Gasboy 70 User Manual

Series 70 and 1800 Consumer Electric Pumps
Installation/Operation/Parts Manual
MDE-4423B
(formerly 035219)
Company Programs and Documentation
S
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 proh ib ited, unless otherw ise licensed by G asboy.
FCC Warning
This equipment has been tested and found to comply with t h e limits for a Class A digital device pursuant to P art 15 of the FCC Rules. These limits are designe d to prov ide re asonable pr ote ction 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 wh ich cas e 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 operat e this equipment.
Approvals
Gasboy, Greensboro, is an ISO 9001:2000 registered facility.
Underwriters Laboratories:
U.L. File# Products listed with U.L. NYFD of A # Product
MH4314 All dispensers and self-
MH6418 Power operated Transfer
MH7404 Hand operated Transfer
MH10581 Key control unit, Model GKE-
Card reader terminals,
Site controller, Model 2000S
Data entry terminals, Model
Fuel Point Reader System
NCWM – Certificate of Compliance
Gasboy pumps and dispensers are evaluated by the National Conference of Weights and Measures (NCWM) under the National Type Evaluation Program (NTEP). NCWM has issued the following Certificates of Compliance (COC):
COC# Product Model # COC # Product Model # COC # Product Model #
95-179A2 Dispenser 95-136A5 Dispenser 9800 Series
contained pumping units
Pump Models 25, 25C, 26, 27, 28, 72, 72S, 72SP, 72X, 73 and 1820
Pump Models 1230 Series, 1243 Series, 1520 and 1720 Series
B Series
Models 1000, 1000P
CFN Series
TPK-900 Series
9100 Retail 8700 Series, 9700 Series
New York City:
4823 9100A, 9140A, 9152A,
4997
5046 9100Q, 9140Q, 9152Q,
91-019A2 91-0573A3
9153A, 9800A, 9840A, 9850A, 9852A, 9853A, 9140
9822A, 9823A
9153Q, 9800Q, 9840Q, 9852Q, 9853Q
Dispenser Dispenser
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM
G-70-150-AE
9100 Commercial Series 1000 Series
2000-CFN Series
Balance Vapor Recovery VaporVac
Patents
Gasboy products are manufactured or sold under one or more of the following U.S. patents:
Dispensers
5,257,720
Point of Sale/Back Office Equipment
D335,673
Trademarks
Non-registered trademarks Registered trademarks
Atlas™ Consola Infinity
This document is subject to change without notice. For information regarding Gasboy Literature, call (336) 547-5661 E-mail: lite rature@gasboy.co m · I nter net: http://www.gasboy.com 2005 GASBOY All Rights Reserved

