GILBARCO VEEDER-ROOT M00016K003 User manual

MDE-4133B Power Supply Kit M00016K003 Installation Manual • November 2003 Page 1
Table of Contents
Figure 1: Relationship Between M02274 and M02774
Section See Page
Introduction 2
Important Safety Information 4
Installation 9
Troubleshooting the M02774 Power Supply Board 21
Appendix: Wiring Diagrams 25
In this manual, references are made to two different devices with similar part numbers.
•M022
74 power supply assembly
•M027
74 power supply board
The M02774 power supply board is part of and is mounted on the M02274 power
supply assembly (Figure 1).
NOTICE
M02774 - power supply board
M02274 - power supply assembly
MDE-4133B
Power Supply Kit M00016K003 Installation
Manual
November 2003

Introduction
Page 2 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Introduction
Purpose of this Manual
This manual provides installation instructions for the Power Supply Kit M00016K003 used in
the Encore®500 units. The transformer (M00151A002) for the M00458A00X Power Supply is
no longer available, so if a transformer needs to be replaced in an Encore 500 unit, the entire
power supply will be replaced with replacement kit M00016K003.
Required Reading
Before installing the Power Supply Kit, the installer must read, understand, and follow:
•this manual
•NFPA 30A, The Automotive and Marine Service Station Code
•NFPA 70, The National Electric Code
•applicable federal, state and local codes and regulations
Failure to do so may adversely affect the safe use and operation of the equipment.
Note: This kit must be installed by a Gilbarco Authorized Service Contractor (ASC) to ensure
warranty will apply.
Related Documents
The following documents are related to the installation of the Power Supply Kit
M00016K003:
Required Tools
The following tools are needed to install the Power Supply Kit M00016K003:
•cutters, wire
•nut drivers, American standard
•nut drivers, metric
•Q12534 CRIND®diagnostic card
•screwdrivers, flat head
•screwdrivers, Phillips®
•static guard wrist strap
Document
Number Title GOLD®Library
MDE-3804 Encore and Eclipse®Series Start-Up/Service
Manual •Encore and Eclipse •Service Manual
MDE-3893 Encore/Eclipse Series Owner’s Manual •Encore and Eclipse
•Encore and Eclipse Installers
PT-1936 Encore Series Pumps and Dispensers Illustrated
Parts Manual •Encore and Eclipse •Encore and Eclipse Installers
•Parts Manual

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 3
Introduction
M00016K003 Kit Parts List
Part No. Description Quantity
M00417B101 screw, metric M5 x 10 2
M03111A001 cable, adapter, backlight power, 432 mm (17 in) 1
M00614A004 cable, main display, backlight power, 950 mm (37.4 in) 1
M02274A001 main power supply assembly, universal 1
M02952A001 cable, adaptor, 50 mm (1.9 in) 1
M02774A001 power supply board 1
M00047A001 STP board 1
M02954A001 cable, STP board, 170 mm (6.7 in) 1
Q10651-02 support, circuit board, locking 8
M01665A001 assembly, cable, VaporVac®, 500 mm (19.7 in) 1
M02993A001 cable, 2-wire pump and CRIND device, 1150 mm (45.3 in) 1
M01591A001 cable, power, 300 mm (11.8 in) 1
N21120-G6 * plug, assembly, 115V 1
N21120-G8 * plug, assembly, 220V 1
N21120-G9 * plug, assembly, 230V 1
N21120-G10 * plug, assembly, 240V 1
M02951A001 * cable, varistor, 50 mm (1.9 in), 130V 1
M02951A002 * cable, varistor, 50 mm (1.9 in), 275V
(for all power source voltages greater than 115V) 1
* Use correct part numbers (N21120-GXX and M02951A00X) based on AC source voltage.

Important Safety Information
Page 4 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Important Safety Information
This section introduces the hazards and safety precautions associated with installing,
inspecting, maintaining or servicing this product. Before performing any task on this product,
read this safety information and the applicable sections in this manual, where additional
hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or
pressure release could occur and cause death or serious injury if these safe service procedures
are not followed.
Safety Symbols and Warning Words
This section provides important information about warning symbols and boxes.
Alert Symbol
This safety alert symbol is used in this manual and on warning labels to alert you to
a precaution which must be followed to prevent potential personal safety hazards. Obey safety
directives that follow this symbol to avoid possible injury or death.
Signal Words
These signal words used in this manual and on warning labels tell you the seriousness of
particular safety hazards. The precautions that follow must be followed to prevent death,
injury or damage to the equipment.
!
This signal word designates a hazard or unsafe practice which may result in minor injury.
This signal word is used to alert you to a hazard or unsafe practice which will result in
death or serious injury.
This alerts you to a hazard or unsafe practice that could result in death or serious injury.
CAUTION
When used by itself, CAUTION designates a hazard or unsafe practice which may result in
property or equipment damage.
CAUTION
DANGER
WARNING
!
!
!

