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Mechanical PCU Option

Pump Control EXPMUX CPU Board

Page 84

MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005

Switches 1 through 4 denote the address. This is factory set and may not have to be corrected.
The table below gives the switch settings for the address selections.

8

Switches SB-5 through SB-8 are not relevant to the operation of this unit and should be set to
Closed.

9

The settings for switch bank SC (1 through 4) determine when the pump control unit begins
counting pulses for a particular pump. When a switch is open, the PCU begins counting pulses
when the corresponding pump is activated. When a switch is closed, as it should be for most
configurations using mechanical pumps, the PCU does not count pulses for the corresponding
pump until the mechanical reset has completed. The table below gives the switch settings for
SC-1 through SC-4.

10

In switch bank SC, 5 through 8, only switch 6 and 8 are active. Switch SC-6 is the Deadman
Timer Switch. If enabled, the pump control unit must be polled at least every 15 seconds by
the TopKAT. If it fails to sense a poll at that time, it turns all relays off. If Reset Complete
Mode is used on any pump on a particular PCU, the deadman timer should be disabled.
Switch SC-8 enables the test mode allowing the basic PCU functions to be tested without the
use of a site controller.

Address

SB-1

SB-2

SB-3

SB-4

ADDR1

ADDR2

ADDR3

ADDR4

1

Closed

Closed

Closed

Closed

2

Open

Closed

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

Open

10

Open

Closed

Closed

Open

11

Closed

Open

Closed

Open

12

Open

Open

Closed

Open

13

Closed

Closed

Open

Open

14

Open

Closed

Open

Open

15

Closed

Open

Open

Open

16

Open

Open

Open

Open

Switch

Function

SC-1

Mode pump 1

Open = Normal, Closed = Reset Complete

SC-2

Mode pump 2

Open = Normal, Closed = Reset Complete

SC-3

Mode pump 3

Open = Normal, Closed = Reset Complete

SC-4

Mode pump 4

Open = Normal, Closed = Reset Complete

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Summary of Contents for TopKAT

Page 1: ...TopKAT Fuel Management System Installation Manual MDE 4319A formerly C35754...

Page 2: ...ies 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 operate...

Page 3: ...Customer Information 5 FCC Part 15 5 FCC Part 68 5 DOC Certification 6 3 General Installation 7 Rules for Proper Installation 7 Component Location and Installation Specifications 8 System 8 Data Termi...

Page 4: ...o TopKAT Cabling 25 Switch Settings 26 Port Communication Wiring 26 TopKAT Master Satellite Communications Wiring 28 Wiring for a Link CRT Terminal and Okidata Printer 29 Wiring for Modems 29 External...

Page 5: ...Submersible Starter Drive Subm Starter Drive 40 Submersible Drive Subm Drive 40 Reset Complete Switch Detect Slow Flow 40 Phase 2 Feed 40 Light Feed 40 Light Neutral 40 Pulser 9800 9820 41 Wiring Diag...

Page 6: ...Diagrams Port Communication 104 TopKAT Master Satellite Communications Wiring 107 Wiring for a Link CRT Terminal and Okidata Printer 108 Wiring for Modems 108 External Modems 108 Internal Modem 108 8...

Page 7: ...pKAT Fuel Managment System Installation Manual November 2005 Page v Table of Contents 11 Testing 123 Completion Check List 123 Manual Override Test 124 12 Appendix Base Layout for Shelf Mounting A 1 I...

Page 8: ...Table of Contents Page vi MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 9: ...stand the procedures before beginning work Follow the Regulations Applicable information is available in National Fire Protection Association NFPA 30A Code for Motor Fuel Dispensing Facilities and Rep...

Page 10: ...side electronic enclosures may present a health hazard if not handled correctly Ensure that you clean hands after handling equipment Do not place any equipment in the mouth In an Emergency Inform Emer...

Page 11: ...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...

Page 12: ...Important Safety Information Page Safety 4 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 13: ...o the installation of conduit and wiring to ensure your TopKAT System is installed properly Faulty installations are the major cause of system malfunctions The TopKAT system must be installed exactly...

