Page 1: ...QGASBOY 9120K and 9820K Series AST Pumps Installation and Operation Manual MDE 4567C...
Page 2: ...wer operatedTransferPump Models 25 9853A 9140 G 70 52 AM Balance Vapor Recovery G 70 150 AE VaporVac MH6418 25C 26 27 28 72 72S 72SP 72X 73 and 4997 9822A 9823A 1820 5046 9100Q 9140Q 9152Q 9153Q MH740...
Page 3: ...Models 9120K and 9820K 13 Conduit Size Charts 14 Terminal Block ID 15 Wiring Diagrams 15 4 Control Lines 23 Purpose 23 Ground 23 Micro Feed 23 Micro Neutral 23 Pump Motor Feed 24 Model 9120K and 9820...
Page 4: ...Power Supply 46 View Reset Totalizer 46 Electronic Totalizer 46 Mechanical Totalizer 47 7 Operating Sequence and Locking the Nozzle 49 Operating Sequence 49 9X20K Nozzle Locking 50 8 9820K Startup an...
Page 5: ...ions ofthe 9120K Series pumps are as follows Discharge elbows A 12 foot length ofhose A working voltage of 115 230 VAC 50 60 Hz Mechanical Volume Totalizer A Switch Detect and optional pulser outputs...
Page 6: ...lizer Discharge elbow Both models use a quiet and efficient pump which features an air eliminator built into the pump casting The pump meter is a three piston positive displacement meter which is test...
Page 7: ...CPR Cardiopulmonary Resuscitation CPU Central Processing Unit DC or dc Direct Current DIP Dual In line Package FPR Fuel Point Reader ICR Island Card Reader J Box Junction Box LCD Liquid Crystal Displ...
Page 8: ...Introduction Abbreviations and Acronyms This page is intentionally left blank Page 4 MDE 4567C 9120K and 9820K Series ASTPumps Installation and Operation Manual September 2008...
Page 9: ...pplied with this equipment Ifyou do not understand a procedure call a Gasboy Authorized Service Contractor or call the Gasboy Service Center at 1 800 444 5529 It is imperative to your safety and the s...
Page 10: ...not place any equipment in the mouth The pump dispenser contains a chemical known to the State of California to cause cancer A WARNING The pump dispenser contains a chemical known to the State of Cali...
Page 11: ...lse in the area Fuel Spill Use station EMERGENCY CUTOFF immediately Turn off all system circuit breakers to the island s Do not use console E STOP ALL STOP and PUMP STOP to shut off power These keys d...
Page 12: ...Important Safety Information This page is intentionally left blank Page 8 MDE 4567C 9120K and 9820K Series ASTPumps Installation and Operation Manual September 2008...
Page 13: ...a separate circuit and installed on a 20 to 30 Amp breaker depending on the motor size andlor the voltage setting and the wiring run Install an emergency power cutoff In addition to circuit breaker re...
Page 14: ...source To do this locate the motor changeover plate typically located on the shaft end ofthe motor and remove the screw which secures it in place Slide the plate so that the desired voltage as marked...
Page 15: ...the distance from the breaker panel The chart below should be used as a guide in selecting the proper wire size according to the specific installation requirements Wire Size Chart Model 9120K Model 9...
Page 16: ...ing Maximum operating voltage of600V Environmental Gas and oil resistant suitable for wet or dry locations Gasboy can supply Belden 1063A PIN C09655 which is a UL listed 4 conductor cable that meets t...
Page 17: ...ribed in Wire Size on page 11 Only AC wires for the system and pumps can be installed in this conduit for this application Wiring between a Fuel Point Reader FPR and its pre amp junction box J Box is...
Page 18: ...2 64 0 009 5 5 14 0 118 2 95 0 011 6 8 12 0 135 3 43 0 014 9 2 10 0 169 4 29 0 022 14 5 8 0 216 5 49 0 037 23 7 6 0 259 6 60 0 053 34 2 4 0 331 8 41 0 086 55 5 3 0 359 9 14 0 102 65 6 2 0 394 10 01 0...
Page 19: ...ALLED ONLYWHEN PULSEROUTPUTOR RS 48S INTERFACE IS SUPPUED Failure to follow the correct wiring diagram and all listed notes and precautions that follow each wiring diagram may result in damage to the...
Page 20: ...IRING 115 230 VAC WIRING 10 1 REED PULSER PHASE 2 rEED 115 230 VAC WIRING 100 I ELECTROkIC PliLSERl PHASE 2 rEED INDICATES FlELO CONNECTION SEE tIITE 3 SEE IflTE 3 Wiring Diagrams t 10 1 Reed Pulser...
Page 21: ...may be wired as 230 VAC to reduce current draw 3 The brown wire AuxAC Control Lead is shipped cappedfrom thefactory When used it connects to a solenoid valve orfuel management system Do not connect th...
