212KT04.INS R04 Installation Manual
Contents
1. 10 2007 3 GTC 200 1M 2M Publication Number 212KY04 INS R04 1L 2L 1MH 2MH 1LH 2LH INFORMATION 1 2 PRODUCT INFORMATION Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 1 2 1 System Components The following is a list of operating components used in this installation along with brief explanation of their operation ATC Board Takes the signals from the temperature probe and flow meter compensates for temperature deviation from 15 then sends the compensated signal back to the main processor board Adapter Board Diverts the signal from the pulser to the ATC board then returns the compensated signal from the ATC board to the main processor board Also supplies a 5 and handle switch signals to the ATC board and display Intrinsic Safety I S Barrier Energy limits the temperature probe signal then sends the same signal onto the ATC board Temperature Probes Converts temperature of the product to a corresponding signal that is sent to the ATC board via the 1 5 Barrier ATC Display Board Gives a visual display of product temperature flow rate and uncompensated volume Also indicates error conditions Probe Connector Assembly Provides secure electrical connection between the temperature probe s and l S Barrier 4 GTC 200 1M 2M 1L 2L 1MH 2 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 Site Preparation THE FOLLOWING LIST OF PRECAUTIONS SHOULD BE2. LEGACY SKIL 447 ADAPTER BOARD 1 BC1022 HIGHLINE SALESMAKER MODULAR MPD BOARD BRACKET 1 BC 1239 SEAL COVER 1 218AY00 DUAL INTRINSIC SAFETY BARRIER 1 212AY04 or DUAL PROBE CONNECTOR ASSEMBLY 212AY05 1 W171 or W172 5 PIN 3 WIRE HARNESS FOR I S BARRIER 1 5 16 HEX NUT FOR I S BARRIER 1 5 16 FLAT WASHER FOR I S BARRIER 10 2 W199 TEMPERATURE PROBES 2or4 BC407 THERMAL WELLS 20r4 120B 02X02 EXTENSION FITTINGS 20r4 213P 2 PVC THERMAL WELL CAPS 1 W150 34 PIN RIBBON CABLE 1 SKIL 432 ATC DISPLAY BOARD 4 BC256B BLACK VOLUME CORRECTED TO 15 C LABELS 1 BC1058 SERIALIZED WEIGHTS amp MEASURES NAMEPLATE 4 or 6 18 22 AWG CRIMP SPLICES 1 W189 3 WIRE ATC DISPLAY HARNESS 20r4 BC 546 120 B 1 8 NPT ADAPTER DRILLED OUT TO 17 64 I D 1 212KT04 INSTALLATION MANUAL Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 37 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH MAINTENANCE 3 1 CONNECTION 3 21 GTC 200 DIAGRAMS The following diagram shows connections for the GTC 200 Refer to preceding parts listing for description of components Figure 17 GTC 200 SKIL 432 ATC DISPLAY TO INTERFACE BOARD 16 OR 60 P102 SKIL 428 OR 447 ADAPTER BOARD J205 P205 P1 SKIL 425 ATC BOARD LOGIC BOARD W171 OR W172 218AY00 DUAL I S BARRIER VAPOUR BARRIER 2 2 YELLOW GREEN 2 PROBE UNIT PROBE CONNECTOR ASSEMBLY 212AY05 TEM
3. to adjust the volume to the actual volume dispensed 7 When the ATC display is showing the correct volume either use DIP switch 5 to exit LEARN MODE or switch the ATC display to show the Side B Volume If you have switched the ATC display to show Side B volume then follow the same procedure as outlined in steps 4 to 6 above to calibrate Side Then use DIP switch 5 to exit LEARN mode 8 Recheck calibration on both sides of pump using ATC display 9 If your pump is equipped with its own ECAL feature now perform Gilbarco calibration instructions such that the volume displayed on the pump matches the volume displayed on the ATC display 10 Activate ATC with DIP switch 8 if required If system not legally inspected yet leave OFF THE INCREMENT SWITCH WILL ONLY ALLOW THE VOLUME TO BE INCREMENTED TO 12 5 OF THE UNCALIBRATED VOLUME AND THE DECREMENT SWITCH WILL ONLY ALLOW THE VOLUME TO BE DECREMENTED TO 12 5 OF THE UNCALIBRATED VOLUME 8 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH 2 1 SYSTEM SET UP NOTE Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 INSTALLATION 2 1 3 1 Electronic Calibration with GTC 200 ECAL ATC CONT D WHEN IN LEARN MODE LIFTING THE PUMP HANDLE WILL SET THE CALIBRATION TO 00 00 IF NO FUEL IS DISPENSED OR IF NEITHER THE INCREMENT DECREMENT SWITCHES ARE USED WHEN IN LEARN MODE ONLY ONE 1 FUEL TRANSACTION PER PUMP SIDE IS PERMITTED ALL ATTEMPTS TO S
4. Automatic Temperature Compensation System 212KT04 INS R04 Installation Manual MODELS GTC 200 1M 2M 1L 2L IMA 2MIH ILA amp 20 Kraus Global Inc 25 Paquin Road Winnipeg Manitoba CANADA R2J 3V9 2006 Kraus Global Inc Publication Number 212KT04 INS R04 Printed in Canada TABLE OF CONTENTS SECTION 1 0 INFORMATION 1 1 Introduction 1 1 1 About This Manual 1 1 2 Helpful Hints and Warnings 1 1 3 Service and Product Support 1 2 Product Information 1 2 1 System Components SECTION 2 0 INSTALLATION 2 1 System Set Up Site Preparation Installation Requirements Unit Configuration 1 Electronic Calibration with GTC200 ECAL ATC Component Installation 2 1 4 1 Thermal Test Well amp Temperature Probe 2 1 4 2 Intrinsic Safety Barrier Mounting 2 1 4 3 Probe Connector Assembly Installation 2 1 4 4 Adapter Board Connection 2 1 4 5 ATC Board Installation 2 1 4 6 ATC Display Board Installation 2 1 4 7 Display Board Functions 2 1 4 8 Display Board Messages NNNNN gt 2 2 Post Installation 2 2 1 Operation Check 2 2 2 Probe Connection Verification 2 2 3 Installation Troubleshooting 2 3 Calibration 2 3 1 Calibration Procedure SECTION 3 0 TECHNICAL DATA 3 1 Components 3 1 1 GTC 200 List of Components 3 2 Connection Diagrams 3 2 1 GTC 200 Kraus Global Inc 10 2007 i GTC 200 1M 2M Publ
