Gasboy 9852K User Manual

Introduction

Purpose

This manual provides instructions for installing the Direct Pulse Out Interface Board (M13949A001), which allows the pumps/dispensers to use both RS-485 and pulse out interfaces for Atlas board will only work with the Atlas 9852K or 9853K models and will not work with any other model. This pulse output provides a DC output to indicate the quantity dispensed. The pulse rate can be configured by a jumper setting for the rates of 1, 10, 100, 250, or 500 pulses per gallon.

MDE-5151

Direct Pulse Out Option Installation Instructions

for Atlas™ 9852K/9853K Pumps/Dispensers

March 2014

™

9852K and 9853K pumps/dispensers. This direct pulse out interface

The output is an open collector transistor output capable of sinking up to 100 mi voltages up to 24 VDC. The DC ground for the circuit comes from the Fuel Management System (FMS). Since the transistor switches between ground and high-impedance, the installer must provide a voltage reference when the transistor is in the high-impedance state. This reference voltage is provided by a pull-up resistor installed at the FMS between the pulser input and the reference voltage. The value of this resistor is calculated based on the voltage and current requirements of the FMS pulser circuit.

Topic Page

Introduction 1 Important Safety Information 3 Before You Begin 5 Installing Direct Pulse Out Interface Board 6

Required Tools

Following tools are required for installing the direct pulse out interface board for the Atlas 9852K and 9853K pumps/dispensers:

• Phillips

•Pliers

Screwdriver

lliamps DC at

Abbreviations and Acronyms

Term Description

CPU Central Processing Unit ESD Electrostatic Discharge FMS Fuel Management System

GOLD Gilbarco J-box Junction Box OSHA Occupational Safety and Health Administration

Online Documentation

Page 2 MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014

Important Safety Information

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. 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.

WARNING

Notes: 1) Save this Important Safety Information section

in a readily accessible location.

2) Although DEF is non-flammable, Diesel is flammable. Therefore, for DEF cabinets that are attached to Diesel dispensers, follow all the notes in this section that pertain to flammable fuels.

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 in jury, 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/dispenser and island. Locate the switch or circuit breakers that shut off all power to all fueling equipment, dispensing devices, and Submerged Turbine Pumps (STPs).

Important Safety Information

Read the Manual

Read, understand and follow this manual and an y other labels or related materials supplied with this equipment. If you do not understand a procedure, call a Gasboy Authorized Serv ice 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 Health Administration

(OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to install, inspect, maintain or service this equipment in accordan ce with these codes, regulations and standards may lead to legal ci tations with penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gasboy replacement p art s and re trofit 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

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical component s or the electronics of the dispenser requires total electric al sh ut 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 o r ba rricades at the affected  unit(s)

• A total electrical shut-off of the affected unit(s)

MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014 Page 3

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 re sult 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.

DEF is non-flammable. Therefore, explosion and fire safety warnings do not apply to DEF lines.

Important Safety InformationImportant Safety Information

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

WARNING

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

WARNING

Gasoline/DEF 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

DEF generates ammonia gas at higher temperatures. When opening enclosed panels, allow the unit to air out to avoid breathing vapors. If respiratory difficulties develop, move victim away from source of exposure and into fresh air. If symptoms persist, seek medical attention.

Gasoline/DEF spilled in eyes may cause burns to eye tissue. Irrigate eyes with water for approximately 15 minutes. 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 on skin may cause burns. Wash area thoroughly with clear water. Seek medical advice immediately.

WARNING

DEF is mildly corrosive. Avoid contact with eyes, skin, and clothing. Ensure that eyewash stations and safety s howers are close to the work location. Seek medical advice recommended treatment if DEF spills into eyes.

WARNING

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 yo u w ill be work ing, a nd c aution them not to activate power while 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.

In an Emergency

Inform Emergency Personnel

Compile the following information and inform emergency personnel:

• Location of accident (for example, address, front/bac k of building, and so on)

• Nature of accident (for example, possible heart atta ck, 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 exampl e, if swallowed or inhaled something, and so on)

Working With Electricity Safely

Ensure that you use safe and established prac tices in working with electrical devices. Poorly wired de vi ces 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 while the equipment is down.

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 a ny equipment in the mouth.

Page 4 MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014

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 sta rtup 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. Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 1910.333 contains specific Lockout/Tagout provision for electrical hazards.

