Gasboy Electric Keytrol User Manual



ELECTRIC KEYTROL

INSTALLATION/PARTS MANUAL

035242

REV. 03/28/03

The information in this document is confidential and proprietary. No further disclosure shall be made without permission from Gasboy International LLC. Gasboy International LLC believes that the information in this document is accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.

GASBOY INTERNATIONAL LLC LANSDALE, PA

CONTENTS

Section 1: INTRODUCTION

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

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

Section 2: SYSTEM FEATURES

Power Supply............................................................................................ 2-1

Power Relay.............................................................................................. 2-1

Anti-Multi Key Count Feature.................................................................... 2-1

Manual/Automatic Bypass Switch............................................................. 2-1

Anti-False Count on Startup...................................................................... 2-2

Missing Pulse Detector (MPD).................................................................. 2-2

Start Delay (SD)........................................................................................ 2-3

Lockout...................................................................................................... 2-4

Anti-Surge Diodes..................................................................................... 2-4

Heater ....................................................................................................... 2-4

Section 3: INSTALLATION

Installation Precautions............................................................................. 3-1

General Instructions.................................................................................. 3-2

Factory-Mounted Units on Pump or Dispenser.................................... 3-2

Field-Mounted Master or Auxiliary Electric Keytrol .............................. 3-2

Section 4: WIRING

Wiring Precautions.................................................................................... 4-1

Grounding ................................................................................................. 4-2

Circuit Breakers......................................................................................... 4-2

Voltage Requirements............................................................................... 4-2

Wire Size................................................................................................... 4-3

Electric Keytrol - Factory-Mounted to Top of Pump or Dispenser........ 4-3

Electric Keytrol - Remotely Mounted from Pump or Dispenser............ 4-3

Conduit...................................................................................................... 4-4

Wiring Diagrams........................................................................................ 4-4

Wiring Schematic ...................................................................................... 4-5

Standard Wiring Diagrams - Remote Mount ............................................. 4-6

Standard Wiring Diagrams - Split.............................................................. 4-7

Wiring Diagram 024267............................................................................. 4-8

Wiring Diagram 024268............................................................................. 4-9

Wiring Diagram 024269............................................................................. 4-10

Wiring Diagram 024270............................................................................. 4-11

Wiring Diagram 024271............................................................................. 4-12

Wiring Diagram 024272............................................................................. 4-13

Wiring Diagram 024273............................................................................. 4-14

Wiring Diagram 024274............................................................................. 4-15

Wiring Diagram 024275............................................................................. 4-16

Wiring Diagram 024276............................................................................. 4-17

Section 5: OPERATING SEQUENCE

Operating Instructions............................................................................... 5-1

Manager Instructions for Bypassing Electric Keytrol................................. 5-1

03/28/03 Contents-1

GASBOY Electric Keytrol

Section 6: MAINTENANCE AND TROUBLESHOOTING

Maintenance of Your Electric Keytrol........................................................ 6-1

Demand Competent Service................................................................ 6-1

Use Authorized Parts........................................................................... 6-1

Operate with Reasonable Care............................................................ 6-1

Preserve the Electric Keytrol Cabinet .................................................. 6-1

Troubleshooting......................................................................................... 6-2

Anti-False Count Relay, P/N 0M0017 ....................................................... 6-2

Power Relay P/N 0M0015......................................................................... 6-2

Power Supply Transformer ....................................................................... 6-3

For 115VAC Units, P/N 0M0008.......................................................... 6-3

For 230VAC Units, P/N 0M0055.......................................................... 6-3

Counter or Totalizer, P/N 0M0010 ............................................................ 6-3

Keyswitch (Microswitch: 0M0011, includes tumbler)................................. 6-4

Keyswitch (Tumbler: 0M0011, includes microswitch)................................ 6-4

Adding Modules in the Field...................................................................... 6-5

Pulser Installation on Existing Registers................................................... 6-5

Section 7: PARTS

Using This Parts List ................................................................................. 7-1

Electrical Keytrol Assembly....................................................................... 7-3

Bottom Bracket Assembly......................................................................... 7-5

Counter Module Assembly........................................................................ 7-7

Bottom Bracket Assembly for Dual Pump Control..................................... 7-9

Contents-2 03/28/03

Section 1

INTRODUCTION

PURPOSE

The Gasboy Electric Keytrol Installation/Oper ation Manual is provided to assist the installer and user in installing and operating the unit. This manual should be supplied to the electrician prior to the installation of conduit and wiring, to ensure the unit is properly installed. The unit must be installed and operated as described in this manual to ensure reliability and satisfactory operation. In addition, this manual contains warnings, safeguards, and procedures on the use and care of the unit. This manual should reside with the owner of the unit after the installation is complete.

