Name: Gallagher PULSE Series
Brand: Gallagher
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Part No. 2A01977

PULSE Series

Installation, Commissioning & Servicing Manual

Revision 19

Table of Contents3
Part A: General8
About this Manual8
Notations8
Pictograms8
Safety Warnings & Precautions9
Hazard Warnings9
Damage Warnings10
Information Relating to DEF (Diesel Exhaust Fluid)10
Materials Not Recommended to be Used with DEF11
Greasing Threaded Connections11
Figure 1 Greasing Threaded Connections11
Fastening of Panel Screws12
Figure 2� Location of Panel Screws12
General Shipping & Transportation Information13
Handling13
Storage14
Pulse Technical Specifications15
Part B: Installation16
Lifting of Units16
Prior to Installing16
Underpump Containment Sump16
Hydraulic Pre-Installation16
Anchoring Bases16
Figure 3� Anchor Point Locations17
Electrical Requirements/Regulations18
Hydraulics19
Pumps19
Dispensers19
Lpg19
Vapour Recovery19
Series Hose Installation (Hanging)20
Remove the Holsters20
Fit the Spreader20
Fit the Hoses21
Replace the Holsters22
Series Hose Installation (Retractor)23
Remove the Spreader Panels23
Prepare Spring Reel Cable for Connection to Hose24
Remove Holster Panels to Allow Access to Hoses24
Connect the Hoses25
Attach the Hose Clamp to the Hose and Retractor Cable26
Refit Panels27
Nozzle Switch Connection28
Correct Fitting of Hoses to Hi-Arm28
Figure 4� Correct Nozzle Switch Connection28
Figure 5� Correct Method of Fitting Hoses to High-Arm28
Bennett Pump Unit29
Pre-Installation Check of Rotor Movement30
Realignment Procedure30
Belt Tension30
Vacuum and Pressure Testing30
Electrical31
General31
Mains31
Comms31
Figure 7� Single Phase Pump Connector Blocks31
Mains Connections32
Figure 9� Comms Connections32
Forecourt Communications33
Figure 10� Location and Positioning of Protocol Pins33
Figure 11� Central Controller DCE33
Float Switch Installation34
Figure 12� Float Switch Installation34
Installing the Head Lighting35
Figure 13� Head Lighting Assembly35
Rear Side of the Head35
Connecting the Light Cable for the Illuminated Spreader38
Part C: Commissioning39
Overview39
Figure 15� Overall Commissioning Process39
Safety Inspection40
System Start-Up Checks40
Lpg Trade Measurement Verification Process40
Service Mode Settings40
Calibration41
Firmware Test41
Adjustment Wheel41
Lobe Meter (Ultra Diesel)42
Calibration Procedure42
Lobe Meter42
Encoder PCB42
Calibration Procedure for Blending Units43
Lpg Section44
LPG Stack Components45
Figure 19� LPG Stack Components45
4-Way Meter Feed Valve Settings46
Return Line Valve46
Figure 20� Meter Feed Valve Settings46
Figure 21� Return Line Valve with LPG Nozzle Attached46
LPG Stack Test - Version 1.1147
LPG Stack Test - Version 1.2048
LPG Trade Measurement Verification Process - Version 1.1149
Figure 22� Location of Dipswitches49
LPG Trade Measurement Verification Process - Version 1.2051
LPG Meter Calibration - Version 1.2052
LPG Electrical Schematics53
Figure 23� LPG Electrical Schematic53
Figure 24� LPG Electrical Schematic Using Integrated Stack Controller53
Part D: Servicing54
General Care and Maintenance55
Daily Maintenance55
Monthly Maintenance55
Annual Maintenance55
Target Torques for Gasket Sealing56
Figure 25� Target Torques for Gasket Sealing56
Nozzles57
Elaflex (Petrol/Diesel)57
Figure 26� Elaflex ZVA Slimline 2 Nozzle57
Elaflex GG1DN / LPG58
Elaflex DEF Nozzles59
Safety Breaks60
Figure 28� Elaflex SSB Safety Break60
Lpg Dry Breaks61
Hoses62
Figure 29� Brass Swivel Nuts and Hose Clamp62
Figure 30� Gaining Access by Moving the Channel Runners62
Shortening Hoses63
Asco 24V Proportional Valve64