5. C 407 See Figure 6 IF CONNECTION IS LESS THAN 5 THREADS THEN SOLDERING IS REQUIRED ANY OTHER CONNECTIONS MUST BE MADE USING THREAD SEALING COMPOUND SUITABLE FOR USE WITH GASOLINE 10 Install the test well Part BC 407 into the extension fitting Part BC 546 and after tightening cover with the supplied protective plug 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker or Single Product 2 Hose Highline Dispensers 1b Thermal Test Well Connection cont d In the case of having Feedline Tube Assemblies Figure 6 Test Well Connection Test Well Part BC 407 Test Well Extension Fitting Part BC 546 Flanged Meter Connection Fitting Feedline Tube Assembly 11 Re connect the feedline tube assemblies by following steps 3 to 7 in reverse order Apply new thread sealing when reattaching the flanged fitting and elbow Kraus Global Inc 10 2007 17 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker or Single Product 2 Hose Highline Dispensers 2a Temperature Probe Connection In the case of a Suction Salesmaker 1 Locate fuel supply inlet Y fitting at the bottom of the pump assembly see Figure 2 2 Remove Y fitting and pipe extension nipple 3 With the pipe section mounted securely dr
6. FOLLOWED BEFORE INSTALLATION CAUTION e Extreme caution should be used to ensure that no ignition sources exist e The dispensing area should be roped off or isolated from public use e Dispenser station operator should be made aware of the work that needs to be completed to prevent accidental turn on of the pump e Any main electrical disconnection should be labeled or locked to prevent accidental power up Kraus Global Inc 10 2007 5 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP ATTENTION Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 2 1 2 Installation Requirements TO COMPLETE THE INSTALLATION THE FOLLOWING POINTS SHOULD BE TAKEN INTO CONSIDERATION Any electrical installation should be carried out by a registered electrician Any gas dispensing connections should be made by qualified and experienced personnel Installation must be performed in accordance with the relevant standards laws and by laws governing the type of application GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 3 Unit Configuration The GTC 200 must be configured for installation This is done by setting the DIP switches on the ATC circuit board see Figure 13 Options can be changed by setting the eight switches in accordance with the table below Table 1 ATC Board DIP Switch Settings GTC 200 SWITCH OPTIO
7. N ATC DISPLAY DOES DIP Switches are set incorrectly DIP switch settings are as NOT AGREE WITH THERMOMETER IN TEST follows see Table 1 WELL e 1 4 product types ON for Diesel OFF for Gasoline With all handles in the OFF position the temperature is still displayed 5 ON for blender and pre modular Salesmaker quad only 6 ON for two hose 2 probe Highline and on pre modular Salesmaker quad 7 ON only for pre modular Highline 1 or 2 hose 8 ON to enable volume correction TEMPERATURE ON ATC DISPLAY DOES DIP switch 6 is set incorrectly Should be ON only if NOT AGREE WITH THERMOMETER IN TEST dispenser is a two hose Highline using 2 probes or for a WELL Pre Modular Salesmaker Quad With all the handles in the OFF With DIP switch 6 OFF both hoses on Highline use probe position temperature displays 1 as for a dual 1 installation or a Salesmaker quad Ona single hose pump DIP switch 6 does not matter A temperature altering device is located between the probe and test well i e pumping unit Relocate probe and test well Product not flowing long enough to stabilize temperatures at test well Probes mixed up in multiple probe installation To check unplug the probe Temperature display for that product should switch to 50 0 C If it doesn t then another probe is plugged into the appropriate socket Re attach probes as necessary Kraus Global Inc 10 2007 35 GTC 200 1M 2M Publi
