GILBARCO VEEDER-ROOT VaporTEK-3 Guide

VaporTEK™/VaporTEK-3 Controller Board 
110 V UL®Vapor Recovery Collection System
for Encore®500 S
Start-Up and Service Manual
MDE-5394B

Computer Programs and Documentation
All Gilbarco Inc. and/or Veeder-Root Company computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall
remain the property of, Gilbarco Inc. and/or Veeder-Root Company. Such computer programs and documents may also contain trade secret information. The duplication, disclosure,
modification, or unauthorized use of computer programs or documentation is strictly prohibited, unless otherwise licensed by Gilbarco Inc. and/or Veeder-Root Company.
Federal Communications Commission (FCC) Warning
This equipment has been tested and found to comply with the limits for a ClassA digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which casethe user will be required to correct the interference at his own expense. Changes or modifications not expressly approved by
the manufacturer could void the user’s authority to operate this equipment.
Approvals
Trademarks
Gilbarco is an ISO 9001:2008 registered company.
Underwriters Laboratories (UL):
U LFile# Products listed with U L
MH1941 All Gilbarco pumps and dispensers that bear
the UL listing mark.
MH8467 Transac System 1000 and PAM 1000
E105106 Dell DHM Minitower
E165027 G-SITE and Passport Systems
National Conference of Weights and Measures (NCWM) - Certificate of Conformance (CoC):
Gilbarco pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:
CoC# Product Model # CoC# Product Model #
02-019 Encore Nxx 02-036 Legacy Jxxx
02-020 Eclipse Exx
02-037
G-SITE Printer (Epson) PA0307
02-025 Meter - C Series PA024NC10 G-SITE Distribution Box PA0306
Meter - C Series PA024TC10 G-SITE Keyboard PA0304
02-029 CRIND — G-SITE Mini Tower PA0301
02-030
TS-1000 Console — G-SITE Monitor PA0303
TS-1000 Controller PA0241 G-SITE Printer (Citizen) PA0308
Distribution Box PA0242 02-038 C+ Meter T19976
Meter - EC Series PA024EC10 02-039 Passport PA0324
VaporVac Kits CV 02-040 Ecometer T20453
05-001 Titan KXXY Series
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac
Registered trademarks
CRIND®Making Things Better®VaporVac®
Dimension®Series MPD®
e-CRIND®Passport®
Eclipse®Performer®
Encore®The Advantage® Series
G-SITE®Transac®
Gilbarco®Transac®System 1000
InfoScreen®Trimline®
Legacy®TRIND®
Additional US and foreign trademarks pending.
Other brand or product names shown may be trademarks or registered trademarks of their respective holders.
Non-registered trademarks
Applause™Media System G-SITE®Lite™SMART CRIND™
CIM™Highline™SMART Meter™
C-PAM™Horizon™SmartPad™
ECR™Insite360™Surge Management System™
EMC™MultiLine™Tank Monitor™
FlexPay™Optimum™Series TCR™
G-CAT™PAM™1000 Titan™
Gilbert™PAM™Ultra-Hi™
G-SITE®Link™SMART Connect™ValueLine™
This document is subject to change without notice.
http://www.gilbarco.com
2019 Gilbarco Inc. All Rights Reserved
Service marks
GOLDSM

Notice-1
Damage Claims/Lost Equipment Notice
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
Notice
Gilbarco®Veeder-Root®makes no warranty of any kind with regard to this publication,
including, but not limited to, the implied warranties of merchantability and fitness for a
particular purpose.
Gilbarco Veeder-Root shall not be liable for errors contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this
publication.
Gilbarco Veeder-Root reserves the right to change system options or features, or the
information contained in this publication.
This publication contains proprietary information that is protected by copyright. All rights
reserved. No part of this publication may be photocopied, modified, or translated to another
language without the prior written consent of Gilbarco Veeder-Root. For additional
troubleshooting information, contact Gilbarco Veeder-Root Regional office.
Damage Claims/Lost Equipment
Thoroughly examine all components and units as soon as they are received. If any cartons are
damaged or missing, write a complete and detailed description of the damage or shortage on
the face of the freight bill. The carrier’s agent must verify the inspection and sign the
description. Refuse only the damaged product, not the entire shipment.
Gilbarco Veeder-Root must be notified of any damages and/or shortages within 30 days of
receipt of the shipment, as stated in the Terms and Conditions.
Gilbarco Veeder-Root’s Preferred Carrier - Missing or
Damaged Shipments
When Gilbarco Veeder-Root’s preferred carrier is used, proceed as follows:
1Contact Gilbarco Veeder-Root Customer Service within 30 days at 1-800-873-3313 or at
[e-mail] to report the specific part numbers and quantities that were
missing or received damaged.
2Send the signed Bill of Lading (BOL) noted with the shortage or damage to Gilbarco 
Veeder-Root Customer Service via e-mail at [e-mail], or fax to 
1-800-234-5350.
3Gilbarco Veeder-Root will file the claim with the carrier (signed BOL required showing the
shortage will be compared to BOL filed with carrier) and will replace the damaged/missing
product at no charge to the customer.
4Customer Service will work with production facility to have the replacement product shipped
as soon as possible.

