Frontier

Single and Dual Installation

Manual

MDE-5341F
Computer Programs and Documentation
All Gilbarco Inc. and/or Veeder-Root Company computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall
remain the property of, Gilbarco Inc. and/or Veeder-Root Company. 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 Gilbarco Inc. and/or Veeder-Root Company.

Federal Communications Commission (FCC) Warning

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Changes or modifications not expressly approved
by the manufacturer could void the user’s authority to operate this equipment.

Follow the Regulations

Relevant national regulations related to installation, inspection, maintenance, and service must be observed. Where a regulation may conflict with information in this manual, the
regulation must be followed.

MID
The Frontier dispenser conforms to Measuring Instruments Directive (MID) 2004/22/EC.
The approval number is UK/0126/0170.

ATEX
The Frontier dispenser is ATEX certified. The approval number is ITS05ATEX53877.

Special Conditions for Safe Use:

If petrol dispensing pumps are supplied without hose, nozzle, breakaway coupling, sight glass, swivel or shear valve, in that case pumps will be suffixed with “X” in the certificate.
Correct installation needs to be ensured. The petrol dispensing pumps are installed with certified components only as per European Directives.

This document is subject to change without notice.

http://www.gilbarco.com
 2021 Gilbarco Inc. All Rights Reserved
 Table of Contents

Table of Contents
1 – Introduction 1-1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Common Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 – Important Safety Information 2-1

3 – Hazardous Locations 3-1

Zoning Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 – Preliminary Installation Information 4-1

Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Read NFPA 30A and NFPA 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Important Considerations when Changing Fuel Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Gaining Access to and from Frontier Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Before Mounting Unit on Fuel Island . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Verifying and Determining Plumbing Requirements . . . . . . . . . . . . . . . . . . . . . . . 4-4
Adapting Pit Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Units with Ground Fault Interrupt (GFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installing Conduit at Pump/Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

5 – Installing Units on Island 5-1

Mounting Unit to Island . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lifting Frontier Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation Instructions for Frontier Suction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Installation Instructions for Frontier Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installation Diagram for Frontier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Connecting Pump/Dispenser Inlet Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Connecting Vapor Return Line to Vapor Shear Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Anchoring Pump/Dispenser to Island . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

6 – Installing Conduit and Wiring in Unit 6-1

Preparing J-box Field Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installing Conduit Through Vapor Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installing Conduit Through Side of Electronics Cabinet . . . . . . . . . . . . . . . . . . . . . 6-4
Installing Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Wiring External to Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Supplying Connections for Three-phase Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Supplying Connections for One-phase Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Completing Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Potting Conduit Stubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Potting up to Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Potting Within Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10


MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page i
Table of Contents

Connecting to In-station Diagnostic (ISD) Vapor Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

At Dispensing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Epoxy Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

7 – Installing Breakaways, Hoses, Swivels, and Nozzles 7-1

Units Without Hose Retractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

8 – Completing Installation 8-1

Do Not Turn on AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Installation Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Mechanical and Hydraulic Related Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Electrical Related Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Purging Air from System and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
For New Dispensers (Purging Through Shear Valve). . . . . . . . . . . . . . . . . . . . . . .8-4
Special Steps to Purge Air from Underground Lines . . . . . . . . . . . . . . . . . . . . . . .8-4
For New and Existing Pumps and Dispensers with Fuel in Lines (Purging
Through Nozzle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Verifying Shear Valve, Nozzle, and Dispenser Shutoff Operation . . . . . . . . . . . . .8-6
Calibration Procedure for Frontier Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Frontier (Liter Unit of Measure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7

9 – Reference Information 9-1

Reference Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
Installation Differences when Replacing The Advantage Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Plumbing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Pipe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

Appendix A: Elevation Diagrams A-1

Appendix B: Wiring Diagrams B-1

Index Index-1

Page ii MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Purpose Introduction

1 – Introduction

Purpose
This manual contains step-by-step instructions for installing Gilbarco® Frontier pumps and
dispensers. Installation of these pumps as a group is similar except for some differences in
field wiring, calibration, parameter setting, and hydraulic connections. This manual does not
include site preparation instructions. After the installation is complete, a Gilbarco Authorized
Service Contractor (ASC) must commission the unit to activate the warranty. Proper
completion of the checklist is required for commissioning of the unit.

IMPORTANT INFORMATION
Read and follow all safety precautions outlined in “Important Safety Information” on
page 2-1 and save it in a readily accessible location.

Biodiesel greater than 5% and ethanol greater than 10% is not evaluated.

Required Tools
The following tools are required for installing the Frontier pumps and dispensers:
• Flat-blade and Phillips® Screwdrivers
• 1/4-inch Nut Driver
• 5/16-inch Nut Driver
• 7-mm Nut Driver
• Putty knife
• Static Guard Wrist Strap
• Cutters
• Pliers
• Electronic Multimeter

Related Documents
Document
Number Title GOLDSM Library
MDE-2755 Gilbarco STP Control and Dispenser Isolation Relay Box PA0287 Environmental Products
MDE-5077 Frontier Owner’s Manual Frontier
MDE-5078 Frontier Technical Manual Frontier
FE-321 Gilbarco STP Isolation Relay Box PA0287 Engineering Diagrams
577013-796 In-station Diagnostic Vapor Flow Meter Installation Guide -

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 1-1
Introduction Abbreviations and Acronyms

Abbreviations and Acronyms

Term Description
ASC Authorized Service Contractor
ASTM American Society for Testing and Materials
ATEX Atmosphere Explosible
CAT5 Category 5
CIM™ Customer Interface Module
CRIND® Card Reader in Dispenser
GFI Ground Fault Interrupt
GOLD Gilbarco Online Documentation
IFSF International Forecourt Standards Forum
ISD In-station Diagnostic
J-box Junction Box
MPD Multi Product Dispenser
NEC ® National Electrical Code
NFPA National Fire Protection Association
NPT • National Pipe Taper
• National Pipe Thread

PEI Petroleum Equipment Institute

POS Point of Sale
PTFE PolyTetraFluoroEthylene (chemical name for Teflon®)
PVC Polyvinyl Chloride
RCD Residual Current Device
STP Submersible Turbine Pump
TCP/IP Transmission Control Protocol/Internet Protocol
TLS Tank Level Sensor
UL ® Underwriters Laboratories
UST Underground Storage Tank
W&M Weights and Measures

Page 1-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Common Terms Introduction

Common Terms
Term Description
CIM Door CIM Door - Main pump and CRIND displays are mounted on this door.
Combo This unit is configured as Master on one side and Satellite on the other.
Dispenser A dispensing device that receives fuel under pressure from the Submersible Turbine Pump
(STP) at the Underground Storage Tank (UST).
Grade Fuel that is dispensed and has an assigned price.
Listed Products bearing authorized Listing Mark of Underwriters Laboratories (UL) as
manufacturer’s declaration that product complies with UL’s requirements in accordance
with terms of UL’s Listing and Follow-up Service agreement.
Master This unit dispenses fuel to one saddle tank and to a second saddle tank through a satellite
unit.
Product Refers to fuel in storage tank.
Pump A dispensing device that utilizes a self-contained pumping unit and motor to move fuel
from the storage tank using suction.
Satellite A dispensing unit that receives product from, and registers at the Master unit allowing both
saddle tanks on a vehicle to be filled at the same time.
SMART Meter™ Electronic device that measures the flow of product from the UST to the end user.
Teflon The DuPont™ trade name for PolyTetraFluoroEthylene (PTFE).

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 1-3
Introduction Common Terms

This page is intentionally left blank.

Page 1-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Important Safety Information

2 – Important Safety Information

Notes: 1) Save this Important Safety Information section in a Follow the Regulations
readily accessible location. Applicable information is available in National Fire Protection
2) Although DEF is non-flammable, Diesel is flammable. Association (NFPA) 30A; Code for Motor Fuel Dispensing
Therefore, for DEF cabinets that are attached to Diesel Facilities and Repair Garages, NFPA 70; National Electrical Code
dispensers, follow all the notes in this section that (NEC), Occupational Safety and Health Administration (OSHA)
pertain to flammable fuels. regulations and federal, state, and local codes. All these
This section introduces the hazards and safety precautions regulations must be followed. Failure to install, inspect, maintain,
associated with installing, inspecting, maintaining, or servicing or service this equipment in accordance with these codes,
this product. Before performing any task on this product, read this regulations, and standards may lead to legal citations with
safety information and the applicable sections in this manual, penalties or affect the safe use and operation of the equipment.
where additional hazards and safety precautions for your task will Replacement Parts
be found. Fire, explosion, electrical shock, or pressure release Use only genuine Gilbarco replacement parts and retrofit kits on
could occur and cause death or serious injury, if these safe your pump/dispenser. Using parts other than genuine Gilbarco
service procedures are not followed. replacement parts could create a safety hazard and violate local
regulations.
Preliminary Precautions
Federal Communications Commission (FCC) Warning
You are working in a potentially dangerous environment of
This equipment has been tested and found to comply with the
flammable fuels, vapors, and high voltage or pressures. Only
limits for a Class A digital device pursuant to Part 15 of the FCC
trained or authorized individuals knowledgeable in the related
Rules. These limits are designed to provide reasonable protection
procedures should install, inspect, maintain, or service this
against harmful interference when the equipment is operated in a
equipment.
commercial environment. This equipment generates, uses, and
Emergency Total Electrical Shut-Off can radiate radio frequency energy, and if not installed and used
The first and most important information you must know is how to in accordance with the instruction manual, may cause harmful
stop all fuel flow to the pump/dispenser and island. Locate the interference to radio communications. Operation of this
switch or circuit breakers that shut off all power to all fueling equipment in a residential area is likely to cause harmful
equipment, dispensing devices, and Submerged Turbine Pumps interference in which case the user will be required to correct the
(STPs). interference at his own expense. Changes or modifications not
expressly approved by the manufacturer could void the user’s
! ! WARNING authority to operate this equipment.
The EMERGENCY STOP, ALL STOP, and PUMP Safety Symbols and Warning Words
STOP buttons at the cashier’s station WILL NOT This section provides important information about warning
shut off electrical power to the pump/dispenser. This symbols and boxes.
means that even if you activate these stops, fuel Alert Symbol
may continue to flow uncontrolled.
You must use the TOTAL ELECTRICAL SHUT-OFF
in the case of an emergency and not the console’s This safety alert symbol is used in this manual and on
ALL STOP and PUMP STOP or similar keys. warning labels to alert you to a precaution which must be followed
Total Electrical Shut-Off Before Access to prevent potential personal safety hazards. Obey safety
Any procedure that requires access to electrical components or directives that follow this symbol to avoid possible injury or death.
the electronics of the dispenser requires total electrical shut off of Signal Words
that unit. Understand the function and location of this switch or These signal words used in this manual and on warning labels tell
circuit breaker before inspecting, installing, maintaining, or you the seriousness of particular safety hazards. The precautions
servicing Gilbarco equipment. below must be followed to prevent death, injury, or damage to the
equipment:
Evacuating, Barricading, and Shutting Off DANGER: Alerts you to a hazard or unsafe practice which
Any procedure that requires access to the pump/dispenser or will result in death or serious injury.
STPs requires the following actions: ! WARNING: Alerts you to a hazard or unsafe practice that
could result in death or serious injury.
! CAUTION with Alert symbol: Designates a hazard or
unsafe practice which may result in minor injury.
!
• An evacuation of all unauthorized persons and vehicles from CAUTION without Alert symbol: Designates a hazard or
the work area unsafe practice which may result in property or equipment
• Use of safety tape, cones, or barricades at the affected unit(s) damage.
• A total electrical shut-off of the affected unit(s) Working With Fuels and Electrical Energy
Read the Manual
Prevent Explosions and Fires
Read, understand, and follow this manual and any other labels or
Fuels and their vapors will explode or burn, if ignited. Spilled or
related materials supplied with this equipment. If you do not
leaking fuels cause vapors. Even filling customer tanks will cause
understand a procedure, call the Gilbarco Technical Assistance
potentially dangerous vapors in the vicinity of the dispenser or
Center (TAC) at 1-800-743-7501. It is imperative to your safety
island.
and the safety of others to understand the procedures before
DEF is non-flammable. Therefore, explosion and fire safety
beginning work.
warnings do not apply to DEF lines.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 2-1
Important Safety Information
No Open Fire In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
Open flames from matches, lighters, welding torches or other personnel:
sources can ignite fuels and their vapors. • Location of accident (for example, address, front/back of
No Sparks - No Smoking building, and so on)
• Nature of accident (for example, possible heart attack, run
over by car, burns, and so on)
Sparks from starting vehicles, starting or using power tools, • Age of victim (for example, baby, teenager, middle-age,
burning cigarettes, cigars or pipes can also ignite fuels and their elderly)
vapors. Static electricity, including an electrostatic charge on your • Whether or not victim has received first aid (for example,
body, can cause a spark sufficient to ignite fuel vapors. Every time you stopped bleeding by pressure, and so on)
get out of a vehicle, touch the metal of your vehicle, to discharge any • Whether or not a victim has vomited (for example, if
electrostatic charge before you approach the dispenser island. swallowed or inhaled something, and so on)
Working Alone
It is highly recommended that someone who is capable of rendering
! WARNING
first aid be present during servicing. Familiarize yourself with Gasoline/DEF ingested may cause unconsciousness
Cardiopulmonary Resuscitation (CPR) methods, if you work with or and burns to internal organs. Do not induce vomiting.
around high voltages. This information is available from the American Keep airway open.
Red Cross. Always advise the station personnel about where you will Oxygen may be needed at scene. Seek medical
be working, and caution them not to activate power while you are advice immediately.
working on the equipment. Use the OSHA Lockout/Tagout
procedures. If you are not familiar with this requirement, refer to this ! WARNING
information in the service manual and OSHA documentation. DEF generates ammonia gas at higher temperatures. When
Working With Electricity Safely opening enclosed panels, allow the unit to air out to avoid
Ensure that you use safe and established practices in working with breathing vapors. If respiratory difficulties develop, move victim
electrical devices. Poorly wired devices may cause a fire, explosion or away from source of exposure and into fresh air. If symptoms
electrical shock. Ensure that grounding connections are properly persist, seek medical attention.
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
! WARNING
contractors need to understand and comply with this program Gasoline inhaled may cause unconsciousness and
completely to ensure safety while the equipment is down. burns to lips, mouth and lungs.
Keep airway open.
Hazardous Materials
Seek medical advice immediately.
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 ! WARNING
Gasoline/DEF spilled in eyes may cause burns to eye
! WARNING tissue.
In the event of inclement weather, including snow, ice, or flooding Irrigate eyes with water for approximately 
that makes driving conditions dangerous, please avoid servicing 15 minutes.Seek medical advice immediately.
units. Always use available door stops to secure upper doors
against unwanted/unexpected movement, especially during high
winds. If necessary, reschedule service to avoid damage to the ! WARNING
equipment. Weather may change unexpectedly; be aware of local Gasoline/DEF spilled on skin may cause burns.
weather conditions. During service, if conditions develop making Wash area thoroughly with clear water.
service unsafe, close the unit(s) and proceed to a safe location. Seek medical advice immediately.