8. N SWITCH STATUS OFF GASOLINE OFF GASOLINE OFF NIA OFF NIA equipped dispensers LEARN Selects one or two product dispenser ON 2 Product Selects pump model being retrofitted PRE MODULAR vs OFF MPD LEGACY MODULAR MPD LEGACY OR MODULAR ATC ON or OFF ON ON Selects Blender 2B kits ECAL LEARN mode ECAL ON BLENDER i 6 e Kraus Global Inc 10 2007 7 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP ATTENTION Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 2 1 3 1 Electronic Calibration with GTC 200 ECAL ATC Available on High Speed H Only Electronic calibration on the GTC 200 1MH 1LH and 200 2MH 2LH can be achieved by following steps 1 to 10 below This is done by setting the DIP switches on the ATC circuit board see Figure 13 and the ATC display switches see Figure 15 Set DIP switch 8 to the OFF position ATC OFF Set ATC Display to show Side A Volume Set DIP switch 5 to the ON position LEARN MODE ON The ATC display will show 1 4 Lift the Side A dispenser pump handle and start the calibration fill For 0 05 precision in the calibration factor the calibration fill must be of at least 200 litres When the fill is complete lower the pump handle Read the volume on the ATC display and use the INCREMENT button switch SW2 on the ATV board or the DECREMENT switch SW3
9. PERATURE PROBES Kraus Global Inc 10 2007 38 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSERTS Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 25 Paquin Road Winnipeg Manitoba R2J 3V9 Telephone 1 204 663 3601 Facsimile 1 204 663 7112 Printed in Canada 39 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH
10. TART ANOTHER SALE WILL CAUSE A PULSER ERROR TO CORRECT AN ERRONEOUS CALIBRATION THE LEARN SWITCH DIP SWITCH 5 MUST BE TURNED TO THE OFF POSITION AND THEN BACK TO THE ON POSITION GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 Component Installation COMPLETE COMPONENT INSTALLATION DIAGRAMS ARE LOCATED IN SECTION 3 2 CONNECTION DIAGRAMS SUGGESTION 1 Open front panel of display on top of pump to expose main control boards see Figure 1 Figure 1 Display Head Controls ATC Board Mounting Location ATC Display Operator Keypad Card Cage Sales Display Mounting Pillars Salesmaker Model Shown 2 f possible disconnect electrical power supply at main breaker or remove fuse located inside the display unit Kraus Global Inc 10 2007 10 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 Component Installation 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker and Dual 1 Product Highline Models 1a Thermal Test Well Connection In the case of having Pressure Regulating Valves 1 Remove the two lower panels to expose the main pump assembly see Figure 2 Figure 2 Main Pump Enclosure Pressure Regulating Valve Piston Flow Meter Motor Assembly Pump and Air Separator Fuel Supply Y Fitting Salesmaker Model Shown 2 Locate the pressure regulating valve before eac
11. aus Global Inc 10 2007 29 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 2 1 4 8 ATC Display Board Messages Error Messages Error message will alternate at 1 second intervals with the information selected by the switches A d A D Converter Error Prob Probe Error PULS Pulser Error The priority of errors is as shown above That is if there is both a probe and pulser error only a probe error is reported Status Messages Will show for 1 second when handle switch is turned on Must be in normal mode With TEMP switch selected re1 5 Software Revision Number for the ATC Main Board Controller With VOL switch selected GAS Shows product type is gasoline dESL Shows product type is diesel OFF ATC Compensation is disabled 30 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 2 POSTINSTALLATION 2 2 1 Operation Check If components have been installed as per the previous instructions and pump has been re assembled power can be restored The following operations should now be verified e Sales displays are operational The pulser error code may be flashing on the price display e ATC display is operational Display may be blank until handle switches are thrown If display is not operating check to see if power is being sent from the Main Processing board in the car
12. cate the feedline tube assemblies connected to each meter see Figures 4 and 9 In order to connect test wells each complete assembly must be removed as follows 3 Disconnect the bolts that mount the flanged fitting end of the assembly to the meter being careful not to damage the O ring seal between the flange and meter inlet see Figure 4 Figure 4 Feedline Assembly Top Flanged Meter Connection Fitting Feedline Assembly Mounting Bolts Feedline Tube Assembly Elbow to Meter Piston Flow Meter 4 Disconnect the tubing from the tee fittings on the solenoid valve assembly see Figure 5 5 Disconnect the bolts mounting the solenoid valve assembly to the pressure regulator see Figure 5 Kraus Global Inc 10 2007 14 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker or Single Product 2 Hose Highline Dispensers 1b Thermal Test Well Connection cont d In the case of having Feedline Tube Assemblies 6 Remove feedline tube assembly and repeat procedure for each one in the enclosure Feedline Tube Assembly Bottom Fuel Filter Tee Fittings Solenoid Valve Assembly Feedline Mounting Bolts DUE TO THE PRESENCE OF COMBUSTIBLE GASSES DO NOT DRILL PROBE HOLES OR SOLDER FITTINGS USING A POWER DRILL TO ANY PARTS DIRECTLY CONNECTED TO THE PUMP CAUTION With the feedline as
