1. Manuals
  2. Brands
  3. Gasboy Manuals
  4. Control Systems
  5. TopKAT
  6. Installation manual

Gasboy TopKAT Installation Manual

Fuel management system
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
TopKAT Fuel Management System
Installation Manual
MDE-4319A
(formerly C35754)

Advertisement

Table of Contents
loading

Related Manuals for Gasboy TopKAT

Summary of Contents for Gasboy TopKAT

  • Page 1 TopKAT Fuel Management System Installation Manual MDE-4319A (formerly C35754)
  • 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.

  • Page 3: Table Of Contents

    AC Power to TopKAT........
  • Page 4 RS-485 - Master/Satellite Option ......17 RS-485 - Standalone TopKAT or Wall-Mount PCU ....18 RS-232 .
  • Page 5 Wiring Precautions ......... 88 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 6 Internal Modem ......... . 117 9 – Wireless Communications Installation 10 – Serial-to-LAN Connection Installation Page iv MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 7 Table of Contents 11 – Testing Completion Check List Manual Override Test 12 – Appendix: Base Layout for Shelf Mounting Index Index-1 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page v...
  • Page 8 Table of Contents This page intentionally left blank. Page vi MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 9 • A total electrical shut-off of the affected unit (s) Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will Page Safety-1 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 10 State of California to cause birth defects or other electrical hazards. Subpart S of 29 CFR Part 1910 - Electrical reproductive harm. Hazards, 29 CFR Part 1910.333 contains specific Lockout/ Tagout provision for electrical hazards. Page Safety-2 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 11 • Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring. • Call emergency numbers. Page Safety-3 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 12 Important Safety Information This page intentionally left blank. Page Safety-4 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 13: General Information

    2 – Introduction Purpose The Gasboy Series 900 TopKAT Installation Manual is provided to assist you in installing your TopKAT System. This manual should be supplied to the electrician prior to the installation of conduit and wiring to ensure your TopKAT System is installed properly. Faulty installations are the major cause of system malfunctions.
  • Page 14 If you have the master/satellite option, you can control up to 8 electronic hoses and 7 satellite readers or up to 16 mechanical (2 hoses per TopKAT), or one 9820 or 9800 single or twin electronic and up to 14 mechanical hoses (2 hoses per TopKAT).

  • Page 15: Communication Ports

    Communication is through direct wire, or by dial-up phone lines using an optional built-in modem. If the TopKAT is equipped with the master/satellite option, the master is the only unit that will need to have a data communication link; it will collect all transactions and maintain the complete data base for the entire site.

  • Page 16: Related Documents

    Introduction Using this Manual Related Documents The following manuals provide additional information about TopKAT Fuel Management System. TopKAT Specific Document Number Title GOLD Library C35755 TopKAT Parts Manual Gasboy Fuel Management Products C35965 TopKAT Host Communications Manual Gasboy Fuel Management Products...

  • Page 17: Fcc Part 15

    FCC Part 68 General Requirements for All Equipment This equipment complies with Part 68 of the FCC rules. The Gasboy Internal Modem is contained within a Gasboy Fuel Management System. On the outside of the rear access door of the Fuel Management System is a label that contains, among other information, the FCC registration number and ringer equivalence number (REN) for this equipment.

  • Page 18: Doc Certification

    The Gasboy Internal Modem does not have any easily repairable or replaceable parts. If you are experiencing trouble, please contact Gasboy. The equipment cannot be used on public coin phone service provided by the telephone company.
  • Page 19 “RS-422 - Short Haul Modems” on page Power for the TopKAT (when used with mechanical interface), data terminal, and external modem must come from a separate, dedicated, circuit breaker. The TopKAT and peripheral equipment must be properly grounded.

  • Page 20: System

    If you order your TopKAT with an optional internal modem, the modem is mounted within the TopKAT at the factory and power for the modem is supplied by the TopKAT. The 2400 baud modem is designed for 300, 1200, or 2400 baud, full duplex, asynchronous communication.