GENERAL DESCRIPTION

The Electrical Keytrol is a Fuel Management System designed to provide 24-hour, unattended control of the dispensing of motor fuel. The basic system consists of a control cabinet containing up to 50 modular keyswitch/electro-mechanical totalizers (counters) in strips of 5 or 10, up to a maximum of 50 counters per unit. Each user has his own key to actuate the pump, and have the quantity of fuel dispensed totalized on his own counter. Auxiliary (slave) units can be added to increase the number of counters required.

The unit may be factory-mounted to the top of a GASBOY pump or dispenser, or mounted remotely. The factory mounted version is available on a single hose pump or dispenser as a Master cabinet for up to 50 counters, or a Master/Auxiliary cabinet (back to back) for up to 100 counters. On twin hose pumps or dispensers, a Master/Master arrangement may be used for up to 50 counters per hose, or a Split Dual Control cabinet may be used. In this case, the counters in a single cabinet are divided to control both hoses, with a combined maximum of 50 counters for the two hoses.

Standard Features on the GASBOY Electric Keytrol include;

Six-digit, non-resettable counters in 0.1 gallon or whole liter increments. Quantity of counters

are available in 5-counter increments.

A working voltage of 115 VAC, 60 Hz. (Optional 230 VAC, 50 or 60 Hz. available).

The standard cabinet finish is painted the color of the dispenser, or white for remote-mounted

units. Other colors available upon request. ( Cabinet dimensions: 18-1/8” high x 17-1/8” wide x 6-3/8” deep)

Anti- Multi Key Count Feature ensures the accumulation of counts on only one counter in the

event that a second (or more) key is inserted while the pump is being operated.

Manual - Automatic By-Pass Switch allows the user to bypass the Electric Keytrol and

operate the dispenser without using a key to activate the system.

Anti-False Count on Start-Up feature prevents a false count from recording upon start-up.

03/28/03 1-1

GASBOY Electric Keytrol

Missing Pulse Detector (MPD) feature alerts the user of a situation where the counter is not

receiving pulses from the pump pulser. After the key is inserted and tur ned on, an alarm will sound if no pulses are received within a preset length of time. This feature also serves as a key reminder alarm. After fueling is complete and the pulser stops, the alarm will sound after the preset time if the key is not turned off. The MPD feature is not available on Split Dual Pump Control Units.

Time Delay on T urn-On (Start Delay:SD) feature prevents pulse counts from being missed if

the key is turned off and on while dispensing fuel. The SD feature is not available on Split Dual Pump Control Units.

Lockout feature allows individual keyswitches to be locked-out from use.

Anti-surge diodes minimize pulser and time delay relay contact erosion.

Optional features include;

Stainless steel cabinet

230V operation

Resettable Accumulative Totalizer

Liter measurement (counters measure in one liter increments)

Universal Electric Keytrol (for remote mounting)

1-2 03/28/03

Section 2

SYSTEM FEATURES

POWER SUPPLY

24 volts DC is supplied via a 115/24 volt transformer (230/24 volt transformer for 230 VAC EK’s) and bridge rectifier made up of diodes D1-D4. Any multimeter or DC voltmeter may be used to check the power supply voltage, which should be 24 +

POWER RELAY

The power relay is rated at 3/4 HP at 115 or 230 VAC. It is permanently wired in to br eak the hot side of the 115 VAC line or L1 of the 230 VAC line. One side of a 115 VAC motor is connected to neutral by the customer, and the other side of the motor is fed from the output of the power relay or motor switch terminal on the Electrical Keytrol terminal block. In case of the 230 VAC motor, one side of the motor is connected to L2 while the other is connected to the Electrical Keytrol motor (switch) terminal.

ANTI-MULTI KEY COUNT FEATURE

The keyswitches are wired in series, which ensures the accumulation of counts on only one counter in the event that a second (or more) key is inser ted while the pump is being operated. See diagram below. For example, if keyswitch 2 is turned on, all keyswitches after this position will not function. If, however, while user 2 is pumping fuel and user 1 inserts his key, the pulses will accumulate on totalizer 1, but not on totalizer 2. Any user will immediately r ealize his error, since the totalizer will start counting while the user still has his hand on the key.

