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MDE-4863 Gasboy 9800A or 2600A Pump Interface Kits Installation Instructions October 2009 Page 1

Introduction

PurposeThis document provides installation instructions for Gasboy 9800A/2600A Pump InterfaceKits.

Table of ContentsTopic Page

Introduction 1

Important Safety Information 3

Installation of the 9800A/2600A Pump Interface Kit 5

Pulse-out I/F Board (M06587A001) Jumper Settings 9

Required ToolsThe following tools are required for the installation of the kits:

Phillips Screwdriver Wrench

Parts ListThe following table lists the parts included in the Pump Interface Kits, C06482 and C07357.

Quantity

Item Description Part Number C06482 C07357

1 Pump I/F PCB M06587A001 1 1

2 Standoff, M/F 6-32 3/4 C08381 2 2

3 Washer, #6 External Tooth 068843 2 2

4 Screw, 6-32 x 3/8 C08759 2 2

Note: The C07357 kit is for use on single-sided dispensers only.

MDE-4863Gasboy 9800A or 2600A Pump Interface Kits

Installation InstructionsOctober 2009

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Introduction

Page 2 MDE-4863 Gasboy 9800A or 2600A Pump Interface Kits Installation Instructions October 2009

Related DocumentsDocumentNumber Title GOLD Library

MDE-4331 Atlas Fuel Systems Installation Manual Gasboy Atlas Pumps/Dispensers

MDE-4334 Atlas Start-up/Service Manual Gasboy Atlas Pumps/Dispensers

MDE-4341 Series 9800A/9800Q Pump and DispenserInstallation/Operation Manual

Gasboy Atlas Pumps/Dispensers

Abbreviations and AcronymsTerm Description

CPU Central Processing Unit

PCB Printer Circuit Board

WarrantyFor information on warranty, refer to MDE-4255 Gasboys Warranty Policy Statement. If youhave any warranty-related questions, contact Gasboys Warranty Department at its Greensborolocation.

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Important Safety Information

Important Safety InformationThis section introduces the hazards and safety precautionsassociated with installing, inspecting, maintaining or servicingthis product. Before performing any task on this product, readthis safety information and the applicable sections in thismanual, where additional hazards and safety precautions foryour task will be found. Fire, explosion, electrical shock or

pressure release could occur and cause death or seriousinjury, if these safe service procedures are not followed.

Preliminary PrecautionsYou are working in a potentially dangerous environment offlammable fuels, vapors, and high voltage or pressures. Onlytrained or authorized individuals knowledgeable in the relatedprocedures should install, inspect, maintain or service thisequipment .

Emergency Total Electri cal Shut-Off The first and most important information you must know ishow to stop all fuel flow to the pump/dispenser and island.Locate the switch or circuit breakers that shut off all power to

all fueling equipment, dispensing devices, and SubmergedTurbine Pumps (STPs).

Total Electrical Shut-Off Befo re Access Any procedure that requires access to electrical componentsor the electronics of the dispenser requires total electricalshut off of that unit. Understand the function and location ofthis 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 vehiclesfrom the work area

Use of safety tape, cones or barricades at the affectedunit(s)

A total electrical shut-off of the affected unit(s)

Read the ManualRead, understand and follow this manual and any otherlabels or related materials supplied with this equipment. If youdo not understand a procedure, call a Gasboy AuthorizedService 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 work.

Follow the Regulations Applicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Fuel DispensingFacilities and Repair Garages , NFPA 70; National ElectricalCode (NEC) , Occupational Safety and Hazard Association(OSHA) regulations and federal, state, and local codes. Allthese regulations must be followed. Failure to install, inspect,maintain or service this equipment in accordance with thesecodes, regulations and standards may lead to legal citationswith penalties or affect the safe use and operation of theequipment.

Replacement PartsUse only genuine Gasboy replacement parts and retrofit kitson your pump/dispenser. Using parts other than genuineGasboy replacement parts could create a safety hazard andviolate local regulations.

Safety Symbols and Warning WordsThis section provides important information about warningsymbols and boxes.

Alert Symb ol

This safety alert symbol is used in this manual andon warning labels to alert you to a precaution which must befollowed to prevent potential personal safety hazards. Obeysafety directives that follow this symbol to avoid possibleinjury or death.Signal WordsThese signal words used in this manual and on warninglabels 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 practicewhich will result in death or serious injury.WARNING : Alerts you to a hazard or unsafe practicethat could result in death or serious injury.CAUTION with Alert symbol: Designates a hazard orunsafe practice which may result in minor injury.CAUTION without Alert symbol: Designates a hazardor unsafe practice which may result in property orequipment damage.