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 5
Important Safety Information
Preliminary Precautions
You are working in a potentially dangerous environment of flammable fuels, vapors, and high
voltage or pressures. Only trained or authorized individuals knowledgeable in the related
procedures should install, inspect, maintain or service this equipment.
The first and most important information you must know is how to stop all fuel flow to the
pump and island.
Emergency Total Electrical Shut-Off
Locate the switch or circuit breakers that shut-off all power to all fueling equipment,
dispensing devices, and submerged turbine pumps (STPs). These you must operate in the
event of an emergency.
Total Electrical Shut-Off Before Access
Any procedure requiring access to electrical components or the electronics of the dispenser
requires total electrical shut-off of that unit.
NFPA 30A, Section 4-1.2, published by the National Fire Protection Association, requires the
installation of an easily accessible switch or circuit breaker to shut-off the power to all fueling
equipment, dispensing devices and STPs in the event of an emergency. Know the function and
location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing
Gilbarco equipment.
The EMERGENCY STOP, ALL STOP, and PUMP STOP buttons at the cashier’s station
WILL NOT shut off electrical power to the pump/dispenser.
This means that even if you activate these stops, fuel may continue to flow uncontrolled.
You must use the TOTAL ELECTRICAL SHUT-OFF in the case of an emergency and not
only these cashier station “stops.”
WARNING
!

Important Safety Information
Page 6 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or STPs requires the following three
actions:
•An evacuation of all unauthorized persons and vehicles
•Using safety tape or cones as barricades to the effected units
•A total electrical shut-off of that unit
Read the Manual
Read, understand and follow this manual and any other labels or related materials supplied
with this equipment. If you do not understand a procedure, call a Gilbarco Authorized Service
Contractor or call the Gilbarco Call Center at 1-800-800-7498. It is imperative to your safety
and the safety of others to understand the procedures before beginning work.
Follow the Regulations
There is applicable information in: NFPA 30A: Automotive and Marine Service Code; NFPA
70: National Electrical Code (NEC); OSHA regulations; and federal, state, and local codes
which must be followed. Failure to install, inspect, maintain or service this equipment in
accordance with these codes, regulations and standards may lead to legal citations with
penalties or affect the safe use and operation of the equipment.

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 7
Important Safety Information
Prevent Explosions and Fires
Fuels and their vapors will become explosive if ignited. Spilled or leaking fuels cause vapors.
Even filling customer tanks will cause explosive vapors in the vicinity of dispenser or island.
No Open Flames
Open flames from matches, lighters, welding torches or other sources can ignite
fuels and their vapors.
No Sparks - No Smoking
Sparks from starting vehicles, starting or using power tools, burning cigarettes,
cigars or pipes can also ignite fuels and their vapors. Static electricity, including an
electrostatic charge on your body, can cause a spark sufficient to ignite fuels and their vapors.
After getting out of a vehicle, touch the metal of your vehicle to discharge any electrostatic
charge before you approach the dispenser island.
Hazardous Materials
Some materials present inside electronic enclosures may present a health hazard if not handled
correctly. Be sure to clean hands after handling equipment. Do not place any equipment in
mouth.
This area contains a chemical known to the State of California to cause cancer.
WARNING
This area contains a chemical known to the State of California to cause birth defects or
other reproductive harm.
WARNING
!
!

