Page 1
Introduction
Purpose
This document provides instructions for the installation of the Central Processing Unit (CPU)
Heater Kit on 9800K Series pumps.
Table of Contents
Topic Page
Introduction 1
Important Safety Information 3
Installation of the CPU Heater Kit 5
MDE-4650
CPU Heater Kit Installation Instructions for
9800K Series Pumps
April 2007
Required Tools
The following tools are required for the installation of the kit:
Parts List
The following table lists the parts included in this kit.
Item Description Part Number
1 Standoff, Printed Circuit Board (PCB)
2 Support, PC Board M04768A002 1 1
3 Cable, Heater 115 VAC M05120A003 1 4 Cable, Heater 230 VAC M05120A004 - 1
5 Nut, Metric, Flange M00414B005 3 3
6 Screw, Sems PH Phil M3 Q12845-36 2 2
7 Washer, Fiber .192ID X .77 067165 3 3
• Phillips® screwdriver
• 8 mm nut driver or socket
Snap in 1/4L-
C09695
M07774A001
(115 VAC)
5 5
Quantity
M07774A002
(220 VAC)
MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007 Page 1
Page 2
Introduction
Related Documents
Document Number Title GOLD Library
MDE-4334 Atlas™ Start-up/Service Manual Atlas
MDE-4363 Atlas Owner's Manual Atlas
Warranty
For information on warranty, refer to MDE-4255 Gasboy’s Warranty Policy Statement. If you
have any warranty-related questions, contact Gasboy’s W arranty Department at its Greensboro
location.
Page 2 MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007
Page 3
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.
Important Safety Information
Read the Manual
Read, understand and follow this manual and any other
labels or related materials supplied with this equipment. If you
do not understand a procedure, call a Gasboy Authorized
Service Contractor or call the Gasboy Service Center at 1800-444-5529. It is imperative to your safety and the safety of
others to understand the procedures before beginning work.
Follow the Regulations
There is applicable information in NFPA 30A; Automotive and
Marine Service Code, NFPA 70; National Electrical Code (NEC),
OSHA regulations and federal, state, and local codes which
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.
Emergency Total Electrical Shut-Off
The first and most important information you must know is
how to stop all fuel flow to the pump and island. Locate the
switch or circuit breakers that shut-off all power to all fueling
equipment, dispensing devices, and submerged turbine
pumps (STPs).
!
WARNING
!
The EMERGENCY STOP, ALL STOP, and
PUMP STOP buttons at the cashier’s station
WILL NOT shut off electrical power to the
pump/dispenser.
Total Electrical Shut-Off Before Access
Any procedure requiring access to electrical components or
the electronics of the dispenser requires total electrical shutoff of that unit. Know the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gasboy equipment.
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or
STPs requires the following three actions:
This means that even if you activate these
stops, fuel may continue to flow uncontrolled.
You must use the TOTAL ELECTRICAL SHUTOFF in the case of an emergency and not only
these cashier station “stops.”
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
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 that follow must be followed to prevent death,
injury or damage to the equipment
DANGER - This signal word is used to alert you to a
!
hazard to unsafe practice which will result in death or
serious injury
WARNING - This alerts you to a hazard or unsafe
!
practice that could result in death or serious injury.
CAUTION with Alert symbol - This signal word
!
designates a hazard or unsafe practice which may
result in minor injury.
CAUTION without Alert symbol - When used by itself,
CAUTION designates a hazard or unsafe practice
which may result in property or equipment damage.
- An evacuation of all unauthorized persons and vehicles
using safety tape, cones or barricades to the effected units
- A total electrical shut-off of that unit
MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007 Page 3
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will become explosive if ignited. Spilled
or leaking fuels cause vapors. Even filling customer tanks will
cause explosive vapors in the vicinity of dispenser or island.
