Gasboy Atlas Fuel Systems Installation Manual

Atlas® Fuel Systems

Installation Manual

MDE-4331M

Computer Programs and Documentation

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 con t r o l u n i t , M o d e l G K E - B S e r i e s

Card reader terminals, Models 1000, 1000P Site Controller, Model 2000S CFN Series Data entry terminals, Model TPK-900 Series Fuel Point Reader System

California Air Resources Board (CARB):

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 Series, 9700 Series

91-019 Dispenser

9100 Commercial Series

05-002 Atlas

8700K, 8800K, 9100K, 9200K, 9800K

95-136 Dispenser 9800 Series 91-057 Controller

1000 Series FMS, 2000S-CFN Series

Registered trademarks

ASTRA

Atlas

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.

Non-registered trademarks

Consola

™

Infinity

™

TopKAT™

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 re quired to correct the inte rference at his own exp ense. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate this equipment.

Approvals

Trademarks

Table of Contents

1 – Introduction 1-1

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

Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Atlas Commercial Electronic Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Atlas Commercial Mechanical Series. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Atlas Model Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Operating Environment - Special Considerations for DEF Dispensers . 1-4

Operating Environment for DEF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Load Table Reference Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Related Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Common Terms Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2 – Important Safety Information 2-1

3 – Hazardous Locations 3-1

Classifying Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Important Considerations for DEF Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4 – Control Lines for Atlas Electronic Series 4-1

Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Micro Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Micro Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Auth/Pump Motor Feed (Self-contained Pumping Units). . . . . . . . . . . . 4-2

External Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Neutral Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Auth Input Dispensers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Units with Standard Submersible Starter Drive (Subm Starter Drive) . . 4-3

Units with Submersible Pump Drive Relay Option. . . . . . . . . . . . . . . . . 4-4

Submersible Starter Drive (Subm Starter Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Submersible Pump Drive (Subm Pump Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Reset Complete (Switch Detect)/Slow Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fast Flow Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Phase 2 Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Slow/Fast Satellite Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Light Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Light Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page i

Table of Contents

RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Local Area Network (LAN)/Wide Area Network (WAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

5 – Control Lines for Atlas Mechanical Series 5-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Reset Motor Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Pump Motor Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Return (Neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Submersible Feed, Submersible Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Reset Complete (Switch Detect)/Slow Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Fast Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Light Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Light Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Phase 2 Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

6 – Installation 6-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Important Requirements for E85 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Important Considerations when Changing Fuel Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Read NFPA 30A and NFPA 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Preparing for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Before Placing Unit on Fuel Island. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Verifying and Determining Plumbing Requirements . . . . . . . . . . . . . . . .6-6

Determining the Unit Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Determining the Unit Side and Type. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Adapting Pit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Lifting Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Lifting Units with Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Connecting Pump/Dispenser Inlet Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Model 9850KXTW1 Shear Valve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

OPW Shear Valve for 9862KXTW1 DEF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

Anchoring Pump/Dispenser to Island. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

Connecting Vapor Return Line to Vapor Shear Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Wiring Dispenser (STP-supplied Unit) for All Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Preparing Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Wiring Pump (Self-contained Unit) for All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Preparing Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Testing New Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

Completing Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Installing Breakaways, Hoses, Swivels, and Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Units with Hose Retrievers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

DEF Dispensers - ZVA™ DEF Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

DEF Nozzle (M10257B001, M10257B002, M10257B003, and 

M10257B004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Do Not Turn on AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

Purging Air from System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

Page ii MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Table of Contents

For New Dispensers (Purging Through Shear Valve) . . . . . . . . . . . . . 6-22

For New and Existing Pumps and Dispensers with Fuel in 

Lines (Purging Through Nozzle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Installation Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Mechanical and Hydraulic Related Items. . . . . . . . . . . . . . . . . . . . . . . 6-24

Electrical Related Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Adjusting Calibration for Standard, Hi-Flow, and Super-Hi Models. . . 6-26

Calibration Adjustment for Ultra-Hi Models . . . . . . . . . . . . . . . . . . . . . 6-27

Calibration Adjustment for E85/DEF Units [Electronic 

Calibration (E-CAL)]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Calibration and Accuracy Checks - DEF Dispensers. . . . . . . . . . . . . . 6-31

7 – Reference Information 7-1

Reference Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Electrical Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Emergency Power Cut-off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

STP Control Relay Boxes for Dispensers . . . . . . . . . . . . . . . . . . . . . . . 7-3

STP Isolation Relays for Electronic Dispensers. . . . . . . . . . . . . . . . . . . 7-3

Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Atlas Commercial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Atlas Retail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Retail Data Wire Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Commercial Data Wire Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

CPU Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Sealing ‘Y’ Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Plumbing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Pumps (Standard Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Pumps (High Flow, Super-Hi, Ultra-Hi) . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Piping and Plumbing Components (DEF) . . . . . . . . . . . . . . . . . . . . . . . 7-9

Dispensers (Standard Flow). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Dispensers (High Flow, Super-Hi, and Ultra-Hi) . . . . . . . . . . . . . . . . . . 7-9

Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Shear Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

8 – Start-up and Test for Atlas Electronic Series 8-1

Installation Completion Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page iii

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9 – Start-up for Atlas Mechanical Series 9-1

Installation Completion Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Power Reset External Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

Appendix: Atlas Diagrams A-1

Elevation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Foundation Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Index Index-1

Page iv MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Purpose Introduction

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 Underwriters Laboratories (UL

) 87A requirements, nozzles dispensing E85 fuel and Diesel Exhaust Fluid (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.

