Gallagher PULSE Series User manual

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

2PULSE Installaon, Commissioning and Servicing Manual - Revision 19
Copyright © Gallagher Fuel Systems Ltd 2021
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.
Gallagher Fuel Systems Ltd
2 Station Rd
PO Box 308
Marton 4741
New Zealand
Phone: [phone]
Emails: [e-mail]
[e-mail]
Web: http://fuelsystems.gallagher.com
How to Contact Gallagher
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.
IMPORTANT
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.

3
PULSE Installaon, Commissioning and Servicing Manual - Revision 19
CONTENTS
PART A: GENERAL 8
1 ABOUT THIS MANUAL.....................................................................................................................8
2 NOTATIONS ......................................................................................................................................8
3 PICTOGRAMS...................................................................................................................................8
4 SAFETY WARNINGS & PRECAUTIONS..........................................................................................9
4.1 Hazard Warnings.............................................................................................................................9
4.2 Damage Warnings .........................................................................................................................10
4.3 Information Relating to DEF (Diesel Exhaust Fluid)........................................................................ 10
4.4 Materials Not Recommended to be used with DEF ......................................................................... 11
5 GREASING THREADED CONNECTIONS...................................................................................... 11
6 FASTENING OF PANEL SCREWS .................................................................................................12
7 GENERAL SHIPPING & TRANSPORTATION INFORMATION .....................................................13
7.1 Handling........................................................................................................................................13
7.2 Storage..........................................................................................................................................14
8 PULSE TECHNICAL SPECIFICATIONS.........................................................................................15
PART B: INSTALLATION 16
1 LIFTING OF UNITS.........................................................................................................................16
2 PRIOR TO INSTALLING .................................................................................................................16
2.1 Underpump Containment Sump......................................................................................................16
2.2 Hydraulic Pre-Installation ..............................................................................................................16
2.3 Anchoring Bases............................................................................................................................ 16
2.4 Electrical Requirements/Regulations..............................................................................................18
3 HYDRAULICS .................................................................................................................................19
3.1 Pumps...........................................................................................................................................19
3.2 Dispensers ....................................................................................................................................19
3.3 LPG............................................................................................................................................... 19
3.4 Vapour Recovery........................................................................................................................... 19
4 C SERIES HOSE INSTALLATION (HANGING)..............................................................................20
4.1 Remove the Holsters .....................................................................................................................20
4.2 Fit the Spreader............................................................................................................................. 20
4.3 Fit the Hoses................................................................................................................................. 21
4.4 Replace the Holsters......................................................................................................................22
5 C SERIES HOSE INSTALLATION (RETRACTOR).........................................................................23
5.1 Remove the Spreader Panels.........................................................................................................23
5.2 Prepare Spring Reel Cable for Connection to Hose........................................................................ 24
5.3 Remove Holster Panels to Allow Access to Hoses.......................................................................... 24
5.4 Connect the Hoses ........................................................................................................................25
5.5 Attach the Hose Clamp to the Hose and Retractor Cable................................................................ 26
5.6 Refit Panels...................................................................................................................................27
6 NOZZLE SWITCH CONNECTION...................................................................................................28
7 CORRECT FITTING OF HOSES TO HI-ARM .................................................................................28
8 BENNETT PUMP UNIT....................................................................................................................29
8.1 Pre-Installation Check of Rotor Movement...................................................................................... 30
8.2 Realignment Procedure..................................................................................................................30
8.3 Belt Tension...................................................................................................................................30
8.4 Vacuum and Pressure Testing........................................................................................................30

4PULSE Installaon, Commissioning and Servicing Manual - Revision 19
9 ELECTRICAL..................................................................................................................................31
9.1 General .........................................................................................................................................31
9.2 Mains ............................................................................................................................................31
9.3 Comms..........................................................................................................................................31
9.4 Forecourt Communications ............................................................................................................33
9.5 Float Switch Installation.................................................................................................................34
9.6 Installing the Head Lighting............................................................................................................35
9.7 Connecting the light cable for the Illuminated Spreader..................................................................38
PART C: COMMISSIONING 39
PART D: SERVICING 54
1 OVERVIEW......................................................................................................................................39
2 SAFETY INSPECTION....................................................................................................................40
3 SYSTEM START-UP CHECKS........................................................................................................40
4 LPG TRADE MEASUREMENT VERIFICATION PROCESS ...........................................................40
5 SERVICE MODE SETTINGS...........................................................................................................40
6 CALIBRATION ...............................................................................................................................41
6.1 Firmware Test................................................................................................................................41
6.2 Lobe Meter (Ultra Diesel)...............................................................................................................42
6.3 Calibration Procedure.................................................................................................................... 42
6.4 Calibration Procedure for Blending Units........................................................................................ 43
7 LPG SECTION.................................................................................................................................44
7.1 LPG Stack Components................................................................................................................. 45
7.2 4-Way Meter Feed Valve Settings ..................................................................................................46
7.3 Return Line Valve .......................................................................................................................... 46
7.4 LPG Stack Test - Version 1.11........................................................................................................47
7.5 LPG Stack Test - Version 1.20 .......................................................................................................48
7.6 LPG Trade Measurement Verification Process - Version 1.11..........................................................49
7.7 LPG Trade Measurement Verification Process - Version 1.20 ........................................................51
7.8 LPG Meter Calibration - Version 1.20.............................................................................................52
7.9 LPG Electrical Schematics.............................................................................................................53
1 GENERAL CARE AND MAINTENANCE.........................................................................................55
1.1 Daily Maintenance .........................................................................................................................55
1.2 Monthly Maintenance.....................................................................................................................55
1.3 Annual Maintenance ......................................................................................................................55
1.4 Target Torques for Gasket Sealing ................................................................................................. 56
2 NOZZLES........................................................................................................................................57
2.1 Elaflex (Petrol/Diesel)....................................................................................................................57
2.2 Elaflex GG1DN / LPG .................................................................................................................... 58
2.3 Elaflex DEF Nozzles ......................................................................................................................59
3 SAFETY BREAKS...........................................................................................................................60
4 LPG DRY BREAKS .........................................................................................................................61
5 HOSES ............................................................................................................................................62
5.1 Shortening Hoses ..........................................................................................................................63
6 ASCO 24V PROPORTIONAL VALVE..............................................................................................64
7 MAINTAINING THE SPRING REEL TENSION (L SERIES)............................................................65
8 REPLACING THE PUMP UNIT /AIR SEPARATOR STRAINERS..................................................66
8.1 To Replace the Inlet Strainer:......................................................................................................... 66
8.2 To Replace the Outlet Strainer: ......................................................................................................67
9 DEF FILTER CARTRIDGE REPLACEMENT ..................................................................................68

