Gasboy 9820K Series User Manual Download

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9820K Series AST Pumps

Installation and Operation



Manual

MDE-4567D

Summary of Contents for 9820K Series

Page 1: ...9820K Series AST Pumps Installation and Operation Manual MDE 4567D ...

Page 2: ...approved by the manufacturer could void the user s authority to operate this equipment 5 257 720 D335 673 Gasboy Greensboro is an ISO 9001 2000 registered facility Underwriters Laboratories UL UL File Products listed with UL MH4314 All dispensers and self contained pumping units MH6418 Power operated Transfer Pump Models 25 25C 26 27 28 72 72S 72SP 72X 73 and 1820 MH7404 Hand operated Transfer Pum...

Page 3: ...5 9 Wire Size 9 Wire Size Chart 9 Model 9820K 10 Conduit 11 Model 9820K 11 Conduit Size Charts 12 Terminal Block ID 13 Wiring Diagrams 13 4 Control Lines 19 Purpose 19 Ground 19 Micro Feed 19 Micro Neutral 19 Pump Motor Feed 20 Model 9820K 20 Neutral Feed 20 Slow Flow Reset Complete Switch Detect 21 Fast Flow 21 Phase 2 Feed 21 Pulse Output 22 RS 485 22 5 Installation 23 Installation Precautions 2...

Page 4: ...itch SW2 38 Pulser Output Rate Switches 39 Timeout Switch if JP2 is Installed 39 Battery Backup Power Supply 41 View Reset Totalizer 41 Electronic Totalizer 41 Mechanical Totalizer 42 7 Operating Sequence and Locking the Nozzle 45 Operating Sequence 45 9820K Nozzle Locking 46 8 9820K Startup and Test 49 Installation Completion Checklist 49 Startup 49 Preliminary Steps 49 Startup Model 9820K 50 Pos...

Page 5: ...embly The second assembly is mounted at a height to permit easy access by a user It contains the electronic register controls display and nozzle boot The standard features and specifications of the 9820K Series pumps are as follows One inch high 6 digit backlighted Liquid Crystal Display LCD 1000 1 dual phase error checking pulser gallons 250 1 dual phase error checking pulser liters AC authorizat...

Page 6: ...e Listed automatic nozzles special lengths of Listed hose assembly Listed dual swivels UL recognized filters Vapor Recovery and Vapor Recovery Ready Abbreviations and Acronyms Term Description AC or ac Alternating Current ASC Authorized Service Contractor AST Aboveground Storage Tank ASTRA Aboveground Storage Tank Remote Access CFR Code of Federal Regulations CPR Cardiopulmonary Resuscitation CPU ...

Page 7: ...ns Applicable information is available in National Fire Protection Association NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 70 National Electrical Code NEC Occupational Safety and Hazard Association OSHA regulations and federal state and local codes All these regulations must be followed Failure to install inspect maintain or service this equipment in accordance with ...

Page 8: ... Emergency Inform Emergency Personnel Compile the following information and inform emergency personnel Location of accident for example address front back of building and so on Nature of accident for example possible heart attack run over 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 pr...

Page 9: ...t off power These keys do not remove AC power and do not always stop product flow Take precautions to avoid igniting fuel Do not allow starting of vehicles in the area Do not allow open flames smoking or power tools in the area Do not expose yourself to hazardous conditions such as fire spilled fuel or exposed wiring Call emergency numbers WARNING Spilled fuels accidents involving pumps dispensers...

Page 10: ...Important Safety Information Page 6 MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 This page is intentionally left blank ...

Page 11: ...lose off the open end of the wire nut with electrical tape 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 and the wiring run Install an emergency power cutoff In addition to circuit breaker requirements of NFPA 70 and NFPA 30A a single control which simultaneously removes Alternating Current AC po...

Page 12: ...re shipped from the factory with motors wired according to the specifications given on the order regarding current frequency and voltage Very often on installation it becomes necessary to change the original setting to suit the AC power source To do this locate the motor changeover plate typically located on the shaft end of the motor and remove the screw which secures it in place Slide the plate ...