CAUTION

The unit is shipped with the hose elbow facing upward. Ensure to install the unit with the hose elbow facing downward.

CAUTION

1 – Introduction

Purpose

This manual provides step-by-step instructions for installing Atlas® pumps and dispensers. This manual does not include site preparation instructions. For site preparation instructions, refer to MDE-4333 Atlas Fuel Systems Site Preparation Manual.

Intended Users

This manual is intended for Authorized Service Contractors (ASCs) who will be involved in the installation of Atlas pumps and dispensers.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 1-1

Introduction General Description

General Description

Atlas Commercial Electronic Series

Gasboy® Atlas dispensing units are UL-listed and are available in a self-contained (suction pump) or remote-controlled (dispenser) package. Both packages offer a variety of models that are available as single-hose outlets or dual-hose outlets (with single or dual product capability). Following self-contained models are available:

• Standard Flow (SF) models up to 15 GPM, 56 LPM, 12 IPM

• High Flow (HF) models up to 22 GPM, 83 LPM, 18 IPM

™

• Single-hose Super-Hi

• Single-hose Ultra-Hi

Flow (SHF) models up to 40 GPM, 151 LPM, 33 IPM

™

Flow (UHF) models up to 50 GPM, 189 LPM, 42 IPM

The rate of delivery for remote-controlled packages varies base pump, as well as the choice of the hanging hardware, including the nozzle type. The delivery rate of both packages also varies depending on installation conditions and additional accessories.

The difference between commercial and retail pumps/dispensers can be visually identified. Commercial pumps/dispensers have only one visual port for gallons/liters on a side(s), while retail pumps/dispensers have visual ports for both gallons/liters and cost per gallon/liter.

The Atlas series pumps/dispensers offer the following features:

Models Suction Pumps Remote Dispensers Features

SF Mechanical Commercial SF Electronic Commercial

SF Mechanical Retail 8752K, 8752KTW1,

SF Electronic Retail 8852K, 8852KTW1,

HF Mechanical Commercial

HF Electronic Commercial

HF Mechanical Retail 8753K, 8753KTW2 8753KX, 8753KXTW2 HF Electronic Retail 8853K, 8853KTW2 8853KX, 8853KXTW2 SHF Mechanical

Commercial SHF Electronic

Commercial UHF Electronic

Commercial

SF Electronic Commercial E85 Unit

DEF Electronic Commercial DEF Unit

Note: All Atlas 9800K commercial electronic series can have the D5 option with the TopKAT of the unit.

9152K, 9152KTW1, 9152KTW2 9852K, 9852KTW1, 9852KTW2

8752KTW2

8852KTW2 9153K, 9153KTW2 9153KX, 9153KXTW2

9853K, 9853KTW2 9853KX, 9853KXTW2

9140K

9840K

9850K 9850KX, 9850KXTW2 • Inlet: 2-inch NPT female threads

9152KX, 9152KXTW1, 9152KXTW2 9852KX, 9852KXTW1, 9852KXTW2

8752KX, 8752KXTW1, 8752KXTW2

8852KX, 8852KXTW1, 8852KXTW2

9140KX

9840KX

9872KX, 9872KXTW1 • Inlet: 1-1/2-inch NPT female threads

9862KX • Bottom Inlet: 1-inch British Standard Pipe Parallel

• Inlet: 1-1/2-inch National Pipe Taper (NPT) female threads

• Discharge: 1-inch NPT female threads (can be reduced to 3/4-inch with bushing)

• Motor: (self-contained) 3/4 HP continuous duty

• Inlet: 1-1/2-inch NPT female threads

• Discharge: 1-inch NPT female threads

• Motor: (self-contained) 3/4 HP continuous duty

• Inlet: 2-inch NPT female threads

• Discharge: 1-inch NPT female threads

• Motor: (self-contained) (2) 3/4 HP continuous duty

• Discharge: 1-inch NPT female threads

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

• Discharge: 3/4-inch NPT female threads

(BSPP) female threads

• Side Inlet: 1-inch BSPP male threads

• Discharge: 1-inch BSPP male threads

d on the size of the submersible

™

PLUS option factory mounted on top

Page 1-2 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Atlas Model Codes Introduction

Atlas Commercial Mechanical Series

Atlas commercial mechanical series dispensing units are UL-listed and are available in a  self-contained (suction pump) packag

e or remote-controlled (dispenser) package. Both packages offer a variety of models that are available as single-hose outlets or dual-hose outlets (with single or dual product capability). Following self-contained models are available:

• Standard speed, up to 15 GPM/56 LPM

• High speed, up to 22 GPM/83 LPM

• As a single-hose model with high capacity spee

d up to 26 GPM/99 LPM.

Note: DEF unit is a standard speed unit.

