Gasboy 552A User Manual

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SERIES 552A/553A

COMMERCIAL PUMPS

INSTALLATION/OPERATION/PARTS

MANUAL

035299

REV. 03/07/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care o f the Series 550A pumps. Please leave this manual with the pump 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.

GASBOY INTERNATIONAL LLC LANSDALE, PA

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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 contain ers 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

Overview ................................................................................................... 1-1

Section 2: INSTALLATION

Before You Begin...................................................................................... 2-1

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

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

Suction Pump............................................................................................ 2-2

Installation Layout ..................................................................................... 2-3

Supply Line................................................................................................ 2-4

Connecting the Suction Pipe................................................................ 2-4

Base Layout - 011982............................................................................... 2-5

Section 3: WIRING

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

Grounding ................................................................................................. 3-1

Circuit Breakers......................................................................................... 3-2

Pump Motor............................................................................................... 3-2

Wiring and Conduit.................................................................................... 3-2

Pump Wiring......................................................................................... 3-2

Pulser Wiring........................................................................................ 3-3

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

Wiring Notes.............................................................................................. 3-4

Wiring Diagram - 024206 .......................................................................... 3-5

Section 4: TESTING AND OPERATION

Testing the Installation .............................................................................. 4-1

Operating Instructions............................................................................... 4-1

Section 5: MAINTENANCE AND TROUBLESHOOTING

General ..................................................................................................... 5-1

Exterior Maintenance ................................................................................ 5-1

Lubricating the Pump’s Components ........................................................ 5-2

Cleaning the Strainer................................................................................. 5-3

Calibrating the Meter................................................................................. 5-3

Correcting Meter Drive Shaft Leak............................................................ 5-3

Adjusting the Belts..................................................................................... 5-4

Troubleshooting......................................................................................... 5-5

Preparing Used Pumps for Storage .......................................................... 5-6

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GASBOY 552A/553A Commercial Pumps

Section 6: PARTS LIST

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

Panels and Trim Diagram.......................................................................... 6-2

Panels and Trim Parts............................................................................... 6-3

Chassis Assembly – Front and Rear View Diagram ................................. 6-4

Chassis Assembly – Front and Rear View Parts....................................... 6-5

Adapter Assembly..................................................................................... 6-6

Dial Enclosure Assembly........................................................................... 6-7

Meter Assembly Diagram.......................................................................... 6-8

Meter Assembly Parts............................................................................... 6-9

Meter Assembly Breakdown Diagram....................................................... 6-10

Meter Assembly Breakdown Parts............................................................ 6-11

Motor Assembly Diagram.......................................................................... 6-12

Motor Assembly Parts............................................................................... 6-13

Pumping Unit Assembly Diagram.............................................................. 6-14

Pumping Unit Assembly Parts................................................................... 6-15

Pumping Unit Assembly Breakdown Diagram........................................... 6-16

Pumping Unit Assembly Breakdown Parts................................................ 6-17

Hand Crank Assembly Diagram................................................................ 6-22

Hand Crank Assembly Parts..................................................................... 6-23

Pulser Assembly Diagram......................................................................... 6-24

Pulser Assembly Parts.............................................................................. 6-25

Accessories and Field Kits........................................................................ 6-26

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Section 1

INTRODUCTION

PURPOSE

The GASBOY 552A/553A Commer cial Pumps Installation/Operation/Parts Manual is provided to assist the installer in installing and operating the unit. This manual should be supplied to the electrician prior to the installation of conduit and wiring to ensure the unit is installed properly. Faulty installations are the major cause of unit malfunctions. This unit must be installed and operated as described in the manual to ensure the reliability and proper operation of the 550A Series pumps. Be sure to leave this manual with the pump owner when the installation is complete. Customers and installers having any questions pertaining to this installation should contact their GASBOY distributor.

