Gasboy 9800Q User Manual
Series 9800Q Pumps and Dispensers
Installation/Operation Manual
MDE-4340A
Computer Programs and Documentation
Federal Communications Commission (FCC) Warning
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.
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
MH6418
MH7404
MH10581 Key control unit, Model GKE-B Series
All dispensers and self-contained pumping
units
Power operated Transfer Pump Models 25,
25C, 26, 27, 28, 72, 72S, 72SP, 72X, 73 and
1820
Hand operated Transfer Pump Models 1230
Series, 1243 Series, 1520 and 1720 Series
Card reader terminals, Models 1000, 1000P
Site controller, Model 2000S CFN Series
Data entry terminals, Model TPK-900 Series
Fuel Point Reader System
New York City Fire Department (NYFD):
NYFD C of A # Product
4823 9100K, 9140K, 9152K, 9153K,
4997 9822K, 9823K, 9822A, 9823A
5046 9100K, 9140K, 9152K, 9153K,
9800K, 9840K, 9850K, 9852K,
9853K, 9140, 9100A, 9140A, 9152A,
9153A, 9800A, 9840A, 9850A,
9852A, 9853A, 9100
9800K, 9840K, 9852K, 9853K,
9100Q, 9140Q, 9152Q, 9153Q,
9800Q, 9840Q, 9852Q, 9853Q, 9850Q
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 #
95-179A2 Dispenser
95-136A5 Dispenser 9800 Series 91-057A3 Controller
9100 Retail Series, 8700
Series, 9700 Series
91-019A2 Dispenser
9100 Commercial
Series
1000 Series FMS,
2000S-CFN Series
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac
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.
This document is subject to change without notice. · For information regarding Gasboy Literature, call (336) 547-5661
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com
© 2006 GASBOY · All Rights Reserved
Table of Contents
Table of Contents
1 – Introduction 1-1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
2 – Important Safety Information 2-1
In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
3 – Installation 3-1
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Suction Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Remote Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Nozzle, Hose, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
4 – Control Lines 4-1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Micro Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Micro Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Control/Pump Motor Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
External Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Neutral Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Control/Submersible Feed (Control/SubM Feed) . . . . . . . . . . . . . . . . . . . . .4-2
Submersible Starter Drive (SubM Starter Drive) . . . . . . . . . . . . . . . . . . . . .4-3
Submersible Pump Drive (SubM Pump Drive). . . . . . . . . . . . . . . . . . . . . . .4-4
Reset Complete (Switch Detect)/Slow Flow. . . . . . . . . . . . . . . . . . . . . . . . .4-4
Fast Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Phase 2 Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Slow/Fast Satellite Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Light Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Light Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
RS-232 and RS-422. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
5 – Wiring 5-1
Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
The Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Motor Amp Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Pulse Output or RS-485 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page i
Table of Contents
6 – Pump/Remote Dispenser Operation 6-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Electronic Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CPU Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
SW1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SW2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Pulser Output Rate Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Timeout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ATC Information Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Battery Back-Up Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
View/Reset Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Standalone Mode Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
7 – Start-Up and Test 7-1
Installation Completion Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Post Start-Up Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8 – Preventive Maintenance 8-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Hints for Better Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Preventive Maintenance Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Page ii MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
1 – Introduction
Purpose
The Gasboy Series 9800Q 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 that the Series 9800Q
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 9800Q dispensing unit. In addition to installation
information, this manual contains warnings, safeguards and procedures on the use and care of
the Series 9800Q pumps and remote dispensers. Ensure that you leave this manual with the
pump/remote dispenser owner after the installation is complete.
Note: Customers and installers having any questions pertaining to the installation should
contact their Gasboy distributor.
This manual provides instructions for safely operating, programming, and maintaining the
Atlas™ Fuel Systems pumps/dispensers.
Introduction
General Description
The Gasboy Series 9800Q dispensing units are UL®-listed and are available in a self-contained
(suction pump) package or in a remote-controlled (remote 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/56 LPM) or in high speed (up to 22 GPM/83 LPM). The self-contained
package also boasts a single hose model with high capacity speed (up to 26 GPM/98 LPM), a
dual flow unit (up to 40 GPM/151 LPM) and a high flow unit (up to 50 GPM/189LPM). 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 9800Q offers the following features:
Standard
Speed
Models
High Speed
Models
Super
Speed
Model (up to
40 GPM)
Suction Pumps Remote Dispensers Features
9852Q
9852QTW1
9852QTW2
9853Q
9853QTW2
9853QTW1M
9840Q 9840QX Inlet: 2" NPT
9852QX
9852QXTW1
9852QXTW2
9853QX
9853QXTW1
9853QXTW2
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"
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 1-1
Introduction
All models of the Series 9800Q offer electronic registration of the quantity dispensed. The
following lists detail the standard features and the available options found in the 9800Q:
Standard Features
• 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 rotary vane with an 80 mesh (300 micron)
strainer and integral air separation.
