Gasboy M06875K00X User Manual

Introduction

This manual provides installation instructions for the Automatic Temperature Compensation (ATC) Kits on Retail Atlas™ (8800K) units.

Note: Filters are required for installation but are not contained in the kits.

Section Page ...

Introduction 1

Important Safety Information 5

Installation 7

Programming the ATC Option 18

MDE-4556

Gasboy ATC Kits M06875K00X

Installation Manual

July 2006

• M06875K001 for Single-Sided 8800K Unit

• M06875K002 for Two-Sided 8800K Unit

Required Reading 1

Required Tools 2

Abbreviations and Acronyms 2

Parts Lists 2

Preparing Site and Dispenser for ATC Option 7

Installing Filter Manifold and Probe 7

Installing the T-Meter Module and Cables 9

Installing I.S. Barrier Assembly 11

Installing ATC Controller Board 12

Connecting ISB Wires and Cable 15

Completing Installation 16

Required Reading

Before installing a kit, the installer must read, understand, and follow:

• This manual

• NFPA 30A, The Automotive and Marine Service Station Code

• NFPA 70, The National Electrical Code

• Applicable Canadian, federal, state and local codes and regulations

Failure to do so may adversely affect the safe use and operation of the equipment.

Note: This kit must be installed by a Gasboy Authorized Service Contractor (ASC) to ensure

warranty.

MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual • July 2006 Page 1

Introduction

Required Tools

The following tools are needed to install the ATC Kits:

• Open-end wrench set

• 1/2-inch socket wrench

• Flat blade screwdriver

• Phillips

• Allen

screwdriver

wrench set

• Sealant, SAF-T-LOK

Abbreviations and Acronyms

The following are abbreviations and acronyms used in this document.

Abbreviation or Acronym Expansion

AT C

ASC Authorized Service Contractor

CFR Code of Federal Regulations (http://www.gpoaccess.gov/cfr/index.html)

DIP Dual Inline Package

ESD Electrostatic Discharge

IC Integrated Circuit

I.D. Inside Diameter

IS Intrinsic Safety

ISB Intrinsic Safety Barrier

NEC National Electrical Code (NFPA 70)

NFPA National Fire Protection Association (http://www.nfpa.org/Home/index.asp)

OSHA Occupational Safety & Health Administration (http://www.osha.gov/)

PCB Printed Circuit Board

RTD Resistance Temperature Detector

STP Submerged Turbine Pump

TPS Teflon Pipe Sealant

VAC Volts Alternating Current

Automatic Temperature Compensation (reference of 15

(http://strategis.ic.gc.ca/epic/internet/inmc-mc.nsf/en/lm01094e.html)

polytetrafluroethylene (Teflon® ) Pipe Sealant (TPS), or equivalent

° C = 59° F)

Parts Lists

M06875K001 - ATC Kit for 115 VAC Single-Sided Unit (Pulse Out)

Part Number Description Quantity

K81105-20 Wire Nut Connector, Length 18 mm, Blue 2

K94160-01 ATC Software Kit (includes Q11594-23 28-pin DIP IC) 1

M00414B001 M5 Metric Nut, Hex Serrated Flange 2

M04607B003 2-Stage Solenoid Valve and Filter Manifold, Low Voltage with ATC 1

MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual (this document) 1

Q10068-09 O-Ring, 1.234” I.D. 2

Q10068-14 O-Ring, 1.609” I.D. 1

Q10178-03 Cable Tie 6

Page 2 MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual • July 2006

Introduction

Part Number Description Quantity

Q13130-01 Thermowell, Meter Cover 1

Q13131-01 RTD Probe Assembly 1

Q13306-02 Meter Identification Decal Set (for probes 1 - 8) 1

R19457 High-Capacity Strainer Insert 1

R19527-G1 34-conductor Calibration Switch Cable Assembly (J204/P802/P204A) 1

R19667-G1 34-conductor Ribbon Cable Assembly (P204/P304 and P205/P405) 2

R19951-G1 10-conductor Ribbon Cable Assembly (J203/J901) 1

R20128-G1 Power Data Cable Assembly (J307) 1

R20146-G2 10-conductor Keypad Interface Cable Assembly (J203/J303) 1

T19405-G4 T-Meter Module Assembly

This includes the following cables as well as other hardware:

