Gasboy Atlas Fuel Systems Owner Manual

Atlas™ Fuel Systems

Owner’s Manual

MDE-4363F

California Air Resources Board (CARB):

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	All dispensers and self-contained pumping
		units
	MH10581	Key control unit, Model GKE-B Series
		Card reader terminals, Models 1000, 1000P
		Site Controller, Model 2000S CFN Series
		Data entry terminals, Model TPK-900 Series
		Fuel Point Reader System

Executive Order #	Product
G-70-52-AM	Balance Vapor Recovery
G-70-150-AE	VaporVac

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	9100 Retail Series, 8700	91-019	Dispenser	9100 Commercial	05-002	Atlas	8700K, 8800K,
		Series, 9700 Series			Series			9100K, 9200K, 9800K
95-136	Dispenser	9800 Series	91-057	Controller	1000 Series FMS,
					2000S-CFN Series

Trademarks

Non-registered trademarks		Registered trademarks
Atlas™		ASTRA®
Consola™		Fuel Point®
Infinity™		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: [e-mail] · 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 Codes . . . .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® 87A requirements, nozzles dispensing E85 fuel and DEF must not be used to dispense any other type of fuel such as Gasoline.

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	Alternating 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

Important Safety Information

2 – 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 the case of an emergency and not the console’s ALL STOP and PUMP STOP or similar keys.

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical components 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 manual 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 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 Hazard Association (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 parts 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 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 result in minor injury.
	CAUTION without Alert symbol: Designates a hazard or
	unsafe practice which may result in property or
	equipment damage.

•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)

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 fluid lines.

MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011

Page 3

Important Safety Information

No Open Fire	In an Emergency
	Inform Emergency Personnel

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 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.

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 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 any equipment in the mouth.

!WARNING

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 cause birth defects or other reproductive harm.

Compile the following information and inform emergency personnel:

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

•Nature of accident (for example, possible heart attack, run over by car, burns, and so on)

•Age of victim (for example, baby, teenager, middle-age, elderly)

•Whether or not victim has received first aid (for example, stopped bleeding by pressure, and so on)

•Whether or not a victim has vomited (for example, if swallowed or inhaled something, and so on)

!WARNING

Gasoline/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.

!WARNING

Gasoline inhaled may cause unconsciousness and burns to lips, mouth and lungs.

Keep airway open.

Seek medical advice immediately.

!WARNING

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/DEF 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 showers are close to the work location. Seek medical advice/recommended treatment if DEF spills into eyes.

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or start-up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. Lockout/Tagout applies to all mechanical, hydraulic, chemical, or other energy, but does not cover electrical hazards. 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

Important Safety Information

Hazards and Actions

!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.

The following actions are recommended regarding these hazards:

Collision of a Vehicle with Unit

Fire at Island

Fuel Spill

•Do not go near a fuel spill or allow anyone else in the area.

•Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).

•Do not use console E-STOP, ALL STOP, 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.

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

Totalizers

Boot Area

Control Lever

Cost Display

Gallon Display

Nozzle and

Pump Handle

Gasboy Atlas

Logo

PPU Display

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

Digital Main

Control Lever

Display

Gallons Display

Nozzle and

PPU

Pump Handle

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										Totalizer
and Boot Area										Volume Display

Door Lock

Access Door

Commercial Electronic - 9800

Figure 3-4: Commercial Electronic - 9800

Boot Area

Volume Display

Control Lever

Sensor

Door Lock

Access Door

MDE-4363F Atlas™ Fuel Systems Owner’s Manual · September 2011

Page 9

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	9152K, 9152KTW1, 9152KTW2 9152KX, 9152KXTW1, 9152KXTW2
SF Electronic Commercial	9852K, 9852KTW1, 9852KTW2 9852KX, 9852KXTW1, 9852KXTW2
SF Mechanical Retail	8752K, 8752KTW1, 8752KTW2	8752KX, 8752KXTW1, 8752KXTW2
SF Electronic Retail	8852K, 8852KTW1, 8852KTW2	8852KX, 8852KXTW1, 8852KXTW2

•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

HF Mechanical Commercial	9153K, 9153KTW2	9153KX, 9153KXTW2
HF Electronic Commercial	9853K, 9853KTW2	9853KX, 9853KXTW2
HF Mechanical Retail	8753K, 8753KTW2	8753KX, 8753KXTW2
HF Electronic Retail	8853K, 8853KTW2	8853KX, 8853KXTW2

•Inlet: 1-1/2” NPT female threads

•Discharge: 1” NPT female threads

•Motor: (self-contained) 1 HP continuous duty

SHF Mechanical Commercial	9140K	9140KX
SHF Electronic Commercial	9840K	9840KX

•Inlet: 2” NPT female threads

•Discharge: 1” NPT female threads

•Motor: (self-contained) (2) 1 HP continuous duty

UHF Electronic Commercial 9850K	9850KX, 9850KXTW2	• Inlet: 2” NPT female threads
		•	Discharge: 1” NPT female
			threads
		• Motor: (self-contained) 1-1/2 HP
			continuous duty
SF Electronic Commercial	9872KX, 9872KXTW1	• Inlet: 1-1/2” NPT female threads
E85 Unit		•	Discharge: 3/4” NPT female
			threads
DEF Dispenser	9862KX	• Bottom Inlet: 1” BSPP female
			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 AT000199” 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		Totalizer Activate Area

Note: For all Series 9800 except 9820.

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

Totalizer

Figure 3-9: Mechanical Totals for 9850 Series - 2

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)

•VeyanceSM Flexsteel® Futura™ Ethan-All for E85

•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.

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 approximately 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

1Unlock 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)

2Remove the two bolts securing the bezel assembly and remove bezel.

3Remove the two bolts securing the display panel and pivot display panel down.

Figure 3-11: Display Panel

Note: Unit will swing forward and down		Loosen and remove
after screws are removed.

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