Notice Customer’s Preferred Carrier
Notice-2 MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
Customer’s Preferred Carrier
It is the customer’s responsibility to file a claim with their carrier.
Customer may submit a replacement purchase order. Customer is responsible for all charges
and freight associated with replacement order. Customer Service will work with production
facility to have the replacement product shipped as soon as possible.
If “lost” equipment is delivered at a later date and is not needed, Gilbarco Veeder-Root will
allow a Return to Stock without a restocking fee.
Gilbarco Veeder-Root will NOT be responsible for any compensation when a customer
chooses his own carrier.
Return Shipping
Use existing return policies for your region.

MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
Table of Contents
Page i
Table of Contents
Notice Notice-1
Damage Claims/Lost Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notice-1
Gilbarco Veeder-Root’s Preferred Carrier - Missing or Damaged Shipments. . . . . . . . . . . . . . . . . . . . . . . Notice-1
Customer’s Preferred Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notice-2
Return Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notice-2
1 – Introduction 1-1
Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 – Important Safety Information 2-1
3 – VaporTEK System Description 3-1
VaporTEK Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
VaporTEK Pump Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
VaporTEK Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
System Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Open-loop vs. Closed-loop Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Changes in System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
VaporTEK-3 Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
VaporTEK Controller Interfaces Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
VaporTEK System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
4 – VaporTEK - Encore Wiring Diagrams 4-1
VaporTEK System for Collection Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5 – VaporTEK Calibration Start-up Sequence 5-1
VaporTEK Start-up Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Programming Pump 02.8.86 or Later for Collection Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Accessing Dispenser Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Programming Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
System Integrity Testing Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
External Flow Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Pulse Rate Setup with FB1 Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pulse Rate Setup on VaporTEK Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pulse Rate Setup with FB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
System Integrity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
OPW 12VW Nozzle - Wet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Page ii
Table of Contents
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
6 – Troubleshooting and Analysis 6-1
Required Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
VaporTEK Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
System Conditions That Can Be Ignored. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
System Conditions That Require Attention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Long-term System Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Nozzle-side Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Dispenser-side Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Troubleshooting Guide for VaporTEK Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Glossary Glossary-1
Index Index-1

Page 1-1
Purpose Introduction
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
1 – Introduction
Purpose
This manual provides start-up and service information for the VaporTEK™Vapor Recovery
System. VaporTEK is a dispenser based, Stage II Vapor Recovery System that collects vapor
during vehicle fueling and returns vapor to the Underground Storage Tank (UST). Each
VaporTEK system is designed to accommodate two active fueling points simultaneously.
The key performance parameter mandated by regulations is the Air Over Liquid (A/L) Ratio,
with “A” being air (actually a vapor-air mixture) and “L” being liquid (or fuel).
The intent of the system is to collect the same amount of vapor as the fuel being dispensed.
However, because the process for capturing vapor is subject to variation from many sources,
the regulatory bodies typically allow for some deviation from a one-to-one relationship
between delivered fuel and recovered vapor. The regulations for system performance take
these variations into account by allowing the A/L Ratio to vary by +/- 5%. That is, values of
the A/LRatio between 95% and 105% are acceptable at a performance of 38 Liters Per Minute
(LPM), with the target being 100% (A= L).
For markets where monitoring of system performance is not mandated, the monitoring and
control components are not required. This manual describes all the functions related to
collection of Vapor Recovery System.

