Vapour Return Line Connection .................................................................34
Figure 34. VR Modules Connections......................................................................................... 35
Figure 35. Connections into the Bürkert Valve Controller........................................................... 35
Figure 36. Phoenix Connector for Vapour Sensor Cables..........................................................36
Figure 37. Phoenix Connectors on the Fafnir Unit.....................................................................36
Figure 38. Service Mode Function Screens............................................................................... 38
Figure 39. Adjustment Wheel....................................................................................................47
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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Definitions
Comms Communicaon
ESD Electro-Static Discharge
GRP Glass Reinforced Plastic
VMS Vapour Management System
VR Vapour Recovery
Pump Fuel delivery unit where the pump is located within the unit itself.
Dispenser Fuel delivery unit where the remotely controlled pump is located in the
underground tank and not within the delivery unit.
Fuel Delivery
System
(FDS)
Self-contained system containing equipment for delivering fuel to a
customer. May contain one or more modules based on mechanical pumps,
dispensers or a combination of both. Does not include any connected
remote fuel storage and pumping facilities.
Intrinsic
Safety
Protection technique for the safe operation of electronic equipment in
explosive atmospheres. The theory behind intrinsic safety is to ensure that
the available electrical and thermal energy in the system is always low
enough that ignition of the hazardous atmosphere cannot occur. This is
achieved by ensuring that only low voltages enter the hazardous area, and
that electric supply and signal wires are protected by safety barriers.
ABOUT THIS MANUAL
This manual describes the installation and commissioning procedure for the Apollo
3000L Fuel Delivery System. This manual is divided into three sections:
• General installation;
• VR2 components installation;
• Commissioning.
This manual does not include the cladding installation, as it is not supplied by Gallagher
Fuel Systems.
5
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

Symbols
INFORMATION
Highlights subject areas that should clarify understanding or provides tips
or hints that should assist users and/or technicians.
 WARNING
Theassociatedtexthighlightsasubjectareainwhichdamagetoequipment
may result if procedures are not carried out correctly.
 General Safety Warnings and Precautions
yInstallation must only be carried out by suitably qualified and competent personnel.
yInitial electrical power-up and opening of fuel supply lines must only be carried
out after inspection and approval by suitably qualified and competent personnel.
yNo naked flames.
yAll personnel working with Fuel Delivery Systems must be made aware of how, in
an emergency, to turn OFF power to the FDS and any remote fuel storage system.
They must also be briefed on fire fighting and other relevant inflammable liquid
safety procedures.
yEnsure fuel pipes, flanges etc. are clear of debris before assembling.
yFuels present a toxic hazard and suitable precautions should be taken at all times
to prevent ingestion, inhalation and contact with skin and eyes.
yOnly use genuine spare parts. Genuine parts as specified in the original design are
integral to the correct function and safety of the system. Gallagher Fuel Systems
Ltd cannot be held responsible for any consequences of using non-genuine parts
and will not support under warranty any Gallagher FDS where substitution has
occurred. Any replacement parts should be like for like. In addition the repairer
may be legally liable for the consequences of any unauthorised modifications.
yDo not short out isolation or intrinsic safety barriers.
yElectronic equipment in the dispenser is susceptible to damage by electro-static
discharge (ESD). Suitable preventative measures should be taken at all times when
working on the electronic system.
yEnsure air is bled from product lines of remote dispensers before delivering
product.
yDamage to equipment caused by failure to correctly follow the procedures
described in this manual is not covered under warranty.
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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3. Modules
1. Underground
Sump Enclosure
2. Vercal Delivery
Pipe Assembly
4. Apollo 3000L
Electronics
Cable duct
Pipe duct
Sump box enclosure
Sump cover and sub-frame
Bulkhead seal
1.1 Underground Sump Enclosure Installation.
The following components are supplied by Gallagher:
• Sump box enclosure assembly, with cable duct, pipe ducts and internal delivery
pipes fitted;
• Bulkhead seals (pre-fitted into sump enclosure);
• Sump box lid;
• Sump cover and sub-frame.
1 APOLLO 3000L INSTALLATION
The Apollo 3000L dispenser is divided into sections, as follows.
Figure 1. Apollo 3000L Components
Figure 2. Underground Sump Enclosure Components
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

Procedure
Figure 3. Apollo Underground Sump Front View
• Establish the proposed/nal forecourt ground level (A); mark this point on the site column.
• Install the sump box enclosure into the correct posion below the proposed ground level
as shown in Figure 3.
• Ensure the pipe delivery ducts protrude 50mm above ground level (B) and 20mm (C)
proud of column for a 250 x 250mm column. For a 250 x 320mm column, the distance
between the end of the protruding delivery ducts and the external side of the column
should be 50mm (D).
• Check the end face of the enclosure is 300mm (E) out from the column.
Note: Ensure the underside of the enclosure is rmly packed to prevent the enclosure
from sinking or moving.
• Pack lling material around the sump enclosure approximately up to a point just under
the bulkhead ngs; this is to ensure the enclosure does not move while further work is
being conducted.
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION

A B C
CBA
ABC
A Premium Unleaded / 98
B Diesel
C Unleaded
Tee connector
3/4” Ball valve
3/4 - 3/4” BSP elbow
• Plug or cover the pipe delivery ducts to stop any foreign maer entering the sump box.
• Install the main product feed lines into the sump, according to the following gure.
Figure 4. Main Product Feed Line Configuration
• Install the feed line within the sump. The picture below shows the typical feed line
assembly. It considers the use of a Tee connector terminated with a ¾” ball valve and a
¾ - ¾” BSP Elbow. These components are not supplied by Gallagher Fuel Systems.
Note: Inside distance between bulkhead seals in hydraulic enclosure is 432mm, therefore
the feed line Tee terminaon arrangement must t within this distance. Ensure the ball valve
faces toward the boom of the sump, no more than 10 degrees o vercal and with the lever
side towards the column.
Figure 5. Typical Feed Line Assembly
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

• Re-check the sump posion in relaon to the column and the forecourt surface as per
Figure 3 and Figure 6.
• Secure the pipe delivery ducts and main feed lines into posion to prevent movement
while backlling.
• Temporarily pack the internal side walls of the sump using mber or similar to prevent
walls collapsing inwards during backlling.
• Re-check seals and sump posion.
• Backll to cover feed lines and secure sump enclosure posion.
• Backll and compact to within 150mm of forecourt surface, 30 – 50mm up skirng walls.
• Concrete the forecourt as per site requirements.
Figure 6. Apollo Sump/Column Position Top View
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION

A. Vercal Delivery
Pipe Assembly
C. Vent Box
Assembly
B. Head Cabinet
1.2 Vertical Delivery Pipe Assembly Installation
The following components are supplied by Gallagher:
• Front and rear vertical delivery pipe assemblies;
• Head cabinet assembly;
• Head cabinet mounting brackets;
• Flexible safety hose assemblies;
• External hose assembly, fitted with nozzles, grade covers and splash guards;
• Vent box assembly front and rear with their respective top caps;
• Serial name plate (to be adhered to top left hand corner of external door).
The installation procedure for this module is explained separately for each section,
according to the following picture.
Figure 7. Vertical Delivery Pipes Assembly Components
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

Procedure
A. Vercal Delivery Pipes Assembly
• Using a spirit level, nd the highest point on the forecourt out to a distance of 160mm
from the main column (in any direcon). Transfer this point onto the front face of the
column (front = sump at right hand side of column) and mark it as a datum point on
the face of the column. It must be established as an inial point to start measuring the
posions of components and mounng brackets and to obtain mounng heights and
ground clearances for nal cladding.
Figure 8. Vertical Delivery Pipes Assembly Mounting Positions
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION

• From the datum line, transfer and mark a point 2300mm vercally up the column. If
preferred, a second but lower point could be marked at 1405.4mm up the column. Having
both these datum points marked on the column could be advantageous as they could
then both serve as double checks.
Note: Marks should be made horizontally, as they will later be used to align vercal pipe
and holster assembly mounng brackets (refer to Figure 8 for details).
• Place the front vercal pipe assembly 8A89826 onto the front face of the column (see
Figure 9 for part numbers). The top angled secon of the pipe assembly should be poinng
out to the right hand side (e.g. towards the sump).
Note: Both of the middle two mounng brackets on the vercal pipe assembly have a
right angle lug welded to them (column stops). These are locaon lugs and should be
posioned up against the right hand face of the column.
• With lugs posioned against the column side face, slide the pipe assembly up unl the top
face of the third horizontal bracket (from the top) aligns with the lower mark at 1405.4mm
on the column and/or the top face of the second horizontal bracket aligns with the upper
mark on the column. Secure into posion with “G” or “F” clamps (or ratchet es).
• Check the column stops on second and third horizontal brackets are hard against the
column face; also check the vercal pipe assembly is vercal. If not, this could indicate
the column is not truly vercal. In this instance, move either top or boom of the pipe
assembly to obtain a true vercal reading. Secure the clamps and re-check heights from
forecourt datum marks.
• Drill pilot holes into the column through holes provided in the horizontal xing brackets
(a minimum of 2 per bracket is required). Fix the brackets to the column using suitable
screws.
• Repeat process on the rear side. Verify that the brackets on the rear pipe assembly are
horizontal with the front set. Also ensure the column stops on rear pipes are posioned
exactly in the same relaonship from the column as per front set.
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

Figure 9. Delivery Pipes Assembly Part Numbers
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION

B. Head Cabinet
• Assemble the head cabinet mounng brackets 4G89711 onto the head cabinet, using the
M5 studs and nuts supplied.
Note: The cut out secon of the brackets must be posioned towards the boom of the
cabinet as shown in Figure 10.
• Posion the lower head mounng bracket onto the top face of the third horizontal xing
bracket of the vercal pipe assembly. The cut out secon in the lower head mounng
bracket must be located over the xing bracket.
• Secure the head into posion with clamps. Drill pilot holes into the column through the
holes in the head mounng brackets and x the head with screws as per vercal pipe
assembly (see Figure 8).
• Aach the Mulplexer board to the underside of the head cabinet assembly (studs are
pre-posioned).
• Fit VR equipment as per Secon 2.
Figure 10. Head Cabinet Mounting Brackets
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

C. Vent Box
• With the top cap of the vent box removed, insert the boom end of the vercal pipes
into the gap and manoeuvre the vent box up into posion, behind vercal pipe assembly
as shown in Figure 11, ensuring the base edge makes contact with the forecourt ground.
• Place the top cap into the gap of the vent box. Ensure the cap is ng correctly into the
recess.
• Seal the cap from the inside using 50mm wide aluminium tape to provide a vapour seal.
Also tape the top of the vent box to the column (refer to Figure 11).
• Using a Bosk Matrix 600 or 700FC polyurethane sealant, seal all joints and pipe holes.
Ensure a good sized llet at the intersecon of the vent box to the forecourt.
Note: Ensure the inside of the vent box assembly is sealed suciently to eliminate the
potenal to leak out into the inside of the dispenser cladding.
Figure 11. Vent Box Position and Sealing Specifications
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION

A
A
B
B
C
C
(Shortest
hose) (Longest hose)
• Fit the safety exible hose assembly between the delivery pipes assembly (from the
sump) and the vercal pipes assembly, as shown in Figure 12.
• Repeat the above process at the rear side of the dispenser.
Figure 12. Safety Hose Position
• Install external hoses after the external cladding has been fitted. Refer to Section
2 for instructions on the installation of coaxial hoses. The hoses have different
lengths according to their position, as shown in Figure 13.
Figure 13. External Hose Positions
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

Manifold delivery
pipe assembly
8A89792
Meter delivery
pipe assembly
8A89626
Ex e enclosure
2A100327
Module frame
assembly 8A89626
Column End
Module C
Module B
FRONT
REAR
Module A
Encoder assembly
2A88918A
Hinge pin
8A89758
Float switch
assembly
2A03198
Solenoid valve
2A52536BF
1.3 Module Installation
The following components are supplied by Gallagher:
• Meter module assemblies;
• Module hinge pins;
• Product feed line hose assemblies x 3 (product feed line to modules);
• Product delivery hose assemblies, 2 per module (valve to delivery pipe assemblies
in pipe ducts);
• Float switch and cable assembly with mounting bracket;
• Ex e enclosure with mounting bracket.
Figure 14. Apollo Sump and Modules Assembly
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION

Column
Float switch
assembly
Procedure
• Connect the product delivery hoses to the internal delivery pipes, starting with
module C (closest to the column), according to the following image.
• Connect the product feed line hoses assemblies (x3) to the feed line assembly
shown in Figure 5.
• Fit the float switch assembly using the studs provided, as shown in the image
below. Position the float switch as low as possible. Verify that float is free to move
upwards without obstruction.
• Using the cable clips, route the float switch cable through the cable duct out of the
sump to the Multiplexer board located under the head cabinet.
• Install module C. Fit the hinge pin then lift above the sump and brace to hold the
module in place.
• Attach feed and delivery hoses to the meter module.
• Repeat the last two steps for modules B and A.
Figure 15. Product Delivery Hoses Connection
Figure 16. Float Switch Assembly Installation
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APOLLO 3000L INSTALLATION
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1

Module A Module B Module C
Column
Side
1 3 5
2 4 6
12
5
6
4
3
Valves Module
V1 and V2 A
V3 and V4 B
V5 and V6 C
PE: Protecve Earth;
BK: Black;
BN: Brown;
GY: Grey.
• Route the solenoid valves cables (1 - 6) through the cable clips provided into the Ex
e enclosure through the glands indicated in the following image.
Figure 17. Solenoid Valves Cable Distribution
• Connect the solenoid valve cables inside the Ex e enclosure according to the wiring
guide decal located inside the enclosure cover.
Figure 18. Wiring Guide Decal
• Attach the Ex e enclosure to the sump box using the supplied mounting bracket and
bolts. Ensure the cables are tidy using the cable clips on the sump wall.
• Run the 18 core cable through the cable duct up to the bottom of the head cabinet.
• Run the encoder cables through the cable duct to the Multiplexer board located
under the head cabinet.
2A03229 APOLLO 3000L Installaon and Commissioning Manual Issue 1
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APOLLO 3000L INSTALLATION