  • Page 21: Power Conditioner

    The power conditioner must be located in an area protected from direct contact with weather (typically near the system circuit breakers) and should be no further than 50 feet from the TopKAT for optimum protection. It must not be used over a hazardous location.
  • Page 22 RS-232 communication must not exceed 100 feet. RS-232 communication wires must be in a separate metal conduit from any AC wires. For communication distances exceeding 100 feet, you must use a Gasboy RS-422 Short Haul Modem. It is recommended that high voltage AC power wires be installed in separate conduit from the low voltage DC signal wires.
  • Page 23 Marine Service Stations Code (NFPA 30A). Canadian users must also comply with the Canadian Electrical Code. Use the tables below as a guideline to determine the proper conduit sizes for the Gasboy TopKAT fuel management system. When planning the orientation of the wiring runs, follow the applicable Gasboy wiring diagram and consider the layout of the components at the site.
  • Page 24 .629 .303 .076 .826 .532 .133 1.063 .862 .215 1-1/4 1.378 1.50 .375 1-1/2 1.614 2.04 1314 .509 2.087 3.36 2165 .839 Page 12 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 25: Ac Power To Topkat

    Power Requirements AC Power to TopKAT When mounted to a 9800 or ASTRA, AC power for the TopKAT comes from the same power source used to power the 9800 or ASTRA Micro Feed. A wiring cable for AC power from the 9800 or ASTRA to the TopKAT is supplied with the TopKAT.

  • Page 26: Suction Pumps

    Power Requirements Suction Pumps The TopKAT System, with Mechanical Interface or Mechanical PCU options, is capable of directly driving pump motors up to 3/4 HP at 115 VAC or 1-1/2 HP at 230 VAC. A starter relay must be used with pump motors exceeding this limitation. A separate circuit breaker should be supplied for each pump to meet the current requirements and to allow for isolated control with the circuit breaker panel in case of problems.

  • Page 27: Mechanical Interface Option

    General Installation Wire Size A wiring cable for AC power from the 9800 or ASTRA to the TopKAT is supplied with the TopKAT. If wiring a pedestal TopKATor wall-mount Mechanical PCUs, the AC power wire size must be 14 AWG or larger for runs of up to 300 feet from the breaker panel to the system.
  • Page 28 230 Volt Wire Gauge Sizes per Feet/Meters of Run (Note) Motor 25’ 50’ 100’ 150’ 200’ 250’ 300’ H.P. 7.6M 15.2M 30.5M 45.7M 76.2M 91.4M 1-1/2 Note: For run over 300 feet, use relay at motor location. Page 16 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 29: Rs-485 - Astra And Mechanical Pcus

    PC. Phone line (modem) communication may also be used when remote communication to the site is desired. In cases where a TopKAT internal modem is used, port 3 is not available for external communication wiring. The specific requirements for each of these modes of communication are listed below.

  • Page 30: Rs-485 - Standalone Topkat Or Wall-Mount Pcu

    1500 feet (455m). RS-485 - Standalone TopKAT or Wall-Mount PCU When the TopKAT is to communicate to a 9800 or wall-mount PCU through Port 1 (RS-485) of the TopKAT and the TopKAT is not directly mounted on the 9800, the appropriate interconnect cable must be used.
  • Page 31 • 1 - 100 feet (1 - 31 meters): RS-232 can be directly connected to a peripheral device. • 101 - 1500 feet (32 - 455 meters): RS-422 and Gasboy short haul modem (SHM) are required. See “RS-422 - Short Haul Modems” on page Conduit: All direct connect RS-232 cables over 15 feet (5m) must be in a metal conduit separate from any AC wires.

  • Page 32: Rs-232 - Termination Box

    A Gasboy short haul modem and the appropriate interconnect cable must be used when the RS-422 communication mode is being used to communicate to the ports of the TopKAT. It must be used for distances between 100 and 1500 feet (31 and 455 meters). It can be used for distances under 100 feet in place of RS-232 wiring.
  • Page 33 • 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 34 To gain access to the inside of the TopKAT, unlock the rear door and open it all the way. Unscrew the two captive screws holding the hood in place. Slide the hood toward the rear of the unit (about 1 inch) and lift straight up.
  • Page 35 Port 1 is a dedicated RS-485 communication loop which allows the TopKAT to control all functions of the ASTRA. Ports 2 and 3 can be set for either RS-232 or RS-422 communications to a data terminal or computer. See “Communication Requirements”...
  • Page 36 Series 9820 ASTRA Installation Figure 4-2: 011889 Base Layout (optional post w/TopKAT) - Models 9822 & 9823 Page 24 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 37 Series 9820 ASTRA Installation ASTRA to TopKAT Cabling The interconnection of the ASTRA to the TopKAT requires two cables: an RS-485 communication cable and an AC power cable. Both of these are supplied by Gasboy. Figure 4-3: RS-485 Communication Cable Figure 4-4: ASTRA to TopKAT AC Power Cable MDE-4319A TopKAT Fuel Managment System Installation Manual ·...

