Mde 3802S
Mde 3802S
Mde 3802S
MDE-3802S
Approvals
Gilbarco is an ISO 9001:2008 registered company.
Underwriters Laboratories (UL):
UL File#
Executive Order #
Product
G-70-52-AM
G-70-150-AE
MH1941
MH8467
E105106
E165027
CoC#
Product
Model #
CoC#
Product
Model #
02-019
02-020
Encore
Eclipse
Meter - C Series
Meter - C Series
CRIND
TS-1000 Console
TS-1000 Controller
Distribution Box
Meter - EC Series
VaporVac Kits
Nxx
Exx
PA024NC10
PA024TC10
PA0241
PA0242
PA024EC10
CV
02-036
Legacy
G-SITE Printer (Epson)
G-SITE Distribution Box
G-SITE Keyboard
G-SITE Mini Tower
G-SITE Monitor
G-SITE Printer (Citizen)
C+ Meter
Passport
Ecometer
Titan
Jxxx
PA0307
PA0306
PA0304
PA0301
PA0303
PA0308
T19976
PA0324
T20453
KXXY Series
02-025
02-029
02-030
02-037
02-038
02-039
02-040
05-001
Trademarks
Non-registered trademarks
Applause Media System
CIM
C-PAM
Ecometer
ECR
EMC
FlexPay
G-CAT
Gilbert
G-SITE Link
G-SITE Lite
Highline
Horizon
MultiLine
Optimum Series
PAM
PAM 1000
PAM 5000
SMART Connect
SMART CRIND
SMART Meter
SmartPad
Super-Hi
Surge Management System
Tank Monitor
TCR
Titan
Ultra-Hi
ValueLine
Registered trademarks
Service mark
CRIND
Dimension Series
e-CRIND
Eclipse
Encore
G-SITE
Gilbarco
InfoScreen
Legacy
GOLDSM
Table of Contents
Table of Contents
1 Introduction
1-1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Gilbarco Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Common Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Other Useful Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Breakaways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Collection of Fuel in Approved Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Read Material Safety Data Sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Fluid Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1
3 Site Preparation
3-1
4 Electrical Requirements
4-1
5 Plumbing Requirements
5-1
Fuel Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Handling Components for DEF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Hose Material for DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skid Mounted Tanks for DEF Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-2
5-2
5-2
5-2
Page i
Table of Contents
STPs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Important Considerations for Sizing STPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Acceptable Pipe Material for DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Check Valves (Used on Pumps and Ultra-Hi Units Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Shear Valves (Generally Used on Dispensers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Encore Ultra-Hi Shear Valve Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Mounting Pit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Index
Page ii
Index-1
Purpose
Introduction
1 Introduction
Purpose
The manual provides information to prepare a site for Encore and Eclipse series pumps or
dispensers.
Intended Users
This manual is intended for individuals who are trained in the construction of gasoline
stations. If you do not have experience with this type of construction (gasoline stations),
contact a licensed, trained engineer, contractor, or Gilbarco Authorized Service Contractor
(ASC).
Contact
Technical assistance
www.gilbarco.com
Page 1-1
Introduction
Required Reading
Required Reading
Before installing, the installer must read, understand, and follow:
This manual
National Fire Protection Association (NFPA) 30A, The Automotive and Marine Service
Station Code
NFPA 70, The National Electrical Code (NEC)
Applicable federal, state, and local codes and regulations
Failure to do so may adversely affect the safe use and operation of the equipment.
Note: Installations must be performed by a Gilbarco ASC to ensure warranty.
For additional information, refer to manufacturers installation instructions. Equipment
manufacturers must provide instructions for other equipment, such as Submersible Turbine
Pumps (STPs), leak detectors, underground tanks, product lines, and shear valves. Gilbarco
does not provide complete or up-to-date installation instructions for other manufacturers
equipment
Perform all site preparation procedures in accordance with NFPA 30A, NFPA 70, and
applicable national, state, and local codes/regulations. For a non-US installation, other codes
may apply. Plan your site ahead of time. Use experienced, licensed personnel that practice
accurate, safe construction techniques. Time, expense, and extra effort in the early stages of
preparing a site can eliminate problems in later stages.
Related Documents
Page 1-2
Document
Number
Title
GOLD Library
FE-321
FE-341
FE-363
Field Wiring Diagram Encore 500/700 (M07555 Power Supply Only) Encore and Eclipse
FE-364
Introduction
Document
Number
Title
GOLD Library
SMARTConnect
Encore and Eclipse
PT-1936
Parts Manual
Encore and Eclipse
Encore and Eclipse Installers
PT-1937
Parts Manual
Encore and Eclipse
Description
ADA
ANSI
API
ASC
BIOS
BRCM
CAT-5
Category 5
CEC
CoC
Certification of Conformance
Distribution Box
DEF
EIA
EPA
FCC
GFI
GLRE
GOLD
HDPE
IEEE
J-box
Junction Box
LAN
LRE
Long-reach Ethernet
MPD
Multi-product Dispenser
MSDS
MTW
NEC
NFPA
OSHA
PEI
POS
Point of Sale
Page 1-3
Introduction
Common Terms
Term
Description
PVC
Polyvinyl Chloride
RFID
STP
TFFN
TIA
UL
Underwriters Laboratories
ULSD
UTP
Unshielded Twisted-pair
Common Terms
Page 1-4
Term
Description
Alternative Fuels
Fuels other than standard gasoline or diesel that may contain high alcohol content. For
example, E85, biodiesel, special additives, or special fuel mixes.
