Gasboy 9100Q User Manual

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SERIES 9100Q

PUMPS AND DISPENSERS

INSTALLATION/OPERATION

MANUAL

038700

REV. 12/03/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the Series 9100Q 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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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.

IMPORTANT WARNINGS AND SAFEGUARDS

OF A FUEL SPILL.

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.

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 FOR COMMERCIAL PUMPS

CONTENTS......................................................................................................................................1

1. INTRODUCTION.......................................................................................................................1-1

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

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

2. INSTALLATION........................................................................................................................2-1

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

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

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

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

Nozzle, Hose, And Accessories.................................................................................................2-3

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

Single Pump/Remote Dispenser Dimensions............................................................................2-4

Twin Pump/Remote Dispenser Dimensions ..............................................................................2-5

011986 Base Layout, Model 9152QTW1...................................................................................2-6

011987 Base Layout, Models 9152QTW2, 9153QTW2.............................................................2-7

011988 Base Layout, Model 9153QTW1M................................................................................2-8

011989 Base Layout, Models 9152Q, 9153Q............................................................................2-9

011990 Base Layout, Models 9152QXTW2, 9153QXTW2......................................................2-10

011991 Base Layout, Model 9140QX......................................................................................2-11

011992 Base Layout, Models 9152QX, 9153QX.....................................................................2-12

011993 Base Layout, Models 9152QXTW1, 9153QXTW1......................................................2-13

011994 Base Layout, Model 9140Q ........................................................................................2-14

3.CONTROL LINES......................................................................................................................3-1

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

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

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

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

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

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

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

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

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

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

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

4.WIRING......................................................................................................................................4-1

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

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

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

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

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

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

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

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

024212 Wiring Diagram.............................................................................................................4-6

024213 Wiring Diagram.............................................................................................................4-7

024214 Wiring Diagram.............................................................................................................4-8

024222 Wiring Diagram.............................................................................................................4-9

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GASBOY Series 9100Q

024223 Wiring Diagram...........................................................................................................4-10

024224 Wiring Diagram...........................................................................................................4-11

024225 Wiring Diagram...........................................................................................................4-12

024320 Wiring Diagram...........................................................................................................4-13

5.PULSERS...................................................................................................................................5-1

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

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

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

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

6.START-UP .................................................................................................................................6-1

Completion Check List...............................................................................................................6-1

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

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

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

7.OPERATING SEQUENCE.........................................................................................................7-1

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

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

8.PREVENTIVE MAINTENANCE.................................................................................................8-1

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

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

Preventive Maintenance Check List...........................................................................................8-2

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Section 1

INTRODUCTION

PURPOSE

The GASBOY Series 9100Q Pumps and Dispensers Installation/Operation 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 Series 9100Q dispensing unit is installed properly. Faulty installations are the major cause of unit malfunctions. The unit must be installed and operated as described in this manual to ensure the reliability and proper operation of the Series 9100Q dispensing unit. In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the Series 9100Q pumps and remote dispensers. Be sure to leave this manual with the pump/dispenser owner after the installation is complete.

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

contact their GASBOY distributor.

GENERAL DESCRIPTION

The GASBOY Series 9100Q dispensing units are UL-listed and are available in a self-contained (suction pump) package or in a remote-controlled (dispenser) package. Both packages offer a variety of models 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; in high speed, up to 22 GPM; or in a single hose model with high capacity speed, up to 40 GPM. The rate of delivery for the remote-controlled packages will vary according to the size of the submersible pump. The delivery rate of both packages will also vary depending upon installation conditions and added accessories.

The Series 9100Q offers the following features: At a glance:

Suction Pumps Remote Dispensers Features Standard Speed Models

High Speed Models

Super Speed Model

9152Q 9152QTW1 9152QTW2

9153Q 9153QTW2 9153QTW1M

9140Q 9140QX Inlet: 2" NPT

9152QX 9152QXTW1 9152QXTW2

9153QX 9153QXTW1 9153QXTW2

Inlet: 1-1/2" NPT Discharge: 3/4" NPT (female threads) Motor: 3/4 HP continuous duty Valves (when used): 3/4" Inlet: 1-1/2" NPT Discharge: 1" NPT (female threads) Motor: 3/4 HP continuous duty Valves (when used): 1"

Discharge: 1-1/4" NPT (female threads) with 1-1/4"x1" reducer bushing Motor: two 3/4 HP continuous duty Valves (when used): 1-1/2"

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GASBOY Series 9100Q

Other standard features and specifications of the Series 9100Q are:

• Cabinet: Painted black top and sides, white front and rear doors and white dial enclosures.

