Gasboy 9120K Series User manual

QGASBOY
9120K and 9820K Series AST Pumps
Installation and Operation
Manual
MDE-4567C

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, orunauthorized use of computer programs or
documentation
is strictly prohibited, unless otherwise licensed by Gasboy.
Federal Communications Commission (FCC) Warning
This equipment has been tested and found to comply with the liiiiits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a commercial enViromnent. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential
area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Changes or modifications not expressly
approved
by the manufactnrer could void the user's authority to operate this equipment.
Approvals
Gasboy, Greensboro, is an ISO 9001 :2000 registered facility.
Underwriters
laboratories (Ul): New York City Fire Department (NYFD): California Air Resources Board (CARB):
UL File# Products listed with UL NYFD C of A # Product Executive Order# Product
MH4314
All dispensers and self-contained pumping
4823
9100A, 9140A, 9152A, 9153A,
units 9800A, 9840A, 9850A, 9852A,
Power operated Transfer Pump Models 25,
9853A,9140
G-70-52-AM Balance Vapor Recovery
G-70-150-AE
VaporVac
MH6418 25C, 26, 27, 28, 72, 72S, 72SP, 72X, 73 and 4997 9822A, 9823A
1820
5046
9100Q, 9140Q, 9152Q, 9153Q,
MH7404
Hand operated Transfer Pump Models 1230
9800Q, 9840Q, 9852Q, 9853Q
Series, 1243 Series, 1520 and 1720 Series
5087 8753K, 8853K, 9153K, 9853K
MHI0581
Key control unit, Model GKE-B Series
(restricted to diesel and non-
Cardreadertermina1s,Models 1000, 1000P
retail gasoline sales)
Site controller, Model2000S CFN Series
5091 8752K, 9152K
Data entry terminals, Model TPK-900 Series
5129 9122K, 9123K, 9822K, 9823K
Fuel Point Reader System
National Conference of Weights and Measures (NCWM) -Certificate of Compliance (CoC):
Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:
CoC# Product Model# CoC# Product Model # CoC# Product Model #
95-179 Dispenser
95-136 Dispenser
Patents
9100 Retail Series, 8700 91-019
Series, 9700 Series
9800 Series
91-057
Gasboy products are manufactnredor sold under one or more of the following US patents:
Dispensers
5,257,720
Point of SalelBack Office Equipmeut
D335,673
Dispenser
Controller
Trademarks
Non-registered trademarks Registered trademarks
Atlas'I1.I
Consola'I1.I
JnfinityTId
ASTRA*
Fuel Point«>
Gasboy«>
Keytrol*
S1im1ine*
This document is subject to change without notice .. For information regarding Gasboy Literatnre, call [phone]
E-mail: [email protected] . Internet: http://www.gasboy.com
© 2008 GASBOY' All Rights Reserved
~!~~sCommercial 05-002
Atlas
8700K, 8800K,
9100K, 9200K, 9800K
1000 Series FMS,
2000S-CFN Series
Additional US and foreign patents pending.
Additional US and foreign trademarks pending.
Other brand or product names shown may be
trademarks or registered trademarks of their
respective holders.
~PEls
qEUM EQlIIPMENT IN~