• Motor: (See chart earlier in this section).
• Reset Complete (switch detect) output which allows monitoring of the unit's operation
when it is connected to an automated Fuel Management System.
• Dual stage solenoid valves (standard only on remote dispensers).
• 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.
• Dual phase, error-checking pulsers.
• Non-computing register (volume only) displays, 1" backlighted LCD displays. Records up
to 999.000 gallons.
• Electronic totalizers, viewed from the back side of the unit, records, up to 999,999 liters or
gallons. Battery-backed, resettable.
• Fluids: Gasoline, diesel, kerosene. Not suitable for methanol/ethanol blends.
• Agencies: UL, CUL, W&M.
Optional accessories
• Pulser output drive lines (open collector) capable of driving 1, 10, 100, 250, or 500 pulses
per unit (gallons) or 1, 10, or 100 pulses per unit (liters)
• Inlet check valve
• Internal hose retractor
• Internal fuel filter adapter
• Solenoid valve
• Satellite piping
• Stainless steel exterior or special painting
• 230 or 380 VAC operation
• Liter registration
• Listed automatic nozzles
• Special lengths of hose
• Listed swivels and breakaways
• Spin-on filter elements
• Listed emergency shutoff valves
• Listed pressure regulating valve for aboveground tank applications used with suction
pumps
•Front load nozzle arrangement
• TopKAT mounting
• Battery-backup for electronic display
• Export packaging
• Automatic Temperature Compensation (ATC)
• RS-485 communication for direct connect to Gasboy CFN or TopKAT equipment
Page 1 -2 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
Introduction
• Submersible drive relays capable of handling 3/4 HP at 115 VAC or 1-1/2 HP at 230 VAC
• Fluorescent lighting for the faceplate and brand panel
Related Documentation
Document
Number
035286 215A/216A Installation /Operation Manual Gasboy Commercial & Retail Pumps
C01918 CFN Site Controller II Installation Manual. Gasboy Fuel Management Products
C35628 Fuel Point Reader Installation and Retrofit Manual Gasboy Fuel Management Products
C35963 CFN Series Islander II Installation Manual Gasboy Fuel Management Products
MDE-4298 CFN Site Controller I Installation Manual Gasboy Fuel Management Products
MDE-4344 Series 1000 Installation Manual Gasboy Fuel Management Products
Document Title GOLD Library
Acronym Table
The following table contains a list of acronyms used in this manual.
Note: Refer the glossary section for more detailed definitions.
Acronym Definition
AC or ac Alternating Current
ASC Authorized Service Contractor
AWG American Wire Gauge
CFR Code of Federal Regulations
CPR Cardiopulmonary Resuscitation
CPU Central Processing Unit
CSA Canadian Standards Association (Canadian equivalent of UL)
DC (or dc) Direct Current
DIP Dual In-line Package
DLT Displaying Last Transaction
FMS Fuel Management System
FPR Fuel Point Reader
GPM (or gpm) Gallons Per Minute
HP Horse Power
IFSF International Forecourt Standards Forum
LPM Liters Per Minute
MOC Major Oil Company
NEC National Electrical Code
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Association
PCB Printed Circuit Boards (preferred term: board)
POS Point Of Sale
PPG Pulses Per Gallon
PPL Pulses Per Liter
PPP Programmable Pump Preset
RS Request-to-Send (modem application)
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 1-3
Introduction
Acronym Definition
RS-485 Recommended Standard number 485 [from Electronic
Industry Association (EIA)]
STP Submerged Turbine Pump
UL Underwriters Laboratory
VAC ( o r vac) Volts Alternating Current
Page 1 -4 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
2 – 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 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.”
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 the Gasboy Customer
Service at 1-800-444-5579, Tech Support 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
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.
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-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 2-1
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.
No Open Flames
Emergency First Aid
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
Be sure to use safe and established practices in working with
electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Be sure grounding connections
are properly made. Make sure that sealing devices and
compounds are in place. Be sure 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. Be sure 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.
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 2-2 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
In an Emergency
The following actions are recommended regarding these hazards:
WARNING
!
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow creates
a serious hazard.
Fire or explosion may result causing serious injury or death.
Follow established emergency procedures.
Collision of Vehicle with Unit Fire at Island Fuel Spill
• Do not go near 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 keys 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. No
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.
