Introduction
TopKAT™ PLUS configuration for mechanical pumps requires adding an external Bypass
Switch (M09680B048) to the existing circuit breaker panel (a switch per dispenser). This must
be used in case of system malfunction to enable refueling. The switch is connected to the Line
(high voltage cable) and Controller (low voltage wires) to provide indication on bypass state.
Purpose
This document provides instructions to install the TopKAT PLUS Bypass Switch.
Table of Contents
Topic Page
Introduction
Terminal Block - Pin-out Connections for Mechanica
Manual Override Feature
Issues, Observation, and Suggestions
MDE-5073
TopKAT™ PLUS Bypass Switch Installation Instructions
March 2013
1
l Pump
s
2
5
6
Related Documents
Document
Number Title GOLD Library
MDE-5013 TopKAT PLUS Installation Manual Gasboy
Parts List
Item Description Part Number Quantity
1 Bypass Switch M09680B048 1
Figure 1: Bypass Switch
®
Series 1000/Fleetkey & Topkat
MDE-5073 TopKAT™ PLUS Bypass Switch Installation Instructions · March 2013 Page 1
Terminal Block - Pin-out Connections for Mechanical Pumps
Terminal Block - Pin-out Connections for Mechanical
Pumps
Following table lists the TopKAT PLUS terminal block connections for mechanical pumps.
TopKAT PLUS Terminal Block Mechanical Pump – Connections Definition
Terminal
No. Signal Name F
1 LINE_IN_(115/230V) Line Connection, TopKAT PLUS power input
2 NEUTRAL_IN_(115/230V) Neutral Connection, TopKAT PLUS power input
3 GROUND_IN_(115/230V) Ground Connection, TopKAT PLUS power input
4 LINE_1 Pump control 220/110 VAC input - Nozzle 1
5 LOAD_1 Pump control output - Nozzle 1
6 LINE_2 Pump control 220/110 VAC input - Nozzle 2
7 LOAD_2 Pump control output - Nozzle 2
8 IN_USE_1_ A(AC) Handle Up - In-use signal input - Nozzle 1
9 IN_USE_1_ B(RETURN) Handle Up - AC In-use signal return - Nozzle 1
10 IN_USE_2_ A(AC) Handle Up - In-use signal input - Nozzle 2
11 IN_USE_2_ B(RETURN) Handle Up - AC In-use signal return - Nozzle 2
12 -DC OUT FOR BY-PASS_2 Connection to external Bypass Nozzle 2
13 BY- PASS_2_IN Connection to external Bypass Nozzle 2
14 PULSER_1 Pulser Input - Nozzle 1
15 PULSER_2 Pulser Input - Nozzle 2
16 +12V_2_P +12 VDC Output to Pulser - Nozzle 2
17 -DC OUT FOR BY-PASS_1 Connection to external Bypass Nozzle 1
18 BY-PASS_1_IN Connection to external Bypass Nozzle 1
19 GND_1_P Nozzle Grounding - Nozzle 1
20 GND_2_P Nozzle Grounding - Nozzle 2
21 +12V_1_P +12 VDC Output to Pulser - Nozzle 1
unctional Description
Page 2 MDE-5073 TopKAT™ PLUS Bypass Switch Installation Instructions · March 2013
Figure 2: Single Mechanical Pump
Terminal Block - Pin-out Connections for Mechanical Pumps
MDE-5073 TopKAT™ PLUS Bypass Switch Installation Instructions · March 2013 Page 3
Terminal Block - Pin-out Connections for Mechanical Pumps
Figure 3: Twin Mechanical Pump
Page 4 MDE-5073 TopKAT™ PLUS Bypass Switch Installation Instructions · March 2013
Manual Override Feature
The Bypass Switch is also connected to the MPI-C (low voltage DC), that triggers the proper
LED on the board and lets the system know that the pump was put in bypass and also triggers
the proper alarm in the controller.
Event Viewer will show an event of pump switched to bypass (with relevant pump number).
Control
Also, device status will show the relevant pump disconnected.
Manual Override Test - Optional
On completion of the system wiring, the pumps and/or dispensers must be tested to verify if
the AC wiring is correct. Following steps indicate the proper procedure for testing and the
expecting results. If any of these tests fail, the wiring must be corrected and the test must be
performed again.
1 Place all the override switches in OFF position.
ler will show yellow triangle over the pump and communication error will be created.
Manual Override Feature
2 Turn on the breakers for all the pumps/dispensers and system.
3 Locate the override switch(s) and place the override switch for hose 1 in the Manual (up)
position.
4 Turn on hose 1. After completing reset, the hose must be able to dispense the product.
5 Turn on all other hoses. No other hoses besides 1 must activate.
6 Turn off all hoses.
7 Place the override switch for hose 1 in OFF position.
8 Repeat steps 3 to 7 for all remaining hoses.
MDE-5073 TopKAT™ PLUS Bypass Switch Installation Instructions · March 2013 Page 5
Issues, Observation, and Suggestions
Issues, Observation, and Suggestions
Following observation and suggestions have been made from reviewing the documentation
™
and field installation drawings from Orpak
TopKAT PLUS mechanical system.
Issues Observation Suggestions
Override/Bypass Switch is
recommended and shown to be
located in
panel.
The double pole switch contains
hig
pole and low DC voltage switch
on the other pole.
the circuit breaker/sub
AC voltage switch on one
h
Due to location and distance of the circuit
reaker panel, and the requirement to run
b
the AC and DC in two separate conduits.
It is not suggested or recommended to
ave low vol
h
voltage AC of the circuit breaker panel
which may/will place noise on the low
voltage line that may/will effect the
operation of the bypass feature not to
function properly.
tage DC around or near high
for the optional Manual Override feature for the
• Place the Bypass Switch in a secured
l
osion/weather proof enclosure on or
exp
near the TopKAT PLUS or fuel island
following the National Electrical Code
(NEC) regulations, 18-inch off the
ground and 18-inch from a pump. Two
conduits must run to the enclosure.
• For kiosk located on or near the fuel
island, suggested applications can
installed and located in the pedestal,
above the 18-inch barrier plate of the
TopKAT PLUS.
be
Gasboy® is a registered trademark of Gasboy International. Orpak™ is a trademark of Orpak Systems Ltd. TopKAT™ is a trademark of
Gasboy International.
© 2013 GASBOY
7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A.
MDE-5073 TopKAT™ PLUS Bypass Switch Installation Instructions · March 2013
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