Biodiesel
Diesel fuel consisting of long-chain alkyl (methyl, propyl or ethyl) esters, which can be used as
fuel in standard diesel engines.
CAT-5 Cable
Category 5 (CAT-5) Cable is a twisted pair cable for carrying signals used in structured cabling
for computer networks such as Ethernet.
CoC
Certificate of Conformance (CoC) (see backside of the front cover for listing of numbers).
Daisy-chain
Communications
Wiring
DEF
Dispenser
Dispensing device that uses STP in storage tank to move fuel from storage tank to dispenser.
E85
An ethanol fuel blend up to 85% denatured ethanol fuel and gasoline or other hydrocarbon by
volume.
High Hose
Junction Box
Is a container for electrical connections, usually intended to conceal them from sight and deter
tampering.
Listed
Products that bear the authorized listing mark of Underwriters Laboratories (UL). This is the
manufacturers declaration that the product complies with ULs requirements in accordance
with the terms of ULs listing and follow-up service agreement.
Low Hose
Master/Satellite
Master dispensers are teamed with satellites for rapid fueling of trucks with saddle tanks. The
master unit meters and computes product flow for both units. The satellite is a dispenser
without the electronics module.
NFPA
Pump
Uses self-contained pumping unit and motor to move fuel from storage tank.
Valves
Mechanical device by which the flow of fuel in bulk may be started, stopped, or regulated by a
movable part that opens, shuts, or partially obstructs one or more ports or passage ways.
Introduction
Breakaways
Required by NFPA 30A, breakaways are emergency devices designed to retain liquid on both
sides of the breakaway point installed on each hose. For proper installation, refer to
manufacturers instructions.
Replacement Parts
Use only genuine Gilbarco replacement parts and retrofits on your pump/dispenser. Using
parts other than genuine Gilbarco replacement parts could create a safety hazard and violate
local regulations.
For replacement parts, ensure to match the component ratings for the fluid being dispensed.
Use the flexible fuel-compatible parts for valves, meters, filters, outlet castings, O-rings, and
in some cases, protected piping. Flexible fuel components utilize plated, coated, and flexible
fuel-resistant elastomers.
Fluid Compatibility
The equipment and plumbing used in the dispensers must be compatible with the fuel that will
be dispensed. Use of equipment and plumbing that is not compatible with the fuel could cause
fuel leaks. For example, E85, high percentages of biodiesel, and DEF are the fuels or fluids
that require special dispensers.
Page 1-5
Introduction
Page 1-6
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).
!
! WARNING
Page 2-1
In an Emergency
No Open Fire
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.
!
WARNING
WARNING
Page 2-2
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.
WARNING
!
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
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.
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.
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.
Fire at Island
Fuel Spill
Page 2-3
Page 2-4
Station Layout
Site Preparation
3 Site Preparation
Station Layout
Gilbarco recommends that you follow the instructions given below:
Consider traffic flow, kiosk, and store location when planning the location of
pumps/dispensers.
Plan islands for efficient routing of plumbing and wiring. Arrange product lines by hose
and foundation layouts (refer to MDE-3985 Encore Installation Manual). Follow local
codes.
Note: Efficient routing of plumbing and wiring potentially improves pump/dispenser flow
rates and minimizes unit power requirements. Refer to Plumbing Requirements
on page 5-1.
Place pumps/dispensers so that customers can dispense fuel safely and conveniently.
Install pumps/dispensers at least 8 feet apart on the island.
Service technician must have easy access to the entire pump/dispenser (top, rear, front,
and sides). Gilbarco recommends at least 60 inches of clearance from any structure (for
example, wall or fence).
Install protective posts at the ends of islands to protect pumps/dispensers against collision.
Posts must not interfere with customer fueling.
Ultra-Hi units with satellites may require a separate fence between the satellite and an
adjacent truck lane. Consult local requirements and allow adequate clearance between the
fence and unit for service access.
Page 3-1
Site Preparation
48
42
Page 3-2
Station Security
Site Preparation
Station Security
It may be impossible with any manufacturers unit, even if designed for security, to prevent
theft. It is possible, however, to greatly reduce the probability that a theft is successful, if
security measures are taken into consideration when designing the station layout and
security-minded actions are planned into site operation. The following recommendations are
intended to decrease the probability of theft by observance and/or incorporating obstacles that
deter criminal activity.
