Gasboy 215A User Manual

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215A/215ATW/216A/216ATW

SATELLITE DISPENSERS

INSTALLATION/OPERATION

MANUAL

035286

REV. 03/07/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the satellite dispensers. Please leave this manual with the dispenser owner after the installation is complete.

The information in this document is confidential and proprietary. No further disclosure shall be made without permission from Gasboy International LLC. Gasboy International LLC believes that the information in this document is accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.

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GASBOY INTERNATIONAL LLC LANSDALE, PA

IMPORTANT WARNINGS AND SAFEGUARDS

Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or property, follow these listed warnings and other warnings and precautions outlined in this manual when installing, using, or working around this equipment. Check with GASBOY Technical Services for compatibility of liquids with pump materials.

TURN OFF AND LOCK OUT ALL POWER TO PUMP BEFORE PERFORMING SERVICE, MAINTENANCE OR IN THE EVENT

All products must be installed by a qualified installer and used in conformance with all building, fire, and environmental codes and other safety requirements applicable to its installation and use, including, but not limited to, NFPA 30, NFPA 30A, NFPA 395 & NFPA 70. A qualified installer is familiar with fuel systems installations under the above stated building, fire, and environmental codes and other safety requirements for the particular type of installation.

This product is only part of a fuel dispensing system and additional equipment and accessories, such as, but not limited to, breakaway connectors, shear valves, pressure regulators, flow limiters, and other safety devices may be necessary to meet the applicable codes.

For maximum safety, we recommend that all employees be trained as to the location and procedure for turning off power to th e enti re system. Instru ctions regarding proper operation of the equipment along with the appropriate safety warnings should be posted in plain view at the fuel island.

Before performing service or maintenance (including changing of fuel filters or strainers) or in the event of a fuel spill, turn off and lock out all power to the system. In battery-powered pumps, disconnect power source. In submersible pump applications, turn off and lock out power at the master panel and close any impact valves to the submersible pump and any other dispensers which use that submersible pump. AC power can feed back into a shut-off dispenser when dispensers share a common submersible pump or starter relay. Also block islands so no vehicles can pull up to the dispenser when the dispenser is being worked on.

DO NOT use Teflon tape for any pipe threads in the product.

DO NOT use consumer pumps for pumping fuel or additives into aircraft.

DO NOT use commercial pumps for direct fueling of aircraft without filters and separators necessary to ensure product purity.

DO NOT use where sanitary design is required (for food products for human consumption) or with water-based liquids.

DO NOT smoke near the pump or when using the pump.

DO NOT use near open flame or electrical equipment which may ignite fumes.

DO NOT permit the dispensing of gasoline or other petroleum products into a vehicle with its motor running.

DO NOT permit the dispensing of gasoline or other petroleum products into unapproved containers or into approved containers in or on vehicles includin g trucks. All containe rs must be filled on the ground to prevent static discharge. Always use Approved and Listed hoses and nozzles with electric pumps and dispensers.

DO NOT block open the nozzle in any manner. Nozzles shall conform to UL and NFPA code requirements for attended or unattended service.

DO ensure that the pump is equipped with proper filters based on the product being dispensed and its intended use.

DO wear safety goggles and protective clothes when dispensing any liquid which may be potentially harmful or hazardous.

DO keep all parts of body and loose clothing clear of belts, pulleys, and other exposed moving parts at all times.

OF A FUEL SPILL.

DO require washing and changing of

clothes if fuel is spilled on a person or his/her clothing. Keep away from open flames, sparks, or people smoking.

DO provide a receptacle for catching product from pump/meter when servicing.

DO clean up product spills on the driveway. Turn off and lock out all power prior to cleanup.

DO insure pump is properly grounded. DO insure hose is compatible with fluid

being dispensed. DO inspect hose, nozzle, and pump on

a regular basis for wear, damage, or other conditions which may create a safety or environmental hazard.

DO make sure all pipe threads are properly cut and the inside reamed to remove burrs. Use UL classified gasoline-resisting compound on all joints of gasoline handling piping. Sealing compound must also be resistant to Gasohol (Ethanol and Methanol). Use gasoline-resistant pipe compound on male threads only; pipe compound used on female threads can be squeezed into the supply line where it can enter the product stream and become lodged in the pump or meter.

DO ensure that junction box covers are in place and properly tightened. Mating surfaces between the box and cover must be free of dirt, nicks, and scratches. All unused entries into the junction box must be properly plugged.