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PULSE Installaon, Commissioning and Servicing Manual - Revision 19
10 ELECTRICAL..................................................................................................................................69
10.1 Remounting a PULSE UI Battery Pack........................................................................................... 69
10.2 Simple Wiring Diagram .................................................................................................................. 70
10.3 Junction Box Wiring Diagrams .......................................................................................................71
11 SD CARD CONTENT.......................................................................................................................72
11.1 Process for Loading Firmware onto the SD Card............................................................................72
11.2 Configuration Reinstall...................................................................................................................72
11.3 Obtaining Dispenser Logs..............................................................................................................73
12 SERVICE MODE FUNCTIONS........................................................................................................73
12.1 Entering Service Mode................................................................................................................... 73
12.2 SD Card Setting.............................................................................................................................73
12.3 Service Mode function screens ......................................................................................................73
12.4 Firmware - FIRMW.........................................................................................................................74
12.5 Setting VR Active - VRCTRL.......................................................................................................... 75
12.6 Setting Pump Numbers - CGFPID.................................................................................................. 75
12.7 Setting a Password - CGPWD........................................................................................................76
12.8 Errors - ERRORS...........................................................................................................................77
12.9 Setting Hoses Active/Inactive - HOSE ............................................................................................78
12.10 Grade Priority - PRIORTY..............................................................................................................78
12.11 5/6 Digit Mode - 5DIGIT.................................................................................................................78
12.12 POS/Standalone - POS.................................................................................................................. 79
12.13 Grade Prices - PRICE....................................................................................................................79
12.14 Hydraulic Stack Test - STACK........................................................................................................80
12.15 Checking Input Status....................................................................................................................81
12.16 View/Set Date & Time....................................................................................................................82
12.17 Maintaining Isolation of Mains Voltage within Head Cabinet............................................................82
13 MANAGER & VIEW TOTES MODES - ALL VERSIONS.................................................................83
13.1 Manager Mode .............................................................................................................................. 83
13.2 View Totes Mode ..........................................................................................................................83
14 SERVICE MODE FUNCTIONS........................................................................................................84
14.1 Summary of New Key Features and Functions ...............................................................................84
14.2 Entering Service Mode................................................................................................................... 85
15 SERVICE MODE FUNCTION SCREENS - VERSION 1.20.............................................................85
15.1 SD Card Setting - SDCARD ........................................................................................................... 86
15.2 Stack Menu - STK MENU...............................................................................................................86
15.3 Setting Pump Numbers - FP ID ......................................................................................................88
15.4 Point of Sale Menu - POS..............................................................................................................89
15.5 Grade Priority - MAPPING ............................................................................................................. 90
15.6 Setting Hoses Active/Inactive - HOSE ............................................................................................91
15.7 Grade Prices - PRICE....................................................................................................................91
15.8 LPG Menu .....................................................................................................................................92
15.9 Errors - ERRORS...........................................................................................................................94
15.10 PULSE Counted Error Codes......................................................................................................... 95
15.11 Timeout Menu - TIMEOUT ............................................................................................................. 96
15.12 Start-Up Delay - STARTDEL ..........................................................................................................97
15.13 Flow Control - FLOWCTRL.............................................................................................................97
15.14 View/Set Time - TIME....................................................................................................................98
15.15 View/Set Date - DATE....................................................................................................................98
15.16 Setting a Password - PASSWD ......................................................................................................99
15.17 Setting VR Active - VR2.................................................................................................................99
15.18 Totes ........................................................................................................................................... 100
15.19 Reload Configuration - CONFIG................................................................................................... 100
15.20 Restart Central Controller - REBOOT........................................................................................... 100
15.21 Operating System Menu - OS....................................................................................................... 101
15.22 Firmware - FIRMWARE................................................................................................................ 102
16 HYDRAULIC STACK TEST (BLENDING)..................................................................................... 104
16.1 Procedure.................................................................................................................................... 104
16.2 Testing the Non-return Valves (circled in diagrams)......................................................106
16.3 Adjusting Flow Rates................................................................................................................... 106