Enhancing Security
Follow these guidelines for enhancing security:
1 Design stations where employees have a complete, unobstructed view of all fueling locations.
Do not block employee views with merchandise displays or other obstructions. If complete
view is not possible, utilize video surveillance equipment. Equipment monitoring must be
made obvious and signs stating its use must be posted. Use surveillance cameras especially for
areas of high risk or locations that are potentially blocked from your view.
2 Use pump/dispenser security kits when available.
3 Plan to use modular programming time out functions that shut down the unit if no pulser
integrity.
6 Enter new programming access codes, as default codes are commonly known. These codes
must only be known by trusted station employees and involved ASCs. Store the codes in a safe
and secure location known to station management. Unit service may be more expensive if
these codes are lost.
7 At installation, and all times thereafter, ensure that the lower door lock levers are adjusted
correctly and not allowing the panels to be removed easily without a key or tools. If you
suspect that keys are available to thieves in your area, consider using special locks or keys
available from locksmiths.
8 Observe Point of Sale (POS) warnings or messages for units that are offline.
Page 3-3
Site Preparation
Page 3-4
Electrical Requirements
4 Electrical Requirements
The electrical requirements are as follows:
Prepare sites as per NFPA 30A, NFPA 70, and applicable national, state, and local
codes/regulations.
Use licensed electricians to make all electrical connections.
Use a dedicated circuit/phase system. Wire all electronic units to the same power leg.
Use an earth ground for circuits.
Mount all circuit breaker panels and relay boxes securely to the wall.
Use UL-recognized/approved components and/or systems.
Recommended voltages for pumping units are 220 VAC single-phase or 380 VAC
three-phase.
Route product wiring to protect from damage, using conduit as required.
Note: Pumping units operate at higher load levels than dispensers. Refer to FE-363 Field
Wiring Diagram Encore 500/700 (M07555 Power Supply Only) and FE-364 Field
Wiring Diagram Encore 300.
In Canada, installing communication circuits, such as data cables and AC cables, in the same
conduit as AC circuits is contrary to the Canadian Electrical Code (CEC) rule 60. New
installations must have separate conduit for data/communication cables and power cables in
the following circumstances (wiring for two-wire, data, communications, intercom, video,
Ethernet, Gilbarco Long Range Ethernet (GLRE), must be in a separate conduit from the
dispensers power and light conduit):
All new installations of fuel dispensers or other electrical equipment, whether or not the
raceways are exposed and made readily accessible as part of the installation process; or
In any event if the raceways are exposed and made readily accessible for any reason.
WARNING
OFF
NFPA 30A and Gilbarco require that you install one or more emergency power
cutoff switches.
An emergency power cutoff switch is a single control that removes AC power to all the
island equipment (pumps/dispensers, STPs, canopies, lights, and so on). The emergency
power cutoff switch must also remove power to the auxiliary devices that are attached to
the dispenser, such as communication wiring, third-party add-on devices, intercoms, and
so on.
Ensure that the emergency power cutoff switch is accessible, label it clearly, and install it
away from any hazards that may occur at the pumps/dispensers. Do not install cutoff
switches more than 100 feet away from the pumps/dispensers.
MDE-3802S Encore and Eclipse Site Preparation Manual August 2016
Page 4-1
Electrical Requirements
Circuit Breakers
Familiarize all employees with the location of the emergency power cutoff switch and its
usage. Ensure that you remind them at frequent intervals.
Note: Do not use E-STOP, ALL-STOP, or PUMP STOP keys on Gilbarco console/cash
registers to shut-off the pump/dispenser power. These keys do not remove AC power
and do not always stop product flow.
IMPORTANT INFORMATION
Devices, such as D-Boxes and PAM 5000, and two-wire must be de-energized or have
wiring disconnected from the dispenser by the emergency stop or equivalent
mechanism. Third-party devices, such as those supplying power to any form of
communication to a dispenser (intercoms, external devices connected to the Applause
Media System (Encore), third-party controllers and so on), must also be de-energized
or the wiring supplying that power be disconnected. Provision to accommodate this
must not introduce noise [Radio Frequency Identifier Device (RFID) or electrical] into
sensitive pump dispenser electronic field wiring circuits during normal pump/dispenser
operation. De-energizing of the external equipment through the emergency stop or
equivalent device is recommended.
Circuit Breakers
Requirements for circuit breakers are as follows:
Figure 4-1: Using Circuit Breakers
Do not use
Use
Page 4-2
Electrical Requirements
Conduit
If not already required, Gilbarco recommends that a spare conduit be run for future high-speed
communications. For details, refer to High-speed Communication Wiring on page 4-6.