  • Page 38: Switch Settings

    Figure 4-5: RS-232 - D Connector Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 39 Figure 4-6: RS-232 - Gasboy Termination Box Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 40 Series 9820 ASTRA Installation ASTRA to TopKAT Cabling Figure 4-8: Internal Modem Note: In cases where a TopKAT internal modem is used, port 3 is not available for external communication wiring. Note: The K2 jumper for port 3 should be removed. See “Terminal Block ID”...

  • Page 41: External Modems

    Internal Modem When the TopKAT internal modem is installed, port 3 communication is routed through the modem in place of being wired at the DC junction box. Jumper K2 should be removed. See “Terminal Block ID”...
  • Page 42 Series 9820 ASTRA Installation Wiring for a Link CRT Terminal and Okidata® Printer This page intentionally left blank. Page 30 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 43 TopKAT and all wiring connections are made within the TopKAT; no electronics or control devices are present in the pedestal. The TopKAT with mechanical interface can also be used in a master/satellite configuration.
  • Page 44 Mechanical Interface Option Dimensions Dimensions Figure 5-1: TopKAT Dimensions (with Pedestal) Page 32 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 45 Conduit Layout Mechanical Interface Option Conduit Layout “General Installation” on page 11 for conduit, power requirements, and wire size considerations. Figure 5-2: TopKAT Conduit Layout MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 33...
  • Page 46 “Terminal Block ID” on page To gain access to the inside of the TopKAT, unlock the rear door and open it all the way. Unscrew the two captive screws holding the hood in place. Slide the hood toward the rear of the unit (about 1 inch) and lift straight up.

  • Page 47: 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/dispenser. To assure a quality installation, follow these rules:...

  • Page 48: Grounding

    This is a 115 VAC input which is supplied through the pump handle switch to activate the reset motor. This line should be switched through the TopKAT and should only be on when the pump/dispenser is authorized or in manual mode. Without power supplied to this line, the pump/dispenser will not reset when the pump handle is turned on.

  • Page 49: Submersible Feed, Submersible Drive

    This is a 115 VAC input which is supplied to the input side of one of the internal switches of the electric reset. This line should be switched through the TopKAT and only be on when the pump/dispenser is authorized or in manual mode. When the reset finishes its cycle, the 115...

  • Page 50: Control Lines For Gasboy 9800 Or 9820 Electronic Pumps/Dispensers

    Note: This section pertains to 9800 electronic pumps/dispensers running as mechanical units (standalone operation). This scenario would only be used when controlling two pumps: one mechanical and one electronic running as mechanical, from a single TopKAT system. Descriptions of the control lines are provided to familiarize the installer with the control inputs and outputs that are used to control the Series 9800 and 9820 dispensing units.

  • Page 51: External Valve

    3/4 HP at 115 VAC or 1-1/2 HP at 230 VAC. The gauge of this wire should be determined according to the size of the motor, the voltage at which the motor will be powered, and the distance from the breaker panel to the pump. MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 39...

  • Page 52: Submersible Starter Drive (Subm Starter Drive)

    It is required when used with a TopKAT fuel management system. It may also be used to control a remote (satellite) slow flow valve. Two lines are provided for twins.

  • Page 53: Pulser - 9800/9820

    Mechanical Interface Option Pulser - 9800/9820 CAUTION The TopKAT Pump Control PCB must be set for electronic pulser (100:1 or higher) as shown in “Terminal Block ID” on page 34. Failure to set the Pump Control PCB jumpers properly will damage the TopKAT.