The rate of delivery for remote-controlled packages varies bas

d on the size of the submersible pump and plumbing to the dispenser . The d elivery rate of both packages also varies depending on installation conditions and additional accessories.

All models of the Atlas commercial mechanical series offer mechanical non-computers, complete with electric resets. Mechanical pump registers display the total volume for a delivery. All non-computers read up to 999.9 gallons/liters.

Atlas Model Codes

Digit 1 and 2 3 4 5 6 Pumps 6-8 or

Product

Series

Product Series

Retail Mechanical 87 Retail Electronic 88 Commercial Mechanical 91 Commercial Electronic 98

Model Type

Super-Hi 4 Standard, High-Flow, Ultra-Hi 5 DEF Dispenser 6 E85 Dispenser 7

Flow Rates

Super-Hi (40 GPM)/Ultra-Hi  (50 GPM)

Standard-Flow (10-15 GPM) 2 High-Flow (18-22 GPM) 3

Atlas Model Designation K Pump/dispenser

Self-contained Pump Blank Dispenser X

Hydraulic Configuration

1-Grade, 1-Hose Blank 1-Grade, 2-Hose TW1 2-Grade, 2-Hose TW2 Combo (Ultra-Hi only) TW3

Model

Typ

Flow

Rates

Atlas Pump/Dispenser Hydraulic

ser 7-9

Dispen

Configuration

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 1-3

Introduction Shipping Weight

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.

CAUTION

Shipping Weight

The Atlas shipping weights listed below are approximate values, as shipping weights vary for different models:

• Standard, Hi, and Super-Hi Dispenser: 315 lbs

• Standard, Hi, and Super-Hi Pump: 325 lbs

• Ultra-Hi Combo Pump with Satellite Piping: 503 lbs

• Ultra-Hi Dual Dispenser with Satellite Piping: 414 lbs

•TopKAT

PLUS with Receipt printer: 41 lbs

• Atlas DEF 9872KXTW1 Dispenser: 361 lbs

• Atlas DEF 9872KXWWTWI Dispenser: 355 lbs

Operating Environment

Environment Range

Relative Humidity 20 to 95% non-condensing Minimum Ambient Temperature -22 °F (-30 °C) Maximum Ambient Temperature 131 °F (55 °C)

Operating Environment - Special Considerations for DEF Dispensers

Operating Environment for DEF Unit

Unit Range

Cold Weather Unit -22 °F (-30 °C) to 131 °F (55 °C) Warm Weather Unit 15 °F (-9.4 °C) to 131 °F (55 °C)

Load Table Reference Locations

Model Unit Field Wiring Diagram

Atlas Dispenser FE-356 Field Wiring Diagram Atlas Retail, Commerc

Electronic and Mechanical Displays

Atlas Pump FE-357 Field Wiring Diagram Atlas Retail/Commercial Pump

ial, E85, and DEF Dispensers with

s Electronic and Mechanical Unit

Page 1-4 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Abbreviations and Acronyms

Term Description

ASC Authorized Service Contractor AST Aboveground Storage Tank ASTM American Society for Testing and Materials BSPP British Standard Pipe Parallel CFN Cash Flow Network CPU Central Processing Unit D-Box Distribution Box DEF Diesel Exhaust Fluid DIP Dual In-line Package E-CAL Electronic Calibration FMS Fuel Management System GFI Ground Fault Interrupter

GOLD Gilbarco GPM Gallons per Minute HDPE High Density Polyethylene HF High Flow J-box Junction Box LAN Local Area Network LPM Liters per Minute

Online Documentation

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 1-5

Introduction Common Terms Used

Term Description

LSD Least Significant Digit MSD Most Significant Digit NCWM National Conference on Weights and Measures

NEC NFPA National Fire Protection Association NPT National Pipe Taper NTEP National Type Evaluation Program PCB Printed Circuit Board SF Standard Flow SHF Super-Hi Flow STP Submersible Turbine Pump TFR-ISO Top Front Right Isometric UHF Ultra-Hi Flow UL Underwriters Laboratories UST Underground Storage Tank W&M Weights and Measures WAN Wide Area Network

National Electrical Code

Common Terms Used

Term Description

Combo This unit is configured as master on one side a Dispenser A dispensing device that receives fuel under pressure fro

underground)] through a Submersible Turbine Pump (STP) or from an Aboveground Storage Tank (AST)

using an aboveground pump located at the tank. Grade Fuel that is dispensed a Listed Products bearing the authorized listing mark of UL as the manufacturer

the product complies with UL’s requirements and is in accordance with terms of the UL’s Listing and

Follow-Up Service agreement. Master This unit dispenses fuel to one saddle t Pump A dispensing device that utilizes a self-contained pumping unit and motor to move fuel from a

tank using suction. Product Fuel in the storage tank. Satellite A dispensing unit that receives the product from a master un

both saddle tanks on a vehicle to be filled at the same time. Urea Urea is a non-flammable liquid chemical from a sepa

reduce emissions to nitrogen and water. Urea is used in DEF.

Warranty

nd has an assigned pr

ank and to a

nd satellite on the other.

m the Underground Storage Tank [UST (if

ice.

