Gasboy 9100A User Manual

SERIES 9100A

PUMPS AND DISPENSERS

INSTALLATION/OPERATION

MANUAL

035257

REV. 03/07/03

INSTALLERS - IMPORT ANT

In addition to installation information, this manual contains warnings, safeguards and proced u res on the u se and care of th e Series 9100A 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 accura te and reliable. However, we assume no responsibility for it s use, nor f or any infringem ents of

patents or other rights of third part ies resulting from its use. We reserve the right to make changes at any time without notice.

GASBOY INTERNATIONAL LLC LANSDALE, PA

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 material s.

TURN OFF AND LOCK OUT ALL PO W ER TO PUMP BEFORE PERFORM ING SERVICE, M AINTENANCE 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 em ployees be trained as to the location and procedure for turning 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 st rainers) or in the event of a fuel spill, turn off and loc k out all power to the system. In battery-powered pumps, disconnect power source. In submersible pump applications, tur n 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

IMPORTANT WARNINGS AND SAFEGUARDS

OF A FUEL SPILL.

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 t he pum p 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 ser v ice.

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.

035282 Rev. 1267

GASBOY INTERNATIONAL LLC

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

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

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 hazar d.

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 f emale 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 ar e 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.

CONTENTS

IMPORTANT WARNINGS AND SAFEGUARDS FOR COMMERCIAL PUMPS

Section 1: INTRODUCTION

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

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

Section 2: INSTALLATION

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

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

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

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

Nozzle, Hose, and Ac cessories ............................................................. 2-3

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

Single Pump/Remote Dis penser Dimensions......................................... 2-4

Twin Pump/Remot e Dis penser Dimensions ........................................... 2-5

9140A Remote Dispenser Dimens ions................................................... 2-6

011865 Base Layout.............................................................................. 2-7

011873 Base Layout.............................................................................. 2-8

011887 Base Layout.............................................................................. 2-9

011888 Base Layout.............................................................................. 2-10

011892 Base Layout.............................................................................. 2-11

011894 Base Layout.............................................................................. 2-12

011898 Base Layout.............................................................................. 2-13

011971 Base Layout.............................................................................. 2-14

011972 Base Layout.............................................................................. 2-15

011981 Base Layout.............................................................................. 2-16

Section 3: CONTROL LINES

Purpose................................................................................................. 3-1

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

Reset Motor Feed.................................................................................. 3-1

Pump Motor Feed.................................................................................. 3-1

Return................................................................................................... 3-2

Submersible Feed, S ubmersible Drive................................................... 3-2

Reset Complete (Switch Detect)/Slow Flow........................................... 3-2

Fast Flow .............................................................................................. 3-2

Light Feed............................................................................................. 3-2

Light Neutral.......................................................................................... 3-2

Phase 2 Feed........................................................................................ 3-2

Pulser.................................................................................................... 3-2

Section 4: WIRING

Wiring Precautions................................................................................ 4-1

Wiring Precautions................................................................................ 4-2

Grounding ............................................................................................. 4-2

Circuit Breakers..................................................................................... 4-2

The Pump Motor.................................................................................... 4-2

Motor Amp Ratings................................................................................ 4-2

Wire Size............................................................................................... 4-3

03/07/03 Contents-1

GASBOY Series 9100A

Conduit.................................................................................................. 4-4

Wiring Diagrams.................................................................................... 4-5

024212 Wiring Diagram (9152AX , 9153AX, 9140AX)............................. 4-6

024213 Wiring Diagram (9152AX TW1 & 2; 9153AXT W1 & 2)................ 4-7

024214 Wiring Diagram (215A/9152AX, 9153AX; 216A /9153AX)........... 4-8

024222 Wiring Diagram (9152ATW2, 9153ATW 2, 9153ATW1M)........... 4-9

024223 Wiring Diagram (9152ATW1) .................................................... 4-10

024224 Wiring Diagram (9152A, 9153A)................................................ 4-11

024225 Wiring Diagram (9153AHC, 9140)............................................. 4-12

024320 Wiring Diagram (215AZ/9152AX, 9153AX; 216AZ 9153AX,

9140AX ) ( Front Load Satellite).......................................................... 4-13

Section 5: PULSERS

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

Wiring.................................................................................................... 5-1