  • Page 54: Wiring Diagrams

    Although it is recommended that DC pulser wires be run in a conduit separate from AC wires, they can be combined in the same conduit with AC wires providing UL-Listed cable with the following specifications is used: Page 42 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 55 • Voltage Rating: Maximum operating voltage of 600 VDC • 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 56 Mechanical Interface Option Wiring Diagrams Figure 5-6: Wiring Diagram: Single Suction Pump, 115 VAC/230 VAC, Veeder-Root Reset Page 44 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 57 Wiring Diagrams Mechanical Interface Option Figure 5-7: Twin Suction Pump, 115 VAC/230 VAC, Veeder-Root Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 45...
  • Page 58 Mechanical Interface Option Wiring Diagrams Figure 5-8: Wiring Diagram: Twin Suction Pump, Single Motor, 115 VAC/230 VAC, Veeder-Root Reset Page 46 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 59 Wiring Diagrams Mechanical Interface Option Figure 5-9: Wiring Diagram: Single Dispenser, Veeder-Root Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 47...
  • Page 60 Mechanical Interface Option Wiring Diagrams Figure 5-10: Wiring Diagram: Twin Dispenser, Veeder-Root Reset Page 48 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 61 Wiring Diagrams Mechanical Interface Option Figure 5-11: Wiring Diagram: Single Suction Pump, 115 VAC/230 VAC, Gasboy Reset Note: Units with two motors may require pump to be operated at 240 VAC to limit the AC current required. MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 62 Mechanical Interface Option Wiring Diagrams Figure 5-12: Wiring Diagram: Twin Suction Pump, 115 VAC/230 VAC, Gasboy Reset Page 50 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 63 Wiring Diagrams Mechanical Interface Option Figure 5-13: Wiring Diagram: Twin Suction Pump, Single Motor, 115 VAC/230 VAC, Gasboy Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 51...
  • Page 64 Mechanical Interface Option Wiring Diagrams Figure 5-14: Wiring Diagram: Single Dispenser, Gasboy Reset Page 52 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 65 Wiring Diagrams Mechanical Interface Option Figure 5-15: Wiring Diagram: Twin Dispenser, Gasboy Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 53...
  • Page 66 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/N C06683) for 230 VAC international units. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID”...
  • Page 67 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/ N C06683) for 230 VAC international units. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID”...
  • Page 68 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/N C06683) for 230 VAC international units. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID”...
  • Page 69 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/ N C06683) for 230 VAC international units. Two assemblies required for twins. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID”...
  • Page 70 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/N C06683) for 230 VAC international units. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID” on page 34.
  • Page 71 1.The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/N C06683) for 230 VAC international units. Two assemblies required for twins. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID”...
  • Page 72 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/N C06683) for 230 VAC international units. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID”...
  • Page 73 1. The power resistor assembly is 8.2K OHM, 10W (P/N C05818) for 115/230 VAC domestic units and 30K OHM, 10W (P/N C06683) for 230 VAC international units. 2. Before applying power, the TopKAT Pump Control PCB jumpers must be set for electronic pulser as shown in “Terminal Block ID” on page 34.
  • Page 74 Figure 5-24: Wiring Diagram: RS-232 - D Connector Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 75 Figure 5-25: Wiring Diagram: RS-232 - Gasboy Termination Box Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 76 Wiring Diagrams Figure 5-26: Wiring Diagram: RS-422 - Gasboy Short Haul Modem Note: In the TopKAT, the green connector goes to P3 on the communication board for port 2 and P5 for port 3. Note: In cases where a TopKAT internal modem is used, port 3 is not available for external communication wiring.
  • Page 77 Wiring Diagrams Mechanical Interface Option Figure 5-28: Wiring Diagram: TopKAT Master/Satellite Communications Wiring Figure 5-29: Wiring Diagram: Link CRT Terminal and Okidata Printer MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 65...

  • Page 78: Wiring For Modems

    Internal Modem When the TopKAT internal modem is installed, port 3 communication is routed through the modem in place of being wired at the DC junction box. Jumper K2 should be removed. See “Terminal Block ID”...