Page 13: ...o unit for driving motor Pump Motor power from unit to motor Neutral Feed Neutral supplied to unit for driving motor and Neutral power from unit to the motor is dependent upon the HP rating of the Pump Motor the voltage at which the pump will be operated 115 VAC or 230 VAC International and the distance from the circuit breaker panel to the pump In cases where multiple units are powered from the s...

Page 14: ...olt maximum operating voltage Aluminum Mylar shielded with drain wire Twisted pair shielded cable is highly recommended for the Pulse Output or RS 485 field wiring when they are used This type of cable provides superior noise immunity and must be used for distances over 100 feet or any time pulse output or RS 485 wiring is included in the same conduit as the AC wires This cable must meet the follo...

Page 15: ...necessary to increase the size of conduit because of a long run or large amount of bends The installer should determine the orientation of the wire runs according to the layout of the components at the site and the applicable Gasboy wiring diagrams Model 9820K It is recommended that high voltage AC power wires to the register assembly not between the register and pumping unit be installed in a sep...

Page 16: ...ea square units Inches Millimeters Inches Millimeters 18 0 090 2 29 0 007 4 1 16 0 104 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 0 122 78 7 1063A 0 417 10 59 0 137 88 4 Areas of Trade Size Conduit Trade Size Internal Diameter Area square units ...

Page 17: ...THIS CONNECTOR IS INSTALLED ONLY WHEN PULSER OUTPUT OR RS 485 INTERFACE IS SUPPLIED Wiring Diagrams Failure to follow the correct wiring diagram and all listed notes and precautions that follow each wiring diagram may result in damage to the Central Processing Unit CPU Printed Circuit Board PCB CAUTION The wiring diagrams provided are as follows Figure 3 3 Model 9820K Wiring Diagram Domestic on pa...

Page 18: ...ation and Operation Manual January 2020 Figure 3 3 Model 9820K Wiring Diagram Domestic 380 4 5 6 L1 L2 L3 3 2 1 380 VAC BREAKER REMOTE REGISTER PUMPING UNIT 115 VAC PUMP MOTOR SINGLE PHASE PUMPING UNIT 230 VAC PUMP MOTOR SINGLE PHASE PUMPING UNIT 380 VAC 3 PHASE PUMP MOTOR ...

Page 19: ...parate relay to prevent false triggering of the authorization signal 3 If the Pump Motor line is controlled by a fuel management system using solid state relays a resistor assembly must be installed between the Pump Motor Feed line and Neutral to prevent false triggering of the authorization input The resistor assembly is 8 2K Ohm 10 Watt P N C05818 for 115 230 VAC domestic and 30K Ohm 10 Watt P N...

Page 20: ...ing Wiring Diagrams Page 16 MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 Figure 3 4 Model 9820K Wiring Diagram International PUMPING UNIT 230 VAC PUMP MOTOR SINGLE PHASE ...

Page 21: ...bly must be installed between the Pump Motor Feed line and Neutral to prevent false triggering of the authorization input The resistor assembly is 30K Ohm 10 Watt P N C06683 for 230 VAC international wiring 3 Slow Flow and Fast Flow lines are typically used when connecting to an optional valve Each of these lines is capable of supplying 300 mA AC maximum 170 mA AC maximum if already connected to t...

Page 22: ... a 9820K This option is available on all 9800K Series pumps dispensers Use this wiring diagram instead of the pulser wiring diagram shown in Figure 3 3 on page 14 Figure 3 5 Dual Pulse Output Note All wiring and conduit runs must conform with all building fire codes all Federal State and Local codes NEC NFPA 70 NFPA 30 and Automotive and Marine Service Station Code NFPA 30A codes and regulations C...

Page 23: ...ice panel One 1 earth ground connection is required per unit The ground rod should be a 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 of the panel We recommend the neutral and ground bus strips be bonded together unless prohibited by local codes Note Do not ...