ASTRA
Fuel Point Gasboy

Keytrol Slimline



Additional U.S. and foreign trademarks pending.
Other brand or product names shown may be trademarks or registered trademarks of their respective holders.
Additional U.S. and foreign patents pending.
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 OF A FUEL SPILL.
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 bu ilding, 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 turni ng off power to the entire system. Instructions 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 shu t-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 performing maintenance on the dispenser.
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 including trucks. All containers 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 t imes.
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 ensure pump is properly grounded. DO ensure 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 properl y tigh tened. Mating surfaces between the box and cover must be free of dirt, nicks, and scratches. Properly plug all unused entries into the junction box.
MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts
July 2005 Safety-1
CONTENTS
IMPORTANT WARNINGS AND SAFEGUARDS FOR CONSUMER PUMPS
Section 1: INTRODUCTION
Purpose..................................................................................................... 1-1
Specifications* .......................................................................................... 1-1
Section 2: INSTALLATION
Installation Precautions............................................................................. 2-1
Supply Line - Underground Tanks............................................................ 2-2
Pump Dimensions - Series 70, Model 1820 ............................................. 2-3
Pump Dimensions - Series 1820R............................................................ 2-3
Installation Instructions ............................................................................. 2-4
Cabinet Removal for Installation or Service (Series
1820 only - Rounded Cabinet).......................................................... 2-4
Cabinet Removal for Installation or Service (Series
1820 only - Squared Cabinet)........................................................... 2-4
Installing Hose and Nozzle.................................................................. 2-4
Direct Mount on Underground Tank.................................................... 2-5
Direct Mount on Aboveground Tank.................................................... 2-6
Pedestal Mount Pump......................................................................... 2-7
Wall Mount........................................................................................... 2-8
Vacuum Breaker.................................................................................. 2-9
Section 3: WIRING
Wiring Precautions.................................................................................... 3-1
Circuit Breakers ........................................................................................ 3-1
Grounding................................................................................................. 3-2
The Pump Motor....................................................................................... 3-2
Wire Size .................................................................................................. 3-2
Pulser Wiring ............................................................................................ 3-3
Conduit...................................................................................................... 3-3
Pump Wiring Diagrams............................................................................. 3-4
Section 4: STARTUP AND OPERATION
Pre-Startup Checklist................................................................................ 4-1
Startup ...................................................................................................... 4-1
Post Startup Tests.................................................................................... 4-2
Voltage................................................................................................. 4-2
Tightness............................................................................................. 4-2
Meter Calibration................................................................................. 4-2
Strainer Cleaning................................................................................. 4-3
Daily Operation......................................................................................... 4-3
Section 5: MAINTENANCE AND TROUBLESHOOTING
Maintaining Trouble-Free Operation......................................................... 5-1
When Your Pump Needs Service............................................................. 5-2
July 2005 Contents-1
GASBOY Series 70 & 1800
Troubleshooting........................................................................................ 5-3
Disassembly of Pump............................................................................... 5-5
Meter-Register Disassembly..................................................................... 5-5
1860 3-Wheel Register Service and Maintenance................................... 5-6
4860 4-Wheel Register Service................................................................ 5-7
Section 6: PARTS
Series 70 Assembly.................................................................................. 6-2
Optional Accessories........................................................................... 6-3
Series 1800 Assembly.............................................................................. 6-4
Optional Accessories........................................................................... 6-5
Direct Drive Motor-Pump Assembly.......................................................... 6-6
Installation Parts ....................................................................................... 6-8
1860 and 4860 Meter-Register................................................................. 6-9
Register Assemblies................................................................................. 6-9
1860 3-Wheel Meter Register (Model 1820) ............................................ 6-10
4860 4-Wheel Register (Model 72S and Series 1820R) .......................... 6-12
Model 1820 Register Setback and Switch Linkage Assembly.................. 6-14
Optional Kits for Series 70 and 1800 Pumps............................................ 6-15
Series 1820R Parts List............................................................................ 6-16
1820R Pulser and Junction Box Assemblies............................................ 6-18
Warranty
Contents-2 July 2005
Section 1
INTRODUCTION
PURPOSE
The Gasboy Series 70 and 1800 Consumer Electric Pumps Installation/Operation Manual is provided to assist the installer in installing and operating the unit. Faulty installations are the major cause of unit malfunctions. This manual s hould be supplied to the electrician prior to the installation of conduit and wiring. The Series 70 or 1800 pumps must be installed and operated as described in this manual. T his m anual also contains warnings, saf eguards and procedures on the use and care of the pump. Be s ure to leave this manual with the pump owner after the installation is complete.
☎☎☎☎ Customers and installers having any questions pertaining to the installation should
contact their GASBOY distributor.
SPECIFICATIONS
Series 70 and Series 1800 pum ps are made specif ically for private use on vented tanks. W hile their outward appearance differs, they basically offer the same features. These pumps can be mounted on aboveground sk id tanks, directly mounted above underground tank s, or m ounted on pedestals for remote underground installations. Table 1-1 summarizes the features for each model.
Pumping Unit: Self-priming, direct-drive rotary vane; 23 PSI (1.6 bars) stainless steel bypass; check
valve with pressure relief valve.
Motor: 1/3 HP, 1725 RPM motor with thermal overload protection and auxiliary AC line.
Standard 115 VAC, 60 Hz; optional 230 VAC, 50 Hz. AC junction box included. Register: 70: 4-wheel push-button reset, 7-digit master totalizer 1820: 3-wheel, volume only; lever-type reset with interlock; 6-digit master totalizer
(Optional, except for 1820R: 4-wheel push-button) Registers show delivery in US gallons, Imperial gallons, or liters and change gears are available to convert registers for unit of measure.
Meter: Nutating disk phenolic measuring chamber in aluminum die-cast housing; adjustable
calibration +
Hose & Nozzle: 12' (3.66 m) UL-Listed hose assembly with integral static discharge wire; manual self-
closing nozzle.
Connections: 2-inch (5.08 cm) NPT for tank opening; 1-inch (2.54 cm) suction; 3/4-inch (1.91 cm) NPT
discharge
Strainer: 100-mesh nylon Delivery Rate: 18 GPM, at 115V, 60 Hz.; 60 LPM at 60 Hz.; 68 LPM at 50 Hz. Finish: High-gloss red urethane or color of choice. 1820 only: Stainless steel extra cost option. Approvals: UL, CSA
Additional extra cost options include: vapor rec overy, vacuum breaker return line, longer hoses, hose breakaways, automatic nozzles, external filters, wall mounting kits, and f or Ser ies 1820 only, 10:1 pulser or rear- or side-mount filter kits.
.5% at full flow
MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005 1-1
GASBOY Series 70 & 1820
Table 1-1. Series 70 and 1820 Features
Stripped-down versions of Series 70 pumps, which mount on customer-supplied piping and fittings, are available. Model 72X has no attachments or register; Model 73 has a hose and nozzle, but no meter or register.
1-2 MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005
Section 2
INSTALLATION
INSTALLATION PRECAUTIONS
All tanks and installations m ust conform with all building/fire c odes, 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 DO's and DON'T's to avoid potential problems:
1. DO read the WARNINGS page at the front of this manual, prec eding the Table of Contents. It contains important information regarding the safe use of your pumps.
2. DO install an emergency power cutoff if the pump is used for other than personal use. In addition to circuit breaker requir ements 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, we recommend that all em ployees be trained as to the location and procedure for turning off power to the dispensing equipment.
3. DO use breakaway couplings on discharge hose. W hile not required for tanks under 1100 gallons, use is recommended for safety reasons.
4. DO have the pump installed by a competent installer/electrician.
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 f iber glass pipe and fittings according to manufacturer's specifications and requirements.
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.
MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005 2-1
GASBOY Series 70 & 1820
15. DO NOT use gaskets on covers of explosion-proof type boxes. The sealing compound found around wires at all j unction box entrances is a requirement of the National Elec trical Code and should not be disturbed. Tighten junction box covers before replacing panels.
16. DO NOT use knock -out box es or f lexible c onduit f or ins talling 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. At com pletion of the installation, it is the installer 's responsibility to ensure that any unused openings are plugged.
SUPPLY LINE - UNDERGROUND TANKS
If you are using an underground tank, pitch the tank away from s uction end. Horizontal runs of suction line should slope down from the pump toward the tank. Do not exceed an equivalent lift of 12' for gasoline or 14' for diesel to the c enter line of the pum ping unit, including friction resistance in the suction pipe.
The end of the suction pipe must be at least three-inches from bottom of tank. The tank or piping should not be located under traffic areas. Swing joints (two ells) will prevent
damage to piping due to frost heave or ground settlement. Use non-hardening, gasoline-resistant pipe c ompound on male threads of all pipe joints for liquid
handling piping.
2-2 MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005
Installation
PUMP DIMENSIONS - SERIES 70, MODEL 1820
Pump diagrams shown are for Model 1820. Pum p dimensions are the same for all Series 70 pumps.
PUMP DIMENSIONS - MODEL 1820R
Pump diagram s shown are for Model 1820R. Pump dim ensions are the same for thes e Model 1820 pumps: 1820R, 1820RSS, 1820RC, 1820RCSS.
MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005 2-3
GASBOY Series 70 & 1820
INSTALLATION INSTRUCTIONS