Page 22: ...380 VAC 3 PHASE PUMP MOTOR r I I cncn 230 VAC PUMP MOTOR SINGLE PHASE SLOW F LOW 181 1 I RED 3 ____ r r iPRE ru C 2 I MOTOR 1 1_ _ Z Y RED I NEUTRAL 181 3 B I g U1 F AST BlK n FAST FLOW TB1 2 L 230 V...
Page 23: ...is controlled by afuel management system using solid state relays a resistor assembly must be installed between the Pump Motor Feed line and Neutral to preventfalse triggering ofthe authorization inpu...
Page 24: ...0 zw w z PUMPING UNIT I w w l VlVl u u 1 0 ou I u 0 l l a i ao l 230VAC PUMP MOTOR SINGLE PHASE J J 1 0 0 OVl Zo o Z J i I Vlu 0 8 0 BLU a a w VlO a u i PULSER ORA J a BRN 0 r Qre YEl Ie RED PUMP IIF...
Page 25: ...triggering ofthe authorization input The resistor assembly is 30K Ohm 10 Watt PIN C06683 for 230 VAC international wiring 3 Slow Flow and Fast Flow lines are typically used when connecting to an optio...
Page 26: ...Wiring Wiring Diagrams This page is intentionally left blank Page 22 MDE 4567C 9120K and 9820K Series ASTPumps Installation and Operation Manual September 2008...
Page 27: ...solid corrosion resistant conductor and must be installed at the main electrical panel in accordance with the National Electrical Code It should be properly tied into the ground bus strip ofthe panel...
Page 28: ...el management system using solid state relays a resistor assembly must be installed between the Pump Motor Feed line and Neutral Feed to prevent false triggering ofthe authorization input The resistor...
Page 29: ...e CPU Printed Circuit Board PCB will occur The Fast Flow line is a 115 VAC 230 VAC International output which is used to control the Fast Flow valve ofthe optional solenoid valve This line is capable...
Page 30: ...measure The pulser type should be selected according to the monitoring equipment the application and the regulations that must be met Refer to the wiring diagrams in Wiring on page 9 for pulser wiring...
Page 31: ...ormation on page 5 It contains important information regarding the safe use ofyour pumping equipment DO install an emergency power cutoff In addition to circuit breaker requirements of NFPA 70 and NFP...
Page 32: ...wiring diagram or the wire chart provided in Wiring on page 9 DO NOT use a circuit breaker ofimproper size refer to Wiring on page 9 DO NOT use the Gasboy fuel pumping equipment to remove water balla...
Page 33: ...ounted flush with the bottom ofthe tank Note Excessive hose lengths can create trip hazards and reduce unitflow rates Hose Register Minimum Hose Register Minimum Length Radius Fueling Radius Height Le...
Page 34: ...57 em 4 6 137 em 13 6 411 em 12 6 381 em 16 488 em 7 213 em 14 6 442 em 13 6 411 em 17 518 em 9 274 em 15 6 472 em 10 6 320 em 11 6 351 em 12 6 381 em 13 6 411 em 14 6 442 em Height Measurement from t...
Page 35: ...ISTED EMERGENCY SHUT OFF VALVE 1 1 2 SUPPLY PIPE LOCALLY APPROVED ANGLE CHECKVALVE 6000 GAL MAXIMUM o 6000 GAL MAXIMUM Installation LISTED EMERGENCY SHUT OFF VALVE 4 VENT PIPE 1 1 2 SUPPLY PIPE MDE 45...
Page 36: ...N LINE SIDEVIEW DCWIRING CONDUIT FRONTVIEW AC DC CONDUIT BETWEEN PUMP AND REGISTER VAPOR RECOVERY RETURN LINE LISTED EMERGENCY SHUT OFF VALVE 1 1 2 SUPPLY LINE LOCALLY APPROVED ANGLE CHECKVALVE DCWIRI...
Page 37: ...llation Base Layouts Figure 5 3 Model 9120K Specific Only Top View Nozzle Mounting o o Front View BackView Nozzle Guide MDE 4567C 9120K and 9820K Series ASTPumps Installation and Operation Manual Sept...
Page 38: ...nit Assembly Dimensions in inches unless otherwise noted Front 3 4 NPT Vapor Recovery Return Vapor Recovery Units Only Front t 1 0 29 3 1 footprint 1 1 2 NPT Inlet o l25 4 REF 1 1 REF Back View MDE 45...
Page 39: ...19mml OR l 25 mml CONDUIT ARE LOCATED ONTHE BOTIOM OF THE CABINET I 17 1 4 12 1 8 438mmJ 30BmmJ l IlaA II BDy 11 Q I I L GALLONS J ASTRA T MDE 4567C 9120K and 9820K Series ASTPumps Installation and Op...
Page 40: ...A1 ON A 1 25mm JOG IN lHE CONDUIT IS REQUIRED ONCE lHE CONDUIT ENTERS lHE POST BEFORE YOU BEGIN ENSURETHATTHE POST IS SECURELY INSTALLED ON THE ISLAND 1 LOOSELY ASSEMBLE HARDWARE SECURING BRACKETTO PO...
