Gasboy 9800Q Series User Manual
Installation/operation manual
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Table of contents
Document Outline
- Table of Contents
- 1 - Introduction
- 2 - Important Safety Information
- 3 - Installation
- Installation Precautions
- 1 DO read the Important Safety Information pages at the front of this manual. It contains important information regarding the safe use of your dispensing equipment.
- 2 DO install an emergency power cutoff. In addition to circuit breaker requirements of NFPA 70 and NFPA 30A, a single control wh...
- 3 In a Fuel Management System application, the EMERGENCY STOP and STOP keys on the console and/or the optional EMERGENCY STOP button on the Island Card Reader do not remove AC power from equipment and under certain conditions, will not stop product flow.
- 4 In order to provide the highest level of safety to you, your employees, and customers, we recommend that all employees be trained as to the location and procedure for turning off power to the entire system.
- 5 DO have the pump/remote dispenser installed by a competent installer/electrician.
- 6 DO install breakaway coupling on discharge hose. If using a high hose retriever, install breakaway approximately 12" downstream of hose clamp on nozzle side of clamp.
- 7 DO NOT attempt to wire a pump/remote dispenser without first reviewing the appropriate wiring diagram and notes. Wiring diagra...
- 8 DO NOT experiment with a pump if you are not sure the installation is correct.
- 9 DO NOT overload sub- or main-breaker panels.
- 10 DO NOT install any underground piping without proper swing joints (Always use shoulder nipples, never close nipples).
- 11 DO NOT cover any lines until they have been both air- and liquid-tested.
- 12 DO NOT back-fill the tank or supply line with cinders or ashes. (Back-fill with clean sand, crushed rock, or pea gravel).
- 13 DO NOT use black iron pipe or fittings for underground installations. (Use only new galvanized or fiberglass* pipe and fittings). *Install all fiberglass pipe and fittings according to manufacturer's specifications and requirements.
- 14 DO NOT use power line wiring of inadequate capacity. (Use gauge specified by the wiring diagram or wire chart provided in “Wiring” on page 5-1).
- 15 DO NOT use a circuit breaker of improper size (See “Wiring” on page 5-1).
- 16 DO NOT install fill pipe to tank where it can be submerged with standing water.
- 17 DO NOT use the Gasboy fuel dispensing equipment to remove water ballast from the storage tank.
- 18 DO NOT use gaskets on covers of explosion-proof type boxes. The sealing compound found around wires at all junction box entra...
- 19 DO NOT use knock-out boxes or flexible conduit for installing this unit. All power and lighting wires should be run in thread...
- Foundation
- Suction Pump
- Remote Dispenser
- Supply Line
- Nozzle, Hose, and Accessories
- Single/Twin Pump/Remote Dispenser Dimensions
- Single/Twin Pump/Remote Dispenser Front Load Nozzle Dimensions
- 012011 Base Layout, Model 9852QTW1
- 012012 Base Layout, Models 9852QTW2, 9853QTW2
- 012013 Base Layout, Model 9853QTW1M
- 012014 Base Layout, Models 9852Q, 9853Q
- 012015 Base Layout, Models 9852QXTW2, 9853QXTW2
- 012016 Base Layout, Model 9840QX
- 012017 Base Layout, Models 9852QX, 9853QX
- 012018 Base Layout, Models 9852QXTW1, 9853QXTW1
- 012019 Base Layout, Model 9840Q
- Installation Precautions
- 4 - Control Lines
- Purpose
- Ground
- Micro Feed
- Micro Neutral
- Control/Pump Motor Feed
- External Valve
- Neutral Feed
- Control/Submersible Feed (Control/SubM Feed)
- Submersible Starter Drive (SubM Starter Drive)
- Submersible Pump Drive (SubM Pump Drive)
- Reset Complete (Switch Detect)/Slow Flow
- Fast Flow
- Phase 2 Feed
- Slow/Fast Satellite Returns
- Light Feed
- Light Neutral
- Pulser
- RS-485
- RS-232 and RS-422
- 5 - Wiring
- Wiring Precautions
- 1 All wiring must be installed to conform with all building/fire codes, all Federal, State, and Local codes, National Electrical...
- 2 Use only threaded, rigid, metal conduit.
- 3 Use only UL-labeled insulated gasoline- and oil-resistant stranded copper wiring of the proper size.
- 4 Wire connections should be tightly spliced and secured with a wire nut; close off the open end of the wire nut with electrical tape.
- 5 The line to the motor should be on a separate circuit and installed on a 20 to 30 AMP breaker depending on the motor size and/or the voltage setting.
- 6 Install an emergency power cutoff. In addition to circuit breaker requirements of NFPA 70 and NFPA 30A, a single control which...
