Page 1
Introduction
This document provides instructions for installing the Atlas™ Hi-Flow Satellite Piping
Conversion Kits M06391K001 through K004.
Kit Number Description
M06391K001 Kit, Atlas Hi-Flow w/Sat Conversion, Single Grade 1 110V
M06391K002 Kit, Atlas Hi-Flow w/Sat Conversion, Dual Grade 1 and Grade 2 110V
M06391K003 Kit, Atlas Hi-Flow w/Sat Conversion, Single Grade 1 220V
M06391K004 Kit, Atlas Hi-Flow w/Sat Conversion, Dual Grade 1 and Grade 2 220V
MDE-4514
Instructions for Installing Atlas™ Hi-Flow
Satellite Piping Conversion Kits
M06391K00X
June 2006
Figure 1:
Manifold Inlet
Feedline Ref
Intended Users
The intended users of this document are Authorized Service Contractors (ASCs).
Atlas Hi-Flow with Satellite Piping Assembly
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006 Page 1
Page 2
Introduction
Related Documents
The following document contains related information and may be helpful when using this
document:
Document Number Document Name GOLD Library
MDE-4331 Atlas Installation Manual Gasboy Commercial & Retail
Required Tools
• 1-3/4 inch diameter hole cutter
• Metric socket wrench set
• 2 Pipe wrenches or 1 wrench and vise
• Silicone grease
Note: Ensure that you have c
Parts List
The M06391K001, K002, K003 and K004 kits contain the following parts:
Pumps
M06391K001
Description Part Number
Discharge line assembly M05677A001 1 2 1 2
O-Ring 1-1/4X1-1/2X1/8 Q10068-09 3 6 3 6
Screw, metric M8 X 16 length M00415B009 2 4 2 4
Elbow ST 1 X 90 MI K02321-20 3 6 3 6
Tee pipe 1X1X1 K12630 1 2 1 2
Nipple 1 X 2 R11495-51 1 2 1 2
Nipple 1X1-1/2 R11495-20 1 2 1 2
Grommet discharge-1” pipe 028960 1 2 1 2
Elbow-1" X 90 (paint) 024895 1 2 1 2
Bracket piping support M05690B001 1 2 1 2
U-Bolt, metric, M8 M00703B002 1 2 1 2
Nut, metric M8 serrated M00414B003 2 4 2 4
Screw, metric M8 X 18 length M00417B009 2 4 2 4
Solenoid valve 110 V 067034 1 2 - Solenoid valve 220 V 067036 - - 1 2
Conduit valve Grade 2 M05680B001 - 1 - 1
Conduit valve Grade 1 M05681B001 1 1 1 1
O-Ring 862 X.103 X.103 N16891-32 1 2 1 2
Fitting discharge M04624B040 1 2 1 2
O-Ring 1-5/8X1-7/8X1/8 Q10068-14 1 2 1 2
Filter manifold M04607B005 1 2 1 2
O-Ring 1-1/8X1-3/8X1/8 Q10068-07 1 2 1 2
Strainer insert high capacity R19457 1 2 1 2
Plug pipe 3/4 square socket K57624 1 - 1 -
Quantity
M06391K002
Quantity
M06391K003
Quantity
M06391K004
Quantity
Page 2 MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006
Page 3
Introduction
M06391K001
Description Part Number
Reducers bush faced 3/4x1/2 K49827 - 1 - 1
Elbow, conduit 1/2X90 M & F K42448 1 2 1 2
Union conduit M&F 1/2 Q10016-04 1 2 1 2
Plug cap plastic Q10554-21 1 2 1 2
Atlas Hi-Flow Conversion Kits
Installation Instructions
MDE-4514 1 1 1 1
Quantity
M06391K002
Quantity
M06391K003
Quantity
M06391K004
Quantity
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006 Page 3
Page 4
Important Safety Information
Important Safety Information
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 or 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 Tot al 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.
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 breaker before inspecting, installing, maintaining, or
servicing Gasboy equipment.
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or
STPs requires the following three actions:
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.”
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
Service Contractor or call the Gasboy Service Center at 1800-444-5529. It is imperative to your safety and the safety of
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 local regulations.
Safety Symbols and Warning Words
This section provides important information about warning
symbols and boxes.
Alert Symbol
on warning labels to alert you to a precaution which must 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 to prevent
death, injury or damage to the equipment
This safety alert symbol is used in this manual and
DANGER - This signal 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 damage.
- 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
Page 4 MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006
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 5
Important Safety Information
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 vapors. After getting 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 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 not familiar with this requirement, refer
to information in the service manual and OSHA
documentation.
Working With Electricity Safely
Be sure to use safe and established practices in working with
electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Be sure grounding connections
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 employees and service contractors
need to understand and comply with this program completely
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. Be sure to
clean hands after handling equipment. Do not place any
equipment in mouth.
!
WARNING
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.
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, 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.)
WARNING
!
Gasoline 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.
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline spilled in eyes may cause burns to eye
tissue.
