Gasboy 580 User Manual
Series 580
Installation/Operation/Parts
Manual
MDE-4766
(formerly C35393)
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 required to correct the interference at his own expense. 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
5091 8752K, 9152K
5129 9122K, 9123K, 9822K, 9823K
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 #
95-179 Dispenser
95-136 Dispenser 9800 Series 91-057 Controller
9100 Retail Series, 8700
Series, 9700 Series
91-019 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
05-002 Atlas
8700K, 8800K,
9100K, 9200K, 9800K
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.
Table of Contents
1 – Introduction 1
Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 – Important Safety Information 3
3 – Installation 7
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Suction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Typical Installation Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Base Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 – Wiring 13
Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pump Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pulsers and Pulser Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5 – Startup and Operation 19
Pre-startup Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Startup and Pump Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Post Startup Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Strainer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Reconfiguration of Pump Pulley for Hand Crank Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6 – Maintenance and Troubleshooting 23
When Your Pump Needs Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Maintaining Trouble-free Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Pump Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Pump Hums but Does Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page i
Pump Runs but Does Not Prime or Deliver Product . . . . . . . . . . . . . . . . 26
Pump Delivers Product but Does Not Register. . . . . . . . . . . . . . . . . . . . 26
Pump Delivery is Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump Loses Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inaccurate Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pump Delivers Product When not Turned On. . . . . . . . . . . . . . . . . . . . . 27
Meter Register Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4860 4 - Wheel Register Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 – Parts List 29
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
582/583 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
582/583 Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
582/583 Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
582/583 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
582/583 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pumping Unit Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Model M04920B003 - Pumping Unit Parts List . . . . . . . . . . . . . . . . . . . . 38
582/583 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
023070 Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
023079 Pipe W/Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
582/583 Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hand Crank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Accessories and Field Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
External Low Flow Filter Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
External High Flow Filter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replacement Elements (For both 582 and 583 Models). . . . . . . . . . . . . 43
Pulser Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pumping Unit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Index Index-1
Page ii MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009
Purpose Introduction
1 – Introduction
Purpose
The Gasboy® Series 580 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 that 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 reliable operation. Ensure that you leave this manual with
the pump owner when the installation is complete, as the manual contains unit operating
instructions.
Note: Customers and installers who have questions pertaining to installation should contact
their Gasboy distributor.
Intended Users
This manual in intended for those responsible for the installation of the 580 unit, such as
installers and electricians.
Overview
The Gasboy 580 Series dispensers are heavy-duty suction pumps designed for the needs of
local and state governments, industrial, commercial, and private fleet operations. Important
information regarding 580 Series dispenser is provided below:
• Dimensions: Base 13-31/32-inch (35 cm) x 18-1/16-inch (46 cm), Height 40-1/8-inch
(102 cm).
• Construction: All panels are galvanized steel and painted with a two-part urethane paint
for rust resistance.
• Cabinet Colors: Painted black with red front door.
• Motor: Model 582 - 1/2 HP continuous duty, dual voltage/dual frequency, 115/230 VAC,
• Pump: A durable rotary vane pump with carbon blades is utilized to produce suction
power. Air elimination achieved through a patented static device using a vortex effect.
• Inlet Control Valve: The valve i s provided with the pump and is installed in the upstream
of the pump strainer.
• Register: 4-wheel push-button reset, 7-digit master totalizer, in US gallons or liters.
50/60 Hz
Model 583 - 3/4 HP continuous duty, dual voltage/dual frequency, 115/230 VAC,
50/60 Hz
MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page 1
Introduction Abbreviations and Acronyms
• Meter: Nutating disk phenolic measuring chamber in aluminum die-cast housing,
adjustable calibration
±.5% at full flow.
• Display: Single-sided
• Dial Face: Black with silver stripes highlighting register readings.
• Hose: 582 - 3/4-inch (2 cm) x 12 feet (3.6 m); 583 - 1-inch (2.5 cm) x 12 feet (3.6 m)
• Suction Connection: 1-1/2-inch NPT union provided.
• Delivery Rate: Model 582 up to 15 GPM/57 LPM. Model 583 up to 22 GPM/83 LPM.
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. Nozzle boot and
®
hook are designed for use with a UL
-listed interchangeable automatic service-station-
type nozzle.
Optional accessories include internal filter adapter, external filter kits, stainless steel cabinet,
manual hand crank, 50 Hz version, 380 V/50 Hz motor, 1:1 or 10:1 pulser, and liter
registration.
Abbreviations and Acronyms
Term Description
CARB California Air Resources Board
CoC Certificate of Compliance
FCC Federal Communications Commission
NCWM National Conference of Weights and Measures
NYFD New York City Fire Department
PC Personal Computer
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.
Page 2 MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009
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 the p ump/
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 injury.
