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.

Installing the Commercial Atlas (9800K) ATC Kits

Installing the ATC M05819K001 or M05819K003 Kit in Single Unit

Preparing for Installation

Request permission from the manager/owner to remove power from the unit and then remove power using normal procedures. Observe the lockout/tagout safety procedures.

Ensure that you have the proper kit for the model dispenser to be retrofitted.

To install the ATC M05819K001 or M05819K003 Kit i

1 Using the proper key for the unit, unlock and remove the doors from both sides of the unit.

Note: Place doors in a safe place to pr

2 Remove the two screws securing the dial-enclosure assembly usi ng a P hillips screwdriver and

remove the assembly. Retain the screws for the replacing assembly after installation.

event damage or scratches.

Single Unit, proceed as follows:

3 Remove the two screws at side 1 of the unit (located above the display) using a Phillips

screwdriver, and pull the display cover forward.

Note: The cover pivots down in a horizontal position to allow access to the electr

of the unit. Save screws for replacing the assembly after installation.

onics section

Installing the ATC Kit

To install the ATC Kit, proceed as follows:

1 Locate the Polycase Box (LP-70) with SK449C mounted inside the M05819K001 Kit.

~OR~  Locate the Polycase Box (LP-70) with Printed Circuit Board [PC M05819K003 Kit.

2 Remove the four mounting screws securing the cover and remove the cover from the box.

Retain the screws and cover for reinstalling later.

B (28017)] mounted inside

Page 10 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

About  1-1/2 inches Clearance

3 Peel the protective cover from the Mounting Sponge (on the back of the Polycase Box) and

mount the box as shown in Figure 3. Mount about 1-1/2 inches up from shelf (1-1/2-inch clearance under the shelf).

Figure 3: Mounting the Polycase Box (LP-70)

4 Locate the two Washers [N23746-01 (mounted to shelf with two screws)] on the two shelves

creating the air gap.

Note: The lower washer location also has a Ga

5 Remove the two screws from each washer and remove the washers. Retain the gasket and

sket (N23761-04).

screws for use later.

6 Locate the two Conduit Seal Washers (N23760-07) provided in the kit.

7 Place the two Conduit Seal Washers (N23760-07) where the two Washers (N23746-01) were

mounted and place the gasket (saved in step 5) under the conduit seal washer on the lower shelf. Secure washers with screws that were

8 Locate the Dual Intrinsic Safety (IS) Barrier (27913) and Sing le Prob e Conn ecto r Assembly

removed in step 5.

(212AY04) provided in the kit. Remove the nut and washer from the mounting stud on the IS barrier and slide them off the wires. Retain the nut and washer for use later.

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 11

Installing the Commercial Atlas (9800K) ATC Kits

IS Barrier

IS Barrier Mounting Stud through Air Gap

Lower Conduit Seal Washer and Gasket

Upper Conduit Seal Washer

Probe Connector

Probe Connector Assembly

IS Barrier Mounting Stud

9 Feed the wires extending from the IS Barrier Mounting S tud through the Conduit Seal Washer

on each shelf as shown in Figure 4 and place the mounting stud through the holes.

Figure 4: Mounting the IS Barrier on the Shelf

10 Place the wires extending from the mounting stud through the mounting hole in the single

Probe Connector Assembly and place the assembly up on the stud (under the shelf as shown in

Figure 5).

Figure 5: Probe Connector Assembly and IS Barrier Stud Mounting (Under the Shelf)

11 Place the washer and nut over the wires and turn nut onto the stud securing the IS Barrier and

Probe Connector. Tighten snugly but do not overtighten.

Page 12 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

Pulser 1 and Handles Jacks

Pulser 2 Jack

LCD Display Jack

Pulser 1 and Handles Jacks

Pulser 2 Jack

(i)

CPU PCB Assembly with Connections

(ii)

CPU PCB Assembly without Connections

12 On the CPU PCB Assembly (see Figure 6), disconnect the Connectors connected to the 

Pulser 1 and Handles jacks.