6PULSE Installaon, Commissioning and Servicing Manual - Revision 19
LIST OF FIGURES
16.4 Calibration................................................................................................................................... 107
16.5 Flow Control - FLOWCTRL........................................................................................................... 107
16.6 Grade Priority - MAPPING ........................................................................................................... 107
16.7 Setting Hoses Active/Inactive - HOSE .......................................................................................... 107
17 RATIO ERROR..............................................................................................................................107
18 ADDRESSING LPG METERS - VERSION 1.20 ...........................................................................108
19 PULSE MEDIA................................................................................................................................111
19.1 Operation .....................................................................................................................................112
19.2 Power Buttons ..............................................................................................................................112
19.3 Adjusting the Volume....................................................................................................................113
19.4 Electrical Protection......................................................................................................................113
19.5 Wiring Diagram.............................................................................................................................113
19.6 Cleaning the LCD Screen..............................................................................................................113
20 TROUBLESHOOTING................................................................................................................... 114
20.1 Dispenser Will Not Deliver Fuel.....................................................................................................114
20.2 Dispenser Will Deliver Fuel...........................................................................................................116
21 QUICK REFERENCE GUIDE - VERSION 1.11 ............................................................................. 117
22 QUICK REFERENCE GUIDE - VERSION 1.20............................................................................. 118
23 APPENDIX - BLENDING INFORMATION..................................................................................... 119
23.1 Flow .............................................................................................................................................119
23.2 Layout ........................................................................................................................................ 120
23.3 Blending Manifold........................................................................................................................ 121
23.4 WIRING....................................................................................................................................... 121
23.5 Stack Controllers ......................................................................................................................... 121
23.6 Multiplexers................................................................................................................................. 122
24 APPENDIX - DISPENSER CONTROL SYSTEMS.........................................................................123
Figure 1. Greasing Threaded Connections......................................................................... 11
Figure 2. Location of Panel Screws.................................................................................... 12
Figure 3. Anchor Point Locations ...................................................................................... 17
Figure 4. Correct Nozzle Switch Connection...................................................................... 28
Figure 5. Correct Method of Fitting Hoses to High-Arm .................................................... 28
Figure 6. Bennett Pump Unit .............................................................................................. 29
Figure 7. Single Phase Pump Connector Blocks................................................................ 31
Figure 8. Mains Connections.............................................................................................. 32
Figure 9. Comms Connections........................................................................................... 32
Figure 10. Location and Positioning of Protocol Pins......................................................... 33
Figure 11. Central Controller DCE........................................................................................ 33
Figure 12. Float Switch Installation ..................................................................................... 34
Figure 13. Head Lighting Assembly ..................................................................................... 35
Figure 14. Rear Side of the Head ......................................................................................... 35
Figure 15. Overall Commissioning Process......................................................................... 39
Figure 16. Adjustment Wheel............................................................................................... 41
Figure 17. Lobe Meter .......................................................................................................... 42
Figure 18. Encoder PCB....................................................................................................... 42
Figure 19. LPG Stack Components ...................................................................................... 45
Figure 20. Meter Feed Valve Settings................................................................................... 46
Figure 21. Return Line Valve with LPG Nozzle Attached...................................................... 46

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PULSE Installaon, Commissioning and Servicing Manual - Revision 19
Figure 22. Location of Dipswitches...................................................................................... 49
Figure 23. LPG Electrical Schematic.................................................................................... 53
Figure 24. LPG Electrical Schematic Using Integrated Stack Controller............................. 53
Figure 25. Target Torques for Gasket Sealing...................................................................... 56
Figure 26. Elaflex ZVA Slimline 2 Nozzle.............................................................................. 57
Figure 27. Elaflex ZVA DEF Nozzle and Adapter..................................................................59
Figure 28. Elaflex SSB Safety Break .................................................................................... 60
Figure 29. Brass Swivel Nuts and Hose Clamp.................................................................... 62
Figure 30. Gaining Access by Moving the Channel Runners............................................... 62
Figure 31. ASCO Proportional Valve .................................................................................... 64
Figure 32. Filter Housing and Y Strainer.............................................................................. 68
Figure 33. Removal of the Filter Housing ............................................................................ 68
Figure 34. Shield Surface with BUP Board and Battery Pack .............................................. 69
Figure 35. Simplified Wiring Diagram .................................................................................. 70
Figure 36. Mains Connections.............................................................................................. 71
Figure 37. Comms Connections........................................................................................... 71
Figure 38. Order of Service Mode Screens .......................................................................... 73
Figure 39. Order of Service Mode Screens .......................................................................... 85
Figure 40. External View .....................................................................................................111
Figure 41. PULSE Media Components.................................................................................111
Figure 42. Windows Keyboard ............................................................................................112
Figure 43. Location of Power Buttons for Media Player and LCD Screen .........................112
Figure 44. Volume Knob ......................................................................................................113
Figure 45. Fuse Location.....................................................................................................113
Figure 46. PULSE Media Basic Wiring Diagram..................................................................113
Figure 47. Hydraulic Flow ...................................................................................................119
Figure 48. Hydraulic Layout............................................................................................... 120
Figure 49. Blending Manifold Assembly............................................................................. 121
Figure 50. Head Contents................................................................................................... 122
Figure 51. Wiring Positions of the Stack Controller .......................................................... 122
Figure 52. Wiring Positions of the Multiplexer Board........................................................ 122
Figure 53. Central Controller.............................................................................................. 123
Figure 54. DC Power Supply .............................................................................................. 124
Figure 55. 3-Board Stack Controller................................................................................... 125
Figure 56. DC Integrated Stack Control - 1 ........................................................................ 126
Figure 57. DC Integrated Stack Control - 2 ........................................................................ 127
Figure 58. AC Integrated Stack Control ............................................................................. 128
Figure 59. 1 or 2 User Interface Modules........................................................................... 129
Figure 60. 3 or 4 User Interface Modules........................................................................... 130
Figure 61. Multiplexer Board Detail.................................................................................... 131
Figure 62. VR2 Subsystem Detail....................................................................................... 132
Figure 63. LPG Additions ................................................................................................... 133
Figure 64. Mains Entry Box................................................................................................ 134