! WARNING ! WARNING
The pump/dispenser contains a chemical known to the State of DEF is mildly corrosive. Avoid contact with eyes, skin, and
California to cause cancer. clothing. Ensure that eyewash stations and safety showers are
close to the work location. Seek medical advice/recommended
treatment if DEF spills into eyes.
! WARNING
The pump/dispenser contains a chemical known to the State of IMPORTANT: Oxygen may be needed at scene if gasoline has
California to cause birth defects or other reproductive harm. been ingested or inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of machines
Gilbarco Veeder-Root encourages the recycling of our and equipment in which the unexpected energization or start-up
products. Some products contain electronics, batteries, of the machine(s) or equipment or release of stored energy
or other materials that may require special could cause injury to employees or personnel. Lockout/Tagout
management practices depending on your location. applies to all mechanical, hydraulic, chemical, or other energy,
Please refer to your local, state, or country regulations but does not cover electrical hazards. Subpart S of 29 CFR Part
for these requirements. 1910 - Electrical Hazards, 29 CFR Part 1910.333 contains
specific Lockout/Tagout provision for electrical hazards.

Page 2-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Important Safety Information

Hazards and Actions

! WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a

serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.

The following actions are recommended regarding these hazards:

Collision of a Vehicle with Unit Fire at Island Fuel Spill

• Do not go near a fuel spill or allow anyone else in the area.

• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.

General Exclusion
Problems caused by faulty installation are not covered by this warranty. This warranty applies
only if equipment has been installed, used, and maintained in-accordance with Gilbarco
installation, operating, and service instruction.

Use of service personnel other than qualified Gilbarco ASCs without prior approval of
Gilbarco product support department will void payment of the warranty claim in question.

Damage suffered by Gilbarco equipment resulting from shipping, accident, power surges,
neglect, misuse, act of God, or abuse is not covered by this warranty.

Use of non-Gilbarco replacement parts, defect caused by the unauthorized addition of 

non-Gilbarco equipment or unauthorized alteration of Gilbarco equipment voids this warranty.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 2-3
Important Safety Information

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Page 2-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Zoning Diagram Hazardous Locations

3 – Hazardous Locations
Zoning Diagram
The dispenser must be installed to not compromise the zones illustrated in Figure 3-1 and
Figure 3-2 on page 3-2.
Figure 3-1: Zoning Diagram with Grill

Frontier pumps and dispensers are Atmosphere Explosible (ATEX) approved. Zoning diagram
is as per ATEX.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 3-1
Hazardous Locations Zoning Diagram

Figure 3-2: Zoning Diagram Without Grill

Frontier pumps and dispensers are ATEX approved. Zoning diagram is as per ATEX.

WARNING
National Fire Protection Association (NFPA) 70® section 514 table 3 defines the area under
the dispenser as a Class 1 Division 1 hazardous location.

Page 3-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Required Equipment and Materials Preliminary Installation Information

4 – Preliminary Installation Information

Required Equipment and Materials

The following items are required to properly install the equipment:
• Anchor bolts.
• U-bolts for fastening piping to braces.
• Sealant that is UL-approved for use with fuels being encountered.
• Pit box cover plates. Use when required to adapt the unit to pre-existing pit boxes.
• Lifting device (crane, backhoe, forklift, and so on) to move and lift the pump/dispenser.
• Nylon slings (with a safety lift factor of 5) and screw-pin anchor shackles to lift high hose
pump/dispenser.
• Breakaways, hoses, nozzles, and swivels.
• Barricades.
• Potting compound and fiber dam material to allow potting of the conduit in accordance
with class I, Division II locations as specified in the National Electrical Code (NEC).
• Any kits required for upgrading the unit to the customer’s requirements, such as hose
retrievers, and so on.

Read NFPA 30A and NFPA 70

WARNING
Where fuels are involved, you are working in a dangerous environment of gasoline,
gasoline vapor, and electricity.

Failure to install this equipment in accordance with NFPA 30A and NFPA 70 could result in
severe injury or death.

Read, understand, and follow NFPA 30A and NFPA 70.

Before installing the equipment, read, understand, and follow:

• The NEC (NFPA 70).
• The Automotive and Marine Service Code (NFPA 30A).
• Any national, state, and local codes that may apply.

Failure to install the equipment in accordance with NFPA 30A and NFPA 70 may adversely
affect the safe use and operation of the system.

Accurate, sound installations reduce service calls. Experienced, licensed contractors must
perform the installation and follow accurate and safe installation techniques. Careful
installation can eliminate potential problems.

The equipment manufacturer must provide instructions for other equipment such as STP, shear
valves, and underground tanks. Gilbarco does not provide complete installation instructions
for other manufacturer’s equipment.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 4-1
Preliminary Installation Information Important Considerations when Changing Fuel Types

Important Considerations when Changing Fuel Types

WARNING
Certain special alternative fuels such as E25 and E85 and additives can degrade 
pump/dispenser performance or integrity if the dispensers are not designed for use with
such fuels. Additionally, converting to certain standard fuels (gasoline, diesel, kerosene,
and so on) from alternative fuels such as those with ethanol (E25 and E85), methanol, or
biodiesel or from alternative fuels to standard fuels can degrade dispenser performance or
integrity. Similar effects can also occur when converting units to different standard fuel
types. As per UL 87A requirements, units dispensing E25 and E85 fuel must not be
used to dispense any other type of fuel such as gasoline.

Leaks and potential environmental hazards can result or components may fail prematurely.

To avoid these issues, follow the guidelines in this section.

The following guidelines must be followed when changing fuel types for a pump/dispenser or
using alternative fuels or fluids:
• Verify with your Gilbarco ASC or Distributor if the fuel which you will be using is
compatible with the pumps/dispensers to be dispensing the fuel.
• For flexible fuel dispensers, do not use standard hydraulic parts used in other Gilbarco
pumps/dispensers for service parts in these units. Standard dispenser parts may not be
compatible with fluids.
• Biodiesel fuels must be of American Society for Testing and Materials (ASTM) standards
for Biodiesel fuels. Mixes of diesel with cooking oils, other plant or animal derived oils,
and so on are not considered Biodiesel. Use of such mixes may void warranty on the
hydraulic components of the unit.
• Review the latest copy of the unit’s warranty statement regarding the use of fuel.
• Certain fuels (especially fuels enhanced with alcohol) when first used in tanks previously
containing a different fuel may clean out the tanks and force a large amount of
contaminant into the dispenser. Other than abnormally clogging filters, this large quantity
of contaminant may damage certain dispenser components. Do not run units without
filters at such times. It is normally required that tanks and lines be cleaned of all water,
sediment, and contaminant before such conversions to minimize potential 
pump/dispenser downtime or damage. Damage to hydraulic components from
contamination when not using filters is not covered by Warranty. Consult your ASC or
Gilbarco Distributor for recommendations.
• Although conversions from one fuel to an equivalent fuel (say from another supplier)
generally do not create issues, it is recommended that after making any fuel type
conversions (including those to alternative fuels such as E25 and E85 or back), all units be
visually inspected for leaks two days, one week, and one month after fuel conversion.
Have your ASC repair any leaks found. This must also be performed for standard fuels
when significant new additives are incorporated.
• Whenever non-equivalent fuel conversions are performed, it is recommended that all units
be checked for calibration within one month of fuel conversion.
• Some non-equivalent fuel conversions will necessitate the requirement to change the 
pump/dispenser filter type previously used. Consult your ASC or Gilbarco Distributor for
any changes required.
• In flexible fuel dispensers, Gilbarco recommends the use of 10 micron filters for 
gasoline-based flexible fuels. Although the use of finer filtration is allowable, filters will
tend to clog prematurely, causing excessive filter maintenance cost.
• An anti-siphon valve must be installed on aboveground storage tanks where the DEF level
can be at a higher elevation than the supply piping or the dispenser. The valve will prevent
a potential leak in the piping from creating a siphon that can cause a product release.
Page 4-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Preparing for Installation Preliminary Installation Information

Preparing for Installation

To prepare for the installation, proceed as follows:

1 Read all instructions before you begin.

2 Follow all safety precautions:

• Barricade the area.

• Do not allow vehicles in the work area.
• Do not smoke or allow open flames in the work area.
• Do not use power tools in the work area.
• Do not allow unauthorized people into the work area.
• Wear eye protection during the installation.
• Ensure that there is no power supplied to the units until required, as per later installation
steps.

3 Use circuit breakers to turn off all power to pumps/dispensers and STPs. Multiple disconnects
may be required.

4 Check the following for proper installation, as recommended by other manufacturers:

• Emergency power cut off switch
• Circuit breakers
• STP control relay boxes - dispensers only (see Note 3)
• Isolation relays - dispensers only (see Note 3)
• Conduit and wiring (see Note 1)
• Grounding
• Shear valves - dispensers only (see Notes 2 and 3)
• Piping and fittings
• Fuel storage tanks
• Pressure regulating valves (aboveground tanks only)
• STP - dispensers only
• Tank and/or line leak detectors
• Pit boxes
• Components must be compatible with the fluid being dispensed. Consult the manufacturer
for information.
Notes: 1) If you are replacing an existing unit, the installer may connect and extend the
existing field wires to the electronics cabinet using an explosion proof Junction Box
(J-box). For details, refer to “Before Mounting Unit on Fuel Island” on page 4-4.
2) A shear valve is a safety device required for every product line at each dispenser.
Shear valves may also be required for aboveground tank installations and other
installations with pumps. Follow local and state requirements.
3) Some locations require shear valves for vapor lines. Follow local and state
regulation.

4 Inspect the pump/dispenser cartons and contents for shipping damage. Gilbarco does not cover
shipping damage under its warranty policy. Notify the shipper of any damage.

5 Remove the lower panels (doors) of the pump/dispenser.

6 Ensure that the fuel grade for product lines matches the pump/dispenser brand panels and the
foundation layout. Product lines from the island pit box must have labels.
MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 4-3
Preliminary Installation Information Before Mounting Unit on Fuel Island

Gaining Access to and from Frontier Cabinet

Frontier cabinets are designed to protect the equipment inside the unit from the elements. The
doors and covers must be installed as directed. For more information, refer to MDE-5077
Frontier Owner’s Manual and MDE-5078 Frontier Technical Manual provided by the ASCs
during commissioning.

Frontier units have features that prevent water intrusion into the dispenser’s interior. However,
the doors and covers must be opened or replaced in a specific order - the bottom panel first,
which provides access, allowing the release of the security latch on the top door and opening
of the door.

Before Mounting Unit on Fuel Island

WARNING
DEF, flexible fuels such as biodiesel, high alcohol percentage fuels, such as E25 and E85, and
so on, may be incompatible with certain plumbing materials and hydraulic components.