OVERVIEW

The GASBOY 552A/553A pumps are UL-listed, heavy-duty, suction pumps designed for the needs of local and state governments, industrial, commercial, and private fleet operations. 550A Series pumps have the following features:

• Dimensions: Base 13-31/32" (35cm) x 18-1/16" (46cm), height 40-1/8" (102cm)

• Construction: Top and side carbon steel panels; front and back hot-dipped galvanized steel,

for rust resistance.

• Cabinet: painted black with white door or color of your choice

• Motor:

1/2 HP intermittent duty, dual voltage/dual frequency, 115/230VAC, 50/60 Hz (552A); 3/4 HP continuous duty, dual voltage/dual frequency, 115/230 VAC, 50/60 Hz (553AMC); 3/4 HP continuous duty, 380 VAC, 50 Hz (553AMC)

• Pump: Rotary gear pump with air eliminator built into pump casting, positive displacement, no

priming necessary.

• Register: 4-wheel volume only, indicating up to 999.9 gallons/liters

• Totalizer: 999,999.9 gallons/liters

• Reset: manual or manual with interlock for use in retail sales

• Meter: positive displacement, Model 898-K

• Display: single-sided

• Dial Face: white with black text

• Hose: 552A - 3/4" (2cm) x 12 feet (3.6m); 553A - 1" (2.5cm) x 12 feet (3.6m)

• Suction connection: 1-1/2" NPT, unions provided

• Delivery Rate: up to 15 GPM/57 LPM (552A); up to 22 GPM/83 LPM (553A). Delivery rates

are maximum test rates. Actual rates will vary depending upon installation conditions, product dispensed, and added accessories.

• Nozzle: Must be purchased separately. Automatic nozzles available.

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GASBOY 552A/553A Commercial Pumps

Optional accessories include: additional hose lengths, external filter kits, vertical check valve, high speed hand attachment, Model 52 pressure regulating valve, pulsers, reset interlock, 380VAC/50 Hz. operation, imperial gallon or liter registration.

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Section 2

INSTALLATION

BEFORE YOU BEGIN

Before uncrating the pump, inspect the crate for damage. A damaged crate indicates possible internal damage to the dispenser, and the delivering carrier should be notified of possible concealed damage. It is recommended the original shipping crate be retained for pump reshipment at some later date.

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.

Plan your installation carefully. A pump cannot be expected to work satisfactorily unless the underground installation is correct. Dispensing troubles, which seem to be pump-related, 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 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 pump/dispenser 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 experiment with a pump if you are not sure the installation is correct.

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

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

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

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

10. 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.

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GASBOY 552A/553A Commercial Pumps

11. DO NOT use power line wiring of inadequate capacity. (Use gauge specified by the wiring diagram or wire chart provided in Section 3).

12. DO NOT use a circuit breaker of improper size. (See Section 3).

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

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

15. 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

free of dirt, nicks, and scratches.

16. DO NOT use knock-out boxes or flexible conduit for installing this unit. All 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.

Tighten junction box covers before replacing panels.

mating surfaces between the box and cover are

FOUNDATION

When constructing the pump 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 pump housing to a minimum and to help prevent fogging of the totalizer window.

Secure the pump/dispenser to the island using anchor bolts through the two mounting holes, which 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 pump to the island. Use two (2) 1/2" x 5" (13mm x 125mm) long 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) long lag screws with 2" (51mm) long expansion shields.

The drawing on the following page, Installation Layout, illustrates a recommended installation of the Model 552A & 553A power pump. In selecting a location for the pump and tank, bear in mind that a suction pump will draw liquid horizontally up to 100 feet, but on a vertical lift it is not advisable to exceed 12 feet (3.6m) for gasoline, or 13 feet (4m) for diesel.

SUCTION PUMP

The pump and the tank should be located close to each other with as few changes in direction of the supply line, as possible. This reduces the possibility of vaporization (gasoline only), attains the highest possible flow rate, and results in a lower installation cost. Avoid long supply lines and excessive vertical lifts. The dynamic lift for this unit is rated at 12 feet (3.6m) for gasoline and 13 feet (4m) for diesel and can vary according to conditions of the installation and fuel temperature.

