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Owner`s Manual

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2. HOSE 2 A a O 2 jJ Q PULSER HANDLES f SER PRPHL PULSER KEYPAD INTFC ASSY HUDIIOARUU c O gt gop U C Cu NO 0 O Se ui Cn cn P WR INPU TO c c FF ma 4 BDM POR 1 R56 59
3. R C82 COO0OT00DO0T7 0000 o 026 LCD DISPLAY 2 3 o o o HE o eee e 1G dU E C8 00 C85 CPLD JI AG CPU Switch S1 Newer Series 9800 CPU Board M06333A CPU Jumpers Note In the following tables SW1 refers to switch banks in older series 9800 boards Jumpers MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 JPI JP9 are used for new CPU boards M06333A Also in new CPU boards Closed indicates that the CPU board is jumpered and Open indicates the absence of a jumper Page 21 The Atlas Fuel System CPU Switch Settings Series 9800 Only Including DEF 9862 Units CPU Jumpers or SW1 for Older CPU Boards SW1 1 or JP1 Baud Rate This switch is set to reflect the communications rate of the Gasboy RS 485 pump loop It is e Open for 9600 baud e Closed for 1200 baud The Gasboy CEN system and TopKAT communicate at 9600 baud Baud Rate SW1 1 JP1 Fuel System 9600 Open CFN TopKAT top mount TopKAT electronic 1200 Closed None currently supported SW1 2 or JP2 Mode If the Series 9800 is controlled by a Gasboy CFN TopKAT top mount or TopKAT electronic fuel management system the switch must open on line mode If the Series 9800 is cont
4. Maintenance of Vendor Supplied Parts Certain parts of the dispenser pump are produced by vendors for Gasboy hoses nozzles and so on and as such may have documentation separate from that which Gasboy supplies In such cases it is required to consult the vendor documentation for service intervals and any adjustments that is required for your dispenser pump Use Authorized Parts The use of unauthorized parts can e Void your warranty e Cause the loss of continuity of the Underwriters Label on the pump e Cause inefficient operation e Possibly cause an operational hazard Always use new gaskets and seals when servicing or rebuilding Gasboy equipment Performing Inspections This section provides instructions for scheduling two types of maintenance inspections e General inspections e Component inspections MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 55 The Atlas Fuel System Preventive Maintenance Page 56 Safety Warnings Follow all safety precautions to prevent injury when inspecting a pump dispenser at the islands AN WARNING You are performing inspections and maintenance in a potentially dangerous environment of flammable fuels vapors and high voltage Fire explosion or electrical shock could result in severe injury or death if you do not follow safe procedures Read and obey all safety precautions in this manual to prevent potential injury or death General Inspections Perform a g
5. Making unapproved modifications could result in improper equipment operation and violation of state and local codes and could also create a hazardous condition such as fire explosion or electrical shock Do not make unapproved modifications to Gasboy equipment Consult your ASC distributor or Gasboy for approved modifications and kits MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preparing for Servicing the Pumps Dispensers The Atlas Fuel System Call Gasboy First Before calling an ASC call the Gasboy Help Desk at 1 800 444 5529 The Help Desk may be able to resolve the issue for you If you have a service maintenance contract with Gasboy you may contact the Help Desk first Service Preparation Use a Gasboy trained ASC to efficiently service and maintain your Gasboy pumps dispensers Gasboy trains and certifies ASCs to service and maintain Gasboy pumps dispensers in a safe manner Before Calling for Service Perform the following tasks before you call for service Obtain complete information from the station personnel about the problem e Confirm that the tank has fuel e Confirm that the power pump lights and circuit breakers are on e Record Error Codes that may exist on the Main Display Electronic Units only e Ensure that you know the unit model number and serial number For details refer to Understanding Date Codes on page 11 Description of Problem Provide the ASC with a complete pro
6. USA UNIT COMM ELECTRONIC TIAI ini NN a 110V 60 HZ AMPS 4 0 CFH MOTOR 13 0 AMPS 1PH LITE NTEP CC NO H5 RR MODEL NO 9852KTW2 LED C FR LLL OOOO OUO NO OE al ik SERIAL MO BPATOOO199 8 N LULU POWER orerareo DISPENSING DEVICE FOR FLAMMABLE LIQUIDS For use with equipment epecirtaa in installation instructions CAUTION H ra 3 1 Lb h oe ul zard of e trical shock pore than pne disconnect SW Mad pe require VICE roP servicing sha es Do not dj Lgconneot connectors fuseholders lampholders etc e circult 15 al lue e ceneralze MRASNRHRHINTI RFU F Serial Number MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 11 The Atlas Fuel System Common Functions For example a serial number plate stamped BP AT000199 contains the following information e Date code BP This unit was manufactured in B February P 2005 e Serial Number AT000199 To determine the date code on a Gasboy pump or dispenser refer to the following tables Month Codes A January E May J September B February F June K October C March G July L November D April H August M December Year Codes P 2005 U 2009 R 2006 W 2010 S 2007 X 2011 T 2008 Y 2012 Pump Totals 9100 Series Pump totals can be read from the totalizers At the close of each day s business the total can be read from the unit and subtracted from the day before to
7. 002343 2 Probe Temperature Display Displays probe temperature in Celsius only 0232 ce Flow Rate Display Displays Flow Rate in LPM only 189 2 4 Software Version Display Displays software version number 1 30 5 ATC Status Display Displays ATC Status 842 2 On the ATC Status Display the rightmost digit 2 indicates whether the temperature compression is enabled or not If enabled it shows which product is being dispensed e 0 temperature compensation enabled e product is gasoline and compensation enabled e 2 product is diesel and compensation enabled Note Not used in the Atlas DEF 9862 units MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 27 The Atlas Fuel System Changing the Price for the Mechanical Retail Pump On the ATC Status Display the leftmost digits 842 are error indicators which are blank when the corresponding error condition is not active When any of the following digits are displayed e 8 temperature probe fault is detected e 4 pulser error occurred e 2 exceptional reset was detected Setting the DIP Switches Found on Kraus ATC Boards DIP Switch Settings Switch Number Switch Function Settings for 9800 Series 1 Prodeti ON Diesel OFF Gasoline 2 Product 2 ON Diesel OFF Gasoline 3 Not Used 4 9840K 9852K and 9853K ON Liters OFF Gallons 5 Pulser Multiplier ON 9850 OFF 9852 9853 6 of Probes ON 2 OFF 1 7 Pulser Adder ON 9840 8 ATC ON ATC on OFF ATC off Figure 3 15
8. 1 PMO Ss soe dete sft io AA AA AA 1 IGtended USERS aa aaa hk DIA AKTO KPA IAN ane ret dps a PIGA NOS det aad ae ese 1 1 6 0 AA ee ene ae 1 Abbreviations ans ACKONVING 4 us my aa Vee os ipd hunde Wa KENA NBA eae NABA NENA NAAN KA 2 2 Important Safety Information 3 3 The Atlas Fuel System 7 Pump Dispenser CompohehlS x 3o9 e xod eat ER obs Eel adh owed dte Mb eere cea ee a 7 Atlas PUmpP DISPENSE vs arua ioter ad Poe RR Rc e o E ma uet od oa d 7 Commercial Mechanical 9100 ccc eee 9 Commercial Electronic 9800 a 9 General Description 9800 Except 9820 10 General Description of 9100K aaa 11 Common FUNCHONS ue eate aea ad os AR Moe oe ete Rec wa eda Bee AA AGA 11 Understanding Date Codes 0 cc ee es 11 Pump Totals 9100 Series E a a ees 12 Commercial Electronic Series 9800 Only 13 Mechanical Totalizers for 9850 Only ee eee teens 14 SIte Prepaballoias us acces epee quid v c Rs Do Sow NADAAN NAGO eet Lie NG Uv e ki pes REWER EBA NOEL A 15 Important Requirements for E85 Units 0 00002 eee 15 Important Considerations for DEF Dispensers 16 Guidelines in Atlas Fuel Systems Documentation and Other Codes 17 General Guidelines 5 23a KA MAKAKA KAN 308 Re eR OR CC P Baws 17 FIO SC vr 18 Install Warning Labels and Signs for Customers 18 Operating Puraps DISpensel
9. Figure 3 10 Front Panel of 9800 Series 4454 11359 Unlock MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 19 The Atlas Fuel System CPU Switch Settings Series 9800 Only Including DEF 9862 Units 2 Remove the two bolts securing the bezel assembly and remove bezel 3 Remove the two bolts securing the display panel and pivot display panel down Figure 3 11 Display Panel Note Unit will swing forward and down Loosen and remove after screws are removed CPU Switch Settings Series 9800 Only Including DEF 9862 Units The Series 9800 can be configured for various operating conditions using the switches located on the CPU PCB Inspect these switches and change their settings if required Switch settings must be changed with the power switch OFF CPU PCB reads the new settings when the power is turned ON again Note Older Series 9800 CPU Diagram board C06394 M05318 M05346 Figure 3 12 Old CPU Board for 9800 Series 41 CPU PCB Switches SW1 and SW2 Page 20 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 CPU Switch Settings Series 9800 Only Including DEF 9862 Units Figure 3 13 New CPU Board for 9800 Series Serial Peripheral I F Port The Atlas Fuel System TOTALIZER REL DRIVE C10 P
10. Inc Futura is a trademark of Veyance Technologies Inc Teflon and Viton are registered trademarks of E I du Pont de Nemours and Company TopKAT is a trademark of Gasboy International Veyance is a service mark of Veyance Technologies Inc UL is a registered trademark of Underwriters Laboratories Inc 2011 GASBOY NN 7300 West Friendly Avenue Post Office Box 22087 G AS B OY Greensboro North Carolina 27420 QZ Phone 1 800 444 5529 http www gasboy com Printed in the U S A O MDE 4363F Atlas Fuel Systems Owner s Manual September 2011
11. Performs the Recommended Maintenance Inspection Repair 1 Lubricate with silicone spray if required e Owner Inspect 2 Inspect for damage ASC only Repair 3 Verify that the locking tab locator is not broken The locking and test tab locator helps hold the nozzle in the nozzle boot and enables the station owner to lock the nozzle boot with a clasp padlock If repair is required call an ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit Lubricate well See VeederRoot manuals for lubrication points ASC only AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit Lubricate with a graphite lubricant or lock oil Follow Owner manufacturer s instructions Do not over lubricate Use a rag to wipe any excess that may drip Remove with a sump pump e Owner Inspect 1 Gasboy recommends removing power to the unit before ASC only R
12. Setting the DIP Switches Commercial Electronic Side B Actuator Full scale ATC Switch Area Changing the Price for the Mechanical Retail Pump Atlas Gallon unit of measure Temporary pricing must have already been entered into the unit as outlined in the purging section to allow dispensing and calibration Follow the procedures given below Current production Atlas pumps dispensers are pre calibrated to US gallons and programmed to default programming values Note Calibration verification is still required Page 26 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Changing the Price for the Mechanical Retail Pump The Atlas Fuel System e They may be operated and purged in normal mode after entering the prices add pricing programming information from service manual or for mechanical units from the directions on the outside of the computer e Purging can be performed for units eventually to be converted to metric mode when the unit is in the gallon mode Figure 3 16 Mechanical Retail Pump PPU Variator Note Directions for changing the price can be found on the outside of the variator cover Note This section and the diagrams pertain to the mechanical models only 1 Unlock and remove the front panel Repeat this procedure for the other side 2 The variator section of the computer register s is exposed to allow price changes Slide the variator cover of the computer register apart to expose th
13. is halted by an operator of a fuel management system e An AC power failure occurs e Station Emergency Stop button is pressed Calibration error DEF or E85 units only Standalone Mode Error Handling Series 9800 When operating the pump dispenser in the standalone mode not connected to a fuel management system the Atlas displays two or three digit error transaction codes on the LCD displays when transactions are terminated abnormally by a means other than turning off the pump handle The possible error conditions that may be displayed are listed in the following table Code Condition 55 Power failure 56 Pulser error 57 Timed out 58 Limit cutoff 59 9840 Only Flow error unit 1 60 9840 Only Flow error unit 2 993 9860 or 9870 Only Calibration error The error codes are displayed for two seconds at the left of the LCD window alternating with a five second display of the last sale amount The display alternates between the two until a new transaction begins In the case of a 993 new transaction will NOT start until the error is cleared When an error occurs the user must note the error code and relay the information to the ASC Transaction error codes are displayed only when the pump dispenser is operating in standalone mode When connected to a fuel management system on line mode transaction error codes are transmitted back to the fuel management system with the completed transaction data Calibration for 985
14. press ENTER where O STOP Test Program 1 START Test Program Depending upon the preset option type testing will convey the following when pressing the preset buttons Five Button Preset Non Customer Programmable Preset Press ENTER after making selections 1 Program Button 1 Default 1 2 Program Button 2 Default 5 3 Program Button 3 Default 10 4 Program Button 4 Default 15 Incremental Preset Non Customer Programmable Preset Press ENTER after making selections 1 Program Button t Default 1 Money 2 Program Button 2 Default 5 Money 3 Program Button 3 Default 10 Money 4 Program Button 1 Default 1 Volume 5 Program Button 2 Default 5 Volume 6 Program Button 3 Default 10 Volume After test is complete follow programming steps to setup Command Code 6 Memory Clear For Error Code 31 or 35 e Press 6 and then press ENTER e Press 1 and then press ENTER MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 35 The Atlas Fuel System Programming 8800 Models Page 36 Command Code 7 Program Totals Input e Press 7 and then press ENTER e Select Side 1 or 2 and then press ENTER e Select Grace and then press ENTER Press Total e Enter money total and then press ENTER Repeat for other side and grade Press Volume Total and repeat above procedure for volume totals Command Code 8 Display Version Number Enter 8 and then press ENTER Select Software Option and then