035282 Rev. 1267

GASBOY INTERNATIONAL LLC

707 North Valley Forge Rd. Lansdale, PA, 19446 ● (215) 855-4631 ● FAX: (215) 855-0341

CONTENTS

IMPORTANT WARNINGS AND SAFEGUARDS

Section 1: INTRODUCTION

Purpose .................................................................................................... 1-1

General Description .................................................................................. 1-1

Section 2: INSTALLATION

Installation Precautions ............................................................................ 2-1

Foundation ............................................................................................... 2-2

Dispenser ................................................................................................. 2-2

Nozzle, Hose, and Accessories................................................................. 2-2

Supply Line ............................................................................................... 2-3

215A/216A Dispensing Unit Dimensions .................................................. 2-4

215A/216A Front Load Dispensing Unit Dimensions ............................... 2-5

215ATW/216ATW Twin Satellite Dispensing Unit Dimensions................. 2-6

011975 Base Layout, 215A/216A ............................................................. 2-7

011919 Base Layout, 215ATW/216ATW .................................................. 2-8

Section 3: WIRING

Wiring Precautions ................................................................................... 3-1

Grounding ................................................................................................ 3-2

Wire Size .................................................................................................. 3-2

Conduit ..................................................................................................... 3-2

Wiring Diagrams ....................................................................................... 3-3

024214 Wiring Diagram, 9100A ............................................................... 3-3

025257 Wiring Diagram, 9800A ............................................................... 3-4

024319 Wiring Diagram, 9800A Front Load.............................................. 3-6

024320 Wiring Diagram, 9100A w/Front Load Satellite ............................ 3-8

Section 4: START-UP

Completion Checklist ................................................................................ 4-1

Start-Up .................................................................................................... 4-1

Section 5: OPERATING SEQUENCE

Section 6: PREVENTIVE MAINTENANCE

General .................................................................................................... 6-1

Hints for Better Pump Performance ......................................................... 6-1

Demand Competent Service ............................................................... 6-1

Use Authorized Parts .......................................................................... 6-1

Operate With Reasonable Care .......................................................... 6-2

Preventive Maintenance Check List ......................................................... 6-2

Keep Water Out .................................................................................. 6-2

Preserve the Finish of Your Pumps .................................................... 6-2

03/07/03 Contents-1

Section 1

INTRODUCTION

PURPOSE

The GASBOY 215A/215ATW/216A/216ATW Satellite Dispensing Units Installation/Operation Manual is provided to assist the installer in installing and operating the units. This manual should

be supplied to the electrician prior to the installation of conduit and wiring to ensure the satellite dispensing unit is installed properly. Faulty installations are the major cause of unit malfunctions. The unit must be installed and operated as described in this manual to ensure the reliability and proper operation of the satellite dispensing unit. In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the satellite units. Be sure to leave this manual with the owner after the installation is complete.

☎ Customers and installers having any questions pertaining to the installation should

contact their GASBOY distributor.

GENERAL DESCRIPTION

The GASBOY satellite dispensing units are used in conjunction with GASBOY Listed Series 9100A and Series 9800A dispensers. This unit provides additional control of a remote dispensing line.

Features and specifications of the 215A/215ATW/216A/216ATW are:

• Hose hangers.

• Discharge elbows.

• A 12-foot Listed gasoline hose assembly.

• A working voltage of 115 VAC, 60 Hz. for domestic units or 230VAC, 50 Hz. or 60 Hz. for

international use.

• Unions are provided at the inlet of all suction pumps and dispensers.

• The standard cabinet finish is top, sides, painted black while the front and back panels are

painted white.

• The height of the cabinets is 45-1/2" (1156mm). The other dimensions may be found in

Section 2 of this manual and on the single sheet base layout for each model.

• Available options and accessories for the satellite dispensing units include Listed automatic

nozzles, high/low slowdown valves, special lengths of Listed hose, Listed dual swivels, front and back panels painted to the color specified by the customer, stainless steel panels and Listed emergency shutoff valves.

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Section 2

INSTALLATION

INSTALLATION PRECAUTIONS

All installations must conform with all building/fire codes, all Federal, State, and Local codes, National Electrical Code, (NFPA 70), NFPA 30, and Automotive and Marine Service Station Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code.

Plan your installation carefully. A dispensing unit cannot be expected to work satisfactorily unless the underground installation is correct. Dispensing troubles are frequently traced to faulty installation. Review the following list of installation DO's and DON'T's to avoid potential problems:

1. DO read the WARNINGS page at the front of this manual, preceding the Table of Contents. It contains important information regarding the safe use of your dispensing equipment.

2. DO install an emergency power cutoff. In addition to circuit breaker requirements of NFPA 70 and NFPA 30A, a single control which simultaneously removes AC power from all site dispensing equipment is recommended. This control must be readily accessible, clearly labeled, and in accordance with all local codes.

In a fuel management system application, the EMERGENCY STOP and STOP keys on the

console and/or the optional EMERGENCY STOP button on the Island Card Reader do not remove AC power from equipment and under certain conditions, will not stop product flow.

In order to provide the highest level of safety to you, your employees, and customers, we

recommend that all employees be trained as to the location and procedure for turning off power to the entire system.

3. DO have the satellite dispensing unit installed by a competent installer/electrician.

4. DO install breakaway coupling on discharge hose. If using a high hose retriever, install breakaway approximately 12" downstream of hose clamp on nozzle side of clamp.

