Gasboy ASTRA 9820Q Series, 9822Q, 9823Q Installation & Operation Manual
Series 9820Q ASTRA
Installation/Operation Manual
MDE-4339
(formerly 035090)
Computer Programs and Documentation
A
,
s
P
e
0
s
All Gasboy International Inc. computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy
International Inc. Such computer programs and documents may also contain trade secret information. The duplication, disclosu re, modification, or unauthorized use of computer programs or
documentation is strictly prohibited, unless otherwise licensed by Gasboy International Inc.
FCC Warning
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used
in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own expense. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate
this equipment.
Approvals
Gilbarco is an ISO 9001:2000 registered company.
Underwriters Laboratories: New York City:
U.L. File# Products listed with U.L. NYFD of A #
MH4314
MH6418
MH7404
MH10581 Key control unit, Model GKE-B Series
NCWM – Certificate of Compliance
Gasboy pumps and dispensers are evaluated by the National Conference of Weights and Measures (NCWM) under the National Type Evaluation Program (NTEP).
NCWM has issued the following Certificates of Compliance (COC):
ll dispensers and self-contained pumping 4823 9100A, 9140A, 9152A, 9153A,
Power operated Transfer Pump Models 25
26, 27, 28, 72, 72S, 72SP, 72X, 73 and 1824997 9822A, 9823A
Hand operated Transfer Pump Models 123
Series, 1243 Series, 1520 and 1720 Serie
Card reader terminals, Models 1000, 1000
Site controller, Model 2000S CFN Series
Data entry terminals, Model TPK-900 Seri
Fuel Point Reader System
5046 pending 9100Q, 9140Q, 9152Q, 9153Q
Product Executive Order # Product
9800A, 9840A, 9850A, 9852A,
9853A, 9140
9800Q, 9840Q, 9852Q, 9853Q
COC# Product Model # COC # Product Model # COC # Product Model #
95-179A2 Dispenser
95-136A5 Dispenser 9800 Series
9100 Retail Series, 870
Series, 9700 Series
91-019A2
91-0573A3
Dispenser
Dispenser
9100 Commercial
Series
1000 Series FMS
2000-CFN Series
California Air Resources Board (CARB):
G-70-52-AM
G-70-150-AE
Balance Vapor Recovery
VaporVac
Patents
Gasboy products are manufactured or sold under one or more of the following U.S. patents:
Dispensers
5,257,720
Point of Sale/Back Office Equipment
D335,673
Trademarks
Non-registered trademarks Registered trademarks
Gasboy
Keytrol
Slimline
Consola ASTRA
Infinity Fuel Point
This document is subject to change without notice. • For information regarding Gasboy Literature, call (336) 547-5661
E-mail: literature@gilbarco.com •· Internet: http://www.gasboy.com and http://www.gilbarco.com
” 2004 Gasboy International Inc. and Gilbarco Inc. • All Rights Reserved
Additional U.S. and foreign trademarks pending.
Other brand or product names shown may be trademark
registered trademarks of their respective holders.
Additional U.S. and foreign patents pending.
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
OF A FUEL SPILL.
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 the entire system. Instructions
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
including trucks. All containers must 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.
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
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 interference, in which case, the user will be
required to correct the interference at his own expense.
Contents
CONTENTS
Product.......................................................................................................................................2
Model #......................................................................................................................................2
Registered trademarks............................................................................................................... 2
CONTENTS i
1. Introduction 1
Purpose......................................................................................................................................1
General Description....................................................................................................................1
Standard Features...............................................................................................................1
Optional Features................................................................................................................2
2. Installation 3
Installation Precautions..............................................................................................................3
Vent Line.................................................................................................................................... 4
Vapor Recovery Option..............................................................................................................4
Hose Length Estimator............................................................................................................... 4
Typical Installation...................................................................................................................... 6
011931 Base Layout, Models: 9822Q, 9823Q.....................................................................7
011930 Base Layout, Models: 9822Q, 9823Q.....................................................................8
011884 Base Layout, Models: 9822Q, 9823Q.....................................................................9
011885 Base Layout, Models: 9822Q, 9823Q...................................................................10
011885 Base Layout, Models 9822Q, 9823Q....................................................................11
3. Control Lines 13
Purpose....................................................................................................................................13
Ground..................................................................................................................................... 13
Micro Feed............................................................................................................................... 13
Micro Neutral............................................................................................................................ 13
Pump Motor Feed .................................................................................................................... 13
Neutral Feed............................................................................................................................ 14
Slow Flow (Reset Complete/Switch Detect) ............................................................................. 14
Fast Flow ................................................................................................................................. 14
Phase 2 Feed........................................................................................................................... 14
Pulser....................................................................................................................................... 14
Pulse Output............................................................................................................................ 14
RS-485..................................................................................................................................... 15
4. Wiring 17
Wiring Precautions................................................................................................................... 17
Ground..................................................................................................................................... 18
Circuit Breakers........................................................................................................................ 18
Pump Motor.............................................................................................................................. 18
Pulse Output............................................................................................................................ 18
RS-485..................................................................................................................................... 18
Wire Size..................................................................................................................................19
Conduit..................................................................................................................................... 20