GENERAL
8PULSE Installaon, Commissioning and Servicing Manual - Revision 19
PART A: GENERAL
1 ABOUT THIS MANUAL
This manual describes the installation, commissioning and servicing of PULSE dispensers.
It is divided into the following parts:
A. General B. Installation C. Commissioning D. Servicing
Included are models dispensing petrol, diesel, LPG and DEF (Diesel Exhaust Fluid).
2 NOTATIONS
3 PICTOGRAMS

DANGER
The associated text highlights a subject area that poses a threat of injury or death
if procedures are not carried out correctly.
 WARNING
The associated text highlights a subject area in which damage to equipment may
result if procedures are not carried out correctly.
INFORMATION
Highlights subject areas that should clarify understanding or provides tips or hints
that should assist users and/or technicians.
Comms Communicaon
DEF Diesel Exhaust Fluid
Gallagher Gallagher Fuel Systems Limited
IS Intrinsically Safe
PCB Printed Circuit Board
SWA Steel Wire Armoured
UI User Interface
VR Vapour Recovery
pump Three context sensitive meanings:
(a) device used to pressurise or transport a liquid.
(b) fuel delivery module based on a mechanical pump.
(c) where followed by a number (ie. Pump 3) denotes a fuelling
position/side of an FDS.
dispenser Fuel delivery module based on fuel supplied under pressure from a
remote storage system and which does NOT contain a mechanical
pump.
In some instances “dispenser” may apply equally to a pump or a
dispenser

GENERAL
9
PULSE Installaon, Commissioning and Servicing Manual - Revision 19

No naked flames.

Isolate fuel supplies and empty pipes before working on them.

Isolate electrical supply before opening a dispenser cabinet for maintenance. Physically
lock, restrict access to, or tag the circuit breakers you turn off when working on a
dispenser.

The dispenser must be supported at all times by all anchor bolts as shown in the
appropriate footprint diagram (see “Gallagher PULSE Series - Footprint Manual.” Part
No. 2A02068). External support must be used until these are secured. In service, all
anchor bolts must be fitted.

All personnel working with dispensers must be made aware of how, in an emergency, to
turn OFF power to the dispenser and any remote fuel storage system. They must also be
briefed on fire fighting and other relevant inflammable liquid safety procedures.

There are exposed belt-drives between mechanical pumps and their motors in fuel pump
equipped dispensers. Ensure that power to the motors is isolated and that the motors
have stopped running before opening external panels.

Have all leaks or defects repaired immediately.

Fuels present a toxic hazard and suitable precautions should be taken at all times to
prevent ingestion, inhalation and contact with skin and eyes.

Only lift units using the correct lifting points as indicated in the installation part of
this manual. Never lift by the nozzle boot, sheet metal, etc. Incorrect lifting also risks
damage to equipment which will not be covered under warranty.

Any repairs must not compromise the safety approval of a dispenser.

The system must not be modified without consulting Gallagher.

Only use genuine spare parts. PULSE dispensers are supplied by Gallagher as a fully
approved system. Genuine parts as specified in the original design are integral to the
correct function and safety of the system. Gallagher cannot be held responsible for
any consequences of using non-genuine parts and will not support under warranty any
PULSE where substitution has occurred. Any replacement parts should be like for like.
In addition the repairer may be legally liable for the consequences of any unauthorised
modifications.

Never operate a non-intrinsically safe circuit without the flameproof enclosure cover
fitted.

Do not short out isolation or intrinsic safety barriers.
4.1 Hazard Warnings
4 SAFETY WARNINGS & PRECAUTIONS
Risk of explosion Electric Shock Hazard Toxic Hazard

GENERAL
10 PULSE Installaon, Commissioning and Servicing Manual - Revision 19

Installation must only be carried out by suitably qualified and competent personnel.