Instructions regarding the conduit specifications are given below:
Use a 1-inch trade-size rigid aluminium conduit with Encore and Eclipse.
pumps/dispensers to connect wires to the pump/dispenser. Two-wire data wires can share
the power-wiring conduit (refer to model-specific wiring diagrams). When retrofitting to
an existing island that uses a 3/4-inch conduit, provisions must be made for transition to a
1-inch conduit to pass through the 1-inch air-gap plates when a unit does not have a
factory-installed J-box. To maintain the integrity of the air gap, it is required that only
1-inch conduit pass through any air-gap conduit adapter plate 1-inch holes.
Use different 1-inch conduits for intercom and other class two-wiring. When retrofitting to
an existing island that uses a 3/4-inch conduit, provisions must be made for transition to a
1-inch conduit to pass through the 1-inch air-gap plates. To maintain the integrity of the air
gap, it is required that only 1-inch conduit pass through any air-gap conduit adapter plate
1-inch holes.
Use threaded, rigid metal conduit or a rigid non-metallic conduit for applications below
the pump/dispenser to carry electrical wires. Conduit must conform to national and local
electrical codes. If you use non-metallic conduit, it must be at least 2 feet underground.
The last 2 feet of the underground run to the ground interface must be a rigid metal conduit
or threaded steel intermediate metal conduit. Tighten all threaded conduits.
Never share dispenser power or two-wire communication conduit with other
manufacturers equipment (for example, speaker wires, canopy lights).
Note: You can use the same conduit for routing power to the pump/dispenser and the
two-wire data loop. The two-wire data loop is a Class 1 circuit.
Page 4-3
Electrical Requirements
Wiring
Never rely on metal conduit to provide an equipment ground. Run a separate ground wire.
Separate and isolate pump/dispenser wiring from other equipment wiring in wiring
troughs.
Never use knock-out boxes or flexible conduit for installation.
Note: Extra J-box added to the pump/dispenser must be listed Class 1, Div. 1, Group C
and D explosion-proof.
Use electrical fittings that are listed for Class 1, Group C and D hazardous locations, as
required by NFPA 30A and NFPA 70.
A seal-off Y fitting (for example, Killark Type EY) must be installed on all units as a
first connection where conduit leaves the ground.
Wiring
For high-speed communications information, proceed to High-speed Communication
Wiring on page 4-6.
Wire all pumps/dispensers as per NFPA 30A, NFPA 70 and applicable national, state, and
local codes/regulations.
Wire all circuits as NEC Class 1 except the speaker (intercom) circuit which must be NEC
Class 2. Install the speaker (intercom) circuit in a separate 1-inch conduit.
Use stranded gas and oil resistant copper wire rated for 300 V (up to 240 VAC source) and
176 F (80 C). Do not use solid wire.
In the main conduit, for two-wire communications, use only twisted-pair wiring as per the
diagram. Do not use shielded twisted-pair wiring.
Unshielded twisted pair wire is required for two-wire communication wiring for new
stations. Previously wired stations may continue to use existing non-twisted pair wiring,
which has passed short and continuity testing, but is more susceptible to noise and
lightning damage.
Leave 6 to 8 feet of wire out of conduit for connection to dispenser.
Dispensers and POS must share the same phase. Phasing and grounding should be verified
prior to start-up and meet all local codes and regulations.
Wire dispensers, POS, D-Boxes, etc., on a single phase in a dedicated electrical panel
(recommended) and have other potentially noise sources, such as compressors, motors,
and so on, in a different electrical panel. Ensure proper care to minimize noise sources
present on the phase that is used for dispensers and related equipment. If multiple phases
are required, use industry best practices to keep noise generating circuits as isolated as
possible from the fueling component circuits.
All equipment that is connected using communication connections, dispenser
communications, and related power outlets and power sources for PIN pads, gas price
signs, scanners and so on must always be kept on the same phase of power as the
dispenser power.
Notes: 1) Communication connections such as CAT-5/6, RS-485, and RS-232.
2) Dispenser communications such as Gilbarco two-wire to the fueling system
including POS/Back Office System/Fuel Monitoring System/Network
Communication/Dispenser Communication and Control System (Applause
Media System or high speed data)/Other Payment, Loyalty Systems, and Car
Wash Controllers.
Use listed wire nuts for all connections. Do not use tape.
Pull spare wires for future use.
Protect conduit ends and wire from water ingress or thread damage after installation,
before installation of the pumps/dispensers.
Seal-off Y fitting(s) must be potted after all wires are run to termination points.
Page 4-4
Electrical Requirements
In Canada, installing communication circuits, such as data cables and AC cables, in the same
conduit as AC circuits is contrary to the CEC rule 60. New installations must have separate
conduit for data/communication cables and power cables in the following circumstances
(Wiring for two-wire, data, communications, intercom, video, Ethernet, GLRE, must be in a
separate conduit from the dispensers power and light conduit.):
All new installations of fuel dispensers or other electrical equipment, whether or not the
raceways are exposed and made readily accessible as part of the installation process; or
In any event if the raceways are exposed and made readily accessible for any reason.