’s declaration, which implies that

second saddle tank through a satellite unit.

it and

registers at the master unit, allowing

rate tank that chemically interacts with exhaust to

storage

For information on warranty, refer to MDE-4255 Gasboy Warranty Policy Statement for USA and Canada. If you have any warranty related questions, contact Gasboy’s Warranty

Department at its Greensboro, N.C. location.

Page 1-6 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

2 – Important Safety Information

Notes: 1) Save this Important Safety Information section

in a readily accessible location.

2) Although DEF is non-flammable, diesel is flammable. Therefore, for DEF cabine ts 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 o r 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 in formation 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).

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 not the console’s ALL STOP and PUMP STOP or similar keys.

WARNING

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical component s or the electronics of the dispenser requires total elect rical shut off of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gasboy equipment.

Evacuating, Barricading and Shutting Off

Any procedure that requires access to the pump/dispenser or STPs requires the following actions:

• An evacuation of all unauthorized persons and vehicles from the work area

• Use of safety tape, cones or barricades at the affected unit(s)

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

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 Gasboy Authorized Serv ice Contractor or call the Gasboy Support Center at  1-800-444-5529. It is imperative to your safety and the safe ty of oth

rs 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), Occupatio nal Safety and Health Administration

(OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lea d to leg al citation s with penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gasboy replacement p art s and re trofit kits on your pump/dispenser. Using parts other than genuine Gasboy replacement parts could create a safety hazard and violate local regulations.

Safety Symbols and Warning Words

This section provides important information about wa rn ing 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 prev

ent 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 followe d to prevent death, injury or damage to the equipment:

DANGER: Al

erts yo

u 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 un

safe practice which may result in minor injury.

CAUTION w

thout Alert symbol: Designates a hazard or unsafe practice which may result in property or equipment damage.

Working With Fuels and Electrical Energy

Prevent Explosions and Fires

Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island.

DEF is non-flammable. Therefore, expl

osion and fire safety

warnings do not apply to DEF fluid lines.

! !

Important Safety Information

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 2-1

Important Safety Information

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

WARNING

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

WARNING

Gasoline/DEF ingested may cause unconsciousness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately.

DEF generates ammonia gas at high er 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 burn s. Wash area thoroughly with clear water. Seek medical advice immediately.

WARNING

DEF is mildly corrosive. Avoid cont act 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.

WARNING

No Open Fire

Open flames from matches, lighters, welding torches or

other sources can ignite fuels and their vapors.

No Sparks - No Smoking

Sparks from starting vehicles, starting or using power tools, burning cigarettes, cigars or pipes can also ig nite 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 capab l e of rendering first aid be present during servicing. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages. This informa tion 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.

In an Emergency

Inform Emergency Personnel

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)

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 complete ly 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.

Page 2-2 MDE-4331M Atlas® Fuel Systems Installation Manual · Sep tember 2014

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

Lockout/Tagout

Lockout/Tagout covers servicin g and maintenance of machines and equipment in which the unexpecte d energization or sta rt-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 electric al haz ards.

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.

Collision of a Vehicle with Unit Fire at Island Fuel Spill

The following actions are recommended regarding these hazards:

Important Safety Information

• 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-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 2-3

Important Safety Information

This page is intentionally left blank.

Page 2-4 MDE-4331M Atlas® Fuel Systems Installation Manual · Sep tember 2014

Classifying Hazardous Locations Hazardous Locations

20'

*DEF dispensers located outside the 20 feet area are unclassified. Notes: 1) Not applicable to DEF-only dispensers.

2) DEF is not flammable and does not generate explosive vapors. For any requirements, consult local regulatory agencies. For example, units dispensing DEF and diesel must follow the flammable fuel regulatory requirements.

20’

18”

Unclassified

18”

Vapor Barrier

20’

DEF

18”

48”

Division 1

Division 2

Division 2*

18”

Division 1

Division 2

Dispenser Without Vapor Barrier Construction

Dispenser with Vapor Barrier Construction

Class 1 Division 1 (Hazardous Location)

Class 1 Division 2 (Hazardous Location)

Vapor Areas

Fuel Containing Components

3 – Hazardous Locations

Classifying Hazardous Locations

Any activity (such as smoking or drilling) that can cause an explosion must be done well outside the vapor area.

Figure 3-1 is b

Figure 3-1: Hazardous Locations Diagram

sed on National Fire Protection Association (NFPA) 30A and NFPA 70®.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 3-1

Hazardous Locations Important Considerations for DEF Dispensers

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 dro ps below this point, 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.

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. Otherwise, damage to a vehicle’s engine or pollution control devices can 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.

CAUTION

Important Considerations for DEF Dispensers

• 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 wit

h 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 3-2 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Purpose Control Lines for Atlas Electronic Series

4 – Control Lines for Atlas Electronic Series

Purpose

This section is provided to familiarize the installer with control inputs and outputs that are available for the Atlas electronic series dispensing unit. It is recommended that installers read these descriptions to obtain a better working knowledge of the unit to guide them in planning the site wiring. For specific wiring diagrams and installation notes, refer to “Installation”  on page 6-1.