Page 14: ...AT A standalone or master satellite with the mechanical pump control unit PCU option can control up to 8 mechanical hoses 4 hoses per PCU up to 2 pedestal or wall mounted PCUs The TopKAT is equipped w...

Page 15: ...ys mounted on a pedestal with a Series 9820 ASTRA mounted on a free standing pedestal for use with mechanical pumps electronic 9800s or ASTRAs as part of a master satellite configuration mounted atop...

Page 16: ...Title GOLD Library C35755 TopKAT Parts Manual Gasboy Fuel Management Products C35965 TopKAT Host Communications Manual Gasboy Fuel Management Products MDE 4338 TopKAT Operation Manual Gasboy Fuel Mana...

Page 17: ...on number and ringer equivalence number REN for this equipment If requested this information must be provided to the telephone company 2 The Gasboy Internal Modem should be connected to a USOC RJ 11C...

Page 18: ...telecommunications company The equipment must also be installed using an acceptable method of connection In some cases the company s inside wiring associated with a single line individual service may...

Page 19: ...operly grounded 7 Use terminal connectors on stranded wire 8 Test pumps in the manual override position prior to system start up 9 DO NOT turn on the system power switch located in the head assembly P...

Page 20: ...connection of a data terminal Extermal Modem When an external modem is used with the system it must be UL Listed and should be located in an office type environment However if this is not possible it...

Page 21: ...lps provide clean power to the TopKAT Poor power conditions are a key cause to system malfunction or failure The power conditioner provides transient and common mode protection for the TopKAT although...

Page 22: ...ated at no less than 10 amps 4 All conduit must be metal to provide the necessary shielding 5 Use the Conduit Size chart to determine the proper conduit size 6 RS 232 communication must not exceed 100...

Page 23: ...make holes at locations other than those provided contact Gasboy for approval first All wiring and conduit runs must conform with all building fire codes all Federal State and Local codes the Nationa...

Page 24: ...of Trade Size Conduit Trade Size Internal Diameter Area square units Fill Area square units 25 fill inches millimeters inches millimeters inches millimeters 1 2 629 16 303 196 076 49 3 4 826 21 532 34...

Page 25: ...control may be powered from this breaker However for 9800 and ASTRA applications it is acceptable to power the data terminal or external modem from the breaker that supplies power to the electronic re...

Page 26: ...the circuit breaker panel in case of problems Dispensers The TopKAT System with Mechanical Interface option is capable of directly driving submersible pumps up to 3 4 HP at 115 VAC or 1 1 2 HP at 230...

Page 27: ...uit breaker panel to the pump The chart below may be used as a guide in selecting the proper size wire according to the specific installation requirements The wire size for the reset complete from the...

Page 28: ...30 5M 150 45 7M 200 61M 250 76 2M 300 91 4M 1 2 14 12 10 8 8 8 8 3 4 14 12 10 8 8 6 4 Note For run over 300 feet use relay at motor location 230 Volt Wire Gauge Sizes per Feet Meters of Run Note Motor...

Page 29: ...ilt in modem 1 All wiring is to be installed and used in accordance with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Se...

Page 30: ...used in accordance with all applicable national state and local building fire electrical codes Additionally in the USA installations must comply with the National Electrical Code NFPA 70 NFPA 30 and t...

Page 31: ...box You must follow these installation requirements when installing the RS 232 communication lines 1 All peripheral equipment connected to the RS 232 ports must be UL listed have an Electronics Indust...

Page 32: ...wire RS 422 Short Haul Modems A Gasboy short haul modem and the appropriate interconnect cable must be used when the RS 422 communication mode is being used to communicate to the ports of the TopKAT...

Page 33: ...of 600V Environmental Gas and oil resistant suitable for wet or dry locations Gasboy can supply Belden 1063A P N C09655 which is a UL Listed 4 conductor cable that meets the requirements listed above...

Page 34: ...ectors on the communication board or the electronic housing assembly To gain access to the inside of the TopKAT unlock the rear door and open it all the way Unscrew the two captive screws holding the...

