Gasboy Fuel Point Reader User Manual

READER INSTALLATION AND

RETROFIT INSTRUCTIONS

MANUAL

C35628

GASBOY INTERNATIONAL LLC

FUEL POINT

READER INSTALLATION AND

RETROFIT INSTRUCTIONS MANUAL

C35628

REV. 03/28/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards
and procedures on the use and care of t he 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

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

OF A FUEL SPILL.

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 the entire system. Instructions
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
including trucks. All containers 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.

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

Fuel Point Reader..................................................................................... 1-2

Dispenser Retrofit Kits.............................................................................. 1-3

I/S Pre-Amplifiers (I/S Pre-Amps) ....................................................... 1-3

N-Ring Nozzle Antenna....................................................................... 1-3

Vehicle Components ................................................................................ 1-3

Section 2: CONDUIT LAYOUT AND FPR INSTALLATION

Purpose.................................................................................................... 2-1

Conduit Requirements.............................................................................. 2-2

Conduit Layout/Installation Specifications................................................ 2-3

Conduit Layout - Series 1000 FMS with FPR...................................... 2-4

Conduit Layout - CFN FMS with Pedestal Pump Control

and Pedestal-Mounted FPR........................................................... 2-5

Conduit Layout - CFN FMS with Wall-Mounted PCU and

Wall-Mounted FPR......................................................................... 2-6

Conduit Layout - CFN FMS with Pedestal Pump Control and

Pole-Mounted FPR......................................................................... 2-6

Conduit Layout - Series 1000 FMS with Wall-Mounted FPR .............. 2-7

Conduit Layout - Series 1000 FMS with Pole-Mounted FPR.............. 2-7

Conduit Detail for Wall- or Pole-Mounted FPR ................................... 2-8

Section 3: SYSTEM WIRING

General Wiring Precautions ..................................................................... 3-1

System Wiring Diagram............................................................................ 3-2

Power Requirements................................................................................ 3-3

Pedestal Mount ................................................................................... 3-3

Wall or Pole Mount.............................................................................. 3-3

RS-485 Communication Requirements.................................................... 3-3

N-Ring Wiring Requirements ................................................................... 3-4

Field Wiring, I/S Pre-Amp to FPR............................................................. 3-5

Field Wiring, Series 1000 AC Power and RS-485.................................... 3-6

Wall- or Pole-Mounted FPR to Series 1000........................................ 3-6

Field Wiring, CFN AC Power and RS-485................................................ 3-7

Wall- or Pole-Mounted FPR to CFN.................................................... 3-7

Pedestal-Mounted to CFN Islander Satellite....................................... 3-7

Pedestal-Mounted to CFN ICR............................................................ 3-7

Section 4: FIELD RETROFIT INSTRUCTIONS

Field Upgrade Kits.................................................................................... 4-1

FPR Field Mounting Options .................................................................... 4-1

Attaching FPR Mounting Brackets ........................................................... 4-1

Wall-Mount - Studded or Masonry Wall ................................................... 4-2

Pole-Mount............................................................................................... 4-2

FPR Dimensions ...................................................................................... 4-3

03/28/03 Contents-1

GASBOY Fuel Point System

FMS Pedestal Mount................................................................................ 4-3

C06790 FPR Mounting Kit................................................................... 4-3

Attaching the FPR to All FleetKey Pedestals, or to CFN

Pedestal with Built-in Pump Control Unit......................................... 4-4

Attaching the FPR to CFN Standard (Blank) and CFN Printer

Pedestals......................................................................................... 4-5

Completing the FPR Mounting - All Pedestal Types ........................... 4-7

Series 1000 Upgrade Kits......................................................................... 4-8

Adding Auxiliary Communications and Comm Port 1

Using the C06822 Kit ..................................................................... 4-8

Adding Comm Port 2 to Series 1000 Using the C06823 Kit................ 4-10

Field Wiring, 1000 AC Power and RS-485............................................... 4-12

Wall- or Pole-Mount ............................................................................ 4-12

Pedestal-Mount................................................................................... 4-12

Field Wiring, CFN AC Power and RS-485................................................ 4-13