15. press ENTER where 1 Pump Controller 3 Customer Programmable Preset Command Code 18 FC 1 Volume Pulse per Unit Programming pai 2 10 default 3 50 4 100 5 1000 Command Code 18 FC 2 Volume Pulse Width Programming 0 5ms 2 1 0ms 3 2 0ms 4 4 0ms default 5 17 0ms 6 19 0 ms 7 26 0ms 8 150 0ms MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Programming 8800 Models The Atlas Fuel System Command Code 18 FC 3 Money Pulse Width Programming 2 0 5ms 2 1 0ms 3 2 0ms 4 4 0ms default 5 17 0ms 6 19 0 ms 7 2 26 0ms Command Code 18 FC 4 Volume Suppression Programming 1 0 030 default 2 0 009 3 0 000 Command Code 18 FC 5 Quad Pulse Option Programming 0 Disabled default 1 Enabled Command Code 18 FC 6 Authorize after Pump Stop Option Programming 0 Disabled default 1 Enabled Command Code 18 FC 7 PRC Restore Option Programming 0 Disabled default 1 Enabled MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 57 The Atlas Fuel System Programming 8800 Models ATC Programming Page 38 At power up units programmed with the ATC option flash 104 before displaying normal information Units with this option but not programmed for ATC flash 100 To program the ATC option proceed as follows Turn on the programming switch on the ATC controller board Note The dispenser must not be used during this
16. suction pumps it is a good practice to take voltage readings while the suction pump is operating on bypass and also while making a delivery Any voltage drop in excess of 10 during either of these operating states must be considered a low voltage condition Corrective action must be taken to insure an adequate power supply to the pump Tightness After determining that the pump is operating satisfactorily and the system is fully primed inspect the pump and piping to ensure that all connections are tight In the case of a remote dispenser follow the submersible pump manufacturer s instructions to ensure the system for tightness We recommend that the tank and the piping must not be covered until this test is complete Belts Suction Pumps Only Since belts stretch slightly during the first few minutes of operation inspect the belt tension after completing the operational test A properly tightened belt permits twisting the belt 180 degrees midway between the motor and pump pulleys On the 9853KHC 9840K 9852KTW2 and 9853KTW2 models the belt can be tightened by loosening the hex nut which holds the idler pulley and sliding the pulley to either side to obtain the correct belt tension of 6 3 4 Ibs 3 4 30N 3 3N When the adjustment is complete remember to retighten the hex nut MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 51 The Atlas Fuel System Preparing for Servicing the Pumps Dispensers On the 9852K 9
17. that the vapor recovery hoses do not touch the ground when the nozzle is seated properly in the nozzle boot Consult the manufacturer for any additional inspections required If repair is required call an ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit AN WARNING Hoses of excessive length may create a trip hazard Serious injury could occur as a result of tripping over an excessive length hose Do not use excessive length hoses MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance The Atlas Fuel System Recommended Who Performs the Components Frequency Recommended Maintenance Inspection Repair Hose retrievers Once aweekorif 1 Inspect hose retrievers for frayed or broken cables Owner Inspect a customer 2 Inspect hose retrievers for cables wrapped around hoses Repair and test complaint arises 3 If repair is required call an ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained perso
18. 0 Only All Gasboy pumps and remote dispensers are adjusted for accurate measure at the factory However since the conditions of the installation can affect pump accuracy it is the responsibility of the installer to inspect the pump for accuracy and make the required adjustments When required it is the owner s responsibility to report this device to the local Weights and Measures officials for their inspection before the unit is put into service Calibration methods are given in gallons When calibrating liter pumps the same procedure is used but gallons is converted to liters 1 gallon 3 78 liters 1 gallon 0 83267 US Imperial gallons MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 45 The Atlas Fuel System Operating Sequence for Series 9800 Only Page 46 9850K and 9850KX Models To adjust the calibration for 9850K and 9850KX Models proceed as follows Inspect the meter registration by delivering the product to a reliable accurate 50 or 100 gallon or metric equivalent Prover Can Convert the amount of error to gallons per 100 provides a percent figure or gallons per thousand provides one tenths of a percent figure Read the setting indicated on the adjuster The amount of error 1s added to or subtracted from this setting The adjuster is shown in graduated divisions of 1 0 1 0 02 Figure 3 26 Models 9850K and 9850KX is CONTROLS LARGER SMALL SMALLER aoe VOLUMES BEY E E Re
19. 011 General Description of 9100K The Atlas Fuel System General Description of 9100K The Gasboy Series 9100K dispensing units are UL listed and are available in a self contained suction pump package or in a remote controlled dispenser package Both packages offer varieties of models which are available as single hose outlets or dual hose outlets with single or dual product capability The self contained models are available in standard speed up to 56 LPM 15 GPM in high speed up to 83 LPM 22 GPM or in a single hose model with high capacity speed up to 99 LPM 26 GPM The rate of delivery for the remote controlled packages will vary according to the size of the submersible pump The delivery rate of both packages will also vary depending on the installation conditions and added accessories All models of the Series 9100K offer mechanical non computers complete with electric resets Mechanical pump registers show the total volume for a delivery All non computers will read up to 999 9 gallons or liters Common Functions This subsection provides instructions for common functions on the Gasboy Atlas pumps dispensers Understanding Date Codes A two letter date code is stamped on the serial number plate before the serial number This code shows the month and year of manufacture To determine the age of the equipment for watranty purposes refer to the date code Figure 3 5 Serial Number Plate Options ATLAS f AcGAsBOY Mfg K NC
20. 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 7 The Atlas Fuel System Pump Dispenser Components The external components of a Gasboy Atlas pump dispenser Electronic Retail Unit are shown in Figure 3 2 Electronic units have digital displays as opposed to mechanical displays In units that are Electronic Commercial instead of Retail the external components are almost the same with the exception that there are only totalizers PPU and the main display showing the gallons pumped Figure 3 2 Atlas Electronic Retail Unit Electronic Retail Unit Boot Area Ww Control Lever Ng Nozzle and s Pump Handle ak 313DIESEL Electro mechanical Totalizer Digital Main mma Display MME Gallons Display o da Lacs cms O atlas Gasboy Atlas Logo i EE Door Lock Access Door Page 8 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Pump Dispenser Components The Atlas Fuel System Commercial Mechanical 9100 Figure 3 3 Commercial Mechanical 9100 Control Lever e Q148 mE Totalizer and Boot Area om Volume Display Door Lock ___ ee oo Access Door Commercial Electronic 9800 Figure 3 4 Commercial Electronic 9800 a Boot Area T lt _ r 3 Door Lock E Access Door 2 MDE 4363F Atlas Fuel Systems Owner s Manual
21. 5 can result in leaks For E85 unexpected failures of components may also occur resulting in fire or explosion or environmental damage When installing components in E85 units refer to Important Requirements for E85 Units on page 15 When dispensing alternative fuels such as E85 or fluids such as DEF verify with the manufacturer if the material of all plumbing components are compatible with the fuel E85 or fluid being dispensed Page 38 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance The Atlas Fuel System Special Setup Required for Aircraft Fueling INQ TT ie Aircraft require finely filtered fuel Improperly filtered fuel could cause the engine to fail Do not use Gasboy pumps dispensers for direct fueling of aircraft without auxiliary filters separators and other equipment is required to ensure product purity Adjusting the Belts Suction Pumps Only With the proper care belts give exceptionally good service A loose belt not only cuts down dispensing speed due to slipping but also results in excessive wear For more information refer to Preventive Maintenance Table on page 60 This service must not be done by untrained individuals Preserve the Finish of Your Pumps Nearly all gasoline pumps are installed outdoors where their surfaces are subjected to the weather conditions As a result it is required to give the finish a reasonable amount of care if an attrac
22. 63F Atlas Fuel Systems Owner s Manual September 2011 Programming 8800 Models The Atlas Fuel System Manager Keypad Key Definitions and Use Key s 0 9 F1 F2 STotals Vol Total ENTER CLEAR Definition Use Numeric Values Function 1 Used to start dispenser programming and sequence among programming and function codes In general each depression of F1 key will take user back to a previous programming function selection Depressing F1 from the normal dispenser state will always initiate programming mode Note Displays are always activated during programming mode Function 2 Used to exit programming mode and return to normal mode Money Totals Used to display money totals by side and grade This key does not require a security code CLEAR key is used to exit money totals mode Volume Totals Used to display volume totals by side and grade This key does not require a security code CLEAR key is used to exit volume totals mode Value entry keys sends the entered value to pump Clear key Used to clear last keypad entry and exit money and volume total mode Pin Code Entry e Press FI e Enter 4 digit ID default 1s 2222 and press ENTER e Press F1 to exit any command code Press F2 to return to normal operation e From Level 1 after entering pin code you may enter any command code directly Command Code 1 Program PPU Press 1 and then press ENTER e Select Side 1 or 2 and then p
23. 853K and 9852KTW1 models the belt can be tightened by loosening the cap screw which holds the idler arm and sliding the arm to obtain the correct belt tension of 6 3 4 Ibs 3 4 30N 3 3N When the adjustment is complete remember to retighten the cap screw On the 9850 model the belt can be tightened by loosening the motor mounting bolts and sliding the motor to obtain the correct belt tension of 6 3 4 Ibs 3 4 30N 3 3N When the adjustment is complete remember to retighten the motor mounting bolts Safety Information For safety information before operating pumps dispensers refer to Important Safety Information on page 3 AN WARNING Running vehicles can generate sparks which could ignite fuel Running vehicles could create a safety hazard such as a fire or an explosion Never dispense fuel into a vehicle with its motor running Preparing for Servicing the Pumps Dispensers Page 52 This section provides instructions for preparing your site for servicing done by a Gasboy trained ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit AN WARNING Unapproved modifications could result in hazardous conditions
24. CPU Switch Settings Series 9800 Only Including DEF 9862 Units JP8 or SW1 8 RS 485 Emergency Pump Stop Detection This switch must be set to open default to enable RS 485 pump stop detection The Gasboy RS 485 pump stop switch when activated places a serial break character on the RS 485 lines When SW1 8 or JP8 is open this breaker character triggers the termination of the sale s immediately if a transaction s is in progress This switch must be set to closed in TopKAT or CFN Plus system Communication to disable RS 485 pump stop detection This resolves the issue associated with the false break characters being detected that may be introduced when 485 half duplex communication is used ESTOP Detection SW1 8 JP8 Enabled Open Disabled Closed JP9 only exists on new boards and is not used SW2 For Older and Newer CPU Boards Page 24 Notes 1 Four position switch bank only exists in older boards C06394 M05318 M05346 for the Series 9800 2 Ten position switch bank only exists on newer Series 9800 CPU Boards M06333A For older CPU Board this four position switch pack serves a dual purpose e As an address setting when communicating using the Gasboy RS 485 PAC Data Protocol CFN or TopKAT or e When using a pulse output board as a pulser output rate selector for pulser data to be sent to a fuel management system other than a Gasboy CFN or TopKAT For newer CPU Board this ten position bank serves a dual purpose e As an
25. EF or vice versa Use stainless steel Prover Cans for DEF DEF and engine fuel must not be mixed with each other or be contaminated by each other Else damage to a vehicle s engine or pollution control devices could occur DEF crystallizes as its water base evaporates Pouring out liquid will not guarantee that no corrosive DEF remains in the Prover Can DEF must not be contaminated with Diesel fuel contaminants or other fluids or materials Such contamination can cause serious damage to vehicle catalytic converters e Conventional fluid handling precautions are also applicable to DEF e Avoid contact with eyes skin and clothing Ensure that eyewash stations and safety showers are close to the work location DEF is mildly corrosive and non flammable Clean the DEF spill with water and dry the area with clean rags especially areas that contain metallic parts Spilt DEF can be slippery and will corrode certain types of metallic parts Wear eye protection and rubber gloves during any cleanup activity e DEF is heavier than gasoline Be aware that prover cans containers filled with DEF and so on will be considerably heavier than gasoline Page 16 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Site Preparation The Atlas Fuel System Guidelines in Atlas Fuel Systems Documentation and Other Codes The following manuals provide guidelines for installing Atlas Fuel Systems pumps dispensers e MDE 4331 Atlas Fuel Systems I
26. LAY VOLUME METER VOLUME CORRECTION FACTOR NUMBER CORRECTION FACTOR DISPLAY FUEL DENSITY METER 730 GAS NUMBER 840 DIESEL DISPLAY METER CURRENT TEMPERATURE NUMBER TEMPERATURE DISPLAY GROSS GROSS GROSS VOLUME TOTALS VOLUME least significant most significant DISPLAY SOFTWARE ATC VERSION VERSION REAL TIME GROSS NET VOLUME CURRENT TRANSACTION MODE VOLUME TEMPERATURE MANAGER S KEYPAD MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 39 The Atlas Fuel System Shear Valve Displaying Pump Totals During service it 1s often required to access pump totals This can be done at the POS or at the pump dispenser Access 1s simple through the manager keypad To View Side 1 Totals 1 Press TOTAL Combined cash and credit total appears for Grade 1 Side 1 2 Select grade Read STOTAL for each grade selected 3 Press VOL TOTAL The volume total appears for the grade selected 4 Select grade Read volume totals for the grade selected 5 Press Enter to view Side 2 totals 6 Press Clear to exit Error Codes and Interpretations for 8800 Retail Electronic Units These codes are useful when troubleshooting a problem Side A is the junction box opening and Side B is the opposite side You may observe the following errors Error Code Description 31 Totals Data Error 35 Configuration Data Error 44 Pump Handle Up at Power Up To recover lower the handle resulting in end o
