Gasboy Islander 4-Hose PCU User Manual

INSTALLING AN ISLANDER 4-HOSE PEDESTAL PUMP CONTROL UNIT

This C06653 kit contains all the hardware necessary to install a 4-hose pedestal pump control unit into an Islander pedestal.
This kit includes:

Item P/N Description

1 C06600 Cage Assy., 3 Slot PCU Card
2 C06591 Cable Assy., DC PWR Ped. PCU
3 C06593 Cable Assy., 4 Relay Control
4 C06567 Cable Assy., PCU Comm.
5 C04037 Screw, #8-32 x 3/8” (Qty 9)
6 C06594 Relay Module Assy. (Qty 4)
7 C02418 Decal, Nos. 1-2-3-4 White
8 C05040 Power Supply Assy.
9 C06595 Cable Assy., AC P/S, Head

Item P/N Description

10 C08237 Connector, 12-position TB/PG
11 C08528 Connector, 8-position TB/PG (Qty 2)
12 C04035 Screw, #6-32 x 1/4” (Qty 4)
13 068843 Washer, #6 Locking
14 C32731 Plate, Silk-Screened Escutcheon
15 067126 Washer, #8 PLTD (Qty 3)
16 068842 Washer, #8 Locking (Qty 9)
17 C02293 Decal, Nos. 1-2-3-4 Black
18 C06757 Surge Protector Assembly

1. Switch off power to the Islander and disconnect all AC power to the unit. Remove the screws that secure the side
covers on the pedestal and remove the covers.

2. Install the C06593 Relay Control Cable. This

cable has four connectors in graduated
lengths. On the left side of the pedestal, start
with the longest of the four connectors and
attach it to the rightmost square opening in the
support bracket so that the pins are pointing
away from the center of the pedestal. Repeat
for all connectors from longest to shortest.
Run the cable between the two support
brackets to the card cage side. See drawing
at right.

3. Install the C05040 power supply using four of the C04037 screws and 068842 locking washers. Do not tighten the
corner screw that holds the power supply cover, as you will need to remove the cover to connect the cable to the card
cage assembly.

If you are installing the power supply into a printer pedestal, one of the AC
power connectors on the top of the supply must be moved so that it is
mounted through the back of the supply. On the printer pedestal, there is a
connector for the AC power coming from terminal block TB2. It must go
through the opening in the mounting bracket and plug into the moved
connector at the back of the power supply before the supply is installed.

4. Install the C06594 relay module assemblies. Connect the cables to the relay control cable installed in Step 2. Apply
the numbers from the C02418 decal to the relay modules. Numbering is 1 2 3 4 from left to right.

5. Install the C06600 card cage assembly using three of the C04037 screws, 067126 washers, and 068842 locking
washers. Connect the relay control cable 12-pin connector to P2 of the motherboard in the card cage assembly.

6. Install the C06591 DC power cable. Connect one end to P1 on the motherboard in the card cage assembly. Remove
the power supply cover. Connect the other end of the cable to P1 of the power supply board. Replace power supply
cover.

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7. On the PCU CPU board, set the address switches to match to site’s configuration. Set the jumpers on the Pump I/O
board to match the pulsers being used. Refer to the Islander II Installation Manual C35963. Install the C32731
escutcheon plate using the C04035 screws and the 068843 washer. The washer goes on the screw closest to TBR
connector. In a non-printer pedestal, apply the number 1 of the C02293 decal to the escutcheon plate.

8. Install the C06567 PCU comm. cable from TBK on the Pump I/O board to P3 on the RS485 Protection board. If the unit
has 2 protection boards, the cable connects to the upper board.

9. On a printer pedestal, the C06595 cable is not needed and you can skip this step. On a printer pedestal, the C06595
AC power cable must be installed.

The existing AC power cable runs from TB2 to a connector near the AC power switch inside the Islander head (inside
right partition). Disconnect the end located near the AC power switch and reconnect it to one of the connectors at the
top of the PCU power supply.

Install the new C06595 cable by connecting one end to the other connector on the PCU power supply and the other end
to the connector located near the AC power switch in the head (where you removed the old cable).

10. While facing the terminal block/bracket assembly, with TB2 on it, locate an unused captive nut in the sheet metal
(several inches below and to the right). Install the C06757 surge protector using a C04037 screw and 068842
lockwasher. Terminate the green/yellow wire from the surge protector to Ground of TB2 and the black wires from the
surge protector to Hot and Neutral on TB2.

11. For pump wiring to the Pump Control Unit, refer to the Islander II Installation Manual C35963. Once wiring is complete
and verified, re-connect the AC power to the Islander. Switch on AC power to the Islander and PCU power supply. After
wiring has been completed and tested, replace pedestal side covers.

Printer Pedestal

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