Gasboy M05819K00X User Manual
Introduction
Purpose
This manual provides installation instructions for the Commercial Atlas™ (9800K) Automatic
Temperature Compensation (ATC) Kits:
• M05819K001 for 9800K Single Unit
• M05819K002 for 9800K Twin Unit
• M05819K003 for 9850K Single Unit
• M05819K004 for 9850K Twin Unit
Table of Contents
MDE-4431C
Gasboy ATC M05819K00X Kits Installation Manual
February 2013
Topic Page
Introduction 1
Important Safety Information 8
Installing the Commercial Atlas (9800K) ATC Kits 10
Appendix: Totalizer Display Information 28
Required Tools
Following tools are required to install the ATC M05819K00X Kits:
• Open-end Wrench Set
• Flat-blade Screwdriver
®
• Phillips
• Allen
Screwdriver
®
-wrench Set
MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 1
Introduction
Parts Lists
ATC M05819K001 Kit for Single Unit (Except 9850K)
Part Number
(see Note) Description Quantity
M06080B001 Kit, ATC Kraus TTC200-1GK 1
Printed Circuit Board (PCB) Assembly in LP-70 Polycase
28017
Sponge 1
SK460A4 460A4 ATC Display Adapter Board (see Figure 1 on page 5) 1
SK461 461A2 Pulser/Handle Adapter Board (see Figure 1 on page 5) 1
27913 Dual Intrinsic Safety Barrier 1
- 5/16-inch Flat Washer (part of 27913) 2
- 5/16-inch Hex Nut (part of 27913) 1
212AY04 Single Probe Connector Assembly 1
W171 Two-wire Harness for Intrinsic Safety Barrier 1
SW199 Probe Assembly 1
20026 Thermowell 1
235-C Thermowell Plug 1
12B02 1/8-inch National Pipe Thread (NPT) Coupling 1
15912 1/8-inch NPT Adapters Drilled to 17/64-inch Inside Diameter (I.D.) 1
103-B02 1/8-inch NPT Couplings 1
W283 Display Adapter Harness 1
W284 Pulser/Handle Ribbon Cable 1
BSN18-C 18-22 American Wire Gauge (AWG) Crimp Splices 10
BC256W White “Volume Corrected to 15° C” Label 2
BC1380 Serialized AV-2322 Nameplate 1
N23760-07 Conduit Seal Washer 2
t-justified part numbers are Kraus part numbers
Note: Left-justified part numbers are Gasboy part numbers; r
contained in the preceding Gasboy part number.
igh
®
Box and BC1379 Mounting
ATC M05819K002 Kit for Twin Unit (Except 9850K)
Part Number
(see Note) Description Quantity
M06080B002 Kit, ATC Kraus TTC200-2GK 1
28017 PCB Assembly in LP-70 Polycase Box and BC1379 Mounting Sponge 1
SK460A4 460A4 ATC Display Adapter Board (see Figure 1 on page 5) 1
SK461 461A2 Pulser/Handle Adapter Board (see Figure 1 on page 5) 1
27913 Dual Intrinsic Safety Barrier 1
- 5/16-inch Flat Washer (part of 27913) 2
- 5/16-inch Hex Nut (part of 27913) 1
212AY05 Dual Probe Connector Assembly 1
W172 Three-wire Harness for Intrinsic Safety Barrier 1
SW199 Probe Assembly 2
20026 Thermowell 2
235-C Thermowell Plug 2
Page 2 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013
Part Number
Note
(see
N23760-07 Conduit Seal Washer 2
Note: Left-justified part numbers are Gasboy part numbe
) Description Quantity
122-B02 1/8-inch NPT X 1-inch Coupling 2
15912 1/8-inch NPT Adapters Drilled to 17/64-inch I.D. 2
103-B02 1/8-inch NPT Couplings 2
W283 Display Adapter Harness 1
W284 Pulser/Handle Ribbon Cable 2
BSN18-C 18-22 AWG Crimp Splices 10
BC256W White “Volume Corrected to 15° C” Label 4
BC1380 Serialized AV-2322 Nameplate 1
rs; ri
ght-justified part numbers are Kraus
part numbers contained in the preceding Gasboy part number.