Initial electrical power-up and opening of fuel supply lines must only be carried out after
inspection and approval by suitably qualified and competent personnel.

Dispensers contain hazardous liquid and vapour. The instructions in this manual must be
followed. In addition, the relevant applicable laws, rules and codes of practice must also
be applied. Where contradictions exist, the local legal requirements take precedence.
4.2 Damage Warnings
 Electronic equipment in a dispenser is susceptible to damage by electrostatic discharge
(ESD). Suitable preventative measures should be taken at all times when working on the
electronics system.
 Do not clean using hoses or other pressurised systems. Pressurised water ingress
damage invalidates the warranty.
 The operating environment should avoid extremes of temperature, humidity, etc.
including: direct and constant sunlight and heat; atmospheric precipitation (rain, snow,
sleet or hail); ice; salt spray; condensing high humidity and dust.
 Do not clean using abrasive materials such as steel wool or abrasive polishes unless
specifically recommended.
 Ensure air is bled from product lines of remote dispensers and mechanical pumps before
dispensing product.
 Flush all fuel supply lines and ensure flanges, etc. are clear of debris before connection.
 Pressure must not be applied to the upper frame or panels by strops or other pieces of
lifting equipment.
 Hoses that have been used to deliver petrol should not be used to deliver diesel.
Plasticisers in the hose lining are replaced by components of the petroleum during use,
which are removed if the hose is subsequently used for diesel.
 The maximum stated delivery pressure (350kpa) must not be exceeded.
 Damage to equipment caused by failure to correctly follow the procedures described in
this manual is not covered under warranty.
4.3 Information Relating to DEF (Diesel Exhaust Fluid)
 Due to its corrosive nature extreme care must be taken to avoid contamination by DEF
(Diesel Exhaust Fluid) when servicing and maintaining DEF equipment. Any DEF product
that comes in contact with other dispenser components must be rinsed off with water
immediately and thoroughly before any corrosion damage can occur.
 The first 10 litres of product flushed through a DEF dispenser and any test vessels must
not be returned to the DEF tank.
 DEF can be returned to the storage tank only if it is not contaminated.
 DO NOT flush DEF down drains. Contact local authorities for acceptable disposal
procedures.
 Petrol/diesel test equipment should not be used for DEF or vice versa. Use only approved
equipment for DEF.

GENERAL
11
PULSE Installaon, Commissioning and Servicing Manual - Revision 19
4.4 Materials Not Recommended to be used with DEF
 Gallagher Fuel Systems have seen instances where severe corrosion has occurred on
components within the Tatsuno flow meter as a direct result of the use of copper, brass,
bronze or other copper alloy components within the Diesel Exhaust Fluid delivery system.
ISO 22241-3 2008 Diesel Engines – NOx Reduction Agent AUS 32 – Part 3 – Handling
Transportation and Storing provides a list of materials not recommended for use within
systems that come in contact with Diesel Exhaust Fluid.
 This list includes non-ferrous metals and alloys; copper, copper alloys (e.g. brass), zinc
and lead.
 All components used in delivery systems for Diesel Exhaust Fluid must comply with ISO
22241-3 2008.
 Any issues arising from the presence of copper or other non-recommend materials
within the delivery system will not be covered by the Gallagher warranty.
5 GREASING THREADED CONNECTIONS
Grease, petroleum jelly or other suitable thread protectant is commonly applied to
threaded connections within fuel dispensers to allow for easy disassembly.
Gallagher endorses this practice and reminds installers and service technicians that grease
should be applied to the threaded pipe when a hose is attached during installation or
service of any Gallagher fuel dispensers.
Be sure not to over-lubricate this connection as no grease should come in contact with the
hose or the Blue face seal on the inside of the hose fitting.
Grease should be applied starting 1-2 threads back from end of the male pipe fitting.
Take care to avoid possible contamination of DEF.
Figure 1. Greasing Threaded Connections

1
2
3
GENERAL
12 PULSE Installaon, Commissioning and Servicing Manual - Revision 19
6 FASTENING OF PANEL SCREWS
The following applies to panels that are fastened with M6 stainless steel button screws.
These screws are torqued to 5-7Nm and have an application of Loctite 243 or Loctite 248
to prevent them from self-loosening.
If panels are removed at install or for servicing, then the screws need to be retorqued to
5-7Nm and must have a new application of Loctite 243 or Loctite 248 applied.*
The diagrams highlight the locations of all the relevant screws that these instructions
apply to.
* Ensure that the manufacturer’s instrucons for
the applicaon of Locte are correctly followed.
C Series
L Series
Q Series
1
2
3
Figure 2. Location of Panel Screws