Introduction Purpose
P a g e 1 - 2
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
System Overview
The VaporTEK Vapor Recovery System consists of the basic components shown in Figure 1-1.
Figure 1-1: Basic Components of VaporTEK Vapor Recovery System
Related Documents
Document
Number Title GOLDSM Library
MDE-3804 Encore®and Eclipse®Start-up/Service Manual Encore and Eclipse
MDE-3985 Encore Installation Manual • Encore and Eclipse
• Encore and Eclipse Installers
• Footprints and Elevations
VaporTEK-3 Controller
Va p o r T E K P u m p / M o t o r

Page 1-3
Purpose Introduction
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
Abbreviations and Acronyms
Term Description
A/L Air Over Liquid
AVRN Asian Veeder-Root Nozzle
BLDC Brushless DC
BOL Bill of Lading
CC Command Code
COM Communication
DEF Diesel Exhaust Fluid
ECAL Electronic Calibration
EPV Electronic Proportional Valve
FC Function Code
GOLD Gilbarco Online Documentation
HV High Voltage
LED Light Emitting Diode
LPM Liters Per Minute
NEC National Electrical Code
NFPA National Fire Protection Association
NPT National Pipe Thread
OSHA Occupational Safety and Health Administration
PCM Pulse Correction Module
PCN Pump Control Node
POS Point of Sale
STP Submersible Turbine Pump
UL®Underwriters Laboratories
USB Universal Serial Bus
UST Underground Storage Tank
VAC Voltage Alternate Current
NEC

Introduction Purpose
P a g e 1 - 4
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
This page is intentionally left blank.

Page 2-1
Important Safety Information
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
2 – Important Safety Information
Notes: 1) Save this Important Safety Information section
in a readily accessible location.
2) Although Diesel Exhaust Fluid (DEF) is 
non-flammable, Diesel is flammable. Therefore,
for DEF cabinets that are attached to Diesel
dispensers, follow all the notes in this section
that pertain to flammable fuels.
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.
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.
Emergency Total Electrical Shut-Off
The first and most important information you must know is how
to stop all fuel flow to the pump/dispenser and island. Locate
the switch or circuit breakers that shut off all power to all fueling
equipment, dispensing devices, and Submerged Turbine
Pumps (STPs).
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical components or
the electronics of the dispenser requires total electrical shut off
of that unit. Understand the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gilbarco equipment.
Evacuating, Barricading and Shutting Off
Any procedure that requires access to the pump/dispenser or
STPs requires the following actions:
• An evacuation of all unauthorized persons and vehicles from
the work area
• Use of safety tape, cones or barricades at the affected unit(s)
• A total electrical shut-off of the affected unit(s)
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 Technical Assistance Center (TAC) at 
1-800-743-7501. It is imperative to your safety and the safety of
others to understand the procedures before beginning work.
Follow the Regulations
Applicable information is available in National Fire Protection
Association (NFPA) 30A; Code for Motor Fuel Dispensing
Facilities and Repair Garages, NFPA 70; National Electrical
Code (NEC), Occupational Safety and Health Administration
(OSHA) regulations and federal, state, and local codes. All
these regulations 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.
Replacement Parts
Use only genuine Gilbarco replacement parts and retrofit kits on
your pump/dispenser. Using parts other than genuine Gilbarco
replacement parts could create a safety hazard and violate
local regulations.
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 below must be followed to prevent death, injury or
damage to the equipment:
DANGER:Alerts you to a hazard or unsafe practice
which will result in death or serious injury.
WARNING: Alerts you to a hazard or unsafe practice
that could result in death or serious injury.
CAUTION with Alert symbol: Designates a hazard or
unsafe practice which may result in minor injury.
CAUTION withoutAlert symbol: Designates a hazard or
unsafe practice which may result in property or
equipment damage.
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will explode or burn, if ignited. Spilled or
leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors in the vicinity of the
dispenser or island.
DEF is non-flammable. Therefore, explosion and fire safety
warnings do not apply to DEF fluid lines.
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
the console’s ALL STOP and PUMP STOP or
similar keys.
!
WARNING
!
!
!
!