Reed Pulsers......................................................................................... 5-2

Electronic Pulsers.................................................................................. 5-3

Section 6: START-UP

Completion Checklist............................................................................. 6-1

Start-Up................................................................................................. 6-1

Post Start-Up Tests............................................................................... 6-2

Voltage............................................................................................. 6-2

Tightness ......................................................................................... 6-2

Belts................................................................................................. 6-3

Calibration........................................................................................ 6-3

Power Reset External Adjustment ......................................................... 6-3

Section 7: OPERATING SEQUENCE

Pump .................................................................................................... 7-1

Remote Dispenser................................................................................. 7-1

Section 8: PREVENTIVE MAINTENANCE

General ................................................................................................. 8-1

Hints for Better Pump Performance....................................................... 8-1

Demand Com petent Service............................................................. 8-1

Use Authorized Parts........................................................................ 8-1

O per ate with Reasonable Care......................................................... 8-2

Preventive Maint enanc e Check List....................................................... 8-2

Keep Water Out ............................................................................... 8-2

Pump Lubrication.............................................................................. 8-2

Meter Lubrication.............................................................................. 8-2

Hose Retrievers................................................................................ 8-2

Keep the Non-Computer Lubricated.................................................. 8-3

Dial Face.......................................................................................... 8-3

Cleaning t he S trainer........................................................................ 8-3

Filter................................................................................................. 8-3

Cleaning By - pas s and Regulating Valve Assemblies......................... 8-4

Adjusting the Belts – Suction Pumps Only........................................ 8-4

Preserve the Finish of Your Pumps .................................................. 8-4

Contents-2 03/07/03

Section 1

INTRODUCTION

PURPOSE

The GASBOY Series 9100A Pumps and Dispensers Installat ion/Operat ion Manual is pr ovided t o assist the installer in installing and operating the unit. This manual should be supplied to the electrician pr ior to the installation of conduit and wiring to ensure the Series 9100A dispensing unit is installed properly . Faulty inst allations are the major c ause of unit malfunct ions. The unit must be installed and operated as described in t his manual to ensure the reliability and pr oper operation of the Ser ies 9100A dispensing unit . In addition to installation information, this manual contains warnings, s afeguards and procedures on t he use and care of the Series 9100A pumps and remote dispensers . Be sure to leave this manual wit h the pump/dispenser owner after the installation is complete.

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

contact their GASBOY distribu t or.

GENERAL DESCRIPTION

The GASBOY Series 9100A dispensing unit s are UL-listed and are available in a self-contained (suction pump) pac kage or in a remote-controlled (dispenser) package. Both packages offer a variety of m odels which are available as single hose outlets or dual hose outlets (with single or dual product capability). The self-contained models are available in standard speed, up to 15 GPM/56 LPM; in high speed, up to 22 G PM/ 83 LPM; or in a single hose model with high capacity speed, up to 26 GPM/ 99 LPM. The rate of delivery for the remote- controlled pack ages will vary according to t he s ize of t he s ubmersible pum p. T he delivery r ate of both pac kages will also v ary depending upon installation conditions and added accessories.

All models of the Series 9100A offer mechanical non-computers complete with electric resets. Mechanical pump register s show the total v olume for a delivery. A ll non-computers will read up to 999.9 gallons or liter s .

Other feat ur es and specifications of the Series 9100A are:

• Hose hangers.

• Discharge elbows.

• A 12-foot Listed gasoline hose assembly.

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

international use.

• Mechanical volume totalizers for each hose outlet.

03/07/03 1-1

GASBOY Series 9100A

• Separate contr ol lines to allow individual control of each hos e outlet if desired.

1-2 03/07/03

GASBOY Series 9100A

• A Reset Complete (s witch detect ) and opt ional pulser outputs which allow monit oring of the register's operation when it is connected to an automated fuel management syst em.

• Unions are provided at t he inlet of all suction pumps and r em ote dispensers.

• All models exc ept the high flow units us e a quiet and efficient gear pump which features an

air eliminator, built into the pump casting. The pump meter is a three piston, positive displacement m eter which is test ed and calibrated for accuracy at any speed or press ure up to the maximum wor k ing pr es s ur e of 50 psi (3.45 Bar).