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Installation

INSTALLATION LAYOUT

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GASBOY 552A/553A Commercial Pumps

SUPPLY LINE

Always start at the pump and work toward the tank. Use new galvanized or fiberglass (see note) pipe, 1-1/2" minimum diameter. (NOTE: Fiberglass pipe is to be installed according to manufacturer’s specifications and requirements.)

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

Make sure all pipe threads ar e proper ly cut and the inside r eamed to remove bur r s. Use UL-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 tank to avoid breaks in the supply line from settling or frost heave.

To avoid product delivery problems on suction pumps, be sure there are no traps in the supply line. Supply lines, for both suction pumps and submersible pumps, should go straight down beneath the pump to a point 18 inches (46cm) below the ground level and pitch at a rate of 1/8 inch per foot (1cm/m) from there down to the storage tank. The supply line should be as short and direct as possible with swing joints (two 90 the horizontal run of pipe at 10-foot (305cm) intervals to maintain pitch and prevent traps. Do not use wood as pipe supports.

New EPA regulations require that only one check valve be used per supply line and located directly below, and as close as practical to the suction pump. Do not use spring-loaded or union check valves since these will unnecessarily reduce the flow rate and contribute to the reduction of atmospheric pressure necessary to keep gasoline in a liquid state.

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

Connecting the Suction Pipe

To connect the suction pipe, remove the tin protector from the flange opening in storage tank. Assemble suction pipe, double tapped bushing and foot valve with suction screen. Insert into tank, and tighten in position. Starting at suction nipple at base of pump, take pipe measurements to union elbow on suction pipe riser at top of tank. Cut pipe, assembly together loosely. If measurements are correct, uncouple all pipe joints and coat them up with a good grade of gasoline-resistant sealing compound. If pipe measurements are incorrect, a new pipe must be cut.

NOTE: Underneath pump, a high grade valve with pressure relief must be used in suction

line.

elbows and one shoulder nipple) at all turns. Support

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Installation

BASE LAYOUT - 011982

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Section 3

WIRING

Customers & installers having any questions pertaining to the installation should contact their GASBOY distributor.

WIRING PRECAUTIONS

The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble-free operation of your pump. To assure a quality installation, follow these rules:

1. All wiring must be installed to 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.

2. Use only threaded, rigid, metal conduit.

3. Use only UL-approved insulated gasoline- and oil-resistant stranded copper wiring of the proper size.

4. Wire connections should be tightly spliced and secured with a wire nut; close off the open end of the wire nut with electrical tape.

5. The line to the motor should be on a separate circuit and installed on a 20 to 30 AMP breaker depending on the motor size and/or the voltage setting.

6. 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 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.

WARNING:

To reduce the risk of electrical shock when servicing, turn off and lock out all power to the pump.

7. Have the pump installed by a competent installer/electrician.

GROUNDING

To ensure proper operation of the equipment and provide the necessary safety factors, this unit must be grounded. A ground wire (preferably green) must be connected between the unit’s AC junction box ground lug and the main electrical service panel. One (1) ear th ground connection is required per unit. The ground rod is to be a solid, corrosion-resistant conductor and must be installed at the main electrical panel in accordance with the National Electrical Code. It should be properly tied into the ground bus strip of the panel. We recommend the neutral and ground bus strips be bonded together (unless prohibited by local codes).

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GASBOY 552A/553A Commercial Pumps

CIRCUIT BREAKERS

Power to the unit must be supplied from a dedicated 20 to 30 amp breaker. No other equipment should be powered from this breaker. A tag on the motor identifies the maximum curr ent draw of the motor. If two units are supplied from one breaker, that breaker must be capable of handling the load of both motors.

PUMP MOTOR

Pumps are shipped from the factory with motors wired according to the specifications given on the order as to kind of current, frequency and voltage.

Very often on installation, it becomes necessary to change the original setting to suit the AC power source. To do this, locate the motor change-over plate (typically located on the shaft end of the motor) and remove the screw which secures it in place. Slide the plate so that the desired voltage, as marked on the plate, lines up with the screw hole. Reinsert the screw and secur e the plate in place. 380 VAC pumps are permanently set and cannot be changed.