13. cation Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 3 CALIBRATION 2 3 1 Calibration When the meters are calibrated in a pump with ATC enabled it will be necessary to use the gross volume reading from the mechanical counter or display The temperature compensated volume on the pump display cannot be used for this purpose BEFORE THE DISPENSER CAN BE USED IN TRADE IN THE ATC MODE IT MUST BE INSPECTED BY WEIGHTS AND MEASURES CANADA ATTENTION The ATC function must be disabled with the appropriate DIP switch until the pump is inspected see Table 1 Once the inspector approves the pump the B256B VOLUME CORRECTED TO 15 C labels should then be applied to the faceplates adjacent to the volume displays and the plate with the AV number must be applied to the side of the dispenser Failure to do so could result in the station being closed down by Weights and Measures inspectors Kraus Global Inc 10 2007 36 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH MAINTENANCE 3 1 MAINTENANCE 3 1 1 GTC 200 List of Components The following is an itemized account of parts supplied to complete an ATC installation for the GTC 200 Table 3 List of Components GILBARCO Two Product Highline Modular ATC Kit GTC 200 QTY PART DESCRIPTION 1 SKIL 425 ATC BOARD 1 SKIL 428 or MODULAR ADAPTER BOARD OR SKIL 447
14. ct Dispenser Shown 2 Remove the pipe sections leading from each meter 3 With pipe section mounted securely drill two holes of size Q or 21 64 about one inch apart near the center Kraus Global Inc 10 2007 20 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP SUGGESTION CAUTION ATTENTION Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 2 1 4 1 Thermal Test Well and Temperature Probe 3a Test Well and Temperature Probe Connection For Single highline and Dual 2 Product Highline Models The following guidelines should be followed for installing the test well e The hole should be drilled so that the extension will be at an angle within 45 of vertical when the extension is installed and assembly is reconnected This is so that it will hold thermally conductive fluid for measuring purposes e The fitting should provide easy access for insertion of a thermometer e The fitting should be placed in an appropriate position so as not to hinder reinstallation of the assembly 4 Tap the holes for 1 8 NPT and install temperature probe and test well extension fittings into the holes using thread sealing compound suitable for use with gasoline THE TEMPERATURE PROBE END SHOULD IDEALLY BE PLACED IN THE CENTER OF FUEL FLOW TWO EXTENSION FITTINGS ARE SUPPLIED IN ORDER TO ADJUST THE POSITION OF THE PROBE 5 Install temperature probe inside
15. d Installation 1 Remove backing paper to expose adhesive strips 2 Position the display board in the upper right hand corner of operator keypad and adhere firmly to the metal plate making sure the display is visible when enclosure is replaced see Figures 1 and 16 Figure 14 ATC Display Board Mounting ATC Display Board Operator Keypad Outside Enclosure 3 Attach the wire harness Part W189 from Display to connector P3 on middle left hand side of the ATC Board Kraus Global Inc 10 2007 28 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 7 ATC Display Board Functions The three switches on the board see Figures 15 amp 16 determine what information is displayed SWITCH 1 A B Selects the temperature and uncompensated volume reading for either A side or B side SWITCH 2 TEMP VOL Selects between the product temperature and uncorrected volume of product in normal mode SWITCH 3 FLOW NORM Selects between having the flowrate or the temperature and volume as above of a product displayed Note The NORM position may be labelled BLEND Figure 15 ATC Display Board wl Ci Ci E m Ll LH Li ATC Display SWITCH 1 SWITCH 2 TEMP VOL SWITCH 3 FLOW NORM ATC Display Switch Settings VOLUME TEMPERATURE Kr