Use of incompatible materials or components with alternative fuels such as E25 and E85 or
DEF can result in leaks or unexpected failures of components resulting in fire or explosion or
environmental damage.

When dispensing alternative fuels such as E25 and E85 or DEF, verify with the manufacturer if
the material of all plumbing components are compatible with the fuels such as E25 and E85 or
DEF being dispensed.

Note: Before mounting the unit on the fuel island, read and understand this section
completely. This information is essential to avoid installation errors.

Verifying and Determining Plumbing Requirements

Before placing a unit on an island, determine the correct location of piping for the unit
involved and the proper orientation of the unit. A common installation error is to install the
units backwards, which will require expensive modifications. This section contains
information regarding plumbing requirements for various models of Frontier dispensers.

IMPORTANT INFORMATION
Do not make assumptions about configurations based on previous experience, hose
positions, or layout of the unit that you are replacing, whether it is a Gilbarco unit or that
of any other manufacturer.

Model grade mapping (inlet piping) for Frontier units is different from The Advantage® Series
and Multi Product Dispenser (MPD)-3 Series as well as other manufacturers units. Incorrect
matching of unit piping to supply lines can cause costly rework and time delays.

The first Grade/product is always left when facing J-box of Frontier units.

Page 4-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Before Mounting Unit on Fuel Island Preliminary Installation Information

Adapting Pit Box

For installation using an existing pit box, some modifications may be required. The following
list highlights the changes that may be required. For more information, refer to “Installation
Differences when Replacing The Advantage Series” on page 9-2. These installation
considerations may also apply when you are replacing competitive units.

To adapt the plumbing/conduit to Frontier stub up locations:

• Use care in sizing and routing flexible piping to avoid bends that restrict flow. This is
especially critical for pumps which may have serious issues with flow or noise if the
flexible pipe cross section becomes significantly restrictive.
• Use flexible piping in the pit box for plumbing adaptation. If piping in the previous box is
rigid, use the adaptability of the Frontier hydraulic cabinet inlets and conduit entry points
instead of making modifications to rigid plumbing and conduit in the pit box.
• When adapting plumbing in the dispenser cabinet, remember that the lower piping cross
brace must be used to secure plumbing above the shear valve and that rigid piping must be
used within the dispenser.
• Modify the pit box rain lip when required (for boxes designed for The Advantage Series
wide frame units). Modifications will also typically be performed to the Frontier base.
• When adapting an Frontier unit to an existing pit box or one that is not specifically
designed for the unit, the rain lip may require modification or removal. If the rain lip is
removed, the entire base of the dispenser must be sealed to the island. Study the
foundation layouts and the existing pit box to determine if modifications are required
before mounting the unit on the island. For working in this area, refer to the following
Warning.

WARNING
Where fuels are involved, you are working in a potentiality hazardous environment where
fuels and their vapors may be present and could be ignited with sparks from grinding and
cutting tools.

Always conduct work at the required safe distance away from a hazardous area and use
the appropriate tools.

Units with Ground Fault Interrupt (GFI)

A GFI consists of a sensor that detects changes in the current to the load, by comparing the
current flowing to the load and the current flowing from the load. A drop-off in the current
equivalent to about 5 milliamperes, turns off all power by tripping a relay within the GFI
within a few hundredths of a second.

When powering a dispenser with a GFI, the return neutral of any device to which the dispenser
supplies power must be the same neutral as that of the dispenser. For example, the STP control
relay.

Installing Conduit at Pump/Dispenser

Options exist for installing the conduit up to the units:
• Use existing conduit commonly through the pit box.
• Conduit not penetrating the pit box but entering the pump dispenser through the side
column(s) of the unit.

The first method is commonly found with existing applications. The second is recommended
for new ground and up installations to reduce installation cost.
MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 4-5
Preliminary Installation Information Before Mounting Unit on Fuel Island

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Page 4-6 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Mounting Unit to Island

5 – Installing Units on Island

Mounting Unit to Island

Before placing the unit on an island, determine the correct location of piping for the unit
involved and verify the proper orientation of the unit. A common installation error is to install
the unit backwards, resulting in required modifications or delay in installation.

Mount the unit using mounting bolt locations specified.

Fill in any openings from the smaller length Frontier cabinet to the potentially longer pit box
opening for other units. Seal as required.

Where low temperatures are expected, dispensing equipment including hanging hardware,
must be insulated, heated, or located in a temperature-controlled enclosure suitable for UL
class 1 division 2 environment to prevent from freezing.

The unit must be located in class 1 where high ambient temperatures are common, consider
insulating the dispenser or placing it in a location where it is out of direct sun to maximize
shelf life.

When mounting dispensers for DEF directly to the island, install sumps to prevent leaks and
spills from migrating off site.

Lifting Frontier Units

WARNING
Lifting heavy equipment can be hazardous.

Equipment could fall and cause severe injury or death.

Use lifting equipment of proper capacity and factor of safety when moving or positioning
the unit. Stand clear from pump/dispenser when lifting and lowering.

Before mounting the unit to the island, verify if the pit box and unit base are compatible. Some
pit box plates have rain lips that require modifications before placing the Frontier unit on the
plate. If the Frontier unit does not fit properly onto the pit box plate, the unit will have to be
lifted according to the instructions in this section and moved to a safe work area. If this
modification is not required, do the following, and then proceed to “Before Mounting Unit on
Fuel Island” on page 4-4.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-1
Lifting Frontier Units Installing Units on Island

To lift Frontier units, proceed as follows:

Note: Frontier units have hoisting brackets mounted on top of the upper housing.

1 Verify if the hoisting brackets are tight. Use the bolts provided with the brackets or grade 8
bolts.

CAUTION
Do not run slings around columns or under the upper piping housing. This will damage the columns
or sheathing.

2 Lift and position the unit to the work area for modification or onto the island.

3 Remove the slings and shackles.

Page 5-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Instructions for Frontier Suction System

Installation Instructions for Frontier Suction System

Figure 5-1: Frontier Suction System - 1

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-3
Installation Instructions for Frontier Suction System Installing Units on Island

Figure 5-2: Frontier Ultra-High Flow Single Three-Phase- Continued

Page 5-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Instructions for Frontier Suction System

Figure 5-3: Frontier Ultra-High Flow Dual Three-Phase - 1

This diagram shows electronics for one side. Refer

to Figure 5-4: Frontier Ultra-High Flow Dual Three-
Phase - 2 on page 5-6 for other side.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-5
Installation Instructions for Frontier Suction System Installing Units on Island

Figure 5-4: Frontier Ultra-High Flow Dual Three-Phase - 2

Page 5-6 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Instructions for Frontier Pressure System

Installation Instructions for Frontier Pressure System

Figure 5-5: Frontier Pressure System - 2

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-7
Installation Instructions for Frontier Pressure System Installing Units on Island

Figure 5-6: Frontier Pressure System for Ultra-High Flow Single Unit

Page 5-8 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Instructions for Frontier Pressure System

Figure 5-7: Frontier Pressure System for Ultra-High Flow Dual Unit - 1

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-9
Installation Instructions for Frontier Pressure System Installing Units on Island

Figure 5-8: Frontier Pressure System for Ultra-High Flow Dual Unit - 2

Page 5-10 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Diagram for Frontier

Installation Diagram for Frontier

Figure 5-9: Installation Diagram for Frontier

TYPICAL INSTALLATION DIAGRAM NOTE :

SCREEN VENT PROTECTOR
1 SUCTION PIPE SHOULD HAVE CONTINUOUS. APPROVED TYPE VENT CAP
THOUGH NOT NECESSARILY UNIFORM PITCH
FROM PUMP TO TANK.

2 PROPER EARTHING TO BE PROVIDED.

PUMP
3 GASOLINE OF RELATIVELY HIGH REID VAPOUR
PRESSURE OR EXCESSIVELY HIGH TEMPERATURES
WILL AFFECT THE DELIVERY RATE OF THE SYSTEM. VENT PIPE

DISCHARGE SIDE
SUCTION LINE
OF PUMP
CONNECTED TO PUMP SYSTEM

DEPTH OF PIPE AT WATER TIGHT

THIS POINT SHOULD LOCK BOX
BE MINIMUM OF 0.45 m.

CONDUIT FOR ELECTRICAL

SUPPLY FOR PUMP
JUNCTION BOX FILL PIPE

ELBOWS = 2 TO 4 MAX.
RECOMMENDATION AT LEAST
10 mm RISE PER METER FOR
THIS SECTION

50 mm INTERNAL
DIAMETER
DEAD STOCK D SUCTION PIPE
"V"=3.5m
STORAGE TANK
"H"
100 mm FROM
BOTTOM OF TANK

SPECIFIED CONDITION FOR SUCTION LIFT =3.5METER A THIS END OF TANK TO

PITCH DOWN APPROX. 50 mm
FUEL TYPE PURE GASOLINE E5 E10 E15

MAX MIN MAX MIN MAX MIN MAX MIN

IMPORTANT:
ALTITUDE METER 2200 400 1400 100 1500 100 1600 100 RECOMMENDED INLET PIPE DIAMETER= 50 mm ID
DETAIL VIEW A HORIZONTAL PIPE LENGTH "H" = 20 Meters Maximum
-20 55 -20 40 -20 45 -20 45 VERTICAL LENGTH OF PIPE= "V" AS PER THE RESPECTIVE GRAPHS FOR OTHER THAN SPECIFIED CONDITION
DEAD STOCK D = 200MM MINIMUM.
BEND QUANTITY 4 2 4 2 4 2 4 2

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-11
Installation Diagram for Frontier Installing Units on Island

Figure 5-10: Installation Diagram for Frontier (Pure Gasoline)

P20025

Page 5-12 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Diagram for Frontier

Figure 5-11: Installation Diagram for Frontier (E5)

SP20025

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-13
Installation Diagram for Frontier Installing Units on Island

Figure 5-12: Installation Diagram for Frontier (E10)

Page 5-14 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Installation Diagram for Frontier

Figure 5-13: Installation Diagram for Frontier (E15)

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-15
Connecting Pump/Dispenser Inlet Pipes Installing Units on Island

Connecting Pump/Dispenser Inlet Pipes

WARNING
Flexible fuels such as biodiesel, high alcohol percentage fuels, and so on, may be incompatible
with certain plumbing materials and hydraulic components.

Use recommended sealant, Loctite® #567 (Part Number 56747) and Loctite Primer-N 7649
(Part Number 21347) for pipe threads. Do not use thread tape.

Use of incompatible materials or components with alternative fuels such as E25 and E85 or
DEF can result in leaks or unexpected failures of components resulting in fire or explosion or
environmental damage.

When dispensing alternative fuels such as E25 and E85 or DEF, verify with the manufacturer of
the material or component that all plumbing components are compatible with the fuels or DEF
being dispensed. Do not replace the dispenser or pump parts with those incompatible with the
fuel or DEF involved.

WARNING
The shear valves must be installed correctly.

Improperly or insufficiently anchored shear valves can lead to fire or explosion that could
result in severe injury or death.

Anchor all the shear valves as per the manufacturer’s instructions.

Note: Pumps do not have to use shear valves, except in special circumstances. The following
procedure for a pump is identical to that of a dispenser, except that a shear valve may
not be used. The contractor must provide and install pipe unions whether shear valves
are used or not.

IMPORTANT INFORMATION
National Pipe Taper (NPT) pipe threads can at times be difficult to seal during installation or
later, because of various conditions such as minor thread damage, contamination, slight
thread imperfections, poor assembly practice and other reasons. Gilbarco has found that
although NPT threads can be sealed normally with a good quality pipe sealant alone (the
normal recommendation), on many occasions, fewer issues are created during installation by
using a combination of sealant and Teflon pipe tape. The additional expense incurred to apply
both will save money for the installer in the long run by spending less time correcting leaks
during installation.

When using a Teflon pipe tape, it is extremely important to apply it properly so that no tape
stringers are created to enter the hydraulic system. Tape stringers can cause serious issues
with valves, nozzles, and other hydraulic components. For information on how to properly use
the Teflon pipe tape and thread sealant to ensure fewer installation issues and fewer
subsequent pump/dispenser problems, refer to “Inlet Pipe Assembly” on page 5-18.

This information and recommendation does not apply to hanging hardware connections.
Damage to aluminum parts of the hanging hardware or dispenser can occur since it is very
difficult to control proper torque tightening because of the thread-assembly friction.

Page 5-16 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Connecting Pump/Dispenser Inlet Pipes

To connect pump/dispenser inlet pipes, proceed as follows:

1 Remove the vertical low hydraulic cabinet brace (found only in some units) to gain access
during the installation of plumbing. Reinstall this brace after you complete the installation of
the plumbing.