• R20148-G3, T-Meter Probe Cable Assemblies, quantity 2

• R20147-G1 T-Meter ISB Cable Assembly (J201/PS1), quantity 1

T19428-G1 115 VAC ISB Assembly (J1S) 1

T20569-G1 ATC Controller Printed Circuit Assembly 1

M06875K002 - ATC Kit for 115 VAC Two-Sided Unit

Part Number Description Quantity

K81105-20 Wire Nut Connector, Length 18 mm, Blue 2

K94160-01 ATC Software Kit (includes Q11594-23 28-pin DIP IC) 1

M00414B001 M5 Metric Nut, Hex Serrated Flange 2

M04607B003 2-Stage Solenoid Valve and Filter Manifold, Low Voltage with ATC 2

MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual (this document) 1

Q10068-09 O-Ring, 1.234” I.D. 4

Q10068-14 O-Ring, 1.609” I.D. 2

Q10178-03 Cable Tie 6

Q13130-01 Thermowell, Meter Cover 2

Q13131-01 RTD Probe Assembly 2

Q13306-02 Meter Identification Decal Set (for probes 1 - 8) 1

R19457 High-Capacity Strainer Insert 2

R19527-G1 34-conductor Calibration Switch Cable Assembly (J204/P802/P204A) 1

R19667-G1 34-conductor Ribbon Cable Assembly (P204/P304 and P205/P405) 2

R19951-G1 10-conductor Ribbon Cable Assembly (J203/J901) 1

R20128-G1 Power Data Cable Assembly (J307) 1

R20146-G2 10-conductor Keypad Interface Cable Assembly (J203/J303) 1

T19405-G4 T-Meter Module Assembly

This includes the following cables as well as other hardware:

• R20148-G3, T-Meter Probe Cable Assemblies, quantity 2

• R20147-G1 T-Meter ISB Cable Assembly (J201/PS1), quantity 1

T19428-G1 115 VAC ISB Assembly (J1S) 1

T20569-G1 ATC Controller Printed Circuit Assembly 1

MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual • July 2006 Page 3

Introduction

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 Total 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.

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 Canadian, 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

This safety alert symbol is used in this manual and 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.

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:

- 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

MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual • July 2006 Page 5

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.

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.

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.

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.

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

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

WARNING

This area contains a chemical known to the State of California to cause birth defects or other reproductive harm.

Lockout/Tagout covers servicing and maintenance of machines and equipment in which unexpected energizing 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

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice

Hazards, 29 CFR Part 1910.333 contains specific Lockout/ Tagout provision for electrical hazards.

immediately.

Page 6 MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual • July 2006

Installation

Preparing Site and Dispenser for ATC Option

1 Record all electronic and mechanical totals.

2 Isolate each unit to have ATC kit installed at distribution box.

3 Open door to hydraulics area.

4 Turn off (close) shear valve.

5 Test shear valve for proper closure by activating fueling position nozzle and verifying no flow

occurs.

6 Turn OFF associated STP circuit breakers for the unit(s) being upgraded.

This may require multiple STP disconnects.

Installation

7 Turn OFF all power to unit at system circuit breaker, including unit lights.

8 Disconnect power cable to the following boards:

• M05200A001 Retail Pulse Out

• T20011-G1 Pump Controller

CAUTION

Maintaining power to the boards during installation could result in board failures. Do not rely on the circuit breakers to disconnect power to the boards.

9 Turn off system battery by pressing CLEAR then ENTER on manager keypad.

10 Tag shear valve according to OSHA lock-out and tag-out requirements.

Installing Filter Manifold and Probe

The kit parts used in this section are:

• M04607B003 2-Stage Solenoid Valve and Filter Manifold with Probe Port

• Q10068-09 O-Ring, 1.234-inch I.D.

• Q10068-14 O-Ring, 1.609-inch I.D.

• Q13130-01 Thermowell, Meter Cover

• Q13131-01 RTD Probe Assembly

• R19457 High-Capacity Strainer Insert

WARNING

Residual pressure may exist in the hydraulic system. Wear eye protection.

1 Remove filter from current M04607B001 Valve and Filter Manifold.

MDE-4556 Gasboy ATC Kits M06875K00X Installation Manual • July 2006 Page 7

+ 15 hidden pages

Gasboy M06875K00X User Manual

Introduction

Contents

Required Reading

Required Tools

Abbreviations and Acronyms

Parts Lists

M06875K001 - ATC Kit for 115 VAC Single-Sided Unit (Pulse Out)

M06875K002 - ATC Kit for 115 VAC Two-Sided Unit

Related Documentation

Important Safety Information

Installation

Preparing Site and Dispenser for ATC Option

Installing Filter Manifold and Probe