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-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page 3
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 sufficient to ignite
fuel vapors. Every time you get out of a vehicle, touch the
metal of your vehicle, to discharge any ele c tro static 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 other
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-4766 Series 580 Installation/Operation/Parts Manual · April 2009
Hazards and Actions
Important Safety Information
!
WARNING
Spilled fuels, accidents involving pump s/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. Turn off all system circuit breakers 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-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page 5
Important Safety Information
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Page 6 MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009
Before You Begin Installation
3 – 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 that the original shipping crate be used for any pump
returns.
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 DOs and
DON’Ts to avoid potential problems:
1 DO read the “Important Safety Information” on page 3. It contains important information
regarding the safe use of your dispensing equipment.
2 DO install an emergency power cutoff. In additio n 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.
3 DO have the pump installed by a competent installer/electrician familiar with all applicable
local, state and national codes that may apply.
4 DO install breakaway coupling on discharge hose. If using a high hose retriever, install
breakaway approximately 12-inches downstream of hose clamp on nozzle side of clamp.
5 DO NOT experiment with a pump if you are not sure that the installation is correct.
6 DO NOT overload sub or main breaker panels.
MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page 7
Installation Foundation
7 DO NOT install any underground piping without proper swing joints (always use shoulder
nipples, never close nipples).
8 DO NOT cover any lines, or UL and code approved flexible pipes approved for the fuels and
application, 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).
Note: Install all fiberglass pipe and fittings according to manufacturer’s specifications and
requirements.
Foundation
When constructing the pump island for the dispensing equipment, ensure that you 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 to the island using anchor bolts through the two mounting holes, which are
indicated on each base layout. 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-inch x 5-inch (13 mm x 125 mm) long machine bolts
embedded in the concrete or to meet minimum UL and API requirements for universal
interchangeability of pumps, use two 1/2-inch x 3-1/2-inch (13 mm x 90 mm) long lag screws
with 2-inch (51 mm) long expansion shields.
Suction Pump
If a pump is to be used with an above-ground tank, a pressure regulator valve (model 52) is
required on the suction side of the pump; consult your Gasboy representative for details. The
tank should be free of water and dirt. It is recommended that the tank be pressure-tested to
verify it is tight.
Note: The outlet fitting at the top of the float chamber should be connected to drain back to
the storage tank. The pipe size for the return line to the storage tank should be at least
3/8-inch (9.525 mm). Ensure that this line is not kinked or reduced in diameter.
Page 8 MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009
Typical Installation Layout Installation
Typical Installation Layout
Supply Line
The pump and the tank should be located close to each other (preferably within 50 feet) with
as few changes in direction of the supply line, as possible. This reduces the possibility of unit
vapor lock (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 (3.66 m) for gasoline and 13 feet (3.96 m) for diesel and can vary
according to conditions of the installation and fuel temperature. To increase maximum flow
rate, attempt to keep the lift as small as possible.
Use new galvanized or fiberglass pipe. The riser should be 1-1/2-inches (38.1 mm) diameter.
Note: Fiberglass pipe is to be installed according to manufacturer’s specifications and
Note: Do not install an in-line
check valve, as the unit
already has an internal
valve.
requirements.
MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page 9
Installation Supply Line
Use a 2-inches pipe for standard flow units (excluding the riser) for runs up to 50 feet from the
tank. Use 2-1/2-inches to 3-inches for longer (excluding the riser) runs up to 75 feet. High
gallonage units should use larger pipes such as 3-inches (excluding the riser) for runs up to
50 feet. Use 3-1/2-inches to 4-inches (excluding the riser) for runs up to 75 feet.
Ensure that 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.
Ensure that all pipe threads are properly cut and the inside reamed to remove burrs. Use
UL-listed, non hardening sealing compound suitable for the fluid being dispensed, on all joints
of the fuel handling plumbing. The sealing compound must also be resistant to Gasohol
(Ethanol and Methanol) when used with those fuels. Do not use Teflon Pipe Sealing Tape. Use
the sealing 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 or approved flexible pipes 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, ensure that there are no traps in the
supply line. Supply lines should go straight down beneath the pump to a point 18-inches
(45.7 cm) below the ground level and pitch at a rate of 1/8-inch (3.18 mm) per fo ot (.305 m)
from there down to the storage tank. The supply line should be as short and direct as possible
with swing joints at all turns. Support the horizontal run of pipe at 10 foot int ervals to maintain
pitch and prevent traps. Do not use wood as pipe supports. No additional check valves are
required as the suction pump contains an inlet check valve.
Note: After completion of installation, all liquid-carrying lines must be checked for leaks.
Page 10 MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009
Dimensions Installation
Dimensions
MDE-4766 Series 580 Installation/Operation/Parts Manual · April 2009 Page 11
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