Gasboy 9820A User Manual

SERIES 9820A

ELECTRONIC

COMMERCIAL PUMPS

INSTALLATION/OPERATION

MANUAL

035391

Rev. 03/07/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the Series 9820A 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 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

IMPORTANT WARNINGS AND SAFEGUARDS

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 en ti re syste m. Inst ruct ion s 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.

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 tru cks. All conta iners mu st 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.

OF A FUEL SPILL.

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

FCC INFORMATION

The US Federal Communications Commission (FCC) requires specific information be supplied to the users of any equipment which may emit radio frequency energy. Please read the following information.

FCC PART 15

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 device is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed 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 inter ference, in which case, the user will be required to correct the interference at his own expense.

CONTENTS

IMPORTANT WARNINGS AND SAFEGUARDS

FCC Information

Section 1: INTRODUCTION

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

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

Standard Features............................................................................... 1-1

Optional Features ................................................................................ 1-2

Section 2: INSTALLATION

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

Vapor Recovery Option ............................................................................ 2-2

Hose Length Estimator ............................................................................. 2-2

Typical Installation .................................................................................... 2-4

011930 Base Layout (View 1 - Pumping Unit Assembly).......................... 2-5

011930 Base Layout (View 2 - Register Assembly).................................. 2-6

011884 Base Layout (Optional Post) ........................................................ 2-7

011885 Base Layout (Side and Rear Brackets - View 1).......................... 2-8

011885 Base Layout (Side and Rear Brackets - View 2).......................... 2-9

Section 3: CONTROL LINES

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

Ground ..................................................................................................... 3-1

Micro Feed ................................................................................................ 3-1

Micro Neutral............................................................................................. 3-1

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

Neutral Feed ............................................................................................ 3-2

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

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

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

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

Pulse Output.............................................................................................. 3-3

RS-485...................................................................................................... 3-3

Section 4: WIRING

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

Ground ..................................................................................................... 4-2

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

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

Pulse Output ............................................................................................. 4-2

RS-485 ..................................................................................................... 4-2

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

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

Terminal Block ID...................................................................................... 4-5

023866 Wiring Diagram (9822A, 9823A) .................................................. 4-6

023867 Wiring Diagram (9822A-25, 9823A-25)........................................ 4-8

03/07/03 Contents-1

GASBOY Series 9820A

Section 5: PUMP OPERATION

Overview ................................................................................................... 5-1

Electronic Component Access .................................................................. 5-2

CPU Switch Settings................................................................................. 5-3

Battery Back-up Power Supply.................................................................. 5-6

View/Reset Totalizers................................................................................ 5-6

Electronic Totalizer............................................................................... 5-6

Mechanical Totalizer............................................................................ 5-7

Operating Sequence ................................................................................. 5-8

Nozzle Locking ......................................................................................... 5-9

Section 6: START-UP AND TEST

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

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

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

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

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

Belts .................................................................................................... 6-2

Calibration ........................................................................................... 6-2

Section 7: PREVENTIVE MAINTENANCE

General .................................................................................................... 7-1

Hints for Better Pump Performance ......................................................... 7-1

Demand Competent Service................................................................ 7-1

Use Authorized Parts........................................................................... 7-1

Operate With Reasonable Care........................................................... 7-1

Preventive Maintenance Checklist ........................................................... 7-2

Keep Water Out .................................................................................. 7-2

Lubricate the Pumping Unit ................................................................. 7-2

Clean the Dial Face ............................................................................. 7-2

Clean the Strainer ............................................................................... 7-2

Change the Filter ................................................................................ 7-2

Adjust the Belts ................................................................................... 7-2

Preserve the Finish of Your Pumps .................................................... 7-3

Warranty

Contents-2 03/07/03

Section 1

INTRODUCTION

PURPOSE

The GASBOY ASTRA Series 9820A Electronic Commercial Pumps Installation/Oper ation 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 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 9820A unit. In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the Series 9820A pumps. Be sure to leave this manual with the pump owner after the installation is complete.

GENERAL DESCRIPTION

The GASBOY Series 9820A ASTRA (aboveground storage tank remote access) pump units are UL-listed and are available in two models. Model 9822A is available in standard speed (up to 15 GPM/56 LPM) with an intermittent-duty motor. Model 9823A is available in high speed (up to 22 GPM/83LPM) with a continuous-duty motor. The deliver y rate varies depending upon installation conditions and added accessories. Both models of the 9820A offer electronic registration of the quantity dispensed.

NOTE: NFPA regulations do not allow tank-mounted pumps to be used for the resale of fuel.