Table of Contents
1 - Introduction 1
Purpose .......................................................................... 1
General Description ................................................................. 1
Model 9120K ............................................... 1
Model 9820K ............................................... 2
Abbreviations and Acronyms
.......................................................... 3
2 -Important Safety Information 5
3-Wiring 9
Wiring Precautions ................................................................. 9
Ground
.......................................................................... 10
Circuit Breakers ................................................................... 10
Pump Motor ...................................................................... 10
Pulse Output
..................................................................... 10
RS-485
......................................................................... 11
Wire Size ........................................................................ 11
Wire Size Chart ............................................ 11
Model 9120K .............................................. 11
Model 9820K .............................................. 11
Conduit ......................................................................... 12
Models 9120K and 9820K .................................... 13
Conduit Size Charts
......................................... 14
Terminal Block ID ................................................................. 15
Wiring Diagrams
.................................................................. 15
4 - Control Lines 23
Purpose ......................................................................... 23
Ground
.......................................................................... 23
Micro Feed
....................................................................... 23
Micro Neutral
..................................................................... 23
Pump Motor Feed
................................................................. 24
Model 9120K and 9820K ..................................... 24
Neutral Feed ..................................................................... 24
Switch Detect. .................................................................... 24
Slow Flow (Reset Complete/Switch Detect) ............................................. 25
Fast Flow
........................................................................ 25
Phase 2 Feed
.................................................................... 25
Pulser ............................................................. " ........... 26
Pulse Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................... 26
RS-485 ......................................................................... 26
5 - Installation 27
Installation Precautions ............................................................. 27
Installation DOs ............................................ 27
Installation DO NOTs ........................................ 28
MDE-4567C 9120K and 9820KSeries AST Pumps Installation and Operation Manual· September 2008 Pagei

AST Vent Line " ................................................................. 28
Vapor Recovery Option
............................................................ 29
Hose Length Estimatorfor 9820K
.................................................... 29
Angle Check Valve ................................................................ 30
Typical Installations
............................................................... 31
Base Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 - 9820K Setup and Special Features 39
Purpose ........................................................................ 39
Electronic Component Access ....................................................... 39
CPU Switch Settings .............................................................. 41
Switch SW1 ............................................... 42
Switch SW2
............................................... 44
Pulser Output Rate Switches ................................. 44
Timeout Switch
............................................ 45
Battery Backup Power Supply
....................................................... 46
View/Reset Totalizer
............................................................... 46
Electronic Totalizer ......................................... 46
Mechanical Totalizer ........................................ 47
7 - Operating Sequence and Locking the Nozzle 49
Operating Sequence ............................................................... 49
9X20K Nozzle Locking ............................................................. 50
8 - 9820K Startup and Test
53
Installation Completion Checklist ..................................................... 53
Startup
......................................................................... 53
Preliminary Steps .......................................... 53
Startup -Model 9120K
...................................... 54
Startup -Model 9820K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Post Startup Tests
................................................................ 54
Voltage .................................................. 54
Tightness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Reset External Adjustment
.................................................... 56
Index Index-1
Page ii
MDE-4567C 9120Kand9820KSeries AST Pumps Installation and Operation Manual· September 2008

Purpose
Introduction
1-Introduction
Purpose
The purpose of this manual is to assist Gasboy Authorized Service Contractors (ASCs) in
installing and operating the following units used with Aboveground Storage Tanks (ASTs):
• 9120K Compact Mechanical Commercial pump
• 9820K Electronic Commercial pump
Note: Whenever information in this document applies to all the units listed above, the 9X20K
model reference is used.
General Description
Model 9120K
The Gasboy Series 9120K pump units are UL®-listed.
Note: NFPA regulations do notallow tank-mountedpumps to be usedfor the resale of fuel.
Model 9120K offers four-wheel mechanical-interlock registers. Mechanical pump registers
show the total volume for a delivery up to 999.9 gallons.
The standard features and specifications of the 9120K Series pumps are as follows:
• Discharge elbows
• A 12-foot length of hose
• Aworking voltage of 115/230 VAC, 50/60 Hz
• Mechanical Volume Totalizer
• A Switch Detect and optional pulser outputs which allow monitoring of the register's
operation when it is connected
to an automated fuel management system.
• Four-piston, positive-displacement meter
• Belt-driven, positive-displacement rotary-vane pump with an 80 mesh (300 micron)
strainer and integral air-separation
• Cabinet height of25.4 inches. The other dimensions may be found on the base layout.
• Standard Cabinet fmish has the top, sides, and back painted black while the front panel is
painted white.
• Filters
The available options and accessories for the Gasboy Series 9120K pumps are as follows:
• Interchangeable Automatic Nozzles
• Pulsers
• Special Lengths
of Hose
• Vapor Recovery System
•
380 VAC 3-Phase Motor
MDE-4567C 9l20K and 9820KSeries AST Pumps Installation andOperation Manual· September 2008 Pagel