Dimensions are 29-1/16"W, 18-3/8"D, 52-5/8"H.

• Meter: Four piston, positive displacement.

• Pump: Belt-driven, positive-displacement rotar y vane with an 80 mesh (300 micron) strainer

and integral air separation.

• Motor: (See chart earlier in this section).

• Electric reset with a reset complete (switch detect) lead. When used with optional pulser

outputs, allows fueling to be monitored by an automated fuel management system.

• Two stage electric solenoid valves (on all remote dispensers and 9152QTW1)

• Island-oriented nozzle boots.

• UL-Listed hose assembly, 3/4"x 12’ for standard speed; 1" x 12’ for high and super speed.

• Designed to support UL-Listed Interchangeable service station nozzles (not included).

• Hose hangers.

• Non-computing register (volume only) records up to 999.9 gallons or liters.

• Mechanical totalizer, viewed from the back side of the unit, records, up to 9,999,999.9 liters

or gallons.

• Fluids: Gasoline, diesel, kerosene. Not suitable for methanol/ethanol blends.

• Agencies: UL, CSA, W&M.

Optional accessories:

 Pulsers 10:1, 100:1  electrical keytrol operation  ticket printer  internal hose retractor  inlet check valve on suction pumps  internal fuel filter adapter  front totalizer option  lighted displays  solenoid valves  satellite piping  stainless steel exterior  230 or 380VAC operation  liter registration  manual hand crank  Listed automatic nozzles  special lengths of hose  Listed swivels and breakaways  spin-on filter elements  special painting  Listed emergency shutoff valves  Listed pressure regulating valve for aboveground tank applications used with suction pumps.

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Section 2

INSTALLATION

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. Canadian users must also comply with the Canadian Electrical Code.

Plan your installation carefully. A pump/remote dispenser 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 a fuel management system application, the EMERGENCY STOP and STOP keys on the

console and/or the optional EMERGENCY STOP button on the Island Card Reader do not remove AC power from equipment and under certain conditions, will not stop product flow.

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/remote 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.

11. DO NOT use power line wiring of inadequate capacity. (Use gauge specified by the wiring diagram or wire chart provided in Section 4).

12. DO NOT use a circuit breaker of improper size. (See Section 4).

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

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GASBOY Series 9100Q

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 the mating surfaces between the junction box and cover are free of dirt, debris, nicks and scratches. Tighten junction box covers befor e replacing panels.

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

FOUNDATION

Make sure that your installation conforms to the applicable codes required by Federal, State, and local agencies concerning secondary containment underneath the dispenser. Follow the installation requirements of the secondary containment manufacturer to ensure that your site is environmentally safe and to minimize the entrance of water under the dispenser.

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. 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) 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 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 (3.66m) 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 used with an above-ground tank, a pressure regulator valve 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" (9.525mm).

REMOTE DISPENSER

Locate the remote dispenser and tank with submersible pump as close to each other as possible to attain minimum possible pressure drop and the highest possible flow rate, consistent with the pump capacity. Consult the submersible pump manufacturer’s recommendations for pipe sizing and installation instructions pertaining to the model of submersible pump being installed.

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12/03/03

Installation

A Listed emergency shut-off valve (OPW 10RUS or equal) must be installed under each remote dispenser with the shear groove at the same level as the top of the concrete island +

1/2" (12.7mm). The shutoff valve should be rigidly supported to insure proper shearing and closure of the valve in the event the remote dispenser is dislodged. According to the type of shear valve, a different supply nipple may be required.

After a shear valve h as operated on an emergency basis from f ire or mechanical shock, o r if it does not operate co rrectly when inspected, repairs must be made before putt ing the remote dispenser into service.

It is required by the Flammable and Combustible Liquids Code that a leak detector be installed in the system to prevent underground leaks from going unnoticed.

NOZZLE, HOSE, AND ACCESSORIES

This unit is normally equipped for use with a UL-Listed interchangeable service station type nozzle. Only UL-Listed hose assemblies and accessories are to be used with this device. A Listed breakaway connector must be installed on all hose assemblies.

SUPPLY LINE

Important: Use a Mo del 52 pressure regulator valve with all self-con tained models except 9140Q and 9153QTW1M. These models are not recommended for aboveground tanks. A zero differential of pressure, electric solenoid valve is req uired in the line at th e top of the tank. Do not use an anti-siphon valve.

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 damage. Obstructions in the supply line can create pump problems and reduced flow rate.

Make sure all pipe threads are properly cut and the inside 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 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 (45.7cm) below the ground level and pitch at a rate of 1/8 inch (3.18mm) per foot (.305m) 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 10foot 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.

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