ATC M05819K003 Kit for Single Unit
Part Number
(see Note) Description Quantity
039087 Kit, ATC 9800 Single (TTC200-1G) 1
SK449C PCB Assembly in LP-70 Polycase Box and BC1379 Mounting Sponge
SK460A4 460A4 ATC Display Adapter Board (see Figure 1 on page 5) 1
SK461 461A2 Pulser/Handle Adapter Board (see Figure 1 on page 5) 1
27913 Dual Intrinsic Safety Barrier 1
- 5/16-inch Flat Washer (part of 27913) 2
- 5/16-inch Hex Nut (part of 27913) 1
212AY04 Single Probe Connector Assembly 1
W171 Two-wire Harness for Intrinsic Safety Barrier 1
SW199 Probe Assembly 1
20026 Thermowell 1
235-C Thermowell Plug 1
122-B02 1/8-inch NPT Coupling 1
15912 1/8-inch NPT Adapters Drilled to 17/64-inch I.D. 1
103-B02 1/8-inch NPT Couplings 1
W283 Display Adapter Harness 1
W284 Pulser/Handle Ribbon Cable 1
BSN18-C 18-22 AWG Crimp Splices 10
BC256W White “Volume Corrected to 15° C” Label 2
BC1380 Serialized AV-2322 Nameplate 1
N23760-07 Conduit Seal Washer 2
s; ri
Note: Left-justified part numbers are Gasboy part number
part numbers contained in the preceding Gasboy part number.
ght-justified part numbers are Kraus
1
Introduction
MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 3
Introduction
ATC M05819K004 Kit for Twin Unit
Part Number
(see Note) Description Quantity
039086 Kit, ATC 9800TW (TTC200-2G) 1
SK449C PCB Assembly in LP-70 Polycase Box and BC1379 Mounting Sponge 1
SK460A4 460A4 ATC Display Adapter Board (see Figure 1 on page 5) 1
SK461 461A2 Pulser/Handle Adapter Board (see Figure 1 on page 5) 1
27913 Dual Intrinsic Safety Barrier 1
- 5/16-inch Flat Washer (part of 27913) 2
- 5/16-inch Hex Nut (part of 27913) 1
212AY05 Dual Probe Connector Assembly 1
W172 Three-wire Harness for Intrinsic Safety Barrier 1
SW199 Probe Assembly 2
20026 Thermowell 2
235-C Thermowell Plug 2
122-B02 1/8-inch NPT X 1-inch Coupling 2
15912 1/8-inch NPT Adapters Drilled to 17/64-inch I.D. 2
103-B02 1/8-inch NPT Couplings 2
W283 Display Adapter Harness 1
W284 Pulser/Handle Ribbon Cable 2
BSN18-C 18-22 AWG Crimp Splices 10
BC256W White “Volume Corrected to 15° C” Label 4
BC1380 Serialized AV-2322 Nameplate 1
N23760-07 Conduit Seal Washer 2
Note: Left-justified part numbers are Gasboy part
part numbers contained in the preceding Gasboy part number.
numbers; right-
justified part numbers are Kraus
Page 4 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013
Parts Identification
Probe Assembly (W199)
Display Adapter Harness (W283)
Pulser (W284)/Handle
Ribbon Cable
Single Probe (212AY04)/
Dual Probe Connector
(212AY05) Assembly
Display Adapter
Board (460A4)
Pulser (461A2)/Handle
Adapter Board
Crimp Splices
Thermowell Plugs
(235C)
103-B Couplings
120-B Adapters (BC546)
122-B Nipples
Thermowells (BC407)
Label (BC256W)
Nameplate (BC1380)
Dual Intrinsic Safety Barrier (27913)
Three-wire Harness [W172 (For Twin Unit)]
~OR~
Two-wire Harness [W171 (For Single Unit)]
Figure 1 and Figure 2 on page 6 show the parts in the M05819K00X Kits.
Figure 1: Identification of Parts in Kits
Introduction
MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 5
Note: Kits for single units have only one of these items.
Introduction
PCB Assembly
(28017 or SK449C)
Polycase Box
(LP-70)
Cover
Figure 2: Polycase Box (LP-70) and Cover with 28017 or SK449C
Related Document
Document
Number Title GOLD Library
MDE-4431 Gasboy ATC M05819K00X Kits Installation Manual Gasboy
Required Reading
Before installing a kit, the installer must read, understand, and follow:
• This manual
• National Fire Protection Association (NFPA) 30A, The
Station Code
• NFPA 70, The National Electric Code
• Applicable federal, state, and local codes and regulations
Failure to do so may adversely affect the safe use and op
Note: To ensure warranty, this kit must be installed
by a Gasboy Authorized Service
Contractor (ASC).
Page 6 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013
Automotive and Marine Service
eration of the equipment.
Abbreviations and Acronyms
Term Description
ASC Authorized Service Contractor
ATC Automatic Temperature Compensation
AWG American Wire Gauge
CPU Central Processing Unit
DIP Dual Inline Package
I.D. Inside Diameter
IS Intrinsic Safety
LCD Liquid Crystal Display
LPM Liters Per Minute
NFPA National Fire Protection Association (http://www
NPT National Pipe Thread
PCA Printed Circuit Assembly
PCB Printed Circuit Board
®
TPS Teflon
Pipe Sealant
.nfp
a.org/Home/index.asp)
Introduction
MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 7
Important Safety Information
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
SHUT-OFF in the case of an emergency and not
the console’s ALL STOP and PUMP STOP or
similar keys.
