Gasboy EQ 25 XXX User Manual

Page 1

Introduction

This manua l provides installation instructions for the following Gasboy Pulser Kits:

Required Reading

Before installing a kit, the installer must read, understand, an d follow:
• This manual
• NFPA 30A, The Automotive and Marine Service Station Code
• NFPA 70, The National Electric Code
MDE-4485
Gasboy Pulser Kits X:1 EQ 25 XXX
Installation
June 2005
Kit number Kit Description
032796 Pulser Kit X:1 EQ 25 GAS 033088 Pulser Kit X:1 EQ 25 LTR GAS 033140 Pulser Kit X:1 EQ 25 LTR DSL 033148 Pulser Kit X:1 EQ 25 DSL
Failure to do so may adversely affect the safe use and operation of the equipment.
Note: This kit must be installed by a Gasboy Authorized Service Contractor (ASC) to ensure

Required Tools

The following tools are needed to install the Pulser Kits:
warranty.
• Standard Wrench Set
• Flat tip screwdriver
• Cross tip screwdriver
• Punches (to remove and install pins)
MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation • June 2005 Page 1
Page 2
Introduction

Parts Lists

032796 - Pulser Kit X:1 EQ 25 Gas

Part Number Description Quantity 037219 25 Gas Pulser Register Meter 1
M06028A001 Pulser Module Model 25 1 M05613B001 Gasket 1 M05617B001 Gasket 1

033088 - Pulser Kit X:1 EQ 25 Liter Gas

Part Number Description Quantity 037217 25 Liter Gas Pulser Register Meter 1
M06028A001 Pulser Module Model 25 1 M05613B001 Gasket 1 M05617B001 Gasket 1

033140 - Pulser Kit X:1 EQ 25 Liter Diesel

Part Number Description Quantity 038926 25 Liter Dsl Pulser Register Meter 1
M06028A001 Pulser Module Model 25 1 M05613B001 Gasket 1 M05617B001 Gasket 1

033148 - Pulser Kit X:1 EQ 25 Diesel

Part Number Description Quantity 038947 25 Dsl Pulser Register Meter 1
M06028A001 Pulser Module Model 25 1 M05613B001 Gasket 1 M05617B001 Gasket 1
Page 2 MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation • June 2005
Page 3