Figure 31� ASCO Proportional Valve64
Maintaining the Spring Reel Tension (L Series)65
Replacing the Pump Unit / Air Separator Strainers66
To Replace the Inlet Strainer66
To Replace the Outlet Strainer67
Def Filter Cartridge Replacement68
Figure 32� Filter Housing and y Strainer68
Figure 33� Removal of the Filter Housing68
Electrical69
Remounting a PULSE UI Battery Pack69
Figure 34� Shield Surface with BUP Board and Battery Pack69
Simple Wiring Diagram70
Figure 35� Simplified Wiring Diagram70
Junction Box Wiring Diagrams71
Figure 37� Comms Connections71
Sd Card Content72
Process for Loading Firmware Onto the SD Card72
Configuration Reinstall72
Obtaining Dispenser Logs73
Service Mode Functions73
Entering Service Mode73
SD Card Setting73
Service Mode Function Screens73
Figure 38� Order of Service Mode Screens73
Firmware - FIRMW74
Setting VR Active - VRCTRL75
Setting Pump Numbers - CGFPID75
Setting a Password - CGPWD76
Errors - ERRORS77
Setting Hoses Active/Inactive - HOSE78
Grade Priority - PRIORTY78
5/6 Digit Mode - 5DIGIT78
Pos/Standalone - POS79
Grade Prices - PRICE79
Hydraulic Stack Test - STACK80
Checking Input Status81
View/Set Date & Time82
Maintaining Isolation of Mains Voltage Within Head Cabinet82
Manager & View Totes Modes - All Versions83
Manager Mode83
View Totes Mode83
Service Mode Functions84
Summary of New Key Features and Functions84
Entering Service Mode85
Service Mode Function Screens - Version 1�2085
Figure 39� Order of Service Mode Screens85
SD Card Setting - SDCARD86
Stack Menu - STK MENU86
Setting Pump Numbers - FP ID88
Point of Sale Menu - POS89
Grade Priority - MAPPING90
Setting Hoses Active/Inactive - HOSE91
Grade Prices - PRICE91
LPG Menu92
Errors - ERRORS94
PULSE Counted Error Codes95
Timeout Menu - TIMEOUT96
Start-Up Delay - STARTDEL97
Flow Control - FLOWCTRL97
View/Set Time - TIME98
View/Set Date - DATE98
Setting a Password - PASSWD99
Setting VR Active - VR299
Totes100
Reload Configuration - CONFIG100
Restart Central Controller - REBOOT100
Operating System Menu - os101
Firmware - FIRMWARE102
Hydraulic Stack Test (Blending)104
Procedure104
Testing the Non-Return Valves (Circled in Diagrams)106
Adjusting Flow Rates106
Calibration107
Flow Control - FLOWCTRL107
Grade Priority - MAPPING107
Setting Hoses Active/Inactive - HOSE107
Ratio Error107
Addressing Lpg Meters - Version 1�20108
Pulse Media111
Figure 41� PULSE Media Components111
Operation112
Power Buttons112
Figure 42� Windows Keyboard112
Figure 43� Location of Power Buttons for Media Player and LCD Screen112
Adjusting the Volume113
Electrical Protection113
Wiring Diagram113
Cleaning the LCD Screen113
Figure 46� PULSE Media Basic Wiring Diagram113
Troubleshooting114
Dispenser will Not Deliver Fuel114
Dispenser will Deliver Fuel116
Quick Reference Guide - Version 1�11117
Quick Reference Guide - Version 1�20118
Appendix - Blending Information119
Flow119
Layout120
Blending Manifold121
Wiring121
Stack Controllers121
Figure 49� Blending Manifold Assembly121
Multiplexers122
Figure 51� Wiring Positions of the Stack Controller122
Figure 52� Wiring Positions of the Multiplexer Board122
Appendix - Dispenser Control Systems123
Figure 55� 3-Board Stack Controller125
Figure 56� DC Integrated Stack Control - 1126
Figure 57� DC Integrated Stack Control - 2127
Figure 58� AC Integrated Stack Control128
Figure 59� 1 or 2 User Interface Modules129
Figure 60� 3 or 4 User Interface Modules130
Figure 61� Multiplexer Board Detail131
Figure 62� VR2 Subsystem Detail132

Brand	Gallagher
Model	PULSE Series
Category	Power Supply
Language	English

Gallagher PULSE Series User Manual

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