27. M Totalizer SW2 7 Enabled Closed Disabled Open SW2 8 BDM Enable New M06333KXXXX CPU Only This switch must always be set to OPEN for normal operation SW2 9 Software Download Enable New M06333KXXXX CPU Only This switch must be OPEN for normal operation When this switch is closed it enables loading new M06333KXXXX CPU software Software Download Enable SW2 9 Enabled Closed Disabled Open SW2 10 New M06333KXXXX CPU Only This switch is not used Page 26 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Battery Backup Power Supply for Series 9800 The Atlas Fuel System Battery Backup Power Supply for Series 9800 Figure 3 14 9800 Series Power Supply P1 Connector Series 9800 models can be equipped with an optional battery backup power supply This allows the last transaction data to be displayed for a minimum of 15 minutes After the batteries reach a certain low voltage point the power will automatically shut off If you have to shut off the battery power before the low voltage point is reached momentarily disconnect and then re connect the cable that plugs into P1 on the power supply The Atlas DEF 9862 cold and warm weather units do not use the battery on the power supply Information for ATC Series 9800 Only By activating the magnet located at the opposite side of the totalizer various items will appear on the display 1 Volume Display Displays uncompensated volume
28. NN KA GASBOY Atlas Fuel Systems Owner s Manual MDE 4363F Computer Programs and Documentation All Gasboy computer programs including software on diskettes and within memory chips and documentation are copyrighted by and shall remain the property of Gasboy Such computer programs and documents may also contain trade secret information The duplication disclosure modification or unauthorized use of computer programs or documentation is strictly prohibited unless otherwise licensed by Gasboy Federal Communications Commission FCC Warning This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense Changes or modifications not expressly approved by the manufacturer could void the user s authority to operate this equipment Approvals Gasboy Greensboro is an ISO 9001 2000 registered facility Underwriters Laboratories UL California Air Resour
29. September 2011 Page 9 The Atlas Fuel System Pump Dispenser Components General Description 9800 Except 9820 The Gasboy Atlas dispensing units are UL listed and are available in a self contained suction pump package or in a remote controlled dispenser package Both packages offer varieties of models which are available as single hose outlets or dual hose outlets with single or dual product capability The self contained models are available in standard flow SF models up to 15 GPM 56 LPM 12 IGPM high flow HF models up to 22 GPM 83 LPM 18 IGPM single hose super high flow SHF models up to 40 GPM 151 LPM 33 IGPM single hose ultra high flow UHF models up to 50 GPM 189 LPM 42 IGPM The rate of delivery for the remote controlled packages will vary according to the size of the submersible pump The delivery rate of both packages will also vary depending on the installation conditions and added accessories Visual identification can be quickly made between Commercial and Retail pumps dispensers Commercial pumps dispensers have displays only for gallons liters on a side s when Retail has displays for both gallons liters and cost per gallon liter The Atlas units can either have Side Load or Front Load nozzle configuration The Atlas pump dispenser offers the following features Models SF Mechanical Commercial 9152K 9152KTW1 9152KTW2 9152KX 9152KXTW1 9152KXTW2 SF Electronic Commercial 9852K 9852KTW1 9852KT
30. W2 9852KX 9852KXTW1 9852KXTW2 SF Mechanical Retail SF Electronic Retail HF Mechanical Commercial 9153K 9153KTW2 9153KX 9153KXTW2 HF Electronic Commercial 9853K 9853KTW2 9853KX 9853KXTW2 HF Mechanical Retail HF Electronic Retail SHF Mechanical Commercial 9140K 9140KX SHF Electronic Commercial 9840K 9840KX UHF Electronic Commercial 9850K 9850KX 9850KXTW2 SF Electronic Commercial 9872KX 9872KXTW1 E85 Unit DEF Dispenser Page 10 Suction Pumps Remote Dispensers Features Inlet 1 1 2 NPT female threads Discharge 1 NPT female threads can be reduced to 3 4 with bushing Motor self contained 1 HP continuous duty 8752K 8752KTW1 8752KTW2 8752KX 8752KXTW1 8752KXTW2 8852K 8852KTW1 8852KTW2 8852KX 8852KXTW1 8852KXTW2 Inlet 1 1 2 NPT female threads Discharge 1 NPT female threads Motor self contained 1 HP continuous duty 8753K 8753KTW2 8753KX 8753KXTW2 8853K 8853KTW2 8853KX 8853KXTW2 Inlet 2 NPT female threads Discharge 1 NPT female threads Motor self contained 2 1 HP continuous duty Inlet 2 NPT female threads Discharge 1 NPT female threads Motor self contained 1 1 2 HP continuous duty Inlet 1 1 2 NPT female threads Discharge 3 4 NPT female threads 9862KX Bottom Inlet 1 BSPP female threads Side Inlet 1 BSPP male threads Discharge 1 BSPP male threads MDE 4363F Atlas Fuel Systems Owner s Manual September 2
31. address setting for the Gasboy RS 485 PAC Data Protocol CFN or TopKAT Unit of Measure BDM Enable Software Load Enable and Electro mechanical Totalizer Enable or e As a pulse output rate selector when pulser data is sent to a fuel management system other than Gasboy CFN or TopKAT Unit of Measure BDM Enable Software Load Enable and Electro mechanical Totalizer Enable Address Switches A unique address identifier must be set when the Series 9800 is connected to the Gasboy RS 485 pump loop via the 9800 RS 485 I F PCB There are 16 possible address combinations Addressing must start at 1 and continue sequentially through 16 The physical wiring order does not have to correspond with the address order that is the first unit on the RS 485 loop does not have to be address With the TopKAT top mounted option the address must be set to 1 The following chart gives the switch settings and address selections MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Address SW2 1 SW2 2 SW2 3 SW2 4 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 CPU Switch Settings Series 9800 Only Including DEF 9862 Units Address SW2 1 SW2 2 SW2 3 SW2 4 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 Cl
32. as Fuel Systems Owner s Manual September 2011 Index Index A Acronym table 1 Alert symbol 1 B Barricading 1 C Caution warnings 1 Component inspections 42 D Danger warnings 1 Date codes 6 E Electrical Shut off 1 Emergency Electrical shut off 1 In Case Of 3 Personnel contacting 2 Encore series Diagram 1 Evacuation 1 Explosions Preventing F Fires Preventing G General inspections 41 Glossary 1 I Inspections Component 42 General 41 M Maintenance 40 Safety warnings 41 O Operating pumps dispensers 12 P Parts Replacing 39 Personnel Emergency informing 2 R Replacement parts 39 S Safety Maintenance 41 Safety Information 1 Alert symbol 1 Barricading 1 Emergency electrical shut off 1 Emergency personnel 2 Evacuation 1 NFPA regulations 1 Open flames 2 Preventing explosions and fires 1 Regulations 1 Replacement parts 1 Safety symbols 1 Shut off 1 Signal words 1 Smoking 2 Sparks 2 Warning words 1 Working alone 2 Safety symbols 1 Service Preparing for 38 Warranty 39 Shut off 1 Emergency electrical 1 Signal words Safety 1 Specialized training 39 T Training Specialized 39 W Warning words 1 Warnings 1 Warranty service 39 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Index 1 Bar Keepers Friend is a registered trademark of SerVaas Laboratories Inc Flexsteel is a registered trademark of Veyance Technologies
33. as 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 A WARNING Gasoline DEF ingested may cause dom unconsciousness and burns to internal organs Do not induce vomiting Keep airway open Oxygen may be needed at scene Seek medical advice immediately AY WARNING DEF generates ammonia gas at higher temperatures When opening enclosed panels allow the unit to air out to avoid breathing vapors If respiratory difficulties develop move victim away from source of exposure and into fresh air If symptoms persist seek medical attention AY WARNING Gasoline inhaled may cause unconsciousness he E and burns to lips mouth and lungs A Keep airway open Seek medical advice immediately AY WARNING Gasoline DEF spilled in eyes may cause burns to eye tissue Irrigate eyes with water for approximately 15 minutes Seek medical advice immediately AY WARNING x Gasoline DEF spilled on skin may cause burns Wash area thoroughly with clear water Seek medical advice immediately N WARNING DEF is mildly corrosive Avoid contact with eyes skin and clothing Ensure that eyewash stations and safety showers are close to the work location Seek medical advice recommended treatment if DEF spills into eyes IMPORTANT Oxygen may be needed at scene if gasoline has been ingested or inhaled See
34. ax is recommended to protect the surface and prolong the interval between cleaning MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 59 The Atlas Fuel System Preventive Maintenance Preventive Maintenance Table Recommended Components Frequency Stainless Steel sheathing Monthly and lower doors Hoses swivels At lease once a week or ifa customer complaint arises Page 60 Who Performs the Recommended Maintenance Inspection Repair For stains on stainless steel use a cleaner specifically Once every three formulated for cleaning stainless steel Gasboy recommends months in harsh Bar Keepers Friend Ensure that you thoroughly rinse off all environments once a cleaner Ensure that you do not spray water cleaner directly at month or into card readers cash acceptors or printer chutes 1 Owner Inspect Inspect each hose for leaks abuse and excessive wear Repair and test AN WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leaks or damage stop using the pump dispenser and contact your local ASC Inspect each hose break away whip hose and vapor hose for the following wear or damage Bulges Reinforcement showing e Cracks Soft spots Damage Tears Flattened spots Weaknesses Holes wear through Ensure
35. blem description including all symptoms Give the serviceman complete and accurate information This ensures faster repairs and keeps downtime costs to a minimum Warranty Service All warranty service must be performed by an ASC Failure to use an ASC to perform warranty service could result in loss of warranty coverage Replacement Parts Use only genuine Gasboy replacement parts and retrofit kits on your pump dispenser AN WARNING Non Gasboy replacement parts may create safety hazards and violate local regulations Non Gasboy replacement parts could also affect the pump dispenser s performance reliability and warranty Use of non Gasboy replacement parts could create a hazardous condition such as fire explosion or electrical shock Only use Gasboy replacement parts and retrofit kits MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 53 The Atlas Fuel System Preventive Maintenance Specialized Training For safety reasons do not attempt to service Gasboy pump dispenser yourself unless you have been trained and certified by Gasboy or an authorized Gasboy certified trainer A WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must ser
36. boy pumps dispensers can become damaged if cleaned with harsh cleaners Harsh cleaners can damage the units adversely affecting the appearance of the units Do not use solvents harsh detergents degreasers steel wool abrasive cleaners or petroleum based solvents on the pumps dispensers Clean with nonabrasive cloth or paper towel with commercial Owner glass cleaner Do not use window cleaner with Ammonia Do not wax or use any abrasive cleaners or fuels Page 70 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Glossary Glossary A Access Door Locked Access door on pump dispenser Authorized Service Contractor ASC A Gasboy trained and authorized service contractor B Boot Area The part of the pump dispenser where the nozzle is stored Breakaway Device attached to the hoses on pump dispensers that detaches if a customer drives off with the nozzle still attached to the cars the device protects against gasoline being spilled and a resulting fire and it minimizes damage to the pump dispensers in the event of a drive off and stops fuel flow through the separated hose Component Inspections Periodic inspections by the station manager of various pump dispenser components the station manager must look for signs of damage and wear for each component Note For a list of components and the recommended frequency of inspection refer to Component Inspections on page 57 Couplings Plumbin
37. cated over the tabs of the bezel assembly Lift the bezel assembly upward and remove it from the unit When reattaching the bezel to the dispensing unit ensure that the top inner edge of the bezel assembly slides into the U shaped channel located on the upper edge of the dispensing unit Page 30 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Programming 8800 Models The Atlas Fuel System Programming 8800 Models General Programming Programming the unit is divided into three levels Level 1 2 and 3 Level 1 codes are explained here The default code for level is 2222 This code can be changed for station security however losing the codes will require a master reset of the unit Reprogramming codes found in Level are shown below CC 1 Manual programming of PPU unit pricing Pricing can also be downloaded through the Two wire communication using the Point Of Sale POS device CC 2 Sitting mode of operation as being stand alone isolates sale control from the POS or Two wire unit control through the POS CC 3 Programming Volume Allocation This basically sets the maximum sale size in units of measure gallons for example CC 4 Manual Blank and Five Button Preset This dual use code allows turning the displays off manually or is used to activate different preset modes depending on the options included with the unit CC 5 Test Programmable Customer Preset This code is used to initiate testing for the 5 Butto
