Gasboy Atlas Fuel Systems Owner Manual
Atlas™ Fuel Systems
Owner’s Manual
MDE-4363F
Computer Programs and Documentation
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.
Federal Communications Commission (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
Gasboy, Greensboro, is an ISO 9001:2000 registered facility.
Underwriters Laboratories (UL):
UL File# Products listed with UL
MH4314
MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s
All dispensers and self-contained pumping
units
Card reader terminals, Models 1000, 1000P
Site Controller, Model 2000S CFN Series
Data entry terminals, Model TPK-900 Series
Fuel Point Reader System
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 #
95-179 Dispenser
95-136 Dispenser 9800 Series 91-057 Controller
9100 Retail Series, 8700
Series, 9700 Series
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac
91-019 Dispenser
9100 Commercial
Series
1000 Series FMS,
2000S-CFN Series
05-002 Atlas
8700K, 8800K,
9100K, 9200K, 9800K
Trademarks
Non-registered trademarks
Atlas™
Consola™
Infinity™
Registered trademarks
®
ASTRA
®
Fuel Point
®
Gasboy
®
Keytrol
®
Slimline
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.
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com
© 2011 GASBOY · All Rights Reserved
Table of Contents
Table of Contents
1 – Introduction 1
Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 – Important Safety Information 3
3 – The Atlas Fuel System 7
Pump/Dispenser Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Atlas Pump/Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Commercial Mechanical - 9100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Commercial Electronic - 9800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
General Description - 9800 (Except 9820). . . . . . . . . . . . . . . . . . . . . . . .10
General Description of 9100K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Common Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Understanding Date Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Pump Totals (9100 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Commercial Electronic (Series 9800 Only) . . . . . . . . . . . . . . . . . . . . . . .13
Mechanical Totalizers for 9850 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Site Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Important Requirements for E85 Units. . . . . . . . . . . . . . . . . . . . . . . . . . .15
Important Considerations for DEF Dispensers. . . . . . . . . . . . . . . . . . . . .16
Guidelines in Atlas Fuel Systems Documentation and Other Co de s . . . .17
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Install Warning Labels and Signs for Customers. . . . . . . . . . . . . . . . . . .18
Operating Pumps/Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Electronic Component Access (Series 9800 Only, Except 9820 Series).19
CPU Switch Settings (Series 9800 Only Including DEF 9862 Units). . . . . . . . . . . . . . . . . . . . . . . . . . .20
CPU Jumpers (or SW1 for Older CPU Boards) . . . . . . . . . . . . . . . . . . . .22
SW2 (For Older and Newer CPU Boards) . . . . . . . . . . . . . . . . . . . . . . . .24
SW2-5 and SW2-6: Unit of Measure Setting
(New M06333KXXXX CPU Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SW2-7: Electro-Mechanical Totalizer Enable
(New M06333KXXXX CPU Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SW2-8: BDM Enable (New M06333KXXXX CPU Only) . . . . . . . . . . . . .26
SW2-9: Software Download Enable (New M06333KXXXX CPU Only) . .26
SW2-10 (New M06333KXXXX CPU Only). . . . . . . . . . . . . . . . . . . . . . . .26
Battery Backup Power Supply for Series 9800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Information for ATC (Series 9800 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Setting the DIP Switches (Found on Kraus ATC Boards) . . . . . . . . . . . .28
Changing the Price for the Mechanical Retail Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Programming 8800 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
General Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Programming the 8800 Series Retail Electronic Units. . . . . . . . . . . . . . .32
Level 1 Programming and Data Access. . . . . . . . . . . . . . . . . . . . . . . . . .32
ATC Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
ATC Inspection Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page i
Table of Contents
Shear Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operating Sequence for Series 9100 Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating Sequence for Series 9800 Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Standalone Mode Error Handling (Series 9800). . . . . . . . . . . . . . . . . . . 45
Calibration for 9850 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Series 9800 Start-up Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Start-up and Test Section for Series 9800 (except 9820). . . . . . . . . . . . 50
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Preparing for Servicing the Pumps/Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Call Gasboy First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specialized Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Maintenance of Vendor Supplied Parts. . . . . . . . . . . . . . . . . . . . . . . . . . 55
Performing Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Reset External Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Filter Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Adjusting the Belts (Suction Pumps Only) . . . . . . . . . . . . . . . . . . . . . . . 59
Preserve the Finish of Your Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Glossary Glossary-1
Index Index-1
Page ii MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Purpose Introduction
1 – Introduction
Purpose
This manual provides instructions for safely operating, programming, and maintaining the
™
Atlas
Fuel Systems pumps/dispensers.