Many motor failures result from improper setting of the motor change-over plate. If set for 120 VAC and a 240 VAC feed is used, the motor will burn out after running only a short time. If set for 240 VAC and a 120 VAC feed is used, the motor will run very slowly and the starting field will soon burn out.

WIRING AND CONDUIT

Pump Wiring

The table below shows the required AC wire size based on the HP rating of the pump motor and the distance from the circuit breaker to the pump for both 115 and 230 volt units. Use this table as a guide for selecting the proper size wire for your installation. Consult local wiring requirements for wiring of 380 VAC motors.

If multiple units are powered from the same breaker through the same wires, you must increase the gauge of the wires to handle the added load according to the distance from the breaker panel and the HP rating (if applicable).

Wire Size

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Wiring

Pulser Wiring

Pulser wiring must be 18AWG. If it is run in the same conduit as the AC wiring, it must also conform to the following wiring requirements:

• Wire must be 2-wire twisted-pair Belden 88760 (C08850) or 4-wire Belden 89418 or

equivalent (C08864).

Both types of cable provide superior noise immunity and are rated as follows:

Belden 88760 Gas and oil resistant insulation & jacket

18 AWG tinned, stranded, copper One twisted pair (two conductors) 300 volt maximum operating voltage Aluminum/Mylar shielded w/drain wire

NOTE: If using 88760 cable with a 3-wire pulser, you must run two lengths of cable to

attain two twisted pairs (four conductors). Cap off the unused wire.

Belden 89418: Gas and oil resistant insulation & jacket

18 AWG tinned, stranded, copper Stranded, four conductors 300 volt maximum operating voltage Aluminum/Mylar shielded w/drain wire

• Cable connections to pulser must be made in DC junction box. Pulser cables will pass

through AC junction box.

• Cable drain wire must be connected to the grounding screw in the DC junction box in the

pump/dispenser. The drain wire is not connected at the fuel management system end.

• Rigid metal conduit must be used to connect the AC and DC junction boxes.

Conduit

All wiring to the Gasboy 550A Series dispensing unit must be installed in threaded, rigid, metal conduit. PVC is not acceptable. It is recommended that DC pulser wiring be run in separate conduit from any AC wiring; however, it is acceptable to run DC pulser wiring in the same conduit as AC wiring as long as the requirements outlined in Pulser Wiring are met.

All wiring and conduit runs must also conform with the National Electrical Code (NFPA 70) and the Automotive and Marine Service Station Code (NFPA 30A). All wiring and conduit runs must conform to local codes. Canadian users must also comply with the Canadian Electrical Code.

The table that follows shows conduit capacity for rigid, metal conduit with a 50% fill of gas- and oil-resistant wire. Use this chart as a guideline to determine the proper conduit sizes for the Gasboy 550A Series dispensing units. When planning the orientation of the wiring runs, follow the applicable wiring diagram and consider the layout of the components at the site. Long runs or a large number of bends may require you to increase conduit size over what is listed.

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GASBOY 552A/553A Commercial Pumps

Conduit Size

To connect the rigid conduit for the motor, start at the electrical connection box in pedestal of pump, and take necessary measurements for pipe between motor and switchboard in building. The conduit must be connected to make it water-and vapor-tight. Do not use flexible conduit.

When pulling wires through conduits, be careful not to damage insulation or break wires. To connect wires, ends of wires must have insulation removed. Splice them tightly together, apply solder, and follow with an application of electrical tape equal in thickness to insulation of wire leads.

WIRING NOTES

1. All wiring and conduit runs 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.

2. The brown wire (Switch Detect) is shipped capped from the factory. When used, it connects to a solenoid valve or fuel management system. Do not connect this wire without first checking the ON voltage of this line to ascertain compatibility with the equipment being connected.

3. All wiring must be installed according to the requirements outlined in this section.

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