GENERAL
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PULSE Installaon, Commissioning and Servicing Manual - Revision 19
7 GENERAL SHIPPING & TRANSPORTATION INFORMATION
Each Gallagher PULSE dispenser is supplied in
protective packaging consisting of a forklift
compatible wood and cardboard crate.
Upon receipt the crate should immediately
be inspected for external damage. If any is
found it should be recorded at once on the
delivery documentation and MUST be notified
to Gallagher in writing (email or fax) within 3
working days;
It is strongly recommended that photographs of
damaged packaging and equipment be sent to
Gallagher to assist the claim process;
All damaged products AND packaging must be
retained for inspection by Gallagher.
Prompt action will significantly assist problem
resolution.
7.1 Handling
Storage conditions must be met during handling and transportation.
Dispensers in their factory supplied packaging are compatible with forklifts. Always insert
forks at the points indicated to avoid tipping to one side.
The estimated maximum external dimensions (cm) and weights (kg) of PULSE dispensers
in their factory-supplied packaging are shown in the following tables.
The prefix V signifies models fitted with Vapour Recovery.
The suffixes (S) and (F) stand for Spreader and Flexi respectively.
Fork Lift Points
TYPE Weight Width Depth Height
LX 8-Hose Pump 476 201 58 221
LX 6-Hose Pump 398 186 58 221
LX 4-Hose Pump 325 168 58 221
LX 8-Hose Dspnsr 340 200 58 221
LX 6-Hose Dspnsr 287 186 58 221
LX 4-Hose Dspnsr 250 168 58 221
LS 8-Hose Pump 450 167 58 221
LS 6-Hose Pump 370 150 58 221
LS 4-Hose Pump 290 130 58 221
LS 2-Hose Pump 280 120 58 221
LS 8-Hose Dspnsr 300 167 58 221
LS 6-Hose Dspnsr 360 150 58 221
TYPE Weight Width Depth Height
LS 4-Hose Dspnsr 231 135 58 221
LS 2-Hose Dspnsr 300 120 58 221
V LX 8-Hose Pump 340 200 58 221
V LX 6-Hose Pump 431 186 58 221
V LX 6-Hose Dspnsr 300 176 58 221
V LX 8-Hose Dspnsr 380 200 58 221
CX 8-Hose Pump(S) 400 125 58 175
CX 6-Hose Pump(S) 375 125 58 175
CX 4-Hose Pump(S) 350 125 58 175
CX 8-Hose Dspnsr(S) 233 125 58 176
CX 6-Hose Dspnsr(S) 350 125 58 175
CX 4-Hose Dspnsr(S) 325 125 58 175
Sample
Packaging

GENERAL
14 PULSE Installaon, Commissioning and Servicing Manual - Revision 19
 Dispensers present a tipping risk, and they are heavy. Do not attempt to manoeuvre a
dispenser by hand, e.g. DO NOT use a hand trolley (sack barrow).
 Any contact with the upper crate or dispenser by ropes, chains, etc. risks seriously
damaging the dispenser.
 Tying down during transport should only be via the tying points marked on the crate.
Note the following key points:
(a) Lifting forces are applied to pipes inserted through brackets in each top corner of
the hydraulic cabinet.*
(b) Spacers must be used to prevent lifting strops from applying pressure to the head
and frame. This is essential to avoid damage.*
*Refer to Part B: Installation, 1. Lifting of Units
 Pressure must not be applied to the upper frame or panels by strops or other pieces of
lifting equipment.
7.2 Storage
The storage or transportation environment must be:
(a) Dry and reasonably dust-free;
(b) Reasonably vibration-free;
(c) Have a level surface to minimise tipping risk.
Dispensers should be stored in their delivery crates.
If it is necessary to inspect the equipment prior to storage, record the orientation of the
upper cardboard packaging with respect to the base so that it can be replaced correctly
with the marked tie-down points in their correct positions.
TYPE Weight Width Depth Height
CX 8-Hose Pump(F) 430 125 58 221
CX 6-Hose Pump(F) 400 125 58 221
CX 4-Hose Pump(F) 380 125 58 221
CX 8-Hose Dspnsr(F) 350 125 58 221
CX 6-Hose Dspnsr(F) 320 125 58 221
CX 4-Hose Dspnsr(F) 300 125 58 221
CS 4-Hose Pump(S) 250 90 58 175
TYPE Weight Width Depth Height
CS 2-Hose Pump(S) 220 90 58 175
CS 4-Hose Dspnsr(S) 200 90 58 175
CS 2-Hose Dspnsr(S) 180 90 58 175
CS 4-Hose Pump(F) 240 90 58 205
CS 2-Hose Pump(F) 220 90 58 205
CS 4-Hose Dspnsr(F) 220 90 58 205
CS 2-Hose Dspnsr(F) 200 90 58 205