16. d cage to the ATC Board by measuring for 5 VDC on the ATC Display harness Power can be measured across pins 1 amp 3 of P3 IF ERROR MESSAGES ARE FLASHING ON THE PRICE DISPLAYS RESET THEM WITH THE HANDLE SWITCHES ATTENTION Kraus Global Inc 10 2007 31 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 2 Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 POST INSTALLATION 2 2 2 Probe Connection Verification With the dispenser ready to be tested Make sure power is applied to the unit Ensure ATC is ON DIP switch 8 is ON Initialize the system as per the Gilbarco pump requirements Set the ATC display to show volume for the side being tested Run a delivery into a test can The ratio of the net volume on the dispenser and the gross volume on the ATC display should be the correct VCF Volume Correction Factor for the temperature displayed and the product selected Now unplug the temperature probe for the product being delivered The pump should stop and the ATC display should indicate a temperature probe failure Repeat the test procedure for each hose 32 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH 2 2 POSTINSTALLATION 2 2 3 INSTALLATION Installation Troubleshooting The following tables give examples of problems that may be faced after installation as well as their cause and solution This troubleshooting section should be referred to b
17. e The inside will be drilled out larger to accommodate the test well Part BC 407 See Figure 3 Kraus Global Inc 10 2007 12 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker and Dual 1 Product Highline Models 1a Thermal Test Well Connection cont d In the case of having Pressure Regulating Valves IF CONNECTION IS LESS THAN 5 THREADS THEN SOLDERING IS REQUIRED ANY OTHER CONNECTIONS MUST BE MADE USING THREAD SEALING COMPOUND SUITABLE FOR USE WITH GASOLINE ATTENTION 6 Install the test well Part BC 407 into the extension fitting Part BC 546 and after tightening cover with the supplied protective plug see Figure 3 7 Re connect the completed assembly 8 Repeat procedure for each test well to be installed PRESSURE REGULATING VALVE ASSEMBLY OPERATES AS A CHECK VALVE IN FORWARD FLOW CASES AND THEREFORE DOES NOT ALTER THE TEMPERATURE OF PRODUCT BEING MEASURED ATTENTION Kraus Global Inc 10 2007 13 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker and Dual 1 Product Highline Models 1b Thermal Test Well Connection cont d In the case of having Feedline Tube Assemblies 1 Remove the two lower panels to expose the main pump assembly 2 Lo
18. efore calling for technical support Table 2 Troubleshooting GTC 200 PROBLEM POSSIBLE CAUSE AND SOLUTION PULSER ERROR ON PUMP ERROR CODE 20 ATC Display for that side indicates PULS or shows no error PULSER ERROR ON PUMP ERROR CODE 20 ATC Display for that side indicates Prob and temperature for that side reads 50 0C Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 DIP Switches are set incorrectly DIP switch settings are as follows see Table 1 e 111 4 product types ON for Diesel OFF for Gasoline 5 ON for blender and pre modular Salesmaker quad only 6 ON for two hose 2 probe Highline and pre modular Salesmaker quad 7 ON only for pre modular Highline 1 or 2 hose 8 ON to enable volume correction Defective adapter board ribbon cable or ATC board Replace as necessary 50 0C Reading indicates an open probe circuit Defective 1 5 barrier probe connector assembly associated wiring ATC board or probe Replace as necessary DIP switch 6 is set incorrectly Should be ON only if dispenser is a two hose Highline using 2 probes 33 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 2 POSTINSTALLATION 2 2 3 Installation Troubleshooting Cont d Table 2 Troubleshooting Cont d GTC 200 PROBLEM POSSIBLE CAUSE AND SOLUTION PULSER ERROR ON PUMP 50 0C Reading indicates shorted probe circuit Defective ERROR CODE 20 1 5 barrier probe connector a
19. fold THE HOLE SHOULD BE PLACED SO THAT WITH THE PROBE INSTALLED THE MANIFOLD CAN BE RE CONNECTED WITHOUT THE PROBE INTERFERING WITH THE FRONT PANEL OF THE ENCLOSURE SUGGESTION 4 Tap the hole for 1 8 NPT and install temperature probe extension fitting using thread sealing compound suitable for use with gasoline THE TEMPERATURE PROBE END SHOULD IDEALLY BE PLACED IN THE CENTER OF FUEL FLOW INSIDE THE MANIFOLD TWO EXTENSION FITTINGS ARE SUPPLIED IN ORDER TO ADJUST THE POSITION OF THE PROBE SUGGESTION iAP hs 5 Install temperature probe inside the extension fitting also using thread sealing compound suitable for use with gasoline 6 Re connect manifold to pump assembly Kraus Global Inc 10 2007 19 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE 3a Test Well and Temperature Probe Connection For Single highline and Dual 2 Product Highline Models NOTE Test well and Temperature probe will be installed in the same location for each product 1 Locate the pipe extension nipple leading from the meters to the dispensing hoses inside the main enclosure see Figure 9 below Figure 9 Test Well and Temperature Probe Connection Meter Outlet Pipe Extension Feedline Tube Assembly Piston Flow Meter Pressure Regulator Main Product Inlet Manifold for Single Product Dispenser Dual Produ