5 VDC. for 115 or 230 VAC, 50-60HZ.

MANUAL/AUTOMATIC BYPASS SWITCH (AUTO/MAN)

The function of the Electric Keytrol may be bypassed by setting the Auto/Man switch to the Manual position. This setting allows fueling without using a key and/or without totalizing the fuel

on any counter. It is also used in the event of a failure of any electrical portion of the Keytrol.

03/28/03 2-1

GASBOY Electric Keytrol

ANTI-FALSE COUNT ON STARTUP

A time delay relay is used to prevent a false count during startup (See figure below). If the pulser is open, no count occurs upon start-up since the circuit is open. When the pulser is in a closed position, Relay K2 (the time delay relay) is energized and its contact (K2-1B, which is normally closed) is open, again preventing a count.

Upon receiving pulses from the pulser, the relay will drop out in 50 milliseconds. The next pulser closure causes current flow through the normally closed (NC) contact, and actuates the totalizer. Fifty milliseconds later, while the pulser is still closed, K2 (or Ktd) energizes, its contact opens, dropping power to the totalizer, thereby reading the fuel in 0.1 gallon increments and not one-half counts as other devices are prone to do. The 50 millisecond delay of the relay permits a maximum pumping rate of 60 gpm (227 liters) dispensing and totalizing in 0.1 gallon (or whole liter) increments.

MISSING PULSE DETECTOR (MPD)

Not available on Split Dual Pump Control Units The Missing Pulse Detector (MPD) circuitry senses pulses from the pump pulser. If no pulses are received after the key is inserted and turned in the Electric Keytrol within a preset time, the main power relay will open and an alarm will sound. The alarm will continue to sound until the key is turned off, whereby the MPD circuitry is reset.

This circuit is primarily designed to prevent dispensing of fuel if the pulser is not functioning properly. This could be due to a broken cable or shaft linking the pulser to the computer, or a broken wire from the pulser to the Electric Keytrol.

2-2 03/28/03

System Features

The MPD delay is set by applying a slotted screwdriver to the adjuster, K4, located on the relay at the extreme left of the bottom bracket. It is factory-set to 30 seconds, but can be adjusted to between 2 to 180 seconds. This same timer also detects the time between pulses, so that a pulser that malfunctions after fueling has started will also actuate the MPD circuitry. Ever y pulse resets the timer to zero.

The MPD option also serves as a key reminder alarm. After fueling is complete, and the pulser stops, the alarm will sound (and power relay open) within the pre-set time (nominally 30 seconds).

This relay may be bypassed by a toggle switch located on the upper left portion of the bottom bracket.

START DELAY (SD)

Not available on Split Dual Pump Control Units. The GASBOY Electric Keytrol is supplied with an additional time delay relay that provides a delay on initial turn-on. The delay is adjustable from 3 to 180 seconds. It has been factory set for 3 seconds. Just like the missing Pulse Detector (MPD) relay, it can be set by the owner to the time desired. See figure below for the location of the different relays.

Upon actuation of a key, there will be a three second delay before power is applied to the Electric Reset in the pump or dispenser. Consequently, the register will reset to zero after this delay time and the fuel can then be dispensed. However, rapid switching of the key will not turn the pump on and off. It is suggested that the time be set for three seconds to minimize customer inconvenience. However, to prevent excessive product losses, set the time to ten seconds or greater.

This relay may be bypassed by a toggle switch located on the upper left portion of the bottom bracket.

7176 2-3

GASBOY Electric Keytrol

LOCKOUT

Individual lockout is provided by means of a 10PST switch mounted at the bottom of each module. (5PST on 5 counter versions). Access to this portion is accomplished by removing the locked bezel. The switch can be actuated with the tip of a ball-point pen or any other pointed object. To reinstate, push the top of the switch lever in firmly. The switch is numbered 1-10 from left to right on 10 counter modules and 1-5 on 5 counter modules.

ANTI-SURGE DIODES

Diodes D5 and D6 are placed across the time delay relay (K2) and selected totalizer in the reverse direction. Upon opening of the inductive circuit, the current surges through the diode, minimizing pulser and K2 relay contact erosion.