GENERAL
15
PULSE Installaon, Commissioning and Servicing Manual - Revision 19
Sucon System
1 pump and motor per product Dedicated meter for each product hose/nozzle
Standard - sucon head limit 4.0m (petrol @ 25°C @ sea-level) max, includes vercal li and losses in supply pipe lines and ngs
Standard - sucon head limit 5.0m (diesel @ 25°C @ sea-level) max, includes vercal li and losses in supply pipe lines and ngs
Ultra - sucon head limit 3.0m maxiumum eecve sucon head with the T140 only for Ultra/High Diesel ow
Air Separaon
Tatsuno PGS-0257 FP1001 Pumping Unit
Benne T140 Hydrauic High Flow Pumping Unit
Pressure System
Submersible pump unit (STP) in the remote fuel tank - controlled from on-board AC Control system. Minimum 1 STP/product
Inlet manifold pressure 100 - 350kPa max (MUST NOT exceed 350kPa)
Delivery Flow Rate
Standard up to 40L/min Standard nozzle with reduced spout (38L/min target)
Boost buon up to 60L/min Standard nozzle with 19mm standard diesel spout
Diesel High Flow up to 80L/min Nozzle 25mm with 25mm standard spout
Diesel Ultra Flow up to 120+L/min Nozzle 25mm with 25mm standard spout
DEF - Euro5: Trucks up to 40L/min DEF - Euro 6: Passenger cars up to 5L/min (DEF - Diesel Exhaust Fluid)
LPG up to 40L/min Gas Guard GG1DN LPG Nozzle with latching opon
* All quoted delivery ow rates dependent on supply pressure, condion of the underground piping and fuel quality impacts
Metering
Tatsuno FM-1007 Flow Meter
Tatsuno FM-1002 Lobe Meter (Ultra Flow Diesel)
Electronic System
All electronic components located in the hazardous areas (hydraulic cabinet and hose stowage area) are intrinsically safe
All other electronic components are located in the non-hazardous area within the User Interface
Display Total Price 7 Digit Transecve backlit LCD. Limited to MAX $9990.00 by POS protocols
5 or 6 digit opons available
Total Volume 7 Digits Transecve backlit LCD. Limited to MAX 9990.00 litres by POS protocols
5 or 6 digit opons available
Preset 5 or 6 Digit Transecve backlit LCDs. Limited to MAX $9990.00
Unit Price 5 Digit Transecve backlit LCDs
Tote Digital 8 digit totalisator for total volume and dollars per hose
Electro Mechanical 7 digit totalisator for total volume per hose (opon)
Pulser 88918/07434 Intrinsically safe pulser, IECEx cered Ex ib
Forecourt Communicaons PEC Two wire 12V parallel system
Gilbarco Australia Two wire current loop system
Electrical System
Motor Elnor 750W IECEx cered Ex d single phase
Motor Elnor 1500W IECEx cered Ex d single phase (Ultra sucon soluons)
Solenoid Valves ASCO 24VDC proporonal solenoid valve. IECEx cered Ex m
Temperature Range -10°C to +50°C
Electrical Requirements 220-240 VAC
Mechanical System
Hose Elaex 16mm AS 2683 compliant
High Flow Hose Elaex 21mm or 25mm - AS2683 compliant
Ultra, High or Boosted Flow Switch Illuminated buon available on all models with diesel
Nozzle Elaex ZVA Automac Nozzle: ZVA Slimline 2 / ZVA25
Dry-break couplings Elaex SSB16/ SSB25 Straight - Safety Swivel Break at the Nozzle
MAX No. of Products Dispensed L Series: 5 per side C Series: 4 per side
Ethanol, LPG, Biodiesel and DEF capable Yes. (Limits: Ethanol up to E10 or E85. Biodiesel up to B20)
Vapour Recovery opon Yes. Integral with Elaex VR Hoses and Nozzles
Hose Reach L Series: Reach: 3.3m - Hanging hose 4.0m - Retractor slide acvates at 3.3m
C Series:
Reach: 3.8m - Hanging hose 4.5m - Retractor reel acvates at 3.8m
CS Q: Reach: 4.2m - Standard Flexi-arm 5.2m - Extended Flexi-arm
8 PULSE TECHNICAL SPECIFICATIONS

INSTALLATION
16 PULSE Installaon, Commissioning and Servicing Manual - Revision 19
PART B: INSTALLATION
1 LIFTING OF UNITS
PULSE Fuel Delivery Systems have
brackets in each upper corner of the
hydraulic cabinet through which lengths
of 32mm (1¼”) diameter steel bar are
inserted from front to rear. Care must
be taken so as not to snag components,
wiring etc.
Suitable strops are then attached to
the ends of the bars as shown in the
accompanying diagram.
2 PRIOR TO INSTALLING
The mechanical, hydraulic and electrical work that must be completed on site prior to
installation of the dispenser is described below.
2.1 Underpump Containment Sump
Sumps with secondary containment pipework must be provided at all sites. These can be
sourced from an appropriate manufacturer.
The installation method will depend on local, legal and customer requirements.
At all sites with sumps, dispensers must be installed with a liquid level detection device
fitted in the sump that will raise an alarm if liquid is detected in the base of the sump. (see
Installation - Section 9.5 Float Switch Installation)
2.2 Hydraulic Pre-Installation
The footprint, anchor points and perimeter of the PULSE Series are contained in the
document entitled “Gallagher PULSE Series - Footprint Information.” (Part No. 2A02068)
To view this document access the following website and enter the name (eg footprint
manual) in the search window.
https://fuelsystems.gallagher.com/support
2.3 Anchoring Bases
Requirements applicable to all system sizes include:
• all anchor points must be bolted to a rigid horizontal surface (see illustration);
• bases must be fixed or anchored to a rigid and level surface. The surface that the
pump is fixed to must contact the whole of the base plate’s ‘ground’ contact surface.
The bar length should be a minimum of 750mm so that the
ends extend away from the cabinet sufficiently for strops/
ropes to be attached with no risk of slipping off.
bracket
 All lifting equipment used must comply
with appropriate standards and regulations.