- 7 Have the pump/remote dispenser installed by a competent installer/electrician.
- Ground
- Circuit Breakers
- The Pump Motor
- Motor Amp Ratings
- Wire Size
- Conduit
- Pulse Output or RS-485 Wiring
- Wiring Diagrams
- 024251 Wiring Diagram Models 9852QTW1
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 Pump motor can be wired as 230 VAC to reduce current draw. See breakaway view of 230 VAC WIRING. All other wiring should remai...
- 3 To avoid damage to the CPU PC board, all unused wires must be individually capped, and before applying power, you must verify that the RESET COMPLETE and FAST FLOW wires are not shorted to conduit or chassis.
- 4 COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 5 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 6 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 7 When used with an aboveground tank, the anti-siphon valve mounted on the tank must be driven from the EXTERNAL VALVE line, hav...
- 8 Use the wire size chart listed on page 5-4 when determining the wire size for the control wiring.
- 9 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram.
- 10 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 024252 Wiring Diagram Models 9852Q, 9853Q
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 Pump motor can be wired as 230 VAC to reduce current draw. See breakaway view of 230 VAC WIRING. All other wiring should remai...
- 3 To avoid damage to the CPU PC board, all unused wires must be individually capped, and before applying power, you must verify that the RESET COMPLETE and FAST FLOW wires are not shorted to conduit or chassis.
- 4 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 5 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 6 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 7 When used with an aboveground tank, the anti-siphon valve mounted on the tank must be driven from the EXTERNAL VALVE line, hav...
- 8 Use the wire size chart listed on page 5-4 when determining the wire size for the control wiring.
- 9 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram.
- 10 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 024253 Wiring Diagram Model 9840Q
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 Pump motors must be wired as 230 VAC to reduce current draw (requires 230 VAC breaker for control). If connected to equipment ...
- 3 To avoid damage to the CPU PC board, all unused wires must be individually capped, and before applying power, you must verify that the RESET COMPLETE and FAST FLOW wires are not shorted to conduit or chassis.
- 4 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 5 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 6 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 7 If this unit is equipped for 230 VAC operation (international) wire as shown in the standard 115 VAC wiring diagram. In this c...
- 8 Use the wire size chart listed on page 5-4 when determining the wire size for the control wiring.
- 9 Model 9840Q should not be used with aboveground tanks.
- 10 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 024254 Wiring Diagram Models 9852QX, 9853QX, 9840QX
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 The input line CONTROL/SUBM FEED is comprised of two wires which are tied together at the factory.
- 3 To avoid damage to the CPU PC board, all unused wires must be individually capped, and before applying power, you must verify ...
- 4 SUBM. STARTER DRIVE line can supply 300 mA AC maximum to control submersible starter relays. This line must not be directly connected to a submersible pump!
- 5 External submersible relays are required unless the remote dispenser is equipped with the submersible drive relay option. The ...
- 6 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry and in applications where control of a remote slow flow valve (satellite) is required.
- 7 FAST FLOW line can supply 170 mA AC maximum and is provided to allow for control of a satellite along with remote control or monitoring of the fast flow valve found in the pump.
- 8 FAST SAT. RETURN and SLOW SAT. RETURN lines are used when the remote dispenser is supplied with satellite piping and connected...
- 9 If the CONTROL/SUBM FEED line is controlled by a fuel management system using solid state relays, a resistor assembly must be ...
- 10 When used with an aboveground tank, the valve mounted at the tank MUST NOT be connected to the RESET COMPLETE or SUBM STARTER...
- 11 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram.
- 12 Second meter and pulser available only on 9840Q models.
- 13 Use the wire size chart listed on page 5-4 when determining the wire size for the control wiring.
- 14 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 15 When multiple dispensers are used to control a common submersible starter relay or pump, and the 9800 is controlled (authoriz...
- 024255 Wiring Diagram Models 9852QXTW1, 9852QXTW2, 9853QXTW1, 9853QXTW2
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 The input line CONTROL/SUBM FEED is comprised of two wires which are tied together at the factory.
- 3 SUBM. STARTER DRIVE line can supply 300 mA AC maximum to control submersible starter relays.
- 4 External submersible relays are required unless the remote dispenser is equipped with the submersible drive relay option. The ...
- 5 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry and in applications where control of a remote slow flow valve (satellite) is required.
- 6 FAST FLOW line can supply 170 mA AC maximum is provided to allow for control of a satellite along with remote control or monitoring of the fast flow valve found in the pump.
- 7 FAST SAT. RETURN and SLOW SAT. RETURN lines are used when the remote dispenser is supplied with satellite piping and connected...
