Husky 1800, 70 User Manual

SERIES 70 AND 1800

CONSUMER ELECTRIC PUMPS

INSTALLATION/OPERATION/PARTS

MANUAL

035219

REV. 0259

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards and procedures on the use and care of the Series 70 and 1800 pumps. Please leave this manual with the pump owner after the installation is complete.

Copyright 1999 by Gasboy International, Inc. All rights reserved. The information in this document is confidential and proprietary. No further disclosure shall be made without permission from Gasboy International, Inc. Gasboy International, Inc. believes that the information in this document is accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.

GASBOY INTERNATIONAL, INC. A TOKHEIM SUBSIDIARY LANSDALE, PA

IMPORTANT WARNINGS AND SAFEGUARDS

Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or property, follow these listed warnings and other warnings and precautions outlined in this manual when installing, using, or working around this equipment. Check with GASBOY Technical Services for compatibility of liquids with pump materials.

TURN OFF AND LOCK OUT ALL POWER TO PUMP BEFORE PERFORMING SERVICE, MAINTENANCE OR IN THE EVENT

OF A FUEL SPILL.

All products must be installed by a qualified installer and used in conformance with all building, fire, and environmental codes and other safety requirements applicable to its installation and use, including, but not limited to, NFPA 30, NFPA 30A, NFPA 395 & NFPA 70. A qualified installer is familiar with fuel systems installations under the above stated building, fire, and environmental codes and other safety requirements for the particular type of installation.

This product is only part of a fuel dispensing system and additional equipment and accessories, such as, but not limited to, breakaway connectors, shear valves, pressure regulators, flow limiters, and other safety devices may be necessary to meet the applicable codes.

For maximum safety, we recommend that all employees be trained as to the location and procedure for turning off power to the entire system. Instructions regarding proper operation of the equipment along with the appropriate safety warnings should be posted in plain view at the fuel island.

Before performing service or maintenance (including changing of fuel filters or strainers) or in the event of a fuel spill, turn off and lock out all power to the system. In battery-powered pumps, disconnect power source. In submersible pump applications, turn off and lock out power at the master panel and close any impact valves to the submersible pump and any other dispensers which use that submersible pump. AC power can feed back into a shut-off dispenser when dispensers share a common submersible pump or starter relay. Also block islands so no vehicles can pull up to the dispenser when the dispenser is being worked on.

Federal DOT regulations prohibit dispensing flammables, such as gasoline, from portable tanks.

DO NOT

threads in the product.

DO NOT

pumping fuel or additives into aircraft.

DO NOT

direct fueling of aircraft without filters and separators necessary to ensure product purity.

DO NOT

required (for food products for human consumption) or with water-based liquids.

DO NOT

using the pump.

DO NOT

electrical equipment which may ignite fumes.

DO NOT

gasoline or other petroleum products into a vehicle with its motor running.

DO NOT

gasoline or other petroleum products into unapproved containers or into approved containers in or on vehicles including trucks. All containers must be filled on the ground to prevent static discharge. Always use Approved and Listed hoses and nozzles with electric pumps and dispensers.

DO NOT

manner. Nozzles shall conform to UL and NFPA code requirements for attended or unattended service.

with proper filters based on the product being dispensed and its intended use.

clothes when dispensing any liquid which may be potentially harmful or hazardous.

clothing clear of belts, pulleys, and other exposed moving parts at all times.

use Teflon tape for any pipe

use consumer pumps for

use commercial pumps for

use where sanitary design is

smoke near the pump or when

use near open flame or

permit the dispensing of

block open the nozzle in any

ensure that the pump is equipped

wear safety goggles and protective

keep all parts of body and loose

require washing and changing of clothes if fuel is spilled on a person or his/her clothing. Keep away from open flames, sparks, or people smoking.

provide a receptacle for catching product from pump/meter when servicing.

clean up product spills on the driveway. Turn off and lock out all power prior to cleanup.