Important Safety Information

Important Safety Information
This section introduces the hazards and safety precautions associated with ins talling, i nspecting, ma intainin g or servicing this product. Before perform ing any tas k on this produ ct, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death or serious injury if these safe service procedures are not followed.
Preliminary Precautions
You are working in a potentially dangerous environment of flammable fuels , v ap ors, an d high voltage or p r es su res . O nly trained or authorized ind ividuals kn owledgeable in th e related procedures should install, inspect, maintain or service this equipment.
Emergency Total Electrical Shut-Off
The first and most important information you must know is how to stop all fuel flow to the pump and island. Locate the switch or circuit breakers that shut-off all power to all fueling equipment, dispensing devices, and submerged turbine pumps (STPs).
!
WARNING
!
The EMERGENCY STOP, ALL STOP, and PUMP STOP buttons at the cashier’s station WILL NOT shut off electrical power to the pump/dispenser.
This means that even if you activate these stops, fuel may continue to flow uncontrolled.
You must use the TOTAL ELECTRICAL SHUT­OFF in the case of an emergency and not only these cashier station “stops.”
Total Electrical Shut-Off Before Access
Any procedure requiring access to electrical components or the electronics of the dispenser requires total electrical shut­off of that unit. Know the function and location of this switch or circuit breake r be fore ins pe cti ng , in stalling, maint ai nin g, or servicing Gasboy equipment.
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or STPs requires the following three actions:
Read the Manual
Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand a pro cedure, call a G asboy Authorized Service Contractor or call the Gasboy Service Center at 1­800-444-5529. It is imp erative to yo ur safety a nd the safety o f others to understand the procedures before beginning work.
Follow the Regulations
There is applicable information in NFPA 30A; Automotive and Marine Service Code, NFPA 70; National Electrical Code (NEC),
OSHA regulations and federal, state, and local codes which must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment.
Replacement Parts
Use only genuine Gasboy replacement parts and retrofit kits on your pump/dispenser. Using parts other than genuine Gasboy replacement parts could create a safety hazard and violate loc al regulations.
Safety Symbols and Warning Words
This section provides important information about war ning symbols and boxes. Alert Symbol
This safety alert symbol is used in this manual and on warning labels to alert you to a precauti on whi c h mu st be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death.
Signal Words
These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions that follow must be followed t o prev ent death, injury or damage to the equipment
DANGER - This signa l word is used to alert you to a hazard to unsafe practice which will result in death or serious injury WARNING - This alerts you to a hazard or unsafe practice that could result in death or serious injury. CAUTION with Alert symbol - This signal word designates a hazard or unsafe practice which may result in minor injury. CAUTION without Alert symbol - When used by itself, CAUTION designates a hazard or unsafe practice which may result in property or equipment dam age.
- An evacuation of all unauthorized persons and vehicles using safety tape, cones or barricades to the effected units
- A total electrical shut-off of that unit
MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation June 2005 Page 3
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will become explosive if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause explosive vapors in the vicinity of dispenser or island.
Page 4
Important Safety Information
This area contains a chemical known to the State of California to cause cancer.
WARNING
!
This area contains a chemical known to the State of California to cause birth defects or other reproductive harm.
WARNING
!
No Open Flames
Open flames from matches, lighters, welding torches or other sources can ignite fuels and their vapors.
No Sparks - No Smoking
Sparks from starting vehicles, starting or using power tools, burning cigarettes, cigars or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic charge on your body, can cause a spark sufficient to ignite fuels and their vapo rs. After gettin g out of a vehi cle, tou ch the metal of your vehicle to discharge any electrostatic c harge before you approach the dispenser island.
Working Alone
It is highly recommended that someone who is capable of rendering first aid be present during servicing. Be familiar with Cardiopulmonary Resuscitation (CPR) methods if you are working with or around high voltages. This information is available from the American Red Cross. Always advise the station personnel about where you will be working, and caution them not to activate power while you are working on the equipment. Use the OSHA tag out and lock out procedures. If you are n ot fami liar wit h this r equirem ent, re fer to information in the service manual and OSHA documentation.
IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice
immediately.
Emergency First Aid
Informing Emergency Personnel
Compile the following information for emergency personnel: Location of accident (for example, address, front/back of building, and so on.) Nature of accident (for example, possibl e heart attack, run over by car, burns, and so on.) Age of victim (for example, baby, teenager, middle-age, elderly.) Whether or not victim has received first aid (for example, stopped bleeding by pressure, and so on.) Whether or not a victim has vomited (for example, if swallowed or inhaled something, and so on.)
WARNING
!
Gasoline ingeste d may c ause unc onsciou sness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately.
WARNING
!
Working With Electricity Safely
Be sure to use safe and est abli shed pr actic es in work ing with electrical devices. Poorly wired devices may cause a fire, explosion or electric al sh oc k. Be sure grounding conne ctions
Gasoline inhaled may caus e unconsciousness and burns to lips, mouth an d lungs. Keep airway open.
Seek medical advice immediately. are properly made. Make sure that sealing devices and compounds are in place. Be sure not to pinch wires when replacing covers. Follow OSHA Lock-Out and Tag-Out requirements. Station emp loy ee s and service contractors need to understan d and compl y with this program compl etely to ensure safety while the equipment is down.
WARNING
!
Gasoline spilled in ey es may cause burns to ey e tissue. Irrigate eyes with water for approximately 15 minutes.
Hazardous Materials
Seek medical advice immediately Some materials present inside electronic enclosures may present a health hazard if not handled correctly. Be sure to
WARNING
clean hands after handling equipment. Do not place any equipment in mouth.
!
Gasoline spilled on skin may cause burns. Wash area thoroughly with clear/water. Seek medical advice immediately.
IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. Lockout/Tagout applies to all mechanical, hydraulic, chemical or other ene rgy, but does not cover electrical hazards. Referen ce Subpar t S of 29 CFR Part 1910
- Electrical Hazards, 29 CF R Part 191 0.3 33 c ontains specific
Page 4 MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation June 2005
Lockout/Tagout provision for electrical hazards.
Page 5

Installing the X:1 EQ 25 XXX Pulser Kit

Preparation

1 Request permission from the manager/owner to remove power from the unit and then remove
power using normal procedures. Observe the lockout/tagout safety procedures.
2 Make sure you have the proper kit for the model dispenser to be retrofitted.
3 Be prepared to follow all applicable s afety rules and procedures.
4 Using the proper tools, re move the cover s from the uni t. Place cove rs in a safe place to pr event
damage or scratches. Save the mounting hardware for reuse later.