Pa g e 2 -2
Important Safety Information
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
No Open Fire
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 fuel vapors.
Every time you get out of a vehicle, touch the metal of your
vehicle, to discharge any electrostatic charge before you
approach the dispenser island.
Working Alone
It is highly recommended that someone who is capable of
rendering first aid be present during servicing. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods, if
you work with or around high voltages. This information is
available from the American Red Cross. Always advise the
station personnel about where you will be working, and caution
them not to activate power while you are working on the
equipment. Use the OSHA Lockout/Tagout procedures. If you
are not familiar with this requirement, refer to this information in
the service manual and OSHA documentation.
Working With Electricity Safely
Ensure that you use safe and established practices in working
with electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure that grounding
connections are properly made. Take care that sealing devices
and compounds are in place. Ensure that you do not pinch
wires when replacing covers. Follow OSHA Lockout/Tagout
requirements. Station employees and service contractors need
to understand and comply with this program completely to
ensure safety while the equipment is down.
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any
equipment in the mouth.
In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
personnel:
• Location of accident (for example, address, front/back of
building, and so on)
• Nature of accident (for example, possible heart attack, run
over by car, burns, and so on)
• Age of victim (for example, baby, teenager, middle-age,
elderly)
• Whether or not victim has received first aid (for example,
stopped bleeding by pressure, and so on)
• Whether or not a victim has vomited (for example, if
swallowed or inhaled something, and so on)
IMPORTANT: Oxygen may be needed at scene if gasoline has
been ingested or inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of machines
and equipment in which the unexpected energization or start-
up of the machine(s) or equipment or release of stored energy
could cause injury to employees or personnel. Lockout/Tagout
applies to all mechanical, hydraulic, chemical, or other energy,
but does not cover electrical hazards. Subpart S of 29 CFR Part
1910 - Electrical Hazards, 29 CFR Part 1910.333 contains
specific Lockout/Tagout provision for electrical hazards.
The pump/dispenser contains a chemical known to the
State of California to cause cancer.
WARNING
!
The pump/dispenser contains a chemical known to the
State of California to cause birth defects or other
reproductive harm.
WARNING
!
Gasoline/DEF ingested may cause
unconsciousness and burns to internal organs.
Do not induce vomiting. Keep airway open.
Oxygen may be needed at scene. Seek medical
advice immediately.
DEF generates ammonia gas at higher temperatures.
When opening enclosed panels, allow the unit to air out to
avoid breathing vapors.
If respiratory difficulties develop, move victim away from
source of exposure and into fresh air. If symptoms persist,
seek medical attention.
WARNING
!
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline/DEF spilled in eyes may cause burns to
eye tissue.
Irrigate eyes with water for approximately 
15 minutes.
Seek medical advice immediately.
WARNING
!
Gasoline/DEF spilled on skin may cause burns.
Wash area thoroughly with clear water.
Seek medical advice immediately.
WARNING
!
DEF is mildly corrosive.Avoid contact with eyes, skin, and
clothing. Ensure that eyewash stations and safety
showers are close to the work location. Seek medical
advice/recommended treatment if DEF spills into eyes.
WARNING
!

Page 2-3
Important Safety Information
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
Hazards and Actions
The following actions are recommended regarding these hazards:
• Do not go near a fuel spill or allow anyone else in the area.
• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
WARNING
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.
Collision of a Vehicle with Unit Fire at Island Fuel Spill
!

Pa g e 2 -4
Important Safety Information
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
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Page 3-1
VaporTEK Pump VaporTEK System Description
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
3 – VaporTEK System Description
VaporTEK Pump
The VaporTEK pump is a variable-speed piston pump capable of drawing up to 
120 LPM of vapor through a vapor recovery nozzle and delivering it to the UST at the
dispensing site. The piston pump works on the floating piston principle, i.e., piston rod and
piston form a rigid unit. On each complete rotation of the shaft, the gas mixture is aspirated at
the inlet valve and compressed in the cylinder. The inlet or outlet valve blocks a flow
direction, i.e., the aspirated gas mixture is expelled via the outlet side of the pump.
The following are the features/requirements of the VaporTEK pump:
• The ambient and the inlet temperature must not exceed 130 °F (55 °C).
• The gas temperature in the outlet line must not exceed 203 °F (95 °C).
• The maximum pressure with closed discharge shall not exceed 1600 mbar (g) at any
speed.
• The inlet/outlet ports have standard National Pipe Thread (NPT) 3/8-inch female threads.
Technical Considerations (Not for Field Representative’s Use):
Use - For use only in products where the acceptability of the combination is determined by
Underwriters Laboratories (UL) LLC.
The following are the conditions of acceptability:
1When mounted in the end-use application, these assemblies are not to be supported by any
fluid handling pipes. The suitability of the mounting means of the device are to be reviewed in
the end-use.
2These devices are intended for use as part of a Listed retrofit assembly or as a factory installed
component for Listed power-operated flammable liquid dispensing devices.
3The suitability of the grounding means of this device with respect to UL 79 Ninth Edition,
shall be evaluated in the end-use.
4These pumps are intended to be mounted to the inside of a dispenser housing. Consideration
should be given to the need for guards to restrict access to moving parts in the end use.
5This pump has not been evaluated for outdoor use.
Do not install piping that can stress the pump housing.
WARNING