20. h meter see Figure 2 3 Remove the valves from each section DUE TO THE PRESENCE OF COMBUSTIBLE GASSES DO NOT DRILL PROBE HOLES OR SOLDER FITTINGS USING A POWER DRILL WHILE THE PIPE IS CONNECTED TO THE PUMP ASSEMBLY CAUTION Kraus Global Inc 10 2007 11 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker and Dual 1 Product Highline Models 1a Thermal Test Well Connection cont d In the case of having Pressure Regulating Valves 4 With the valve mounted securely drill 1 hole of size Q or 21 64 in the leg that leads to the meter and tap for 1 8 NPT see Figure 3 Figure 3 Thermal Well Connection Pressure Regulating Valve Test Well Extension Part BC 546 Thermal Test Well Part BC 407 The following guidelines should also be followed for installing the test well e The hole should be drilled so that the extension will be at an angle within 45 of vertical when the extension is installed and assembly is reconnected This is so that it will hold thermally conductive fluid for measuring purposes e The fitting should provide easy access for insertion of a thermometer e The fitting should be placed in an appropriate position so as not to hinder reinstallation of the assembly 5 Install the 1 8 NPT test well extension fitting Part BC 546 into the newly drilled hol
21. ication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INFORMATION 1 1 INTRODUCTION 1 1 1 About This Manual This manual introduces the functions and operations as well as installation and maintenance procedures for the Kraus Automatic Temperature Compensation system In an effort to help our customers take full advantage of our state of the art products we have provided this handbook to aid in the initial set up and later to be used as a reference guide should the need arise The three divided sections are Section 1 INFORMATION Gives general information on system functions as well as cautionary advice Section 2 INSTALLATION Gives all information needed to successfully install and operate the system as well as technical illustrations to aid in understanding text Section 3 TECHNICAL DATA Gives information on products that make up the system in the form of drawings manufacturer s literature and references to related systems and products These three sections are set up in such a way that information is easily understood and instantly available to those who need it whether they are engineers technicians or supply managers Kraus Global Inc 10 2007 1 GTC 200 1M 2M Publication Number 212KY04 INS R04 1L 2L 1MH 2MH 1LH 2LH INFORMATION 1 1 INTRODUCTION SUGGESTION ATTENTION CAUTION 1 1 2 Helpful Hints and Warnings Throughout this handbook in the left hand margin there will be indica
22. ill 1 hole of size Q or 21 64 in the extension nipple and tap for 1 8 NPT see Figure 7 Figure 7 Temperature Probe Extension Nipple Probe Extension Fitting Y Fitting SUGGESTION Kraus Global Inc 10 2007 Publication Number 212KT04 INS 4 Temperature Probe Connection 4 Install extension fitting Part BC 546 into hole using sealing compound suitable for use with gasoline 5 Install the temperature probe into the extension fitting THE TEMPERATURE PROBE END SHOULD IDEALLY BE PLACED IN THE CENTER OF FUEL FLOW INSIDE THE PIPING TWO EXTENSION FITTINGS ARE SUPPLIED IN ORDER TO ADJUST THE POSITION OF THE PROBE 6 Re install the pipe section into the pump assembly Repeat procedure for each temperature probe 18 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 1 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker or Single Product 2 Hose Highline Dispensers 2b Temperature Probe Connection In the case of having a manifold assembly 1 Locate the fuel supply manifold at the bottom of the pump assembly inside the main enclosure see igures 8 amp 9 2 Remove manifold 3 With the manifold mounted securely drill one hole of size Q or 21 64 in the center of the manifold body or in a location where the probe is common to both meters see Figure 8 for hole location Single Product Supply Manifold Mounting Hole Location Main Fuel Supply Mani
23. pen front panel of display see Figure 1 2 Tilt the right hand LCD sales display board by loosening plastic locks on top and pulling down Board will have a hinge on the bottom See Figure 13 3 Locate and loosen the Donna bolt on the right hand side of the mounting plate see Figure 13 4 Insert bracket end of ATC board between the nut and the mounting plate then tighten making sure tab is against the plate siding 5 Connect the wire harness from the 1 5 Barrier to the connector P5 on the ATC board Figure 13 ATC Control Board Mounting Pin Connection for 1 5 Barrier Wiring cable W171 or W172 Seal Cover Mounting Hole Unit Configuration DIP Switches Pin Connection for ATC Display ATC Board Mounting Bolt 34 Pin Ribbon Cable W150 Right hand LCD Sales Display 6 Connect the 34 Pin Ribbon Cable Part W150 to the connector P1 on the lower left hand side of the board and run to the Modular Adapter Board already attached to the Main Processing Board in the Card Cage For Legacy model pumps connect to the Legacy adapter board attached to the Hydraulic Interface Board 7 Place seal cover BC 1239 over DIP switch section by inserting tab through hole then twist tie cover to board with some wire See Figure 13 for hole location Kraus Global Inc 10 2007 27 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2 1LH 2LH INSTALLATION 2 4 SYSTEM SET UP 2 1 4 6 ATC Display Boar