CAUTION
Certain special alternative fuels such as E85 and additives can degrade pump/dispenser
performance or integrity if the dispensers are not designed for use with such fuels.
Additionally, converting to certain standard fuels (gasoline, diesel, kerosene, and so on)
from alternative fuels such as those with ethanol (E85), methanol, or Biodiesel or from
alternative fuels to standard fuels can degrade dispenser performance or integrity.
Similar effects can also occur when converting units to different standard fuel types. As
®
per UL
to dispense any other type of fuel such as Gasoline.
87A requirements, nozzles dispensing E85 fuel and DEF must not be used
Leaks and potential environmental hazards can result or components may fail
prematurely.
To avoid these issues, follow the guidelines provided for dispensing E85 fuel and DEF in
this manual and MDE-4331K Atlas Fuel Systems Installation Manual.
Intended Users
This manual is written for the owners and the operators of the Atlas Fuel Systems pumps and
dispensers.
Scope
This manual provides the following information about the Atlas Fuel Systems pumps and
dispensers:
• Operating the pumps/dispensers
• Preparing the pumps/dispensers for service
• Maintaining the pumps/dispensers
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 1
Introduction Abbreviations and Acronyms
Abbreviations and Acronyms
The following table contains a list of abbreviations and acronyms used in this manual.
Note: For more detailed definitions, refer to “Glossary” on page G-1.
Term Description
AC or ac Altern ating Current
ASC Authorized Service Contractor
ATC Automatic Temperature Compensation
CFR Code of Federal Regulations
CPR Cardiopulmonary Resuscitation
CPU Central Processing Unit
DC (or dc) Direct Current
DEF Diesel Exhaust Fluid
DIP Dual In-line Package
GPM (or gpm) Gallons Per Minute
HF High Flow
LPM Liters Per Minute
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
PPU Price Per Unit (that is, price per gallon or liter)
RAM Random Access Memory
ROM Read-Only Memory
RS Request-to-Send (modem application)
SF Standard Flow
SHF Super High Flow
STP Submerged Turbine Pump
UHF Ultra High Flow
UL Underwriters Laboratory
VAC (or vac) Volts Alternating Current
Page 2 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
2 – Important Safety Information
Important Safety Information
Note: 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 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/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).
!
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. This means that even if you
activate these stops, fuel may continue to flow
uncontrolled.
You must use the TOTAL ELECTRICAL
SHUT-OFF in th e cas e of an emerge nc y a nd no t
the console’s ALL STOP and PUMP STOP or
similar keys.
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical component s or
the electronics of the dispenser requires total electrical shut off
of that unit. Understand the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gilbarco equipment.
Evacuating, Barricading and Shutting Off
Any procedure that requires access to the pump/dispenser or
STPs requires the following actions:
Read the Manual
Read, understand and follow this man ual and any other labels
or related materials supplied with this equipment. If you do not
understand a procedure, call a Gilbarco Authorized Service
Contractor or call the Gilbarco Support Center at
1-800-800-7498. It is imperative to your safety and the safe ty 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 Hazard Associati o n
(OSHA) regulations and federal, state, and local codes. All
these regulations 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 Gilbarco replacement pa rts and retrofit kits on
your pump/dispenser. Using parts other than genuine Gilbarco
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 possib le inj ury
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 result in minor injury.
CAUTION without Alert symbol: Designates a hazard o r
unsafe practice which may result in property or
equipment damage.
Working With Fuels and Electrical Energy
• An evacuation of all unauthorized persons and vehicles from
the work area
• Use of safety tape, cones or barricades at the affected unit(s)
• A total electrical shut-off of the affected unit(s)
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 3
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 fluid lines.