Before You Begin

A properly grounded Electrostatic Discharge (ESD) wrist strap must be worn

while servicing any electronic devices or components. Failure to use electrostatic precautions may damage electronic components and void

warranty.

CAUTION

Failure to turn off the unit during the installation of the kit may cause injury or bodily harm from electrical shock. Ensure that all power to the unit is switched off before opening the door to the unit and during kit installation.

WARNING

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 the mouth.

WARNING

Installing the direct pulse output interface board involves DC wiring to a FMS. Read the following manuals before you begin:

• MDE-4331 Atlas Fuel Systems Installation Manual - section 4 (wiring and conduit re

quirements)

• Your FMS Installation Manual

To prepare the site and dispenser for the installation, proceed as follows:

1 Inform the manager. 2 Barricade the unit to be worked on.

Before You Begin

Remove power to the unit at the breaker panel. Follow OSHA lockout/tagout procedures.

MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014 Page 5

Installing Direct Pulse Out Interface BoardInstalling Direct Pulse Out Interface Board

Installing Direct Pulse Out Interface Board

To install the direct pulse out interface board, proceed as follows:

1 Unlock and remove the front panel.

2 Remove the two bolts located over the tabs of the bezel assembly. Lift the bezel assembly

upward and out to remove.

3 Loosen and remove the two screws located on the left and right display panel brackets and

pivot the display panels down.

4 Pull the connector off P1 on the power supply. After a few seconds, reconnect P1.

Figure 1: Pump Central Processing Unit (CPU) Board

5 Disconnect the cables from the P3, P4, and P5 connectors on the pump CPU board. Disconnect

the pulser(s) from the Adaptor Cable (M05201A001).

Page 6 MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014

Installing Direct Pulse Out Interface Board

Single Pulser Connects Here

6 On the direct pulse out interface board, set the jumper to the desi red pulse out rate (1, 10, 100,

250, or 500 pulses per gallon) for the side 1 on JP1. For dual pump, ensure to set the pulse out rate for the side 2 on JP2.

Figure 2: Direct Pulse Out Interface Board

7 Connect the pulser cable to P2 of the direct pulse out interface board. For single unit with only

one pulser, it connects to the first four pins of P2. Connect the pump handles cable to P4. Locate the DC cable connecto r labele d J3 (4-co nductor cable with brown, orange, yellow, and gray wires) that is part of the DC conduit assembly. Attach the J3 cable connector to P3 of the direct pulse out interface board.

8 Align the J3, J4, and J5 connectors on the direct pulse out interface board with P3, P4, and P5

of the CPU board. Gently press the two together. Be careful when pushing the direct pulse out interface board directly toward the CPU board and avoid any side to side motion.

Note: The three connectors on ea

ch 9800 CPU board and d irect pulse out interface board are

keyed to allow the boards to be connected properly.

MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014 Page 7

Installing Direct Pulse Out Interface Board

Note: Connectors on the board are keyed and only go one way.

9 Complete the wiring between the FMS and DC Junction Box (J-box) as shown in your FMS

Installation Manual. For more information, refer to MDE-4331 Atlas Fuel Sys

wiring diagram shown in Figure 3.

Figure 3: FMS and Direct Pulse Out Connections

ems Installation Manual and the

10 Secure the display panel in the upright position. 11 Attach the bezel. Seat the bezel properly to ensure watertight seal. 12 Attach and lock the front panel. 13 Turn on all the circuit breakers supplying power to the pump.

Installing the direct pulse out interface board on the Atlas 9852K and 9853K  pumps/dispensers is now complete.

Atlas™ is a trademark of Gasboy International. Gasboy® is a registered trademark of Gasboy International. Gilbarco® is a register ed trademark of Gilbarco Inc. GOLD

is a service mark of Gilbarco Inc. Phillips® is a registered trademark of Phillips Screw Company.

© 2014 GASBOY 7300 West Friendly Avenue · Post Office Box 22087 Greensboro, North Carolina 27420 Phone (336) 547-5000 · http://www.gilbarco.com · Printed in the U.S.A. MDE-5151 Direct Pulse Out Option Installation Instructions for Atlas™ 9852K/9853K Pumps/Dispensers · March 2014

Gasboy 9852K User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Purpose

Table of Contents

Required Tools

Related Documents

Abbreviations and Acronyms

Important Safety Information

Before You Begin

Installing Direct Pulse Out Interface Board