24. semblies removed 7 Remove the flanged fitting from the assembly in order that the sealant is not destroyed due to soldering Kraus Global Inc 10 2007 15 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP ATTENTION Kraus Global Inc 10 2007 16 GTC 200 1M 2M Publication Number 212KT04 INS R04 2 1 4 4 THERMAL TEST WELL AND TEMPERATURE PROBE For Salesmaker or Single Product 2 Hose Highline Dispensers 1b Thermal Test Well Connection cont d In the case of having Feedline Tube Assemblies 8 With the pipe section mounted securely drill 1 hole of size or 21 64 in the middle of the elbow that is located just before the meter and tap for 1 8 NPT see Figure 6 The following guidelines should also be followed for installing the test well e hole should be drilled so that the extension will be at an angle within 45 of vertical when the extension is installed and assembly is reconnected This is so that it will hold thermally conductive fluid for measuring purposes e fitting should provide easy access for insertion of a thermometer e The fitting should be placed in an appropriate position so as not to hinder reinstallation of the assembly 9 Install and silver solder the 1 8 NPT test well extension fitting Part BC 546 into the newly drilled hole The inside will be drilled out larger to accommodate the test well Part B
25. sembly Installation 1 Find a suitable mounting location to attach the probe connector assembly bracket mounting bracket can accommodate bolt up to 5 16 See Figure 11 2 With connector assembly securely mounted attach the wires from the back of the Probe Connector Assembly to the wires coming from the 1 5 Barrier Refer to connection diagrams Section 3 2 Figures 17 and 18 e For GTC 200 1M 1L connect the blue wires from the probe connector assembly using the supplied crimp on connectors to the yellow wires from the 1 5 Barrier e For GTC 200 2M 2L connect the wires from the assembly using the supplied crimp on connectors to the like colored wires of the 1 5 Barrier Yellow Product 1 Green Product 2 CONNECTIONS MUST BE MADE USING CRIMP ON WIRE NUTS OR BUTT CONNECTORS THIS IS A WEIGHTS AND MEASURES REQUIREMENT TO MAKE THE CONNECTION TAMPER RESISTANT ATTENTION Figure 11 Probe Connector Assembly Installation CRIMP ON WIRE CONNECTORS W78 HARNESS TO ATC BOARD 1 5 GROUND VAPOUR BARRIER 1 5 BARRIER o wy ay PROBE CONNECTOR ASSEMBLY Kraus Global Inc 10 2007 24 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 4 Adapter Board Connection 1M 2M 1MH 2MH 1 For Modular Pumps 1 Tilt the Operator Keypad down to expose the pump card cage see Figure 1 2 De
26. ssembly associated wiring ATC board or temperature probe could be the problem The ATC Display for that side indicates following procedure should indicate the source Prob and temperature for that side reads 50 0C Unplug the probe If it is faulty the display temperature will switch to 50 0C If display doesn t change detach the l S barrier plug from the ATC board If the temperature still reads 50 0C then the ATC board is bad If the temperature changes to 50 0C then the short is somewhere in the 1 5 barrier or the associated wiring PULSER ERROR ON PUMP Display may be too dim to read in daylight with front bezel ERROR CODE 20 off It may be necessary to shade ATC display with hand ATC display is dead Ensure that DIP switch 7 is set correctly Should be ON only if pre modular Highline Lift one handle switch and see if display comes ff it doesn t flip DIP switch 8 on and off to see if display comes on If it doesn t check for 5VDC across outer two pins of ATC display If there is no power present defective adapter board ribbon cable ATC display harness or ATC board are possible causes Replace as necessary Kraus Global Inc 10 2007 34 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 2 POSTINSTALLATION 2 2 3 Installation Troubleshooting cont d Table 2 Troubleshooting cont d GTC 200 PROBLEM POSSIBLE CAUSE AND SOLUTION TEMPERATURE O