Page 35: ...ls the dispenser activation The TopKAT communicates with the ASTRA through the first of its three asynchronous ports Port 1 is a dedicated RS 485 communication loop which allows the TopKAT to control...

Page 36: ...Series 9820 ASTRA Installation Page 24 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 4 2 011889 Base Layout optional post w TopKAT Models 9822 9823...

Page 37: ...abling Series 9820 ASTRA Installation ASTRA to TopKAT Cabling The interconnection of the ASTRA to the TopKAT requires two cables an RS 485 communication cable and an AC power cable Both of these are s...

Page 38: ...unication Wiring The following diagrams show the pin to pin layout of the possible wiring schemes for the TopKAT ports Each port may be wired for any of the wiring schemes provided the installation re...

Page 39: ...he port being used should be set to RS 232 See Terminal Block ID on page 26 for the location of K1 K2 jumpers Figure 4 7 RS 422 Gasboy Short Haul Modem Note In the TopKAT the green connector goes to P...

Page 40: ...rnal Modem Note In cases where a TopKAT internal modem is used port 3 is not available for external communication wiring Note The K2 jumper for port 3 should be removed See Terminal Block ID on page 2...

Page 41: ...of modem used and the method of communication desired Consult the manual that comes with the modem for specific requirements Internal Modem When the TopKAT internal modem is installed port 3 communic...

Page 42: ...Series 9820 ASTRA Installation Wiring for a Link CRT Terminal and Okidata Printer Page 30 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 43: ...re mounted within the head of the TopKAT and all wiring connections are made within the TopKAT no electronics or control devices are present in the pedestal The TopKAT with mechanical interface can al...

Page 44: ...Mechanical Interface Option Dimensions Page 32 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Dimensions Figure 5 1 TopKAT Dimensions with Pedestal...

Page 45: ...stem Installation Manual November 2005 Page 33 Conduit Layout Mechanical Interface Option Conduit Layout See General Installation on page 11 for conduit power requirements and wire size considerations...

Page 46: ...omponents Refer to Terminal Block ID on page 22 To gain access to the inside of the TopKAT unlock the rear door and open it all the way Unscrew the two captive screws holding the hood in place Slide t...

Page 47: ...30A and the Canadian Electrical Code Canadian users only a single control which simultaneously removes AC power from all site dispensing equipment is recommended This control must be readily accessibl...

Page 48: ...p handle is turned on Two feed lines are provided for twins This feed is also connected to the input of one of the internal switches of the electric reset When the reset finishes its cycle the 115 VAC...

Page 49: ...se 2 Feed Reset Complete Switch Detect This is a 115 VAC output which is used to indicate the reset is complete and the pump dispenser is ready to dispense product Two lines are provided for twins Thi...

Page 50: ...rosion 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 recom...

Page 51: ...s a 115 VAC 230 VAC Int l input which is required to power and authorize the control line This line is used to provide authorization for the dispensing unit when enabled through the DIP switches A res...

Page 52: ...cannot exceed 3 4 HP at 115 VAC or 1 1 2 HP at 230 VAC Two lines are provided for twins In cases where both lines will be controlling the same starter relay or pump they can be combined Reset Complet...

Page 53: ...k up to 100 milliamps DC at voltages up to 24 VDC The output pulse rate can be configured by a DIP switch on the 9800 CPU PCB for rates of 1 10 100 250 500 or 1000 pulses per gallon or 1 10 100 or 250...

Page 54: ...e Pump Control PCB must be properly jumpered according to the pulser type This should be done by the person performing the start up Power to the system must not be turned on prior to this set up 3 See...

Page 55: ...pped 100 coverage and or tinned copper braid 90 coverage Drain Wire Stranded tinned copper 20 AWG or larger or braided shield Voltage Rating Maximum operating voltage of 600 VDC Environmental Gas and...

Page 56: ...chanical Interface Option Wiring Diagrams Page 44 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 5 6 Wiring Diagram Single Suction Pump 115 VAC 230 VAC Veeder Root Res...

