Page 1
Model 52 Pressure Regulator Valve
Installation/Parts Manual
MDE-4645A
(formerly 035340)
Page 2
Computer Programs and Documentation
Federal Communications Commission (FCC) Warning
All Gasboy computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy. 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 Gasboy.
This equipment has been tested and found to comply with the limits for a Class A 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 case the user will be re quired to correct the inte rference at his own exp ense. Changes or modifications not expressly approved by
the manufacturer could void the user’s authority to operate this equipment.
Approvals
Gasboy, Greensboro, is an ISO 9001:2000 registered facility.
Underwriters Laboratories (UL):
UL File# Products listed with UL
MH4314
MH6418
MH7404
MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s
All dispensers and self-contained pumping
units
Power operated Transfer Pump Models 25,
25C, 26, 27, 28, 72, 72S, 72SP , 72X, 73 and
1820
Hand operated Transfer Pump Models 1230
Series, 1243 Series, 1520 and 1720 Series
Card reader terminals, Models 1000, 1000P
Site controller, Model 2000S CFN Series
Data entry terminals, Model TPK-900 Series
Fuel Point Reader System
New York City Fire Department (NYFD):
NYFD C of A # Product
4823 9100A, 9140A, 9152A, 9153A,
4997 9822A, 9823A
5046 9100Q, 9140Q, 9152Q, 9153Q,
5087 8753K, 8853K, 9153K, 9853K
9800A, 9840A, 9850A, 9852A,
9853A, 9140
9800Q, 9840Q, 9852Q, 9853Q
(restricted to diesel and nonretail gasoline sales)
National Conference of Weights and Measures (NCWM) - Certificate of Compliance (CoC):
Gasboy 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 # CoC# Product Model #
95-179A2 Dispenser
95-136A5 Dispenser 9800 Series 91-057A3 Controller
9100 Retail Series, 8700
Series, 9700 Series
91-019A2 Dispenser
9100 Commercial
Series
1000 Series FMS,
2000S-CFN Series
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac
Patents
Gasboy products are manufactured or sold under one or more of the following US patents:
Dispensers
5,257,720
Point of Sale/Back Office Equipment
D335,673
Trademarks
Non-registered trademarks
Atlas™
Consola™
Infinity™
Registered trademarks
ASTRA
Fuel Point
Gasboy
Keytrol
Slimline
Additional US and foreign patents pending.
®
®
®
®
®
Additional US and foreign trademarks pending.
Other brand or product names shown may be
trademarks or registered trademarks of their
respective holders.
This document is subject to change without notice.
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com
© 2009 GASBOY. All Rights Reserved
Page 3
Table of Contents
1 – Introduction 1
Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2 – Important Safety Information 3
3 – Installation 7
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Valve Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4 – Parts 11
Model 52 Pressure Regulator Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page i
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Page ii MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009
Page 5
Purpose Introduction
1 – Introduction
Purpose
The Model 52 Pressure Regulator Valve Installation/Parts Manual is provided to assist the
installer in installing and operating the unit and should be provided to the installer prior to the
installation of conduit. Faulty installations are the major cause for unit malfunctions. The
Model 52 Pressure Regulator Valve must be installed and operated as described in this manual.
Ensure that you leave this manual with the owner after the installation is complete.
Note: Customers and installers who have queries pertaining to the installation should contact
their Gasboy
The Model 52 Pressure Regulator Valve is a unique control valve developed for use with
suction-type island dispensers. The Model 52 Pressure Regulator can be used for
Aboveground Storage Tank (AST) installations or in booster systems with a submersible pump
in an Underground Storage Tank (UST).
The standard Model 52 Pressure Regulator Valve can be used in temperatures between -13 °F
to 130 °F (-25 °C to 54 °C). The Model 52 is not for use with methanol/ethanol applications.
®
distributor.
Abbreviations and Acronyms
Term Description
AST Aboveground Storage Tank
NEC National Electrical Code
NFPA National Fire Protection Association
PSI Pounds per Square Inch
UST Underground Storage Tank
Warranty
For information on warranty, refer to MDE-4255 Gasboy’ s Warranty Policy Statement. If you
have any warranty-related questions, contact Gasboy’s Warranty Department at its Greensboro
location.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 1
Page 6
Introduction Warranty
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Page 2 MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009
Page 7
2 – Important Safety Information
Important Safety Information
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).