Figure 6: CPU PCB Assembly

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 13

Installing the Commercial Atlas (9800K) ATC Kits

Assembly (461A2)

Pulser 1, Handles, and Pulser 2 Connectors

LCD Display Connector

Assembly (460A4)

13 Locate the Circuit Board Assembly (461A2) provided in the kit (for identification, 

see Figure 1 on page 5). Connect the assembly to the jacks labeled Pulser 1, Handles, and Pulser

Figure 7: CPU with New Connections

2 at the CPU Printed Circuit Assembly [PCA (see Figure 7)].

14 Reconnect the Connectors disconnected in step 12 on page 13 to the Circuit Board Assembly

[461A2 (directly above the Pulser 1 and Handles Connectors)].

15 At the CPU PCA (see Figure 6 on page 13), disconnect the Connector connected to the LCD

Display jack.

16 Locate the Circuit Board Assembly (460A4) provided in the kit (for identification, see 

Figure 1 on page 5). Connect the assembly to the jack labeled LCD Display on the CPU PCA.

17 Reconnect the Connector disconnected in step 15 to the Circuit Board Assembly (460A4) J1

jack (in center of the board).

18 Locate the Pulser/Handle Ribbon Cable (W284) provided in the kit (for identification, see

Figure 1 on page 5).

Page 14 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

PCB (461A2)

P6/P7

DIP Switches

19 Connect one end of the Cable (W284) to P1 on the Board [461A2 (see Figure 8)] and the other

end to P2 in the Polycase Box [LP-70 (see Figure 9)].

Figure 8: Circuit Board (461A2) with Connections

Figure 9: Polycase Box (LP-70) Showing Connections

20 Locate the Display Adapter Harness (W283) provided in the kit (for identification, see 

Figure 1 on page 5).

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 15

Installing the Commercial Atlas (9800K) ATC Kits

J4 Display Adapter Connector (W283)

Circuit Board Assembly (460A4)

21 Connect one Connector on the harness (both are the same) to J4 on the Circuit Board

Assembly (460A4) and the other Connector to P6/P7 in the Polycase Box [LP-70 (see 

Figure 10)].

Figure 10: Circuit Board (460A4) in Place with Connections Made

22 Locate the Two-wire Harness (W171) for IS barrier provided in the kit.

23 Place the Connector on the harness on P5 in the Polycase Box [LP-70 (see Figure 9 on 

page 15)].

24 Using two of the crimp splices, connect the wires of the harness to the wires extending from

the top of the IS barrier. Match color codes.

25 Cap the end of the green wire from the IS Safety Barrier, using a Cap (0M0205) or an

appropriate size wire nut (these are not part of the kit).

26 Connect the ground wire (the wire with eyelet connector) to the nearest true ground.

27 Disconnect the cable going to P6 Connector of the Pump CPU Board.

28 Connect the cable that was disconnected in step 27 to P9 Connector in the Polycase Box 

(LP-70).

Note: If the user wants to be able to display

electronic totals, another Cable (M05119A001)

must be installed and connected to the P6 Connector on the Pump CPU Board.

Page 16 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

29 In the Polycase Box (LP-70), locate the DIP Switches shown in Figure 9 on page 15 and set

the switches for the proper unit as shown in the fol

DIP Switch Settings

Switch Number

1 Product 1 ON for Diesel, OFF for Gasoline ON for Diesel, OFF for Gasoline 2 Product 2 ON for Diesel, OFF for Gasoline ON for Diesel, OFF for Gasoline 3 Not used N/A N/A 4 Unit of Measure N/A ON for Liters, OFF for Gallons 5 Pulser Multiplier ON for 9850 and 9850K, OFF for

6 Number of

7 Pulser Adder ON for 9840 ON for 9840K 8 ATC ON for ATC ON, OFF for ATC OFF ON for ATC ON, OFF for ATC OFF

Switch

nction

Probes

Settings for Existing and Model 9850K

9853

9852/ ON fo

r two (2) probes, OFF for one (1)

probe

lowing table.