Introduction
Model 9820K
Page 2
General Description
The Gasboy Series 9820K Aboveground Storage Tank Remote Access (ASTRA) pump units
are UL-listed.
Note: NFPA regulations do not allow tank-mountedpumps to be usedfor the resale of fuel.
The 9820K Series units consist of two metal cabinet assemblies.
• One assembly is mounted on top of the tank and contains the pumping unit, meter,
electronic pulser, and all hydraulics. The hose and nozzle are connected to this assembly.
• The second assembly is mounted at aheight 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)
• 1000: 1dual-phase, error-checking pulser (gallons); 250:1 dual-phase, error-checking
pulser (liters)
• AC authorization line for control of the unit
• Reset complete (Switch Detect) output that allows monitoring of the unit's operation when
it is connected to an automated fueling system
• Resettable electronic totalizer
• Discharge elbow
• Both models use a quiet and efficient pump which features an air eliminator built into the
pump casting. The pump meter is a three-piston, positive displacement meter which is
tested and calibrated for accuracy at any speed or pressure up to the maximum working
pressure
of 50 psi.
• The standard pumping cabinet finish is white. The electronic register cabinet is black with
a blue graphics panel.
• Dual Stage Solenoid Valve
• Filter
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)
• RS-485 communication for direct connect to Gasboy eFN equipment
• Batterybackup for display of last transaction and capture of stored pulse count in the event
ofa power failure.
• Mechanical totalizer
• A working voltage of 115 VAC (115/230 for motor) 60 Hz for domestic use, 230 VAC 50
Hz/60 Hz for international use.
• Other options include Listed automatic nozzles, special lengths of Listed hose assembly,
Listed dual swivels, UL-recognized filters, Vapor Recovery, and Vapor Recovery Ready.
MDE-4567C 9120K and 9820KSeries AST Pumps Installation and Operation Manual- September 2008

Abbreviations and Acronyms
Introduction
Abbreviations and Acronyms
The following table contains a list of abbreviations and acronyms used in this manual.
Term Description
AC (or ac)
Alternating Current
ASC
Authorized Service Contractor
AST Aboveground Storage Tank
ASTRA
Aboveground Storage Tank Remote Access
CFR Code of Federal Regulations
CPR
Cardiopulmonary Resuscitation
CPU Central Processing Unit
DC (or dc)
Direct Current
DIP Dual In-line Package
FPR
Fuel Point Reader
ICR
Island Card Reader
J-Box Junction-Box
LCD
Liquid Crystal Display
NEC National Electrical Code
NFPA National Fire Protection Association
OSHA
Occupational Safety and Health Association
PCB Printed Circuit Boards (preferred term: board)
PPG Pulses Per Gallon
PPL Pulses Per Liter
STP Submerged Turbine Pump
MDE-4567C 9120Kand 9820KSeries AST Pumps Installation and Operation Manual· September 2008 Page 3

Introduction
Abbreviations and Acronyms
This page is intentionally left blank.
Page 4 MDE-4567C 9120K
and 9820KSeries AST Pumps Installation and Operation Manual· September 2008

