Gasboy 03908X User Manual
Introduction
This manual provides installation instructions for the Gasboy Automatic Temperature
Compensation (ATC) Kits:
Contents
Section Page ...
Introduction 1
Important Safety Information 6
Installation 8
Appendix: Totalizer Display Information 25
MDE-4351A
Gasboy ATC Kits 039086 and 039087
Installation Manual
February 2006
• 039086 for Twin 9800 Unit
• 039087 for Single 9800 Unit
Required Reading 1
Required Tools 1
Abbreviations and Acronyms 2
Parts Lists 3
Installing the 039086 ATC Kit in Single Unit 8
Installing the 039087 ATC Kit in T win Unit 16
Required Reading
Before installing a kit, the installer m ust read, understand, and follow:
• This manual
• NFPA 30A, The Automotive and Marine Service Station Code
• NFPA 70, The National Electric Code
• Applicable federal, state and local codes and regulations
Failure to do so may adversely affect the safe use and operation of the equipment.
Note: This kit must be installed by a Gasboy Authorized Service Contractor (ASC) to ensure
warranty.
Required Tools
The following tools are needed to install the ATC Kits:
• Open end wrench set
• Flat-tip s crewdriver
• Cross-tip screwdriver
•Allen
MDE-4351A Gasboy ATC K its 039086 and 039087 Installation Manual • February 2006 Page 1
®
wrench set
Introduction
Abbreviations and Acronyms
The following are abbreviations and acronyms used in this document.
Abbreviation
or Acronym Expansion
ATC Automatic Temperature Compensation
ASC Authorized Service Contractor
AWG American Wire Gauge
CFR Code of Federal Regulations
CPU Central Processing Unit
DIP Dual Inline Package
ESD Electrostatic Discharge
I.D. Inside Diameter
IS Intrinsic Safety
LCD Liquid Crystal Display
LPM Liters Per Minute
NEC National Electrical Code
NFPA National Fire Protection Association (http://www.nfpa.org/Home/index.asp)
NPT National Pipe Thread
OSHA Occupational Safety & Health Administration (http://www.osha.gov/)
PCB Printed Circuit Board
STP Submerged Turbine Pump
®
TPS Teflon
Pipe Sealant
Page 2 MDE-4351A Gasboy ATC Kits 039086 and 039087 Installation Manual • February 2006
Introduction
Parts Lists
039086 - ATC Kit for Twin Unit
Kraus Part Number Description Quantity
®
SK449C PCB Assembly in LP-70 Polycase
SK460 ATC Display Adapter Board (460A4 in Figure 1)1
SK461 Pulser/Handle Adapter Board (461A2 in Figure 1)1
218AY00 Dual Intrinsic Safety Barrier 1
- 5/16-inch Flat Washer (part of 218AY00) 2
- 5/16-inch Hex Nut (part of 218AY00) 1
212AY05 Dual Probe Connector Assembly 1
W172 3-Wire Harness for Intrinsic Safety Barrier 1
W199 Probe Assembly 2
BC407 Thermowell 2
235-C Thermowell plug 2
122-B 1/8-inch NPT X 1-inch Coupling 2
BC546 120-B 1/8-inch NPT Adapters Drilled to 17/64-inch I.D. 2
103-B 1/8-inch NPT Couplings 2
W283 Display Adapter Harness 1
W284 Pulser/Handle Ribbon Cable 2
- 18-22 AWG Crimp Splices 10
DC256W White “Volume Corrected to 15° C” Label 4
BC1380 Serialized AV-2322 Nameplate 1
Box and BC1379 Mounting Sponge 1
039087 - ATC Kit for Single Unit
Kraus Part Number Descri ption Quantity
SK449C PCB Assembly in LP-70 Polycase Box and BC1379 Mounting Sponge 1
SK460 ATC Display Adapter Board (460A4 in Figure 1)1
SK461 Pulser/Handle Adapter Board (461A2 in Figure 1)1
218AY00 Dual Intrinsic Safety Barrier 1
- 5/16-inch Flat Washer (part of 218AY00) 2
- 5/16-inch Hex Nut (part of 218AY00) 1
212AY04 Single Probe Connector Assembly 1
W171 2-Wire Harness for Intrinsic Safety Barrier 1
W199 Probe Assembly 1
BC407 Thermowell 1
235-C Thermowell plug 1
122-B 1/8-inch NPT Coupling 1
BC546 120-B 1/8-inch NPT Adapters Drilled to 17/64-inch I.D. 1
103-B 1/8-inch NPT Couplings 1
W283 Display Adapter Harness 1
W284 Pulser/Handle Ribbon Cable 1
- 18-22 AWG Crimp Splices 10
DC256W White “Volume Corrected to 15° C” Label 2
BC1380 Serialized AV-2322 Nameplate 1
MDE-4351A Gasboy ATC K its 039086 and 039087 Installation Manual • February 2006 Page 3
Introduction
Parts Identification
Figure 1 and Figure 2 provide an identification of the parts in the 039086 and 039087 kits.
