Gasboy 9216K User Manual

Atlas™ 9216K/9216KTW Satellite Dispensers

Installation/Operation Manual

MDE-4906

Computer Programs and Documentation

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.

Federal Communications Commission (FCC) Warning

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 All dis p e n s e r s a n d s e l f - c o n t a i n e d p u m p i n g u n i t s 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

Card reader terminals, Models 1000, 1000P Site controller, Model 2000S CFN Series Data entry terminals, Model TPK-900 Series Fuel Point Reader System

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

California Air Resources Board (CARB):

Executive Order # Product

G-70-52-AM Balance Vapor Recovery G-70-150-AE VaporVac

91-019 Dispenser

9100 Commercial Series

1000 Series FMS, 2000S-CFN Series

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.

Table of Contents

1 – Introduction 1

Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

Related Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 – Important Safety Information 3

3 – Installation 7

Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Nozzle, Hose, and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

9216K Front Load Satellite Dispensing Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

9216KTW Twin Satellite Dispensing Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Base Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Model 9216K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Model 9216KTW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4 – Wiring 15

Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Wire Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

9100K/8700K Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .18

9800K Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

9850K Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5 – Start-up 25

Completion Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6 – Operating the Satellite Dispenser 27

MDE-4906 Atlas™ 9216K/9216KTW Satellite Dispensers Installation/Operation Manual · June 2010 Page i

Table of Contents

7 – Preventive Maintenance 29

General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tips for Better Pump Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Demand Competent Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Use Authorized Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operate with Reasonable Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Preventive Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Keep Water Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Preserve the Finish of Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Page ii MDE-4906 Atlas™ 9216K/9216KTW Satellite Dispensers Installation/Operation Manual · June 2010

Purpose Introduction

1 – Introduction

Purpose

This manual provides instructions for the installation and operation of Gasboy® Atlas™ 9216K/9216KTW satellite dispensers. This manual must be supplied to the electrician prior to the installation of conduit and wiring to ensure the satellite 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 satellite dispensing unit. Ensure that this manual is left with the owner after the installation is complete.

Note: For any assistance pertaining to the installation, contact the Gasboy distributor.

Intended Users

This manual is intended for Authorized Service Contractors (ASCs) who will be involved in the installation of Atlas satellite dispensers.

General Description

Gasboy Atlas satellite dispensing units are used in conjunction with Gasboy-listed Atlas dispensers. This unit provides additional control of a remote dispensing line.

The features and specifications of the 9216K/9216KTW satellite dispenser are as follows:

• Hose hangers

• Discharge elbows

• A 12 feet gasoline hose assembly

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

• Unions are provided at the inlet of all suction pumps and dispensers.

• The top and side panels are painted black and the front and rear panels are painted white for the standard cabinet.

• The height of the cabinets is 39.92” (1013.90 mm). For other dimensions of the base layout for each model, refer to

• Available options and accessories for the satellite dispensing units include automatic nozzles, high or low slowdown valves, special lengths of hose, dual swivels, front and back panels painted to the color specified by the customer, stainless steel panels, and emergency shutoff valves.

“Installation” on page 7.

MDE-4906 Atlas™ 9216K/9216KTW Satellite Dispenser Installation/Operation Manual · June 2010 Page 1

Introduction Related Documents

Abbreviations and Acronyms

Term Description

AC Alternate Current ASC Authorized Service Contractor DC Direct Current NEC National Electric Code NFPA National Fire Protection Association STP Submerged Turbine Pump

Underwriters’ Laboratories

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-4906 Atlas™ 9216K/9216KTW Satellite Dispenser Installation/Operation Manua l · June 2010

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 Tot al Electrical Shut-Off

The first and most important information you must know is how to stop all fuel flow to the pump/dispenser and islan d. 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 power to the pump/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 1-800-444-5529. 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 SHUT-OFF 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-4906 Atlas™ 9216K/9216KTW Satellite Dispensers Installation/Operation Manual · June 2010 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 electrostatic 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 when 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 when 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.

WARNING

Hazardous Materials

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

Gasoline spilled on skin may cause burns. Wash area thoroughly with clear water. Seek medical advice immediately.

equipment in the mouth.

WARNING

The pump/dispenser contains a chemical known to the State of California to cause cancer.

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of

WARNING

machines and equipment in which the unexpected energization or start-up of the machine(s) or equipment or

The pump/dispenser contains a chemical known to the State of California to cause birth defects or other reproductive harm.

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-4906 Atlas™ 9216K/9216KTW Satellite Dispensers Installation/Operation Manual · June 2010

Hazards and Actions

Important Safety Information

WARNING

Spilled fuels, accidents involving pumps/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.

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Important Safety Information

This page is intentionally left blank.

Page 6 MDE-4906 Atlas™ 9216K/9216KTW Satellite Dispensers Installation/Operation Manual · June 2010

Installation Precautions Installation

3 – Installation

Installation Precautions

All installations must confirm with all building or fire codes, all Federal, State, and Local codes, NEC, 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 the installation carefully. A dispensing unit cannot be expected to work satisfactorily unless the underground installation is correct. Dispensing troubles are frequently traced to faulty installation. Review the following list of installation DO’s and DO NOT’s to avoid potential problems:

•Read the “Important Safety Information” on page 3. It contains important information regarding the safe use of dispensing equipment.

• Install an emergency power cutoff. In addition to circuit breaker requirements of NFP A 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. To provide the highest level of safety to individual, staff, and customers, we recommend that all personnel be trained as to the location and procedure for turning off power to the entire system.

• A competent installer/electrician must install the satellite dispensing unit.

• Install breakaway coupling on discharge hose. If using a high hose retriever, install breakaway approximately 12” downstream of hose clamp on nozzle side of the clamp.

• DO NOT attempt to wire a pump or remote dispenser without first reviewing the appropriate wiring diagram and notes. This manual contains instructions for wiring mechanical and electronics units. If the mechanical wiring diagram is used for an electronic pump, then it will cause CPU PCB damage to the electronic pump.

• DO NOT experiment with a pump if you are not sure the installation is correct.

• DO NOT overload sub or main breaker panels.

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

• DO NOT cover any lines until they are both air-tested and liquid-tested.

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

• 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.

• DO NOT use power line wiring of inadequate capacity.

Note: Use gauge specified by the wiring diagram or wire chart provided in “Wiring

Diagrams” on page 18.

• DO NOT use a circuit breaker of improper size (refer to “Wiring” on page 15).

MDE-4906 Atlas™ 9216K/9216KTW Satellite Dispensers Installation/Operation Manual · June 2010 Page 7

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