5. DO NOT attempt to wire a pump/remote dispenser without first reviewing the appropriate wiring diagram and notes. This manual contains instructions for wiring mechanical and electronics units. Using the mechanical wiring digram for an electronic pump will cause CPU PCB damage to the electronic pump.

6. DO NOT experiment with a pump if you are not sure the installation is correct.

7. DO NOT overload sub- or main breaker panels.

8. DO NOT install any underground piping without proper swing joints. (Always use shoulder nipples, never close nipples).

9. DO NOT cover any lines until they have been both air- and liquid-tested.

10. DO NOT back-fill the tank or supply line with cinders or ashes. (Back-fill with clean sand, crushed rock, or pea gravel).

11. DO NOT use black iron pipe or fittings for underground installations. (Use only new galvanized or fiberglass* pipe and fittings). *Install all fiberglass pipe and fittings according to manufacturer's specifications and requirements.

03/07/03 2-1

GASBOY 215A/215ATW/216A/216ATW Satellite Dispensing Units

12. DO NOT use power line wiring of inadequate capacity. (Use gauge specified by the wiring diagram or wire chart provided in Section 4).

13. DO NOT use a circuit breaker of improper size. (See Section 4).

14. DO NOT install fill pipe to tank where it can be submerged with standing water.

15. DO NOT use the GASBOY fuel dispensing equipment to remove water ballast from the storage tank.

16. DO NOT use gaskets on covers of explosion-proof type boxes. The sealing compound found around wires at various locations within conduit is a requirement of the National Electrical Code and should not be disturbed. Ensure that the mating surfaces between the junction box and cover are free of dirt, debris, nicks and scratches. Tighten junction box covers before replacing panels.

17. DO NOT use knock-out boxes or flexible conduit for installing this unit. All power and lighting wires should be run in threaded, rigid, metal conduit. All threaded connections must be drawn up tight with five (5) threads minimum engagement. Only one opening in the AC junction box is provided with a plug at the factory. At completion of the installation, it is the installer's responsibility to ensure that any unused openings are plugged.

FOUNDATION

When constructing the island for the dispensing equipment, be sure to extend the island excavation beyond the depth of the frost line. Leave open an area from the inside edge of the unit's base as shown on the specific base layout. Unless required by local regulations, do not cement the pipes and conduits into the island. The open area within the base will provide access for future servicing of the fittings and conduit assemblies. Fill in the boxed-in section with dry sand to keep condensation in the satellite housing to a minimum.

Secure the dispensing unit to the island using anchor bolts through the two mounting holes, which are 12-3/16 inches (310mm) apart and are indicated on each base layout by an X. If the dispensing unit is not securely fastened to the island, supply line leaks at unions and pipe joints may occur. Use one of two types of bolts to anchor the satellite to the island. Use two (2) 1/2" x 5" (13mm x 125mm) machine bolts imbedded in the concrete, or, to meet minimum UL and API requirements for universal interchangeability of pumps, use two 1/2" x 3 1/2" (13mm x 90mm) lag screws with 2" (51mm) expansion shields.

DISPENSER

Refer to the installation/operation manuals supplied with the dispenser for the proper installation and operation of this unit.

• Series 9100A Installation/Operation Manual, 035257

• Series 9800A Installation/Operation Manual, 035296

NOZZLE, HOSE, AND ACCESSORIES

This unit is normally equipped for use with a UL-Listed interchangeable service station type nozzle. Units equipped with suffix N are equipped for use with a UL-Listed Richards Mark XIIL nozzle. Only UL-Listed hose assemblies and accessories are to be used with this device. A Listed breakaway connector must be installed on all hose assemblies. On front-load twin satellites, each start lever corresponds with the hose outlet to its right.

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Installation

SUPPLY LINE

The supply line for satellite dispensing units is connected to the satellite outlet of the dispenser. Use new galvanized or fiberglass (see note) pipe, 1 1/2" (38.1mm) minimum diameter.

NOTE: Fiberglass pipe is to be installed according to manufacturer’s specifications and

Be sure both the pipe and the tank are clean. Foreign matter entering the satellite can cause extensive damage. Obstructions in the supply line can create pump problems and reduced flow rate.

Make sure all pipe threads are properly cut and the inside reamed to remove burrs. Use Listed gasoline-resistant compound on all joints of gasoline handling piping. Sealing compound must also be resistant to Gasohol (Ethanol and Methanol). Do not use Teflon Pipe Sealing Tape. Use gasoline-resistant pipe compound on male threads only; pipe compound used on female threads can be squeezed into the supply line where it can enter the product stream and become lodged in the pump or meter. Install swing joints under the pump and at the satellite to avoid breaks in the supply line from settling or frost heave.

Upon completion of installation, all liquid-carrying lines must be checked for leaks.

requirements.

1052 2-3

GASBOY 215A/215ATW/216A/216ATW Satellite Dispensing Units

215A/216A SATELLITE DISPENSING UNIT DIMENSIONS

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