Irrigate eyes with water for approximately 15
minutes.
Seek medical advice immediately
WARNING
!
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 energy, but does not cover
electrical hazards. Reference Subpart S of 29 CFR Part 1910
- Electrical Hazards, 29 CFR Part 1910.333 contains specific
Lockout/Tagout provision for electrical hazards.
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006 Page 5
Page 6
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
Installing Atlas Hi-Flow Satellite Conversion Kits
M06391K001, K002, K003 and K004
To install Atlas Hi-flow with the Satellite conversion kit, proceed as follows:
Preparing for the Installation
!
CAUTION
Bleed pressure prior to disassembly and wear proper eye protection.
1 Close and test shear valves. Run the unit to bleed off pressure and drain the fuel into an
approved container.
2 Request permission from the manager/owner to remove power from the unit and then remove
power using normal procedures. Perform the lockout/tagout safety procedures.
3 Ensure that you have the proper kit for the model dispenser to be retrofitted.
4 Follow all applicable safety rules and procedures.
Installing the Conversion Kits (M0639K00X)
Removing the Existing Solenoid Valve and Discharge Line
1 Remove the exterior discharge fitting and any grommet. Residual pressure may exist. Wear
eye protection.
2 Remove and retain the two screws holding the discharge casting to the bottom of the meter.
Remove the discharge casting and the attached discharge piping. Collect fuel in an approved
container, clean up any spills and dispose properly.
3 Disconnect the solenoid valve wiring in the junction box. Mark the connections in the junction
box for all wires connected to the solenoid valve, so that the valve replacement can easily be
connected to the correct wires.
4 Disconnect the feedline from the solenoid valve/filter manifold on the meter . Disconnect the
valve conduit union.
5 Loosen but do not remove the nut holding the meter stabilizer bracket to the frame so that the
bracket can be maneuvered to permit removal of the valve/filter manifold. Remove the
solenoid valve/filter manifold from the meter and pull the coil wires through the conduit.
Retain the mounting hardware.
Page 6 MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006
Page 7
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
Mounting the No-Valve Filter Manifold and Meter Discharge Fitting
See Figure 2.
1 Insert the filter strainer (R19457) into the no-valve filter manifold (M04607B005) from the
kit. Push the strainer fully into the cavity so that it does not interfere with the filter boss
threads.
2 Ensure that the meter check valve is still in place in the meter inlet, and grease the O-Rings
and insert them into the grooves in the meter inlet and in the no-valve filter manifold discharge
flange. Attach the flange to the meter inlet and replace the two screws on the right. Reposition
the meter stabilizer bracket to the back side of the manifold flange and replace the two screws
on the left. Tighten all four screws. Tighten the meter stabilizer bracket nut against the frame.
Figure 2: No-V alve Filter Manifold and Meter Discharge Fitting
(4) 5/16 x 1” Screw (Existing) (2) M8 x 16 Flange Screws
Manifold inlet
No-valve filter manifold
(M04607B005)
Meter Stabilizer
bracket (Ref)
O-Ring 1.234 x
0.139 (Q10068-09)
(Existing)
(M00415B009)
O-Ring 1.609 x
0.139 (Q10068-09)
Strainer insert
high capacity
(R19457)
O-Ring 0.862 x
0.103 (N16891-32)
Casting discharge
(M04624B040)
(2) M8 x 25 Flange Screws
(Existing)
O-Ring 1.234 x
0.139 (Q10068-09)
Feedline (Ref)
3 Insert the feedline O-Ring into the manifold inlet and lightly grease to retain and attach the
feedline. Insert and tighten the two screws.
4 Lightly grease the meter discharge O-Ring and insert it into the groove in the meter discharge.
Ensure that the O-Ring is fully seated in the groove and is not offset by the O-Ring retainer
tabs in the meter discharge.
5 Attach the meter discharge casting to the meter discharge and insert the two screws and tighten
them.
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006 Page 7
Page 8
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
Modifying the Junction Box
See Figure 3.
1 Remove all conduits and fittings associated with the old solenoid valves.
2 Add the new fittings.
Figure 3: Modifying the Junction Box
Elbow, 1/2 x
90M x F
(K42448)
Goes to
Grade 2
side
3/4 x 1/2 Reducer
(K47458)
Goes to
Grade 1
side
Conduit union
1/2 inch
(Q10016-04)
Elbow, 1/2 x
90M x F
(K42448)
Conduit union
1/2 inch
(Q10016-04)
Pipe plug Csunk 3/4
(K57624)
Page 8 MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006
Page 9
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
Discharge Line Assembly
See Figure 4.
Note: In this assembly, you will assemble all parts in Figur e 4 except the 1 x 1-1/2 Nipple,
Discharge Grommet and Painted elbow.