Important Safety Information
No Open Fire
In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
Open flames from matches, lighters, welding torches or
other sources can ignite fuels and their vapors.
No Sparks - No Smoking
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 )
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
• 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)
vehicle, to discharge any electrostatic charge before you
WARNING
approach the dispenser island.
!
Gasoline/DEF ingested may cause
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
unconsciousness and burns to internal organs.
Do not induce vomiting. Keep airway open.
Oxygen may be needed at scene. Seek medical
advice immediately.
you work with or around high voltages. This information is
available from the American Red Cross . Alw ay s ad vise 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 Lockout/Tagout procedures. If you
are not familiar with this requirement, refer to this information in
the service manual and OSHA documentation.
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.
Working With Electricity Safely
Ensure that you use safe and established practices in working
with electrical devices. Poorly wired devices 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 th is program completely to
ensure safety while the equipment is down.
WARNING
!
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
Gasoline/DEF spilled in eyes may cause burns to
eye tissue.
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 any
equipment in the mouth.
!
Irrigate eyes with water for approximately
15 minutes.
Seek medical advice immediately.
WARNING
Gasoline/DEF spilled on skin may cause burns.
!
WARNING
The pump/dispenser contains a chemical know n to the
State of California to cause cancer.
!
Wash area thoroughly with clear water .
Seek medical advice immediately.
WARNING
DEF is mildly corrosive. Avoid cont act with eyes , skin, and
WARNING
!
The pump/dispenser contains a chemical known to the
State of California to cause birth defects or other
reproductive harm.
clothing. Ensure that eyewash stations and safety
showers are close to the work location. Seek medical
advice/recommended treatment if DEF spills into eyes.
IMPORTANT: Oxy ge n may be ne ed e d 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 st art-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. Subpart S of 29 CFR Part
1910 - Electrical Hazards, 29 CFR Part 1910.333 contains
specific Lockout/Tagout provision for electrical hazards.
Page 4 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Hazards and Actions
Important Safety Information
!
The following actions are recommended regarding these hazards:
• Do not go near a fuel spill or allow anyone else in the area.
• Use station EMERGENCY CUTOFF immediately. T u rn of f all system circuit br eakers to the island(s).
• Do not use console E-STOP, ALL ST OP, and PUMP STOP 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. Do not allow
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.
WARNING
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.
Collision of a Vehicle with Unit Fire at Island Fuel Spill
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 5
Important Safety Information
This page is intentionally left blank.
Page 6 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Pump/Dispenser Components The Atlas Fuel System
3 – The Atlas Fuel System
Pump/Dispenser Components
This section provides figures that show the internal and external components of pumps and
provides information about these components. Refer this section as you perform the
procedures in this manual.
Atlas Pump/Dispenser
The external components of a Gasboy® Atlas pump/dispenser (Mechanical Retail Unit) are
shown in Figure 3-1. Mechanical units have mechanical digital type displays as opposed to
electronic digital type displays. In units that are Commercial instead of Retail, the external
components are almost the same with the exception that there are no cost displays, Price per
Unit (PPU) and the main display showing only the total fuel pumped.
Figure 3-1: Atlas Mechanical Retail Unit
Mechanical Retail Unit
Boot Area
Control Lever
Nozzle and
Pump Handle
PPU Display
Totalizers
Cost Display
Gallon Display
Gasboy Atlas
Logo
Door Lock
Access Door
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 7
The Atlas Fuel System Pump/Dispenser Components
The external components of a Gasboy Atlas pump/dispenser (Electronic Retail Unit) are
shown in Figure 3-2. Electronic units have digital displays as opposed to mechanical displays.
In units that are Electronic Commercial instead of Retail, the external components are almost
the same with the exception that there are only totalizers, PPU, and the main display showing
the gallons pumped.