insure pump is properly grounded.

insure hose is compatible with fluid being dispensed.

inspect hose, nozzle, and pump on a regular basis for wear, damage, or other conditions which may create a safety or environmental hazard.

make sure all pipe threads are properly cut and the inside reamed to remove burrs. Use UL classified gasoline-resisting compound on all joints of gasoline handling piping. Sealing compound must also be resistant to Gasohol (Ethanol and Methanol). Use gasoline-resistant pipe compound on male threads only; pipe compound used on female threads can be squeezed into the supply line where it can enter the product stream and become lodged in the pump or meter.

ensure that junction box covers are in place and properly tightened. Mating surfaces between the box and cover must be free of dirt, nicks, and scratches. All unused entries into the junction box must be properly plugged.

035282 Rev. 0215

GASBOY INTERNATIONAL, INC.

A TOKHEIM SUBSIDIARY

707 North Valley Forge Rd. Lansdale, PA, 19446

(215) 855-4631

●

FAX: (215) 855-0341

●

CONTENTS

IMPORTANT WARNINGS AND SAFEGUARDS FOR CONSUMER PUMPS

Section 1: INTRODUCTION

Purpose..................................................................................................... 1-1

Specifications* .......................................................................................... 1-1

Section 2: INSTALLATION

Installation Precautions............................................................................. 2-1

Supply Line - Underground Tanks............................................................ 2-2

Pump Dimensions - Series 70, Model 1820 ............................................. 2-3

Pump Dimensions - Series 1820R............................................................ 2-3

Installation Instructions ............................................................................. 2-4

Cabinet Removal for Installation or Service (Series

1820 only - Rounded Cabinet).......................................................... 2-4

Cabinet Removal for Installation or Service (Series

1820 only - Squared Cabinet)........................................................... 2-4

Installing Hose and Nozzle.................................................................. 2-4

Direct Mount on Underground Tank .................................................... 2-5

Direct Mount on Aboveground Tank.................................................... 2-6

Pedestal Mount Pump ......................................................................... 2-7

Wall Mount........................................................................................... 2-8

Vacuum Breaker.................................................................................. 2-9

Section 3: WIRING

Wiring Precautions.................................................................................... 3-1

Circuit Breakers ........................................................................................ 3-1

Grounding................................................................................................. 3-2

The Pump Motor....................................................................................... 3-2

Wire Size .................................................................................................. 3-2

Pulser Wiring ............................................................................................ 3-3

Conduit...................................................................................................... 3-3

Pump Wiring Diagrams............................................................................. 3-4

Section 4: STARTUP AND OPERATION

Pre-Startup Checklist................................................................................ 4-1

Startup ...................................................................................................... 4-1

Post Startup Tests .................................................................................... 4-2

Voltage................................................................................................. 4-2

Tightness............................................................................................. 4-2

Meter Calibration ................................................................................. 4-2

Strainer Cleaning................................................................................. 4-3

Daily Operation......................................................................................... 4-3

Section 5: MAINTENANCE AND TROUBLESHOOTING

Maintaining Trouble-Free Operation......................................................... 5-1

When Your Pump Needs Service............................................................. 5-2

0144 Contents-1

GASBOY Series 70 & 1800

Troubleshooting........................................................................................ 5-3

Disassembly of Pump............................................................................... 5-5

Meter-Register Disassembly..................................................................... 5-5

1860 3-Wheel Register Service and Maintenance ................................... 5-6

4860 4-Wheel Register Service................................................................ 5-7

Section 6: PARTS

Series 70 Assembly.................................................................................. 6-2

Optional Accessories........................................................................... 6-3

Series 1800 Assembly.............................................................................. 6-4

Optional Accessories........................................................................... 6-5

Direct Drive Motor-Pump Assembly.......................................................... 6-6

Installation Parts ....................................................................................... 6-8

