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