HEATER

A heating element controlled by a thermostat set at 40 temperatures fall below the recommended operating temperature. The heater/thermostat circuitry is continuously connected to the 115 VAC (or 230 VAC) line, but will operate only when the temperature drops below 40

When an auxiliary unit is used, the 115 VAC or 230 VAC line must be connected from the master unit for powering the heater, along with the other interconnections.

°F.

°F protects electrical components when

2-4 03/28/03

Section 3

INSTALLATION

INSTALLATION PRECAUTIONS

All installations must conform with all building/fire codes, all Federal, State, and Local codes, National Electrical Code, (NFPA 70), NFPA 30, and Automotive and Marine Service Station Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code.

Plan your installation carefully. Dispensing troubles, which seem to be related to the pump or Electric Keytrol, are frequently traced to the installation. Review the following list of installation DO’s and DON’T’s to avoid potential problems:

1. DO read the WARNINGS page at the front of this manual, preceding the Table of Contents. It contains important information regarding the safe use of your dispensing equipment.

2. DO install an emergency power cutoff. In addition to circuit breaker requirements of NFPA 70 and NFPA 30A, a single control which simultaneously removes AC power from all site dispensing equipment is recommended. This control must be readily accessible, clearly labeled, and in accordance with all local codes.

In order to provide the highest level of safety to you, your employees, and customers, we

recommend that all employees be trained as to the location and procedure for turning off power to the entire system.

3. DO have the Electric Keytrol installed by a competent installer/electrician.

4. DO NOT experiment with a pump or Electric Keytrol if you are not sure that the installation is correct.

5. DO NOT overload sub or main breaker panels.

6. DO NOT use power line wiring of inadequate capacity. (Use gauge specified by the wiring diagram or wire chart provided in the Wiring section of this manual.)

7. DO NOT use circuit breaker of improper size (See Wiring section of this manual).

8. DO NOT use knock-out boxes or flexible conduit for installing this unit. All wires should be run in threaded, rigid metal conduit. All threaded connections must be drawn up tight with five (5) threads minimum engagement. At completion of the installation, it is the installer’s responsibility to ensure that any unused openings are plugged.

03/28/03 3-1

GASBOY Electric Keytrol

GENERAL INSTRUCTIONS

Upon receiving, perform the following:

1. Unpack carefully and report any damage immediately.

2. Using the door key, unlock and open door. (Door opens only 90

this point.)

3. Using the bezel key, remove the bezel by pulling gently outward and down after clearing the

bottom, front of the cabinet. (NOTE: Do not overtighten bezel locks. Tighten lock with key

making 3 to 4 complete turns.)

4. Ensure that all screws holding the modules are in place and tight.

5. Ensure that all terminal block screws are tight.

6. Ensure that no damage has occurred during shipment. Report any damage immediately.

7. Ensure that the time delay relay is properly installed in the upper octal socket (not available

on Split Dual Pump Control units).

CAUTION! Relay and socket are “keyed”, so be careful to align these properly when

reinstalling.

8. Ensure that the missing pulse detector is set for 15 seconds (not available on Split Dual

Pump Control units).

Factory-Mounted Units on a Pump or Dispenser

Follow installation instructions supplied with pump or dispenser.

Field-Mounted Master or Auxiliary Electric Keytrol

IMPORTANT: Do not install in Class 1, Division 1 or Division 2 hazardous location.

1. When mounting on a wall or post, the use of a shelf is recommended; order GASBOY P/N

014632.

2. Auxiliary Keytrol units must be of the appropriate power rating. Units are available for 115

VAC or 230 VAC applications.

3. Install wires in accordance with the National Electrical Code (NF PA 70). Also, all wiring must

conform with local electrical codes. Units must be properly grounded.

4. Seal conduit as per NEC requirements.

°, so do not force it beyond

3-2 03/28/03

Section 4

WIRING

☎ Customers and installers having any questions pertaining to the installation should

contact their GASBOY distributor.

WIRING PRECAUTIONS

The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble-free operation of your GASBOY Electric Keytrol and your pump/remote dispenser. To assure a quality installation, follow these rules:

1. All wiring must be installed to conform with all building/fire codes, all Federal, State, and

Local codes, National Electrical Code, (NFPA 70), NFPA 30, and Automotive and Marine Service Station Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code.

2. Use only threaded, rigid, metal conduit.

3. Use only UL-labeled, insulated, gasoline and oil-resistant, stranded copper wiring of the

proper size.