Page 24: ...from the breaker panel to the pump It however does not supply power to the motor for 3 Phase motors Separate wiring is required for 3 Phase motors Pump Motor Feed wires must not be used to supply the Micro Neutral Feed If the line to the Model 9820K is controlled by a fuel management system using solid state relays a resistor assembly must be installed between the Pump Motor Feed line and Neutral ...

Page 25: ... requiring more than stated maximum allowable current If these restrictions are not followed damage to the CPU PCB will occur CAUTION Fast Flow The Fast Flow line is a 115 VAC 230 VAC International output which is used to control the Fast Flow stage of the solenoid valve This line is capable of supplying 300 mAAC maximum 170 mA maximum if already connected to the valve This line must not be shorte...

Page 26: ...ages up to 24 VDC The pulse rate can be configured by a sealable DIP switch for rates of 1 10 100 250 and 500 pulses per gallon PPG or 1 10 and 100 pulses per liter PPL This output should only be used when monitoring of the unit s operation is desired RS 485 When the pumping unit includes the optional RS 485 interface RS 485 lines are provided This interface allows the user to connect a Gasboy Fue...

Page 27: ...nstallation DOs and DO NOTs to avoid potential problems Installation DOs DO read the Important Safety Information on page 3 It contains important information regarding the safe use of your pumping equipment DO install an emergency power cutoff In addition to circuit breaker requirements of NFPA 70 and NFPA 30A a single control which simultaneously removes AC power from all site pumping equipment i...

Page 28: ...main breaker panels DO NOT use power line wiring of inadequate capacity use gauge specified by the wiring diagram or the wire chart provided in Wiring on page 7 DO NOT use a circuit breaker of improper size refer to Wiring on page 7 DO NOT use the Gasboy fuel pumping equipment to remove water ballast from the storage tank DO NOT use gaskets on covers of explosion proof type boxes The sealing compo...

Page 29: ...uce unit flow rates Component Company Model Approved for Use Nozzles Emco Wheaton Inc Model A4015 Husky Corporation Model 5010 OPW Fuel Components Model 211V Hose UL listed Hose Assembly Height in cm Hose Length ft cm Register Minimum Radius ft cm Fueling Radius ft cm Height in cm Hose Length ft cm Register Minimum Radius ft cm Fueling Radius ft cm 60 65 152 165 cm 8 244 cm 6 15 cm 8 244 cm 96 101...

Page 30: ... 6 442 cm 14 427 cm 8 6 259 cm 13 6 411 cm 17 518 cm 9 274 cm 15 6 472 cm 90 95 229 241 cm 11 335 cm 6 15 cm 10 6 320 cm 12 366 cm 4 6 137 cm 11 6 351 cm 13 396 cm 6 6 198 cm 12 6 381 cm 14 427 cm 8 244 cm 13 6 411 cm 15 457 cm 9 6 290 cm 14 6 442 cm Legend Height Measurement from the ground to the hose connection assuming the pumping unit is mounted on top of the tank with the feet provided Hose ...

Page 31: ...Typical Installation for Model 9820K SIDE VIEW DISCHARGE LINE LISTED HOSE BREAKAWAY VENT RETURN LINE VAPOR RECOVERY RETURN LINE LISTED EMERGENCY SHUT OFF VALVE 1 1 2 SUPPLY LINE LOCALLY APPROVED ANGLE CHECK VALVE FRONT VIEW DC WIRING CONDUIT AC DC CONDUIT BETWEEN PUMP AND REGISTER AC DC CONDUIT BETWEEN PUMP AND REGISTER AC WIRING CONDUIT DC WIRING CONDUIT ...

Page 32: ... Layouts Figure 5 2 Model 9820K Base Layout Pumping Unit Assembly Dimensions in inches unless otherwise noted Footprint Right View Back View AC Power 1 NPT Conduit Connection Alternate 3 4 NPT Conduit Connection Front Discharge for all units Front 3 4 NPT Vapor Recovery Return Vapor Recovery Units Only 1 1 2 NPT Inlet ...