The high flow model uses a vane- type pump with a separate air elim inator. The pump meter

is a 1 1/2" (38.1mm), six-step, rotary motion, positive displacement unit.

• The st andard cabinet finish is top, s ides, and bezel painted black while the front and back panels are painted white.

• The height of the cabinet s is 52-5/8" (1336.7mm). The other dimensions may be found in Section 2 of this m anual and on the single sheet base layout for each model.

• Available options and accessories for the GASBOY Series 9100A dispensing units include Listed automatic nozzles, light s, high/low s lowdown valves, pulser s, special lengt hs of Listed hose, List ed dual swivels, internal hos e r etrievers, filters, front and bac k pump panels painted to the color specified by the customer, stainless steel panels, Listed emergency shutoff valves, satellite piping, top mount t i c k et printer, and elect r ic k ey trol and hand cranks.

Contents-2 7120

Section 2

INSTALLATION

INSTALLATION PRECAUT IONS

All installations must conform with all building/fire codes, all Federal, State, and Local codes, National Elect r ical Code, (NFP A 70) , NFPA 30, and Aut om otive and Marine Service S tation Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code.

Plan your installation carefully. A pump/remote dispenser cannot be expected to work satisfact orily unless the underground inst allation 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 av oid potential problems:

1. DO read the WARNINGS page at the f ront of t his manual, preceding t he Table of Content s.

It contains im portant information regarding the safe use of your dispensing equipment.

2. DO install an emergency power cutoff. In addition to circuit break er requirements of NFPA

70 and NFPA 30A, a single control which simultaneously rem oves AC power from all site dispensing equipment is recommended. This control must be readily accessible, clearly labeled, and in accordance with all loc al c odes.

In a fuel management system application, the EMERGE NCY STOP and STO P keys on the

console and/or the optional EMERGENCY STOP but ton on the Island Card Reader do not remove AC power fr om equipm ent and under certain conditions , will not stop product flow.

In order to provide t he 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/remote dis penser installed by a compet ent installer/elect r ician.

4. DO install breakaway coupling on discharge hose. If using a high hose retriever, install

breakaway approximat ely 12" downs tream of hose clamp on noz z le s ide of clamp.

5. DO NOT experiment wit h a pum p if you are not sure t he ins tallation is correct .

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

7. DO NOT install any underground piping without proper swing joints. (Alway s use shoulder

nipples, never close nipples ) .

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

9. DO NOT back-fill t he tank or supply line with cinders or ashes. (Back-fill wit h clean sand,

crushed rock, or pea gr av el) .

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 accor ding to manufactur er's specificat ions and r equir em ents.

11. DO NOT use power line wir ing of inadequate capacity. (Use gauge specified by t he wiring

diagram or wire chart pr ov ided in S ec tion 4).

03/07/03 2-1

GASBOY Series 9100A

12. DO NOT use a cir c uit breaker of improper s iz e. (See Section 4).

13. DO NOT inst all fill pipe to tank where it c an be s ubmerged with standing water .

2-2 03/07/03

Installation

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. Ensur e that the mating surfaces between the junction box and cover are free of dirt, debris, nicks and scratches. Tighten junction box covers before r eplac ing panels .

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

lighting wires should be run in t hreaded, rigid, m etal conduit . A ll threaded c onnections must be drawn up tight with f ive (5) threads minim um engagement. Only one opening in the AC junction box is provided with a plug at the fac tory. A t completion of the installat ion, it is t he installer's responsibility to ensure t hat any unused openings are plugged.

FOUNDATION

When construc ting the pump island for the dispensing equipment , be sure to extend the island excavation beyond t he depth of the frost line. Leave open an area from the inside edge of the unit's base as shown on t he specific base layout. Unles s required by local regulations, do not cement the pipes and conduit s int o the island. T he open area within the base will provide access for future servicing of the fittings, check valve 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/remote dispenser to the island using anchor bolts through the two mounting holes, which are 13 inches (330mm) apart and are indicated on each base layout by an X. If the dispensing unit is not sec urely fastened to t he island, supply line leaks at unions and pipe joints may occur. Use one of two types of bolts to anchor the pump to t he island. Use two (2) 1/ 2" x 5" (13mm x 125mm) machine bolts imbedded in the concrete, or, to meet minimum UL and API requirements for universal interchangability of pumps, use two 1/ 2" x 3 1/2" (13mm x 90mm) lag screws with 2" (51mm) expansion shields.

