Gasboy Fuel Point Dispenser User Manual

DISPENSER AND HOSE RETROFIT

INSTALLATION MANUAL

C35593

GASBOY INTERNATIONAL LLC

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FUEL POINT

DISPENSER AND HOSE RETROFIT

INSTALLATION

MANUAL

C35593

REV. 03/28/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards
and procedures on the use and care o f the Fuel Point System. Please leave this
manual with the system owner after the installation is complete.

Copyright 2003 by Gasboy International LLC All rights reserved.
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

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IMPORTANT WARNINGS AND SAFEGUARDS

Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or
property, follow these listed warnings and other warnings and precautions outlined in this manual when installing, using,
or working around this equipment. Check with GASBOY Technical Services for compatibility of liquids with pump
materials.

TURN OFF AND LOCK OUT ALL POWER TO PUMP BEFORE PERFORMING SERVICE, MAINTENANCE OR IN THE EVENT

All products must be installed by a
qualified installer and used in
conformance with all building, fire, and
environmental codes and other safety
requirements applicable to its
installation and use, including, but not
limited to, NFPA 30, NFPA 30A, NFPA
395 & NFPA 70. A qualified installer is
familiar with fuel systems installations
under the above stated building, fire,
and environmental codes and other
safety requirements for the particular
type of installation.

This product is only part of a fuel
dispensing system and additional
equipment and accessories, such as,
but not limited to, breakaway
connectors, shear valves, pressure
regulators, flow limiters, and other
safety devices may be necessary to
meet the applicable codes.

For maximum safety, we recommend
that all employees be trained as to the
location and procedure for turning off
power to th e enti re system. Instru ctions
regarding proper operation of the
equipment along with the appropriate
safety warnings should be posted in
plain view at the fuel island.

Before performing service or
maintenance (including changing of fuel
filters or strainers) or in the event of a
fuel spill, turn off and lock out all power
to the system. In battery-powered
pumps, disconnect power source. In
submersible pump applications, turn off
and lock out power at the master panel
and close any impact valves to the
submersible pump and any other
dispensers which use that submersible
pump. AC power can feed back into a
shut-off dispenser when dispensers
share a common submersible pump or
starter relay. Also block islands so no
vehicles can pull up to the dispenser
when the dispenser is being worked on.

DO NOT use Teflon tape for any pipe
threads in the product.

DO NOT use consumer pumps for
pumping fuel or additives into aircraft.

DO NOT use commercial pumps for
direct fueling of aircraft without filters
and separators necessary to ensure
product purity.

DO NOT use where sanitary design is
required (for food products for human
consumption) or with water-based
liquids.

DO NOT smoke near the pump or when
using the pump.

DO NOT use near open flame or
electrical equipment which may ignite
fumes.

DO NOT permit the dispensing of
gasoline or other petroleum products
into a vehicle with its motor running.

DO NOT permit the dispensing of
gasoline or other petroleum products
into unapproved containers or into
approved containers in or on vehicles
includin g trucks. All contain ers must be
filled on the ground to prevent static
discharge. Always use Approved and
Listed hoses and nozzles with electric
pumps and dispensers.

DO NOT block open the nozzle in any
manner. Nozzles shall conform to UL
and NFPA code requirements for
attended or unattended service.

DO ensure that the pump is equipped
with proper filters based on the product
being dispensed and its intended use.

DO wear safety goggles and protective
clothes when dispensing any liquid
which may be potentially harmful or
hazardous.

DO keep all parts of body and loose
clothing clear of belts, pulleys, and other
exposed moving parts at all times.

OF A FUEL SPILL.

DO require washing and changing of

clothes if fuel is spilled on a person or
his/her clothing. Keep away from open
flames, sparks, or people smoking.

DO provide a receptacle for catching
product from pump/meter when
servicing.

DO clean up product spills on the
driveway. Turn off and lock out all
power prior to cleanup.

DO insure pump is properly grounded.
DO insure hose is compatible with fluid

being dispensed.
DO inspect hose, nozzle, and pump on

a regular basis for wear, damage, or
other conditions which may create a
safety or environmental hazard.

DO make sure all pipe threads are
properly cut and the inside reamed to
remove burrs. Use UL classified
gasoline-resisting compound on all
joints of gasoline handling piping.
Sealing compound must also be
resistant to Gasohol (Ethanol and
Methanol). Use gasoline-resistant pipe
compound on male threads only; pipe
compound used on female threads can
be squeezed into the supply line where
it can enter the product stream and
become lodged in the pump or meter.