For units with a shear valve, a contractor-provided union must be installed on the shear valve.
For proper tightening of the union to the shear valve, refer to the shear valve manufacturer’s
instructions. For units without shear valves, a contractor-provided union must be installed on
the ground stub pipe.

For additional shear valve information, see Figure 5-16 on page 5-20. Since Frontier units
require special considerations, ensure that you read and understand the information on shear
valves later in this section for those units.

CAUTION
The shear valves or other dispenser components can be damaged or broken if improper
wrench techniques are used. The installer must use two wrenches so that stress is not
applied to the shear portion of the valve during tightening.

2 To maximize installation ease, Standard Frontier units are shipped with inlet plumbing. The
installer provides and installs the plumbing in the lower Hydraulics Cabinet when required.
Where required, use a approved sealant suitable for the applicable fuel type.

CAUTION
Units used with alternative fuels such as ethanol (E25 and E85), biodiesel, or others require
contractor-supplied plumbing components to be suitable for use with such components.
Consult your part suppliers for recommendations for their hydraulic parts based on the fuel
types to be utilized.

Fuel leaks or component failure may occur if the components are not compatible with these
fuels.

3 Ensure that you remove any shipping plugs or caps that may be present in the pipes, shear
valves, and unions. Leave the mounting bolts a little loose at this time to allow more
adjustment when aligning the piping.

Notes: 1) The contractor-supplied pipe and fittings must be 1-1/2-inch NPT Schedule 40 black
iron. The Frontier pipe and fittings must be 2-inch NPT Schedule 40 black iron.
Vapor Recovery is 1-inch NPT.
2) Flexible pipes are not allowed within the dispenser.

For information regarding the valves or shear valves required for vapor recovery return lines
consult the Local Regulatory Agencies.

To ensure proper operation of the shear valve during a vehicle collision, all piping above the
shear valve must be secured to the lower cross brace using U-bolts sized according to the
plumbing involved.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-17
Connecting Pump/Dispenser Inlet Pipes Installing Units on Island

Inlet Pipe Assembly

To ensure proper sealing during installation, assembly of pipe nipples to all 1-1/2-inch NPT
inlet tubes must follow the following guidelines.
• Ensure that the threads are of good quality, full-NPT threads without obvious damage for
all pipe nipples.
• Assemble using 1/2-inch wide Teflon thread-seal tape.
• Assemble using a high quality, UL-approved sealant that will not harden or wash out
with the fuel being dispensed. Use Loctite PN 56747 (TM 567) PST Pipe Sealant with
PTFE (also known as Loctite 567) or equivalent.

To assemble the inlet pipe assembly, proceed as follows:

1 From the pipe nipple end (about 2 to 3 threads), wrap the inlet pipe with Teflon tape 
[12 to 15 revolutions (see Figure 5-14)].

CAUTION
Do not use tape at the very end of the pipe nipple to avoid tape entering the dispenser hydraulics.
Tape in the hydraulics can cause failures of valves, nozzles, or other significant problems.

Pipe Threads: Use recommended sealant, Loctite #567 (Part Number 56747) and Loctite 
Primer-N 7649 (Part Number 21347) for pipe threads. Do not use thread tape.

CAUTION
Applicable to Dispensers Rated for E25 and E85 Use:

Do not use tape at the very end of the pipe nipple to avoid tape entering the dispenser hydraulics.
Tape in the hydraulics can cause failures of valves, nozzles, or other significant problems.

Use only UL-listed TPS PTFE Pipe Sealant manufactured by SAF-T-LOC International Corp.

Use only UL-listed Taega Technologies Inc. Teflon tape.

Note: Teflon tape must be used only at the inlet pipe connection.

Figure 5-14: Inlet Pipe Wrapped with Teflon Tape

Teflon tape wrapped 12 - 15 revolutions

Teflon tape started 2 - 3 threads away from

Pipe Nipple end

Page 5-18 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Connecting Pump/Dispenser Inlet Pipes

2 Apply a moderate bead of sealant completely around the nipple end at the edge of the Teflon
tape (see Figure 5-15).
Note: For pipe threads, ensure that you apply the primer before applying the sealant.
Follow the manufacturer’s instructions.

Figure 5-15: Bead of Sealant at Teflon Tape Edge

Teflon tape applied in step 1 on page 5-18

Bead of Sealant at the edge of Teflon tape

3 After the sealant has been properly applied, tighten the connection to 130 foot-pounds.

WARNING
Always use the provided adjustable cross brace to secure plumbing in the dispenser, or the
shear valve may not operate properly during a vehicle collision.
The cross brace is not an optional feature!
Also, use of non-rigid piping materials such as field-bendable tubing to connect to the inlet may
also result in the shear valve not operating properly during a collision.
Use of black iron pipe inside the dispenser is required for fuel lines at the outlet of the
shear valves.

4 Loosely connect the union halves together.

CAUTION
Do not use pry (crow) bar to position pump/dispenser over conduit or pipes. This could
damage valves, conduit, or other parts of the unit.

5 Double-check the alignment of the frame, conduit, and pipes. Secure the piping to the safety
brace using U-bolts or pipe clamps that are supplied by the contractor.
Note: Misaligned piping can result in a leak.

WARNING
For Frontier units, do not permanently remove the strainer under any circumstances to
accommodate the shear valves from certain manufacturer’s that may not properly position the
shear section of the valve as shown in Figure 5-16 on page 5-20.

Use a Morrison or equivalent shear valve to ensure proper position of the shear section of the
shear valve.

Failure to use the strainer could result in failure of the valves or meters, void warranty, and
create a safety hazard with an improperly operating valve.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-19
Connecting Pump/Dispenser Inlet Pipes Installing Units on Island

Figure 5-16: Shear Valve at Grade

1-1/2” NPT Coupling on Unit

2” NPT Coupling on Frontier Unit

Installing the contractor-supplied Black

Iron Piping to Coupling, including Union

Shear Valve with Shear Point

installed Flush with grade ±0.75”

Notes: 1) Regular (non-double wall) shear valve is shown.

2) OPW® supplies an Frontier compatible double poppet shear valve with a union top
(OPW part # 10RUP-2006).
3) It is a mandatory code requirement that the shear section of the shear valve be within
±3/4-inches (or to shear valve manufacturer’s requirement, whichever is tighter)
from the plane of the bottom of the base of a dispenser. Not all shear valve styles
allow the maintenance of this tolerance for Frontier units. A N23047 single poppet
male top Morrison 2 X 2 636M-0200AV or a code-approved equivalent shear valve
meets the code requirements. Do not modify the dispenser plumbing (for example,
remove the strainer housing) to accommodate other model valves, or install units
such that the shear groove of the shear valve is not within ± 3/4 inches of the base
plane of the dispenser. Use a Check Valve (N23274) between the union and strainer
housing to ensure that the shear section is properly located.

6 Tighten the union halves together.

7 Tighten the anchor bolts at this time. Verify if the shear valves are properly tightened to the pit
box or shear valve anchor bracket, as required. If removed earlier, reinstall the vertical cabinet
brace in the lower hydraulic cabinet.

Page 5-20 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Connecting Pump/Dispenser Inlet Pipes

For Frontier installations:

• Selection of proper components mounted to the bottom of the strainer housing is critical in
maintaining the proper location of the shear valve groove of the shear valve to the base
plane of the dispenser. You must follow the shear valve manufacturer’s required
positioning for this groove.
• A check valve is strongly recommended. When installed, Gilbarco recommends using
N23274, which is approximately 2-1/2-inch long and can take the place of the close nipple
located above the union. Failure to install a check valve here can result in fuel sale
indication when the fueling position is activated with the nozzle closed and the check
valve back at the STP is leaking.
• A union is required above the shear valve.
• A Morrison male end Shear Valve [N23047 (Morrison # 636M-0200AV)] can be used to
properly maintain the position of the shear groove. The installer must verify if other
manufacturer’s shear valves will ensure proper positioning of the shear groove as per their
specifications.
• Not all double poppet shear valve models or styles will fit the Frontier unit.
• Other combinations of unions, check valves, and shear valves may be possible and still
maintain proper location of the shear groove.
• Removal of a strainer from the system will void warranty.
Follow the shear valve manufacturer’s instructions for installation procedures, testing, and so
on.
• Install the shear valve on each product inlet pipe.
Note: Frontier dispensers require 1-1/2-inch male top shear valves. Gilbarco strongly
recommends using double poppet shear valves that shut off flow from both storage
tanks and internal to the unit (for example, OPW #10BHMP or 
Exxon® - OPW # 10RMSP). The Frontier dispensers use 2-inches male top shear
valve (for example, Morrison Bros. 2” 636 m).
• For Frontier units, install the shear valve on each 2-inch inlet and outlet.
• Install a shear valve on the master dispenser satellite outlet and at satellite inlet.
• Do not mount the shear valve upside down.
• Ensure that the valve linkage is accessible and has no interference to open or close from
other piping, structure, or components.
Note: The dispenser product inlet pipes must be aligned with the shear valve. Do not
restrict shear valve linkage with pipes, braces, and so on.
• Test shear valve operation.
• Close the shear valve until equipment start-up. Cap the inlet pipe. This prevents dirt and
other particles from entering the product line. It also prevents fuel spillage.

Figure 5-17: Shear Valve

Shear valve groove location must be

Shear Valve flush to island surface ± 0.75’
Shear Groove
Island Surface

Product Inlet Pipe

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-21
Connecting Vapor Return Line to Vapor Shear Valve Installing Units on Island

Connecting Vapor Return Line to Vapor Shear Valve

Do not create any liquid traps when connecting the vapor return line to the Vapor Line Shear
Valve (see Figure 5-18). A liquid trap is a low spot in the vapor return line that can accumulate
fuel and cause blockage, which can cause a system to fail vapor recovery certification tests or
create operation issues with vapor balance nozzles.
Notes: 1) The contractor must provide and install the pipe union for connecting to the 1-inch
NPT coupling in the unit.
2) Follow the Vapor Line Shear Valve’s manufacturer information regarding mounting
of the shear valve to the unit.

Figure 5-18: Correct Vapor Line Connection Method

Not Allowed Correct

Contractor-supplied
1” NPT Vapor Return Pipe supplied
Fittings, Pipe, and
in the Unit
Shear Valve

Contractor-supplied
Fittings, Pipe, and Shear
Valve

No place for liquid to

be trapped

Do not allow Liquid Traps Vapor Line Shear Valve

Page 5-22 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Units on Island Anchoring Pump/Dispenser to Island

Anchoring Pump/Dispenser to Island

Note: Pumps do not normally require shear valves. The following procedure for a pump is
identical to that of a dispenser, except that the shear valve may not be used.

WARNING
Improper anchoring of units could cause damage, severe injury, or death resulting from the
unit tipping over from the impact or drive-off.

NFPA 30A requires the anchoring of pumps/dispensers.

Securely install anchor bolts at all anchoring locations as shown on foundation diagrams for
safe operation of shear valves and hose breakaways.

To anchor pumps/dispensers to the island, proceed as follows:

1 Verify if the shear valves are firmly anchored to the island form [concrete or pit box
(see Figure 5-19)].
Note: If the shear valve is not anchored properly, it may not operate correctly during a severe
impact. Follow the shear valve manufacturer’s instructions.
Figure 5-19: Anchoring Shear Valves Using Anchor Brackets

Pump/Dispenser Base

Anchor Bracket

2 Loosely anchor the pump/dispenser to the island according to the foundation layout locations,
using all the required anchoring points as follows:
• Use 1/2-inch anchor studs with heavy duty large washers (slot designed for that size).
• Use bolts or studs that are of 5-grade steel.
• Use hardware that is corrosion-protected or resistant.
Note: Do not use plastic, low strength, or pallet bolts.
• Studs/bolts must be securely anchored to the island or pit box (see Figure 5-20).
• For additional important information, refer to the anchor or pit box manufacturer’s
instructions.

Figure 5-20: Anchors for Pump/Dispenser

Contractor-supplied Fittings (for example, Union)

Anchor Bolts

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 5-23
Anchoring Pump/Dispenser to Island Installing Units on Island

This page is intentionally left blank.

Page 5-24 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Installing Conduit and Wiring in Unit

6 – Installing Conduit and Wiring in Unit

1 For units with the J-box, run a 1-inch rigid conduit to the J-box entering the unit from Side 2.
Run any existing wiring to the main J-box through the 1-inch J-box conduit that enters the unit
from Side 2. Connect the 1-inch conduit with class 1 Division 1 explosion-proof conduit
union.

If the conduit is entering the unit from outside the dispenser pit box, refer to “Electrical
Related Items” on page 8-3 and “Reference Information” on page 9-1 before proceeding.

Use an 8 X 1-inch diameter conduit, to run to the electronics cabinet of the unit from Side 2.
Use additional conduits and coupling, if required.