Working With Fuels and Electrical Energy

Prevent Explosions and FiresFuels and their vapors will explode or burn, if ignited. Spilledor leaking fuels cause vapors. Even filling customer tanks willcause potentially dangerous vapors in the vicinity of thedispenser or island.

The EMERGENCY STOP, ALL STOP, andPUMP STOP buttons at the cashier s stationWILL NOT shut off electrical power to the pump/dispenser. This means that even if you activatethese stops, fuel may continue to flowuncontrolled.

You must use the TOTAL ELECTRICAL SHUT-OFF in the case of an emergency and not theconsole s ALL STOP and PUMP STOP orsimilar keys.

! WARNING!

!

!

!

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Important Safety Information


No Open Fire

Open flames from matches, lighters, weldingtorches or other sources can ignite fuels and their vapors.

No Sparks - No Smok ing Sparks from starting vehicles, starting or using power tools,burning cigarettes, cigars or pipes can also ignite fuels andtheir vapors. Static electricity, including an electrostaticcharge on your body, can cause a spark sufficient to ignitefuel vapors. Every time you get out of a vehicle, touch themetal of your vehicle, to discharge any electrostatic chargebefore you approach the dispenser island.

Working AloneIt is highly recommended that someone who is capable ofrendering first aid be present during servicing. Familiarizeyourself with Cardiopulmonary Resuscitation (CPR) methods,if you work with or around high voltages. This information is

available from the American Red Cross. Always advise thestation personnel about where you will be working, andcaution them not to activate power while you are working onthe equipment. Use the OSHA Lockout/ Tagout procedures. Ifyou are not familiar with this requirement, refer to thisinformation in the service manual and OSHA documentation.

Working With Electricity SafelyEnsure that you use safe and established practices inworking with electrical devices. Poorly wired devices maycause a fire, explosion or electrical shock. Ensure thatgrounding connections are properly made. Take care thatsealing devices and compounds are in place. Ensure that youdo not pinch wires when replacing covers. Follow OSHA

Lockout/Tagout requirements. Station employees and servicecontractors need to understand and comply with this programcompletely to ensure safety while the equipment is down.

Hazardous MaterialsSome materials present inside electronic enclosures maypresent a health hazard if not handled correctly. Ensure thatyou clean hands after handling equipment. Do not place anyequipment in the mouth.

In an Emergency

Inform Emergency PersonnelCompile the following information and inform emergencypersonnel:

Location of accident (for example, address, front/back ofbuilding, and so on)

Nature of accident (for example, possible heart attack, runover 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)

IMPORTANT : Oxygen may be needed at scene if gasolinehas been ingested or inhaled. Seek medical adviceimmediately.

Lockout/TagoutLockout/Tagout covers servicing and maintenance ofmachines and equipment in which the unexpectedenergization or start-up of the machine(s) or equipment orrelease of stored energy could cause injury to employees orpersonnel. Lockout/Tagout applies to all mechanical,hydraulic, chemical or other energy, but does not coverelectrical hazards. Subpart S of 29 CFR Part 1910 - ElectricalHazards, 29 CFR Part 1910.333 contains specific Lockout/Tagout provision for electrical hazards.

The pump/dispenser contains a chemical known to theState of California to cause cancer.

WARNING!

The pump/dispenser contains a chemical known to theState of California to cause birth defects or otherreproductive harm.

WARNING!

Gasoline ingested may cause unconsciousnessand 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 unconsciousnessand burns to lips, mouth and lungs.Keep airway open.Seek medical advice immediately.

WARNING!

Gasoline spilled in eyes may cause burns to eyetissue.Irrigate eyes with water for approximately 15minutes.Seek medical advice immediately.

WARNING!

Gasoline spilled on skin may cause burns.Wash area thoroughly with clear water.Seek medical advice immediately.

WARNING!

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Installation of th e 9800A/2600A Pump Interface Kit

Installation of the 9800A/2600A Pump Interface Kit

Installing these kits involves DC wiring to the Fuel Management System. Read the MDE-4341Series 9800A/9800Q Pump and Dispenser Installation/Operation Manual and your FuelManagement System Installation Manual before you proceed. Also refer to Figure 7 on

page 10 and Figure 8 on page 11 .

To install the Pump Interface Kits, proceed as follows:

1 Turn off the Circuit Breakers that supply power to the MICRO, LIGHTS, and FEED.

2 Unlock and remove the front panel.

Figure 1: Unlocking the Front Panel

Unlock

3 Remove the two bolts located over the tabs of the Bezel Assembly. Lift the Bezel Assemblyupwards and out to remove.

Figure 2: Removin g the Bolts o n the Front Panel

Bolts

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Installation of t he 9800A/2600A Pump Interface Kit


4 Loosen and remove (if necessary) the two screws located on the left and right door support brackets and pivot the Display Panel down.