Page 4
Important Safety Information
No Open Flames
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
fuels and their vapors. After getting 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. Be familiar
with Cardiopulmonary Resuscitation (CPR) methods if you
are working with or around high voltages. This information is
available from the American Red Cross. Always advise the
station personnel about where you will be working, and
caution them not to activate power while you are working on
the equipment. Use the OSHA tag out and lock out
procedures. If you are not familiar with this requirement, refer
to information in the service manual and OSHA
documentation.
Working With Electricity Safely
Ensure to use safe and established practices in working with
electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure grounding connections
are properly made. Ensure that sealing devices and
compounds are in place. Ensure not to pinch wires when
replacing covers. Follow OSHA Lock-Out and Tag-Out
requirements. Station employees and service contractors
need to understand and comply with this program completely
to ensure safety while the equipment is down.
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Ensure to
clean hands after handling equipment. Do not place any
equipment in mouth.
!
WARNING
This area contains a chemical known to the State of
California to cause cancer.
WARNING
!
This area contains a chemical known to the State of
California to cause birth defects or other reproductive
harm.
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Emergency First Aid
Informing Emergency Personnel
• Compile the following information for 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
!
Gasoline spilled on skin may cause burns.
Wash area thoroughly with clear/water.
Seek medical advice immediately.
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of
machines and equipment in which the unexpected
energization or start up of the machine(s) or equipment or
release of stored energy could cause injury to employees or
personnel. Lockout/Tagout applies to all mechanical,
hydraulic, chemical or other energy, but does not cover
electrical hazards. Reference 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-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007
Page 5
Installation of the CPU Heater Kit
To install the CPU Heater Kit for 9800K Series pumps, proceed as follows:
1 Ensure that power has been removed before you service the equipment.
2 Remove the dispenser side panels and bezels.
3 Remove the screws and lower display panel.
4 Locate the power supply. On the power supply, locate the regulators as shown in Figure 1.
Figure 1: Location of LM117 Regulators
Installation of the CPU Heater Kit
Regulators
LM117
5 Verify if the regulators are of LM117 type (the part number will be printed on the part). If they
are not, then do not install the mounting heater assembly. Replace the power supply with the
one that has the correct regulators.
The following table provides the power supply part numbers.
Power Supply Part Number
115V (battery backed) C06397
115V (without battery) C06396
220V (battery backed) C06489
220V (without battery) C06488
6 Locate the existing CPU on the mounting plate.
MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007 Page 5
Page 6
Installation of the CPU Heater Kit
7 Remove all cables connected to the CPU board. If your dispenser has a pulse output board or
RS-485 board, disconnect it from the CPU and remove the CPU board.
Figure 2: Removal of Bolts
Remove Bolts
8 Locate the four bolts that hold the existing mounting plate on the dispenser. Remove the four
bolts (
Figure 2) and the existing mounting plate.
9 Install the new mounting plate/heater assembly.
Note: Ensure that no wires are caught below the new mounting plate.
10 Use the four bolts removed in step 8 to secure the mounting plate.
11 Locate the power bracket inside the unit (near the end of the AC conduit) shown in Figure 3 on
page 7.
12 Run the heater cable to the power bracket.
Note: Ensure that the cable does not run with DC cables and interfere with the pulser in any
way.
Page 6 MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007
Page 7
Figure 3: Heater Cable Connection
Installation of the CPU Heater Kit
13 Connect the new heater cable to the heater connector on the power bracket (see Figure 3).
Note: If the unit has an existing battery heater cable, unplug it from the connector on the
bracket and plug it into the mating connector on the new heater cable.
14 Reinstall the CPU board and connect all cables that were removed in step 6.
15 Reinstall the pulse output or RS-485 board, if needed.
16 Reassemble the dispenser after the assembly and testing is complete.
The installation of the CPU Heater Kit for 9800K Series pumps is complete.
MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007 Page 7
Page 8
Installation of the CPU Heater Kit
Atlas™ is a trademark of Gasboy International. Phillips® is a registered trademark of Phillips Screw Company.
© 2007 GASBOY
7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A.
MDE-4650 CPU Heater Kit Installation Instructions for 9800K Series Pumps · April 2007
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