Page 57: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 45 Wiring Diagrams Mechanical Interface Option Figure 5 7 Twin Suction Pump 115 VAC 230 VAC Veeder Root Reset...

Page 58: ...al Interface Option Wiring Diagrams Page 46 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 5 8 Wiring Diagram Twin Suction Pump Single Motor 115 VAC 230 VAC Veeder Roo...

Page 59: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 47 Wiring Diagrams Mechanical Interface Option Figure 5 9 Wiring Diagram Single Dispenser Veeder Root Reset...

Page 60: ...Mechanical Interface Option Wiring Diagrams Page 48 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 5 10 Wiring Diagram Twin Dispenser Veeder Root Reset...

Page 61: ...Manual November 2005 Page 49 Wiring Diagrams Mechanical Interface Option Figure 5 11 Wiring Diagram Single Suction Pump 115 VAC 230 VAC Gasboy Reset Note Units with two motors may require pump to be o...

Page 62: ...Mechanical Interface Option Wiring Diagrams Page 50 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 5 12 Wiring Diagram Twin Suction Pump 115 VAC 230 VAC Gasboy Reset...

Page 63: ...19A TopKAT Fuel Managment System Installation Manual November 2005 Page 51 Wiring Diagrams Mechanical Interface Option Figure 5 13 Wiring Diagram Twin Suction Pump Single Motor 115 VAC 230 VAC Gasboy...

Page 64: ...Mechanical Interface Option Wiring Diagrams Page 52 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 5 14 Wiring Diagram Single Dispenser Gasboy Reset...

Page 65: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 53 Wiring Diagrams Mechanical Interface Option Figure 5 15 Wiring Diagram Twin Dispenser Gasboy Reset...

Page 66: ...damage the TopKAT 3 Wire colors shown reflect current production since June 1998 If your 9800 is older than June 1998 your wire colors may vary 4 When used with an aboveground tank the anti siphon va...

Page 67: ...ers will damage the TopKAT 3 Wire colors shown reflect current production since June 1998 If your 9800 is older than June 1998 your wire colors may vary 4 When used with an aboveground tank the anti s...

Page 68: ...es 1 The power resistor assembly is 8 2K OHM 10W P N C05818 for 115 230 VAC domestic units and 30K OHM 10W P N C06683 for 230 VAC international units 2 Before applying power the TopKAT Pump Control PC...

Page 69: ...the jumpers will damage the TopKAT 3 Wire colors shown reflect current production since June 1998 If your 9800 is older than June 1998 your wire colors may vary 4 When used with an aboveground tank th...

Page 70: ...reflect current production since June 1998 If your 9800 is older than June 1998 your wire colors may vary 4 When multiple dispensers are used to control a common submersible starter relay or pump and...

Page 71: ...Wire colors shown reflect current production since June 1998 If your 9800 is older than June 1998 your wire colors may vary 4 When multiple dispensers are used to control a common submersible starter...

Page 72: ...Domestic Dispensers Notes 1 The power resistor assembly is 8 2K OHM 10W P N C05818 for 115 230 VAC domestic units and 30K OHM 10W P N C06683 for 230 VAC international units 2 Before applying power th...

Page 73: ...ernational Dispensers Notes 1 The power resistor assembly is 8 2K OHM 10W P N C05818 for 115 230 VAC domestic units and 30K OHM 10W P N C06683 for 230 VAC international units 2 Before applying power t...

Page 74: ...port may be wired for any of the wiring schemes provided the installation requirements are met as outlined in Communication Requirements on page 17 Figure 5 24 Wiring Diagram RS 232 D Connector Note I...

Page 75: ...terface Option Figure 5 25 Wiring Diagram RS 232 Gasboy Termination Box Note In the TopKAT the green connector goes to P4 on the communication board for port 2 and P6 for port 3 The K1 K2 jumper for t...

Page 76: ...s where a TopKAT internal modem is used port 3 is not available for external communication wiring Note The K1 K2 jumper for the port being used should be set to RS 422 See Terminal Block ID on page 34...