Page 41: ...1 4 235mm BACKVIEW SIDE VIEW LEFT SIDE MOUNT RIGHT SIDE MOUNT OPTIONAL MOUNTING METHOD 1 jl I ul II I I I FOR RIGHTSIDE MOUNTS I I II t BRACKETS ARE OFFSET i I nI 0 i TO ALLOW FOR CLEARANCE 11 I II 0...
Page 42: ...2 I eo _ _p 54mmJ I 51 J I I r B 0 l mm 1 i I I II 5 8 16mmJ BY II AST 1 9 16 40mmJ SLOT REGISTER I III I I I II I I I t E I I L I E J II I I l r i f 1 I N E I I I I J E I I CONDUIT II I I TERMINATIO...
Page 43: ...ng electronic totalizers using the actuator Operating the pump Locking the nozzle Electronic Component Access Before attempting to startup the 9820K it is important to become familiar with the locatio...
Page 44: ...CK DV II l I I Tr 4l0_ u iO T 9o r d I GALLONS I hlFT HE PUSH DOWN TO TURN OFr 0 0 r t JL ASTRA 2 Loosen the two screws located on the left and right door support brackets and pivot the display panel...
Page 45: ...operating conditions using the switches located on the CPU PCB Figure 6 3 on page 42 Check these switches and change their settings if necessary Switch settings shouldbe changed with the power switch...
Page 46: ...e Ifthe 9820K is controlled by a Gasboy CFN or TopKAT electronic fuel management system the switch should be open online mode Ifthe 9820K is controlled by a Gasboy Series 1000 or TopKAT mechanical sys...
Page 47: ...d SW1 5 Not used SW1 6 Authorization This switch allows activation ofthe 9820K from some types offuel management systems When the switch is closed a 115 VAC 230 VAC International signal must be presen...
Page 48: ...losed Closed Closed 3 Closed Open Closed Closed 4 Open Open Closed Closed 5 Closed Closed Open Closed 6 Open Closed Open Closed 7 Closed Open Open Closed 8 Open Open Open Closed 9 Closed Closed Closed...
Page 49: ...dalone mode positions to the right ofthe decimal point are displayed based on the pulse rate selected as shown in the chart below Pulse Rate Display 1 1 XXX 10 1 XXX x 100 1 XXX XX 250 1 XXX XXX 500 1...
Page 50: ...r Electronic Totalizer Page 46 The 9820K stores a running quantity total This electronic totalizer works independent ofthe optional mechanical totalizer that may be installed at the pump module and is...
Page 51: ...ssembly procedure outlined under Electronic Component Access on page 39 earlier in this section 1 Turn off the breaker supplying the 9820K AC power 2 Close SWl 7 on the CPU PCB 3 Hold the actuator aga...
Page 52: ...9820K setup and Special Features View Reset Totalizer This page is intentionally left blank Page 48 MDE 4567C 9120K and 9820K Series ASTPumps Installation and Operation Manual September 2008...
Page 53: ...ed However all pulses will be sent out on the Pulse Output line ifequipped At 0 010 gallons 0 04 liters the Fast Flow valve turns on ifequipped The pump continues to run until one ofthe following cond...
Page 54: ...he nozzle onto the hook assembly with the nozzle tip inside the boot 2 Slide the rear bracket ofthe nozzle hook assembly upward until the holes near the bottom of the nozzle are aligned 3 Slide the op...
Page 55: ...Figure 7 1 Locking Mechanism Model 9820K Lock Lock holes aligned for locking Lock hole in __ normal position Slide outside bracket upward to align holes for lock MDE 4567C 9120K and 9820K Series ASTP...
Page 56: ...Operating Sequence and Locking the Nozzle 9X20K Nozzle Locking This page is intentionally left blank Page 52 MDE 4567C 9120K and 9820K Series ASTPumps Installation and Operation Manual September 2008...
Page 57: ...ems AC and DC wires should not share any conduits J Boxes or troughs All conduit work must be complete All J Box covers must be secured Conduits should not be sealed until the wiring is verified throu...
Page 58: ...izer on page 46 5 Dispense fuel and verify ifthe high flow valve opens ifequipped Check all plumbing for leaks at this time 6 Turn off the pump handle and open the nozzle No fuel should be dispensed a...
Page 59: ...oduct to a reliable accurate 50 or 100 gallon prover can or a smaller can size approved by local Weights and Measures for the flow rate of the unit 2 Remove the seal wire from the seal pin Figure 8 1...
Page 60: ...er to the ON position 3 Turn adjustment screw in until reset motor starts 4 Advance adjustment screw an additional 112 to 3 4 turn Hold the screw in this position and tighten the lock nut 5 Move the r...
Page 61: ...Emergency informing 6 Phase 2 Feed 25 Post Startup Tests 54 Pulse Output 10 Pulser 26 Pump Motor 10 Pump Motor Feed 11 R Reset Complete 25 RS 485 11 26 S Safety Information Alert symbol 5 Barricading...
Page 62: ...fUnderwriters Laboratories Inc QGASBOY 2008 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 456...