Settings for Models 9840K, 9852K, 9853K

N/A

ON for two ( probe

2) probes, OFF for one (1)

30 Remount the Polycase Box (LP-70) cover removed in step 1 on page 10.

31 Using two of the crimp splices, connect the two yellow wires extending from the bottom of the

IS Barrier Mounting Stud to the two blue wires attached to the Single Probe Connector Assembly.

32 Cap the end of the two green wires extending from the bottom of the IS barrier, using two

Caps (0M0205) or suitable size wire nuts (these are not part of the kit).

33 Locate the following parts provided in the kit (for parts identification, see Figure 1 on page 5):

• Probe Assembly (W199)

• Thermowell (BC407)

• Thermowell Plug (235-C)

• Adapter (BC546)

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 17

Installing the Commercial Atlas (9800K) ATC Kits

Probe Assembly

Holes plugged when Probe is not installed

Adapter

Thermowell Plug

Thermowell

When applying SAF-T-LOK® TPS Sealant on threads, leave the two threads that enter the hole first free of sealant to prevent the sealant from entering, and possibly damaging or inhibiting proper operation of the unit.

CAUTION

34 Under the shelf (where the IS Barrier Stud is secured), locate the two plugs in the hydraulic

coupling (see Figure 11).

Figure 11: Hydraulic Coupling (Probe Assembly Mounting Location)

Remove the two plugs using an appropriate size Allen-wrench.

36 Coat the Thermowell Threads (BC407) with SAF-T-LOK TPS Sealant and threads into one of

the holes where the plugs were removed in step 35 (see Figure 11).

37 Tighten the Thermowell using a proper size wrench and place the Thermowell Plug (235-C)

into the Thermowell.

38 Coat the threads of the Adapter (BC546) with SAF-T-LOK TPS Sealant and turn it into the

other hole where the plugs were removed in step 35 (see Figure 11).

39 Coat the threads of the Probe Assembly (W199) with SAF-T -LOK TPS S ealant and turn it into

Page 18 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

the Adapter (BC546) mounted in step 38 on page 26.

Installing the Commercial Atlas (9800K) ATC Kits

Ensure the threads on the Thermowell, Adapter, and Probe Assembly are properly coated with the SAF-T-LOK TPS Sealant and tightened to prevent leaks.

CAUTION

Tighten both the Adapter and Probe using an appropriate size wrench.

41 Connect the other end of the Probe to Probe Connector Assembly in the connector labeled “1”

(for Probe Connector Assembly location, see Figure 5 on page 12).

42 Go to “Completing Installation” on page 27 in this manual.

Installing the ATC M05819K002 or M05819K004 Kit in Twin Unit

Preparing for Installation

Request permission from the manager/owner to remove power from the unit and then remove power using normal procedures. Observe the lockout/tagout safety procedures.

Ensure that you have the proper kit for the model dispenser to be retrofitted.

1 Unlock and remove the doors from both sides of the unit using proper key for the unit. Place

doors in a safe place to prevent damage or scratches.

2 Remove the two screws securing the dial enclosure assembly using a Phillips screwdriver and

remove the assembly. Retain the screws for replacing assembly after installation.

3 Loosen the two screws (one on each side of the display cover) using a Phillips screwdriver, at

side 1 of the unit. Spring the screw holders and screws out from the display cover and pull the display cover forward.

Note: The cover pivots down in a horizontal position allowing access to the electronics

section

of the unit.

Installing ATC Kit

1 Locate the Polycase Box (LP-70) with PCB (SK449C) mounted inside, in the M05819K003

Kit. ~OR~ Locate the Polycase Box (LP-70) with PCB (2801

2 Remove the four mounting screws securing the cover and remove the cover from the box.

Retain screws and cover for reinstalling later.

7) mounted inside, in the M05819K004 Kit.

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 19

Installing the Commercial Atlas (9800K) ATC Kits

About 1-1/2 inches Clearance

3 Peel the protective cover from the Mounting Sponge (on the back of the Polycase Box) and

mount the box as shown in Figure 12. Mount about 1-1/2 inches up from shelf.