  • Page 79: Topkat Master/Satellite

    • All electronic, where the TopKAT can control up to 8 electronic 9800/ASTRAs and up to 7 satellite readers • All mechanical, where the master TopKAT controls up to 2 mechanical hoses and up to 14 other hoses (2 hoses per up to 7 TopKATs) •...
  • Page 80 TopKAT Master/Satellite Figure 6-1: Wiring Diagram: TopKAT Master/Satellite Communications Wiring - 9820 Figure 6-2: Wiring Diagram: TopKAT Master/Satellite Communications Wiring - 9800 Page 68 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 81 TopKAT Master/Satellite Figure 6-3: Wiring Diagram: RS-422 - Gasboy Short Haul Modem - Master/Satellite Modem MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 69...
  • Page 82 Figure 6-4: Wiring Diagram: Mechanical Pump Control Unit - Remote (Wall-Mount) Figure 6-5: Wiring Diagram: Internal Modem with Master/Satellite Option Note: In the TopKAT, port 3 is not available for external communication wiring when an internal modem is used. For port 2, reference the Master/Satellite Wiring drawing...

  • Page 83: Wiring For Modems

    Internal Modems When the TopKAT internal modem is installed, port 3 communication is routed through the modem in place of being wired at the DC junction box. Jumper K2 should be removed. See “Terminal Block ID”...
  • Page 84 TopKAT Master/Satellite This page intentionally left blank. Page 72 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 85: Mechanical Pcu Option

    (Individual PCU power must be present in order for the override switches to place the pump in MANUAL.) The TopKAT can handle quantity pulsing rates of 1, 10, 100, 500, and 1000 per gallon measurement and 1, 10, 100 and 250 per liter measurement.
  • Page 86 Mechanical PCU Option Figure 7-1: Pedestal Dimensions - Pedestal-Mounted PCU Page 74 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 87 Mechanical PCU Option Figure 7-2: Pedestal Dimensions - Wall-Mounted PCU MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 75...
  • Page 88 Mechanical PCU Option Figure 7-3: Wall-Mount PCU Dimensions Page 76 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 91: Terminal Block Id

    Mechanical PCU Option Terminal Block ID To gain access to the inside of the TopKAT, unlock the rear door and open it all the way. Unscrew the two captive screws holding the hood in place. Slide the hood toward the rear of the unit (about 1 inch) and lift straight up.
  • Page 92 PCU components. Refer to “Terminal Block ID” on page 22 for the TopKAT Comm Assembly. Figure 7-6: Terminal Block ID: Standard Pedestal - Left Side Page 80 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 93 Terminal Block ID Mechanical PCU Option Figure 7-7: Terminal Block ID: Standard Pedestal - Right Side MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 81...
  • Page 94 Mechanical PCU Option Terminal Block ID Figure 7-8: Terminal Block ID: Wall-Mounted PCU Page 82 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 95: Pump Control Expmux Cpu Board

    Verify that the pump control CPU board switch bank, SB (1 through 4), is set for the proper address. An address must be set to identify the pump control unit when it is connected to the TopKAT System. This address is a unique identifier for multiple PCUs that are connected on the same RS-485 line.
  • Page 96 Timer Switch. If enabled, the pump control unit must be polled at least every 15 seconds by the TopKAT. If it fails to sense a poll at that time, it turns all relays off. If Reset Complete Mode is used on any pump on a particular PCU, the deadman timer should be disabled.
  • Page 97 Open = deadman timer enabled SC-7 No function in on-line mode SC-8 TEST Open = Test mode, Closed = On-line mode Re-install the EXPMUX Pump Control CPU board. MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 85...

  • Page 98: Pump Control I/O Pcb

    PCB and remove the cover ® plate. Pulse Connection: Verify that the K1 through K4 jumpers (pulse type jumpers) match the type Page 86 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 99 Replace the five green connectors into the proper sockets on the front of the Pump Control I/O board (Figure 7-10). Repeat all steps for both the EXPMUX Pump Control CPU and Pump Control I/O PCBs for each pump control unit. MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 87...

  • Page 100: System Pump And Dispenser Wiring

    The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble-free operation of your Gasboy pump/dispenser. To assure a quality installation, follow these rules: All wiring is to be installed and used in accordance with local building/fire codes, all Federal, State, and Local codes, the National Electrical Code (NFPA 70), NFPA 30, and the Automotive and Marine Service Station Code (NFPA 30A) codes and regulations.

  • Page 101: Grounding

    This is a 115 VAC input which is supplied through the pump handle switch to activate the reset motor. This line should be switched through the TopKAT and should only be on when the pump/dispenser is authorized or in manual mode. Without power supplied to this line, the pump/dispenser will not reset when the pump handle is turned on.