Wall- or Pole-Mount FPR to CFN ICR................................................. 4-13

Pedestal-Mount FPR to CFN ICR ....................................................... 4-13

Wall- or Pole-Mount FPR to CFN Pedestal PCU................................ 4-14

Pedestal-Mount FPR to CFN Pedestal PCU....................................... 4-14

Wall- or Pole-Mount FPR to CFN Islander Series............................... 4-15

Pedestal-Mount FPR to CFN Islander Series ..................................... 4-15

WARRANTY

Contents-2 03/28/03

Section 1

INTRODUCTION

PURPOSE

The GASBOY Fuel Point Reader Installation and Retrofit Instr uctions Manual is provided to ass ist
you in installing the Fuel Point option to your GASBOY fuel management system (F MS) It also
provides the necessary instructions for installing a Fuel Point Reader on a FMS pedestal (Sec tion

4). This manual should be supplied to the elec trician prior to the ins tallation of conduit and wiring
to ensure your Fuel Point system is installed properly. Faulty installations are the major caus e of
system malfunctions . The system must be installed as described in this m anual to ensure the
reliability and proper operation of the system. Please read this entire manual before starting
installation.

GASBOY provides a toll-free num ber for customer s and ins taller s having any questions per taining
to the installation: 1-800-444-5529

SYSTEM OVERVIEW

Fuel Point adapts to Listed GASBOY fuel management systems for has sle-free fueling. System
applications determine actual components required. Your system will consist of the following
components:

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

●

Fuel Point Reader (FPR)

●

Pumps/dispensers m odified using Listed Dispenser and Hose Retrofit Kits (consisting of I/S

●

Pre-amp and one or two kits)
T-Ring Tank Antenna (See Manual C35699)

●

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

●

Vehicle Module(s) (VM's)

●

03/28/03 1-3

GASBOY Fuel Point System

FUEL POINT READER

Description

The Fuel Point Reader (FPR) is housed in a weatherpr oof cabinet. It is micropr ocessor-based
and consists of modular components and configured software. It communicates vehicle
information to the GASBOY fuel management system c ontroller for up to eight fueling positions.
Multiple fuel point readers may be used for systems with m ore than eight f ueling positions. When
used with the CFN II FMS, multiple FPR's may be connected for controlling up to 32 fueling
positions.

Location

The Fuel Point Reader may be factory-mounted to a new FMS, located independently on the
island, or retrofitted to an existing GASBOY FMS, as described in Section 4. It can also be wall­mounted inside a building, but this option may increase the installation costs because each N­Ring requires a two-wire run to the FPR. W hen wall-mounted, the FPR should be located near
other fuel system components such as pump control unit, circuit breakers, wiring trough, etc..

1-4 03/28/03

Introduction

DISPENSER RETROFIT KITS

Dispenser retrofit k its provide the wires, couplings, and hardware needed to m odify the hose and
nozzle to accept the fuel point hardware. They also contain the I/S Pre-amps and N- ring nozzle
antennas. These kits are described in detail in the Dispenser and Hose Retrofit Installation
Manual, C35593.

I/S Pre-Amplifiers (I/S Pre-Amp)

The I/S Pre-Amp assemblies are small PCB's mounted in
junction boxes within the dispenser. An I/S Pre-Am p am plifies
the antenna signal to the FPR, assuring reliable
communic ation. The Pre-Amps come factor y-installed inside
a metal junction box. Wiring between the I/S Pre-Amp and the
Fuel Point Reader is shown in the System Wiring section of
this manual. W iring between the I/S Pre-Amp and the nozzle
ring is shown in the Dispenser and Hose Retrofit Installation
Manual, C35593.

N-Ring Nozzle Antenna

The N-Ring nozzle antenna mounts on the base of the nozzle spout and is concealed by a spec ial
nozzle cover. It is connected to the I/S Pre-Amp via antenna wire that is run down the inside or
outside of the hose. It transmits/receives com munication to/from the vehicle's T-Ring antenna.
Installation of the N-Ring is detailed in the Dispenser and Hose Retrofit Installation Manual,
C35593.