1860 and 4860 Meter-Register................................................................. 6-9

1860 3-Wheel Meter Register (Model 1820) ............................................ 6-10

4860 4-Wheel Register (Model 72S and Series 1820R) .......................... 6-12

Model 1820 Register Setback and Switch Linkage Assembly.................. 6-14

Optional Kits for Series 70 and 1800 Pumps............................................ 6-15

Series 1820R Parts List............................................................................ 6-16

1820R Pulser and Junction Box Assemblies............................................ 6-18

Warranty

Contents-2 0144

Section 1

INTRODUCTION

PURPOSE

The GASBOY provided to assist the installer in installing and operating the unit. Faulty installations are the major cause of unit malfunc tions. This manual should be supplied to the electr ician prior to the installation of conduit and wiring. The Series 70 or 1820 pum ps as described in this manual. This manual also c ontains warnings, saf eguards and proc edures on the use and care of the pump. Be sure to leave this manual with the pump owner after the installation is complete.

Customers and installers having any questions pertaining to the installation should

☎☎☎☎

contact their GASBOY distributor.

Series 70 and 1820 Consumer Electric Pumps Installation/Operation Manual

must

be installed and operated

SPECIFICATIONS

Series 70 and Series 1820 pumps are m ade specifically for private use on vented tank s. W hile their outward appearance differs, they basically offer the sam e features. These pum ps can be mounted on aboveground skid tank s, directly mounted above underground tank s, or mounted on pedestals for remote underground installations. Table 1-1 summarizes the features for each model.

Pumping Unit: Self-priming, direct-drive rotary vane; 23 PSI (1.6 bars) stainless steel bypass; check

valve with pressure relief valve.

Motor: 1/3 HP, 1725 RPM motor with thermal overload protection and auxiliary AC line.

Standard 115 VAC, 60 Hz; optional 230 VAC, 50 Hz. AC junction box included.

1820: 3-wheel, volume only; lever-type reset with interlock; 6-digit master totalizer

(Optional, except for 1820R: 4-wheel push-button) Registers show delivery in US gallons, Imperial gallons, or liters and change gears are available to convert registers for unit of measure.

Meter: Nutating disk phenolic measuring chamber in aluminum die-cast housing; adjustable

calibration +.5% at full flow

Hose & Nozzle: 12' (3.66 m) UL-Listed hose assembly with integral static discharge wire; manual self-

closing nozzle.

Connections: 2" (5.08 cm) NPT for tank opening; 1" (2.54 cm) suction; 3/4" (1.91 cm) NPT discharge Strainer: 100-mesh nylon Delivery Rate: 18 GPM, at 115V, 60 Hz.; 60 LPM at 60 Hz.; 68 LPM at 50 Hz. Finish: High-gloss red urethane or color of choice. 1820 only: Stainless steel extra cost option. Approvals: UL, CSA

Additional extra cost options include: vapor rec overy, vacuum breaker return line, longer hoses, hose breakaways, automatic nozzles, external filters, wall m ounting kits, and for Ser ies 1820 only, 10:1 pulser or rear- or side-mount filter kits.

9312 1-1

GASBOY Series 70 & 1820

Table 1-1. Series 70 and 1820 Features

Stripped-down versions of Series 70 pumps, which mount on customer-supplied piping and fittings, are available. Model 72X has no attachments or register, Model 73 has a hose and nozzle, but no meter or register.

1-2 9312

Section 2

INSTALLATION

INSTALLATION PRECAUTIONS

All tanks and installations m ust conform with all building/fire c odes, all Federal, State, and Local codes, National Electrical Code, (NFPA 70), NFPA 30, Automotive and Marine Service Station Code (NFPA 30A) and NFPA 395 codes and regulations.

