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Related Manuals for Gasboy 9820K Series
Summary of Contents for Gasboy 9820K Series
- Page 1 9820K Series AST Pumps Installation and Operation Manual MDE-4567D...
- Page 2 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.
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Page 3: Table Of Contents
Angle Check Valve ............... . 26 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... - Page 4 Calibration ............50 Index Index-1 Page ii MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 5: Introduction
• The second assembly is mounted at a height to permit easy access by a user. It contains the electronic register, controls, display and nozzle boot. The standard features and specifications of the 9820K Series pumps are as follows: • One-inch high, 6-digit, backlighted Liquid Crystal Display (LCD) •... -
Page 6: Abbreviations And Acronyms
Introduction Abbreviations and Acronyms The available options and accessories for the Gasboy Series 9820K pumps are as follows: • Pulser output drive line (open collector), capable of driving 1, 10, 100, 250 and 500 pulses per unit (gallons) or 1, 10, and 100 pulses per unit (liters) •... -
Page 7: Important Safety Information
• Use of safety tape, cones or barricades at the affected dispenser or island. unit (s) • A total electrical shut-off of the affected unit (s) MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 3... - Page 8 Hazards, 29 CFR Part 1910.333 contains specific Lockout/ Please refer to your local, state, or country Tagout provision for electrical hazards. regulations for these requirements. Page 4 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
- Page 9 • Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring. • Call emergency numbers. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 5...
- Page 10 Important Safety Information This page is intentionally left blank. Page 6 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 11: Wiring
Wiring Precautions The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble-free operation of your Gasboy pump. To assure a quality installation, follow these rules: • All wiring must be installed to conform with all building/fire codes, all Federal, State, and... -
Page 12: Ground
If set for 230 VAC and a 115 VAC feed is used, the motor will run very slowly and the starting field will soon burn out. Page 8 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... -
Page 13: Pulse Output
115 Volt Wire Gauge Sizes per Feet of Run Motor Over 300', Use Relay at 100' 150' 200' 250' 300’ Motor Location 230 Volt Wire Gauge Sizes per Feet of Run MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 9... -
Page 14: Model 9820K
• Voltage Rating: Maximum operating voltage of 600V • Environmental: Gas and oil-resistant; suitable for wet or dry locations. Gasboy can supply Belden 1063A (P/N C09655) which is a UL-listed, 4-conductor cable that meets the requirements listed above. Note: Belden 1063A is UL-Listed but not CSA-listed. -
Page 15: Conduit
All wiring to the Gasboy Series 9820K pumping unit must be installed in threaded, rigid, metal conduit. PVC IS NOT ACCEPTABLE. The Gasboy Warranty will not apply to any pump in which the AC and DC wires are run in the same conduit, Junction Box (J-Box) or wireway, except as noted. -
Page 16: Conduit Size Charts
Inches Millimeters Inches Millimeters 0.629 0.303 0.076 0.826 0.532 0.133 1.063 0.862 0.215 1-1/4 1.378 1.50 0.375 1-1/2 1.614 2.04 1314 0.509 2.087 3.36 2165 0.839 Page 12 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... -
Page 17: Terminal Block Id
The wiring diagrams provided are as follows: • Figure 3-3: Model 9820K Wiring Diagram – Domestic page 14 • Figure 3-4: Model 9820K Wiring Diagram – International page 16 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 13... - Page 18 PUMPING UNIT 115 VAC PUMP MOTOR (SINGLE PHASE) PUMPING UNIT 380 VAC 3 PHASE PUMP MOTOR PUMPING UNIT 230 VAC PUMP MOTOR (SINGLE PHASE) 380 VAC BREAKER Page 14 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
- Page 19 CPU PCB will occur. 5) Use the wire size chart in “Wire Size” page 9 to determine the wire size for the control wiring. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 15...
- Page 20 Wiring Wiring Diagrams Figure 3-4: Model 9820K Wiring Diagram – International PUMPING UNIT 230 VAC PUMP MOTOR (SINGLE PHASE) Page 16 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
- Page 21 CPU PCB will occur. 4) Use the wire size chart in “Wire Size” page 9 to determine the wire size for the control wiring. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 17...