Important Safety Information
2-Important Safety Information
This section introduces the hazards and safety precautions
associated
with installing, inspecting, maintaining or servicing
this product. Before performing any task on this product, read
this safety information and the applicable sections in this
manual, where additional hazards and safety precautions for
your task will
be found. Fire, explosion, electrical shock or
pressure release could occur
and cause death or serious
injury, ifthese safe service procedures are not followed.
Preliminary Precautions
You are working in a potentially dangerous environment of
flammable fuels, vapors,
and high voltage or pressures. Only
trained or authorized individuals knowledgeable in the related
procedures should install, inspect, maintain or service this
equipment. .
Emergency Total Electrical Shut-Off
The first and most important information you must know is
how to stop all fuel flow to the pump/dispenser and island.
Locate the switch or circuit breakers that shut off all power to
all fueling equipment, dispensing devices, and Submerged
Turbine
Pumps (STPs).
A. WARNING
The EMERGENCY STOP, ALL STOP, and
PUMP STOP buttons at the cashier's station
WILL NOT shut offelectrical power to the pump/
dispenser. This means that even if you activate
these
stops, fuel may continue to flow
uncontrolled.
You must use the TOTAL ELECTRICAL SHUT-
OFF in the case of an emergency and not the
console's ALL
STOP and PUMP STOP or
similar
keys.
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical components
or the electronics ofthe dispenser requires total electrical
shut offofthat unit. Understand the function and location of
this switch or circuit breaker before inspecting, installing,
maintaining, or servicing Gasboy equipment.
Evacuating, Barricading and Shutting Off
Any procedure that requires access to the pump/dispenser or
STPs requires the following actions:
• An evacuation of all unauthorized persons and vehicles
from the work area
• Use of safety tape, cones or barricades at the affected
unit
(s)
• A total electrical shut-off of the affected unit (s)
Read the Manual
Read, understand and follow this manual and any other
labels or related materials supplied with this equipment. If you
do not understand a procedure, call a Gasboy Authorized
Service Contractor or call the Gasboy Service Center
at 1-
800-444-5529. It is imperative to your safety and the safety of
others
to understand the procedures before beginning work.
Follow the Regulations
Applicable information is available in National Fire Protection
Association
(NFPA) 30A; Gode for Motor Fuel Dispensing
Facilities and Repair Garages, NFPA 70; National Electrical
Gode (NEG), Occupational Safety and Hazard Association
(OSHA) regulations and federal, state, and local codes. All
these regulations must be followed. Failure to install, inspect,
maintain or
service this equipment in accordance with these
codes, regulations
and standards may lead to legal citations
with penalties
or affect the safe use and operation ofthe
equipment.
Replacement Parts
Use only genuine Gasboy replacement parts and retrofit kits
on your pump/dispenser. Using parts other than genuine
Gasboy replacement
parts could create a safety hazard and
violate local regulations.
Safety Symbols and Warning Words
This section provides important information about warning
symbols
and boxes.
Alert Symbol
& This safety alerlsymbol is used in this manual and
on warning labels to alert you to a precaution which must be
followed to prevent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible
injury or
death.
Signal Words
These signal words
used in this manual and on warning
labels tell you the seriousness of particular safety hazards.
The precautions below must be followed to prevent death,
injury or
damage to the equipment:
It... DANGER: Alerts you to a hazard or unsafe practice
~ which will result in death or serious injury.
~ WARNING: Alerts you to a hazard or unsafe practice
• that could result in death or serious injury.
It... CAUTION with Alert symbol: Designates a hazard or
~ unsafe practice which may result in minor injury.
CAUTION without Alert symbol: Designates a hazard
or unsafe practice which
may result in property or
equipment damage
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will explode or burn, ifignited. Spilled
or leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors
in the vicinity ofthe
dispenser
or island.
MDE-4567C 9120Kand 9820KSeries AST Pumps Installation and Operation Manual· September 2008 Page 5