Page 77: ...System Installation Manual November 2005 Page 65 Wiring Diagrams Mechanical Interface Option Figure 5 28 Wiring Diagram TopKAT Master Satellite Communications Wiring Figure 5 29 Wiring Diagram Link C...

Page 78: ...ernal Modem When the TopKAT internal modem is installed port 3 communication is routed through the modem in place of being wired at the DC junction box Jumper K2 should be removed See Terminal Block I...

Page 79: ...9800 pumps to communicate to their pumps or the mechanical interface The interface must be the same for each pump within an individual TopKAT However both types of pump interface may be combined withi...

Page 80: ...68 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 6 1 Wiring Diagram TopKAT Master Satellite Communications Wiring 9820 Figure 6 2 Wiring Diagram TopKAT Master Satelli...

Page 81: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 69 TopKAT Master Satellite Figure 6 3 Wiring Diagram RS 422 Gasboy Short Haul Modem Master Satellite Modem...

Page 82: ...agram Internal Modem with Master Satellite Option Note In the TopKAT port 3 is not available for external communication wiring when an internal modem is used For port 2 reference the Master Satellite...

Page 83: ...fic requirements Internal Modems When the TopKAT internal modem is installed port 3 communication is routed through the modem in place of being wired at the DC junction box Jumper K2 should be removed...

Page 84: ...TopKAT Master Satellite Page 72 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 85: ...all pump dispenser wiring connections are made within the wall mounted PCUs The TopKAT with the Mechanical PCU option can also be used in a master satellite configuration The mechanical PCU includes...

Page 86: ...Mechanical PCU Option Page 74 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 1 Pedestal Dimensions Pedestal Mounted PCU...

Page 87: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 75 Mechanical PCU Option Figure 7 2 Pedestal Dimensions Wall Mounted PCU...

Page 88: ...Mechanical PCU Option Page 76 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 3 Wall Mount PCU Dimensions...

Page 89: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 77 Mechanical PCU Option Figure 7 4 Conduit Layout Wall Mounted PCU...

Page 90: ...Page 78 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 5 Conduit Layout Pedestal PCU Note See General Installation on page 11 for conduit power requirements and wir...

Page 91: ...open it all the way Unscrew the two captive screws holding the hood in place Slide the hood toward the rear of the unit about 1 inch and lift straight up See the following figures for Terminal Block I...

Page 92: ...0 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 6 shows the mechanical PCU components Refer to Terminal Block ID on page 22 for the TopKAT Comm Assembly Figure 7 6...

Page 93: ...MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 81 Terminal Block ID Mechanical PCU Option Figure 7 7 Terminal Block ID Standard Pedestal Right Side...

Page 94: ...Mechanical PCU Option Terminal Block ID Page 82 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 8 Terminal Block ID Wall Mounted PCU...

Page 95: ...the rear portion of the card cage by pulling on the top white tab 6 Locate the K1 jumper patch and install the jumper This jumper allows battery voltage to the RAM It should be installed for normal op...

Page 96: ...d 8 are active Switch SC 6 is the Deadman Timer Switch If enabled the pump control unit must be polled at least every 15 seconds by the TopKAT If it fails to sense a poll at that time it turns all rel...

Page 97: ...Board Mechanical PCU Option The table below gives the switch settings for SC 5 through SC 8 11 Re install the EXPMUX Pump Control CPU board Switch Function SC 5 No function in on line mode SC 6 DEAD...

Page 98: ...hes on the I O PCB you must remove all the connectors and the cover plate Figure 7 10 Pump Control I O Cover Plate and PCB 1 Remove the five green connectors from the front of the Pump Control I O boa...

Page 99: ...UX Pump Control CPU and Pump Control I O PCBs for each pump control unit Jumper Pin Function Voltage VR Reed Switch Pulser 1871 Series P Pulser signal input sink 12 VDC square wave signal when pulsing...

Page 100: ...and the Canadian Electrical Code Canadian users only a single control which simultaneously removes AC power from all site dispensing equipment is recommended This control must be readily accessible c...