Figure 3-2: Atlas Electronic Retail Unit
Electronic Retail Unit
Electro-mechanical
Totalizer
Boot Area
Control Lever
Nozzle and
Pump Handle
Digital Main
Display
Gallons Display
PPU
Gasboy Atlas Logo
Door Lock
Access Door
Page 8 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Pump/Dispenser Components The Atlas Fuel System
Commercial Mechanical - 9100
Figure 3-3: Commercial Mechanical - 9100
Control Lever
and Boot Area
Door Lock
Commercial Electronic - 9800
Totalizer
Volume Display
Access Door
Figure 3-4: Commercial Electronic - 9800
Volume Display
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 9
Boot Area
Control Lever
Sensor
Door Lock
Access Door
The Atlas Fuel System Pump/Dispenser Components
General Description - 9800 (Except 9820)
The Gasboy Atlas dispensing units are UL-listed and are available in a self-contained (suction
pump) package or in a remote-controlled (dispenser) package. Both packages offer varieties 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 flow (SF) models up
to 15 GPM (56 LPM/12 IGPM); high flow (HF) models up to 22 GPM (83 LPM/18 IGPM);
single-hose super high flow (SHF) models up to 40 GPM (151 LPM/33 IGPM); single-hose
ultra high flow (UHF) models up to 50 GPM (189 LPM/42 IGPM). 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 on the installation conditions and
added accessories.
Visual identification can be quickly made between Commercial and Retail pumps/dispensers.
Commercial pumps/dispensers have displays only for gallons/liters on a side(s), when Retail
has displays for both gallons/liters and cost per gallon/liter.
The Atlas units can either have Side Load or Front Load nozzle configuration. The Atlas
pump/dispenser offers the following features.
Models Suction Pumps Remote Dispensers Features
SF Mechanical Commercial
SF Electronic Commercial
SF Mechanical Retail 8752K, 8752KTW1, 8752KTW2 8752KX, 8752KXTW1, 8752KXTW2
SF Electronic Retail 8852K, 8852KTW1, 8852KTW2 8852KX, 8852KXT W1, 8852KXTW2
HF Mechanical Commercial 9153K, 9153KTW2 9153KX, 9153KXTW2 • Inlet: 1-1/2” NPT female threads
HF Electronic Commercial 9853K, 9853KTW2 9853KX, 9853KXTW2
HF Mechanical Retail 8753K, 8753KTW2 8753KX, 8753KXTW2
HF Electronic Retail 8853K, 8853KTW2 8853KX, 8853KXTW2
SHF Mechanical Commercial 9140K 9140KX • Inlet: 2” NPT female threads
SHF Electronic Commercial 9840K 9840KX
UHF Electronic Commercial 9850K 9850KX, 9850KXTW2 • Inlet: 2” NPT female threads
SF Electronic Commercial
E85 Unit
DEF Dispenser 9862KX • Bottom Inlet: 1” BSPP female
9152K, 9152KTW1, 9152KTW2
9852K, 9852KTW1, 9852KTW2
9152KX, 9152KXTW1, 9152KXTW2
9852KX, 9852KXTW1, 9852KXTW2
9872KX, 9872KXTW1 • Inlet: 1-1/2” NPT female threads
• Inlet: 1-1/2” NPT female threads
• Discharge: 1” NPT female
threads (can be reduced to 3/4”
with bushing)
• Motor: (self-contained) 1 HP
continuous duty
• Discharge: 1” NPT female
threads
• Motor: (self-contained) 1 HP
continuous duty
• Discharge: 1” NPT female
threads
• Motor: (self-contained) (2) 1 HP
continuous duty
• Discharge: 1” NPT female
threads
• Motor: (self-contained) 1-1/2 HP
continuous duty
• Discharge: 3/4” NPT female
threads
threads
• Side Inlet: 1” BSPP male
threads
• Discharge: 1” BSPP male
threads
Page 10 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
General Description of 9100K The Atlas Fuel System
General Description of 9100K
The Gasboy Series 9100K dispensing units are UL-listed and are available in a self-contained
(suction pump) package or in a remote-controlled (dispenser) package. Both packages offer
varieties 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
56 LPM/15 GPM; in high speed, up to 83 LPM/22 GPM; or in a single hose model with high
capacity speed, up to 99 LPM/26 GPM. 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 on the installation conditions and added accessories.
All models of the Series 9100K offer mechanical non-computers complete with electric resets.
Mechanical pump registers show the total volume for a delivery. All non-computers will read
up to 999.9 gallons or liters.