!
WARNING
!
Important Safety Information
Notes: 1) Save this Important Safety Information section
in a readily accessible location.
2) Although DEF is non-flammable, Diesel is
flammable. Therefore, for DEF cabinets that are
attached to Diesel dispensers, follow all the
notes in this section that pertain to flammable
fuels.
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, mainta in 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/dispenser and island. Locate
the switch or circuit breakers that shut of f all p ower to all fueling
equipment, dispensing devices, and Submerged Turbine
Pumps (STPs).
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
1-800-444-5529. It is imperative to your safety and the safety of
others to understand the procedures before beginning wo rk.
Follow the Regulations
Applicable information is available in National Fire Protection
Association (NFPA) 30A; Code for Motor Fuel Dispensing
Facilities and Repair Garages, NFPA 70; National Electrical
Code (NEC), Occupational Safety and Health Administration
(OSHA) regulations and federal, state, and local codes. All
these regulations 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 operat ion 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 warn ing
symbols and boxes.
Alert Symbol
This safety alert symbol is used in this manual and on
warning labels to alert you to a precaution wh ich must be
followed to prevent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible injury
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical co mponent s or
the electronics of the dispenser requires total electrical shut off
of that unit. Understand the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gasboy equipment.
Evacuating, Barricading and Shutting Off
Any procedure that requires access to the pump/dispenser or
STPs requires the following actions:
• An evacuation of all unauthorized persons and vehicles
from the work area
• Use of safety tape, cones or barricades at the affected
unit(s)
• A total electrical shut-off of the affected unit(s)
Page 8 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013
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 below must be followed to prevent death, injury or
damage to the equipment:
DANGER: Alerts you to a hazard or unsafe practice
!
which will result in death or serious injury.
WARNING: Alerts you to a hazard or unsafe practice
!
that could result in death or serious injury.
CAUTION with Alert symbol: Designates a hazard or
!
unsafe practice which may result in minor injury.
CAUTION without Alert symbol: Designates a hazard
or unsafe practice which may result in property or
equipment damage.
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will explode or burn, if ignited. Spilled or
leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors in the vicinity of the
dispenser or island.
DEF is non-flammable. Therefore, explosion and fire safety
warnings do not apply to DEF lines.
Important Safety Information
The pump/dispenser contains a chemical known to the
State of California to cause cancer.
WARNING
!
The pump/dispenser contains a chemical known to the
State of California to ca use birth defects or other
reproductive harm.
WARNING
!
Gasoline/DEF 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
!
WARNING
!
DEF generates ammonia gas at higher temperatures.
When opening enclosed panels, allow the unit to air out to
avoid breathing vapors.
If respiratory difficulties develop, move victim away from
source of exposure and into fresh air. If symptoms persist,
seek medical attention.
Gasoline/DEF spilled in eyes may cause burns to
eye tissue. Irrigate eyes with water for
approximately 15 minutes. Seek medical advice
immediately.
WARNING
!
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs. Keep airway
open. Seek medical advice immediately.
WARNING
!
Gasoline spilled on skin may cause burns.
Wash area thoroughly with clear water.
Seek medical advice immediately.
WARNING
!
DEF is mildly corrosive. Avoid contact with eyes, skin, and
clothing. Ensure that eyewash stations and safety s howers
are close to the work location. Seek medical advice
recommended treatment if DEF spills into eyes.
WARNING
!
No Open Fire
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 fuel vapors.
Every time you get 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. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods, if
you work 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 Lockout/Tagout procedures. If you
are not familiar with this requirement, refer to this information in
the service manual and OSHA documentation.
In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
personnel:
• Location of accident (for example, address, front/bac k of
building, and so on)
• Nature of accident (for example, possible heart attack, run
over by car, burn s, 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)
Working With Electricity Safely
Ensure that you use safe and established practices in working
with electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure that grounding
connections are properly made. Take care that sealing devices
and compounds are in place. Ensure that you do not pinch
wires when replacing covers. Follow OSHA Lockout/Tagout
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. Ensure that
you clean hands after handling equipment. Do not place any
equipment in the mouth.
MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 9
IMPORTANT: Oxygen may be needed at sc ene if g asoline has
been ingested or inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/T agout covers servicing and maintenance of machines
and equipment in which the unexpected energization or s tart-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. Subpart S of 29 CFR Part
1910 - Electrical Hazards, 29 CFR Part 1910.333 contains
specific Lockout/Tagout provision for electrical hazards.
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