  • Page 102: Submersible Feed, Submersible Drive

    This is a 115 VAC input which is supplied to the input side of one of the internal switches of the electric reset. This line should be switched through the TopKAT and only be on when the pump/dispenser is authorized or in manual mode. When the reset finishes its cycle, the 115...
  • Page 103 • Figure 7-18: Wiring Diagram: Twin Suction Pump, Gasboy Reset on page 100 • Figure 7-19: Wiring Diagram: Twin Suction Pump, Single Motor, Gasboy Reset on page • Figure 7-20: Wiring Diagram: Single Remote Dispenser, Gasboy Reset on page 102 •...
  • Page 104 Mechanical PCU Option Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-11: Wiring Diagram: Pulsers Page 92 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 105 • 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 106 Mechanical PCU Option Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-12: Wiring Diagram: Single Suction Pump, Veeder-Root Reset Page 94 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 107 Wiring Diagrams: Pulsers, Pumps, Dispensers Mechanical PCU Option Figure 7-13: Wiring Diagram: Twin Suction Pump, Veeder-Root Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 95...
  • Page 108 Mechanical PCU Option Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-14: Wiring Diagram: Twin Suction Pump, Single Motor, Veeder-Root Reset Page 96 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 109 Wiring Diagrams: Pulsers, Pumps, Dispensers Mechanical PCU Option Figure 7-15: Wiring Diagram: Single Remote Dispenser, Veeder-Root Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 97...
  • Page 110 Mechanical PCU Option Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-16: Wiring Diagram: Twin Remote Dispenser, Veeder-Root Reset Page 98 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 111 Wiring Diagrams: Pulsers, Pumps, Dispensers Mechanical PCU Option Figure 7-17: Wiring Diagram: Single Suction Pump, Gasboy Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 99...
  • Page 112 Mechanical PCU Option Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-18: Wiring Diagram: Twin Suction Pump, Gasboy Reset Page 100 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 113 Wiring Diagrams: Pulsers, Pumps, Dispensers Mechanical PCU Option Figure 7-19: Wiring Diagram: Twin Suction Pump, Single Motor, Gasboy Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 101...
  • Page 114 Mechanical PCU Option Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-20: Wiring Diagram: Single Remote Dispenser, Gasboy Reset Page 102 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 115 Wiring Diagrams: Pulsers, Pumps, Dispensers Mechanical PCU Option Figure 7-21: Wiring Diagram: Twin Remote Dispenser, Gasboy Reset MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 103...
  • Page 116 Figure 7-22: Wiring Diagram: RS-232 - D Connector Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 117 Figure 7-24: Wiring Diagram: RS-232 - Gasboy Termination Box Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 118 Wiring Diagrams: Pulsers, Pumps, Dispensers Figure 7-25: Wiring Diagram: RS-422 - Gasboy Short Haul Modem Note: In the TopKAT, the green connector goes to P3 on the communication board for port 2 and P5 for port 3. Note: In cases where a TopKAT internal modem is used, port 3 is not available for external communication wiring.
  • Page 119 TopKAT Master/Satellite Communications Wiring Mechanical PCU Option TopKAT Master/Satellite Communications Wiring Figure 7-27: Wiring Diagram: TopKat Master, 2 TopKAT Satellites, 2 Wall-Mount PCUs MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 107...

  • Page 120: External Modems

    Internal Modem When the TopKAT internal modem is installed, port 3 communication is routed through the modem in place of being wired at the DC junction box. Jumper K2 should be removed. See “Terminal Block ID”...
  • Page 121 Port 1 is a dedicated RS-485 communication loop which allows the TopKAT to control all functions of the 9800. Ports 2 and 3 can be set for either RS-232 or RS- 422 communications to a data terminal or computer. See “Communication Requirements”...
  • Page 122 Series 9800 Field Installation Figure 8-1: Series 9800 Dimensions Page 110 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 123 Conduit Layout Series 9800 Field Installation Conduit Layout Note: See “General Installation” on page 11 for conduit, power requirements, and wire size considerations. Figure 8-2: Series 9800 Conduit Layout MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 111...