Grounding

Atlas electronic series units may be provided for

use with 230 VAC power for international applications. The operating voltage for control lines to these units is shown in parentheses as (230 VAC International).

If you are connecting the Atlas electronic series unit to a Gasboy Fuel Management System (FMS), refer to the following documents:

Document Number Title GOLD Library

MDE-4298 CFN Series Site Controller III Installation Manual Gasboy CFN Series MDE-4319 TopKAT Fuel Management System Installation Manual Gasboy Series 1000/Fleetkey &

MDE-4811 Islander PLUS and ICR PLUS Installation Manual Gasboy Fleet PLUS System MDE-4813 CFN Plus Installation Manual Gasboy Fleet PLUS System MDE-5013 TopKAT PLUS Installation Manual N/A

TopKAT

To ensure proper operation of the equipment and required safety factors, a good ground line must be provided. A ground wire (preferably green) must be connected between the ground wire of the system and the main electrical service panel. One earth ground connection is required per unit. The ground rod must be a solid, corrosion-resistant conductor and must be installed at the main electrical panel as per the National Electrical Code (NEC). It must be properly tied into the ground bus strip of the panel. It is recommended that n eutral and g round bus strips be bonded together (unless prohibited by local codes).

Ground Fault Interrupter (GFI) breakers are required for DEF

only units installed on and with a skid tank platform because of no underground piping, AC power in potentially wet area, and a potential for earth ground to become broken if skid tank moves.

A GFI works by having a sensor that detects changes in current to the load, by comparing the current owing to and from the load. A drop off in the current equivalent to about 5 mA, turns off all power by tripping a relay within the GFI within a few hundredths of a second.

When powering a dispenser with a GFI, any device that the dispenser supplies power must have its return to the same neutral as the dispenser. For example, the STP control relay.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 4-1

Control Lines for Atlas Electronic Series Micro Feed

Micro Feed

The micro feed is a 115 VAC (230 VAC international) input required to power the microprocessor of the register’s electronics. This power must always remain on and must be on a separate breaker from control lines (control/pump motor feed or control/submersible  feed - side 1, side 2). It must also be on a separate electrical noise and allow separate control of lights. In a site configuration using multiple dispensing units, the power for microprocessors of up to eight units can be supplied by one breaker (except cold weather DEF units). This line also supplies power to the optional T opKAT PLUS. If this unit is equipped with a TopKAT PLUS option, for wiring requirements and information, refer to MDE-5013 TopKAT PLUS Installation Manual.

breaker from fluorescent lights to reduce

The cold weather DEF unit’s internal heater ca circuit. These units must not share breakers with other dispenser.

n share the micro feed AC line and neutral

Micro Neutral

The micro neutral is a return line for AC from the microprocessor of the dispensing unit to the breaker panel. This line also serves as the return for the optional TopKAT PLUS.

Auth/Pump Motor Feed (Self-contained Pumping Units)

The auth/pump motor feed is a 115 VAC (230 VAC international) input that is required to power and authorize the auth control line. This line is used to provide authorization for the self-contained pumping unit (when enabled, refer to MDE-4334 Atlas Start-up/Service Manual). If this line is controlled by an FMS using solid state relays, a resistor assembly must be installed between the auth feed line and feed neutral to prevent false triggering of the authorization input. The resistor assembly is 8.2 K Ohm, 10 W (part number C05818) for  115/230 VAC domestic; and 30 K Ohm, 10 W (part number C06683) for 230 VAC international wiring.

Note: The auth/pump motor feed is not r

The auth/pump motor feed line is used to powe installed). The power used to control the pump is also provided by this line. It is possible to combine control lines for twins and supply them from one breaker. However, the gauge of the wire must be adjusted to handle the load of two motors. The reset complete signal used for external monitoring of the pump also originates from the auth/pump motor feed line.

Two auth/pump motor feed lines are provided for twins.

equired for the TopKAT PLUS system.

r slow flow and fast flow valves (when

Page 4-2 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

External Valve Control Lines for Atlas Electronic Series

External Valve

The external valve line is used to directly power an anti-siphon valve mounted on top of an AST . The valve must operate at the same voltage as the pump motor and the current draw must not exceed 1 A, or the valve must be switched through an external relay controlled by the external valve line. Do not connect two or more external valve lines together. If more than one pump is drawing from the tank, separate anti-siphon valves must be installed, or each external valve line must operate an external relay, which then operates the valve.

Neutral Feed

The neutral feed is the AC current return line back to the breaker panel for all attached devices (pump motor, reset motor, and solenoid valves).