VEHICLE COMPONENTS

Each vehicle is modified to work with the Fuel Point system by installation of a T-Ring tank
antenna connected to a Vehicle Module (VM). Vehicle installation kits provide the required
elements to install the T-ring and VM. Vehicle kit installation instructions are contained in the
Vehicle Module (VM) Installation Manual, C35699.

03/28/03 1-5

Section 2

CONDUIT LAYOUT AND FPR INSTALLATION

PURPOSE

Use this section for detailed planning of the installation of your system. This section covers
conduit requirements and shows conduit layout examples for basic system configurations.
Careful planning of the site layout will help eliminate possible problem s with the start-up of your
system and will ensure continued, reliable system operation.

03/28/03 2-1

GASBOY Fuel Point System

CONDUIT REQUIREMENTS

The conduit requirements outlined in this section are relevant to all components mak ing up the
GASBOY system. The GASBOY Warranty will not apply to any system deviating from the
requirements outlined in this section.

All wiring and conduit runs must conf orm with all building/fire c odes, all Federal, State, and Local
codes, National Electrical Code (NFPA 70), NF PA 30, and Automotive and Marine Service Station
Code (NFPA 30A) codes and regulations. Canadian user s must also com ply with the Canadian
Electrical Code.

All wiring (AC and DC) connecting the different components of the Fuel Point System and all
communica tion equipment signal wires must be installed underground in thread ed, rigid, metal
conduit. PVC IS NOT ACCEPTABLE. High voltage AC power wires must be installed in
separate conduit from the low voltage DC signal wires; they cannot be run in any sort of com mon
conduit or trough. Exceptions to these requirem ents are noted in Section 3, Communication
Requirements (RS-485). I/S wires must be in separate conduit from all AC or DC wires.

All holes and knockouts accept up to 3/4" conduit. All conduit must be connected to the
components through the holes and k nockouts provided by the factory. Do not mak e any other
holes in these units. If alternate holes are required, contact GASBOY for approval first.

The chart below shows conduit capacity for rigid metal conduit with 50% fill of gas- and oil­resistant wire. Use this chart as a guideline to determine the proper conduit sizes for the
GASBOY Fuel Point System wiring. When planning the orientation of the wire runs, f ollow the
applicable GASBOY wiring diagrams and consider the layout of the com ponents at the s ite. Long
runs or a large number of bends may require you to increase conduit size over what is listed.

Table 2-1. Conduit Size Chart

2-2 03/28/03

Conduit Layout and FPR Installation

CONDUIT LAYOUT/INSTALLATION SPECIFICATIONS

1. All wiring must be installed and used in accordance 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. Power must come from a separate dedicated circuit break er rated at no less than 10 AMPS
or may share the fuel management system breaker. W hen mounted to an island pedestal
(factory or retrofit), the FPR will get its power from the pedestal device via a GASBOY­supplied AC power cable.

3. All conduit must be rigid metal to provide the necessary shielding.

4. All conduit must be run underground, not overhead.

5. The I/S Pre-Amp comes fac tory-installed in a metal junction box and mounts in the bas e of
the pump or dispenser. Twin pumps or dispensers have two Pre-Amps mounted in the same
junction box. The box is secured by threading onto conduit. It can be mounted wherever it is
convenient as long as it does not interfere with other dispenser com ponents. The junction
box has 1/2 inch hubs, so you need to use a reducer if running larger conduit for the I/S
wiring. Strain relief connectors must be used to protect the N-ring wiring entering the box.

I/S Pre-Amp wires are intrinsically safe and must be in a separate conduit from any AC
or DC wires. The distance between the Pre-Am p and the Fuel Point Reader c annot exc eed

1000 feet.

6. It is recomm ended that the RS-485 wiring be in a separate m etal c onduit f rom any AC wires.
However, the RS-485 wires may be run in the AC conduit if the requirements outlined in
Communication Requirements (RS-485) in Section 3 are followed.

7. Use the wire size chart (Table 4-1) to determine the wire gauge.

8. Use the conduit size chart (Table 2-1) to determine the size according to the number of wires
and wire gauge.

9. Consult the applicable section of this manual for specific system installation requirements.

6213 2-3