Figure 1: The 039086 and 039087 Kits Parts Identification
W199 Probe Assembly
212AY04 Single Probe/
W284 Pulser/
Handle Ribbon
Cable
W283 Display
Adapter Harness
W172 3-Wire Harness
(For Twin Unit)
~ OR ~
W171-2 Wire Harness
(For Single Unit)
212AY05 Dual Probe
Connector Assembly
Crimp Splices
103B Couplings
122-B Nipples
235C Thermowell Plugs
BC546 120-B Adapters
BC407 Thermowells
218AY00 Dual Intrinsic Safety
Barrier (Newer Version)
460A4 Display
Adapter Board
218A Y00 Dual Intrinsic
Safety Barrier (Older
Version)
461A2 Pulser/Handle
Adapter Board
BC256W Label
BC1380 Nameplate
Note: If your kit is for a single unit, you will have only one of some of these items.
Page 4 MDE-4351A Gasboy ATC Kits 039086 and 039087 Installation Manual • February 2006
Introduction
Figure 2: SK449C LP-70 Polycase Box and Cover (Part of 039086 and 039087 Kits)
Cover
LP-70 Polycase
Box
SK449C PCB
Assembly
MDE-4351A Gasboy ATC K its 039086 and 039087 Installation Manual • February 2006 Page 5
Important Safety Information
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 SHUTOFF in the case of an emergency and not only
these cashier station “stops.”
!
WARNING
!
Important Safety Information
This section introduces the hazards and safety precautions
associated with inst alling , inspecting, main tainin g or servicing
this product. Before performin g any t ask on this pro duct, 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 indiv iduals know ledgeable in the related
procedures should install, inspect, maintain or service this
equipment.
Read the Manual
Read, understand and follow this manual and any other
labels or related mate rials suppli ed with this eq uipment. If y ou
do not understand a procedure, call a Gasboy Authorized
Service Contractor or call the Ga sb oy Serv ic e Center at 1800-444-5529. It is imp erative to y our safety and the sa fety of
others to understand the procedures before beginning work.
Follow the Regulations
There is applicable information in NFPA 30A; Automotive and
Marine Service Code, NFPA 70; National Electrical Code (NEC),
OSHA regulations and federal, state, and local codes which
must be followed. Failure to install, inspect, maintain or
service this equipment in accordance with these codes,
regulations and standards may lead to legal citations with
penalties or affect the safe use and operation of the
equipment.
Emergency Total Electrical Shut-Off
The first and most impo rtant information you mus t know is
how to stop all fuel flow to the pump 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 requiring access to electrical components or
the electronics of the dispenser requires total electrical shutoff of that unit. Know the function and location of this switch
or circuit breaker before in sp ect ing , installing, maintaining, or
servicing Gasboy equipment.
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or
STPs requires the following three actions:
- An evacua tion of all unauthorized persons and vehicles
using safety tape, cones or barricades to the effected units
- A total electrical shut-off of that unit
Replacement Parts
Use only genuine Gasboy replacement parts and retrofit kits
on your pump/dispenser. Using parts other than genuine
Gasboy replacement parts could create a safety hazard and
violate loc al regulations.
Safety Symbols and Warning Words
This section provides important informati on 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 whi c h m ust be
followed to prevent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible
injury or death.
Signal Words
These signal words used in this manual and on warning labels
tell you the seriousness of particular safety hazards. The
precautions that follow must be followed t o pre vent death,
injury or damage to the equipment
DANGER - This signal word is used to alert you to a
hazard to unsafe practice which will resul t in deat h or
serious injury
WARNING - This alerts you to a hazard or unsafe
practice that could result in death or serious injury.
CAUTION with Alert symbol - This signal word
designates a hazard or unsafe practice which may
result in minor injur y.