Auth Input Dispensers

The auth input is a 115 VAC (230 VAC international) input that is required to power and authorize the auth control line. This line is used to provide authorization for the dispensing unit (when enabled, refer to MDE-4334 Atlas Start-up/Service Manual). If this line is controlled by an FMS using solid state relays, a resistor assembly must be installed between the auth feed line and feed neutral to prevent false triggering of the authorization input. The resistor assembly is 8.2 K Ohm, 10 W (part number C05818) for 115/230 VA C domestic and 30 K Ohm, 10 W (part number C06683) for 230 VAC international wiring. Cash Flow Network (CFN) systems require the resistor assembly only when they are used with the Atlas commercial electronic pump/dispenser operating in standalone mode. Operating the Atlas commercial electronic unit in standalone mode with a CFN system requires an optional mechanical pump control unit. This line also supplies power, which is switched to slow flow and fast flow valves along with the switch detect signal. Two lines are provided for twins.

If the Atlas commercial electronic unit is to be controlled t special care must be taken in the wiring of submersible control lines when a common submersible is used for more than 1-hose outlet. For more information, refer to “Submersible

Starter Drive (Subm Starter Drive)” and “Submersible Pump Drive (Subm Pump Drive)” 

on page 4-4.

hrough the authorization of this line,

Units with Standard Submersible Starter Drive (Subm Starter Drive)

Power for the submersible start drive line originates from the AUTH input. The submersible starter relay line in standard remote dispensers is not capable of directly powering a submersible pump. A starter relay must be used. Control lines for twin remote dispensers can be combined together and powered by one breaker if individual control of each side is not required. In site configuration using multiple remote dispensers, power for control lines of up to 8-hose outlets (eight singles or eight twins) can be supplied from one breaker.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 4-3

Control Lines for Atlas Electronic Series Submersible Starter Drive (Subm Starter Drive)

Units with Submersible Pump Drive Relay Option

Power for the submersible pump drive line originates from the motor feed input. Units equipped with optional relays for direct submersible pump drive can be connected directly to submersible pumps up to 3/4 HP at 115 VAC, or 1-1/2 HP at 230 VAC. The gauge of this wire must be determined according to the size of the motor, the voltage at which the motor will be powered, and the distance from the breaker panel to the pump.

Submersible Starter Drive (Subm Starter Drive)

The submersible starter drive is a 115 VAC (230 VAC International) output used to control a submersible starter relay. Two lines are provided for twins. This line is capable of supplying 300 mA of AC current to control the coil of the submersible motor contactor (starter relay). This is sufficient for directly connecting to popular models, but if in doubt, check the contactor (relay) manufacturer’s data sheet for the sealed VA rating. Divide the sealed VA by the coil voltage to determine the current. This line must not be connected directly to the submersible pump, shorted to any conduit or chassis metal, or incorrectly wired; otherwise, the Central Processing Unit (CPU) Printed Circuit Board (PCB) will be instantly damaged. This line must be left capped when not in use. To avoid accidental damage, follow checks before applying power.

Note: When multiple dispensers are used to contr

pump, and the Atlas commercial electronic unit is controlled (authorized) through the auth/pump motor feed line (as in the case of some FMSs), it is important that lines from the Atlas commercial electronic unit to the submersible equipment be isolated from each other. This can be accomplished by running submersible control lines through a secondary set of relay contacts in the FMS. If a secondary set of contacts is not available, external control re lays must be used between the Atlas commercial electr onic unit and the submersible starter relay or pump. Another option is to provide a separate submersible starter relay for each hose outlet. In no case must the submersible drive lines from the Atlas commercial electronic unit be tied together.

ol a common submersible starter relay or

Submersible Pump Drive (Subm Pump Drive)

The submersible pump drive is not available on all Atlas models for remote dispensers, and is active only when submersible drive relays are supplied. The submersible drive is a  115/230 VAC (230 VAC international) submersible pump. When connected directly to the submersible pump, the motor size cannot exceed 3/4 HP at 115 VAC, or 1-1/2 HP at 230 V AC. Two lines are provided for twins. In cases where both lines control the same starter relay or pump, they can be combined. This line is also used to control an external valve used on AST installations.

Note: For situations where more

to the note in “Submersible Starter Drive (Subm Starter Drive)”.

output used to control the submersible starter relay or

than one-hose outlet uses the same submersible pump, refer

Page 4-4 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Reset Complete (Switch Detect)/Slow Flow Control Lines for Atlas Electronic Series

Reset Complete (Switch Detect)/Slow Flow

The reset complete/slow flow is a 115 VAC (230 VAC international) output used to indicate that the reset process is complete and the unit is ready to dispense the product. It may be required when used with an FMS. It may also be used to control a remote (satellite)  slow flow valve. Two lines

are provided for twins.

In addition to the internal load of the slow flow valve, maximum of 170 mA AC to the satellite valve and FMS. When you are connecting it to a  non-Gasboy satellite or FMS, ensure that this limit is not exceeded. This line must not be shorted to any conduit or chassis metal, incorrectly wired, used to control both stages of a satellite valve, or be connected to equipment requiring more than 170 mA AC from this line to operate; otherwise, the CPU PCB will be instantly damaged. This line must be left capped when not in use. To avoid accidental damage, follow checks before applying power.