Figure 12: Mounting the Polycase Box (LP-70)

4 On the two shelves creating the air gap, locate the two washers [N23746-01 (mounted to shelf

with two screws)].

Note: The lower washer location als o has a Gasket (N23761-04).

5 Remove the two screws from each washer and remove the washers. Retain the gasket and

screws to use later.

6 Locate the two Conduit Seal Washers (N23760-07) provided in the kit.

7 Place the two conduit seal washers where the two Washers (N23746-01) were mounted, place

the gasket (saved in step 5) under the conduit seal washer on the lower shelf, and secure washers with screws removed in step 5.

8 Locate the Single IS Barrier (27913) and Dual Probe Connector Assembly (212AY05)

provided in the kit. Remove the nut and washer from the mounting stud on the IS Barrier and slide them off the wires. Retain the nut and washer to use later.

Page 20 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

IS Barrier

IS Barrier Mounting Stud

through Air Gap

Lower Conduit Seal

Washer and Gasket

Upper Conduit Seal Washer

Probe Connector

Probe Connector Assembly

IS Barrier Mounting Stud

9 Feed the wires extending from the IS Barrier Mounting Stud through the hole in the shelf as

shown in Figure 13 and place the mounting stud through the hole.

Figure 13: Mounting the IS Barrier on the Shelf

10 Place the wires extending from the mounting stud through the mounting hole in the Dual

Probe Connector Assembly. Place the Connector Assembly up on the stud [under the shelf  (see Figure 14)].

Figure 14: Probe Connector Assembly and IS Barrier Stud Mounting (Under the Shelf)

Note: The probe connection to the Probe Connector Assembly shown is for a single unit. The

dual unit has two probe connectors connected to the assembly.

11 Place the washer and nut over the wires and turn nut onto the stud securing the IS Barrier and

Probe Connector. Tighten snugly but do not overtighten.

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 21

Installing the Commercial Atlas (9800K) ATC Kits

Pulser 1 and Handles Jacks

Pulser 2 Jack

LCD Display Jack

Pulser 1 and Handles Jacks

Pulser 2 Jack

(i)

(ii)

CPU PCB Assembly with Connections

CPU PCB Assembly without Connections

12 At the CPU PCA (see Figure 15), disconnect the Connector connected to the Pulser 1,

Handles, and Pulser 2 jacks.

Figure 15: CPU PCB Assembly

13 Locate the Circuit Board Assembly (461A2) provided in the kit (for identification, see 

Figure 1 on page 5). Connect the assembly to the jacks labeled Pulser 1, Ha

ndles, and Pulser 2

at the CPU PCA.

14 Reconnect the Connector removed in step 8 on page 20 to the Circuit Board Assembly [461A2

(directly above the Pulser 1, Handles, and Pulser 2 Connectors)].

Page 22 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

Ensure the Cables are connected to the Connectors as follows:

• From P1 of 461A2 to P2 of LP-70 Polycase Box.

• From P8 of 461A2 to P3 of LP-70 Polycase Box.

IMPORTANT INFORMATION

PCB (461A2)

15 At the CPU PCA (see Figure 15 on page 22), disconnect th e Connector connected to the LCD

Display jack.

16 Locate the Circuit Board Assembly (460A4) provided in the kit (for identification, see 

Figure 1 on page 5). Conne

17 Reconnect the Connector removed in step 11 on page 21 to the Circuit Board Assembly

ct the assembly to the jack labeled LCD Display at the CPU PCA.

(460A4) J1 jack (in center of board).

18 Locate the two Pulser/Handle Ribbon Cables (W284) provided in the kit (for identification,

see Figure 1 on page 5).

19 Connect one end of one Cable (W284) to P1 on the Board [461A2 (see Figure 16)] and the

other end to P2 in the Polycase Box [LP-70 (see Figure 17 on

20 Connect one end of the second Cable (W284) to P8 on the Board [461A2 (see Figure 16 )] and

the other end to P3 in the Polycase Box [LP-70 (see

Figure 17 on page 24)].

page 24)].