Page 101: ...andle is turned on Two feed lines are provided for twins This feed is also connected to the input of one of the internal switches of the electric reset When the reset finishes its cycle the 115 VAC in...

Page 102: ...2 Feed Reset Complete Switch Detect This is a 115 VAC output which is used to indicate the reset is complete and the pump dispenser is ready to dispense product Two lines are provided for twins This l...

Page 103: ...page 95 Figure 7 14 Wiring Diagram Twin Suction Pump Single Motor Veeder Root Reset on page 96 Figure 7 15 Wiring Diagram Single Remote Dispenser Veeder Root Reset on page 97 Figure 7 16 Wiring Diagra...

Page 104: ...Mechanical PCU Option Wiring Diagrams Pulsers Pumps Dispensers Page 92 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 11 Wiring Diagram Pulsers...

Page 105: ...it 18 AWG wires are required for installation Although it is recommended that DC pulser wires be run in a conduit separate from AC wires they can be combined in the same conduit with AC wires providin...

Page 106: ...anical PCU Option Wiring Diagrams Pulsers Pumps Dispensers Page 94 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 12 Wiring Diagram Single Suction Pump Veeder Root R...

Page 107: ...4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 95 Wiring Diagrams Pulsers Pumps Dispensers Mechanical PCU Option Figure 7 13 Wiring Diagram Twin Suction Pump Veeder Root Re...

Page 108: ...PCU Option Wiring Diagrams Pulsers Pumps Dispensers Page 96 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 14 Wiring Diagram Twin Suction Pump Single Motor Veeder R...

Page 109: ...19A TopKAT Fuel Managment System Installation Manual November 2005 Page 97 Wiring Diagrams Pulsers Pumps Dispensers Mechanical PCU Option Figure 7 15 Wiring Diagram Single Remote Dispenser Veeder Root...

Page 110: ...nical PCU Option Wiring Diagrams Pulsers Pumps Dispensers Page 98 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 16 Wiring Diagram Twin Remote Dispenser Veeder Root...

Page 111: ...E 4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 99 Wiring Diagrams Pulsers Pumps Dispensers Mechanical PCU Option Figure 7 17 Wiring Diagram Single Suction Pump Gasboy Rese...

Page 112: ...echanical PCU Option Wiring Diagrams Pulsers Pumps Dispensers Page 100 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 18 Wiring Diagram Twin Suction Pump Gasboy Rese...

Page 113: ...A TopKAT Fuel Managment System Installation Manual November 2005 Page 101 Wiring Diagrams Pulsers Pumps Dispensers Mechanical PCU Option Figure 7 19 Wiring Diagram Twin Suction Pump Single Motor Gasbo...

Page 114: ...anical PCU Option Wiring Diagrams Pulsers Pumps Dispensers Page 102 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 7 20 Wiring Diagram Single Remote Dispenser Gasboy R...

Page 115: ...4319A TopKAT Fuel Managment System Installation Manual November 2005 Page 103 Wiring Diagrams Pulsers Pumps Dispensers Mechanical PCU Option Figure 7 21 Wiring Diagram Twin Remote Dispenser Gasboy Re...

Page 116: ...s for the TopKAT ports Each port may be wired for any of the wiring schemes provided the installation requirements are met as outlined at Communication Requirements on page 17 Figure 7 22 Wiring Diagr...

Page 117: ...ram RS 485 Communication Cable TopKAT to Wall Mount Remote Mechanical PCU Figure 7 24 Wiring Diagram RS 232 Gasboy Termination Box Note In the TopKAT the green connector goes to P4 on the communicatio...

Page 118: ...te In cases where a TopKAT internal modem is used port 3 is not available for external communication wiring Note The K1 K2 jumper for the port being used should be set to RS 422 See Terminal Block ID...

Page 119: ...m Installation Manual November 2005 Page 107 TopKAT Master Satellite Communications Wiring Mechanical PCU Option TopKAT Master Satellite Communications Wiring Figure 7 27 Wiring Diagram TopKat Master...