  • Page 124: Switch Settings

    “Communication Requirements” on page 21 for wiring considerations. Figure 8-3: RS-485 Communication Cable Switch Settings In order for the 9800 to communicate to the TopKAT via RS-485, the switch settings on the 9800 CPU must be as follows: Switch Function...
  • Page 125 Figure 8-4: RS-232 - D Connector Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 126 Figure 8-5: RS-232 - Gasboy Termination Box Note: In the TopKAT, the green connector goes to P4 on the communication board for port 2 and P6 for port 3. The K1 & K2 jumper for the port being used should be set to RS-232.
  • Page 127 Series 9800 Field Installation Figure 8-6: RS-422 - Gasboy Short Haul Modem Note: In the TopKAT, the green connector goes to P3 on the communication board for port 2 and P5 for port 3. Note: In cases where a TopKAT internal modem is used, port 3 is not available for external communication wiring.
  • Page 128 Series 9800 Field Installation TopKAT Master/Satellite Communications Wiring TopKAT Master/Satellite Communications Wiring Figure 8-8: 2 Top-Mounted TopKATS, 1 Series 9800 with Short Haul Modem Page 116 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...

  • Page 129: External Modems

    Series 9800 Field Installation Wiring for a Link CRT Terminal and Okidata Printer The following diagram shows the connections between the TopKAT port and the Link CRT terminal and Okidata printer. Figure 8-9: Wiring Diagram: TopKAT Port, Link CRT, and Okidata Printer...
  • Page 130 Series 9800 Field Installation Wiring for a Link CRT Terminal and Okidata Printer This page intentionally left blank. Page 118 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 131 The wireless communications is accomplished by using a modem and antenna at each end (Figure 9-1). The distance between the TopKAT and POS system can be up to 3 miles (4.8 kilometers). The wireless communications option is NOT intended to provide, nor can it extend communications between the following devices: •...
  • Page 132 Wireless Communications Installation This page intentionally left blank. Page 120 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 133 CAT-5 LAN connection Figure 10-2: Gasboy Termination Box The part number for the cable used with a serial-to-LAN converter is C04532. The serial-to-LAN converter can replace this modem. MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page 121...
  • Page 134 Serial-to-LAN Connection Installation For more information on the TopKAT serial-to-LAN connection, refer to the following: • 900-360 Lantronix UDS-10 UDS-100 User Guide ® (http://www.lantronix.com/pdf/UDS10-UDS100_UG.pdf) • 900-363 Lantronix UDS-10, UDS100, UDS200 Quick Start Guide (http://www.lantronix.com/pdf/UDS10-100-200_QS.pdf) • MDE-4338 TopKAT Fuel Management System Operation Manual •...
  • Page 135 11 – Testing Completion Check List The information below will help verify proper installation of the TopKAT System. Review it before testing the pumps and/or dispensers in the manual, override position. Is the optional data terminal located in a clean, office-type environment?
  • Page 136 Place the system override switch, located in the pedestal, for hose 1 in the OFF position. Repeat steps 3 through 7 for all remaining hoses. Substitute the hose under test for hose 1. Page 124 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 137 12 – Appendix: Base Layout for Shelf Mounting The TopKAT can be mounted on a shelf of your own design, if desired. If you choose to do this, use the following base layout, in addition to following all installation precautions and instructions for your system type as outlined in earlier sections of this manual.
  • Page 138 Appendix: Base Layout for Shelf Mounting This page intentionally left blank. Page 2 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 139 Signal words Safety-1 Explosions Smoking Safety-2 Preventing Safety-1 Sparks Safety-2 Warning words Safety-1 Working alone Safety-2 Fires Safety symbols Safety-1 Preventing Safety-1 Settings Switch 26, 84, 85, 112 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005 Page Index-1...
  • Page 140 Index This page intentionally left blank. Page Index-2 MDE-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 142 Western Pacific Industries. © 2005 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-4319A TopKAT Fuel Managment System Installation Manual · November 2005...
  • Page 143 • Warranty services must be performed by the nearest Authorized Service Contractor qualified to perform service on the defective equipment. • Gasboy will supply new or rebuilt parts to replace parts which are found to be defective within the warranty period. Parts returned to Gasboy must be shipped with trans- portation charges paid and will be replaced with parts with transportation charges prepaid by Gasboy.

Table of Contents