38. ces Board CARB UL File Products listed with UL Executive Order Product MH4314 i Pee and self contained pumping G 70 52 AM 7873 alance Vapor Recovery G 70 150 AE VaporVac MH10581 Key control unit Model GKE B Series Card reader terminals Models 1000 1000P Site Controller Model 2000S CEN Series Data entry terminals Model TPK 900 Series Fuel Point Reader System National Conference of Weights and Measures NCWM Certificate of Compliance CoC Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program NTEP NCWM has issued the following CoC CoC Product Model CoC Product Model Model 9100 Retail Series 8700 9100 Commercial 8700K 8800K ME Dispenser Series 9700 Seres P1 puspenset Series Mose Alas 9100K 9200K 9800K 1000 Series FMS Product 95 136 Dispenser 9800 Series 91 057 Controller 2000S CEN Series Trademarks Non registered trademarks Registered trademarks AtlasTM ASTRA Consola Fuel Point Infinity Gasboy Additional US and foreign trademarks pending Keytrol Other brand or product names shown may be Slimline trademarks or registered trademarks of their respective holders This document is subject to change without notice E mail literature gasboy com Internet http www gasboy com 2011 GASBOY gt All Rights Reserved AOU Id ITUTE EUM EQUIPMENT INS Table of Contents Table of Contents 1 Introduction
39. d Dispenser Units Fueling Unit with No Motor and Pump in the Bottom Turn on the pump handle If AC is present on the AUTH Control Feed line the reset cycle begins and the submersible pump switches on The display Electronic Unit e Goes blank for one second e Shows all 8s for one second 3 seconds for US Gallons or if JP5 or SW1 5 for older CPU boards 1s set e Goes to 0 000 gallons or 0 00 liters and remains until fueling begins The display mechanical units e Resets to 0 000 gallons or 0 00 liters The user begins to dispense fuel The remote dispenser continues to run until one of the following conditions occurs These conditions turn off all relays as follows e The handle is turned off e The AUTH Control Feed line is turned off AC power line to pump dispenser is turned off at the POS MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Operating Sequence for Series 9800 Only The Atlas Fuel System e A pulser error 1s detected electronic unit only e A time out is reached if the unit is programmed with a time out value If connected to a fuel management system the time out loaded into the system will be used commercial electronic only The unit will turn off if it is idle for a preprogrammed time when no fuel is flowing 9800 models A quantity of 990 000 gallons 9900 00 liters 1s reached If connected to a fuel management system the limit set in the system will be used e The pump
40. d Other Codes MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 17 The Atlas Fuel System Site Preparation Hoses Hoses must be UL approved and conductive from end to end To determine the hose length refer to Determining Hose Length Note When determining the hose length the effect of adding breakaways adds significantly to the actual hose length AN WARNING Hoses of excessive length may create a trip hazard Serious injury could occur as a result of tripping over an excessively long hose Do not use excessive length hoses Also ensure that hose retrievers are installed and are in good operating condition Do not install soft wall hoses they commonly cause a small sale to indicate when the unit is activated and the nozzle is closed Determining Hose Length To determine the correct hose length for various types of hoses refer to the following table Type Length Standard hardwall 5 8 or 3 4 ID without breakaway 10 feet 6 inches Standard hardwall 5 8 or 3 4 ID with breakaway 9 feet 6 inches Standard breakaway whip hose 1 foot O inches Install Warning Labels and Signs for Customers Page 18 Install warning labels and signs to ensure that customers are warned of potential safety hazards Ensure that the warning labels and the signs are readily visible At a minimun install the following signs e Turn off the vehicle before fueling e No smoking do not use matches or lighters
41. d result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit Warning tags and Once a week Inspect for and replace all missing damaged or unreadable e Owner Inspect operating instructions warning tags or operating instructions e Owner or ASC Replace Hose continuity Once a month Verify that the hose continuity including breakaway whip hose Owner lInspect complies with the hose manufacturer s requirements ASC only Repair Page 64 Z WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance Recommended Components Frequency Meters Valves Once a month after drive offs or as notified about a potential leak 1 The Atlas Fuel System Who Performs the Recommended Maintenance Inspection Repair Whenever possible Gasboy recommends removing power Owner lInspect to the unit before performing these inspections ASC only Repair Block off the pump dispenser to prevent custome
42. d the display because the display may appear hazy Do not wax the displays on the pump dispenser MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 69 The Atlas Fuel System Recommended Components Frequency Wash pump dispenser As required Note Gasboy recommends more frequent cleaning for pumps dispensers located in salty or corrosive environments such as near the ocean or near pollution sources Display windows As required Preventive Maintenance Who Performs the Recommended Maintenance Inspection Repair Clean with automobile cleaning products Clean plastic surfaces Owner and poly carbonate graphics with water and mild detergent Do not wash with a hose Do not use window cleaner with Ammonia on Electronic display windows Adhere to the following guidelines for washing the pumps dispensers Clean and protect your equipment with automobile cleaning and protection products Clean plastic surfaces and poly carbonate graphics with a solution of water and mild detergent Use a soft cloth paper towel or sponge to clean displays separately Window cleaners are preferred e Wash pumps dispensers by hand or use a hose nozzle set to a fine gentle spray CAUTION Moisture can damage the internal components of a pump dispenser Internal components exposed to moisture may not operate correctly Do not use a pressure washer to clean the pumps dispensers The exterior surface of Gas
43. death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance The Atlas Fuel System Recommended Who Performs the Components Frequency Recommended Maintenance Inspection Repair Leaks external Once a week or 1 Inspect the following for any signs of damage or leaks such Owner lInspect as notified about as cracks or cuts ASC only Repair a potential leak Couplings and test Hose outlet castings Swivels 2 Review all documentation provided by each component s manufacturer 3 If you find any leak stop using the pump dispenser and Displays Once a week 1 make arrangements to repair the leak AN WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leak or damage stop using the pump dispenser and contact your local ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must servic
44. e supplied to the input contacts of the submersible starter relay 2 When the pump handle is switched on power 115 230 VAC International is supplied to the electric reset motor which immediately begins to reset the values on the pump non computer register to zero 3 When the reset is complete power is removed from the reset motor and the internal switches in the reset unit change to the normally open contacts This supplies power 115 230 VAC International to the submersible starter relay which in turn closes and supplies power to the submersible motor If a starter relay is not used the hot leg is supplied directly to the submersible motor The remote dispenser contains a slow flow fast flow or closure type solenoid valve which opens at this time At the same time that the valve opens the Reset Complete line goes to 115 230 VAC International 4 The user begins to dispense fuel 5 The register displays the total volume If an optional pulser kit is attached it supplies pulses which may be recorded by an external Fuel Management System such as the Gasboy Series 1000 6 The fueling transaction continues to run until the user turns off the pump handle MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 43 The Atlas Fuel System Operating Sequence for Series 9800 Only Operating Sequence for Series 9800 Only Page 44 The exact sequence of events that occur during the operation of the pump or remote dispenser is de
45. e a Gasboy unit Inspect displays for proper reading of all digits e Owner Inspect Electro Mechanical Units 2 Verify that displays are properly backlit ASC Repair and test MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 63 The Atlas Fuel System Preventive Maintenance Recommended Who Performs the Components Frequency Recommended Maintenance Inspection Repair Breakaways Once a week or 1 Inspect breakaways for secure connection to hose and for e Owner Inspect after drive offs Note Not all breakaways are reusable after separation Follow manufacturer directions for inspection and resetting for inspection and resetting adjustable types 4 any leaks ASC only Repair AN WARNING Leaking fuel can be ignited causing a fire or explosion and test Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leak or damage stop using the pump dispenser and contact your local ASC For units with hose retrievers position the breakaway coupling between the retriever connection to the hose and the nozzle The breakaway whip hose must be attached to the nozzle Consult the breakaway manufacturer for any additional required inspections If repair is required call an ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly coul
46. e installed ensure that the installer considers the guidelines in the following section Important Requirements for E85 Units The following equipment and materials are required to properly install E85 units UL listed E85 Hose Q13486 e Veyance M Flexsteel Futura Ethan All for E85 e Veyance Flexsteel Futura for E25 Note Extended Reach hoses are not available for the E85 applications UL listed E85 Nozzle M11298 OPW 21GE Note Approved for use with the E85 dispensers as required under UL 87A UL listed E85 Swivel N23748 04 OPW 241 TPS 0492 Note Approved for use with E85 dispensers as required under UL 87A UL listed E85 Shear Valve T19695 23 OPW 10P 0152E85 Note Approved for use with E85 dispensers as required under UL 87A UL listed E85 Breakaway N23010 10 OPW 66V 0492 Note Approved for use with E85 dispensers as required under UL 87A Filter Use only filters specifically marked for use with E85 UL listed Pipe Sealant Use only UL listed TPS PTFE Pipe Sealant manufactured by SAF T LOC International Corp UL listed Teflon Tape Use only UL listed Taega Technologies Inc Teflon tape Note Teflon tape must be used only at the inlet pipe connection IMPORTANT INFORMATION For E85 Front Load units side B is the side with the Junction Box For nozzle boot positioning for the different models refer to Atlas Foundation Diagrams section in MDE 4331 Atlas Fuel Systems Installation Manual MDE 4363F A
47. e of lubricant used on the door locks of pumps dispensers Hose Outlet Castings Fuel discharge port on the pump dispenser where the hose is attached to the unit Hose Retriever Device option at the pump dispenser that retracts and pulls the hose close to the pump dispenser after the customer has completed fueling Hydraulic Connections Any fuel handling hardware where castings hoses and pipes are joined through threads O rings or other seals Inspections Refer to Component Inspections on page 57 and General Inspections on page 56 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Glossary Junction Box The explosion proof box on the pump dispenser that contains the main electrical connections between the pump dispenser and the main power and data source L Lock Oil Type of lubricant used on the door locks of pumps dispensers M Meter Device in the pump dispenser that measures fuel flow Mode of Operation The method of functioning of the pump dispensers N National Fire Protection Association NFPA An international nonprofit organization dedicated to protecting lives and property from the hazards of fire publishes 280 recognized codes and standards including the National Electrical Code Nozzle On the pump dispenser the projecting part at the end of the hose that regulates and directs the flow of fuel Nozzle Hook In the boot area on the pump dispenser place upon which the nozzl
48. e power to the unit before servicing it AN WARNING Self contained pumps have a pinch point between the belts and the pulleys Severe injury could occur if part of the body is pulled into the pinch point To prevent injury when inspecting self contained units do not place your hands near the belts pulleys or motors Turn off the power before servicing the unit Do not operate the unit with the door removed 2 Inspect belts for fraying cracks 3 Inspect pulleys for excessive wear in grooves and excessive bearing play Tank Every six months 1 Monitor water levels in tank with electronic tank monitor or Owner Inspect water detection pasted on tank measuring stick 2 If repair is required call an ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 67 The Atlas Fuel System Recommended Components Frequency Nozzle hooks and shafts Every six months Mechanical computers Every six months Door locks Every six months or if door locks become difficult to open and close Water in Tank After every fuel tank fill up Page 68 Preventive Maintenance Who
49. e price range arms MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 29 The Atlas Fuel System Changing the Price for the Mechanical Retail Pump 3 There are three range arms located in the variator section One sets the tenths of a cent position one sets the one cent position and the last one sets the ten cents position To change a setting grasp a range arm and raise it to clear the range arm locator and relocate the range arm to the required setting Ensure that the range arm is totally bottomed on its setting Repeat this for all range arm settings if required Figure 3 17 Location of Range Arms Y Range Arm Locator 4 To change the money unit setting locate the control lever which is located above the variator section on the same level as the price display There are three available positions 0 00 1 00 and 2 00 Remove the cotter pin grasp the lever and raise it slightly to clear the position locators Position the lever to the required setting and release Reinsert the cotter pin through the lever and plate Note If the lever does not move to the required position rotate the right hand money wheel until the lever is free to move Figure 3 18 Control Lever 5 If you have difficulty reaching the money shift lever when changing prices remove the two cap screws lo
50. e rests when the pump dispenser is not in use Occupational Safety and Health Association OSHA U S agency that develops and enforces regulations for the safety and health of workers engaged in interstate commerce Price Per Unit PPU The price of each unit of gasoline dispensed Pump A device that uses a self contained pumping unit and motor to move fuel from the storage tank MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Glossary 3 Glossary Glossary 4 Pump Pulleys Ordinary pulley wheels used on self contained suction pumps and motors Seals Substances used to prevent seepage of gasoline or vapor from the pump dispenser Shear Valves Device at the base of each pump dispenser that shuts off the fuel flow in case of a vehicle impact or fire at the base of the pump dispenser Side A Normally the side of the pump dispenser with the electrical junction box For front load units Side A may be the side opposite to the junction box side B The side opposite to that of side A silicone Grease Type of lubricant used on the nozzle hooks and shafts of pumps dispensers Standalone Mode Authorization and payout occur at the pump Submerged Turbine Pump STP Submerged turbine pump in underground storage tank Swivels A fastening that permits the free turning of attached parts to the pump dispenser Volume Allocation The maximum amount of product the pump dispenser will dispenser MDE 4363F Atl