Important Safety Information
No Open Fire
@ Open flames from matches, lighters, welding
torches or other sources can ignite fuels and their vapors.
~
No Sparks - No Smoking \01
Sparks from starting vehicles, starting or using power tools,
burning cigarettes, cigars or pipes
can also ignite fuels and
their vapors. Static electricity, including an electrostatic
charge
on your body, can cause a spark sufficient to ignite
fuel vapors.
Every time you get out ofa vehicle, touch the
metal ofyour vehicle, to discharge any electrostatic charge
before
you approach the dispenser island.
Working Alone
It is highly recommended that someone who is capable of
rendering first
aid be present during servicing. Familiarize
yourselfwith Cardiopulmonary Resuscitation (CPR) methods,
if
you work with or around high voltages. This information is
available
from the American Red Cross. Always advise the
station personnel about where
you will be working, and
caution them not to activate power while you are working on
the equipment. Use the OSHA Lockout! Tagout procedures. If
you are not familiar with this requirement, refer to this
information
in the service manual and OSHA documentation.
Working With Electricity Safely
Ensure that you use safe and established practices in
working with electrical devices. Poorly wired devices may
cause a fire, explosion or electrical shock. Ensure that
grounding connections
are properly made. Take care that
sealing devices
and compounds are in place. Ensure that you
do not pinch wires when replacing covers. Follow OSHA
Lockout/Tagout requirements. Station employees and service
contractors
need to understand and comply with this program
completely
to ensure safety while the equipment is down.
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any
equipment in the mouth.
The pump/dispenser contains a
chemical known to the
State ofCalifornia to cause cancer.
A WARNING
The pump/dispenser contains achemical known to the
State ofCalifornia to cause birth defects or other
reproductive
harm.
In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
personnel:
• Location ofaccident (for example, address, front!back of
building,
and so on)
• Nature ofaccident (for example, possible heartattack, run
over by car, burns, and so on)
• Age ofvictim (for example, baby, teenager, middle-age,
elderly)
• Whether ornot victim has received first aid (for example,
stopped bleeding
by pressure, and so on)
• Whether or not a victim has vomited (for example, if
swallowed or inhaled something,
and so on)
A WARNING
-+-
Gasoline ingested may cause unconsciousness
and burns to internal organs.
Do not induce vomiting.
Keep airway open.
Oxygen may be needed at scene.
Seek medical advice immediately.
A WARNING
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
A WARNING
Gasoline spilled in eyes may cause burns to eye
tissue.
Irrigate eyes with water for approximately 15
minutes.
Seek medical advice immediately.
A WARNING
~1 Gasoline spilled on skin may cause burns .
..!!!!!II!a. Wash area thoroughly with clear water.
~ Seek medical advice immediately.
IMPORTANT: Oxygen may be needed at scene ifgasoline
has been ingested or inhaled. Seek medical advice
immediately.
LockoutlTagout
Lockout/Tagout covers servicing and maintenance of
machines
and equipment in which the unexpected
energization or start-up of
the machine(s) or equipment or
release ofstored energy
could cause injury to employees or
personnel. Lockout/Tagout applies
to all mechanical,
hydraulic, chemical
or other energy, but does not cover
electrical hazards. Subpart Sof
29 CFR Part 1910 -Electrical
Hazards,
29 CFR Part 1910.333 contains specific Lockout!
Tagout provision for electrical hazards.
Page 6 MDE-4567C 9120K
and 9820KSeries AST Pumps Installation and Operation Manual· September 2008

Important Safety Information
Hazards and Actions
A WARNING
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury ordeath.
Follow established
emergency procedures.
The following actions are recommended regarding these hazards:
Collision of a Vehicle with Unit Fire at Island
• Do not go near a fuel spill or allow anyone else in the area.
Fuel Spill
• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the
island(s).
• Do not use console E-STOP, ALL STOP and PUMP STOP to shut off power. These keys do not
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting ofvehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
MDE-4567C 9120Kand 9820KSeries AST Pumps Installation and Operation Manual· September 2008 Page 7

Important Safety Information
This page is intentionally left blank.
Page 8 MDE-4567C 9120K
and 9820KSeries AST Pumps Installation andOperation Manual· September 2008