Common Functions
This subsection provides instructions for common functions on the Gasboy Atlas
pumps/dispensers.
Understanding Date Codes
A two letter date code is stamped on the serial number plate before the serial number. This
code shows the month and year of manufacture. To determine the age of the equipment for
warranty purposes, refer to the date code.
Figure 3-5: Serial Number Plate
Serial Number
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 11
The Atlas Fuel System Common Functions
For example, a serial number plate stamped “BP AT0001 99” contains the following
information:
• Date code [BP]—This unit was manufactured in B=February P=2005.
• Serial Number [AT000199]
To determine the date code on a Gasboy pump or dispenser, refer to the following tables.
Month Codes
A = January E = May J = September
B = February F = June K = October
C = March G = July L = November
D = April H = August M = December
Year Codes
P = 2005 U = 2009
R = 2006 W = 2010
S = 2007 X = 2011
T = 2008 Y = 2012
Pump Totals (9100 Series)
Pump totals can be read from the totalizers. At the close of each day’s business, the total can
be read from the unit and subtracted from the day before to obtain the total for that day. If the
unit is in use 24 hours a day, it is advisable to take the readings in the morning also, so as to
monitor the night usage.
Figure 3-6: Pump Totals - 9120
Totalizer
Page 12 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Common Functions The Atlas Fuel System
Commercial Electronic (Series 9800 Only)
Figure 3-7: Commercial Electronic Totals - 9800
Commercial Electronic
Electrical Mechanical
Totalizer
ATC Switch
Note: For all Series 9800 except 9820.
Totalizer Activate Area
The Atlas stores a running quantity total for each pump side. These electronic totalizers work
independent of the optional electrical mechanical totalizers that may be installed and are
shown as whole gallons (liters) on the displays (decimal point is shown, although it is
disregarded). The totalizer data is stored in battery-backed memory. The Atlas is supplied with
an actuator (shown in the above illustration) which allows you to view and reset electronic
totalizers.
To view pump totalizers, ensure that the pump handles are off; and no transaction is in
progress. Locate the actuator area (where the Gasboy dial face logo is located) that is on the
same pump side as the serial number tag. Touch the actuator area with the actuator as shown.
The totalizer data for each pump side will be displayed for 10 seconds. If more time is
required, touch the actuator to the actuator area for an additional 10 second period. To reset the
electronic totalizers, refer to “Electronic Component Access (Series 9800 Only, Except 9820
Series)” on page 19.
• Turn off the 9800K power switch.
• Close JP7 (or SW1-7 for older CPU boards) on the CPU PCB. Hold the actuator against
the totalizer bracket and turn the power switch ON. The displays must change to all
zeroes.
• Remove the actuator and open the switch JP7 (or SW1-7).
Note: Returning switch 1-7 to the open position prevents the totalizers from being reset the
next time the actuator is used to read them.
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 13
The Atlas Fuel System Mechanical Totalizers for 9850 Only
Mechanical Totalizers for 9850 Only
An optional mechanical totalizer for each side is available for 9850 models only . Each totalizer
has:
• Eight digits
• Seven whole gallons
• One tenth-gallon column
• Eight whole digits for liters
The mechanical totalizers are located below each nozzle hook (see Figure 3-8).
Figure 3-8: Mechanical Totals for 9850 Series - 1
Nozzle Hook
Figure 3-9: Mechanical Totals for 9850 Series - 2
Totalizer
Totalizer Cable
Totalizer Unit
Page 14 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Site Preparation The Atlas Fuel System
Site Preparation
To ensure safety and long-term reliability of your equipment, ensure that your units are
installed by a knowledgeable ASC. When your units are installed, ensure that the installer
considers the guidelines in the following section.
Important Requirements for E85 Units
The following equipment and materials are required to properly install E85 units:
UL-listed E85 Hose (Q13486)
• Veyance
• Veyance Flexsteel Futura for E25
Note: Extended Reach hoses are not available for the E85 applications.
UL-listed E85 Nozzle (M11298)
OPW 21GE
Note: Approved for use with the E85 dispensers, as required under UL 87A.