Cabinet Removal for Installation or Service (Series 1820 Only) - Rounded Cabinet

1. Remove two screws, one on each side of the cabinet.
2. Pull front panel assembly forward at bottom. As it clears the pumping unit, lift up to remove.
3. To replace f ront panel, engage pins at top in matching holes in rear panel. With front panel assembly tilted back , pins m ay be seen through dial opening. Fr ont panel asse m bly will now drop back into position.
4. Reinstall two screws in sides.

Cabinet Removal for Installation or Service (Series 1820R Only) - Squared Cabinet

1. Remove two screws on lower front of cabinet.
2. Remove two screws from upper back of cabinet.
3. Push in and hold the reset button and pivot the cabinet front panel upward until it c lears the button (Be careful not to damage the button). Remove panel.
4. For calibration or service, rem ove the lefthand side panel by unscrewing the two screws on the bottom side of the cabinet.
5. To reassemble pump cabinet, align side panel screw holes with holes on base of cabinet and screw tight. Replace the cabinet top and front panel by positioning the back plate and pivoting the assembly forward. Be sure to press in the reset button until the front panel clears it. Then replace the screws in the front and back of cabinet.

Installing Hose and Nozzle

To prevent undue s tress and possible damage, ins tall hose and nozzle after installation of pump. Hose must have static wire which provides electrical continuity between hose couplings to dissipate static electrical charge.
1. Screw the pipe elbow (provided with the pump) into the product outlet on the back of the pump. Apply gasoline-resistant pipe compound to male threads.
NOTE: Elbow fitting is not required, however, it provides strain relief for the hose.
2. Screw the hose into the open end of the elbow and tighten. Apply gasoline-resistant pipe compound to male threads.
3. Screw nozzle onto hose.
NOTE: 1820R models are shipped with a vacuum breaker assembly (P/N 032701)
consisting of a tee, pipe nipple and vacuum breaker. This assembly should be installed in the pump outlet before connecting the hose.
2-4 MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005
Installation