51. eneral inspection of each pump dispenser as follows e Each week to ensure that all pumps dispensers are operating properly e Whenever you receive a complaint about potential unit problems As part of your general inspection inspect all areas for signs of damage or sharp edges Replace any missing or damaged warning labels Gasboy also strongly recommends that an ASC inspects the equipment periodically as outlined in the next subsection AN WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leaks or damage stop using the pump dispenser and contact your local ASC AN WARNING Personnel servicing a pump dispenser can be injured if the pump dispenser is not barricaded to all unauthorized personnel and vehicles If proper precautions are not taken the person servicing the unit can be injured by a vehicle Before servicing a pump dispenser evacuate all unauthorized persons and vehicles then use safety tape or cones as barricades MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance The Atlas Fuel System Component Inspections To schedule component inspections refer to Preventive Maintenance Table on page 60 The station owner must only inspect for problems For safety reasons several tasks in the Preventive Maintenance Table on
52. epair performing these inspections and process and test 2 Block off the pump dispenser to prevent customers from 3 operating the pump dispenser during procedure Access and Insert sump pump into tank and draw off water MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance Recommended Components Frequency Wax pump dispenser Every six months or once a month in harsh areas Note Gasboy recommends more frequent waxing for pumps dispensers located in salty or corrosive environments such as near the ocean or near pollution sources The Atlas Fuel System Who Performs the Recommended Maintenance Inspection Repair Wax metal parts with high grade detergent resistant Owner nonabrasive automobile wax Do not wax textured surfaces Adhere to the following guidelines for waxing the pumps dispensers Before waxing clean the pumps dispensers and touch up deep scratches on painted surfaces Wax painted surfaces with a high grade long lasting detergent resistant non abrasive automobile wax CAUTION Textured surfaces of Gasboy pumps dispensers can become damaged if waxed Waxing the textured surfaces can damage the units adversely affecting the appearance of the units Do not wax textured surfaces CAUTION The main and PPU displays of Gasboy pumps dispensers can become difficult to read if waxed Waxing the main and PPU displays may impede a customer s ability to rea
53. es access to electrical components or the electronics of the dispenser requires total electrical shut off of that unit Understand the function and location of this switch or circuit breaker before inspecting installing maintaining or servicing Gilbarco equipment Evacuating Barricading and Shutting Off Any procedure that requires access to the pump dispenser or STPs requires the following actions OSAGA e An evacuation of all unauthorized persons and vehicles from the work area e Use of safety tape cones or barricades at the affected unit s A total electrical shut off of the affected unit s MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Read the Manual Read understand and follow this manual and any other labels or related materials supplied with this equipment If you do not understand a procedure call a Gilbarco Authorized Service Contractor or call the Gilbarco Support Center at 1 800 800 7498 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 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 e
54. eviations and acronyms used in this manual Note For more detailed definitions refer to Glossary on page G 1 Term Description AC or ac Alternating Current ASC Authorized Service Contractor ATC Automatic Temperature Compensation CFR Code of Federal Regulations CPR Cardiopulmonary Resuscitation CPU Central Processing Unit DC or dc Direct Current DEF Diesel Exhaust Fluid DIP Dual In line Package GPM or gpm Gallons Per Minute HF High Flow LPM Liters Per Minute NEC National Electrical Code NFPA National Fire Protection Association OSHA Occupational Safety and Health Association PCB Printed Circuit Boards preferred term board POS Point Of Sale PPG Pulses Per Gallon PPL Pulses Per Liter PPP Programmable Pump Preset PPU Price Per Unit that is price per gallon or liter RAM Random Access Memory sits ROM Read Only Memory RS Request to Send modem application SF Standard Flow SHF Super High Flow STP Submerged Turbine Pump UHF Ultra High Flow UL Underwriters Laboratory VAC or vac Volts Alternating Current Page 2 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Important Safety Information 2 Important Safety Information Note Although DEF is non flammable Diesel is flammable Therefore for DEF cabinets that are attached to Diesel dispensers follow all the notes in this section that pertain to flammable fuels This section introduces the hazards and safety p
55. f sale and restart new sale Shear Valve AN WARNING High alcohol percentage fuels such as E85 or fluids such as DEF may be incompatible with certain plumbing materials and hydraulic components Use of incompatible materials or components with E85 can result in leaks For E85 unexpected failures of components may also occur resulting in fire or explosion or environmental damage When installing components in E85 units refer to Important Requirements for E85 Units on page 15 When dispensing alternative fuels such as E85 or fluids such as DEF verify with the manufacturer if the material of all plumbing components are compatible with the fuel E85 or fluid being dispensed Note The Atlas 9862 utilizes a special shear valve manufactured by OPW model 60 Page 40 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Shear Valve The Atlas Fuel System CAUTION Applicable to Dispensers Rated for E85 Use Do not use tape at the very end of the pipe nipple to avoid tape entering the dispenser hydraulics Tape in the hydraulics can cause failures of valves nozzles or other significant problems Use only UL listed TPS PTFE Pipe Sealant manufactured by SAF T LOC International Corp Use only UL listed Taega Technologies Inc Teflon tape Note Teflon tape must be used only at the inlet pipe connection Shear valves required by NFPA 30A are intended to shut off the flow of fuel at the dispenser base hydrau
56. ference View Viton Disc ii Page 42 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Operating Sequence for Series 9100 Only The Atlas Fuel System Operating Sequence for Series 9100 Only Pump 1 AC Power 115 230 VAC International must be provided to the pump motor feed Reset the motor feed slow flow reset motor feed if applicable 2 When the pump handle is switched on power 115 230 VAC International is supplied to the electric reset motor which immediately begins to reset the values on the pump s non computer register to zero 3 When the reset is complete power is removed from the reset motor and the internal switches in the reset unit change to the normally open contacts This supplies power 115 230 VAC International to the pump motor and to the reset complete line If this pump contains a slow flow fast flow or closure type solenoid valve the valves will open at this time 4 The user begins to dispense fuel 5 The register displays the total volume If an optional pulser kit is attached it supplies pulses which may be recorded by an external Fuel Management System such as the Gasboy Series 1000 6 The fueling transaction continues to run until the user turns off the pump handle Remote Dispenser 1 AC power 115 230 VAC International must be provided to the submersible feed and slow flow reset motor feed If a submersible starter relay is used AC power 115 230 VAC must b
57. g used to join ordinary pipes or hoses together see also Breakaway Cradle Refer to Boot Area Date Code Two letter code that is stamped on the pump dispenser before the serial number shows the month and year of manufacture DEF Diesel Exhaust Fluid A clear colorless non toxic non flammable non combustible liquid It is made up of 32 5 urea with the balance distilled or de ionized water Urea and water are completely miscible and do not separate in storage DEF is mildly corrosive MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Glossary 1 Glossary Glossary 2 Dispenser A device that uses an STP in the storage tank to move fuel from the storage tank Drive Offs Situations where customers forget to remove the nozzles from the tanks in their cars and drive away from the pump dispenser the hose detaches from the pump dispenser at the breakaway Electrical Junction Box Refer to Junction Box on page G 3 E85 E85 is an alcohol fuel mixture that contains up to 85 denatured fuel ethanol and gasoline or other hydrocarbon by volume General Inspections Weekly inspections by the station manager of all of the pumps dispensers on the site the station manager must ensure that all pumps dispensers are operating properly that no warning labels are missing and that there is no evidence of damage or sharp edges Grade Quality of fuel such as unleaded or premium Graphite Lubricant Typ
58. he Series 9800 program is configured for Liters or Imperial Gallons this switch will control whether pump pressurization is enabled If a pump has been idle for more than ten minutes or this 1s the first use after start up a maximum of 0 02 units of unrecorded volume will be pumped into the pump hydraulics during the pump s segment test Pressurization SW1 5 JP5 Enable Closed Disable Open SW1 6 or JP6 Authorization This switch allows activation of the Series 9800 from some types of fuel management systems When the switch is closed a 115 VAC 230 VAC international signal must be present on the AUTH Control Feed line for pump activation to occur required setting for Series 1000 TopKAT mechanical and all non Gasboy systems When open the Series 9800 ignores the AUTH Control Feed line normal setting for CFN TopKAT top mount TopKAT electronic or no fuel system Authorization SW1 6 JP6 Fuel System Yes Closed Series 1000 TopKAT mechanical All Non Gasboy systems No Open CFN TopKAT top mount TopKAT electronic No fuel system JP7 or SW1 7 Electronic Totalizers This switch must be open for normal operation When closed this switch enables the reset of the electronic totalizers For more information refer to Commercial Electronic Series 9800 Only on page 13 Totalizers JP7 or SW1 7 Reset Closed Normal Open MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 23 The Atlas Fuel System
59. his information in the service manual and OSHA documentation Working With Electricity Safely Ensure that you use safe and established practices in working with electrical devices Poorly wired devices may cause a fire explosion or electrical shock Ensure that grounding connections are properly made Take care that sealing devices and compounds are in place Ensure that you do not pinch wires when replacing covers Follow OSHA Lockout Tagout requirements Station employees and service contractors need to understand and comply with this program completely to ensure safety while the equipment is down Hazardous Materials Some materials present inside 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 A WARNING The pump dispenser contains a chemical known to the State of California to cause cancer AY WARNING The pump dispenser contains a chemical known to the State of California to cause birth defects or other reproductive harm Page 4 In an 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 h
60. in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 65 The Atlas Fuel System Preventive Maintenance Recommended Who Performs the Components Frequency Recommended Maintenance Inspection Repair Filter change and strainer New Replace filters and clean strainers regularly An ASC must ASC cleaning Installations perform these tasks After 50 000 gallons 200 000 liters or after one month After first filter change Every 300 000 gallons VAN WARNING 1 0 million liters every six months The pump dispenser contains pressurized flammable fuel and lethal delivery rate ee Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit Inspect and lubricate Every six months To inspect valve operation perform the following tasks If you e Owner Inspect shear valves are not sure which device is the shear valve have the ASC ASC only Repair inspect and lubricate this device for you and test Note Shear valves are typically only used on dispensers If you have pumps consult your installer to determine if the
61. k medical advice immediately Lockout Tagout Lockout Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machine s or equipment or release of stored energy could cause injury to employees or personnel Lockout Tagout applies to all mechanical hydraulic chemical or other energy but does not cover electrical hazards Subpart S of 29 CFR Part 1910 Electrical Hazards 29 CFR Part 1910 333 contains specific Lockout Tagout provision for electrical hazards MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Important Safety Information Hazards and Actions WARNING Spilled fuels accidents involving pumps dispensers or uncontrolled fuel flow create a serious hazard Fire or explosion may result causing serious injury or death Follow established emergency procedures DEF is non flammable However it can create a slip hazard Clean up spills promptly The following actions are recommended regarding these hazards Collision of a Vehicle with Unit Fire at Island Fuel Spill Do not go near a fuel spill or allow anyone else in the area 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 do not remove AC power and do not always stop product flow Take precautions to avoid igniting fuel Do not allow starting of