!
WARNING
!
The EMERGENCY STOP, ALL STOP, and
PUMP STOP buttons at the cashier’s station
WILL NOT shut off electrical po wer to th e pump/
dispenser. This means that even if you activate
these stops, fuel may continue to flow
uncontrolled.
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 Gasboy Authorized
Service Contractor or call the Gasboy Service Center at 1800-444-5529. 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 Hazard Association
(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 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 local regulations.
Safety Symbols and Warning Words
This section provides important information about warning
symbols and boxes.
Alert Symbol
You must use the TOTAL ELECTRICAL SHUTOFF in the case of an emergency and not the
console’s ALL STOP and PUMP STOP or
similar keys.
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 Gasboy 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)
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 inju ry.
CAUTION without Alert 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.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 3
Page 8
Important Safety Information
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 suffi c ien t to ig nite 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.
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)
WARNING
!
Gasoline 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
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline spilled in eyes may cause burns to eye
tissue.
Irrigate eyes with water for approximately 15
minutes.
Seek medical advice immediately.
Hazardous Materials
WARNING
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
The pump/dispenser contains a chemical known to the
State of California to cause cancer.
!
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
!
Lockout/Tagout covers servicing and maintenance of
machines and equipment in which the unexpected
The pump/dispenser contains a chemical known to the
State of California to cause birth defects or ot her
reproductive harm.
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.
Page 4 MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009
Page 9
Hazards and Actions
Important Safety Information
!
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.
The following actions are recommended regarding these hazards:
Collision of a Vehicle with Unit Fire at Island Fuel Spill
• Do not go near a fuel spill or allow anyone else in the area.
• Use station EMERGENCY CUTOFF immediately. T urn of f all system circuit br eakers 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.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 5
Page 10
Important Safety Information
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Page 6 MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009
Page 11
Installation Precautions Installation
3 – Installation
Installation Precautions
All tanks and installations must conform with all building/fire codes, all Federal, State, and
Local codes, National Electrical Code (NFPA 70), NFPA 30, Automotive and Marine Service
Station Code (NFPA 30A), and NFPA 395 codes and regulations.
Plan your installation carefully. Dispensing troubles, which seem to be pump-related, are
frequently traced to faulty installation. Review the following list of installation DOs and
DO NOTs to avoid potential problems:
• DO read the “Important Safety Information” on page 3. It contains important information
regarding the safe use of fuel dispensing equipment.
• DO have the valve installed by a qualified installer.
• DO remove the shipping plug from the vent opening for proper operation of valve.
• DO NOT experiment with fuel dispensing equipment if you are not sure whether the
installation is correct.
• DO NOT install any underground piping without proper swing joints. Always use
shoulder nipples, never close nipples.
• DO NOT cover any lines until they have been both air and liquid-tested.
• DO NOT back-fill the tank or supply line with cinders or ashes. Back-fill with clean sand,
crushed rock, or pea gravel.
• 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.
• DO NOT install the fill pipe to a tank where it can be submerged with standing water.
• DO NOT use the Gasboy fuel dispensing equipment to remove water ballast from the
storage tank.
• DO NOT use gaskets on covers of explosion-proof type boxes. The sealing compound
found at various locations within conduit is a requirement of the National Electrical Code
and should not be disturbed. Tighten the Junction Box covers before replacing panels.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 7
Page 12
Installation Valve Requirements
Valve Requirements
The requirements of the Model 52 Pressure Regulator Valve are as follows:
• It must conform with all building/fire codes, all Federal, State, and Local codes, National
Electrical Code (NFPA 70), NFPA 30, Automotive and Marine Service Station Code
(NFPA 30A), and NFPA 395 codes and regulations.
• It is designed to operate in fueling systems that have a maximum pressure of 50 psi.
• Installation must include thermal expansion relief valves. Thermal expansion can cause
pressures in the system greater than 50 psi and can result in failure of the valve and loss of
product to the environment.
• Installation must include a solenoid valve positioned adjacent to the shutoff valve at the
tank. Its purpose is to prevent loss due to failure of the downstream piping or the system.