Important Safety Information
Page 8 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Other Useful Safety Information
This subsection provides additional safety information.
OSHA Lock-Out and Tag-Out Requirements
OSHA Standard 29 CFR 1910-147 Control of Hazardous Energy Sources (Lock-Out/Tag-Out)
covers ways to avoid personal injury because power was turned on or fuel pressure was
applied unexpectedly while servicing equipment. The rule requires:
(1) Turning off equipment power and fuel under pressure.
(2) Use of a locking device (breaker, valve, etc.) or label device with a warning tag.
Station employees and service contractors need to understand and comply with this program
completely to ensure safety while the equipment is down.
Use Electrostatic Discharge Precautions
Place yourself at a neutral static-free potential by doing the following:
1Touch an unpainted metal surface.
2Use a wrist strap connected to a grounded metal frame or chassis.
3Make sure all power has been removed from unit and the CRIND device.

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 9
Installation
Installation
Installing the Power Supply Kit M00016K003 for the Encore 500 unit includes the following
tasks:
•“Preparing for Installation”on page 10
•“Removing the M00458A00X Power Supply Assembly”on page 11
•“Installing the M00016K003 Kit”on page 15
•“Completing Installation”on page 20
OSHA Lock-Out and Tag-Out Requirements
OSHA Standard 29 CFR 1910-147 Control of Hazardous Energy Sources (Lock-Out/Tag-Out)
covers ways to avoid personal injury because power was turned on or fuel pressure was applied
unexpectedly while servicing equipment. The rule requires:
(1) Turning off equipment power and fuel under pressure.
(2) Use of a locking device (breaker, valve, etc.) or label device with a warning tag.
Station employees and service contractors need to understand and comply with this program
completely to ensure safety while the equipment is down.
WARNING
!
Working on dispenser electronics with power applied may result in electrocution and damage
to electronic components. Power down unit before beginning work.
WARNING
!
Be sure the STP wires are connected to isolation relays. Also be sure no more than one
dispenser is connected to one isolation relay. If these conditions are not met, the STP wires can
be hot even if the pump is not powered up.
WARNING
!
Power supplies are heavy. Handle with care to avoid personal injury. Also handle with
care to avoid dropping the unit and causing possible equipment damage.
CAUTION
!

Installation
Page 10 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Preparing for Installation
Perform the following steps to prepare for the installation of Power Supply Kit M00016K003.
1Read all instructions before beginning.
2Observe all safety precautions.
3Remove all power to the dispenser.
4Locate the Customer Interface Module (CIM) Door (Figure 2), insert the key, and open the
door. Perform this step on both sides of the dispenser.
5Disengage the main door latches (Figure 2) and open the main door (Figure 2).
Figure 2: Encore Unit with CIM Door Opened
Main Door Latches CIM Door

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 11
Installation
Removing the M00458A00X Power Supply Assembly
Perform the following steps to remove the M00485A00X Power Supply Assembly.
1Locate and disengage any cable ties or cable clamps that may hinder the disconnect of cabling
attached to the Power Supply Assembly.
2Remove the Power Supply Module Cover (Figure 3) to access the STP board (Figure 4).
Figure 3: M00458A00X Power Supply Assembly
Be careful to not short out or touch terminals and/or the lands on printed circuit boards
during handling or removal of the M00485A00X power supply assembly. The large
capacitors may contain a residual charge which may cause shock, personal injury, and/or
equipment damage.
CAUTION
!
P1402 on 18 Volt
Board (M00050)
P3502B
P3503B
P3502A
P3503A
on 24 Volt Board
(M00053)
Module
Cover
Rear View
Front View
9.4 VAC
transformer
connection
Transformer
9.4 VAC
transformer
connection
Transformer

Installation
Page 12 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Figure 4: M00458A00X Power Supply Assembly with Cover Removed
3Disconnect the STP feed wire that goes to P1302 on the M00047A001 STP board (Figure 5).
4Label and disconnect the 10-pin connector (P1301) on top of the STP board (Figure 5). Route
the cable through the grommet located in the side of the Power Supply Assembly housing.
Separate the 10-pin cable from the cable assembly for reinstallation.
5Leaving the STP output wires connected, remove the M00047A001 STP board (Figure 4 and
Figure 5) and lay it on an insulated anti-static bag inside the dispenser.
6One by one, remove a field 2-wire conductor from the grey field wiring block (P1302) on the
STP board and DIRECTLY attach it to its corresponding red/yellow or blue/yellow data wire
(Figure 4 and Figure 5) using a small blue wire nut.
Note: When disconnecting wires, ensure that the wires are properly labeled for reinstallation.
3PoleSelf
Grounded
Terminal
Block
STP Board
Red/yellow or
blue yellow
data wires
attached here
2-wire conductors
from STP board
available here
If the STP wires are not connected to isolation relays, the STP wires will be hot even if the
pump is not powered up. Exercise extreme caution.
WARNING
!