SM
Flexsteel® Futura™ Ethan-All for E85
UL-listed E85 Swivel (N23748-04)
OPW 241 TPS-0492
Note: Approved for use with E85 dispensers, as required under UL 87A.
UL-listed E85 Shear Valve (T19695-23)
OPW 10P-0152E85
Note: Approved for use with E85 dispensers, as required under UL 87A.
UL-listed E85 Breakaway (N23010-10)
OPW 66V-0492
Note: Approved for use with E85 dispensers, as required under UL 87A.
Filter
Use only filters specifically marked for use with E85.
UL-listed Pipe Sealant
Use only UL-listed TPS PTFE Pipe Sealant manufactured by SAF-T-LOC International Corp.
UL-listed Teflon
®
Tape
Use only UL-listed Taega Technologies Inc. Teflon tape.
Note: Teflon tape must be used only at the inlet pipe connection.
IMPORTANT INFORMATION
For E85 Front Load units, side B is the side with the Junction Box. For nozzle boot
positioning for the different models, refer to Atlas Foundation Diagrams section in
MDE-4331 Atlas Fuel Systems Installation Manual.
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 15
The Atlas Fuel System Site Preparation
Important Considerations for DEF Dispensers
CAUTION
Applicable during Installation and Operation of the Dispenser: DEF freezes at appro ximately
11 °F (-11.5 °C). Power to the dispenser and heater must always remain ON in cold weather. If
power is lost and the temperature drops below this point within the DEF cabinet, the system must
be inspected for freeze damage before restart. For sites that experience occasional power losses
or for sites that are located in very cold climates, it is recommended that a backup power generator
be used to maintain constant power to the dispenser. Do not use any additives to lower the freezing
point of DEF. Additives of any type must not be used in DEF. Freezing can result in damage or
inoperative hose breakaways, fluid lines or components, valves, nozzles and meters.
Prolonged storage at temperatures above 77 °F (25 °C) can impair the quality of DEF and reduce
its shelf life.
CAUTION
DEF is mildly corrosive. It can corrode components that are made from incompatible material(s)
and reduce their integrity. The use of incompatible material(s) may lead to leaks and spills, and can
contaminate and degrade the DEF. When dispensing DEF, verify with the manufacturer if the
material of all plumbing components are compatible with the DEF being dispensed.
CAUTION
Do not use Prover Cans meant for engine fuel with DEF or vice versa. Use stainless steel Prover
Cans for DEF. DEF and engine fuel must not be mixed with each other or be contaminated by each
other. Else, damage to a vehicle’s engine or pollution control devices could occur. DEF crystallizes
as its water base evaporates. Pouring out liquid will not guarantee that no corrosive DEF remains in
the Prover Can. DEF must not be contaminated with Diesel fuel, contaminants, or other fluids or
materials. Such contamination can cause serious damage to vehicle catalytic converters.
• Conventional fluid handling precautions are also applicable to DEF.
• Avoid contact with eyes, skin, and clothing. Ensure that eyewash stations and safety
showers are close to the work location.
• DEF is mildly corrosive and non-flammable.
• Clean the DEF spill with water and dry the area with clean rags, especially areas that
contain metallic parts. Spilt DEF can be slippery and will corrode certain types of metallic
parts. Wear eye protection and rubber gloves during any cleanup activity.
• DEF is heavier than gasoline. Be aware that prover cans, containers filled with DEF, and
so on will be considerably heavier than gasoline.
Page 16 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Site Preparation The Atlas Fuel System
Guidelines in Atlas Fuel Systems Documentation and Other Codes
The following manuals provide guidelines for installing Atlas Fuel Systems
pumps/dispensers:
• MDE-4331 Atlas Fuel Systems Installation Manual
• MDE-4333 Atlas Fuel Systems Site Prep Manual
• FE-356 Atlas Pump and Dispenser Field Wiring
• FE-357 Atlas Pump Retail/Commercial Field Wiring
• FE-361 Atlas Master & Satellite Field Wiring Diagram
Ensure that the installer follows the instructions in the above listed manuals and adheres to all
applicable local, state, and national codes.
General Guidelines
Ensure that the installer, at a minimum, performs the following tasks:
• Attaches the hose breakaways.