Figure 4: Discharge Line Assembly
Discharge line
assembly
(M05677A001)
Nipple 1x1-1/2
(R11495-20)
Grommet
discharge -1”
(028960)
Elbow-1” x 90
(painted)
(024895)
1” Solenoid valve
(067034 or 067036)
Nipple 1 x 2
(R11495-51)
Pipe tee 1 x 1 x 1
(K12630)
Nut, metric M8
serrated
(M00414B003)
Elbow ST 1 x 90
(K02321-20)
Screw, metric M8 x 18
(M00417B009 - threadforming)
To Meter discharge casting
Elbow ST 1 x 90
(K02321-20)
!
Valve conduit Grade 2
(M05680B001)
O-Ring 1.234 x 0.139
(010068-09)
Screw, metric M8 x 16
(M00415B009 - not
thread - forming)
Valve conduit
Grade 1
(M05681B001)
Elbow ST 1 x 90
(K02321-20)
U-Bolt, metric M8
(M00703B002)
Bracket, Satellite piping
support
(M05690B001)
1 Assemble the following parts as shown in Figure 4 using pipe sealant on the male threads:
• 1 inch Solenoid valve
•Nipple 1x2
• Pipe tee 1x1x1
• Elbow ST 1x90
• Discharge line assembly
CAUTION
Use a pipe sealant approved for use with fuels. DO NOT USE TEFLON TAPE.
2 Depending on whether you are assembling the discharge for Grade 1 or Grade 2, route
solenoid coil wires through the appropriate conduit (refer to
Figure 4). Grade 1 is on the left
when facing the junction box.
3 Lightly grease the O-Ring and insert it into the groove on the meter discharge casting (refer to
Figure 2 on page 7). Attach the flange on the copper tube assembly (Figure 4) to the meter
discharge flange and insert two M8 x 16 screws and tighten them.
CAUTION
Ensure that you select the M00415B009 screws, not the M00417B009 thread formers
or the threads will be damaged.
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006 Page 9
Page 10
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
4 Route the valve coil wires into the junction box. Attach the conduit to the fitting in the
junction box and tighten them.
5 Check discharge piping alignment and adjust as needed. Attach the satellite piping support
bracket (
Figure 4) to the dispenser inlet support plate, insert and tighten the two M8 thread
forming screws.
6 Insert the U-bolt (Figure 4) around the pipe elbow and through the slots on the support bracket.
Attach two nuts and tighten all fasteners.
7 Stuff a clean rag into the elbow on the top end of the discharge line and proceed to “Modifying
the Side Sheathing for the Discharge” on page 10.
Modifying the Side Sheathing for the Discharge
See Figure 5 on page 11.
!
WARNING
The use of power tools or any means to cut the sheathing hole (step 3) with flammable
fuels or vapors present is hazardous and can result in fire or explosion causing serious
injury or death.
Remove the sheathing from the unit and transport to a safe distance from potentially
hazardous locations to cut the sheathing hole.
1 Mark the location of the discharge elbow on the side sheathing as shown in Figure 5 on page
11. Check the dimensions against the location of the discharge elbow in the assembly to ensure
that the marked location is correct. Adjust the mark, if necessary.
2 Remove the sheathing from the unit.
Page 10 MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006
Page 11
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
Figure 5:
3.04
17.12
Frame Modification (Dimensions are in inches)
Q10554-21 Plug
Ø1.75 hole (cut this hole
through sheathing and frame)
Sheathing shown cutaway for
clarity
Face of frame
column
3 Using a 1-3/4 inch diameter cutter, cut a hole through the sheathing so the discharge can
protrude through when completed. Deburr the hole on the sheathing.
4 Reassemble the sheathing to the unit. 5 Assemble the black painted elbow (Figure 4 on page 9) and the 1 x 1-1/2 inch nipple. Insert the
grommet (Figure 4 on page 9) over the nipple. The elbow should point down.
6 Remove the rag from the elbow in the dischar ge assembly. Insert the nipple from the assembly
made in step
5 through the hole cut in the frame and screw it into the discharge elbow on the
assembly. Tighten the nipple. Use UL approved sealant suitable for use with the fuel involved.
Note: If a Grade 2 exists, repeat all the steps from “Removing the Existing Solenoid Valve and
Discharge Line” on page 6 till step 6 in this procedure.
7 Rewire the solenoid valves in the junction box. 8 Connect the satellite piping to the elbow on the lower end of the assembly. 9 Insert Q10554-21 (1-3/4 inches diameter) plastic plug into the hole where the previous
discharge exited the unit.
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006 Page 11
Page 12
Installing Atlas Hi-Flow Satellite Conversion Kits M06391K001, K002, K003 and K004
Completing the Installation
1 Replace the junction box cover.
2 If the unit is modified on the island, inform the manager/owner that power will be restored to
the unit and then restore power using normal procedures. Purge the unit of air.
3 Check for leaks.
4 Release the emergency shutoff valve.
5 Remove the lockout/tagout and return to normal operation.
.
© 2006 GASBOY
7300 West Friendly Avenue • Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 • http://ww w.gasboy.com • Printed in the U.S.A.
MDE-4514 Instructions for Installing Atlas™ Hi-Flow Satellite Piping Conversion Kits M06391K00X • June 2006
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