Plan your installation carefully. Dispensing troubles, which seem to be pump-related, are frequently traced to faulty installation. Review the following list of installation to avoid potential problems:

DO's

and

DON'T's

read the

It contains important information regarding the safe use of your pumps.

install an emergency power cutoff, if the pump is used for other than pers onal use. In addition to circuit breaker requirements of NFPA 70 and NFPA 30A, a single c ontrol which simultaneously removes AC power from all site dispensing equipment is recommended. This control must be readily accessible, clearly labeled, and in accordance with all local codes. In order to provide the highest level of saf ety, we recommend that all em ployees be trained as to the location and procedure for turning off power to the dispensing equipment.

use breakaway couplings on discharge hose. W hile not required for tanks under 1100 gallons, use is recommended for safety reasons.

have the pump installed by a competent installer/electrician.

DO NOT

nipples, never close nipples).

DO NOT

crushed rock, or pea gravel).

WARNINGS

experiment with a pump if you are not sure the installation is correct. overload sub- or main breaker panels.

install any underground piping without proper swing joints. (Always use shoulder

cover any lines until they have been both air- and liquid-tested.

back-fill the tank or supply line with cinders or ashes. (Back -fill with clean sand,

page at the front of this manual, preceding the Table of Contents .

DO NOT

10. galvanized or fiberglass* pipe and fittings). *Install all fiberglass pipe and fittings acc or ding to manufacturer's specifications and requirements.

DO NOT

11. diagram or wire chart provided in Section 3).

DO NOT

12.

DO NOT

13.

DO NOT

14. storage tank.

9312 2-1

use black iron pipe or fittings for underground installations. (Use only new

use power line wiring of inadequate capacity. (Use gauge specified by the wiring

use a circuit breaker of improper size. (See Section 3). install fill pipe to tank where it can be submerged with standing water.

use the GASBOY fuel dispensing equipment to remove water ballast from the

GASBOY Series 70 & 1820

DO NOT

15. found around wires at all junction box entrances is a requirement of the National Elec trical Code and should not be disturbed. Tighten junction box covers before replacing panels.

DO NOT

16. wires should be run in threaded, rigid, metal conduit. All threaded connections must be drawn up tight with five (5) threads minimum engagement. Only one opening in the AC junction box is provided. At completion of the installation, it is the installer's res ponsibility to ensure that any unused openings are plugged.

use gaskets on covers of explosion-proof type boxes. The sealing compound

use knock-out boxes or flexible conduit for installing this unit. All power and lighting

SUPPLY LINE - UNDERGROUND TANKS

If you are using an underground tank, pitch the tank away from s uction end. Horizontal runs of suction line should slope down from the pump toward the tank. Do not exceed an equivalent lift of 12' for gasoline or 14' for diesel to the center line of the pumping unit, including f riction res istance in the suction pipe.

The end of the suction pipe must be at least three inches from bottom of tank. The tank or piping should not be located under traffic ar eas. Swing joints (two ells) will prevent

damage to piping due to frost heave or ground settlement. Use nonhardening, gasoline-resistant pipe compound on male thr eads of all pipe joints for liquid

handling piping.

2-2 9312

Installation

PUMP DIMENSIONS - SERIES 70, MODEL 1820

Pump diagrams shown are for Model 1820. Pump dimensions are the same for all Series 70 pumps.

PUMP DIMENSIONS - MODEL 1820R

Pump diagrams s hown are for Model 1820R. Pump dimensions are the same for these Model 1820 pumps: 1820R, 1820RSS, 1820RC, 1820RCSS.

9312 2-3

GASBOY Series 70 & 1820

INSTALLATION INSTRUCTIONS

Cabinet Removal for Installation or Service (Series 1820 Only) - Rounded Cabinet

1. Remove two screws, one on each side of the cabinet.

2. Pull front panel assembly forward at bottom. As it clears the pumping unit, lift up to remove.

3. To replace front panel, engage pins at top in matching holes in rear panel. W ith front panel assembly tilted back, pins m ay be seen through dial opening. Fr ont panel assembly will now drop back into position.