2 If required, install the conduit for call buttons, Ethernet®, and speaker wires using similar
procedures as outlined for the power conduit. However, when facing Side 1, call button, and so
on, the conduit must be to the right side of the unit and power wiring to the left. Ensure that
you follow earlier steps and warnings for installing the conduit through the air gap plate or
side of the electronics cabinet.
Note: Call button, Ethernet, and speaker wires cannot be in the same conduit as the power and
two communication wiring to the unit. They must be in a separate conduit.

Preparing J-box Field Conduit

To prepare the field wiring, proceed as follows:

1 Open the CIM door on Side 1 of the unit.

Note: Side 1 has electronics module access to the field connections, boards, and wiring. The
main J-box is installed on Side 1.

2 Commonly, a field connection conduit runs through the side column to the J-box with a 
1-inch NPT male end. Run all the field wiring through this field conduit. All wiring
connections may take place in the factory-installed J-box. Before proceeding, refer to
“Electrical Related Items” on page 8-3 and “Reference Information” on page 9-1.

3 In all units where a J-box is used (factory or contractor-supplied), the following are mandatory
requirements:
• The connection of the conduit to the J-box must be made with a clearance of at least 
9 inches from the pump/dispenser base to the bottom of the J-box connection stub. To
accomplish this, the conduit can be routed to enter the J-box from the side or top.
• The J-box must be securely fastened to the unit by means of a bracket or brace. It must not
be held in place only by a conduit. Factory-supplied boxes are fastened only by a conduit.
• Installation of the J-box and all fittings must be performed to allow the installer to turn any
and all threaded fittings by a minimum of 45° in a single movement using appropriate
tools (for example, pipe wrench).

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-1
Installing Conduit and Wiring in Unit

WARNING
The bottom plate of the electronics cabinet and the top plate of the hydraulics cabinet
are separated to provide an air gap between the electrical and hydraulic housings.

Loss of air gap integrity due to improper installation can allow fuel vapors into areas
where they may ignite. The resulting fire and/or explosion can lead to serious injury or
death.

Running the conduit through the air gap requires strict compliance with procedures
outlined in this manual. No holes in air gap plates can be left unsealed the following
installation.

WARNING
The electronics cabinet is an unclassified area and as such must be protected against
flammable vapor entry.

Improper installation of the conduit through the side of the electronics cabinet may
result in flammable vapors penetrating the electronics cabinet where it may ignite
resulting in fire and/or explosion that can lead to serious injury or death.

Running the conduit through the side of the electronics cabinet requires strict
compliance with the procedures outlined in this manual.

IMPORTANT INFORMATION
For conduit entry through the vapor barrier, the air gap penetration conduit must not be
longer than 8 inches. This will allow removal of the dispenser (if required) in the future
and accommodate wiring a new dispenser without pulling a new wire.

When a dispenser without a J-box is removed from the island, the conduit and wires
will be cut immediately below the potting dam. This will leave enough wire to splice into
a class 1, Div 1, Group C, and D explosion-proof J-box when a new (or previously
removed) unit is installed/reinstalled over the containment box.

For conduit entry through the vapor barrier, the Frontier unit contains eight sets of conduit
knockout holes (four on the right and four on the left) for access to the electronics cabinet.
Knock out the aligned (top and bottom air gap plate) 1-inch plugs for the required number and
positions of contractor-supplied conduits (do not use conduits smaller than 1inch with the
conduit plate provided). For field installations, only two conduits at opposite corners can be
installed per plate. Use the knockouts on the left (facing Side 1) for all power and two-wire
connections. Ethernet, International Forecourt Standards Forum (IFSF), speaker, intercom,
and/or call button wiring must use knockouts on the right. For conduit entry through the side
of the electronics cabinet, the Frontier unit contains eight sets of conduit knockout holes (four
on the right and four on the left) for access to the electronics cabinet. Knock out the 1-inch
plugs for the required number and positions of contractor-supplied conduits.

Note: Do not use conduits smaller than 1 inch size.

Page 6-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Installing Conduit and Wiring in Unit

Installing Conduit Through Vapor Barrier

Note: This is not required for units with factory-installed J-boxes.

To seal the air gaps and conduits in Frontier units, proceed as follows:

1 Install the contractor-supplied 1 listed metal, rigid, threaded conduit through both the top and
bottom air gap conduit plate holes according to the following procedure (see Figure 6-1).

Figure 6-1: Frontier Conduit Sealing Plates

Top Air Gap Conduit Plate

Metallic Conduit Capped
Bushing
Flat Conduit Lock Nut WARNING
Fuel vapors allowed to
travel between the
Washer Hydraulics and electronics
cabinet presents the risk of
fire or explosion.
Conduit
The resulting fire or
explosion may lead to
serious injury or death.
Thread End of Never compromise the
Top Air Gap Conduit vapor barrier integrity by
Plate leaving out conduit plates
Bottom Air Gap or open holes (for example,
Conduit Plate by using conduit smaller
than 1-inch diameter). For
Canadian applications, do
Gasket for Plate
not leave out any gaskets.
An approved metallic
conduit capped bushing
must be installed at the top
of the 8-inch conduit for
mechanical retention of
potting in the event of
Bottom Air Gap explosion.
Plate

2 From the electronics cabinet, remove two screws (not shown) and the upper conduit plate from
the top air gap plate. Retain all parts for reassembly.

3 Thread end of conduit approximately 1-1/2-inches from the end.

Note: The conduit can be installed to the top air gap conduit plate away from the unit.

4 Fasten the conduit to the conduit plate removed using a machined flat conduit lock nut and
washer on the bottom of the plate. Fasten a listed, metallic conduit capped bushing on the top
of the plate.

5 Remove the two screws (not shown) and the bottom air gap conduit plate from the bottom air
gap plate. Retain all parts for reassembly.
Note: (Canada only) The gasket for the plate will come off with the plate. The gasket must be
reinstalled with the plate.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-3
Installing Conduit and Wiring in Unit

6 Remove the aligned knockout plugs from the bottom air gap conduit plate as required, and
reinstall the plate and screws.

7 From the electronics cabinet, slide the conduit down through the knockout in the bottom air
gap plate.

8 Reinstall the top air gap conduit plate onto the top air gap plate using screws, to secure the
conduit in place.

Installing Conduit Through Side of Electronics Cabinet

WARNING
Installation using this method requires Gilbarco Installation Kit (M07838K001). Failure to use the
kit will result in damage or injury.

Figure 6-2: Conduits and Potting Discs

UL-listed Conduit 1-inch

Funnel X 90 FF Elbow

Sealing Electronics
Compound Cabinet

Potting Disc

Potting Disc

Machined Nut (2X)

Machined Washer (2X)
UL-listed Conduit 1-inch Straight Nipple
See warning below
Potting Required (Entry from Division 1 to 2)
Potting Disc 2 inches Deep from
Top of Conduit
48-inches Minimum Height
from Dispenser Base
Conduit Seal Boot
EY with Contractor-supplied 1-inch Conduit
Nipple
Potting Required (Seal-off “Y” Fitting)
UL listed EYS Fitting. Install per manufacturer’s
instructions.

Page 6-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Wiring Installing Conduit and Wiring in Unit

WARNING
Installation using this method requires Gilbarco Installation Kit (M07838K001). Failure to use the
kit will result in damage or injury.

Notes: 1) Conduit seal boots and liquid deflectors are not used on all dispensers.
2) Use UL-listed metallic conduit capped bushing for wire protection.
3) On dispensers without the factory-installed J-box, run conduits for:
• The power and two-wire communications.
• Speakers and call buttons (if required), and
• SMARTConnect™ (if required) through the side column into the electronics
cabinet as shown in Figure 6-2 on page 6-4.

Installing Wiring
Note: The wiring must be gas and oil-resistant, color-coded, or tagged for identification
purposes, and rated for 300 V or higher. Data wires for new installations must be a
twisted-pair (unshielded) with 10 to 12 twists per foot.

Operating Environment
Environment Range
Relative Humidity 20 to 95% (non-condensing)
Minimum outside ambient temperature -4 °F (-20 °C)
Maximum outside ambient temperature 140 °F (60 °C)*
*Electronics have been evaluated and are rated for use at a maximum
of 131 °F (55 °C) outside ambient temperature.

To ensure proper unit performance, operation under severe environmental conditions may
require special options such as card reader heaters and so on.

Wiring External to Dispenser

To install the wiring external to the dispenser, proceed as follows:

1 Pull the wiring through the stub up and sealing fitting.

Notes: 1) Ensure that enough extra wire length (minimum of 5 feet or 2 meters) is provided to
make the run to the stub up location at the bottom of the electronics cabinet.
2) Remember that you may be routing the conduit over to come up at the stub up to the
electronics cabinet. Depending on which end of the unit the stub up is on, you may be
routing across the entire unit length.

2 For the side column conduit entry, install a short two-inch threaded nipple into the top of the
sealing fitting.

3 For the side column conduit entry, install a capped pulling elbow. The use of a Killark® Y-3
fitting is recommended.

4 The remaining conduit must be made up to match the installation layout for the unit at the site.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-5
Installing Conduit and Wiring in Unit Installing Wiring

The following is the list of the most common procedures for conduit entry to the right when
facing Side 1:
• The length of the conduit must extend straight out from the capped Y fitting or pulling
elbow.
• For the side column entry, the conduit must then be turned by 90°, vertical under the air
gap plate knock out.
• Use the required air gap plate knock out. Do not knock out any knock out plugs that will
not be used as an opening for conduit.
• All the conduits that enter into the electronics cabinet must be potted.
• At least 1 inch of conduit must extend above the bottom shelf of the electronics cabinet.
• Complete the conduit run with a conduit nut on the inside of the cabinet.
• Pull all wires properly through the conduit. Finalize the procedure by potting the conduit
end.
• Allow 18 inches of wire in the electronics cabinet for field connections. The wire must be
trimmed as required on field connection.
• All the conduits and fittings must be listed and suitable for use in class 1, Division 1
hazardous locations from the seal off fitting to the potted conduit.

Testing New Field Wiring

WARNING
Sparks can ignite fuel/vapors.
Fire/explosion can result in severe injury or death.
Use caution when testing wires. Do not test when exposed fuel and vapors are
present.
Only use a Megger® tester on new field wiring.
For existing wiring, use a digital multimeter to test for continuity/resistance.

Test the insulation of the new wiring from the station and to the electronics cabinet before
connecting the wires. Refer to the Warning above. This checks for damage that can occur
while pulling wires through the conduit.

To test the new field wiring, proceed as follows:

1 Ensure that wires are disconnected at both ends. If you do not disconnect wires at both ends,
you can damage the pump/dispenser electronics.

2 Test the conduit wiring ends by using an insulation/Megger tester.

3 Connect one tester lead to the wire under test.

4 Connect the other tester lead to the ground.

5 Measure the resistance. Follow the test equipment manufacturer’s instructions. Insulation
resistance of more than 50 megohms is satisfactory. Check the local authority requirements.

6 Repeat steps 1 through 5 for all the new wires.

7 Repeat the test between all the new wires.

8 When all wiring tests are complete, the wiring may be potted.

Page 6-6 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installing Wiring Installing Conduit and Wiring in Unit

Wiring Frontier Dispenser

Depending on the application, Frontier units require that a specific set of cables be installed.
These cables are used to intercept the existing cables and provide connection points from the
master and/or satellite units.

Preparing Field Wiring

To prepare for the field wiring, proceed as follows:

1 Open the door on Side 1 of the unit.

Note: Side 1 has electronics module access to field connections, boards, and wiring.

2 For units with the J-box installed, remove the box cover and save for reassembly.
Note: For Frontier units that are replacing older units, if the existing wire is too short to reach
the installed J-box and a splice must be made, the contractor must provide and use a
class 1 Division 1 explosion-proof J-box to make connections according to the code.
Refer to “Before Mounting Unit on Fuel Island” on page 4-4.

3 The following table contains information on cables that are used for specific applications.
Description Part Number Application
Main AC M02338 All Frontier Master Units
Valve Intercept M02372 Master of Combo Unit - for Satellite Light Only
Combo Neutral M02384 Satellite Side of Combo Unit, Satellite
Transformer M02370 Master of Combo Unit
Subassembly ~ OR ~
Frontier Satellite - for Satellite Light Only
~ OR ~
Legacy Satellite
Combo Pump M02385A001 Frontier Satellite, Combo
Handle
Combo 9 VAC M02386A001 Frontier Satellite, Combo

4 Some cable configurations require that one of the existing connectors be cut off the wires. This
allows the wire to be secured to other wires with wire nuts. For more information, see
“Appendix B: Wiring Diagrams” on page B-1 and for illustrations noted in the table refer to 
step 3.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-7
Installing Conduit and Wiring in Unit Supplying Connections for Three-phase Pump

Supplying Connections for Three-phase Pump

Figure 6-3: Connections for Three-phase Pump

Page 6-8 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Supplying Connections for One-phase Pump Installing Conduit and Wiring in Unit

Supplying Connections for One-phase Pump

Figure 6-4: Connections for One-phase Pump





MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-9
Installing Conduit and Wiring in Unit Potting Conduit Stubs

Completing Field Wiring

To complete the field wiring, proceed as follows:

1 Remove the cover of the J-box for models so equipped.

2 Make the connections as shown in Figure 6-3 on page 6-8 and Figure 6-4 on page 6-9. Do not
disturb the factory wiring in the J-box and electronics cabinet.