For additional wiring notes and requirements, refer to the following documents:
FE-341 Field Wiring Diagram The Eclipse Series Dispensers.
FE-363 Field Wiring Diagram Encore 500/700 (M07555 Power Supply Only).
FE-364 Field Wiring Diagram Encore 300.
CAUTION
Failure to follow the requirements in the table below could result in communication
issues between the pumps/dispensers and POS that are not covered by warranty.
D-Box
PA0133, PA0187 G-SITE
Total data wire system run no more than 2600 feet with 14 AWG
PA0306 D-Box
PA0409
Note: When installing new two-wire communication wiring, use unshielded twisted-pair data
wires. Shielded wire must not be used. Wiring and insulation specifications are as
follows:
Wiring specification: Two-wire twisted-pair [Unshielded Twisted-pair (UTP)] with 10
to 12 twists per foot, stranded annealed copper tinned with 18 AWG minimum
required for runs up to 1000 feet or 14 AWG minimum for runs up to 2600 feet. Do not
daisy-chain communications wiring.
Insulation specification: Polyvinyl Chloride (PVC) insulation of type Thermoplastic
Flexible Fixture Wire Nylon Jacketed (TFFN) or Machine Tool Wire (MTW),
UL-approved gasoline, and oil-resistant. Refer C&M Corporation part number 27525
(18 AWG) or equivalent. The Gilbarco part number for the wire is Q13221-2.
Page 4-5
Electrical Requirements
UPS/Surge
Protection
(Required)
Conduit
Seal-off
Fittings
(Potted)
Q13850 Internal
LAN Cable
10 Base-T
Wall Plate
Forecourt
Twisted-pairs
Back Room
Front Counter
J-box
(If the Twisted-pair Cable is running
in the primary or AC Conduit,
use a DSL Isolation Box)
POS
Note 2: Run of up to 2000 of
LAN Cable must be
continous. LAN Cable
cannot be spliced.
Electronics Cabinet
1 Secondary
Conduit
Eclipse Series
Hydraulics Area
Electronics Cabinet
Potted Conduit (8 x 1)
Encore Series
Hydraulics Area
Pit Box
Page 4-6
Auxiliary Conduit
Electrical Requirements
Auxiliary Conduit
Gilbarco recommends the use of 1-inch rigid metallic conduit and fittings
(refer to Conduit on page 4-3) for the auxiliary conduit used for wiring, apart from the
dispenser power or two-wire communications. This will allow up to two speakers and
two call/stop buttons per side, and high-speed communications.
Ethernet Cable
Gilbarco requires use of 10 Base-T Cable or CAT-5 Cable as specified in this manual for
high-speed communication wiring. Gilbarco specified cables must be used to permit issuance
of a CoC and/or warranty. Use of other cable types may also create a hazardous situation or
result in equipment malfunction.
WARNING
Petroleum vapors may migrate inside the cable insulation between conductors and
sheathing of various cables, including 10 Base-T or CAT-5E Cable. Vapors may ignite,
leading to serious injury or death.
It is crucial that the installer follow NECs, Article 501 requirements by removing the outer
jacket and spreading the wire pairs at the seal-off points of the CAT-5E Cable, so that a
good vapor seal is achieved. This is required because all CAT-5E Cables will conduct
vapors inside their outer jacket.
Use only 10 Base-T wiring specified by Gilbarco. Failure to follow this may result in bad or
intermittent communication to the POS device.
The cable has the following properties:
Safety Certification: UL Listing AWM Style 21094 176 F (80 C) 300 V.
Vapor Test: Compliant to UL Standard 87, Section 36A, Para. 22.17
IMPORTANT INFORMATION
A copy of the ANSI/TIA/EIA TSB-67 Certification of Conformance from the wiring
personnel must be provided to the ASC before the site can be commissioned. The
certificate is part of the documentation that must be on file at the installation site. A
certification of the field test will be required at equipment start-up. Contact Gilbarco
with any questions regarding this procedure.
Page 4-7
Electrical Requirements
Grounding
Following table lists the documents that must be read and understood by the technician
who installs:
Document
Title
ANSI/ Institute of Electrical Recommended Practice for Grounding of Industrial and Commercial Power
and Electronics Engineers Systems (IEEE Green Book)
(IEEE) 142-1991
ANSI/IEEE 1100
ANSI/TIA/EIATSB67
ANSI/TIA/EIA568-B
Grounding
Following are the requirements for grounding:
NFPA 70 requires that you connect the following to system ground:
- Consoles
- Pumps and dispensers
- STPs
- Relay control boxes
- Circuit breaker panel
- Electronic leak detectors
Gilbarco requires that you connect each pump/dispenser to an equipment grounding
conductor located in the conduit as per NFPA 70, Article 250.