4. Reinstall two screws in sides.

Cabinet Removal for Installation or Service (Series 1820R Only) - Squared Cabinet

1. Remove two screws on lower front of cabinet.

2. Remove two screws from upper back of cabinet.

3. Push in and hold the reset button and pivot the cabinet front panel upward until it clears the button (Be careful not to damage the button). Remove panel.

4. For calibration or service, remove the lef thand side panel by unscrewing the two screws on the bottom side of the cabinet.

5. To reassemble pum p cabinet, align s ide panel s cr ew holes with holes on base of c abinet and screw tight. Replace the cabinet top and front panel by positioning the back plate and pivoting the assembly forward. Be sure to press in the reset button until the front panel clears it. Then replace the screws in the front and back of cabinet.

Installing Hose and Nozzle

To prevent undue stress and poss ible damage, install hos e and nozzle after installation of pump. Hose must have static wire which provides electrical continuity between hose couplings to dissipate static electrical charge.

1. Screw the pipe elbow (provided with the pump) into the product outlet on the back of the pump. Apply gasoline-resistant pipe compound to male threads.

NOTE: Elbow fitting is not required, however, it provides strain relief for the hose.

2. Screw the hose into the open end of the elbow and tighten. Apply gasoline-resistant pipe compound to male threads.

3. Screw nozzle onto hose.

NOTE: 1820R models are shipped with a vacuum breaker assembly (P/N 032701)

consisting of a tee, pipe nipple and vacuum breaker. This assembly should be installed in the pump outlet before connecting the hose.

2-4 9312

Installation

Direct Mount on Underground Tanks

1. Screw 2" coupling onto 2" standard pipe.

2. Screw 2" standard pipe into 2" tank flange. Apply compound to threads at bottom of base to prevent surface water from entering the tank.

3. Screw 1" suction pipe into install-a-soc ket. Suction pipe should be long enough to allow 3" clearance from bottom of tank. Apply gasoline-resistant pipe compound to male threads.

4. Lower 1" suction pipe through 2" standard pipe into tank. Tighten install-a-socket into coupling at top of standard pipe.

5. Screw pump (2" threaded base) into ins tall-a-socket. This is a suction line connection and must be tight. Apply gasoline-resistant pipe compound to male threads.

See the

Conduit

section for correct installation of electrical conduit.

9312 2-5

GASBOY Series 70 & 1820

Direct Mount on Aboveground Tank

Aboveground tanks require both a pressure/vacuum vent and an emergency vent. The pressure/vacuum vent r educes losses due to evaporation and is an air quality control m easure. The emergency vent provides a relief from the pressur e resulting from heating and boiling of the tank contents during a fire situation. Both vents must be properly sized for a given tank.

1. Screw 1" suction pipe into install-a-soc ket. Suction pipe should be long enough to allow 3" clearance from bottom of tank. Apply gasoline-resistant pipe compound to male threads.

2. Screw install-a-socket directly into 2" flange in the aboveground tank.

3. Lift the pump to the height of the tank and tighten it into the install- a-sock et. Apply gasolineresistant pipe compound on male thread.

extended nozzle hanger, you may need to use a 2" coupling and close nipple in between the pump and the install-a-socket. This will prevent interference of the hanger with the top of the tank.

NOTE: If using an automatic nozzle with the

See the

Conduit

section for correct installation of electrical conduit.

NOTE: Aboveground tanks, located at commercial, industrial, governmental, or manufacturing

establishments and intended for fueling vehicles used with their busines s, cannot exceed a capacity of 6000 gallons.

2-6 9312

Installation

Pedestal Mount Pump

1. Screw 2" coupling onto threaded end of 2" standard pipe.

2. Slide cast iron pedestal base up over the unthreaded end of 2" standard pipe.

3. Screw 1" suction pipe into install-a-soc ket. Suction pipe should be long enough to allow 3" clearance from bottom of tank. Apply gasoline-resistant pipe compound to male threads.