Figure 16: Circuit Board (461A2) with Connections

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 23

Installing the Commercial Atlas (9800K) ATC Kits

P6/P7

DIP Switches

J4 Display Adapter Connector (W283)

Circuit Board Assembly (460A4)

Figure 17: Polycase Box (LP-70) Showing Connections

21 Locate the Display Adapter harness (W283) provided in the kit (for identification, see Figure 1

on page 5).

22 Connect one Connector on the harness (both are the same) to J4 on the Circuit Board

Assembly [460A4 (see Figure 18)] and the other Connector to P6/P7 in the Polyc [LP-70 (see Figure 17)].

ase Box 

Figure 18: Circuit Board (460A4) in Place with Connections Made

23 Locate the Three-wire Harness (9W172) for IS Barrier provided in the kit.

24 Place the Connector on the harness on P5 in the Polycase Box [LP-70 (see Figure 17)].

25 Using three of the crimp splices, connect the wires of the harness to the wires extending from

the top of the IS barrier. Match color codes.

26 Connect the ground wire (the wire with eyelet connector) to the nearest true ground.

Page 24 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

27 Disconnect the cable going to P6 Connector of the Pump CPU Board.

28 Connect the cable that was disconnected in step 27 to P9 Connector in the Polycase Box 

(LP-70).

Note: If the user wants to be able to display

electronic totals, another Cable (M05119A001)

must be installed and connected to the P6 Connector on the Pump CPU Board.

29 In the Polycase Box (LP-70), locate the DIP switches shown in Figure 17 on page 24 and set

the switches for the proper unit as shown in the fol

DIP Switch Settings

Switch Number

1 Product 1 ON for Diesel, 

2 Product 2 ON for Diesel, 

3 Not used N/A N/A 4 Unit of Measure N/A ON for Liters, 

5 Pulser Multiplier ON for 9850 and 9850K, 

6 Number of

7 Pulser Adder ON for 9840 ON for 9840K 8 ATC ON for ATC ON, 

Switch

nction

Probes

Settings for Existing and Model 9850K

OFF for Gasoline

OFF for 9852/9853 ON for two (2) probes, 

OFF for one (1) probe

OFF for ATC OFF

lowing table.

Settings for Models 9840K, 9852K, 9853K

ON for Diesel,  OFF for Gasoline

OFF for Gallons N/A

ON for two (2) probes,

F for one (1

ON for ATC ON,  OFF for ATC OFF

) probe

30 Remount the Polycase Box (LP-70) cover removed in step 1 on page 19.

31 Using two of the crimp splices, connect the two green wires extending from the bottom of the

IS Safety Barrier Mounting Stud to the two green wires attached to the Dual Probe Connector Assembly.

32 Using two of the crimp splices, connect the two yellow wires extending from the bottom of the

Intrinsic Safety Barrier Mounting Stud to the two yellow wires attached to the Dual Probe Connector Assembly.

33 Locate the following parts provided in the kit (for parts identification, see Figure 1 on page 5):

• Probe Assembly [W199 (2)]

• Thermowell [BC407(2)]

• Thermowell Plug [235-C (2)]

• Adapter [BC546 (2)]

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 25

Installing the Commercial Atlas (9800K) ATC Kits

Probe Assembly

Holes plugged when Probe is not installed

Adapter

Thermowell Plug

Thermowell

When applying SAF-T-LOK TPS Sealant on threads, leave the two threads that enter the hole first free of sealant to prevent the sealant from entering, and possibly damaging or inhibiting proper operation of the unit.

CAUTION

34 Under the shelf (where the IS Barrier is mounted), locate the two plugs in the hydraulic

coupling toward the right side of the unit (see Figure 19).

Figure 19: Hydraulic Coupling (Probe Assembly Mounting Location)

35 Remove the two plugs using an appropriate size Allen-wrench.

36 Coat the Thermowell Threads (BC407) using SAF-T-LOK TPS Sealant and thread into one of

the holes where the plugs were removed in step 35 (see Figure 19).