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 13
Installation
Figure 5: M00047A001 STP Board Connections
7Label and disconnect the AC Power Distribution Cable at the Three Pole Self Grounded
Terminal Block (Figure 4) on the Power Supply Assembly using a Phillips screwdriver. Place
a wire nut on each wire for re-installation.
Note: When disconnecting wires, ensure that the wires are properly labeled for reinstallation.
In some cases, a 2-wire VaporVac connection may also be made at the terminal block. If a
VaporVac connection is made, label the wires and remove the wires from the terminal block.
Place a wire nut on each wire for re-installation.
Note: When disconnecting wires, ensure that the wires are properly labeled for reinstallation.
8Locate the 18V Power Supply Board M00050 (Figure 3). Label and disconnect the wire
connection for the “Pump/CRIND”connection at plug P1402.
9Locate the 24V Power Supply Board M00053 (Figure 3). Label and disconnect wire
connections for cables at plugs P3502A, P3502B, P3503A, and P3503B.
10 Locate the Power Supply Assembly Transformer (Figure 3). Label and disconnect the 9.4V
connection (for backlight) made with the transformer.
11 Locate the Power Supply Assembly Terminal Block M00044 (Figure 6). Label and disconnect
any wire connections for the Monochrome Display back light at plugs P1614A and P1614B.
12 Disconnect the wire connection at plug P1615 (Figure 6) for the Valve board, next, disconnect
the other end of this cable at the plug P1206 on the Valve board (Figure 7) and discard the
cable.
STP 1
Plug P1301 (to Pump Control Node)
STP FEED
connection
STP 2 STP 3 STP 4
Grey field
wiring block
P1302
From Field Wiring

Installation
Page 14 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Figure 6: Power Supply Assembly Terminal Block M00044A001
Figure 7: Valve Board (M00059)
13 Verify all electrical and mechanical connections have been removed from the power supply
per the preceding steps.
14 Remove the two M5 metric fasteners that secure the Power Supply Assembly to unit’s shelf,
using a size 8 metric nut driver. The fasteners may be retained for reinstallation in the event the
M00417B101 fasteners in the kit are lost or misplaced.
15 Remove the Power Supply Assembly away from the unit.
Display Back Light
Connections Valve Board Connection
P1206 connector
Power supplies are heavy. Handle with care to avoid personal injury. Also handle with
care to avoid dropping the unit and causing possible equipment damage.
CAUTION
!

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 15
Installation
Installing the M00016K003 Kit
Perform the following steps to install the M02274A001 Power Supply Assembly.
1Insert four plastic standoffs (Q10651-02) into the new power supply chassis for the new power
supply board (M02774). See Figure 9 for power supply board location.
2Insert four plastic standoffs (Q10651-02) into the new power supply chassis for the STP board
(M00047). See Figure 8 for STP board location.
3Mount the power supply board on the four plastic standoffs on the power supply assembly
(Figure 9).
4Mount the M00047A001 STP board on four plastic standoffs (Figure 5 and Figure 8).
Figure 8: Power Supply Assembly M02274A001 - STP Board Location
5From Side 1 of the unit, position the M02274A001 Power Supply Assembly onto the
electronics shelf where the previous power supply was mounted (hanging from the top
crossbrace). Install the power supply such that the front (Figure 9) of the power supply is
facing Side 2 and the power supply support brackets align with the holes in the unit’s frame.
Power supplies are heavy. Handle with care to avoid personal injury. Also handle with
care to avoid dropping the unit and causing possible equipment damage.
CAUTION
!
STP board
varistor cable
(M02951A00X)

Installation
Page 16 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Figure 9: Power Supply Assembly M02274A001
6Insert the two M5 metric hex head fasteners (M00417B101) through the two outward slotted
holes in the lower part of the power supply (Figure 9) and into unit frame, and secure the
power supply assembly to frame by tightening the fasteners using a size 8 metric nut driver
(Figure 10).
Power supply 2 board (M02774) Power supply chassis
J606
J607
AC adapter cable harness
J1200
J108
J604
J1206
Slotted mounting holes
J605
cable