CAUTION
When a 52 valve is installed at the pump, never install a vacuum anti-siphon valve
at the top of a tank. An electric solenoid valve is required.
• Installation must locate the shear groove at the same level as the top of the concrete island
+1/2-inch (13 mm).
• Installation must include shutoff or gate valve to close the system and prevent product loss
when the equipment utilized in the fueling system downstream from the AST is being
serviced or replaced.
Refer to Figure 3-1 on page 9, Figure 3-2 on page 9, Figure 3-3 on page 10, and Figure 3-4 on
page 10 for additional requirements.
Troubleshooting
Refer to the parts drawing Figure 4-1 on page 12 for item references.
Problem Possible Cause
Product leaking out valve vent and/or pumping unit
vent.
No delivery when pump is turned on. • Failed Diaphragm (11).
• Diaphragm (11) has failed and an obstruction in the valve is
holding open the poppet complete (12).
• Gasket (7) and Diaphragm (11) have failed.
• Pressure Relief Valve assembly (4) and Diaphragm (11)
have failed.
• Valve vent blocked or shipping plug never removed.
Page 8 MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009
Page 13
Troubleshooting Installation
Figure 3-1: Flow Chart Model 52 Pressure Regulator
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MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 9
Page 14
Installation Troubleshooting
Figure 3-3: Booster System with Model 52 Pressure Regulators
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Page 10 MDE-4645A Model 52 Pressure Reg ulator Valve Installation/Parts Manual · Ap ril 2009
Page 15
4 – Parts
Parts
Using part numbers when you place an order will expedite your order and reduce the
possibility of the wrong parts being shipped. When ordering replacement parts, ensure that
you give the complete name and part number as shown in the appropriate parts lists.
Procedures that require the disassembly of portions of the fueling installation should be
performed by qualified service personnel. Do not depend upon the repair service of a general
mechanic unless he is thoroughly familiar with the mechanism. Gasboy has a distributor
network which services fuel dispensing equipment and management systems in every section
of the country.
WARNING
To reduce the risk of electrical shock when servicing, turn off and lock out all power to the
fuel dispensing system.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 11
Page 16
Parts
Figure 4-1: Model 52 Pressure Regulator Valve
Page 12 MDE-4645A Model 52 Pressure Reg ulator Valve Installation/Parts Manual · Ap ril 2009
Page 17
Model 52 Pressure Regulator Valve Parts List Parts
Model 52 Pressure Regulator Valve Parts List
Note: For the complete Model 52 Valve Assembly, order Gasboy Part Number 048577PG8.
Item Part Number Description
1 026768 Square Ring
2 014273 Square Ring
3 014274 Valve Cover
4 014319 Pressure Relief Valve Assembly
5 063312 Suction Screen Complete, Gas
063313 Suction Screen Complete, Diesel
6 014262 Pilot Valve Spring
7 014318 Gasket
8 014277 Valve Spring
9 063203 Suction Strainer Cap
10 014267 Safety Shear Section
11 014317 Diaphragm (for Model 52)
12 014276 Poppet Complete
13 014280 Poppet Assembly
14 014263 Valve Actuator
15 014320 Valve Body Assembly, Model 52
Note: When replacing this assembly on a Model 52, the Model 52
Diaphragm is also required.
16 014282 Diaphragm Cover
17 003433 Screen Adapter Coupling
18 K43625 1/4-20 X 3/4" Long Hex Head Cap Screw
19 K01914-75 7/16-14 X 1-1/4" Long Hex Head Cap Screw
20 K08674
21 K02278 1/8” Plug Pipe
22 K78953-30 1/4” Plug, Protective Closure
°
90
Street Elbow
Note: Gasboy has redesigned the Model 52 Pressur e Regulator Valve eliminating the need for
a “cold weather” version of the valve. A new Diaphragm and standardized diesel
strainer are now included with the standard valve making it appropriate for warm and
cold weather conditions.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009 Page 13
Page 18
Parts Model 52 Pressure Regulator Valve Parts List
© 2009 GASBOY
7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A.
MDE-4645A Model 52 Pressure Regulator Valve Installation/Parts Manual · April 2009
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