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 2-3
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Page 2-4 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
3 – 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 DOs and DON’Ts to avoid potential problems:
1 DO read the Important Safety Information pages at the front of this manual. 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.
Installation
3 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.
4 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.
5 DO have the pump/remote dispenser installed by a competent installer/electrician.
6 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.
7 DO NOT attempt to wire a pump/remote dispenser without first reviewing the appropriate
wiring diagram and notes. Wiring diagrams contain important restrictions regarding the
connection of additional equipment. Failure to follow the correct wiring diagram may result in
damage to the CPU PCB.
8 DO NOT experiment with a pump if you are not sure the installation is correct.
9 DO NOT overload sub- or main-breaker panels.
10 DO NOT install any underground piping without proper swing joints (Always use shoulder
nipples, never close nipples).
11 DO NOT cover any lines until they have been both air- and liquid-tested.
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-1
Installation
12 DO NOT back-fill the tank or supply line with cinders or ashes. (Back-fill with clean sand,
crushed rock, or pea gravel).
13 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.
14 DO NOT use power line wiring of inadequate capacity. (Use gauge specified by the wiring
diagram or wire chart provided in
15 DO NOT use a circuit breaker of improper size (See “Wiring” on page 5-1).
16 DO NOT install fill pipe to tank where it can be submerged with standing water.
17 DO NOT use the Gasboy fuel dispensing equipment to remove water ballast from the storage
“Wiring” on page 5-1).
tank.
18 DO NOT use gaskets on covers of explosion-proof type boxes. The sealing compound found
around wires at all junction box entrances 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 before replacing
panels.
Foundation
19 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. On completion of the installation, it is the
installer's responsibility to ensure that any unused openings are plugged.
When constructing the pump island for the dispensing equipment, be sure to extend the island
excavation beyond the depth of the frost line. Leave open an area from the inside edge of the
unit's base as shown on the specific base layout. Unless required by local regulations, do not
cement the pipes and conduits into the island. The 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 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 interchangeability of pumps, use two 1/2" x 3 1/2" (13mm x
90mm) lag screws with 2" (51mm) expansion shields.
Page 3-2 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
Suction Pump
Installation
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 (4m)
for gasoline and 13 feet (4m) 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.
This type of installation is not recommended for Models 9840Q and 9853QTW1M; consult
your Gasboy representative for details.
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" (10mm).
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.
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 +
(plus) 1/2" (13mm). The shear valve should be rigidly supported to ensure proper shearing and
closure of the valve in the event that the remote dispenser is dislodged. According to the type
of shear valve, a different supply nipple may be required.
After a shear valve has operated on an emergency basis from fire or mechanical shock, or if it
does not operate correctly when inspected, repairs must be made before putting 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.
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-3
Installation
Supply Line
IMPORTANT INFORMATION
Use a Model 52 pressure regulator valve with all self-contained models
except 9840Q and 9853QTW1M. These models are not recommended for
aboveground tanks. A zero differential of pressure, electric solenoid valve is
required in the line at the top of the tank. Do not use an anti-siphon valve.
Use new galvanized or fiberglass (see note) pipe, 1 1/2" (38mm) minimum diameter. When
installing a 9840Q or 9840QX, 9850Q or 9850QX model, use a minimum of 2" (51mm)
diameter supply pipe to obtain the highest possible flow rate and to reduce the possibility of
vaporization (gasoline only).
Note: Fiberglass pipe is to be installed according to manufacturer's specifications and
requirements.
Ensure that 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.
Ensure that 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, ensure that 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 (46cm) below the ground level and pitch at a rate
of 1/8 inch (3mm) 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 10-foot (3.05m) 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.
Page 3-4 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
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.
Single/Twin Pump/Remote Dispenser Dimensions
Note: Unit shown is a twin unit.
Installation
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-5
Installation
Single/Twin Pump/Remote Dispenser Front Load Nozzle Dimensions
Note: Unit shown is a front load twin unit.
Page 3-6 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
012011 Base Layout, Model 9852QTW1
Installation
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-7
Installation
012012 Base Layout, Models 9852QTW2, 9853QTW2
Page 3-8 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
012013 Base Layout, Model 9853QTW1M
Installation
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-9
Installation
012014 Base Layout, Models 9852Q, 9853Q
Page 3-10 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
012015 Base Layout, Models 9852QXTW2, 9853QXTW2
Installation
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-11
Installation
012016 Base Layout, Model 9840QX
Page 3-12 MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006
012017 Base Layout, Models 9852QX, 9853QX
Installation
MDE-4340A Series 9800Q Pumps and Dispensers Installation/Operation Manual · January 2006 Page 3-13
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