The following applies to ground conductor:
- Gilbarco recommends using wire no smaller than 12 AWG. A larger wire may be
required as per NFPA 70, Article 250.
- Use wire with green or green and yellow striped insulation.
- Connect to green grounding screw in the J-box or designated connection in the electrical
cabinet for units without J-boxes.
- Provide the proper ground as provided for under NFPA 70, Article 250.
- Bond the neutral bus to an approved grounding electrode.
Page 4-8
Sealing Y Fittings
Electrical Requirements
Main Circuit
Breaker Panel
Insulated Grounding
Conductor
Metal Conduit
Switched
Neutral
Circuit
Breaker
Dispenser/Pump
Circuit Breaker Panel
Conduit
Neutral Bus
Ground Bus
Neutral Bus
Ground Bus
Dispenser/Pump J-box
Ground Screw
12 AWG Green Ground Wire
Grounding Electrode
Note 2:
= Ground Bond
2 feet
Adapter
Sealing Y Fittings
Y seals are installed in the conduit runs to minimize passage of vapors, gases, or flames from
one portion of the electrical installation to another through the conduit. Fittings must be
installed in accordance with Articles 501-5 and 502-5 of the NEC and fitting manufacturers
instructions.
IMPORTANT INFORMATION
Wiring must be tested for proper continuity and verification. No shorts must exist
between individual wires or any wire to metallic before potting any Y fittings.
MDE-3802S Encore and Eclipse Site Preparation Manual August 2016
Page 4-9
Electrical Requirements
Sealing Y Fittings
Gilbarco uses Killark type EY fittings and recommends them or their equivalent for vertical
conduit runs.
Note: The following sealing directions are for Killark fittings only, and instructions may vary
for other manufacturers fittings. Read all instructions completely before you begin.
Figure 4-4: Sealing Killark Fittings
Wires
Conduit
Close-up Plug
Fill to bottom
of threads
Floor Dam
Sealing Compound
Conduit
packing fiber to a floor dam to ensure that the fluid sealing compound is held.
Note: Floor dam must be even with the conduit stop in the lower hub of fitting. Ensure that
you prevent damage to the conductor insulation. Force the packing between conductors
and hubs, pushing any shreds of packing fiber away from conductors to prevent leakage
path.
3 Use only Killark type SC sealing compound with Killark fittings, and do the following:
Note: Initial setting of sealing compound will occur within 30 minutes. Compound requires a
minimum of eight hours above 32 F (0 C) to develop sufficient strength to withstand
explosion pressures.
Page 4-10
Fuel Tanks
Plumbing Requirements
5 Plumbing Requirements
Fuel Tanks
Follow tank manufacturers instructions, national, state, and local regulations for storage tank
installation.
Note: Fiber glass tanks manufactured earlier than 1992 may not be compatible with certain
alternative fuels, such as E85.
On pumps (self-contained units), it is recommended that a vertical lift of 10 feet must not be
exceeded. The Environmental Protection Agency (EPA) and Application Programming
Interface (API) regulates the vapor pressure of gasoline. A lift greater than 10 feet may result
in pumping unit noise and/or low flow rates.
Notes: 1) The maximum lift is defined as the vertical distance from the bottom of the suction
pipe in the storage tank to the pump shaft center line of the pumping device.
2) Install a Gilbarco Model 52 or equivalent vacuum-actuated valve (per NFPA 30)
directly beneath a self-contained pump when above-ground storage tanks are used.
Without a vacuum-actuated valve, sump may overflow. For more information, refer to
the manufacturers installation instructions, Gilbarco Product Service Bulletin
26-91, and Check Valves (Used on Pumps and Ultra-Hi Units Only) on page 5-5.
WARNING
Highly flammable and explosive fuels are present.
Failure to observe all safety precautions could result in severe injury or death.
Observe all safety precautions in this manual and others.
WARNING
DEF, flexible fuels, such as biodiesel; high alcohol percentage fuels, such as E85, may be
incompatible with certain plumbing materials and hydraulic components.
Use of incompatible materials or components with alternative fuels, such as E85, or
alternative fluids can result in leaks or unexpected failures of components, resulting in fire,
explosion, or environmental damage.
When dispensing alternative fuels, such as E85, or alternative fluids verify with the
manufacturer if the material of all plumbing components are compatible with the fuels or
fluids being dispensed.
Page 5-1
Plumbing Requirements
Leak Detectors
Use only listed leak detectors. Follow the manufacturers instructions for leak detector
installation.
Note: Components must be compatible with the fluid type being dispensed. For more
information, contact the respective manufacturer.
Page 5-2
STPs
Plumbing Requirements
STPs
Use only listed STPs. Follow manufacturers instructions for the installation of STPs.
Notes: 1) Components must be compatible with the fluid type being dispensed. For more
information, consult the concerned manufacturer.
2) Air separation provisions must exist within the STPs to ensure that calibration is
accurate and no calibration issues occur.