Direct Mount on Underground Tanks

1. Screw 2-inch coupling onto 2-inch standard pipe.
2. Screw 2-inc h standard pipe into 2-inch tank flange. Apply compound to threads at bottom of base to prevent surface water from entering the tank.
3. Screw 1-inch s uction pipe into install-a-soc ket. Suction pipe s hould be long enough to allow 3-inch clearance from bottom of tank. Apply gasoline-resistant pipe compound to male threads.
4. Lower 1-inch suction pipe through 2-inch standard pipe into tank. Tighten install-a-socket into coupling at top of standard pipe.
5. Screw pump (2-inch threaded base) into install-a-s ocket. This is a suction line connection and must be tight. Apply gasoline-resistant pipe compound to male threads.
See the Conduit section for correct installation of electrical conduit.
MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005 2-5
GASBOY Series 70 & 1820

Direct Mount on Aboveground Tank

Aboveground tanks require both a pressure/vacuum vent and an emergency vent. The pressure/vacuum vent reduces losses due to evaporation and is an air quality control m easure. The emergency vent provides a relief f rom the pressur e resulting from heating and boiling of the tank contents during a fire situation. Both vents must be properly sized for a given tank.
1. Screw 1-inch s uction pipe into install-a-soc ket. Suction pipe s hould be long enough to allow 3-inch clearance from bottom of tank. Apply gasoline-resistant pipe compound to male threads.
2. Screw install-a-socket directly into 2-inch flange in the aboveground tank.
3. Lift the pum p to the height of the tank and tighten it into the install- a-sock et. Apply gasoline­resistant pipe compound on male thread. NOTE: If using an automatic nozzle with the
extended nozzle hanger, you may need to use a 2-inch coupling and close nipple in between the pump and the install-a-socket. This will pr event interfer ence of the hanger with the top of the tank.
See the Conduit section for correct installation of electrical conduit.
NOTE: Aboveground tanks, located at commercial, industrial, governmental, or manufacturing
establishments and intended for fueling vehicles used with their business, cannot exceed a capacity of 6000 gallons.
2-6 MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005
Installation
Pedestal Mount Pump
1. Screw 2-inch coupling onto threaded end of 2-inch standard pipe.
2. Slide cast iron pedestal base up over the unthreaded end of 2-inch standard pipe.
3. Screw 1-inch s uction pipe into install-a-soc ket. Suction pipe s hould be long enough to allow 3--inch clearance from bottom of tank. Apply gasoline-resistant pipe compound to male threads.
4. Ins ert 1-- inch suc tion pipe into 2--inch pipe and s crew install- a-soc k et into coupling on end of 2-inch pipe.
5. As sem ble union onto lower end of 1-inch s uction pipe conf orm ing to your site's piping layout. Note that the GASBOY base is provided with an opening on one side, so that an elbow can be used and the suction br ought out horizontally aboveground if desired, instead of straight down through the island.
6. Slide base down to proper position at the lower end of the pedestal, tighten six set screws.
7. Screw the 2-inch male thread on the base of the pump into the upper end of the install-a­socket. Apply gasoline pipe compound to all male threads.
8. Securely mount pedestal base to concrete. If the pump is not securely fastened to the foundation, supply line leaks at unions and pipe joints may occur.
See the Conduit section for correct installation of electrical conduit. All undergr ound piping
and swing joints are supplied by the customer. All metallic piping should be at least Schedule 40 wrapped/coated black steel pipe with extra-heavy malleable iron screw type fittings. Protect m etallic piping in contact with the ground with a properly designed cathodic protection system.
MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts ● July 2005 2-7
GASBOY Series 70 & 1820

Wall Mount

The optional wall m ount kit can be used with any Series 70 or 1820 pump to be located rem ote from the tank. The wall mount kit consists of a wall-mounting bracket, pump mounting flange, and hardware to attach the flange to the bracket. Har dware to attach the bracket to the wall is not included.
1. Fasten mounting bracket to wall using appropriate 3/8-inch fasteners (customer supplied).
2. Screw mounting flange to pump inlet. The flange with the four holes should be away from the pump. Pipe thread compound is not required. Tighten flange and align parallel with pump.
3. Bolt mounting flange to mounting bracket using the hardware supplied.
4. Remove the 1-inch plastic plug within the 2-inch pum p base inlet and install the 1-inch inlet NPT inlet line from the tank into the pump. Apply gasoline-resis tant pipe compound to male threads. Follow piping instructions shown on previous page for piping to the tank.
See the Conduit section for correct installation of electrical conduit.
2-8 MDE-4423B Series 70 and 1800 Consumer Elect Pumps Installation/Operation/Parts July 2005
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