Fast Flow Valve

The fast flow valve is a 115 VAC (230 VAC International) line that can be used to control a remote (satellite) fast flow valve. Two lines are provided for twins. In addition to the internal load of the fast flow valve, this line is capable of supplying 170 mA AC to the satellite valve. When connected to a non-Gasboy satellite, ensure that this limit is not exceeded. This line must not be shorted to any conduit or chassis metal, incorrectly wired, used to control both stages of a satellite valve, or be connected to equipment requiring more than 170 mA from this line to operate; otherwise, the CPU PCB will be instantly damaged. This line must be left capped when not in use. To avoid accidental damage, follow checks before applying power.

Phase 2 Feed

this line is capable of supplying a

The phase 2 feed is a hot feed, which is the opposite phase of pump motor feed. This line and pump motor feed are used for 230 VAC domestic motor applications. If connected to equipment requiring control of the authorization input, phase 2 feed must be switched through a separate relay to prevent false triggering of the authorization signal.

Slow/Fast Satellite Return

The slow/fast satellite return lines are used only in units that come equipped with satellite piping. They are used in applications where the remote dispenser and satellite may not dispense the product at the same time. These lines are not connected internally as they leave the factory . Four lines ar e provided for twins. These lines must not be shorted to any conduit or chassis metal, or be connected to equipment requiring more than 170 mA from each line to operate; otherwise, the CPU PCB will be damaged instantly. These lines must be left capped when not in use. To avoid accidental damage, follow checks before applying power.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 4-5

Control Lines for Atlas Electronic Series Light Feed

V+ (24 VDC Maximum)

Pulser #1 Input (100 mA Maximum)

Pull-up Resistors not supplied with 9800

Pulser #1 Input (100 mA Maximum)

FMS

Ground

Pulse 1

Pulse 2 Return

Black

White

Green

Gasboy 9800 Pump I/F PCB

Leave Capped in 9800 Junction Box (J-box)

TLP627

Red

Light Feed

The light feed is a 115 VAC input required to power fluorescent lights. In a site configuration using multiple remote dispensers (or pumps), the power for lights of up to eight units can be supplied by one breaker. It is recommended that this be on a separate breaker from the  micro/heater feed to reduce electrical noise and allow separate control

of lights.

Light Neutral

The light neutral is a return line for AC current from lights to the breaker panel. When a separate breaker is not used to control lights, the light neutral is attached to the micro neutral.

Pulser

When the dispensing unit includes the optional pulser interface, a pulser output is provided. This pulser output provides a DC output that indicates the quantity of product dispensed. The pulse rate can be configured by a sealable Dual In-line Package (DIP) switch for rates of 1, 10, 100, 250, or 500 pulses per gallon, or 1, 10, 100, or 250 pulses per liter. For the Atlas commercial electronic pump, pulse rates are 1, 10, 100, 250, or 500 pulses per gallo n, or 1, 10, or 100 pulses per liter.

The output is an open collector transistor capable of sinking up to 100 m A DC at voltages up to 24 VDC. The

DC ground for the circuit comes from the FMS. Since the transistor switches between ground and high impedence, the installer must provide a voltage reference when the transistor is in the high impedence state. This reference voltage is provided by a pull-up resistor installed at the FMS between the pulser input and reference voltage. The value of this resistor is calculated based on the voltage and current requirements of the FMS pulser circuit.

Figure 4-1: Pulsers

Page 4-6 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

RS-485 Control Lines for Atlas Electronic Series

In the main J-box, the optional pulser interface is supplied with eight wires. On Ultra-Hi units, a separate DC J-box with six wires is supplied. The unused wires in the J-box must be individually capped.

RS-485

When the dispensing unit includes the optional RS-485 interface, RS-485 lines are provided. This interface allows you to connect a Gasboy CFN series system directly to the Atlas commercial electronic series dispensing unit. These lines must be capped individually when not in use. The RS-485 interface is included with the TopKAT PLUS option.

Local Area Network (LAN)/Wide Area Network (WAN)

When the dispensing unit includes the optional T opKAT PLUS, lines for communication to the TopKAT PLUS are provided. These lines allow you to communicate directly to the TopKAT PLUS through a LAN/WAN connection. For more information on LAN/WAN wiring, refer to

MDE-5013 TopKAT PLUS Installation Manual.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 4-7

Control Lines for Atlas Electronic Series Local Area Network (LAN)/Wide Area Network (WAN)

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Page 4-8 MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014

Purpose Control Lines for Atlas Mechanical Series

5 – Control Lines for Atlas Mechanical Series

Purpose

This section is provided to familiarize the installer with control inputs and outputs that are available for the Atlas mechanical series dispensing unit. It is recommended that installers read these descriptions to obtain a better working knowledge of the unit to guide them in planning the site wiring. For specific wiring diagrams and installation notes, refer to

“Installation” on page 6-1.

Grounding

The Atlas mechanical series may be provided fo applications. The operating voltage for control lines to these units is shown in parentheses as (230 VAC international).