SUCTION PUMP

The pump and the t ank should be loc ated c lose to eac h other wit h as f ew changes in direc tion of the supply line, as poss ible. This reduces the poss ibility of vaporization (gasoline only), attains the highest possible flow rate, and results in a lower installation cos t. Avoid long supply lines and excessive vert ical lifts. T he dynamic lift f or this unit is rat ed at 12 feet (3.66m ) for gasoline and 13 feet (3.96m) for diesel and can vary according to conditions of the installation and fuel temperature.

If a pump is to be us ed with an above-ground t ank, a press ure regulator valv e is required on the suction side of the pump; consult your GASBOY representat ive for details. The t ank should be free of water and dir t. It is r ec om m ended that the tank be pres sure tested to v er ify it is tight.

NOTE: The out let f itt ing at t he top of the f loat c hamber should be c onnected t o drain back to t he

storage tank. The pipe size for the ret urn line to the storage tank should be at least 3/8" (9.525mm).

REMOTE DISPENSER

0279 2-3

GASBOY Series 9100A

Locate the rem ote dispens er and t ank wit h submers ible pump as cl ose to eac h other as possible to attain minimum possible pressure drop and t he highest possible flow rate, consistent with the pump capacity. Cons ult the submersible pum p manufacturer's recommendations f or pipe sizing and installation instructions pertaining t o the model of submersible pump being installed.

2-4 03/07/03

Installation

A Listed emergency shut-of f v alve (O PW 10RUS or equal) must be installed under each rem ote dispenser with the shear groove at the same level as the top of the concrete island +

1/2" (12.7mm). The shutof f valve should be rigidly supported to insure proper shearing and closure of the valve in the event the r emote dis penser is dis lodged. Ac cording t o the t ype of s hear valv e, a different supply nipple may be required.

After a shear valve has operat ed on an emergency basis from f ire or mechanical shock, or if it do es not op erate correctly wh en inspect ed, repairs mu st be made befo re puttin g the remote disp enser into service.

It is required by t he F lammable and Combus tible Liquids Code t hat a leak detect or be installed in the system to prevent underground leaks f rom going unnoticed.

NOZZLE, HOSE, AND ACCESSORIES

This unit is normally equipped for use with a UL-Listed interchangeable service station type nozzle. Units equipped wit h suffix N are equipped for use with a UL-Listed Richards Mark XIIL nozzle. Only UL-Listed hose assemblies and accessories are to be used with this device. A Listed breakaway connector must be inst alled on all hos e as s em blies .

SUPPLY LINE

Use new galvanized or fiberglass (see note) pipe, 1 1/2" (38.1mm) minimum diameter.

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

requirements.

Be sure both the pipe and the tank are clean. Foreign matter entering the pump can cause extensive dam age. Obst ructions in the supply line can cr eate pump problems and reduced flow rate.

Make sure all pipe threads are properly cut and the ins ide reamed to remove burrs. Use Listed gasoline-resistant compound on all joints of gasoline handling piping. Sealing compound must also be resistant to Gasohol (Ethanol and Methanol). Do not use Teflon Pipe Sealing Tape. Use gasoline-resistant pipe compound on male threads only; pipe compound used on female threads can be squeezed int o the supply line where it can enter t he product stream and become lodged in the pump or meter . I nstall s wing joints under the pump and at the t ank t o avoid breaks in the supply line from settling or fros t heave.

To avoid product deliver y 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 t o a point 18 inches (45. 7cm) below t he ground level and pit ch at a rate of 1/8 inch (3.18mm) per foot (.305m) from t here down to the storage tank. The supply line should be as short and direct as poss ible with swing joint s at all turns . Suppor t t he horizont al run of pipe at 10-foot interv als to maintain pitch and prev ent traps. Do not us e wood as pipe s uppor ts.

New EPA regulations require that only one check valve be used per supply line and located directly below, and as c lose as pract ical to the suc tion pump. Do not use spring-loaded or union check valves since these will unnecessarily r educ e the flow rate and cont r ibute to the reduction of atmospheric pres s ur e nec es s ar y to keep gasoline in a liquid state.

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

0279 2-5