Page 33: ...umps Installation and Operation Manual January 2020 Page 29 Base Layouts Installation Figure 5 3 Model 9820K Base Layout Register Assembly CONDUIT KNOCKOUTS FOR 3 4 19mm OR 1 25 mm CONDUIT ARE LOCATED ON THE BOTTOM OF THE CABINET ...

Page 34: ...ENING FOR ACCESS TO CONDUITS BEFORE YOU BEGIN ENSURE THAT THE POST IS SECURELY INSTALLED ON THE ISLAND 1 LOOSELY ASSEMBLE HARDWARE SECURING BRACKET TO POST 3 PLACES USING WASHERS SPRING LOCK WASHERS AND NUTS DO NOT TIGHTEN 2 TO MOUNT REGISTER TILT BRACKET BACKWARDS AND ATTACH REGISTER TO BRACKET USING HARDWARE PROVIDED 3 RETURN BRACKET TO NORMAL POSITION ALIGNING REGISTER IN GROOVE ON TOP OF POST ...

Page 35: ...ual January 2020 Page 31 Base Layouts Installation Figure 5 5 Model 9820K Base Layout Side and Rear Brackets View 1 of 2 AST REGISTER BACK VIEW RIGHT SIDE MOUNT OPTIONAL MOUNTING METHOD FOR RIGHT SIDE MOUNTS BRACKETS ARE OFFSET TO ALLOW FOR CLEARANCE OF NOZZLE BOOT ...

Page 36: ...Layouts Page 32 MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 Figure 5 6 Model 9820K Base Layout Side and Rear Brackets View 2 of 2 AST REGISTER BACK VIEW REAR MOUNT SIDE VIEW REAR MOUNT ...

Page 37: ...ents Setting up internal switches Viewing and resetting 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 location of some key components as well as the various switch selectable operating modes 1 Unlock and remove the front panel see Figure 6 1 Remove the two...

Page 38: ...MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 2 Loosen the two screws located on the left and right door support brackets and pivot the display panel down see Figure 6 2 Figure 6 2 Door Support Bracket Screw Locations Model 9820K LOOSEN ...

Page 39: ...ecessary Switch and jumper settings should be changed with the power switch OFF The new settings are read by the CPU PCB when the power is turned on again Figure 6 3 CPU PCB Location of Switches and Jumpers The ON position Closed of the switch is towards the center of the board Jumper JP1 JP9 JP1 Baud Rate This jumper is set to reflect the communication rate of the Gasboy RS 485 pump loop jumper i...

Page 40: ...n pumps Delay Time JP3 JP4 0 seconds Installed Installed 4 seconds Installed Open 5 seconds Open Installed 6 seconds Open Open Note Settings that are too short will result in the leak detector tripping incorrectly and the ones that are too long will result in a longer wait for the fuel to be pumped JP5 Hose Pressurization For US Gallons always in Hose Pressurization mode this jumper is ignored Thi...

Page 41: ...Pump Disable Detection This jumper allows the pump dispenser to detect or ignore a pump disable RS 485 break character When detection is enabled the pump dispenser will monitor the RS 485 communications for a pump disable signal When received any transaction in progress will be halted and then completed This setting must be used only when the pump dispenser is communicating to a Gasboy Fuel Contro...

Page 42: ... non Gasboy fuel management systems Address Switches A unique address identifier must be set when the 9820K is connected to the Gasboy RS 485 pump loop via the RS 485 I F PCB Since there are 16 possible address combinations up to 16 units single or twin may be connected to the pump loop Addressing should start at 1 and continue sequentially through 16 The physical wiring order does not have to cor...

Page 43: ...on the pulse rate selected as shown in the chart below Timeout Switch if JP2 is Installed When the 9820K is in standalone mode it will turn off an active hose if it does not detect pulses for 4 minutes 15 seconds This timeout feature can be disabled by setting switch SW2 4 to Open Timeout SW2 4 Enabled Closed Disabled Open 9820K Dual Pulse Output Option When the 9820K is using the Pump I F PCB M06...