If you are connecting the Atlas mechanical unit to a Gasboy FMS, refer to the following documents:

Document Number Title GOLD Library

MDE-4298 CFN Series Site Controller III Installation Manual Gasboy CFN Series MDE-4319 TopKAT Fuel Management System Installation Manual Gasboy Series 1000/Fleetkey & TopKAT MDE-4811 Islander PLUS and ICR PLUS Installation Manual Gasboy Fleet PLUS System MDE-4813 CFN Plus Installation Manual Gasboy Fleet PLUS System MDE-5013 TopKAT PLUS installation Manual Gasboy Series 1000/Fleetkey & TopKAT

To ensure proper operation of the equipment and required safety factors, a good ground line must be provided. A ground wire (preferably green) must be connected between the unit’s AC J-box ground lug and main electrical service panel. One earth ground connection is required per unit. The ground rod must be a solid, corrosion-resistant conductor that must be installed at the main electrical panel as per the NEC. It must be properly tied into the ground bus strip of the panel. It is recommended that the neutral and ground bus strips be bonded together (unless prohibited by local codes).

r use with 230 VAC power for international

GFI breakers are required for DEF only units installed on and because of no underground piping, AC power in potentially wet area, and a potential for earth ground to become broken if skid tank moves.

When powering a dispenser with a GFI, any device that the dispenser supplies power must have its return to the same neutral as the dispenser (for example, the STP control relay).

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 5-1

with a skid tank platform

Control Lines for Atlas Mechanical Series Reset Motor Feed

Reset Motor Feed

The reset motor feed is a 115 VAC (230 VAC international) input supplied through the pump handle switch to activate the reset motor. Without power being supplied to this line, the unit will not reset when the pump handle is turned on. Two feed lines are provided for twins. This feed is also connected to the input of one of the internal switches of the electric reset. When the reset finishes its cycle, the 115 VAC (230 VAC international) input to the switch will be passed through as an output, causing the solenoid valve (optional in some models) to open and the reset complete line to indicate 115 VAC (230 VAC international).

Pump Motor Feed

The pump motor feed is a 115 VAC (230 VAC international) input supplied to the input side of one of the internal switches of the electric reset. When the reset finishes its cycle, the  115 VAC (230 VAC international) input to the switch the pump motor to receive power and begin operation. Without power to this line, the unit will reset and will be unable to fuel. Two feed lines are provided in twins that contain two motors. The gauge of this wire (and its neutral wire) must be determined according to the size of the motor, the voltage at which the motor will be powered (115 VAC or 230 VAC), and the distance from the breaker panel to the pump. It is possible to combine pump motor feeds for twins and supply them from one breaker. However, the gauge of the wire must be adjusted to handle the load of two motors.

is passed through as an output, causing

Return (Neutral)

The return is the AC current return line back to the breaker panel for all attached devices (pump motor, reset motor, and solenoid valves). The gauge of this wire must be equal to that of the pump motor feed (suction pumps) or submersible feed (remote dispensers). This wire is commonly referred to as the neutral wire.

Submersible Feed, Submersible Drive

The submersible feed is a 1 15 VAC (230 VAC international) input supplied to the input side of one of the internal switches of the electric reset. When the reset finishes its cycle, the  115 VAC (230 VAC international) input to the switch is pas (submersible drive) to drive a starter relay or to directly drive a submersible motor up to one HP at 115 VAC/230 VAC. Any submersible motor exceeding this limitation must use a starter relay.

sed through as an output

Reset Complete (Switch Detect)/Slow Flow

The reset complete is a 115 VAC (230 VAC international) output used to indicate that the reset is complete and the dispensing unit is ready to dispense the product. T wo lines are provided for twins. Use this line only when monitoring a dispensing unit that is connected to a FMS. This line must be capped when not in use, and is connected to the slow-flow stage of the solenoid in the pump.

Page 5-2 MDE-4331M Atlas® Fuel Systems In stallation Manual · September 2014

Fast Flow Control Lines for Atlas Mechanical Series

Fast Flow

The fast flow is a 115 VAC (230 VAC international) input that controls the fast flow valve of the pump/remote dispenser (when a slow/fast flow valve is available). If slow/fast-flow control is not required, this line must be tied to reset the complete/slow-flow line. The line must be switched through the FMS and be turned on only when the pump/remote dispenser is authorized and in the fast-flow mode. This line will be switched on when the pump/remote dispenser is in the manual mode.

Light Feed

The light feed is a 115 VAC (230 VAC international) input required to power fluorescent lights. In a site configuration using multiple remote dispensers (or pumps), power for lights for up to eight units can be supplied by one breaker. If separate control of lights is not required, the light feed for each dispensing unit may be taken from its reset motor feed, provided the unit is not connected to a FMS.

Light Neutral

The light neutral is a return line for AC from lights to the breaker panel. When a separate breaker is not used to control lights, the light neutral is attached to the neutral, which is connected to the reset motor.

Phase 2 Feed

The phase 2 feed is a hot feed, which is the opposite phase of pump motor feed. This line and pump motor feed are used for domestic 230 VAC motor applications.

Pulser

The pulser supplies a DC output that indicates the quantity of product dispensed. Pulsers are optional and are used only when monitoring the dispensing unit that is connected to a FMS. The pulser wiring must run in a separate conduit away from AC power control lines.

MDE-4331M Atlas® Fuel Systems Installation Manual · September 2014 Page 5-3

Control Lines for Atlas Mechanical Series Pulser

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