37 Tighten the Thermowell using a proper size wren ch and place the 235-C Thermowell Plug into

the Thermowell.

38 Coat the threads of the Adapter (BC546) with SAF-T-LOK TPS Sealant and turn it into the

other hole where the plugs were removed (see Figure 19).

39 Coat the threads of the Probe Assembly (W199) with SAF-T -LOK TPS S ealant and turn it into

the Adapter (BC546) mounted in step 38.

Page 26 MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Installing the Commercial Atlas (9800K) ATC Kits

Ensure that the threads on the Thermowell, Adapter, and Probe Assembly are properly coated with the SAF-T-LOK TPS Sealant and tightened properly to prevent leaks.

CAUTION

Tighten both the adapter and probe using the proper size wrench.

41 Connect the other end (Connector) of the Probe to Probe Connector Assembly in the connector

labeled “1”.

42 Locate the other two plugs in the hydraulic coupling toward the left side of the unit (see 

Figure 19 on page 26).

43 Repeat steps 28 through 33 on page 25 to mount the second Probe Assembly.

44 Connect the Connector end of the second Probe to Probe Connector Assembly in the

connector labeled “2”.

45 Go to “Completing Installation” to complete the installation procedure.

Completing Installation

1 Dress the cablings by placing them in existing cable ties. Ensure the cables do not create any

obstruction to operation, access, or servicing.

2 Test the ATCs to determine that they are functioning properly.

This will involve running transactions and using the totalizer display (for more information, refer to “Appendix: To

3 After determining that the ATCs are functioning properly:

• using screws saved, remount the dial enclosure assemblies.

• remount the doors on both sides of the unit.

• secure doors with the keylocks.

4 Inform the manager/owner that the unit can be returned back to service.

talizer Display Information” on page 28).

MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013 Page 27

Appendix: Totalizer Display Information

0023.43

0 23.2

189.2

1.30

842 .2

Appendix: Totalizer Display Information

By activating the magnet located at the opposite side of the totalizer, following information will appear on the display.

Information Type Definition Example of Display

Volume Displays uncompensated volume.

Probe Temperature Displays probe temperature (in Celsius only).

Flow Rate Displays flow rate [in Liters Per Minute (LPM only)].

Software Version Displays software version number.

ATC Status Displays ATC status.

Leftmost digits (842) are error indicators, which are blank when the

8 = tempera 4 2 = exceptional reset detected

Rightmost digit (2 comp dispensed.

0 = tempera 1 = product is g 2 = product is d

corresponding error condition is not active.

ture probe fault detected

= pulser error occurred

) indicates whether temperature

ensation is enabled, and if so,

ture compensation disabled

asoline and compensation enabled iesel and compensation enabled

what product is being

Allen® is a registered trademark of Industrial Fasteners, Inc. Atlas™ is a trademark of Gasboy Inc. Phillips® is a registered trademark of Phillips Screw Company. Polycase Chemical Corporation. Teflon

is a registered trademark of ECP Corporation. SAF-T-LOK® is a registered trademark of SAF-T-LOK

is a registered trademark of E.I. DuPont de Nemours and Company.

© 2013 GASBOY 7300 West Friendly Avenue · Post Office Box 22087 Greensboro, North Carolina 27420 Phone (800) 444-5529 · http://www.gasboy.com · Printed in the U.S.A. MDE-4431C Gasboy ATC M05819K00X Kits Installation Manual · February 2013

Gasboy M05819K00X User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Purpose

Table of Contents

Required Tools

Parts Lists

Parts Identification

Related Document

Required Reading

Abbreviations and Acronyms

Important Safety Information

Installing the Commercial Atlas (9800K) ATC Kits

Installing the ATC M05819K001 or M05819K003 Kit in Single Unit

Installing the ATC M05819K002 or M05819K004 Kit in Twin Unit

Completing Installation

Appendix: Totalizer Display Information