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 17
Installation
Figure 10: Location of Power Supply Assembly M02274A001 in Encore Unit
7Use wire nuts to join the field AC wiring (disconnected from old power supply in Step 7 on
page 13) to the 3-wire pigtail (Figure 11).
Note: See Figure 17 in the Appendix for a power supply wiring diagram. See Figure 18,
Figure 19, and Figure 20 in the Appendix for Encore 500 block diagrams related to the
power supply.
Side 1 Side 2
Power
Supply
Assembly

Installation
Page 18 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
Figure 11: M01589A001 AC Adaptor Cable Harness
8Locate the Power Supply Board (Figure 12) and connect the appropriate cables connectors to
P3502B, P3503B, P3502A, and P3503A connectors.
9Connect the “Pump/CRIND”cable to the “Pump/CRIND CTRL Node”connection P1402
(Figure 12) on the power supply assembly.
Figure 12: Power Supply Board M02774
Note: This board supplies all DC power to the dispenser.
Cash Acceptor side A
Push Mount Cable Tie
J404
VaporVac
J550
TRIND®& STP J601
P401
Cash Acceptor side B Ground
Three wire pigtail is on this
connector to be connected to P401.
Green LEDs:
CR17
CR18
P3502B
P3503B
P3502A
P3503A
P1402

MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003 Page 19
Installation
10 Reconnect the Pump Control Node cable to the 10-pin connector P1301 on the STP board
(Figure 5).
11 Use the supplied 3-pin to black wire adapter to pick off AC power from J550 on the AC
harness (Figure 11) to go to the STP feed connector (Figure 5).
12 Look for two 4-pin connectors (J604 and J1206) from the power supply (Figure 9). Use the
supplied 4-pin to 3-pin adapter cable (M02952A001) to connect J604 on the power supply to
P1206 on the M00059A00X valve board (Figure 7).
13 If the dispenser has a monochrome display with a flourescent backlight, locate a three
connector adapter with two red wires. Look at it carefully. One connector has two wires going
to positions 1 and 2; on the other two, two wires go to positions 1 and 3.
14 Plug the connector that has wires going to positions 1 and 2 into the AC adapter cable harness
(Figure 11).
15 Plug the monochrome backlight cables (M03111A001 andM00614A004)into the other two
positions.
16 If the dispenser has a TRIND device, plug the TRIND device into the AC adapter cable
harness (Figure 11).
17 If the dispenser has VaporVac device, use cable assembly M01665A001 (Figure 13) to connect
the VaporVac device to J404 on the power supply AC adapter cable harness (Figure 11) and to
P404 on the M02710A001 VaporVac power cable (Figure 14).
Figure 13: Cable Assembly M01665A001
Figure 14: Cable Assembly M02710A001
P404A
J404A
Cable tie, push mount Cable tie
P404
Ring
terminal
Cable tie, push mount
F6-1
FL1-3

Installation
Page 20 MDE-4133B Power Supply Kit M00016K003 Installation Manual •November 2003
18 Make the remaining connections per Table 1.
Figure 15: Valve Converter Board (M02044)
19 Inspect the dispenser for missing connections prior to power up.
Completing Installation
After the Power Supply Assembly has been installed, perform the following steps.
1Verify that all newly installed cables and wires are properly dressed and do not obstruct main
door and CIM Door closure.
2Restore unit power. Observe that the CR17 and CR18 on Power Supply Board M02774
(Figure 12 or Figure 16) are lit.
3Close and secure all doors.
4Perform a short sale to verify the dispenser is working properly.
5Clean up the work site, removing all materials to be discarded and all tools.
Table 1: Remaining Connections
Connector# via Cable to Board at Connector#
J605
(see Figure 9 and Figure 17)n/a n/a P605 (N21120-GXX)
(see Figure 17)
J606
(see Figure 9)M02774A001 (Universal Power Supply Board) P606 (see Figure 16)
J607
(see Figure 9)M02774A001 (Universal Power Supply Board) P607 (see Figure 16)
J1200
(see Figure 9)M02044 (Valve Converter Board) - used with the Proportional Control Valve P1200 (see Figure 15)
J550 & 3-pin to black wire
adapter
(see Figure 9 and Figure 11)
M02954A001 M00047 (STP Board) STP feed
(see Figure 4 and Figure
5)
Varistor Cable
(M02951A00X) (see Figure 8)n/a n/a Varistor Connector (M01589A001)
P1200 connector