- Page 22 , NFPA 70, NFPA 30, and Automotive and Marine Service ® Station Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code. Page 18 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 23: Control Lines
The purpose of this section is to familiarize the installer with the control inputs and outputs that are available for the 9820K Series. It is recommended that installers read these instructions to obtain a better working knowledge of the unit in order to guide them in planning the site wiring. -
Page 24: Pump Motor Feed
The gauge of this wire should be equal to that of the Pump Motor Feed. Together with the pump feed, it supplies power to the motor and valves. Page 20 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... -
Page 25: Slow Flow (Reset Complete/Switch Detect)
Slow Flow stage of the solenoid valve. This line also indicates when the reset process is complete and the unit is ready to dispense the product. This line can be used in conjunction with a fuel management system (for all Gasboy Controllers using Pulse-Output mode or any non-Gasboy Fuel Management systems). -
Page 26: Pulse Output
RS-485 When the pumping unit includes the optional RS-485 interface, RS-485 lines are provided. This interface allows the user to connect a Gasboy Fuel Controllers using RS-485 Communications directly to the 9820K Series register’s electronics. Page 22... -
Page 27: Installation
This means that even if you activate these stops, fuel may continue to flow uncontrolled. You must use the TOTAL ELECTRICAL SHUT-OFF in case of an emergency and not only these facility building and ICR station “stops”. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 23... -
Page 28: Installation Do Nots
• DO NOT use a circuit breaker of improper size (refer to “Wiring” page • DO NOT use the Gasboy fuel pumping equipment to remove water ballast from the storage tank. • DO NOT use gaskets on covers of explosion-proof type boxes. The sealing compound found around wires at various locations within the conduit is a requirement of the National Electrical Code and should not be disturbed. -
Page 29: Vapor Recovery Option
13’ / 396 cm 8’ 6” / 259 cm 13’ 6” / 411 cm 16’ / 488 cm 10’ / 305 cm 15’ / 457 cm MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 25... -
Page 30: Angle Check Valve
Angle Check Valve Angle check valves must be of a low restriction variety to allow maximum unit flow rate. Check valves with springs are not recommended. Page 26 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... -
Page 31: Typical Installations
LISTED HOSE BREAKAWAY AC/DC CONDUIT BETWEEN PUMP DC WIRING CONDUIT AND REGISTER FRONT VIEW AC/DC CONDUIT BETWEEN PUMP AND REGISTER AC WIRING CONDUIT DC WIRING CONDUIT MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 27... -
Page 32: Base Layouts
1-1/2 NPT Inlet Units Only) Front Discharge for all units Back View Right View Alternate 3/4" NPT AC Power 1" NPT Conduit Connection Conduit Connection Front Footprint Page 28 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... - Page 33 Figure 5-3: Model 9820K Base Layout – Register Assembly CONDUIT KNOCKOUTS FOR 3/4 [19mm] OR 1’ [25 mm] CONDUIT ARE LOCATED ON THE BOTTOM OF THE CABINET MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 29...
- Page 34 BACKWARDS AND ATTACH REGISTER TO BRACKET USING HARDWARE PROVIDED. 3 RETURN BRACKET TO NORMAL POSITION ALIGNING REGISTER IN GROOVE ON TOP OF POST. 4 TIGHTEN ALL HARDWARE. Page 30 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
- Page 35 Figure 5-5: Model 9820K Base Layout – Side and Rear Brackets (View 1 of 2) REGISTER BACK VIEW RIGHT SIDE MOUNT (OPTIONAL MOUNTING METHOD) FOR RIGHT SIDE MOUNTS, BRACKETS ARE OFFSET TO ALLOW FOR CLEARANCE OF NOZZLE BOOT MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 31...
- Page 36 Base Layouts Figure 5-6: Model 9820K Base Layout – Side and Rear Brackets (View 2 of 2) BACK VIEW SIDE VIEW REAR MOUNT REAR MOUNT REGISTER Page 32 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 37: 9820K Setup And Special Features
6-1). Remove the two screws located at the top of the door assembly. Lift the door assembly to remove it. Figure 6-1: Front Panel – Model 9820K REMOVE UNLOCK MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 33... - Page 38 Loosen the two screws located on the left and right door support brackets and pivot the display panel down (see Figure 6-2). Figure 6-2: Door Support Bracket Screw Locations – Model 9820K LOOSEN Page 34 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 39: Cpu Switch Settings
Jumper JP1 - JP9 JP1: Baud Rate This jumper is set to reflect the communication rate of the Gasboy RS-485 pump loop: jumper installed for 1200 baud and jumper not installed for 9600 baud. All Gasboy Fuel Controllers communicate at 9600 baud. - Page 40 If the 9820K is controlled by a Gasboy Fuel Controller using RS-485 Communications, the jumper should be open (online mode). If the 9820K is controlled by a Gasboy Fuel Controller using Pulse-Output mode, all non-Gasboy Fuel Controllers, or no fuel management system, the jumper should be installed (standalone mode).