CAUTION without Alert symbol - When used by itself,
CAUTION 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 become explosive if ignited. Spilled
or leaking fuels cause vapors. Even filling custom er tanks will
cause explosive vapors in the vicinity of dispe nser or island.
Page 6 MDE-4351A Gasboy ATC Kits 039086 and 039087 Installation Manual • February 2006
Important Safety Information
No Open Flames
Open flames from matches, lighters, welding torches
or other sources can ignite fuels and their vapors.
No Sparks - No Smoking
Sparks from starting vehicles, starting or using power tools,
burning cigarettes, cigars or pipes can also ignite fuels and
their vapors. Static electricity, including an electrostatic
charge on your body, can cause a spark sufficient to ignite
fuels and thei r vapo rs. Aft er gett ing ou t of a veh icle, 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. Be familiar
with Cardiopulmonary Resuscitation (CPR) methods if you
are working 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 tag out and lock out
procedures. If you are not fam iliar wit h this require ment, ref er
to information in the service manual and OSHA
documentation.
Working With Electricity Safely
Be sure to use sa fe an d established pra ct ice s in w ork in g with
electrical devices. Poorly wired devices may cause a fire,
explosion or electrica l sh ock . Be su re grou nding connections
are properly made. Make sure that sealing devices and
compounds are in place. Be sure not to pinch wires when
replacing covers. Follow OSHA Lock-Out and Tag-Out
requirements. Station employees and service contractors
need to underst and and comply wit h th is pro gra m c om pl ete ly
to ensure safety while the equipment is down.
Emergency First Aid
Informing Emergency Personnel
Compile the following information for 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 pressu re, and so on.)
Whether or not a victim has vomited (for example, if
swallowed or inhaled something, and so on.)
WARNING
!
Gasoline ingeste d may c ause unc onsciou sness
and burns to internal organs.
Do not induce vomiting.
Keep airway open.
Oxygen may be needed at scene.
Seek medical advice immediately.
WARNING
!
Gasoline inhaled may cause unconsciou sness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline spilled in ey es may cause bur ns to eye
tissue.
Irrigate eyes with water for approximately 15
minutes.
Seek medical advice immediately
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Be sure to
clean hands after handling equipment. Do not place any
equipment in mouth.
!
WARNING
This area contains a chemical known to the State of
California to cause cancer.
WARNING
!
Gasoline spilled on skin may cause burns.
Wash area thoroughly with clear/water.
Seek medical advice immediately.
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Lockout/Tagout
WARNING
!
This area contains a chemical known to the State of
California to cause birth defects or other reproductive
harm.
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. Referenc e Sub part S of 2 9 CFR Pa rt 1910
IMPORT ANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
- Electrical Hazards, 29 CFR Part 1910.333 contains specific
Lockout/Tagout provision for electrical hazards.
MDE-4351A Gasboy ATC K its 039086 and 039087 Installation Manual • February 2006 Page 7
Installation
Installation
Preparation
1 Request permission from the manager/owner to remove power from the unit and then remove
2 Make sure you have the proper kit for the model dispenser to be retrofitted.
3 Using the proper key for the unit, unlock and remove the doors from both sides of the unit.
4 Using a cross-tip screwdriver, at side 1 of the unit, loosen the two screws (one on each side of
Use electrostatic discharge (ESD) precautions to place yourself at a neutral
static-free potential by touching an unpainted metal surface and by using a wrist
strap connected to a grounded metal frame or chassis.
power using normal procedures. Observe the lockout/tagout safety procedures.
Place doors in a safe place to prevent damage or scratches.
the display cove r), s pring the s crew ho lders and scre ws out from t he dis pl ay cove r and pull the
display cover forward. The cover will pivot down in a horizontal position allowing access to
the electronics section of the unit.
Installing the 039086 ATC Kit in Single Unit
1 In the kit, locate the LP-70 Poly case box wit h SK449C PCB mounted insid e. Remove the four
mounting screws securing the cover and remove the cover from the box. Save screws and
cover for reinstalling later.
2 Peel the protective cover from the mounting sponge (on the back of the polycase box) and
mount the box as shown in Figure 3. Mount approximately 1/2-inch up from shelf (1/2-inch
clearance underneath shelf).
Figure 3: Mounting the LP-70 Polycase Box
Approximately 1/2-inch
Clearance
Page 8 MDE-4351A Gasboy ATC Kits 039086 and 039087 Installation Manual • February 2006
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