VaporTEK System Description VaporTEK Pump
Page 3-2 MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
VaporTEK Pump Specifications
The following table lists the VaporTEK pump specifications:
Function Description
Flow Medium Gasoline Vapor
Mounting Four M6 X 1 Mounting Boss (Either Side of Pump)
Motor Type Synchronous Brushless DC (BLDC) Motor
Voltage (Single) 110 Voltage Alternate Current (VAC) (±10%)
Frequency 50/60 Hz
Watts 300 W
Motor Speed 2500 rpm maximum
Maximum Flow Rate Up to 120 LPM
Noise Level 59 dB (A)
Figure 3-1: VaporTEK Pump Specifications
FlowDirection
toUST
MountingBoss(4X)
OutletPortsNPT
ControlLeadWires(5X)
InletPortsNPT(2X)
MotorLeadWires(5X)

Page 3-3
VaporTEK Pump VaporTEK System Description
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
VaporTEK Pump Operation
The VaporTEK pump is a variable-speed piston pump. The flow rate is proportional to the
speed, and the pump achieves maximum flow rate at 2500 rpm.
The inlet and outlet pressure/vacuum also affects the flow. These are determined by the system
in which the pump is operating. That is, the restrictions at the inlet to the pump (nozzle, flow
meters, tubing, and fittings) and at the outlet of the pump (piping to a sealed UST) limit the
flow being delivered. The design point for the VaporTEK pump in the Encore dispenser is
approximately 150 mbar inlet vacuum (850 mbar absolute pressure) and 100 mbar outlet
pressure (1100 mbar absolute pressure).
The relationship between the pump flow and the suction pressure is shown in Figure 3-2.
Figure 3-2: Relationship Between Pump Flow Rate and Suction Pressure
Figure 3-2 shows that the flow at 150 mbar suction pressure and the 100 mbar discharge
pressure is approximately 95 LPM. This is the design point of the system. It defines the
conditions under which the pump operates with the nozzle wide open, and is illustrated by the
small dot on the curve above.
During operation, the inlet vacuum and, to some extent, the vapor flow is controlled by the
vapor valve in the nozzle. When the nozzle is fully open, dispensing the maximum amount of
fuel and collecting the maximum amount of vapor, the pump draws a vacuum of about 
150 mbar through all the other restrictions in the lines. As the nozzle closes, the vacuum
increases with the closing of the vapor valve and the vapor flow decreases accordingly.
However, the vapor valve does not control the flow precisely enough to satisfy the regulations
that govern the recovery of vapor. In most regions where monitoring of the vapor recovery is
mandated, the requirement is that the vapor flow be within 15% of the liquid being dispensed.
If the control of the vapor flow were left up to the opening of the vapor valve in the nozzle
alone, the vapor collection would frequently go outside the allowable range.

VaporTEK System Description VaporTEK Pump
Page 3-4 MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
System Calibration
VaporTEK more precisely controls the amount of vapor being collected so that it is closer to
the fuel delivered. It drives the pump at the speed required to deliver the same vapor flow as
the fuel. A typical relationship between pump flow and speed at 150 mbar inlet suction
pressure and 100 mbar discharge pressure at 2500 rpm is shown in Figure 3-3.
Figure 3-3: Relationship Between Pump Flow and Speed
By characterizing the relationship between the pump speed and vapor flow during system
setup, or calibration, and then controlling the speed of the pump during operation as dictated
by the resulting curve of flow vs. speed, you can maintain the proper A/L Ratio better than by
relying solely on the vapor valve in the nozzle.
The Pump Control Node (PCN) in the dispenser outputs pulses proportional to the flow:
136 pulses = 1 LPM. These pulses are delivered to the Point of Sale (POS) system and the
dispenser display, and determine how much to charge the customer for the fuel dispensed.
These pulses are used by the VaporTEK system to set the vapor flow.
During the calibration process, the VaporTEK Controller Board drives the pump at a series of 
15 speed settings between 1200 rpm and 0 rpm from each side separately. From this set of
data, it develops a curve that it will use to drive the pump during dispensing.
For example, during the calibration procedure, the pump speed required to deliver 
30 LPM is 750 rpm and to deliver 40 LPM it is 1000 rpm. During operation, if the dispenser
pumps 35 LPM of fuel, the VaporTEK Controller will drive the pump at approximately 875
rpm to match this flow. Because the computer develops a smooth curve for the vapor flow
across the entire operating range of the pump, it can derive a speed setting for any level of fuel
flow between zero and the maximum of the dispenser.
150 mbar inlet suction and 100 mbar discharge pressure at 2500 rpm.

