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

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

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

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

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

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.

+ 19 hidden pages

Gasboy M05819K00X User Manual

Introduction

Purpose

Table of Contents

Required Tools

Parts Lists

Parts Identification

Related Document

Required Reading

Abbreviations and Acronyms

Important Safety Information