Wiring Precautions
Wiring
3 -Wiring
Customers and installers having any questions pertaining to the installation should contact
their Gasboy distributor.
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:
I
• All wiring must be installed to conform with all building/fire codes, all Federal, State, and
Local codes, National Electrical
Code, 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.
• Use only threaded, rigid, metal conduit.
• Use only UL-approved insulated gasoline and oil-resistant stranded copper wiring of the
proper size.
• Wire connections should be properly trimmed and secured with a wire nut; close off the
open end of the wire nut with electrical tape.
• The line to the motor should be on a separate circuit and installed on a 20 to 30 Amp
breaker depending on the motor size andlor the voltage setting and the wiring run.
• Install an emergency power cutoff. In addition to circuit breaker requirements ofNFPA 70
and NFPA 30A, a single control which simultaneously removes Alternating Current CAC)
power from all site pumping equipment is recommended. This control must be readily
accessible, clearly labeled,
and in accordance with all local codes.
A WARNING
The DISABLE PUMPS, and STOP buttons at the facility building and the optional
DISABLE PUMPS button on the Island Card Reader (lCR) WILL NOT shut off
electrical power to the pump.
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".
In order to provide the highest level of safety to you, your employees, and customers, it is
recommended that all employees be aware of the location and are trained on the procedure for
turning offpower to the entire system.
MDE-4567C 9120K and 9820KSeries AST Pumps Installation and Operation Manual· September 2008 Page 9

Wiring
Ground
Ground
To ensure proper operation of the equipment and provide the necessary safety factors, this unit
must be grounded. Refer
to "Ground" on page 23.
Circuit Breakers
A separate circuitbreaker is required for the motor and another for the rest of the unit. A tag on
the motor identifies the maximum current draw of the motor. If two (2) pumps are supplied
from one breaker, the breaker must be capable ofhandling the load of bothmotors. Provisions
must be made to break both legs of any AC circuit.
Note: Canadian regulatory requirements may differ.
Pump Motor
Pumps are shipped from the factory with motors wired according to the specifications given
on the order regarding current,
frequency, and voltage.
Very often, on installation, it becomes necessary to change the original setting to suit the AC
power source. To do this, locate the motor changeover plate (typically located on the shaft end
of the motor) and remove the screw which secures it in place. Slide the plate so that the desired
voltage,
as marked on the plate, lines up with the screw hole. Reinsert the screw and secure the
plate
in place.
Many motor failures result
from improper setting of the motor changeover plate. If set for
115 VAC and a 230 VAC feed is used, the motor will bum out after running only for a short
time. If set for 230 VAC and a 115 VAC feed is used, the motor will run very slowly and the
starting field will soon bum out.
Pulse Output
Page 10
The Pulse Output option provides the means for an external system to monitor the quantity
that
is dispensed by the 9820K pumping unit. Refer to "Pulse Output" on page 26. Refer to
"Wiring Diagrams" on page 15, along with the installation manual of the system that will be
connected
to the 9820K pumping unit.
MDE-4567C 9120Kand9820KSeries AST Pumps Installation and Operation Manual· September 2008

RS-485
RS-485
Wire Size
Wiring
For information regarding the RS-485 option, refer to "RS-485" on page 26. Refer to "Wiring
Diagrams" on page
15, along with the installation manual of the CFN Series System for proper
wiring.
The AC wire size of the Pump Motor Feed (power supplied to unit for driving motor), Pump
Motor (power from unit to motor), Neutral Feed (Neutral supplied to unit for driving motor)
and Neutral (power from unit to the motor) is dependent upon the HP rating of the Pump
Motor, the voltage at which the pump will be operated (115 VAC or 230 VAC International),
and the distance from the circuit breaker panel to the pump.
In cases where multiple units are powered from the same breaker through the same wires, the
gauge of the wires should be increased to handle the added load according to the distance from
the breaker panel.
The chart below should be used as a guide in selecting the proper wire size according to the
specific installation requirements.
Wire Size Chart
Model 9120K
Model 9820K
115 Volt Wire Gauge Sizes per Feet of Run
Motor
HP 25' 50' 100' 150'
14 12
10 8
230 Volt Wire Gauge Sizes per Feet of Run
1 14 12 12 10
200' 250'
6 6
10 10
300'
4
8
Over 300', Use Relay at
Motor Location
The AC wire size for the Switch Detect lines must be 14 AWG (when they are used).
The Direct Current (DC) wire size for the Pulser lines must be 18 AWG (when they are used).
The AC wire size for the Micro Feed and Neutral should be 14 AWG. This gauge ofwire will
be sufficient
for runs up to 300 feet from the breaker panel to the pumping unit. Sites with
distances over
300 feet should use 12 AWG wire.
The AC wire size for the Slow Flow and Fast Flow lines should be 14 AWG (when they are
used).
MDE-4567C 9120Kand9820KSeries AST Pumps Installation and Operation Manual· September 2008 Page
11