DO ensure that junction box covers are
in place and properly tightened. Mating
surfaces between the box and cover
must be free of dirt, nicks, and
scratches. All unused entries into the
junction box must be properly plugged.

035282 Rev. 1267

GASBOY INTERNATIONAL LLC.

707 North Valley Forge Rd. Lansdale, PA, 19446 ● [phone] ● FAX: [phone]

CONTENTS

Section 1: INTRODUCTION

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

System Overview ...................................................................................... 1-1

Fueling Sequence ..................................................................................... 1-2

Important Hose Modification Pointers - Read Before Proceeding............. 1-2

Testing the Fuel Point Installation............................................................. 1-3

Component Overview................................................................................ 1-4

Section 2: GETTING STARTED

General Information .................................................................................. 2-1

Before You Begin...................................................................................... 2-2

Approved Nozzles For Use With Dispenser Retrofit Kits .......................... 2-2

Dispenser Retrofit Jbox Assemblies.......................................................... 2-3

Unpacking the Dispenser Retrofit Kit ........................................................ 2-3

Fuel Point Hose Retrofit Kits..................................................................... 2-4

Internal Wire Retrofit Components............................................................ 2-7

Using This Manual..................................................................................... 2-8

Section 3: STANDARD INTERNAL WIRE HOSE RETROFIT

Step A: Disassemble Hose....................................................................... 3-1

Step B: Construct Hose Assemblies (Internal Wire)................................. 3-2

Step C: Final Hose and Nozzle Assembly................................................ 3-4

Step D: Reassemble ............................................................................... 3-5

Step E: Complete N-Ring Wiring.............................................................. 3-6

Step F: Apply Power and Check Installation............................................ 3-6

Section 4: VAPOR RECOVERY RETROFIT KITS

Vapor Recover Small Parts Kit, C07389................................................... 4-2

Step A: Construct Vapor Recovery Hose Assemblies............................... 4-3

Step B: Nozzle Assembly.......................................................................... 4-4

Step C: Final Vapor Recovery Hose Assembly......................................... 4-5

Step D: Reassemble Hose to Pump.......................................................... 4-6

Step E: Complete N-Ring Wiring............................................................... 4-7

Step F: Apply Power and Check Installation............................................. 4-7

03/28/03 Contents-1

Section 1

INTRODUCTION

PURPOSE

The GASBOY Fuel Point Dispenser and Hose Retrofit Installation Manual is provided to assist you
in installing the Listed dispenser retrofit kits for the Fuel Point system on your pumps. This manual
should be supplied to the installer prior to installation to ensure your components are installed
properly. Faulty installations are the major cause of system malfunctions. The system
components must be installed as described in this manual to ensure the reliability and proper
operation of the system. Please read this entire manual before starting installation.

GASBOY provides a toll-free number for customers and installer s having any questions pertaining
to the installation: 1-800-444-5529

SYSTEM OVERVIEW

Fuel Point adapts to Listed GASBOY fuel management systems for hassle-fr ee fueling. System
applications determine actual components required. Your system may consist of several or all of
the following components:

• a GASBOY fuel management system (FMS) (Listed models 1000, 1000P, or 2000S CFN)

• Fuel Point Reader (FPR)

• Pumps/dispensers modified using Listed Dispenser and Hose Retrofit Kits (consisting of I/S

Pre-amp and one or two kits)

• Vehicles equipped with materials from Vehicle Installation Kits (See Manual C35699)

• Vehicle Module(s) (VM’s)

03/28/03 1-1

GASBOY Fuel Point System

FUELING SEQUENCE

Fueling a vehicle with a Fuel Point Vehicle Module (VM) is accomplished as follows:

1. Insert nozzle into vehicle tank. Vehicle ID, fuel control and odometer/hour data is
automatically transmitted from the VM via nozzle (N-Ring) and tank (T-Ring) antennas to the
Fuel Point Reader (FPR).

2. FPR communicates with the Fuel Management System (FMS) CFN or 1000 FleetKey unit.

3. FMS authorizes and records vehicle data.

4. When the nozzle is removed, it suspends the transaction, Reinsertion resumes transaction.

5. Transaction terminates when dispenser is turned off, nozzle is inserted into another vehicle, or
suspended transaction is not resumed.