62. lics area during vehicle impact or fires A single poppet shear valve prevents the fuel flowing from the underground tank A double poppet shear valve prevents fuel flowing from the underground tank and the dispenser In an event that the product fails to exit the dispenser pump hose ensure that the shear valve is not closed A shear valve in the open position is shown in Figure 3 23 Note The shear valve is located inside the dispenser on the lower cross brace in the pit box area Figure 3 23 Open Position of Shear Valve Shear Valve in Open Position Shear Valve Lower Cross Brace 0000349 AN WARNING Shear Valves may stick parochially in the open position causing fuel to flow through a shear valve thought to be closed Always test for proper closing by attempting to dispense fuel into an approved container Fuel must not continue to flow after pressure has been relieved MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 41 The Atlas Fuel System Shear Valve For maintenance information refer to Preventive Maintenance Table on page 60 Figure 3 24 Closed Position of Shear Valve Shear Valve Shear Valve in the OFF Closed Position Figure 3 25 OPW Model 60 Shear Valve Ri Spring Washer Small Snap Ring spring Body Washer Large 1 11 BSPP a 12 41 INA nn far T n ELI WAP vL E y T gt IN NAYUN 2m A A CL T Xj TAL w TFR ISO Re
63. ly To perform the Electronic Calibration ECAL proceed as follows Notes 1 If the unit is two sided then the calibration procedure must be performed individually on each side 2 The calibration switch is located on the junction box side of all three E85 unit types see Figure 3 27 Figure 3 27 Calibration Switch and Junction Box Calibration Switch 1 Slide the back cover and turn the Calibration switch to Calibrate position up a Locate the calibration assembly slide the W amp M seal metal cover towards the exterior of the unit b Locate the inside switch for side B or the outside switch for side A Place the switch in the up position to activate the calibration procedure The number 7 appears in the Most Significant Digit MSD left most digit of the pump display and will remain throughout the procedure see Figure 3 28 Figure 3 28 Turning on the Calibration Switch MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 47 The Atlas Fuel System Operating Sequence for Series 9800 Only After five seconds a can size appears in the two Least Significant Digits LSD digits to the far right of the pump display see Figure 3 29 The can size will appear for five seconds before advancing to the next can size The display will continue to scroll through can sizes until the nozzle is removed and the pump handle is switched on Note If the nozzle is not removed within 10 minutes of tur
64. n Closed 500 Closed Closed Open None Closed Open Open None Open Open Open Note For the last two switch settings no pulse will be sent to the Fuel Management System Pulse Rate 9800 9840 Display Layout 9850 Display Layout 15 XXX XXXX 10 1 XXX X XXXX X 100 1 XXX XX XXXX XX 250 1 XXX XXX XXXX XX 500 1 XXX XXX XXXX XX MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 25 The Atlas Fuel System CPU Switch Settings Series 9800 Only Including DEF 9862 Units Time out Switch When the Series 9800 is in standalone mode it will turn off an active hose if it does not detect pulses for four minutes 15 seconds This time out feature can be disabled by setting switch SW2 4 to OPEN Timeout SW2 4 Enabled Closed Disabled Open SW2 5 and SW2 6 Unit of Measure Setting New M06333KXXXX CPU Only These two switches select the Unit of Measurement US Gallons Imperial Gallons and Liters For information refer to the following table Unit of Measure SW2 5 SW2 6 US Gallons Closed Closed Liters Open Closed Imperial Gallons Closed Open NA Opn Open oU SW2 7 Electro Mechanical Totalizer Enable New M06333KXXXX CPU Only The K model pumps dispensers have an option to use Electro mechanical Totalizers If these are installed then this switch must be set to CLOSED for proper operation of the totalizers This switch does not affect the operation of the electronic totalizer or the mechanical totalizer E
65. n Preset option if used CC 6 Memory Clear This code is useful only to clear a unit displaying an Error Code EC 31 Totals Data Error or EC 35 Configuration Data Error CC 7 Setting Totals Input This code allows setting of non zero totals It is useful for new installs or service old dispensers are replaced or receive certain types of service when the station does not want to restart totals for its dispensers at zero It can only be performed after performing a master reset CC7 or for new units CC 8 display Pump Controller Firmware Version MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 31 The Atlas Fuel System Programming 8800 Models Programming the 8800 Series Retail Electronic Units This section describes the level 1 programming procedures and considerations for the 8800 series Figure 3 19 Programming of 8800 Series Retail Electronic Units Conversion Factor US Gallons Imperial Gallons Liters 1012 Pulses per Gallon Memory Error Code ROM Error RAM Error Sides Single sided Dual sided Pump Controller Software Version The Advantage MPD 70 XX The Advantage Dual amp Quad Highline w LCD Displays Ultra Hi Electronic Calibration w LCD Displays 84 xx Unit Type 1 Grade 2 Grade 3 Grade 4 Grade Two Wire Pump ID 1 16 Level 1 Programming and Data Access Figure 3 20 Manager s Keypad 66000 5 TOTAL YOL 0 MANAGER S KEYPAD Page 32 MDE 43
66. nearby e Use only non breakable approved containers for storing fuel ensure that the container is metal and identified properly for fuel storage e Static electricity hazards during fueling Promptly replace any missing incomplete or illegible labels or operating instructions AN WARNING Static electricity can cause an explosion Static electricity including an electrostatic charge on your body can cause a spark sufficient to ignite fuels and their vapors After getting out of a vehicle touch the metal of your vehicle to discharge any electrostatic charge before you approach the dispenser island MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Operating Pumps Dispensers The Atlas Fuel System Operating Pumps Dispensers This section describes the operation of the pump remote dispenser It provides information on how to e Access the electronic components e Set the standalone switch Tf you are using a point of sale device refer to the manufacturer instructions Electronic Component Access Series 9800 Only Except 9820 Series This section describes the operation of the pump remote dispenser It provides information on how to e Access the electronic components e Set the internal switches e Set the optional battery back up power supply e View and reset the electronic totalizers using the actuator Operate both pumps and remote dispensers 1 Unlock and remove the front panel see Figure 3 10
67. ning the switch to Calibrate position Error Code 574 appears 57 indicates time out and 4 indicates calibration mode error Turn the Calibration switch to Off position down to clear the error Figure 3 29 Displaying the Can Size 2 After the required can size appears on the display remove the nozzle and switch on the pump handle This selects the can size for calibration Notes 1 If the pump handle is switched on for an inappropriate can size and if the dispensing has not started switch off the pump handle Scrolling will resume If dispensing has begun switch off the pump handle turn the Calibration switch to Off position and restart calibration from step I on page 47 2 Must use an approved prover can for DEF calibrations 3 Dispense fuel into the Prover Can exactly to the zero mark The uncalibrated volume appears Notes 1 If the fuel DEF is not dispensed within four minutes approximately of switching on the pump handle or within the time period set by the controller for pulser time out the Error Code 574 appears indicating that the pump handle must be switched off to clear the error Scrolling will resume after you replace the nozzle 2 If fuel DEF dispensing has started but stopped and the pump times out the Calibration switch must be turned to Off position Else Error Code 993 appears as shown in Figure 3 30 on page 49 99 indicates that the product is not available and 3 indicates the p
68. nnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit AN WARNING Hoses that are not recoiled properly create a trip hazard Serious injury could occur as a result of tripping over an excessive length hose Repair or replace broken hose retrievers promptly MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 61 The Atlas Fuel System Components Nozzles and boot area Page 62 Recommended Frequency Once a week or as notified about a potential problem Preventive Maintenance Who Performs the Recommended Maintenance Inspection Repair 1 Inspect nozzles for the following wear or damage e Owner Inspect Damage ASC only Repair Leaks and test 4 Loose nozzle spouts Missing parts such as retainer springs and splash guards AN WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leak or damage stop using the pump dispenser and contact your local ASC Inspect vapor recovery boots bellows for proper seal and damage Consult the nozzle manufacturer for any additional required inspections If repair is required call an ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or
69. nst the completion checklist the unit is ready for start up To perform an orderly start up of the Series 9800K proceed as follows Verify if all switches on the CPU PCB are set properly for the various operating conditions Turn the circuit breakers on for the microprocessor and fluorescent lights Verify if both lights are lit MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Series 9800 Start up Error Codes The Atlas Fuel System 10 Authorize the hose for Side through the fuel management system if available Remove the nozzle for Side 1 from its holder and turn the pump handle on Verify that the display goes through the reset sequence as explained in Operating Sequence for Series 9800 Only on page 44 Dispense fuel Verify that the high flow valve opens if equipped Inspect all plumbing for leaks at this time Turn the pump handle off Open the nozzle No fuel must be dispensed at this time Verify if the correct quantity was recorded by the fuel management system if available If applicable repeat steps 3 to 7 for Side 2 Run the unit through all standard calibration procedures Reset the electronic totalizers as described in Commercial Electronic 9800 on page 9 POST Start up Tests Voltage The incoming voltage to the pump and remote dispenser must be inspected and any reading that is not within 10 of the rated voltage must be corrected before the testing is continued When dealing with
70. nstallation Manual MDE 4333 Atlas Fuel Systems Site Prep Manual e FE 356 Atlas Pump and Dispenser Field Wiring e FE 357 Atlas Pump Retail Commercial Field Wiring e FE 361 Atlas Master amp Satellite Field Wiring Diagram Ensure that the installer follows the instructions in the above listed manuals and adheres to all applicable local state and national codes General Guidelines Ensure that the installer at a minimum performs the following tasks Attaches the hose breakaways Follows all manufacturer installation instructions for devices attached to the dispenser such as hoses nozzles and shear valves Installs a line leak detection system for all dispensers The system must comply with all local and state codes Uses only UL listed or approved attachments with the pump dispenser Installs shear valves for all dispensers and certain above ground tank pump applications properly Follows all codes Bolts units to the 1sland properly Tests hoses for conductivity before use as per the manufacturer s instructions Uses appropriate safety signs as outlined in the manuals listed in Guidelines in Atlas Fuel Systems Documentation and Other Codes Uses isolation relays for dispensers required by National Electrical Codes Uses the recommended hose lengths for each unit unless you are using hose retrievers Note This is not a complete list For other requirements refer to Guidelines in Atlas Fuel Systems Documentation an
71. nt Explosions and Fires Fuels and their vapors will explode or burn if ignited Spilled or leaking fuels cause vapors Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island DEF is non flammable Therefore explosion and fire safety warnings do not apply to DEF fluid lines Page 3 Important Safety Information No Open Fire Open flames from matches lighters welding torches or other sources can ignite fuels and their vapors No Sparks No Smoking Sparks from starting vehicles starting or using power tools burning cigarettes cigars or pipes can also ignite fuels and their vapors Static electricity including an electrostatic charge on your body can cause a spark sufficient to ignite fuel vapors Every time you get out of a vehicle touch the metal of your vehicle to discharge any electrostatic charge before you approach the dispenser island Working Alone It is highly recommended that someone who is capable of rendering first aid be present during servicing Familiarize yourself with Cardiopulmonary Resuscitation CPR methods if you work with or around high voltages This information is available from the American Red Cross Always advise the station personnel about where you will be working and caution them not to activate power while you are working on the equipment Use the OSHA Lockout Tagout procedures If you are not familiar with this requirement refer to t
72. o a shut off dispenser when remote dispensers share a common submersible pump or starter relay e Turn off and lock out all power to the remote dispenser and submerged pumps at the master panel and close and test any impact valve before performing any maintenance or service to the remote dispenser including changing any fuel filters or strainers e Block island so no vehicles can pull up to the remote dispenser when the dispense is being worked on MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance The Atlas Fuel System CAUTION Moisture from rain can damage the internal components of a pump dispenser Internal components that are exposed to moisture may not operate correctly Do not open the electronics cabinet to perform any other tasks when it is raining A WARNING High alcohol percentage fuels such as E85 or fluids such as DEF may be incompatible with certain plumbing materials and hydraulic components Use of incompatible materials or components with E85 can result in leaks For E85 unexpected failures of components may also occur resulting in fire or explosion or environmental damage When installing components in E85 units refer to Important Requirements for E85 Units on page 15 When dispensing alternative fuels such as E85 or fluids such as DEF verify with the manufacturer if the material of all plumbing components are compatible with the fuel E85 or fluid being dispensed
73. obtain the total for that day If the unit is in use 24 hours a day it is advisable to take the readings in the morning also so as to monitor the night usage Figure 3 6 Pump Totals 9120 Totalizer Page 12 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Common Functions The Atlas Fuel System Commercial Electronic Series 9800 Only Figure 3 7 Commercial Electronic Totals 9800 Commercial Electronic Electrical Mechanical Totalizer Side View Top view loo Actuator Full seale ATC Switch Totalizer Activate Area Note For all Series 9800 except 9820 The Atlas stores a running quantity total for each pump side These electronic totalizers work independent of the optional electrical mechanical totalizers that may be installed and are 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 Atlas is supplied with an actuator shown in the above illustration which allows you to view and reset electronic totalizers To view pump totalizers ensure that the pump handles are off and no transaction is in progress Locate the actuator area where the Gasboy dial face logo is located that is on the same pump side as the serial number tag Touch the actuator area with the actuator as shown The totalizer data for each pump side will be displayed for 10 seconds If more time is required touch the ac