- Page 41 Gasboy Fuel Controller using RS-485 Communications. This setting must be disabled (jumper installed) for all other configurations. Detection Disabled Installed Enabled Open This jumper is spare and not in use. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 37...
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Page 42: Switch Sw2
These four switches serve a dual purpose: as an address setting when communicating on the Gasboy RS-485 loop or as a pulser output rate selector when pulser data is sent to all Gasboy Controllers using Pulse-Output mode or any non-Gasboy fuel management systems. -
Page 43: Pulser Output Rate Switches
9820K Setup and Special Features Pulser Output Rate Switches When the 9820K is connected to Gasboy Controllers using Pulse-Output mode or any non-Gasboy fuel management system (standalone), the pulser signals are sent out via the Pump I/F PCB. The pulse rate required by the monitoring equipment can be configured by setting the switches as shown in the chart below. - Page 44 When using the Pump I/F PCB (M06587A001) on the 9820K, jumpers JP4 and JP5 should always be set to the Q/A position. Figure 6-4: JP4 and JP5 Positions Page 40 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 45: Battery Backup Power Supply
Touch this area with the actuator as shown. The totalizer data will be displayed for 10 seconds. If more time is needed, touch the actuator to the same area for an additional 10- second period. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 41... -
Page 46: Mechanical Totalizer
Some 9820K models contain an optional mechanical totalizer. The totalizer has 8 digits; 7 whole gallons and 1 tenth-gallon column, 8 whole digits for liters. The mechanical totalizer is located on the front right side of the pumping module. Page 42 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... - Page 47 • An AC power failure occurs. The 9820K continues to monitor for pulses until a 2-second period with no pulses occurs. At that, time the transaction is considered completed. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 45...
- Page 48 Close the lock. While the nozzle is locked in place, the nozzle cannot be removed from the nozzle hook and the pump cannot be turned on. Page 46 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...
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Page 49: Operating Sequence And Locking The Nozzle
9820K Nozzle Locking Operating Sequence and Locking the Nozzle Figure 7-1: Locking Mechanism – Model 9820K MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 47... -
Page 50: 9820K Nozzle Locking
Operating Sequence and Locking the Nozzle 9820K Nozzle Locking This page is intentionally left blank. Page 48 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... -
Page 51: Installation Completion Checklist
• The unit must be properly secured to the tank. • All plumbing must be complete and tight. • When DC pulsers are used in the pump for connecting to Gasboy fuel management systems, AC and DC wires should not share any conduits, J-Boxes, or troughs. -
Page 52: Voltage
Calibration All Gasboy pumps are adjusted for accurate measure at the factory. However, since the conditions of the installation and fuel types can affect pump accuracy, it is the responsibility of the installer to check the pump for accuracy and make any required adjustments. -
Page 53: 9820K Startup And Test
Repeat the process until the volume in prover can and the amount recorded are within tolerance. After calibration is complete, reinstall the seal pin and secure in place using a seal wire. Figure 8-1: Index Disc MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Page 51... -
Page 54: Startup - Model 9820K
9820K Startup and Test Post Startup Tests This page is intentionally left blank. Page 52 MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020... - Page 55 Smoking Sparks Warning words Ground Working alone Safety symbols Shut-off Emergency electrical Hose Length Estimator Signal words Safety Slow Flow Installation Completion Checklist Switch Detect Installation Precautions MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020 Index-1...
- Page 56 Underwriters Laboratories Inc. © 2020 GASBOY 7300 West Friendly Avenue · Post Office Box 22087 Greensboro, North Carolina 27420 Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A. MDE-4567D 9820K Series AST Pumps Installation and Operation Manual · January 2020...