3 For units with J-boxes, use pipe plugs to seal the unused openings in all J-boxes. Replace the
cover on the boxes.

4 Double-check all wiring connections for wire nuts, lugs, caps, and so on. Reinstall the J-box
cover. Ensure that you do not pinch the wires and use all J-box bolts.

5 Replace the lower doors and close the doors to the electronics cabinet.

Potting Conduit Stubs

Before potting, ensure that all conduits have been installed, wires pulled, and all wires are
tested. All conduits entering the electronics cabinet on dispensers or pumps must be potted.
Any contractor-supplied conduits entering the electronics cabinet must be potted.

Potting up to Unit
Fill the sealing fitting with potting compound to seal the pathway of the field wiring to the
station building. Refer to “Completing Field Wiring” on page 6-10.

Potting Within Unit

To pot within unit, proceed as follows:

Potting to Electronics Cabinet Through Vapor Barrier

In all Frontier units, for conduit entry through the vapor barrier, each of the contractor
provided 8- X 1-inch conduits entering and exiting the electronics cabinet must be sealed with
a sealing compound through the full length of the conduit. This fill-to-length is mandatory
according to UL requirements. Refer to “Important Safety Information” on page 2-1.

To pot the conduit, proceed as follows:

1 Mix the compound in a clean vessel according to the compound manufacturer’s instructions.
Mix only as much potting compound as can be used before the compound hardens.

2 Using a funnel, carefully pour the sealing compound into the conduit from the top until the
compound is within 1/4-inch from the top of the conduit (see Figure 6-5 on page 6-11).
Note: Ensure that you pour slowly to prevent air bubbles from forming in the compound and
wires around.

3 Immediately clean the spilt compound from the conduit threads and cabinet surfaces.

Page 6-10 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Potting Conduit Stubs Installing Conduit and Wiring in Unit

4 Install the UL-listed metallic conduit capped bushing.

Figure 6-5: Potting Conduits

Frontier Unit with Field Conduit Sealing for Conduit Through the Vapor
Barrier WARNING
Note: With Potting Dam in place, carefully pour Sealing Fuel vapors allowed to
Compound through Funnel to fill the Conduit. travel between the
Hydraulics and
electronics cabinets
Funnel presents the risk of fire or
explosion.
The resulting fire or
Electronics explosion may lead to
Cabinet Wires serious injury or death.
UL-listed Metallic Conduit
Capped Bushing(s) Sealing Never compromise the
Compound vapor barrier integrity by
leaving out conduit plates
or open holes (for
example, using conduit
smaller than 1-inch
diameter). For Canadian
applications, do not leave
UL-listed Conduit out any gaskets.
Locknut
Contractor provided
Conduit 8 X 1” The listed metallic conduit
Hydraulics
nut must be installed at
Cabinet
the top of the 8 inches
conduit for mechanical
retention of potting in the
Fiber Potting Dam
event of explosion.
Coupling installed

Coupling

Conduit to Potting “Y” or J-box

then Potting “Y”

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-11
Installing Conduit and Wiring in Unit Connecting to In-station Diagnostic (ISD) Vapor Flow Meter

Connecting to In-station Diagnostic (ISD) Vapor Flow Meter

At Dispensing Unit
The Vapor Flow Meter is part of an ISD system that measures the amount of vapor returning to
the UST. The wiring for this device is intrinsically safe and must be run in a separate conduit
to the Veeder-Root® monitoring equipment or as per other allowable Veeder-Root
recommendations. The conduit must be potted where it enters and leaves any designated
hazardous zones. The potting requirements for hazardous zones must be followed so that fuel
vapors do not migrate to other areas. The ISD Vapor Flow Meter wiring terminates at the Tank
Level Sensor (TLS) console. The flow meter is in-line and near the vapor return shear valve in
the hydraulic area of the unit. Do not create any liquid flow traps. For more information on
liquid traps, see Figure 5-18 on page 5-22.

Figure 6-6: ISD Vapor Flow Meter

Hydraulic Cabinet Area of Unit (only vapor return associated parts shown for clarity)

Vapor Return Line from Vacuum Motor Outlet

(assist) or Hose Manifold (balanced)

Cord Grip J-box

ISD Vapor Flow Meter

Seal-off 
(Contractor-supplied)

Mating Fittings Cable

(Contractor-supplied) Conduit to TLS
Console

Vapor Line Shear Valve

Bottom Rail of Unit (Contractor-supplied)

Pipe and Fittings

(Contractor-supplied)

Vapor Return to Tank

Page 6-12 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Connecting to In-station Diagnostic (ISD) Vapor Flow Meter Installing Conduit and Wiring in Unit

Epoxy Sealing
Sealing of wiring connections is required to ensure proper performance of intrinsically safe
devices where minor corrosion can affect communication to the device.

CAUTION
Epoxy sealant is irritating to the eyes, respiratory system, and skin. It can cause
an allergic skin reaction. It contains epoxy resin and cycloaliphatic
epoxycarboxylate.

Precautions: Wear suitable protective clothing, gloves, eye, and face protection.
Use only in well ventilated areas. Wash thoroughly before eating, drinking, or
smoking.

Figure 6-7: Epoxy Sealing Field Wiring

From Probe,
Sensor, or
Transducer

B C To Console

A Ensure that the

ends of the Cable Tie-wrap
Sheathing are
submerged in the
Sealant

Wire Nuts

Note: When the temperature is below 50 °F (10 °C), keep the resin in a warm place before
mixing (for example, in an inside pocket next to the body).

To seal the wire nuts with an epoxy sealant, proceed as follows:

1 Open the epoxy sealant package, and remove the resin pack.

2 Hold the resin pack as shown in A (see Figure 6-7), and bend the pack along the length.

3 Firmly squeeze the red side of the resin as shown in B (see Figure 6-7), forcing it through the
center seal and into the black side.

4 Mix thoroughly to a uniform color by squeezing the contents back and forth 25-30 times.

5 Squeeze the mixed, warm resin into one end of the bag, and cut off the other end.

6 Slowly insert the wiring connections into the sealing pack until they fit snugly against the
opposite end as shown in C (see Figure 6-7).

7 Twist the open end of the bag and use the tie-wrap to close it. Position the tie-wrapped end
upwards until the resin solidifies.

8 Push the epoxy sealed bag into the J-box. Replace and tighten the J-box cover.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 6-13
Installing Conduit and Wiring in Unit Connecting to In-station Diagnostic (ISD) Vapor Flow Meter

To TLS Console
Wiring from the ISD Flow Meter J-box terminates at the TLS console. For additional
information, refer to the In-station Diagnostic Vapor Flow Meter Installation Guide 
(Veeder-Root document number 577013-796). For correct polarity connections, 
see Figure 6-8.
Note: Correct polarity must be observed when making the connection.
Figure 6-8: Field Wiring ISD Flow Meter Polarity

Seal-off Device Flow Meter J-box

Black (-)
Intrinsically Safe
From ISD Flow
Wiring from  Meter
Veeder-Root TLS
Console
White (+)

Designates
1/2” Rigid Conduit Connection

Page 6-14 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Installing Breakaways, Hoses, Swivels, and Nozzles

7 – Installing Breakaways, Hoses, Swivels, and Nozzles

Teflon tape must not be used for hanging hardware. Sealant must not be used for sealing
connections unless the threads involved are pipe threads. O-ring seals do not require sealant.
However, a small amount of silicone sealant can be used to avoid rolling or damaging of the
O-ring during assembly.

WARNING
Hold-open devices on nozzles that are not of the pressure activated type, can
allow flow to occur through the nozzle for an activated fueling position, without the
subsequent customer manually opening the nozzle.

Spilt or uncontrolled dispensed fuel may result in potential fire, explosion, fuel
chemical burns, or environmental contamination. Serious injury or death may
result.

As per Gilbarco and certain standard requirements, pressure activated nozzles

must be used for installations that use pump/dispenser or Point of Sale (POS)
activated pre-set operation, or alternately, where a latch hold open device is used
on a non-pressure activated nozzle, the latch hold open device must be removed.
Consult the nozzle manufacturer for their recommended nozzle model types and
safety recommendations.

WARNING
The hose pulled away from the pump/dispenser could drain fuel or pull the unit over during
a drive-off. Explosion and fire or pull off of the dispenser during a drive-off could result in
severe injury or death.

Installation of breakaways is required according to NFPA 30A.

WARNING
Use of hoses other than standard lengths may create a tripping hazard.

Tripping could result in severe injury or death.

Do not use excessively long hoses without a hose retractor.

WARNING
Flexible fuels such as Biodiesel, high alcohol percentage fuels, and so on, may be
incompatible with certain plumbing materials and hydraulic components.

Use of incompatible materials or components with alternative fuels can result in leaks or
unexpected failures of components resulting in fire or explosion or environmental damage.

When dispensing alternative fuels, verify with the manufacturer of the material or component
that all plumbing components are compatible with the fuels being dispensed.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 7-1
Installing Breakaways, Hoses, Swivels, and Nozzles Units Without Hose Retractors

CAUTION
Hose Torque 
Recommended torque when installing hoses is 40-50 N.m (30-35 ft-lbs). DO NOT OVER
TIGHTEN or damage to the nozzle could occur. Applicable when connecting hoses to the skid
tank, during internal repairs, and nozzle replacement.

Units Without Hose Retractors

To install breakaways, hoses, and swivels in pumps/dispensers without extended reach or hose
retractors, proceed as follows:

1 Install the breakaway whip hose to the pump/dispenser outlet casting (see Figure 7-1 on
page 7-3).

2 Install the listed breakaways to the whip hoses. Follow the breakaway manufacturer’s
instructions:
• Clean all threads.
• Place the sealant on male threads only. Follow the sealant manufacturer’s instructions.
Note: Use only UL-classified pipe sealant approved for use with petroleum products.
Remove the sealant if it is found inside the hose or fittings. Clean off the excess
sealant. Do not use Teflon tape as it may damage the unit.
• Use a smooth-faced wrench to tighten all fittings securely. Do not overtighten.
Note: Do not tighten the breakaway by twisting the hose. This can damage the coupling.

Page 7-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Units Without Hose Retractors Installing Breakaways, Hoses, Swivels, and Nozzles

3 Install the hose to the breakaway.

Figure 7-1: Hanging Hardware

4 Install the swivel (if used) to the hose. Follow the swivel manufacturer’s instructions.

5 Install the nozzle to the swivel or the hose. Follow the nozzle manufacturer’s instructions.
Note: Check for the correct nozzle cradle/hook type (vapor, non-vapor, and so on). It must not
be possible to activate the nozzle boot switch with the nozzle properly held in place in
the nozzle boot.

6 Use an ohm meter to check for continuity from the end of the nozzle to the conductive metal
surface in the unit (applies to both types of hose-retrievers or non-retrievers).

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 7-3
Installing Breakaways, Hoses, Swivels, and Nozzles Units Without Hose Retractors

This page is intentionally left blank.

Page 7-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Do Not Turn on AC Power Completing Installation

8 – Completing Installation

Do Not Turn on AC Power

WARNING
Applying power before electrical and mechanical inspections have been
completed can be hazardous. Hazardous high voltage, fuel, and fuel vapors may
be present or the equipment may be damaged.

Serious fires, explosions, and electrical shocks could result in injuries or deaths
Power must not be applied to the unit and associated STPs when installing,
servicing or making electrical wiring connections, or replacing any electrical
components, including light bulbs. Multiple disconnects may be required.

Power must only be applied to the unit after the commissioning Gilbarco ASC
checks wiring and so on. The installer must inspect the unit per “Installation
Checklists” before contacting the commissioning ASC. Incorrect installation
could result in an unsafe unit condition. Damage from improper wiring or
installation will not be covered by warranty.

When all installation procedures are complete up to this point, the unit must be inspected by a
Gilbarco ASC.

After the inspection is complete, the system must be purged by the installing contractor.
Irrespective of when the purging operation is performed, proceed to “Installation Checklists”.

Installation Checklists
To ensure proper and safe operation of all equipment and to ensure warranty coverage,
installers must inspect the installation. The “Mechanical and Hydraulic Related Items” on
page 8-2 checklist and “Electrical Related Items” on page 8-3 checklist may be used as a guide
(many of the items on the lists must already have been checked by the electrician as covered
earlier).