Page 120: ...modem used and the method of communication desired Consult the manual that comes with the modem for specific requirements Internal Modem When the TopKAT internal modem is installed port 3 communicatio...

Page 121: ...inch high standalone pedestal All wiring connections are made within the TopKAT no electronics or control devices are present in the pedestal The TopKAT communicates with the 9800 single or twin throu...

Page 122: ...Series 9800 Field Installation Page 110 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 Figure 8 1 Series 9800 Dimensions...

Page 123: ...stallation Manual November 2005 Page 111 Conduit Layout Series 9800 Field Installation Conduit Layout Note See General Installation on page 11 for conduit power requirements and wire size consideratio...

Page 124: ...Cable Switch Settings In order for the 9800 to communicate to the TopKAT via RS 485 the switch settings on the 9800 CPU must be as follows Refer to Section 5 of one of the following for switch setting...

Page 125: ...s for the TopKAT ports Each port may be wired for any of the wiring schemes provided the installation requirements are met as outlined in Communication Requirements on page 17 Figure 8 4 RS 232 D Conn...

Page 126: ...allation Manual November 2005 Figure 8 5 RS 232 Gasboy Termination Box Note In the TopKAT the green connector goes to P4 on the communication board for port 2 and P6 for port 3 The K1 K2 jumper for th...

Page 127: ...In cases where a TopKAT internal modem is used port 3 is not available for external communication wiring Note The K1 K2 jumper for the port being used should be set to RS 422 See Terminal Block ID on...

Page 128: ...Master Satellite Communications Wiring Page 116 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 TopKAT Master Satellite Communications Wiring Figure 8 8 2 Top Mounted TopKATS...

Page 129: ...type of modem used and the method of communication desired Consult the manual that comes with the modem for specific requirements Internal Modem When the TopKAT internal modem is installed port 3 com...

Page 130: ...Series 9800 Field Installation Wiring for a Link CRT Terminal and Okidata Printer Page 118 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 131: ...1 The distance between the TopKAT and POS system can be up to 3 miles 4 8 kilometers The wireless communications option is NOT intended to provide nor can it extend communications between the followi...

Page 132: ...Wireless Communications Installation Page 120 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 133: ...AT commands on the serial port then establishes a network connection to the end device using network connections and bandwidth to replace the dedicated modem and phone line Figure 10 1 Serial to LAN C...

Page 134: ...serial to LAN connection refer to the following 900 360 Lantronix UDS 10 UDS 100 User Guide http www lantronix com pdf UDS10 UDS100_UG pdf 900 363 Lantronix UDS 10 UDS100 UDS200 Quick Start Guide htt...

Page 135: ...ge 15 The only exception to the metal conduit rule is RS 422 as noted in RS 422 Short Haul Modems on page 24 4 Is the AC and DC wiring in separate conduits troughs etc except as noted in RS 422 Short...

Page 136: ...ng should be corrected and the test must be performed again 1 Place all of the system override switches in the OFF position 2 Turn on the breakers for all of the pumps dispensers 3 Place the system ov...

Page 137: ...Layout for Shelf Mounting The TopKAT can be mounted on a shelf of your own design if desired If you choose to do this use the following base layout in addition to following all installation precaution...

Page 138: ...Appendix Base Layout for Shelf Mounting Page 2 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 139: ...2 Precautions Wiring 35 88 R REN 5 6 ringer equivalence number 5 6 RS 232 19 20 26 27 62 63 104 105 113 114 123 RS 422 20 27 64 69 106 115 123 RS 485 17 18 25 67 83 105 112 S Safety Information Safet...

Page 140: ...Index Page Index 2 MDE 4319A TopKAT Fuel Managment System Installation Manual November 2005 This page intentionally left blank...

Page 141: ......

Page 142: ...el Managment System Installation Manual November 2005 Amphenol is a registered trademark of Amphenol Corporation Lantronix is a registered trademark of Lantronix Corporation Okidata is a registered tr...

Page 143: ...itation personal injury death property damage environmental damages product damages loss of product or loss of revenue or profits Gasboy is not liable for any claims or lawsuits against the customer 6...

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