4. Insert 1" suction pipe into 2" pipe and screw install-a-socket into coupling on end of 2" pipe.

5. Assemble union onto lower end of 1" suction pipe conforming to your site's piping layout. Note that the GASBOY base is provided with an opening on one side, so that an elbow can be used and the suction brought out horizontally aboveground if desired, instead of straight down through the island.

6. Slide base down to proper position at the lower end of the pedestal, tighten six set screws.

7. Screw the 2" male thread on the base of the pum p into the upper end of the install-a-soc ket. Apply gasoline pipe compound to all male threads.

8. Securely mount pedestal base to concrete. If the pump is not securely fastened to the foundation, supply line leaks at unions and pipe joints may occur.

See the and swing joints are supplied by the customer. All metallic piping should be at least Schedule 40 wrapped/coated black steel pipe with extra-heavy malleable iron screw type fittings. Protect metallic piping in contact with the ground with a properly designed cathodic protection system.

Conduit

section for correc t installation of electrical conduit. All under ground piping

9312 2-7

GASBOY Series 70 & 1820

Wall Mount

The optional wall mount kit can be used with any Series 70 or 1820 pum p to be located rem ote from the tank. The wall mount kit consists of a wall mounting bracket, pump mounting flange, and hardware to attach the flange to the bracket. Hardware to attach the br acket to the wall is not included.

1. Fasten mounting bracket to wall using appropriate 3/8" fasteners (customer supplied).

2. Screw mounting flange to pum p inlet. The flange with the four holes should be away from the pump. Pipe thread compound is not required. Tighten flange and align parallel with pump.

3. Bolt mounting flange to mounting bracket using the hardware supplied.

4. Remove the 1" plastic plug within the 2" pump bas e inlet and install the 1" inlet NPT inlet line from the tank into the pump. Apply gasoline-resistant pipe compound to male threads. Follow piping instructions shown on previous page for piping to the tank.

See the

Conduit

section for correct installation of electrical conduit.

2-8 9312

Installation

Vacuum Breaker

The vacuum breaker tubing kit can be used with any Series 70 or 1820 pump. The vacuum breaker is used to break a s iphon s hould the nozzle drop below the fluid level in the tank while the pump is stuck in the open position. A threaded vacuum break er, P/N 066570 is shipped installed in the pump. GASBOY recommends that the vacuum breaker be tubed back to the tank.

The illustration below shows two methods for installing tubing for the vacuum breaker. In all instances, the vacuum break er m ust be tubed (us ing 1/4" tubing) to the vapor spac e at the top of the tank; if the tube is installed below the fluid level of the tank, the ability to break vacuum and prevent siphoning will be lost. Using the illustrated m ethods, the tube end m ay terminate into the annular vapor space between the 1" suction pipe and the 2" mounting pipe, or into an opening in the top of the tank. All components shown are provided when you order the kit, P/N 032700.

NOTE: Tubing can be piped to any available opening on top of tank. Use reducer bushings

as required.

The illustration on the next page shows vacuum breaker tubing for inst allations where the pump is installed below the fluid level of the tank. For these inst allations, the tubing must run directly to the tank top. The tubing mus t be horizontal or must slope either toward the pum p or the tank s o there are no traps or low spots. Traps or low spots can severely affect vacuum breaker performance. Tubing length should not exceed eight feet.

9312 2-9

GASBOY Series 70 & 1820

NOTE: Tubing can be piped to any available opening on top of tank. Use reducer bushings

as required.

Testing the Vacuum Breaker

1. Charge tubing completely with fluid.

2. Turn on pump and run for several minutes to purge any air from the system.

3. Turn off pump.

4. With nozzle at ground level and discharging into a container, open nozzle. A small quantity of fluid (several cups) should drain and then stop.

2-10 9312

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