Follow the checklists and perform all the required inspections. The forms must be provided
with each unit, if not, contact the Gilbarco Distributor. It is only required to complete the
station electrical inspection portions of the form (List 3) in every form, (for every unit at the
station).
Note: To preserve the originals for future use, make several copies of all the checklists in this
manual.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 8-1
Completing Installation Installation Checklists

Mechanical and Hydraulic Related Items

MDE-4226
Item Procedure Refer To Checked Related Item
1 Shear valves must be installed according to the valve page 5-23 of this List 1, Item 1
manufacturer’s recommendations. Shear point is ±0.75” manual
of grade and properly mounted. Vapor line shear valves
are required for many localities.
2 The lower piping brace must be installed according to the page 5-16 of this List 1, Item 13
installation manual and all product pipes must be properly manual
anchored to it.
3 Flexible pipes must not be used within the dispenser. - List 1, Item 2
However, flexible pipes that meet the local and state
codes can be used below the pump/dispenser, when
allowed by regulatory authorities.
4 Pumps (self-contained units) must have a vacuum - List 1, Item 3
actuated pressure regulating valve (Gilbarco Model 52 or
equivalent) to prevent positive pressure at the pump base
when used with above ground tanks.
5 Hose breakaways must be used and installed according Manufacturer’s List 1, Item 5
to the manufacturer’s recommendations. For units with specifications
retrievers, breakaways, and whip hoses must be attached
to the nozzle end. For units without retrievers, it is
attached to the dispenser end.
6 All hanging hardware must be checked for continuity. page 7-1 of this List 1, Item 6
manual
7 The unit must be properly anchored to the island or skid page 5-23 of this List 1, Item 7
tank. manual
8 Vapor recovery piping at the pump/dispenser must have page 5-22 of this List 1, Item 8
no traps or sags. Unit must be mounted using proper manual
quantity, size, and strength mounting hardware.
9 Verify correct nozzles, piping and brand panels for each Unit order List 1, Item 9
grade. Also, verify if correct product lines are connected specific
to each pump/dispenser inlet.
10 All code, regulatory agency, or customer-specified safety As provided with List 1, Item 10
warning signs, labels, or decals have been installed. and for unit
11 Long hose lengths beyond Gilbarco recommendations NFPA 30A List 1, Item 11
must not be used without special retrievers.
• For VaporVac hoses, no more than 6” of hose length
may rest on the ground when the nozzle is resting in the
boot.
• For Balance Vapor Recovery hoses, no portion of the
hose may be on the ground.
12 Verify shear valve, Nozzle, and Dispenser proper shutoff page 8-6 of this N/A
operation. manual

Page 8-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Installation Checklists Completing Installation

Electrical Related Items

MDE-4226
Item Procedure Refer To Checked Related Item
1 Conduit entries into the electronics cabinet must be installed List 2, Item 1
according to the installation manual. No unplugged openings must
be allowed between the electronics cabinet interior and the vapor
barrier or at the side of the electronics cabinet.
List 2, Item 2
Field conduit into the electronics cabinet must be properly potted
according to the local, state, and national codes as per the
installation manual. This is in addition to potting requirements for
the conduit below the base of the pump/dispenser.
2 Field conduit installed in dispenser hydraulics cabinet must be List 2, Item 3
securely fastened to the brace supplied with the unit, using
appropriately sized U-bolts or pipe clamps.
3 Equipment must be installed in conjunction with an emergency “Grounding” on List 3, Item 2
power cutoff to remove all power from the equipment in case of an page 9-9
emergency.
4 STP isolation relays are required for all dispensers. List 3, Item 3
5 Use twisted-pair wires as specified for two-wire communication for List 2, Item 5
new installations or where a new wire is pulled. Do not use
shielded wires for video feed, for SMARTConnect and Applause
Media System.
6 Use twisted-pair wires for color display communication wiring. List 2, Item 5
7 All wiring must be of stranded copper of the gauge and insulation List 2, Item 6
casing specified.
8 All grounds must be properly connected according to the List 2, Item 7
installation manual requirements as well as the state, local, and
national codes.
9 Conduit and J-boxes must be approved for hazardous locations • NFPA 30A List 2, Item 8
and properly sized for the wiring involved. • NFPA 70
• UL 87
• NEC

10 Properly size all circuit breakers for the units/unit options involved. NEC and local List 3, Item 5
codes
11 All pump/dispenser wiring must be properly spaced and isolated List 3, Item 6
from wiring for electrically noisy devices such as variable speed
STPs, station equipment motors, and other devices.
12 All power wiring and circuit breakers to Gilbarco equipment must List 3, Item 7

be dedicated and not be shared with other equipment.
13 All circuit breakers to Gilbarco equipment must be clearly labeled List 3, Item 8
and readily accessible.
14 All distribution boxes must be clearly labeled showing the  List 3, Item 9
pump/dispenser number connections.
15 All pumps/dispensers must be wired to the same phase of List 3, Item 10
electrical power.
16 New site wiring must be Megger-tested and wired to the same List 3, Item 11
phase, unless isolation relays are used to protect it against cross
phasing. Old site wiring must be continuity and short-tested with a
digital meter.
17 Wiring must be color-coded or tagged, sized for distance and N/A
application, and resistant to gas and oil.
18 J-boxes must be secured with all bolts and have no unplugged List 2, Item 9
openings.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 8-3
Completing Installation Purging Air from System and Testing

Purging Air from System and Testing

For New Dispensers (Purging Through Shear Valve)

The Frontier dispensers must have some programming changes completed before purging can
be started.

Frontier Units
The Frontier units are received precalibrated, but must be checked for calibration before use.
Purging requires the unit to be configured for gallons, liters, or imperial gallons.

IMPORTANT INFORMATION
When purging Frontier units, if you exceed more than 250 volume units for any meter on a side,
the startup technician will not be able to reset the volume totals to zero or any other value for
opening the station. Avoid purging of more than 200 units of volume per meter as a result.
Purging, calibration, and calibration verification can be performed within this limit and totals
reset, if required.

Programming Units of Measure

For Frontier units, this procedure is referred to as setting the Conversion Factor. For other
Encore units, this is referred to as setting Volume Units.

Special Steps to Purge Air from Underground Lines

For sites with underground lines not filled with fuel, air must be purged from the lines before
purging the dispenser.

CAUTION
Do not attempt to purge these lines using the dispenser nozzle as the dispenser
meters may suffer damage due to overspeed.

To prepare for purging, use the following steps for each shear valve in all units. Be observant
during purging and check for plumbing leaks as you move toward the tank. For blender
nozzles, select a blend grade. Ensure that the prices are set (by the ASC) before you begin.

1 Turn off all power to the STPs involved.

2 Start with the unit farthest from the tank.

3 Use a UL-approved sealant to connect a “gasoline suitable, conductive hose” to the shear
valve test port.

4 Install the mechanical valve (petcock) to the hose.

5 Place the drain end of the closed valve in an approved metallic container. Clean up any spills
promptly.

6 Turn on power to STPs. Activate the STP for the line being purged.

Page 8-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Purging Air from System and Testing Completing Installation

7 Slowly open the mechanical valve until you obtain a slow, constant stream of fuel flow.
Maintain contact between the metallic valve and the can during fuel flow.

8 Turn off STP, bleed pressure using the mechanical valve, remove the valve and hose, and
reinstall the pipe plug to the shear valve using UL-approved sealant suitable for the fuel
involved.

9 For purging air from the system with fuel in lines, perform all steps in “For New and Existing
Pumps and Dispensers with Fuel in Lines (Purging Through Nozzle)”.

For New and Existing Pumps and Dispensers with Fuel in Lines (Purging
Through Nozzle)

CAUTION
Purging air at high flow rates through the meter can permanently damage them.
Noise is not an indication of overspeed in many cases.

Overspeed meter damage is not covered by warranty. Follow all instructions

carefully.

CAUTION
Meters and other hydraulic devices can be permanently damaged by
contamination if units are not equipped with filters during purging and other
installation processes.

Non-use of filters during installation is considered abuse. Meters and other

components that fail due to the contamination introduced during installation are
not covered by warranty.

Never remove filters during installation. Do not substitute.

To purge air in new and existing pumps/dispensers where underground product lines are full
with fuel, proceed as follows:

1 Lift the nozzle handle for the hose being purged.

Note: For purging in Frontier units, perform the procedure for purging in “For New
Dispensers (Purging Through Shear Valve)” on page 8-4 for the selected meter.

2 Place the nozzle in the approved container.

3 Slowly open the nozzle until you obtain a slow, constant stream of fuel flow.
Note: For SMART Meter-equipped units, never exceed the nozzle slow latch setting until fuel
flow is steady.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 8-5
Completing Installation Purging Air from System and Testing

4 Purge the system with the amount of fuel specified in the following table:
For Pump this Amount
Start-ups (installing new systems) 35 gallons (130 liters) per hose
Existing sites where the product lines are full 50 gallons (186 liters) per hose*
*This value depends on the following procedures in the sequence listed (especially for new
sites). Also, a lot can depend on line lengths, unusual plumbing situations (air traps), and so on,
what may be good for most sites may not work for all. Generally, you can observe the effect of
air if successive calibration checks read plus. After they stop reading plus, you have purged all
the air.

5 Return the nozzle to the nozzle boot.

6 Empty the approved container into an appropriate product tank.

7 Repeat steps 1 on page 8-5 through 6 for each affected hose and each meter.

Frontier units have enhanced security software. You must periodically spin the pulser to
maintain a higher purging flow rate.

WARNING
Do not substitute the pulser while power is being supplied to the unit. Lethal voltages exist
within the dispenser and damage to the unit could occur if certain critical steps are not
followed. It is recommended that only Gilbarco-certified ASCs, who are trained in the
service and operation of Frontier dispensers perform this procedure.

Note: Dispense a minimum of 75 gallons (341 liters) through each DEF hose. For overhead
lines where no air bleed is used at a high point, purge amount can sometimes run into
hundreds of gallons.

Verifying Shear Valve, Nozzle, and Dispenser Shutoff Operation

To verify correct shutoff function of the shear valve, nozzle, and dispenser, perform the
following after purging air for all nozzles:

1 Close the shear valve.

2 Activate the fueling position associated with the shear valve.

3 Open the nozzle. Fuel must not continue to dribble out of the nozzle for more than a few
seconds. If fuel continues to flow for a longer period, check the shear valve or nozzle for
problems.

4 Close the nozzle.

5 Open the shear valve.

6 Activate the fueling position for the same fuel on the opposite side of the unit.

Page 8-6 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Calibration Procedure for Frontier Units Completing Installation

7 For the side to be tested (opposite activated side), remove the nozzle from the boot but do not
activate the boot switch by raising the nozzle boot lever or allowing the auto on flapper to
activate.

8 Open the nozzle. Fuel must not continue to dribble out of the nozzle for more than a few
seconds. If fuel continues to flow for a longer period, check the nozzle or inform the ASC to
check the dispenser valve or valve O-rings.

Calibration Procedure for Frontier Units

IMPORTANT INFORMATION
Units must be properly purged before calibration or calibration verification. Incomplete
purging of air can result in inaccurate calibration or errors in calibration verification
testing (normally, subsequent calibration checks will read plus). Always verify any
calibration after setting.

The Frontier meters are precalibrated, but calibration must be verified. Depending on the type
of unit, the procedure is slightly different. After calibration, the Weights and Measures
(W&M) switch must be seal-wired to prevent calibration tampering. Ensure that you draw the
seal wire tightly.

Frontier (Liter Unit of Measure)

Temporary pricing must be entered into the unit, as outlined in “Installation Checklists” on
page 8-1 to allow dispensing and calibration.

The currently produced Frontier units are precalibrated to Litre and programmed to default
programming values.
Note: Perform the calibration verification procedure after calibration.

Programming Instructions - Level 1 Command Codes (Setting PPU)

For more information, refer to “Frontier Commissioning Document”.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 8-7
Completing Installation Calibration Procedure for Frontier Units

This page is intentionally left blank.

Page 8-8 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Reference Contents Reference Information

9 – Reference Information

Information in this section is provided for the installing contractor’s reference. The contractor
may or may not be required by individual contract to perform all or any of the requirements
outlined. However, all installations must conform to the requirements of this section.