74. osed Open Open 14 Open Closed Open Open 15 Closed Open Open Open 16 Open Open Open Open The Atlas Fuel System Pulser Output Rate Switches When the Series 9800 is connected to external control equipment other than a Gasboy CFN Gasboy TopKAT top mount or Gasboy TopKAT electronic standalone the pulser signals are sent out via the 9800 Pump I F PCB The pulse rate required by the monitoring equipment can be configured by setting the switches as shown in the following chart The pulse rate represents pulses per gallon PPG for US Gallons and Imperial Gallons or pulses per liter PPL most international For US Gallons or Imperial Gallons configurations the pulse rate can be up to 100 PPG for the 9850 and 500 PPG for all others models For liters configurations the pulse rate can be up to 10 PPL for the 9840 and 9850 and 100 PPL for all other models For Imperial Gallons configurations the pulse rate can be 100 PPG for the 9850 and 500 PPG for all other models This switch must be sealed by a Weights and Measures paper seal if the Series 9800 unit 1s used for the resale of product Leading zeroes are always suppressed in the hundreds and tens positions to the left of the decimal point When in standalone mode positions to the right of the decimal point are displayed based on the pulse rate selected as shown in the following table Pulse Rate SW2 1 SW2 2 SW2 3 1 Closed Closed Closed 10 Open Closed Closed 100 Closed Open Closed 250 Open Ope
75. page 60 including all repairs must be performed only by an ASC To determine if an ASC must perform a task refer to Who Performs the Inspection Repair on page 60 AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit AN WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leak or damage stop using the pump dispenser and contact your local ASC CAUTION Improperly installed or maintained equipment can create a hazard Improperly installed or maintained equipment could cause a fire explosion or electrical shock For any component not supplied by Gasboy for example hoses and nozzles consult and follow the installation and maintenance instructions provided by the manufacturer Power Reset External Adjustment If the pump or remote dispenser unit fails to reset or shut off properly the reset motor must be adjusted To adjust proceed as follows 1 Loosen the lock nut on the adjusting screw and back screw out until it stops 2 Move the reset lever to the ON position 3 Turn adju
76. programming and all pump handles must be down or inactive Press 100 on the keypad and then press ENTER e The money position showing fueling position selected displays 1 e The volume position showing the fuel type selected displays 1 where a 2 Gasoline b 2 Diesel e The PPU position showing fuel density selected displays 730 where a 740 Gasoline b 840 Diesel c Default 2 730 Select the fuel type and press ENTER Each fueling position is sequenced through by the firmware sequence Select the fuel type for each position Diesel or Gasoline Turn the programming switch on the ATC controller board off Press F2 to exit the ATC programming mode MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Programming 8800 Models The Atlas Fuel System ATC Inspection Mode Inspection of ATC states and data collection can be obtained by following a similar procedure as outlined for ATC Programming on page 38 Instead of pressing 100 other codes can be used as described in Figure 3 21 Figure 3 21 ATC Inspection Modes ATC INSPECTION MODES On Manager Keypad press the ATC Function Code below when unit is idle Note that all pump handles must be down or inactive Then press ENTER meter number if appropriate then ENTER Exit by pressing F1 MAN VOLUME GRADE 1 PPU _ DESCRIPTION DISPLAY DISPLAY DISPLAY AUDIT LAST GROSS NET VOLUME AVERAGE TRANSACTION VOLUME TEMPERATURE DISP
77. ps dispensers CAUTION Certain special alternative fuels such as E85 and additives can degrade pump dispenser performance or integrity if the dispensers are not designed for use with such fuels Additionally converting to certain standard fuels gasoline diesel kerosene and so on from alternative fuels such as those with ethanol E85 methanol or Biodiesel or from alternative fuels to standard fuels can degrade dispenser performance or integrity Similar effects can also occur when converting units to different standard fuel types As per UL 87A requirements nozzles dispensing E85 fuel and DEF must not be used to dispense any other type of fuel such as Gasoline Leaks and potential environmental hazards can result or components may fail prematurely To avoid these issues follow the guidelines provided for dispensing E85 fuel and DEF in this manual and MDE 4331K Atlas Fuel Systems Installation Manual Intended Users This manual is written for the owners and the operators of the Atlas Fuel Systems pumps and dispensers Scope This manual provides the following information about the Atlas Fuel Systems pumps and dispensers e Operating the pumps dispensers e Preparing the pumps dispensers for service e Maintaining the pumps dispensers MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 1 Introduction Abbreviations and Acronyms Abbreviations and Acronyms The following table contains a list of abbr
78. quipment in accordance with these codes regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment Replacement Parts Use only genuine Gilbarco replacement parts and retrofit kits on your pump dispenser Using parts other than genuine Gilbarco replacement parts could create a safety hazard and violate local regulations Safety Symbols and Warning Words This section provides important information about warning symbols and boxes Alert Symbol AN This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazards Obey safety directives that follow this symbol to avoid possible injury or death Signal Words These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards The precautions below must be followed to prevent death injury or damage to the equipment A DANGER Alerts you to a hazard or unsafe practice which will result in death or serious injury A WARNING Alerts you to a hazard or unsafe practice that could result in death or serious injury A CAUTION with Alert symbol Designates a hazard or unsafe practice which may result in minor injury CAUTION without Alert symbol Designates a hazard or unsafe practice which may result in property or equipment damage Working With Fuels and Electrical Energy Preve
79. recautions associated with installing inspecting maintaining or servicing this product Before performing any task on this product read this safety information and the applicable sections in this manual where additional hazards and safety precautions for your task will be found Fire explosion electrical shock or pressure release could occur and cause death or serious injury if these safe service procedures are not followed Preliminary Precautions You are working in a potentially dangerous environment of flammable fuels vapors and high voltage or pressures Only trained or authorized individuals knowledgeable in the related procedures should install inspect maintain or service this equipment Emergency Total Electrical Shut Off The first and most important information you must know is how 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 Submerged Turbine Pumps STPs AX WARNING The EMERGENCY STOP ALL STOP and PUMP STOP buttons at the cashier s station WILL NOT shut off electrical power to the pump dispenser This means that even if you activate these stops fuel may continue to flow uncontrolled You must use the TOTAL ELECTRICAL SHUT OFF in the case of an emergency and not the console s ALL STOP and PUMP STOP or similar keys Total Electrical Shut Off Before Access Any procedure that requir
80. ress ENTER e Select Grade and then press ENTER e Select Price Level and then press ENTER Enter new PPU and then press ENTER Repeat for other Side Grade and Price Level Command Code 2 Program Two Wire Standalone Press 2 and then press ENTER Press Configuration number and then press ENTER where 0 Standalone mode 1 Two wire mode default 2 Pulse Output mode Command Code 3 Program Allocation e Press 3 and then press ENTER e Select Side 1 or 2 and then press ENTER e Select Hose Grade and then press ENTER e Select Allocation amount and then press ENTER Repeat for other Side Hose and Grade MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 33 The Atlas Fuel System Programming 8800 Models Page 34 Command Code 4 Program Manual Blank Display Cash Volume Preset Select e Press 4 and then press ENTER e Select Function Code 1 or 2 and then press ENTER where Function Code 1 Manual Blank Displays Press option code and then press ENTER where 0 Display OFF l Display ON Function Code 2 Cash Volume Preset Select Press option code and then press ENTER where 02 No 5 Button Preset or PPP Preset installed l Money Preset 2 Volume Preset 3 Incremental Preset MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Programming 8800 Models The Atlas Fuel System Command Code 5 Test Customer Programmable Preset Press 5 and then press ENTER Select Configuration and then
81. roduct is not calibrated The procedure must then be restarted from step I on page 47 Page 48 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Operating Sequence for Series 9800 Only The Atlas Fuel System Figure 3 30 Displaying the Error Code 4 Switch off the pump handle and return nozzle to boot After three seconds the calibration factor appears on the display for three seconds and then zeros are displayed indicating that the meter is now calibrated No further transactions will be allowed until the Calibration switch is turned to Off position Note If an additional transaction is attempted Error Code 994 appears 99 indicates product not available and four indicates calibration mode error Turn the Calibration switch to Off position and switch off the pump handle to clear the error The Error Code 993 appears indicating that the Calibration procedure must be restarted from step I on page 47 5 Turn the Calibration switch to Off position and slide switch cover back over switch MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 49 The Atlas Fuel System Series 9800 Start up Error Codes Series 9800 Start up Error Codes The following Series 9800 start up codes constantly appear at the far left on the power up e 0I RAM Failure RAM read write tests failed e 02 ROM Failure bad ROM chip and checks failed Start up and Test Section for Series 9800 except 9820 Page 50 In
82. rolled by a Gasboy Series 1000 or TopK AT mechanical system or controlled by any non Gasboy system or not controlled by any fuel management system at all the switch must be closed standalone mode Note The 9800K is shipped in the standalone mode unless it has the TopKAT top mount option With the TopKAT top mount option the unit is shipped in on line mode Mode SW1 2 JP2 Fuel System On line Open CFN TopKAT top mount TopKAT electronic Standalone Closed Series 1000 TopKAT Mechanical All non Gasboy systems No fuel system SW1 3 SW1 4 or JP3 JP4 Delay Time These two switches set the delay time used by leak detectors in submersible pump applications The delay time is the period between the activation of the submersible pump and the activation of the slow flow valve This time must be set according to the type of leak detector installed on the submersible pump to allow a normal leak test for each transaction The delay time must be set to zero seconds for suction pumps Delay Time SW1 3 JP3 SW1 4 JP4 0 seconds Closed Closed 4 seconds Closed Open 5 seconds Open Closed 6 seconds Open Open Page 22 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 CPU Switch Settings Series 9800 Only Including DEF 9862 Units The Atlas Fuel System SW1 5 or JP5 Hose Pressurization If the Series 9800 program is configured for US Gallons this dip switch setting is ignored and the program will always act as if it is enabled If t
83. rs from and test operating the pump dispenser during inspection Remove the lower panels slowly and carefully Inspect all hydraulic connections and seals including the following Meters Valves If wetness or dripping fuel is found stop using the pump dispenser and make arrangements for repairing the leak Note Some staining of parts around seals is normal and does not necessarily indicate a leak Monitor repaired components closely AN WARNING Gasoline or other fuels can damage the eyes Fuel sprayed into the eye can burn eye tissue To prevent potential injury wear eye protection when performing these inspections AN WARNING Self contained pumps have a pinch point between the belts and the pulleys Severe injury could occur if part of the body is pulled into the pinch point To prevent injury when inspecting self contained units do not place you hands near the belts pulleys or motors Turn off the power before servicing the unit Do not operate the unit with the door removed AN WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you find any leak or damage stop using the pump dispenser and contact your local ASC AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result
84. s 235 Xd SEs ech cata S BG Dan Roxas a EO CR AGAD Od d 19 Electronic Component Access Series 9800 Only Except 9820 Series 19 CPU Switch Settings Series 9800 Only Including DEF 9862 Units 005 20 CPU Jumpers or SW1 for Older CPU Boards 22 SW2 For Older and Newer CPU Boards 24 SW2 5 and SW2 6 Unit of Measure Setting New M06333KXXXX CPU Only 2 2 0 0 aaa 26 SW2 7 Electro Mechanical Totalizer Enable New M06333KXXXX CPU Only 26 SW2 8 BDM Enable New M06333KXXXX CPU Only 26 SW2 9 Software Download Enable New M06333KXXXX CPU Only 26 SW2 10 New M06333KXXXX CPU Only aaa 26 Battery Backup Power Supply for Series 9800 ee eee 27 Information for ATC Series 9800 Only ee eee eens 27 Setting the DIP Switches Found on Kraus ATC Boards 28 Changing the Price for the Mechanical Retail Pump a 28 Programming 6800 Model 4a aaa Paman nA PAA AKA EE Su tst ni oed Beata d a 31 General Programming a 31 Programming the 8800 Series Retail Electronic Units 32 Level 1 Programming and Data Access 32 ATO Programming s urs eae 39 3 BA AGA BAGAN BG ace par LAT KANA e d 38 ATC Inspection Mode eee eee 39 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page i Table of Contents ENCA NANG MEI EU Lec EE 40 Operating Seq