Pipe Installation
Figure 5-1 shows the product inlet and vapor pipes for Gilbarco pumps/dispensers.
Figure 5-1: Marking Fuel Grade Names
Mark the name of the fuel grade (for example: unleaded, super) on the product
lines coming out of the ground.
Refer to Petroleum Equipment Institute (PEI) publication RP100 Recommended Practices for
Installation of Underground Liquid Storage Systems (Chapter 9) and PEI publication RP200
Recommended Practices for Installation of Above-ground Storage Systems for Motor Vehicle
Fueling.
Product inlet pipes and vapor pipes for Gilbarco pumps/dispensers vary in location between
models. Product piping order differs from blenders to previous Advantage models.
See model-specific footprint before installing pipes.
Check national, state, and local regulations for installation of pipe system.
Use containment system as required by national, state, and local regulations.
Below the unit, use UL and code-approved flexible pipe (constructed of UL-approved
pipe material and UL-approved fittings).
Note: Some regulatory agencies do not allow the use of a galvanized piping component
when diesel is involved. Consult local regulators. Also, galvanized piping is not
usable for certain alternative fuels, such as E85, or biodiesel.
Alternative fuels, such as E85, or fluids, such as DEF, may require special piping materials
or components. Consult the manufacturer to determine whether the piping material is
compatible with the fluid being used. Use 2-inch risers on Ultra-Hi units that use a
2-inch shear valve.
Leak detectors may not detect leaks reliably in plumbing between master and satellite
Ultra-Hi units. Secondary containment and likely specialized leak-detection equipment is
required. Consult codes.
MDE-3802S Encore and Eclipse Site Preparation Manual August 2016
Page 5-3
Plumbing Requirements
Pipe Installation
Pipe Size
The required pipe size depends on the number of units sharing lines, size of the STPs
(dispensers only), and length of the run. Follow the guidelines below:
Page 5-4
Plumbing Requirements
Page 5-5
Plumbing Requirements
Notes: 1) Shear valves are not typically required on pumps but installation is discretionary
and sometimes required. Consult local codes.
2) Components must be compatible with the fluid type being dispensed. For more
information, consult the concerned manufacturer.
Refer to PEI publication RP100 Recommended Practices for Installation of Underground
Liquid Storage Systems (Chapter 9) and PEI publication RP200 Recommended Practices for
Installation of Above-ground Storage Systems for Motor Vehicle Fueling. A shear valve is a
NFPA 30A required safety device. It closes automatically to stop product flow during a fire or
if the dispenser gets knocked off the island. It also provides a means of manually closing inlet
pipes.
Note: Shear valves are recommended and sometimes required for vapor recovery lines. For
more information, consult local or state regulatory agencies.
Figure 5-2: Installing Shear Valve
Follow shear valve manufacturers instructions for installation procedures, testing, and so on.
Install the shear valve on each product inlet pipe.
Notes: 1) Standard Encore and Eclipse dispensers require male top shear valves of
1-1/2 inch. Gilbarco strongly recommends using double poppet shear valves
that shut-off flow from storage tanks and drain from the unit (for example,
OPW #10BHMP or Exxon - OPW # 10RMSP).
2) Encore Ultra-Hi - It is a mandatory code requirement that the shear section of
the shear valve be within 3/4 inch (or to shear valve manufacturers
requirement, whichever is tighter) from the plane of the bottom of the base of a
dispenser. Not all shear valve styles will allow maintenance of this tolerance
for Encore Ultra-Hi units. A Single Poppet Male Top (N23047) Morrison 2X2
636M-0200AV or code-approved equivalent shear valve meets code
requirements. Do not modify dispenser plumbing (for example, remove strainer
housing) to accommodate other model valves or installation units such that the
shear groove of the shear valve is not within 3/4 inch of the base plane of the
dispenser. Use of a Check Valve (N23274) between the union and strainer
housing will also ensure that the shear section is properly located.
Page 5-6
Plumbing Requirements
Island Surface
CAUTION
Ultra-Hi units require a strainer before the meter.
Unfiltered fuel passing through the Ultra-Hi can affect the operation or life of the
meter, valve, and nozzle. Premature failure of these components because of lack of
filtration is not covered by warranty.
Never remove the strainer to install a shear valve. Use a shear valve that fits and
allows use of the strainer.
CAUTION
Page 5-7
Plumbing Requirements
Following considerations are critical to the success of installing the Encore Ultra-Hi shear
valve:
Selection of proper components mounted to the bottom of the strainer housing is critical in
maintaining the proper location of the shear valve groove of the shear valve to the base
plane of the dispenser. You must follow the shear valve manufacturers required
positioning for this groove.
A check valve is required to insure accurate metering of fuel. Gilbarco recommends using
N23274, which is about 2-1/2 inches long and can take the place of the close nipple
located above the union.
A union is required above the shear valve.