The Series 9820A consists of two metal cabinet assemblies. One assembly is mounted on top of the tank and contains the pumping unit, meter, electronic pulser, and all hydraulics. The hose and nozzle are connected to this assembly. The second assembly is mounted at a height to permit easy access by a user. It contains the electronic register, controls, display and nozzle boot.

The following lists detail the standard and optional features for the Series 9820A.

Standard Features

• One-inch high, 6-digit, backlighted LCD display

• 1000:1 dual-phase, error-checking pulser (gallons); 250:1 dual-phase, er ror-checking pulser

(liters)

• AC authorization line for control of the unit

• Reset complete (switch detect) output which allows monitoring of the unit's operation when it

is connected to an automated fueling system

• Resettable electronic totalizer

• Discharge elbow

• Both models use a quiet and efficient gear pump which features an air eliminator, built into

the pump casting. The pump meter is a three piston, positive displacement meter which is tested and calibrated for accuracy at any speed or pressure up to the maximum working pressure of 50 psi.

• The standard pumping cabinet finish is white. The electronic r egister cabinet is black with a

blue graphics panel.

03/07/03 1-1

GASBOY Series 9820A

Optional Features

• Pulser output drive line (open collector), capable of driving 1, 10, 100, 250, 500, or 1000

pulses per unit (gallons) or 1, 10, 100, or 250 pulses per unit (liters)

• RS-485 communication for direct connect to Gasboy CFN equipment

• Battery backup for display of last transaction and capture of remnant pulse count in the event

of a power failure

• Mechanical totalizer

• Dual stage solenoid valve

• A working voltage of 115 VAC (115/230 for motor) 60 HZ for domestic use, 230 VAC 50

HZ/60 HZ for international use

• Other options include Listed automatic nozzles, special lengths of Listed hose assembly,

Listed dual swivels, UL-recognized filters, vapor recovery, and vapor recovery ready.

1-2 03/07/03

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 cannot be expected to work satisfactorily unless the 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 fr ont 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 installed by a competent installer/electrician.

4. DO install breakaway coupling on discharge hose. If using a high hose retriver, 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 use power line wir ing of inadequate capacity. (Use gauge specified by the wiring diagram or wire chart provided in Section 4).

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

9. DO NOT use the GASBOY fuel dispensing equipment to remove water ballast from the storage tank.

10. 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 before replacing panels.

11. DO NOT use knock-out boxes or flexible conduit for installing this unit. All power wires should be run in threaded, rigid, metal conduit. All threaded connections must be drawn up tight. All but one opening in the power junction box are provided with plugs at the factory. At completion of the installation, it is the installer's responsibility to ensure that any unused openings are plugged.

03/07/03 2-1

GASBOY Series 9820A

VENT LINE

The vent line for standard units is vented to the atmosphere. Whenever possible, it is recommended that the line be returned to the tank. A hole is pr ovided above the normal vent opening to allow this line to exit the pumping unit and return to the tank.

VAPOR RECOVERY OPTION

This dispenser can be supplied with components necessary to provide vapor recovery. If the dispenser is equipped for vapor recovery, a splitter is located in the pump housing. A 3/4" discharge line will exit from the rear of the pump housing to return vapor/fluid to the tank. No changes are required to the nozzle hook or boot assembly when using vapor re covery nozzles. Please note that the vapor recovery nozzles approved for use ar e the "short spout" type. The following nozzles and hose are approved for use with vapor recovery systems:

Nozzles: Emco Wheaton Model A4015 Husky Corp. Model 5010 OPW Model 211V Hose: UL-Listed Hose Assembly

HOSE LENGTH ESTIMATOR

Use the chart on the next page to estimate the length of hose needed for your 9820A application. The correct length will prevent the hose from touching the ground when the nozzle is placed into the nozzle boot/hook arrangement of the register. This chart assumes that the 9820A register is mounted on the standard pedestal and that the bottom of the pedestal is mounted flush with the bottom of the tank. The illustration below provides a visual reference for the chart.

2-2 03/07/03

Installation

Key for Chart Headings

Height Measurement from the ground to the hose connection assuming the

Tank height + 6" , standard units; tank height + 12" for vapor recovery units.

Hose Length Length of hose less nozzles and fittings. Register Minimum Radius Indicates the closest the register assembly can be to the specified starting

Fueling Radius Indicates the approximate fueling radius. Measured from a point directly

pumping unit is mounted on top of the tank with the feet provided.

point; any closer than this distance may allow hose to touch the ground when unit is not in use. This radius is measured starting from a point directly below pumping unit discharge to the center of the nozzle boot/hook of the register assembly.

below pumping unit discharge to the nozzle.

03/07/03 2-3