Terminal Block ID..................................................................................................................... 21
023866 Wiring Diagram, Models: 9822Q, 9823Q .............................................................22
MDE-4339 9820Q ASTRA Installation/Operation • Juy 2004 Contents-i
GASBOY Series 9820Q
023866 Wiring Diagram, Models: 9822Q, 9823Q .............................................................23
023867 Wiring Diagram, Models: 9822Q-2, 9823Q-2.......................................................24
023867 Wiring Diagram, Models: 9822Q-2, 9823Q-2.......................................................25
5. Pump Operation 27
Overview.................................................................................................................................. 27
Electronic Component Access..................................................................................................28
CPU Switch Settings................................................................................................................ 29
ATC Information Sheet............................................................................................................. 32
Battery Back-Up Power Supply................................................................................................ 33
View/Reset Totalizer ................................................................................................................ 33
Electronic Totalizer............................................................................................................33
Mechanical Totalizer..........................................................................................................34
Operating Sequence................................................................................................................ 34
Nozzle Locking......................................................................................................................... 35
6. Start-Up and Test 36
Installation Completion Checklist.............................................................................................. 36
Start-Up....................................................................................................................................37
Post Start-Up Tests.................................................................................................................. 37
Voltage...............................................................................................................................37
Tightness...........................................................................................................................37
Belts...................................................................................................................................37
Calibration..........................................................................................................................37
7. Preventive Maintenance 39
General.................................................................................................................................... 39
Hints For Better Pump Performance........................................................................................ 39
Demand Competent Service .............................................................................................39
Use Authorized Parts.........................................................................................................39
Operate With Reasonable Care........................................................................................39
Preventive Maintenance Checklist............................................................................................ 39
Keep Water Out.................................................................................................................39
Clean the Dial Face...........................................................................................................40
Clean the Strainer..............................................................................................................40
Change the Filter...............................................................................................................40
Adjust the Belts..................................................................................................................40
Preserve the Finish of Your Pumps...................................................................................40
Warranty
Contents-ii MDE-4339 9820Q ASTRA Installation/Operation • July 2004
1. Introduction
Purpose
The GASBOY ASTRA Series 9820Q Electronic Commercial Pumps 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 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 9820Q unit. In addition to installation information, this manual contains warnings,
safeguards and procedures on the use and care of the Series 9820Q pumps. Be sure to leave this
manual with the pump owner after the installation is complete.
General Description
The GASBOY Series 9820Q ASTRA (aboveground storage tank remote access) pump units are
UL-listed and are available in two models. Model 9822Q is available in standard speed (up to 15
GPM/56 LPM) with an intermittent-duty motor. Model 9823Q is available in high speed (up to 22
GPM/83LPM) with a continuous-duty motor. The delivery rate varies depending upon installation
conditions and added accessories. Both models of the 9820Q offer electronic registration of the
quantity dispensed.
Introduction
NOTE: NFPA regulations do not allow tank-mounted pumps to be used for the resale of fuel.
The Series 9820Q 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 9820Q.
Standard Features
• One-inch high, 6-digit, backlighted LCD display
• 1000:1 dual-phase, error-checking pulser (gallons); 250:1 dual-phase, error-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
• Four piston, positive displacement meter.
• Belt-driven, positive-displacement rotary vane pump with an 80 mesh (300 micron) strainer
and integral air separation.
• The standard pumping cabinet finish is white. The electronic register cabinet is black with a
blue graphic s panel.
MDE-4339 9820Q ASTRA Installation/Operation • July 2004 1
GASBOY Series 9820Q
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.
2 MDE-4339 9820Q ASTRA Installation/Operation • July 2004
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 front 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 coup l i ng 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 wiring 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 p anels.
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 resp onsibility to ensure that any unused
openings are plugged.
Installation
MDE-4339 9820Q ASTRA Installation/Operation • July 2004 3
GASBOY Series 9820Q
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 provided 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 recovery nozzles.
Please note that the vapor recovery nozzles approved for use are 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 9820Q 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 9820Q 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.
4 MDE-4339 9820Q ASTRA Installation/Operation • July 2004
Installation
Key for Chart Headings
Height Measurement from the ground to the hose connection assuming the pumping unit is mounted
on top of the tank with the feet provided.
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 t he register assembly can be to the specified st arting point; an y 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.
Fueling Radius Indicates the approximate fueling radius. Measured from a point directly below pumping unit
discharge to the nozzle.
MDE-4339 9820Q ASTRA Installation/Operation • July 2004 5
GASBOY Series 9820Q
Typical Installation
See page 19 for cable requirements
6 MDE-4339 9820Q ASTRA Installation/Operation • July 2004
011931 Base Layout, Models: 9822Q, 9823Q
(View 1 - Pumping Unit Assembly)
Installation
MDE-4339 9820Q ASTRA Installation/Operation • July 2004 7
GASBOY Series 9820Q
011930 Base Layout, Models: 9822Q, 9823Q
(View 2 - Register Assembly)
8 MDE-4339 9820Q ASTRA Installation/Operation • July 2004
011884 Base Layout, Models: 9822Q, 9823Q
(Optional Post)
Installation
MDE-4339 9820Q ASTRA Installation/Operation • July 2004 9
Loading...