A Morrison Male End Shear Valve [N23047 (Morrison # 636M-0200AV)] can be used to
properly maintain the position of the shear groove. The installer must verify if other
manufacturers shear valves ensure proper positioning of the shear groove as per
specifications.
Double poppet shear valves will not fit the Ultra-Hi and may cause performance problems.
Other combinations of unions, check valves, and shear valves may be possible and still
maintain proper location of the shear groove.
Removal of a strainer from the system will void warranty.
Shear valves of 1-1/2 inches will restrict flow noticeably. Double poppet shear valves of
1-1/2 inches can create unit performance problems not covered by warranty.
Safety Signs
Following are some guidelines on safety signs:
Safety signs warning of potential hazards may be required, depending on state and local
codes, and NFPA regulations.
Gilbarco requires installing applicable signs in locations likely to be noticed and read by
the users of the equipment.
Signs must be easily read, bilingual, durable, and fade-resistant. Unless local regulations
dictate otherwise, nationally recognized safety symbols with brief text are recommended.
Signs must include, but are not limited to the following:
- Use approved containers
- Turn vehicles off during fueling
- Static electricity hazards during fueling
- Health related warnings (involving fuels), advisement of fuel
flammability/explosiveness, and others, as required
- No smoking/match warnings
- Emergency procedures
Page 5-8
Index
Index
A
B
Base-T 4-7
Bilingual 5-8
Biodiesel 1-5, 5-1
BRCM 1-3
C
canopies 4-1
CAT-5E 4-7
Check Valve 3-4
check valve 5-8
Circuit breaker 3-4
Circuit breaker panel 4-8
Class 1 4-4
clearance 3-1
code 3-1
Collision 3-1
conduit, electrical 3-4, 4-3, 4-4, 4-8
console 4-2
Control Relay 4-3
CUL 4-2
D
D-Box 1-3, 3-4, 4-2, 4-5
De-energizing 4-2
DEF 1-5, 4-2, 5-2, 5-8
Kiosk 3-1
Knock-out box 4-4
L
lights 4-1
local codes 5-6
Locks 3-3
LRE 1-3
M
Model 52 5-1
Morrison 5-6, 5-8
MSDS 1-5
MTW 1-3, 4-5
N
F
Fade-resistant 5-8
Flexible fuels 5-1
G
gasoline 4-5
GFI 3-4
GFI breakers 4-2
Green Book 4-8
ground 4-1, 4-4, 4-8
Group C 4-4
G-SITE 4-5
H
Hazards 4-1
HDPE 5-2
High-speed 4-7
I
IEEE 4-8
Intercom 4-4
isolation relay 4-3
J
J-box 4-3, 4-4, 4-8
N23274 5-8
NEC 4-2, 4-4, 4-7
NFPA 30 4-4
NFPA 30A 1-5, 4-1, 5-6, 5-7
NFPA 70 4-4, 4-8
O
oil-resistant 4-5
P
PA0133 4-5
PA0242 4-5
PA0287 4-3
PA0306 4-5
PA0409 4-5
PAM 3-4, 4-2
PEI publication 5-6
pipe 5-3
pipe, plumbing 5-3, 5-4, 5-5, 5-6, 5-7
Pit Box 3-4
plumb 3-1, 5-1
POS 3-3, 3-4, 4-5
Potting 3-4
Programming 3-3
PUMP STOP 4-2
Pump/dispenser 1-5
PVC 4-5
K
Killark 4-4, 4-10
Index-1
Index
Q
Q13221-2 4-5
R
Relay control boxes 4-8
Retrofits 1-5
RFID 4-2
routing 3-1
RP200 5-6
S
sealing compound 4-10
Section 36A 4-7
security measures 3-3
Service Center 1-1
shear section 5-6
shear valve 3-4, 5-3, 5-6, 5-7, 5-8
Shut-off Valve 3-4
Single Poppet Male Top 5-6
T
Technical Support 1-1
TFFN 1-4, 4-5
Three-phase 4-1
Transac 4-5
Twisted-pair 4-4, 4-5
Two-wire 4-4, 4-5
U
UL 3-4, 4-7, 5-2
UL/CUL 4-2
Ultra-Hi 3-1, 5-5
Underwriters Laboratories 1-4
Universal D-Box 4-5
Unshielded 1-4
UTP 4-5
V
vapor recovery lines 5-6
W
WAGO 3-4
wiring, electrical 3-1, 3-4, 4-3, 4-4
Cisco is a registered trademark of Cisco Systems Inc. Ethernet is a registered trademark of Xerox Corporation. Exxon is a registered
trademark of Exxon Mobil Corporation. Killark is a registered trademark of Killark Electrical Manufacturing Company. NEC and
NFPA 70 are registered trademarks of the National Fire Protection Association. OPW is a registered trademark of OPW Fuel
Management Systems. UL is a registered trademark of Underwriters Laboratories Inc. WAGO is a registered trademark of WAGO
Corporation.