4. Wire connections should be tightly spliced and secured with a wire nut; close off the open end

of the wire nut with electrical tape.

5. The line to the motor should be on a separate circuit and installed on a breaker sufficiently

sized for the motor size and/or the voltage setting.

6. Install an emergency power cutoff. In addition to circuit breaker r equirements of NFPA 70

and NFPA 30A, a single control which simultaneously removes AC power from all site dispensing equipment is recommended. This control must be readily accessible, clearly labeled, and in accordance with all local codes.

In order to provide the highest level of safety to you, your employees, and customers, we

recommend that all employees be trained as to the location and procedure for turning off power to the entire system.

WARNING:

To reduce the risk of electrical shock when servicing, turn off all power to the pump/remote dispenser. In submersible pump applications, turn off power to the submersible pump and any other remote dispensers which use that submersible pump. AC power can feed back into a shutoff dispenser when dispensers share a common submersible pump or starter relay.

7. Have the Electric Keytrol and the pump/remote dispenser installed by a competent

installer/electrician.

03/28/03 4-1

GASBOY Electric Keytrol

GROUNDING

To ensure proper operation of the equipment and provide the necessary safety factors, this unit must be grounded. A ground wire (preferably green) must be connected between the ground terminal position of a remotely-mounted Electric Keytrol, and the main electrical service panel. When the Keytrol is factory-mounted to a pump or dispenser, the pump or dispenser must be properly grounded. One (1) earth ground connection is r equir ed per unit. T he ground r od is to be a solid, corrosion-resistant conductor and must be installed at the main electrical panel in accordance with the National Electrical Code. It should be properly tied into the ground bus strip of the panel. We recommend the neutral and ground bus strips be bonded together (unless prohibited by local codes).

CIRCUIT BREAKERS

Power to the unit should be supplied from a dedicated breaker . No other equipment should be powered from this breaker. Units directly driving pumps (suction or submersible) should be supplied power from a separ ate breaker. A tag on the motor identifies the maximum cur rent draw of the motor. If two (2) pumps are supplied from one breaker, that breaker must be capable of handling the load of both motors. In cases where multiple remote dispensers supply power to a single submersible pump, all breakers controlling the remote dispenser must be on the same phase of power. Failure to do this will damage the equipment. Provisions must be made to break both legs of any AC circuit.

VOLTAGE REQUIREMENTS

This unit must be supplied with at least 105VAC (210VAC for 230VAC units) to ensure proper operation. Power should be checked between positions 7 and 8 (H and N or L1 and L2) of the main terminal block in the Keytrol housing while the pump is idle and running in bypass. If the power drops below the minimum allowable levels during either of these operation modes, the Keytrol controls may not function properly.

4-2 03/28/03

Wiring

WIRE SIZE

Electric Keytrol - Factory Mounted to Top of Pump or Dispenser

When installing a GASBOY Electric Keytrol, wiring of sufficient size is required. When the Keytrol is mounted directly to the top of a GASBOY pump or dispenser, the Keytrol is pre-wired to the dispenser at the factory. Field wiring for this configuration may be referenced by the wiring diagram for your model pump or dispenser.

Electric Keytrol - Remotely Mounted from Pump or Dispenser When the Electric Keytrol is mounted remotely from the dispenser, use the following Wire Size

table as a guide to determine the required sizes for the AC wiring to the master Electric Keytrol unit. As shown in the table, the wire size is dependent on the HP rating of the pump motor, the distance from the circuit breaker to the pump/remote dispenser, and the operating voltage ( 115 or 230 VAC) of the circuit.

If multiple units are powered from the same breaker through the same wires, you must increase the gauge of the wires to handle the added load according to the distance from the breaker panel and the HP rating (if applicable).

AC wiring from a Master Electric Keytrol unit to an Auxiliary Keytrol unit (Hot, Neutral, and Ground for 115 VAC, or L1, L2, and Ground for 230 VAC) must be 14 AWG minimum, and sized according to the breaker feeding the Keytrol. Positions 4 through 7 on an Auxiliary Keytrol unit (marked A, B, C, and D on the terminal block) handle DC current and should be connected to the Master Keytrol, or other Auxiliary Keytrol Units, with 18 AWG wiring.

The DC wire size for the Pulser lines must be 18 AWG minimum.

Wire Size

8021 4-3

+ 33 hidden pages