Wiring
Conduit
Page 12
Conduit
The DC wire size for the Pulser lines connecting the pumping unit to the AST register
assembly must
use 4-conductor, 18 AWG shielded cable (Belden 89418, Gasboy PIN
C08864). This cable allows the pulser wires to run in the same conduit as the AC wiring for
the short distance between the pumping unit and the register assembly. Belden 89418 is rated
as follows:
• Gas and oil-resistant insulation andjacket
• 18 AWG tinned, stranded, copper
• Four conductors
• 300 Volt maximum operating voltage
• AluminumlMylar shielded with drain wire
Twisted-pair shielded cable
is highly recommended for the Pulse Output or RS-485 field
wiring (when they
are used). This type of cable provides superior noise immunity and must be
used for distances over 100 feet or any time pulse output. RS-485 wiring is included in the
same conduit as the AC wires. This cable must meet the following specifications:
• Conductor: 18 AWG stranded wire. 2 twisted-pairs.
• Shield: Foil-wrapped 100% coverage and/or tinned copper braid 90% coverage
• Drain Wire: Stranded, tinned copper, 20 AWG or larger/or braided shield
• Voltage Rating: Maximum operating voltage of 600V
• Environmental: Gas and oil-resistant; suitable for wet or dry locations.
Gasboy
can supply Belden 1063A (PIN C09655) which is a UL-listed, 4-conductor cable that
meets
the requirements listed above.
Note: Belden l063A is UL-Listed but not CSA-listed.
Cable with a voltage rating of less than 600 V must be installed in a conduit separate from all
AC wires.
See the Gasboy Fuel Management System Installation Manual for specific requirements.
IMPORTANT INFORMATION
All wiring to the Gasboy Series 9x20K pumping unit must be installed in threaded, rigid, metal
conduit. PVC IS NOTACCEPTABLE. The GasboyWarrantywill not apply to any pump in which the
AC and DC wires are run in the same conduit, J-Box or wireway, except as noted. The Gasboy
Warranty will not apply to any pump using PVC as conduit.
All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and
Local codes, National Electrical Code, 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.
Metallic conduit is not considered an adequate equipment ground. Separate ground wiring
must be used.
MDE-4567C 9120K and 9820KSeries AST Pumps Installation and Operation Manual· September 2008

Conduit Wiring
Use the charts in "Conduit Size Charts" on page 14 as a guideline for determining the
necessary conduit sizes for wiring of the Gasboy Series 9120K and 9820K pumping unit.
When actually determining
the size of conduit, it may be necessary to increase the size of
conduit because ofa long run or large amount of bends. The installer should determine the
orientation of the wire runs according to the layout of the components at the site and the
applicable Gasboy wiring
diagrams.
Models 9120K and 9820K
It is recommended that high voltage AC power wires to the register assembly (not between the
register and pumping unit) be installed in a separate conduit from the DC pulser output wires
(when used)
and must not be run in any sort of common conduit or trough.
However,
if AC and DC power wires share the conduit, the DC wiring must consist of UL-
listed cable with the specifications described in "Wire Size" on page 11. Only AC wires for the
system and pumps can be installed in this conduit for this application. Wiring between a Fuel
Point Reader
(FPR) and its pre-amp junction box (J-Box) is intrinsically safe and must be run
in a conduit with only other intrinsically safe
wiring. It cannot be run in conduit with AC, DC,
RS-485, or pulser wiring, regardless of the cable type used. See C35628 Fuel Point Reader
Installation
and Retrofit Manual for details.
When the Gasboy Series 9X20K
and 9820K pumps are being installed with a fuel
management system other than a Gasboy System, see the manufacturer installation manual for
their specific conduit requirements.
Wiring between
the 9820K register and pumping unit is installed in a single conduit. This
includes the wiring for the AC control of the pumping unit and the internal pulser. A special
cable,
as described in "Wire Size" on page 11 must be used for the connection between the
pulser inside the pumping unit to the register assembly.
MDE-4567C 9l20K and 9820KSeries AST Pumps Installation and Operation Manual' September 2008 Page 13