- 8 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 9 Use the wire size chart listed on page 5-4 when determining the wire size for the control wiring.
- 10 When used with an aboveground tank, the valve mounted at the tank MUST NOT be connected to the RESET COMPLETE or SUBM STARTER...
- 11 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram.
- 12 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 13 When multiple dispensers are used to control a common submersible starter relay or pump, and the 9800 is controlled (authoriz...
- 024256 Wiring Diagram Models 9852QTW2, 9853QTW2, 9853QTW1M
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 Pump motor can be wired as 230 VAC to reduce current draw. See breakaway view of 230 VAC WIRING. All other wiring should remai...
- 3 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 4 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 5 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 6 When used with an aboveground tank, the anti-siphon valve mounted on the tank must be driven from the EXTERNAL VALVE line, hav...
- 7 Use the wire size chart listed on page 5-4 when determining the wire size for the control wiring.
- 8 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram. I...
- 9 Model 9853QTW1M should not be used with aboveground tanks.
- 024257 Wiring Diagram Models Satellite 215Q/ Satellite 216Q
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 See Weights and Measures Handbook 44 to determine which mode of satellite operation is relevant for your application. In many ...
- 3 The input line CONTROL/SUBM FEED is comprised of two wires which are tied together at the factory.
- 4 SUBM. STARTER DRIVE line can supply 300 mA AC maximum to control submersible starter relays.
- 5 External submersible relays are required unless the remote dispenser is equipped with the submersible drive relay option. The ...
- 6 If the CONTROL/SUBM FEED line is controlled by a fuel management system using solid state relays, a resistor assembly must be ...
- 7 The FAST FLOW line (pink wire) is supplied from the factory disconnected. It must be connected, in the upper junction box, to the pink wire (fast flow control) coming from the electronic platform assembly.
- 8 If using a 9800Q and satellite in an application where both master and satellite cannot dispense product at the same time, a m...
- 9 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram.
- 10 These wiring diagrams are intended only to show the connections between the satellite and the dispenser. See wiring diagram for master dispenser (according to model number) for applicable warnings and proper connection of all wires.
- 024294 Wiring Diagram Models 9853Q 380VAC
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 3 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 4 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 5 Use the wire size chart (230VAC section) on page 5-4 when determining the wire size for the control wiring.
- 6 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See the TopKAT Installation Manual for wiring requirements and information.
- 7 When used with an aboveground tank, the anti-siphon valve mounted on the tank must be driven from the EXTERNAL VALVE line, hav...
- 024295 Wiring Diagram Model 9840Q 380 VAC
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 3 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 4 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 5 Second meter and pulser available only on 9840Q models.
- 6 Use the wire size chart (230VAC section) on page 5-4 when determining the wire size for the control wiring.
- 7 Model 9840Q should not be used with aboveground tanks.
- 8 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 024297 Wiring Diagram Models 9853QTW2 380 VAC and 9853QTW1M 380 VAC
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 RESET COMPLETE (switch detect) line can supply 170 mA AC maximum for connecting to fuel management system circuitry.
- 3 FAST FLOW line can supply 170 mA AC maximum for remote control or monitoring of the fast flow valve found in the pump.
- 4 If the CONTROL/PUMP MOTOR FEED line is controlled by a fuel management system using solid state relays, a resistor assembly mu...
- 5 Use the wire size chart (230VAC section) on page 5-4 when determining the wire size for the control wiring.
- 6 If this unit is equipped with a TopKAT option, there will be 10 wires in the junction box. See The TopKAT Installation Manual for wiring requirements and information.
- 7 Model 9853QTW1M should not be used with aboveground tanks.
- 024319 Wiring Diagram Models Satellite 215Q Front Load Satellite 216Q Front Load
- 1 All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrica...
- 2 See Weights and Measures Handbook 44 to determine which mode of satellite operation is relevant for your application. In many ...
- 3 The input line CONTROL/SUBM FEED is comprised of two wires which are tied together at the factory.
- 4 SUBM. STARTER DRIVE line can supply 300 mA AC maximum to control submersible starter relays.
- 5 External submersible relays are required unless the remote dispenser is equipped with the submersible drive relay option. The ...
- 6 If the CONTROL/SUBM FEED line is controlled by a fuel management system using solid state relays, a resistor assembly must be ...
- 7 The FAST FLOW line (pink wire) is supplied from the factory disconnected. It must be connected, in the upper junction box, to the pink wire (fast flow control) coming from the electronic platform assembly.
- 8 If using a GASBOY 9800Q and satellite in an application where both master and satellite cannot dispense product at the same ti...
- 9 If this unit is equipped for 230 VAC operation (international), wire as shown in the standard 115 VAC wiring layout diagram.