6. Transactions are stored in memory for on-demand retrieval and logger printout.

IMPORTANT HOSE MODIFICATION POINTERS - READ BEFORE
PROCEEDING

Modifying the hose at a work bench is recommended. Use appropriate tools and components. For
reliable and long-lasting installations pay particular attention to the following points as you read the
remainder of the manual:

• Handle the internal hose wire assemblies carefully. Make sure the wire doesn’t become

nicked or cut. A damaged wire within the hose will allow fuel to enter and wick past O-ring
seals inside the jacket, leaking fuel at the connectors and inside the J-box/pre-amp assembly
in the base of the pump.

• If the system does not read the VM after installation of the antenna, first check for continuity

between the N-ring and pre-amp located in the J-box amplifier.

• PVC breakaway and nozzle covers are designed to conceal the breakaway connectors and

wire. The covers must be properly installed.

1-2 03/28/03

Introduction

TESTING THE FUEL POINT INSTALLATION

The following test procedures are helpful:

• If the system is set up for use with cards or key activation, first test the pump using the card

or key. Pump a small amount of fuel and check the logger printout to insure the correct
amount is registered. This will test the complete system without the Fuel Point.

• If a master authorizer is available and programmed for the site, it can be used to test the

pump assembly. Hold the authorizer near the N-ring and activate.

• Test the modified pump with a vehicle equipped for use with Fuel Point.

• Verify the hose wiring. At the amplifier/j-box 35 to 40 ohms through the N-ring is required.

• The following chart provides details for using the Fuel Point Reader LED indicators (on

C08886 PCB) while troubleshooting wiring problems. The chart assumes only one vehicle is
fueling as DL3 and 4 are shared by up to 8 hoses. DL3 and 4 indicate the communications
between the FP Reader and FMS unit. DL1 and 2 indicate communications between the FP
Reader and Vehicle Module.

DL4 DL3 DL2 DL1
* * * *
Red Grn Red Grn

Pump/Nozzle Status Indicator Status Remarks
Not Pump/Nozzle dependent DL4,3 Flashing RS 485 communications.

Should be flashing
continuously. Should mirror the

2 Red LED’s on RS 485 PCB.
Nozzle inserted in vehicle DL1 flashes once Acknowledges Vehicle present.
Nozzle inserted in vehicle DL1,2 flash rapidly Vehicle Module sending data

to FP Reader.
Nozzle starts fueling DL1 flashes on-off Indicates nozzle is stilll present

in vehicle.
Nozzle removed DL1 ceases flashing after short

delay.

NOTE: Turning the pump handle to off or a system time out will cease all activity on DL3

and 4. When testing several vehicles, a small quantity of fuel should be pumped. If
quantity is not pumped, the system will shut off after a programmable number of no
quantity operations. The system must be re-enabled at the terminal. Refer to the
appropriate manual for system in use. When testing several transactions (nozzle
in/outs) you must delay about 5 seconds if communications is lost.

System in suspend mode.

Allows fueler to start fueling

second tank.

1065 1-3

GASBOY Fuel Point System

COMPONENT OVERVIEW

As you read the following descriptions, refer to the
drawing at the right for an overall view of the
assembled hose.

The GASBOY Fuel Point system requires
modification of existing pumps and hoses using
retrofit kits or installing internal-wired, factory­assembled hoses. Each hose outlet requires a
Fuel Point Amplifier available in single, twin or 2-4
hose multiple product assemblies. Hose retrofit
kits provide the parts for field modification of UL­approved fueling dispensers and pumps. To
discourage tampering, hose wiring is internal to the
hose or enclosed in flexible metal tubing.
Connectors are concealed by PVC covers and the
breakaway connector can be reconnected after
drive-offs

Hose assemblies and kits are available in a variety
of configurations for UL-Listed ¾” and 1” standard
and most Vapor Recovery style nozzles. Kits can
be assembled differently based on the breakaway
location. A list of kits and assembly instructions
are discussed later in this manual. Kits include
parts shown in the diagram at right except hoses,
nozzles and fuel breakaway which are to be
supplied by the installer. Wired hoses include
same parts plus the hoses.

The N-Ring assembly (nozzle antenna) mounts at
the base of the fueling spout of the nozzle. The N­Ring transmits and receives communications to
and from a Fuel Point-equipped vehicle via a T­Ring (tank ring antenna).

The hose wire provides communications between
the N-ring and Fuel Point J-Box/Amplifier mounted
in the base of the pump. Internal hose wiring
enters and exits the hose through special brass
fittings outfitted with O-ring compression seals.
Hose wires are constructed with a factory-installed
slack loop to compensate for hose stretch that can
occur during a drive-off.

1-4 03/28/03