INSTALLATION
17
PULSE Installaon, Commissioning and Servicing Manual - Revision 19
2.3.1 Anchor Point Locations
Ensure that all anchor points as shown below are fastened with a M12 bolt.
Dispensers are to be installed on a flat surface to ensure that the anchor bolts can be
secured sufficiently.
Figure 3. Anchor Point Locations
C Series
L Series
Q Series

INSTALLATION
18 PULSE Installaon, Commissioning and Servicing Manual - Revision 19
2.4 Electrical Requirements/Regulations

All cabling must comply with all relevant National and Local Acts, Regulations and
Standards, and must be installed by suitably qualified personnel.
yA constant and quality power source is required for all PULSE dispensers in
accordance with local regulations.
yAll wiring and installation work shall comply with AS/NZS 3000.
yEach dispenser should be protected by a suitable circuit breaker and Residual
Current Device (RCD) that is capable of being locked off.
yWhen designing the site, cable selections should comply with AS/NZS 3008.1 for
Australia and AS/NZS 3008.2 for New Zealand.
yWhen terminating external cables in the dispenser, crimp joints should be used
and should comply with AS/NZS 3000.
yIf the dispenser is to be installed in a Marina then all wiring shall be performed in
compliance with AS/NZS 3004.
Electrical cabling is required by the dispenser for the following purposes:
(a) Power supply;
(b) Pump control circuit for dispenser models;
(c) Communications with Forecourt Controller equipment;
(d) Sump float switch communication (optional).
General cabling requirements are:
(a) Cabling must be laid in accordance with the appropriate local standards;
(b) At least 2m free length of cabling above ground level must be allowed for termination
at the dispenser;
(c) Cabling must be routed so that it emerges through the base-plate and is entirely
enclosed within the dispenser’s panels;.
Details of the electrical connections are given in Installation - Section 9 ELECTRICAL.
Mains wiring configurations for a 4-product dispenser and a single-phase pump are shown
in Figure 8.
2.4.1 Mains Power Supply
The mains power supply requirement is 230/240V 50Hz. The maximum certified voltage
is 264V, while the minimum operating voltage is 210V.
2.4.2 Remote Pump Control Power Supply (Dispensers)
The electrical load of each remote pump control relay should be less than 15VA.

INSTALLATION
19
PULSE Installaon, Commissioning and Servicing Manual - Revision 19
3 HYDRAULICS
 Inlet transit gaskets must be discarded and replaced with suitable new gaskets at
the time of installation.
Refer to Part D “Servicing” 1.4 for target torques for gasket sealing.
 If the dispenser has been in storage for longer than 3 months, the following checks
and actions must be carried out during the installation and commissioning process:
a Hoses - Visually check over each hose and ensure no kinking has occurred;
b Nozzles and swivels - Check that the swivels on each hose move freely through a full
range of movement. Check that the rotatory joints are free and not seized;
c Head - Visually inspect the interior of the head for any signs of moisture or
condensation. Inspect all PCB’s for any sign of corrosion. Remember to also check
the Multiplexer Board which is usually located underneath the top panel of the
Hydraulic Cabinet;
d Vee Belt (pumps only) - Check the Vee Belts for any permanent distortion or
delamination due to sticking to the pulley.
3.1 Pumps
Fuel lines in are connected to their respective pumps by means of flex-connectors. To
facilitate ease of installation, motors may be temporarily removed and the tension of the
drive-belts adjusted upon replacement.
3.2 Dispensers
Fuel lines in (from one or more submersible pumps) are connected to their respective
meters by means of fixed piping via a shear valve chosen and supplied by the installer.
3.3 LPG
The LPG return valve is not attached to the hydraulic cabinet in order to allow it to be
placed in the best position.
Additional LPG Information may be found in Part C “Commissioning” - Section 7 LPG
SECTION.
3.4 Vapour Recovery
Vapour Recovery (VR) components are common throughout the Gallagher PULSE range.
Integral models are equipped with their own vapour recovery pump. This pump’s vapour
line should be connected to underground vapour lines by means of a shear valve.
All VR models in the PULSE range have vapour recovery pipes and hose components fitted
prior to despatch.
A separate Install/Commissioning Manual for VR2 equipment is available, part number
2A03039

INSTALLATION
20 PULSE Installaon, Commissioning and Servicing Manual - Revision 19
4 C SERIES HOSE INSTALLATION (HANGING)
4.1 Remove the Holsters
Remove each holster as follows:
The installation of the spreader and hoses must be
carried out in a specific order of steps, namely:
i. Remove the holsters.
ii. Fit the spreader on top of the lower assembly.
iii. Fit the hoses.
iv. Refitting of holsters.
Hoses SHOULD NOT be fitted to the spreader prior to
placing it on top of the lower assembly. Placing the
spreader will require two people.
(a) Remove the 2 screws at the
bottom of the holster panel.
(b) Pull the holster panel out at the
bottom and lift up to remove
from the top panel.
4.2 Fit the Spreader
Inspect the spreader unit and dispenser to confirm they are free from damage. Then complete
the following steps: (Note that there is no front or back, both sides are the same)
(a) Remove all nuts and washers
from the top of the dispenser.
(b) Carefully lower the base of the
spreader unit down on the top
of the dispenser.
(c) Disconnect the holster switch.