Replacing the Pulser Meter

1 Using the proper wrench, remove the five mo unt ing bolt s (See Figure 1) securing the existing
meter in place and remove the meter.
Installing the X:1 EQ 25 XXX Pulser Kit
2 Be sure all the existing gasket is removed and the surfaces are clean.
3 In the kit, locate the new meter, the M05617B001 gasket, and the M05613B001 gasket.
4 Position the two gaskets and the meter in place (where the existing meter was removed in step
1) and loosely secure with the five mounting bolts removed from the existing meter.
5 When meter is seated properly in place, tighten the mounting bolts securely.
MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation June 2005 Page 5
Page 6
Installing the X:1 EQ 25 XXX Pulser Kit
Figure 1: Meter Mounting (Left Side View)
Mounting Bolts
Existing Meter
Mounting Bolts

Installing the Pulser Module

1 In the kit, locate the M06028A001 Pulser Module.
2 At the end of the pulser module conduit (Figure 2), remove the union fitting. Keep fitting for
remounting later.
3 Position the pulser module on the unit as shown in Figure 2.
4 Secure the pulser module in place by removing the two bolts indicated in Figure 2, align the
mounting bracket holes with the bolt holes, and remount the two bolts.
5 Remount the union fitting on the conduit.
6 Locate the pulser cable, two spiral pins, and cable tie (part of the pulser meter assembly).
7 Place the coupling on one end of the cabl e on the pul ser sha ft (Fi gure 2) and secure by pl acing
one spiral pin in the hole in the ca ble c oupling and through t he hol e i n the shaft. Allow t he pin to extend equally on both sides of the coupling.
8 Place the coupling on the othe r end of the cabl e on the shaft on the pulser meter. Secure in the
same manner as the first end.
9 Place the cable tie around the cable and around t he pi pe ( ext end ing from the meter to the hose
fitting). The position for placement is indicated in Figure 2.
Page 6 MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation June 2005
Page 7
Installing the X:1 EQ 25 XXX Pulser Kit
Figure 2: Placement of M06028A001 Pulser Module (Back View)
Conduit Junction Box
Placement of cable tie (around pipe and cable ­after installation)
Union Fitting
10
Using a flat-tip screwdriver, remove the conduit junction box cover (Figure 2).
Pulser Shaft
Pulser Mounting Bracket and Bolts
11 Feed the field p uls er wir es up through the pulser module conduit an d i nto the conduit junct io n
box.
Note: The field pulser wires extending up are field-installed wires.
12 Connect the wires from the pulser (alrea dy in the j uncti on box) to th e wires j ust fed i n (in S tep
11). If possible, connect matching colors for easier future servicing. S ecure with wire nuts.
13 Remount the junction box cover and secure with screws.
14 Connect the pulser module conduit to the existing conduit and secure with the union fitting.

Testing/Checking Operation

1 Restore power to the unit.
2 Connect a voltmeter to the signal wires in the control system.
3 Set the voltmeter to read Ohms.
4 Slowly dispense fuel and observe that the needle d eflects upsc ale for each 1/10 gallon fuel.
MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation June 2005 Page 7
Page 8
Installing the X:1 EQ 25 XXX Pulser Kit

Completing Installation

1 After determinin g that the p ulser s a re fun ction ing pro perly, remount the covers re moved at the
beginning of the installation.
2 Inform the manager/owner that the unit can be returned back to service.
.
© 2005 Gilbarco Inc. 7300 West Friendly Avenue Post Office Box 22087 Greensboro, North Carolina 27420 Phone (336) 547-5000 http://www.gilbarco.com Printed in the U.S.A. MDE-4485 Gasboy Pulser Kits X:1 EQ 25 XXX Installation June 2005
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