85. set the adjuster by loosening the clamp To decrease the amount delivered turn the thimble in on the barrel To increase the amount delivered turn the thimble out unscrew it After resetting the adjuster tighten the clamp Note Always make the final adjustment by turning the thimble in If the new setting is a higher number than the original turn it back beyond the required figure and come back to it For example Assume that the adjuster setting at the start of the test reads 2 05 The product is run through the meter into a Prover Can until the counter registers 100 gallons Assume that the Prover Can shows a volume of 98 7 gallons 1 3 gallons short Since the adjuster graduations are in percent readings this 1 3 could be added directly to the adjuster reading 2 05 plus 1 3 equals 3 35 on the adjuster A rerun through the meter must then show 100 gallons both on the meter counter and on the Prover Can If you are measuring in increments of less than 100 gallons use this simple formula to determine the percentage by which the adjuster must be adjusted P M M A where P is the prover measurement M is the meter reading and A is the percent adjustment for the adjuster MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Operating Sequence for Series 9800 Only The Atlas Fuel System Calibration Adjustment for E85 and DEF Units Electronic Calibration ECAL E85 and DEF units must be calibrated electronical
86. stallation Completion Checklist Review the following information to verify the proper installation of the Series 9800K dispensing unit If the installation does not meet the criteria listed correct the problem before the start up 1s performed To avoid damage to the CPU PC board verify that the RESET COMPLETE FAST FLOW SUBM STARTER DRIVE and SLOW and FAST SATELLITE RETURN wires are not shorted to the conduit or chassis The unit must be secured to the island properly All plumbing must be complete and tight All liquid carrying lines must be checked for leaks 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 not share any conduits junction boxes or troughs All conduit work must be complete All junction box covers must be secured Conduits must not be sealed until the wiring is verified through proper operation The unit must be grounded properly Before any testing begins remove any water in the tank through a fill opening using a suitable pump Note Do not use the Gasboy pump or remote dispenser and submersible pump to remove water Serious damage may occur A sufficient volume of fuel must be put in the tank to insure that the liquid level is above the bottom of the suction pipe suction pumps or 1s high enough to allow the submersible pump to operate efficiently remote dispensers Start up After successfully verifying the installation agai
87. stment screw in until reset motor starts 4 Advance adjustment screw an additional 1 2 to 3 4 turn Hold screw in this position and tighten the lock nut MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 57 The Atlas Fuel System Preventive Maintenance 5 Move the reset lever to the OFF position and then back to the ON position to verify if the reset motor operates properly The reset coupling must make one revolution and stop Figure 3 31 Power Reset for Pump or Remote Dispenser Unit Adjustment Screw Lock Nut Filter Strainer Replacement If the unit is equipped with a strainer and filter inspect and change it at regular intervals refer to Filter change and strainer cleaning in Preventive Maintenance Table on page 60 A dirty strainer or filter in a pump or remote dispenser causes a slower delivery rate Refer to the accessories section of your parts manual to ensure that you replace the strainer if required and filter with one designed for your model Always use a drip pan and absorbent material directly below the filter when removing the cartridge to prevent contamination of both the soil and the electrical components within the cabinet This service must not be done by untrained individuals AN WARNING High alcohol percentage fuels such as E85 or fluids such as DEF may be incompatible with certain plumbing materials and hydraulic components Use of incompatible materials or components with E8
88. termined by various switch settings inputs and the user A typical transaction is explained below Pump Unit Motor and Pump in Unit Base Turn on the pump handle If AC is present on the AUTH Control Feed line the reset cycle begins The display electronic units Goes blank for one second if 0 Delay Time is set or for 4 6 seconds depending on the setting Delay Time is set to e Shows all 8s for one second three seconds for US Gallons or if JP5 or SW1 5 for older CPU boards is set e Goes to 0 000 gallons or 0 00 liters until fuel starts The pump motor switches on and the Reset Complete line becomes active The pump continues to run until one of the following conditions occur These conditions switch off all relays as follows e The handle is turned off e The AUTH Control Feed line AC power line to pump dispenser 1s switched off by the POS A pulser error is detected electronic units only A time out is reached if the unit is programmed with a time out value If connected to a fuel management system the time out loaded into the system is used commercial electronic only The unit turns off if it is idle for a preprogrammed time when no fuel 1s flowing A quantity of 990 000 gallons 9900 00 liters is reached If connected to a fuel management system the limit set in the system is used The pump is halted by an operator of a fuel management system An AC power failure occurs Station Emergency Stop button is presse
89. tive appearance is to be maintained The finish on Gasboy pump housings is a high heat baked synthetic enamel similar to that used on automobiles The life of this finish can be lengthened several years if at regular intervals the painted surfaces are thoroughly cleaned with a high grade automobile polish and then protected with a coat of paste wax Do not use abrasive cleaners or polish Do not use high pressure spraying equipment Do not use window cleaner with ammonia on the electronic display In order to retain the unmarked finish on stainless steel occasional cleaning is required In corrosive atmospheres such as coastal areas a more frequent cleaning schedule is required Under ordinary conditions washing with detergent or soap and water followed by a clean water rinse is sufficient If hard water is used the surface must be wiped dry with a soft clean cloth to prevent the formation of water spots Marks or spots such as grease oily fingerprints and smudges that resist soap and detergents may have to be removed with a stronger cleaner IMPORTANT INFORMATION DO NOT use ordinary steel wool as iron particles may adhere to the surface and cause corrosion Care must be taken in choosing a cleaner because any cleaning compounds or powders which contain abrasives can scratch a mill rolled finish Exercise care to ensure that any polishing is done with the lines in the steel never across them After cleaning an application of paste w
90. tlas Fuel Systems Owner s Manual September 2011 Page 15 The Atlas Fuel System Site Preparation Important Considerations for DEF Dispensers CAUTION Applicable during Installation and Operation of the Dispenser DEF freezes at approximately 11 F 11 5 C Power to the dispenser and heater must always remain ON in cold weather If power is lost and the temperature drops below this point within the DEF cabinet the system must be inspected for freeze damage before restart For sites that experience occasional power losses or for sites that are located in very cold climates it is recommended that a backup power generator be used to maintain constant power to the dispenser Do not use any additives to lower the freezing point of DEF Additives of any type must not be used in DEF Freezing can result in damage or inoperative hose breakaways fluid lines or components valves nozzles and meters Prolonged storage at temperatures above 77 F 25 C can impair the quality of DEF and reduce its shelf life CAUTION DEF is mildly corrosive It can corrode components that are made from incompatible material s and reduce their integrity The use of incompatible material s may lead to leaks and spills and can contaminate and degrade the DEF When dispensing DEF verify with the manufacturer if the material of all plumbing components are compatible with the DEF being dispensed CAUTION Do not use Prover Cans meant for engine fuel with D
91. tuator to the actuator area for an additional 10 second period To reset the electronic totalizers refer to Electronic Component Access Series 9800 Only Except 9820 Series on page 19 e Turn off the 9800K power switch e Close JP7 or SW1 7 for older CPU boards on the CPU PCB Hold the actuator against the totalizer bracket and turn the power switch ON The displays must change to all Zeroes e Remove the actuator and open the switch JP7 or SW1 7 Note Returning switch 1 7 to the open position prevents the totalizers from being reset the next time the actuator is used to read them MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 13 The Atlas Fuel System Mechanical Totalizers for 9850 Only Mechanical Totalizers for 9850 Only An optional mechanical totalizer for each side is available for 9850 models only Each totalizer has e Fight digits e Seven whole gallons e One tenth gallon column e Fight whole digits for liters The mechanical totalizers are located below each nozzle hook see Figure 3 8 Figure 3 8 Mechanical Totals for 9850 Series 1 Nozzle Hook Totalizer N Totalizer Cable Totalizer Unit Page 14 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Site Preparation The Atlas Fuel System Site Preparation To ensure safety and long term reliability of your equipment ensure that your units are installed by a knowledgeable ASC When your units ar
92. uence for Series 9100 Only anaana 43 Operating Sequence for Series 9800 Ons qa apu e Sod ha Coe v de ra ED UR ete Fac lod bata 44 Standalone Mode Error Handling Series 9800 45 Calibration Tor 9850 Only 25 92 9E BAG Eee REI RIP EIER 45 Series 9800 Start up Error Codes 0 0 ee eee eee eee 50 Start up and Test Section for Series 9800 except 9820 50 Safety Information a 52 Preparing for Servicing the Pumps Dispensers aa 52 Gall Gasboy First 3e ERES HEREREUA RERO aia Ec Sea ies e 53 Service Preparal bls m en daos ae eet dd bones EE SEC ep etur oe o 53 Replacement Parts 0 0 00 ccc ee eee eens 53 Specialized Tralhllig misra mer DAD ts eed eel ead sae we NAL NA 54 Preventive Maintenance 2 ee hh hh eee ees 54 Maintenance of Vendor Supplied Parts 55 Performing Inspections 0 0 ce eee eee 55 Power Reset External Adjustment 0 0000 cece eee 57 Filter Strainer Replacement 0 0 00 cece eee ee 58 Adjusting the Belts Suction Pumps Only 59 Preserve the Finish of Your Pumps 0000 eee ees 59 Glossary Glossary 1 Index Index 1 Page ii MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Purpose Introduction 1 Introduction Purpose This manual provides instructions for safely operating programming and maintaining the Atlas Fuel Systems pum
93. 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 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Page 5 Important Safety Information This page is intentionally left blank Page 6 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Pump Dispenser Components The Atlas Fuel System 3 The Atlas Fuel System Pump Dispenser Components This section provides figures that show the internal and external components of pumps and provides information about these components Refer this section as you perform the procedures in this manual Atlas Pump Dispenser The external components of a Gasboy Atlas pump dispenser Mechanical Retail Unit are shown in Figure 3 1 Mechanical units have mechanical digital type displays as opposed to electronic digital type displays In units that are Commercial instead of Retail the external components are almost the same with the exception that there are no cost displays Price per Unit PPU and the main display showing only the total fuel pumped Figure 3 1 Atlas Mechanical Retail Unit Mechanical Retail Unit Totalizers Boot Area Control Lever Nozzle and Gallon Display Hump Nanaig i _ Gasboy Atlas E E i Logo PPU Display Door Lock q oe Access Door f AGASBOY te MDE
94. vice a Gasboy unit To receive specialized training for servicing Gasboy pumps dispensers contact a Gasboy trained contractor or distributor Training may be available locally at various regional centers Contractors and distributors may charge a nominal training fee For more information contact your nearest distributor To locate a distributor near you visit www gasboy com and click the Locate Distributor link Preventive Maintenance Page 54 Gasboy pumps and remote dispensers are designed for many years of uninterrupted service However certain dispenser or pump parts experience normal wear and therefore require periodic inspections For example detecting fuel leaks that may occur belt tension and belt condition lubrication and strainer cleanliness are all important to maintain safe and efficient unit operation Therefore to avoid annoying pump shut downs a periodic preventive maintenance inspection plan must be established and followed Procedures requiring leak repair shear valve maintenance and disassembly of portions of the pump remote dispenser must be performed by an ASC AN WARNING To avoid electrical shock or hazard of an explosion or fire when servicing remote pump dispenser e Turn off and lock out all power to the pump remote dispenser in submersible pump applications turn off and lock out power to the submersible pump and any other remote dispensers which use that submersible pump AC power can feed back int
95. y were installed on your pump 1 Trip the valve For details refer to Shear Valve on page 40 Authorize the hose at the console if required Lift the operating handle Place the discharge nozzle in an approved container Squeeze the nozzle operating lever If flow continues after several seconds the valve is defective Place a few drops of SAE10 oil on valve body shaft Open and close valve with a wrench several times Place valve back in service If repair is required call an ASC C1 4A Con O 00 N O AN WARNING The pump dispenser contains pressurized flammable fuel and lethal voltages Servicing a Gasboy unit incorrectly could result in severe injury or death Do not attempt to service Gasboy pump dispenser yourself and do not allow untrained personnel to service Gasboy pumps dispensers Only Gasboy trained ASCs must service a Gasboy unit Page 66 MDE 4363F Atlas Fuel Systems Owner s Manual September 2011 Preventive Maintenance The Atlas Fuel System Recommended Who Performs the Components Frequency Recommended Maintenance Inspection Repair Pump pulleys belts and Every six months 1 Remove power to the unit e Owner Inspect belt tension or if a squealing ASC only Repair noise occurs and test during unit operation AN WARNING Failure to remove power to the unit before servicing it could result in injury Failure to remove power could create a hazard such as electrical shock Remov

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