Figure 3: Removing th e Screws on the Front Panel

Screws

5 Pull the connector off P1on the Power Supply. After a few seconds, reconnect P1 (see

Figure 4 ).

Figure 4: Power Supply

P1

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Installation of th e 9800A/2600A Pump Interface Kit

6 Slip the washers onto the threaded end of the standoffs. Screw the standoffs on the platform base (see Figure 5 ). Note: Newer platforms will have two pre-fixed standoffs, in which case, the loose washers and

standoffs will not be used.

Figure 5: Side View

Washer

Standoff 6-32 Screw

CPU PCB

7 Connect the Pump I/F PCB to P8 of the CPU PCB.

8 Secure the PCB using two 6-32 screws.

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Installation of t he 9800A/2600A Pump Interface Kit


9 Feed the DC Cable up through the platform bushing. The DC Cable is a 4-conductor GrayCable with red, green, white, and black wires terminated to a 5-position connector; it is part ofthe DC Conduit Assembly. Attach the DC Cable to P1 of the Pump I/F PCB (P1 is a 4-pinconnector). Ensure that you align Pin 1 of the Cable Connector with Pin 1 of the P1 Connector.If present, Pin 5 of the Cable Connector is not used and will hang off to the end of the P1Connector.

Figure 6: Platform Ass embly

PlatformBushing

P1

10 Connect the wiring between the Card System and DC Junction Box as shown in MDE-4341Series 9800A/9800Q Pump and Dispenser Installation/Operation Manual.

11 Secure the Display Panel in the upright position.

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Pulse-out I/F Board (M06587A001) Jumper Settings

12 Attach the Bezel. Ensure that the Bezel is seated properly to ensure a watertight seal.

13 Attach and lock the front panel.

14 Turn on the Circuit Breakers.


Jumpers JP1, JP2, and JP3This Board Assembly can be configured for use in one of the following pump/dispenserconfigurations:

Single-channel, Dual/Single-hose Pulse-out I/F (see Figure 7 on page 10 ) Dual-channel, Single-hose Pulse-out I/F (see Figure 8 on page 11 )

The chart below shows the jumper settings and wires to connect to in the Junction Box, basedon the configuration.

Check JP1 - JP3 jumpers and change them, if necessary. The jumper settings must be changedonly when the power to the pump/dispenser is removed, to protect the circuit that they areconnected to.

For models 9800A, 2600A, or 9800Q, the P3 connector is not connected.

Jumper Settings

Single-channel,Dual/Single-hose Pulse-out I/F (Default Setting)

Dual-channel,

Single-hose Pulse-out I/F(C07357 kits )

Wire Color JP1 Position 1JP2 Positio n 1JP3 Open

JP1 Positio n 2JP2 Positio n 2JP3 Open

Red Pulse-out Side 1 Pulse-out Side1A

Green Pulse-out Side 2 Pulse-out Side1B

White Common Return Side 1A Return

Black No Connection Side 1B Return

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Jumpers JP4 and JP5When this board is used in a model A or Q pump/dispenser or 9850K, jumpers JP4 and JP5 areset to the Q/A position.

Figure 7 illustrates the proper output for using a Pump I/F Board (M06587A001) jumpered to provide two pulse outputs, one from each Pulser (C06482 kits).

Figure 7: Single-channel, Dual/Single-hose Pulse-out I/F

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Figure 8 illustrates the proper output for using a Pump I/F Board (M06587A001), jumpered to provide two isolated pulse outputs from a single Pulser (C07357 kits). This option is availableonly for 9800A or 9800Q single pumps/dispensers.

Figure 8: Dual-channel, Single-hose Pulse-out I/F

Note: 1) All wiring and conduit runs must conform with all building/fire codes, all Federal,State, and Local codes, National Electrical Code, (NFPA 70), NFPA 30, and

Automotive and Marine Service Station Code (NFPA 30A) and regulations. Canadianusers must also comply with the Canadian Electrical Code.

2) Refer to MDE-4341 Series 9800A/9800Q Pump and Dispenser Installation/Operation Manual for complete installation instructions.

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Atlas is a trademark of Gasboy Inc. Gasboy is a registered trademark of Gasboy Inc. Phillips is a registered trademark of The PhillipsScrew Co.

2009 GASBOY 7300 West Friendly Avenue Post Office Box 22087 Greensboro, North Carolina 27420Phone 1-800-444-5529 http://www.gasboy.com Printed in the U.S.A.

MDE 4863 G b 9800A 2600A P I f Ki I ll i I i O b 2009
http://www.gasboy.com/http://www.gasboy.com/