- 10 These wiring diagrams are intended only to show the connections between the satellite and the dispenser. See wiring diagram for master dispenser (according to model number) for applicable warnings and proper connection of all wires.
- 024251 Wiring Diagram Models 9852QTW1
- Wiring Precautions
- 6 - Pump/Remote Dispenser Operation
- Overview
- Electronic Component Access
- CPU Switch Settings
- SW1
- SW2
- Pulser Output Rate Switches
- Timeout Switch
- ATC Information Sheet
- Battery Back-Up Power Supply
- View/Reset Totalizers
- Operating Sequence
- Pump
- 1 Turn on the pump handle. If AC is present on the Control Feed line, the reset cycle begins. The display:
- 2 The user begins to dispense fuel. Quantity is not be recorded on the display until 0.010 gallons (0.04 liters) are reached, ho...
- 3 The pump continues to run until one of the following conditions occurs. These conditions turn off all relays.
- 4 The 9800Q continues to monitor for pulses until a 2-second period with no pulses occurs. At this time, the transaction is considered completed.
- Remote Dispenser
- 1 Turn on the pump handle. If AC is present on the Control Feed line, the reset cycle begins and the submersible pump turns on. The display:
- 2 The user begins to dispense fuel. Quantity is not be recorded on the display until 0.010 gallons (0.04 liters) are reached, ho...
- 3 The remote dispenser continues to run until one of the following conditions occurs. These conditions turn off all relays.
- 4 The 9800Q continues to monitor for pulses until a 2-second period with no pulses occurs. At this time the transaction is considered completed.
- Pump
- Standalone Mode Error Handling
- 7 - Start-Up and Test
- Installation Completion Checklist
- 1 The unit must be properly secured to the island.
- 2 All plumbing must be complete and tight. All liquid-carrying lines must be checked for leaks.
- 3 When DC pulser or RS-485 lines are used in the pump for connecting to Gasboy Fuel Management Systems, the AC and DC wires must...
- 4 All conduit work must be complete. All junction box covers must be secured. Conduits should not be sealed until the wiring is verified through proper operation.
- 5 The unit must be properly grounded.
- 6 A sufficient volume of fuel must be put in the tank to ensure that the liquid level is above the bottom of the suction pipe (suction pumps) or is high enough to allow the submersible pump to operate efficiently (remote dispensers).
- Start-Up
- 1 Verify if all switches on the CPU PCB are set properly for the various operating conditions as explained in “Pump/Remote Dispenser Operation” on page 6-1.
- 2 Turn on the circuit breakers for the microprocessor and fluorescent lights. Ensure that both lights are lit.
- 3 Turn on the power to the 9800Q.
- 4 Authorize the hose for side 1 through the Fuel Management System, if available.
- 5 Remove the nozzle for side 1 from its holder and turn on the pump handle. Verify if the display goes through the proper reset sequence as explained in “Pump/Remote Dispenser Operation” on page 6-1, 3Operating Sequence.
- 6 Dispense fuel. Verify if the high flow valve opens, if equipped. Check all plumbing for leaks at this time.
- 7 Turn the pump handle off. Open the nozzle. No fuel should be dispensed at this time.
- 8 Verify if the correct quantity was recorded by the Fuel Management System, if available.
- 9 If applicable, repeat steps 4 through 8 for side 2.
- 10 Run the unit through all standard calibration procedures.
- 11 Reset the electronic totalizers as described in View/Reset Totalizers in “Pump/Remote Dispenser Operation” on page 6-1.
- Post Start-Up Tests
- Voltage
- Tightness
- Belts (Suction Pumps Only)
- Calibration
- 1 Check meter registration by delivering product to a reliable, accurate, 50 or 100 gallon prover.
- 2 Remove the seal wire from the locking pin.
- 3 Remove locking pin and turn wheel to adjust measurement. Turn clockwise to decrease the amount in the prover to match the disp...
- 4 Repeat the process until volume in prover and amount recorded are within tolerance.
- 5 After calibration is complete, reinstall locking pin and secure in place using a seal wire.
- 9850Q and 9850QE Models
- 1 Check meter registration by delivering product to a reliable, accurate, 50 or 100 gallon prover.
- 2 Convert the amount of the error to gallons per 100 (which gives a percent figure) or gallons per thousand (which gives tenths of a percent figure).
- 3 Read the setting indicated on the adjuster. The amount of the error is added to or subtracted from this setting. The adjuster is shown in graduated divisions of 1%, 0.1%, 0.02%.
- 4 Reset the adjuster by loosening the clamp.
- Installation Completion Checklist
- 8 - Preventive Maintenance