27. tach the 60 Pin Ribbon Cable from the Logic Board in the Card Cage see Figure 12 3 Attach the Modular Adapter Board Part SKIL 428 to the Logic Board on the connector to which the cable was attached 4 Re attach Ribbon Cable in 60 pin receptacle on the Modular Adapter board 5 Attach Ribbon Cable Part W150 from ATC board to the remaining 34 Pin upper receptacle on Modular Adapter Board Figure 12 Modular Adapter Board Modular Adapter Board 34 Pin Ribbon Cable W150 mium 60 Pin CPU Board Ribbon Cable Kraus Global Inc 10 2007 25 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 2 1 4 4 Adapter Board Connection 1L 2L 1LH 2LH For Legacy Pumps Tilt the Operator Keypad down to expose the pump card cage see Figure 1 Detach the 16 Pin Ribbon Cable from the Legacy Logic Board in the Card Cage Attach the Legacy Adapter Board Part SKIL 447 to the Logic Board on the connector to which the cable was attached Re attach Ribbon Cable in 16 pin receptacle on Legacy Adapter board Attach Ribbon Cable Part W150 from ATC board to the remaining 34 Pin upper receptacle on Legacy Adapter Board 26 GTC 200 1M 2M 1L 2L 1MH 2 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 5 ATC Board Installation 1 O
28. the extension fitting using thread sealing compound suitable for use with gasoline 6 Install the test well Part BC 407 into the extension fitting Part BC 546 and after tightening cover with a PVC thermal well cap Part 213 2 7 Re connect pipe section to pump assembly DUE TO THE PRESENCE OF COMBUSTIBLE GASSES DO NOT DRILL PROBE HOLES OR SOLDER FITTINGS TO PARTS DIRECTLY CONNECTED TO THE PUMP IF CONNECTION IS LESS THAN 5 THREADS THEN SOLDERING IS REQUIRED ANY OTHER CONNECTIONS MUST BE MADE USING THREAD SEALING COMPOUND SUITABLE FOR USE WITH GASOLINE 21 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 2 SYSTEM SET UP 2 1 4 2 Intrinsic Safety Barrier Mounting Refer to Section 3 2 for complete connection details 1 Once the temperature probes have been installed remove pillar panels between sales display head and vapour barrier BE SURE TO LABEL ALL WIRES BEFORE DISCONNECTING SO THAT THEY MAY BE RECONNECTED PROPERLY SUGGESTION Steps 2 to 5 apply to Salesmaker model only 2 Disconnect the meter pulser wires attached by harness terminals and ballast wires black and white With the wires disconnected the display head can be taken off as follows 3 Remove the sales head mounting bolts located on the bottom of the pillars 4 Remove the bolts on side of the panel to separate the pump handle receptacles from the vapour barrier THE NEXT STEP REQUIRES TWO PEOPLE CAUTION 5 Slo
29. tors with text to give various hints and warnings The following are examples of what you will see and their meanings PROVIDES A HINT ON HOW TO BEST USE THE EQUIPMENT OR ADVICE ON PROPER PROCEDURES PROVIDES NOTICE TO AN IMPORTANT ASPECT OF SYSTEM OPERATION PROVIDES A WARNING TO PREVENT DAMAGE TO EQUIPMENT AND OR HUMAN INJURY Kraus Global Inc assumes no responsibility for personal injury or equipment damage caused by non observance of safety warnings Kraus Global Inc 10 2007 Publication Number 212KT04 INS R04 2 GTC 200 1M 2M 1L 2L 1MH 2MH 1LH 2LH INFORMATION 1 1 INTRODUCTION 1 1 3 Service and Product Support Should you experience any difficulties in system operation and you have referred to the troubleshooting tables in the handbook Section 2 2 without success customer assistance is available through our Service Department phone and fax numbers are listed below The procedure to receive such assistance is as follows 1 Document the following information i System disfunctions ii Any corrective measures taken iii System Model Number iv System Serial Number v Purchase Order Information vi Date of installation vii Equipment location i e city address etc 2 Call or Fax our Service Department at Company Service number 1 204 663 3601 Company Fax number 1 204 663 7112 One of our qualified personnel will provide assistance in getting your system operational Kraus Global Inc
30. wly raise pump head 6 Use the I S Barrier threaded extension to replace one of the bolts as shown in Figure 10 on the pillar mounting plate 1 5 Barrier should be mounted above the vapour barrier Kraus Global Inc 10 2007 22 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 2 Intrinsic Safety Barrier Mounting cont d Figure 10 I S Barrier Mounting Pulser Wires Sales Head Mounting Plate 1 5 Barrier Mounting Bolt Vapour Barrier 7 Crimp the wires coming from the top of the I S Barrier to the 5 Pin 3 wire harness 2 wire harness for GTC 200 1M amp 1L that will connect to the ATC Board part W172 or W171 Wires will correspond by colour 8 Replace the Sales Display Head while running the wires through the appropriate pillars 9 Return Sales Display Head to its normal position and tighten the bolts 10 Connect the ground wire Green 20 AWG from the I S Barrier to the 1 5 ground screw of the Pump Head Unit on the pillar GROUND WIRE CONNECTION IS CRITICAL FOR SAFE OPERATION OF THE EQUIPMENT CAUTION 11 Run the crimp wired harness up and through to the Sales Display Head control panel to the site where the ATC board will be mounted see Figures 1 and 13 Kraus Global Inc 10 2007 23 GTC 200 1M 2M Publication Number 212KT04 INS R04 1L 2L 1MH 2MH 1LH 2LH INSTALLATION 2 1 SYSTEM SET UP 2 1 4 3 Probe Connector As
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