• Follows all manufacturer installation instructions for devices attached to the dispenser,
such as hoses, nozzles, and shear valves.
• Installs a line leak detection system for all dispensers (The system must comply with all
local and state codes).
• Uses only UL-listed or approved attachments with the pump/dispenser.
• Installs shear valves for all dispensers and certain above ground tank pump applications
properly.
• Follows all codes.
• Bolts units to the island properly .
• Tests hoses for conductivity before use as per the manufacturer’s instructions.
• Uses appropriate safety signs as outlined in the manuals listed in “Guidelines in Atlas Fuel
Systems Documentation and Other Codes”.
• Uses isolation relays for dispensers (required by National Electrical Codes).
• Uses the recommended hose lengths for each unit unless you are using hose retrievers.
Note: This is not a complete list. For other requirements, refer to “Guidelines in Atlas Fuel
Systems Documentation and Other Codes”.
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 17
The Atlas Fuel System Site Preparation
Hoses
Hoses must be UL approved and conductive from end-to-end. To determine the hose length,
refer to “Determining Hose Length”.
Note: When determining the hose length, the effect of adding breakaways adds significantly to
the actual hose length.
WARNING
Hoses of excessive length may create a trip hazard.
Serious injury could occur as a result of tripping over an excessively long hose.
Do not use excessive length hoses. Also ensure that hose retrievers are installed
and are in good operating condition.
Do not install soft-wall hoses, they commonly cause a small sale to indicate when the unit is
activated and the nozzle is closed.
Determining Hose Length
To determine the correct hose length for various types of hoses, refer to the following table.
Type Length
Standard hardwall 5/8 or 3/4 ID (without breakaway) 10 feet, 6 inches
Standard hardwall 5/8 or 3/4 ID (with breakaway) 9 feet, 6 inches
Standard breakaway whip hose 1 foot, 0 inches
Install Warning Labels and Signs for Customers
Install warning labels and signs to ensure that customers are warned of potential safety
hazards. Ensure that the warning labels and the signs are readily visible. At a minimum, install
the following signs:
• Turn off the vehicle before fueling.
• No smoking; do not use matches or lighters nearby.
• Use only non-breakable, approved containers for storing fuel; ensure that the container is
metal and identified properly for fuel storage.
• Static electricity hazards during fueling.
Promptly replace any missing, incomplete, or illegible labels or operating instructions.
WARNING
Static electricity can cause an explosion.
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.
Page 18 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
Operating Pumps/Dispensers The Atlas Fuel System
Operating Pumps/Dispensers
This section describes the operation of the pump/remote dispenser. It provides information on
how to:
• Access the electronic components
• Set the standalone switch
If you are using a point of sale device, refer to the manufacturer instructions.
Electronic Component Access (Series 9800 Only, Except 9820 Series)
This section describes the operation of the pump/remote dispenser. It provides information on
how to:
• Access the electronic components
• Set the internal switches
• Set the optional battery back-up power supply
• View and reset the electronic totalizers using the actuator
• Operate both pumps and remote dispensers
1 Unlock and remove the front panel (see Figure 3-10).
Figure 3-10: Front Panel of 9800 Series
TURN OFF ENGINE
Atlas
Unlock
MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011 Page 19
The Atlas Fuel System CPU Switch Settings (Series 9800 Only Including DEF 9862 Units)
2 Remove the two bolts securing the bezel assembly and remove bezel.
3 Remove the two bolts securing the display panel and pivot display panel down.
Figure 3-11: Display Panel
Note: Unit will swing forward and down
after screws are removed.
Loosen and remove
CPU Switch Settings (Series 9800 Only Including DEF 9862 Units)
The Series 9800 can be configured for various operating conditions using the switches located
on the CPU PCB. Inspect these switches and change their settings, if required. Switch settings
must be changed with the power switch OFF. CPU PCB reads the new settings when the
power is turned ON again.
Note: Older Series 9800 CPU Diagram (board C06394, M05318, M05346).
Figure 3-12: Old CPU Board for 9800 Series
CPU PCB Switches SW1 and SW2
Page 20 MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011
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