Wiring Conduit
Conduit Size Charts
Page 14
To determine conduit size needed, use the THHN/THWN Wire Areas chart (fIrst chart) to fmd
the area for each wire gauge. Add up all wire areas. Use the Areas of Trade Size Conduit chart
(second chart)
to select the smallest number in the 25% fIll area (based on NEC 501-1) that
comes closest without exceeding the total wire area.
THHNITHWN Wire Areas Diameter Area (square units)
Gauge Inches Millimeters Inches Millimeters
18 0.090 2.29 0.007
4.1
16 0.104 2.64 0.009 5.5
14 0.118 2.95
0.011 6.8
12 0.135 3.43 0.014 9.2
10 0.169 4.29 0.022 14.5
8 0.216 5.49 0.037 23.7
6 0.259 6.60 0.053 34.2
4 0.331 8.41 0.086 55.5
3 0.359 9.14 0.102 65.6
2 0.394 10.01 0.122 78.7
1063A 0.417 10.59 0.137 88.4
Areas of Trade-Size Conduit
Internal Diameter Area (square units) Fill Area (square units) 25% Fill
Trade Size Inches Millimeters Inches Millimeters Inches Millimeters
1/2 0.629 16 0.303 196 0.076 49
3/4
0.826 21 0.532 343 0.133 86
1.063 27 0.862 556 0.215 139
1-1/4 1.378 35 1.50 968 0.375 242
1-1/2 1.614 41 2.04 1314 0.509 329
2 2.087 53 3.36 2165 0.839
541
MDE-4567C 9120Kand9820KSeries AST Pumps Installation and Operation Manual· September 2008

Terminal Block 10
Terminal Block ID
The terminal blocks shown below are located in the 9820K register assembly.
Figure 3-1: Register Assembly Terminal Block
MICROPROCESSOR --+_-iJ
FUSE
Wiring Diagrams
CAUTION
1 SLOW
1
~
a:
i?
J
TB2 ~
l
POWER 4
TB1
'""<1
7 NEUL~ _ IPULSE/TXil
ti NC/TX-2
«
TB3l:E GND/RX+3
~
-NC/RX-4
l SHIELD 5
1MIS CONNECTOR IS INSTALLED
ONLY WHEN PULSER OUTPUT OR
RS-48S INTERFACE IS SUPPUED
Failure to follow the correct wiring diagram and all listed notes and precautions that follow
each wiring diagram may result in damage to the CPU PCB.
The wiring diagrams provided are as follows:
• Figure 3-2: Model 9120K Wiring Diagrams on page 16
• Figure 3-3: Model 9820K Wiring Diagram -Domestic on page 18
• Figure 3-4: Model 9820K Wiring Diagram -International on page 20
MDE-4567C 9l20K and9820KSeries AST Pumps Installation and Operation Manual- September 2008
Wiring
Pagel5

Wiring
Page 16
Figure 3-2: Model 9120K Wiring Diagrams
OPTIONAL
3aDVAC 3·PHASE MOTOR WIRING
OPTIONAl.
230 VAC t,lOTOR \\IRING
115/230 VAC WIRING
(10 1 REED PULSER)
PHASE 2 rEED
115/230 VAC WIRING
(100 I ELECTROkIC PliLSERl
PHASE 2 rEED
@ INDICATES FlELO CONNECTION
SEE
tIITE: 3
SEE
IflTE: 3
Wiring Diagrams
t
10:1 Reed
Pulser
100:1 Electronic
Pulser
MDE-4567C 9120Kand9820KSeries AST Pumps Installation and Operation Manual· September 2008