Page 44: ...40 MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 JP4 and JP5 When using the Pump I F PCB M06587A001 on the 9820K jumpers JP4 and JP5 should always be set to the Q A position Figure 6 4 JP4 and JP5 Positions JP1 JP2 JP3 JP4 JP5 ...

Page 45: ...ical totalizer that may be installed at the pump module and is shown as whole gallons liters on the displays decimal point is shown although it is disregarded The totalizer data is stored in battery backed memory The 9820K is supplied with an actuator see Figure 6 5 which allows you to view and reset the electronic totalizer When the 9820K is shipped the actuator is attached with a tie wrap to the...

Page 46: ...he CPU PCB 3 Hold the actuator against the totalizer bracket and have someone turn the breaker on The display should change to all zeroes 4 Remove the actuator and remove jumper on JP7 Note Remove jumper from JP7 to prevent the totalizer from being reset the next time the actuator is used to read it Mechanical Totalizer Some 9820K models contain an optional mechanical totalizer The totalizer has 8...

Page 47: ...pense fuel Quantity will not be recorded on the display until 0 010 gallons 0 04 liters is reached However all pulses will be sent out on the Pulse Output line if equipped At 0 010 gallons 0 04 liters the Fast Flow valve turns on The pump continues to run until one of the following conditions occurs Note These conditions turn off all relays The handle is turned off The Pump Motor Feed line is turn...

Page 48: ...mp for example Master No 1LJ D To lock the nozzle in place proceed as follows 1 Insert the nozzle onto the hook assembly with the nozzle tip inside the boot 2 Slide the rear bracket of the nozzle hook assembly upward until the holes near the bottom of the nozzle are aligned 3 Slide the open padlock through holes in the moveable and stationary portions of the hook arrangement thus capturing the noz...

Page 49: ...MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 Page 47 9820K Nozzle Locking Operating Sequence and Locking the Nozzle Figure 7 1 Locking Mechanism Model 9820K ...

Page 50: ...Operating Sequence and Locking the Nozzle 9820K Nozzle Locking Page 48 MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 This page is intentionally left blank ...

Page 51: ...When DC pulsers are used in the pump for connecting to Gasboy fuel management systems 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 through proper operation The unit must be properly grounded Startup After successfully verifying the installation against t...

Page 52: ...izer as described in View Reset Totalizer on page 41 Post Startup Tests Voltage The incoming voltage to the pump should be checked and any reading not within 10 of the rated voltage should be corrected before testing is continued Take voltage readings while the pump is operating on bypass and also while making a delivery Any voltage drop in excess of 10 during either of these operating states shou...

Page 53: ...the seal pin see Figure 8 1 3 Remove the seal pin and turn the wheel to adjust measurement see Figure 8 1 Turn clockwise to decrease the amount in the prover to match the display Turn counter clockwise to increase the amount in the prover to match the display Note Moving the wheel one hole position changes the calibration by 2 3 cubic inch per 5 gallons 18 9 liters To change by half of this amount...

Page 54: ...9820K Startup and Test Post Startup Tests Page 52 MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 This page is intentionally left blank ...

Page 55: ...23 Micro Neutral 23 Model 9120K 1 N Neutral Feed 11 Nozzle Locking 50 P Personnel Emergency informing 6 Phase 2 Feed 25 Post Startup Tests 54 Pulse Output 11 Pulser 26 Pump Motor 10 Pump Motor Feed 11 R Reset Complete 25 RS 485 11 26 S Safety Information Alert symbol 5 Barricading 5 Emergency electrical shut off 5 Emergency personnel 6 Evacuation 5 NFPA regulations 5 Open flames 6 Preventing explo...

Page 56: ...http www gasboy com Printed in the U S A MDE 4567D 9820K Series AST Pumps Installation and Operation Manual January 2020 NEC and NFPA 70 are registered trademarks of the National Fire Protection Association TopKATTM is a trademark of Gasboy International UL is a registered trademark of Underwriters Laboratories Inc ...

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