Page 3-5
VaporTEK-3 Controller Board VaporTEK System Description
MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
Open-loop vs. Closed-loop Flow Control
For Collection Only systems, the A/L Ratio is controlled with prior knowledge of pump
operation, that is, the calibration curve. This is an open-loop control scheme.
In Collection + Monitoring systems, the primary control of the A/L Ratio is the same as in the
Collection Only systems, using the calibration curve to set the appropriate pump speed.
However, making continuous measurements of the vapor flow allows us to control it more
precisely than when the flow is not measured. In addition to using the calibration curve, which
drives the pump close to the fuel flow, there is also a closed-loop control function that refines
the speed command to deliver an A/L Ratio closer to 100%. This function is performed by a
Vapor Monitoring system, which is not a part of this document. For more information about
close loop systems using a vapor monitoring system, contact your dispenser supplier.
Changes in System Performance
The calibration procedure maintains a close relationship between the fuel flow and vapor flow
as long as the system performance remains constant. However, the system performance varies
over the lifetime of the system. Over time, the seals on the pump piston wear, the system
develops slight leaks and restrictions, and other long-term effects cause the flow to change at
every speed. The flow can either rise or fall, but it typically falls as the system ages. Thus, the
vapor flow will begin to deviate from the fuel flow, and the A/L Ratio will go out of range,
initially only on occasion, but eventually often enough that it will repeatedly fall below the
allowable. For information about calibrating the system, refer to “System Calibration” on
page 3-4. Whenever the calibration procedure is performed, the computer develops a new
curve to use for driving the pump in the future. The system can be recalibrated at any time as
required to return the A/L Ratio closer to its target value until the maximum allowable speed
of the pump is reached (1200 rpm) for each side, and no more flow is available. At this point,
the pump needs to be replaced.
VaporTEK-3 Controller Board
VaporTEK-3 Controller Board is shown in Figure 3-4 on page 3-7. This is the motor driver
that translates a fuel flow into speed information delivered by the RS-422 serial or 
VVAC-Port Encore 500 S interface connection and drives the motor on this calculated specific
speed.
Mode selections for the VaporTEK-3 Controller Board require jumper settings as shown in the
following table:
Configuration Type VaporTEK Controller Mode
Mode Selection
J1 J2 J3 - PROG.
VaporTEK Plus Electronic Signal of Fuel Flow Required No No No
Board Programming Mode Power OFF/ON Cycle required No No Yes

VaporTEK System Description VaporTEK Controller Interfaces Connectors
Page 3-6 MDE-5394B VaporTEK™/VaporTEK-3 Controller Board 110 V UL® Vapor Recovery Collection System for Encore® 500 S
Start-Up and Service Manual · March 2019
VaporTEK Controller Interfaces Connectors
The following table lists the VaporTEK Controller Interface Connectors:
Connector Description
X1 (L, N, PE) Mains Electricity Connection 110 V AC. X1 - (M1, M2) High Voltage (HV) Inputs
X2 Motor Power (U, V, W) Connection
X3 Motor Sensor Connection
X4 RS-422 Connection to FB1 - Handheld service terminal. Performs system calibration and simulation
X5 Programming connector for software updates and enhanced system debug / setup
X6 External Electronic Proportional Valve (EPV) - Interface connection
X7 External 3 - Color Light Emitting Diode (LED) - Interface connection
X9 VaporTEK Pulse interface pin compatible to Encore 500 S VaporVac®- Port