Reference Contents
Section and Information Location
Installation Differences when Replacing The Advantage Series page 9-2
Electrical Requirements page 9-3
Emergency Power Cutoff Switch
Circuit Breakers page 9-3
STP Control Relay Boxes for Dispensers
STP Isolation Relays for Electronic Dispensers
Conduit page 9-4
Wiring
Twisted-pair Wiring - Data Wire Lengths page 9-6
Twisted-pair Conduit
Twisted-pair Cable
Ethernet Cable page 9-7
Cable Ordering Information
Ethernet Cable Installation Personnel and Procedures
Grounding page 9-9
Sealing ‘Y’ Fittings page 9-10
Plumbing Requirements page 9-11
Pipe Installation
Pipe Size
Pumps (Standard Flow)
Pumps (High Flow)
Dispensers (Standard Flow) page 9-13
Dispensers (High Flow)
Dispensers (Frontier High Gallon)
Check Valves (Used on Pumps and Frontier Units only) page 9-13
Shear Valves (Generally Used on Dispensers Only)

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-1
Reference Information Installation Differences when Replacing The Advantage Series

Installation Differences when Replacing The Advantage

Series
The following table shows critical differences between The Advantage Series and Frontier
Series that will affect installation:
Item Description
Side To emphasize plumbing differences between the Frontier Series and The Advantage Series, the
Identification nomenclature has been changed. There is no longer a reference to the sides as A and B as with
The Advantage Series. The serial plate front of the Frontier Series (manufactured on or before
December, 2002) is now Side 1 and the back is Side 2. Units manufactured after December, 2002
have the serial plate (label) mounted on the main door behind the CIM door on Side 1. Side 1 is the
primary service access side for electronics. Importantly, Side 1 on an Frontier unit replacing an
existing The Advantage Series unit does not always replace The Advantage Series A Side. In
most cases:
• The Advantage A Side and Frontier Side 1 are reversed for Frontier Single-hose and Blender
units.
• The Advantage A Side and Frontier Side 1 are the same for Multi-hose units.
Also, the Frontier Series uses letters (W, X, Y, and Z) to differentiate the product pipes. The
Advantage Series units are typically labeled as low and high or A, B, and so on.
Piping Layout Do not assume piping connections for the Frontier unit based on The Advantage Series or
other unit piping.
Dispensers: Frontier product plumbing, in some cases, is in the reverse order from The Advantage
Series, is spaced differently and has other differences. For more information, see “Plumbing
Requirements” on page 9-11.
Pumps: Frontier product inlet and electrical connection locations on self-contained pumps are
different from The Advantage Series.
Piping Dispensers: The Frontier unit is provided with a lower piping brace. The installer must secure
installation plumbing to the lower brace as per the installation document else, improper operation of the shear
valves may result if a unit is knocked over. Flexible pipe cannot be used within the dispenser, but
may be used below the dispenser. The Frontier inlet plumbing only extends partially into the
Hydraulics Cabinet. This allows much greater installation adaptability by using rigid piping when
retrofitting to competitive equipment pit boxes and plumbing layouts. In addition to side-to-side inlet
adjustment capability, the lower piping brace can be mounted forward or rearward for additional
adaptation.
Pumps: Pumping units in self-contained pumps are shipped without inlet fittings. At installation, the
protective closure in the pumping unit inlet must be removed and replaced with proper inlet fittings.
Frame width There is only one frame width for the Frontier. The Advantage Series units come in wide and narrow
frame types. The Frontier width is intermediate between the wide and narrow frame width of The
Advantage Series. However, it is recommended to use a pit box designed or adaptor for the Frontier
for new stations or major renovations.
J-box Dispensers: The Frontier units may ship with or without a J-box or field conduit. The conduit and 
J-box not part of an order is provided by the installer. This allows more versatility for electrical
conduit routing. As the installer may install the J-box towards the front or rear of the unit, it is not
recommended to use the location of the J-box openings as an indication of front or rear of the unit.
Always use the serial plate to identify Side 1.
Pumps: The Frontier Pumps have a factory-installed J-box, located on Side 1, but the electrical
power connection is a 1” NPT conduit inlet located on Side 2. All electrical power wiring to the unit
must enter the conduit on Side 2 and feed to the J-box. The Ethernet and intercom connections
must enter the unit on Side 2. Refer to “Appendix A: Elevation Diagrams” on page A-1.
• J-boxes, conduit, and fittings must conform to all requirements listed and referenced in this
manual.
• For new installations, with proper pull of additional wire, it is possible for Frontier to eliminate a
J-box. The Advantage Series units always have a J-box.
Electronics The Frontier electronics cabinet has two field conduit inlets. Facing Side 1, the ones to the center
Cabinet left are for power wiring while the ones to the center right are for intercom/Ethernet/call button/
speaker wiring. In The Advantage Series, the power goes into the J-box and intercoms, and so on,
usually in a special conduit up a side column. Ethernet will be an option for future Frontier units with
installation of an optional board in the electronics cabinet. All the Encore units have knockouts for
Ethernet wiring although the option board is not currently available. Ethernet wiring can share the
conduit with a speaker/intercom/call button.

Page 9-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Electrical Requirements Reference Information

Item Description
Wiring in The Encore Series units use wiring terminal blocks, as appropriate, for field wiring whereas The
Electronics Advantage Series units use wire nut connections.
Cabinet
Mandatory The installer must pot each conduit entering the electronics cabinet in two locations as specified in
conduit this manual. One is at the entry into the electronics cabinet and the other is in the pit box. The
potting Advantage Series units only require potting below the unit.
requirements
Calibration All the Frontier meters are electronically calibrated. The Advantage meters are mechanically
calibrated.

Electrical Requirements
Electrical requirements are as follows:
• Sites must be prepared according to NFPA 30A, NFPA 70, and applicable national, state,
and local codes/regulations.
• All circuit breaker panels and relay boxes must be mounted securely to the wall.
• Only UL-recognized/approved components and/or systems may be used.
• Licensed electricians experienced with pump and dispenser installations must be used to
make all electrical connections.
• Installation requires a dedicated circuit phase system. All electronic units must be wired to
the same power leg.
• An earth ground is required for all circuits.

Emergency Power Cutoff Switch

• NFPA 30A and Gilbarco require the installation of one or more emergency power 
cutoff switches.
• An emergency power cutoff switch is a single control that removes AC power to all island
equipment [pumps/dispensers, STPs, canopies, lights, and so on (see Figure 9-1)].
• The emergency power cutoff switch must be accessible, labeled clearly, and installed away
from any hazard that may occur at the pumps/dispensers. Cutoff switches must not be
located more than 100 feet away from the pumps/dispensers.

Circuit Breakers

Figure 9-1: Switched Neutral Circuit Breaker

Do not use Use

• A dedicated UL/CUL/CSA/IEC 60947-2-listed switched neutral breaker is required for

each circuit leading to a pump/dispenser or dispenser and STPs. It must be able to
disconnect hot and neutral conductors simultaneously. Single-pole breakers with handle
ties cannot be used.
• Only UL/CUL/CSA-listed circuit breaker panels are permitted for use.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-3
Reference Information Electrical Requirements

• Circuit breakers must be installed away from the pumps/dispensers, readily accessible and
clearly marked.
• A separate circuit breaker is required for each STP (dispenser models) or each pump
motor (self-contained models).
• One circuit breaker is required for each pump/dispenser to allow the isolation of the 
pump/dispenser.

Units with Ground Fault Interrupt (GFI)/Residual Current Device (RCD)

A Ground Fault Interrupt (GFI), also referred to as Residual Current Device (RCD) in some
regions, consists of a sensor that detects changes in the current to the load, by comparing the
current flowing to the load and the current flowing from the load. A drop-off in the current
equivalent to about 25 mA can turn off all power by tripping a relay within the GFI/RCD
within a few hundredths of a second. 

When powering a dispenser with a GFI/RCD, the return neutral of any device to which the
dispenser supplies power must be the same neutral as that of the dispenser. For example, the
STP control relay.

STP Control Relay Boxes for Dispensers

• Gilbarco requires installation of STP isolation relays in addition to STP control relays.
Combined STP Control Relay/Isolation Relay boxes are recommended.
• Each STP requires a separate control relay for each STP.
• Dispenser relay must not be used to power the STP.

STP Isolation Relays for Electronic Dispensers

STP isolation relays provide electrical isolation between dispensers and prevent damage from
cross phasing. Refer to MDE-2755 Gilbarco STP Control and Dispenser Isolation Relay Box
PA0287 and
FE-321 Gilbarco STP Isolation Relay Box PA0287.

Note: For 3-phase STP, use isolation relay at the input of the 3-phase STP control box.
• Gilbarco requires installation of STP isolation relays in addition to STP control relays.
Combined STP Control Relay/Isolation Relay boxes are recommended.
• Isolation relays must be installed for each STP control line at each dispenser or dispenser
grouping on a single circuit breaker.
• Neutral wire must be routed to the control relays from the dispenser circuit breaker (For
more information, see “Appendix B: Wiring Diagrams” on page B-1).

Conduit
Gilbarco recommends that spare conduits be run for future high speed communications. For
details, refer to “Twisted-pair Conduit” on page 9-6.
• Use a minimum of 1-inch conduit for all Frontier pumps/dispensers except for Frontier,
where you must use 3/4-inch conduit to connect wires to the pump/dispenser. Infoscreen®
and Two-wire data wires can share this conduit (For model-specific wiring diagrams, see
“Appendix B: Wiring Diagrams” on page B-1).

Page 9-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Electrical Requirements Reference Information

• Use separate 1-inch conduit for e-CRIND or intercom wiring. This is required for higher
data rate Transmission Control Protocol/Internet Protocol (TCP/IP) communication.
• Run all power and light wires in threaded, rigid metal conduit or in a rigid non-metallic
conduit. The conduit must conform to national and local electrical codes. If non-metallic
conduit is used, it must be at least two feet underground. The last two feet of the
underground run to the J-box must be a rigid metal conduit or threaded steel intermediate
metal conduit.
• Never share the conduit or wire troughs with other manufacturer’s equipment (that is,
speaker wires, and so on).
Note: The same conduit may be used for routing power to the pump/dispenser and the 
two-wire data loop (class 1 circuit). The two-wire data loop is a class 1 circuit.
• Metal conduit is not sufficient to provide an equipment ground. A separate ground wire
must be used.
• Knock-out boxes or flexible conduit are not permitted for installation.
Note: Extra J-boxes added to the pump/dispenser must be listed class 1, Div. 1, Group C
and D explosion-proof.
• All electrical fittings must be listed for class 1, Group C and D hazardous locations, as
required by NFPA 30A and NFPA 70.
• A Seal-off ‘Y’ fitting (for example, Killark Type EY) must be installed on all units as a
first connection where the conduit leaves the ground.

Wiring
For high speed communications information, refer to “Twisted-pair Conduit” on page 9-6.
• All pumps/dispensers must be wired according to NFPA 30A, NFPA 70, and applicable
national, state, and local codes/ regulations.
• All circuits must be class 1 N.E.C wired except the speaker (intercom) circuit which must
be class 2 N.E.C. The speaker (intercom) circuit requires a separate 1-inch conduit.
• Only stranded gas and oil-resistant copper wire rated for 300 Volts (up to 240 VAC source)
and 176°F (80 °C) may be used.
• In the main conduit, for communications, only twisted-pair, Two-wire data pairs may be
used.
• All dispensers must be wired on the same phase.
Note: If the Gilbarco isolation relay box is installed, dispensers are not required to be on
the same phase.
• Only listed wire nuts may be used for connections. Tape is not permitted.
• Seal-off Y fitting(s) must be potted after all wires are run and tested to termination points.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-5
Reference Information Electrical Requirements

Twisted-pair Wiring - Data Wire Lengths

Refer to the following table to determine maximum data wire lengths.
The Distance Between the The Distance Between the Distribution
For this Distribution Box Distribution Box and Dispenser Box and Console/Controller
PA0133, PA0187 G-SITE® “Total” data wire system run no more than 2600 feet with 14 AWG.
PA0242 Transac® System No more than 2600 feet with 14 AWG. No more than 2600 feet with 14 AWG.
1000
PA0261 Universal No more than 2600 feet with 14 AWG. No more than 2600 feet with 14 AWG.
Distribution Box (Two-wire
Mode)
PA0306 Distribution Box No more than 2600 feet with 14 AWG. No more than 2600 feet with 14 AWG.
PA0409 Distribution Box No more than 2600 feet with 14 AWG. No more than 2600 feet with 14 AWG.
PA0261 (RS-422 Mode) No more than 50 feet with 14 AWG. No more than 2600 feet with 14 AWG.
PA0409 (RS-422 Mode) No more than 50 feet with 14 AWG. No more than 2600 feet with 14 AWG.

Note: When installing new two-wire communication wiring, use unshielded twisted-pair data
wires. Do not use shielded wires. Wiring specifications: two-wire twisted-pair (UTP)
with 10 to 12 twists per foot, stranded annealed copper tinned with 18 AWG minimum
required for runs up to 1000 feet or 14 AWG minimum for runs up to 2600 feet. Do not
use daisy chain communications wiring. Insulation specifications: Polyvinyl chloride
(PVC) insulation of type TFFN or MTW, UL-approved gasoline and oil-resistant. Refer
C&M Corporation Part #27525 (18 AWG) or equivalent. Gilbarco part number for the
wire is Q13221-02.

Twisted-pair Conduit
Gilbarco recommends the use of 1-inch rigid conduit and fittings (refer to “Conduit” 
on page 9-4) for twisted-pair cable(s). This will allow up to two speakers and two call/stop
buttons per side, plus Ethernet.
Note: Terminate the conduit in the dispenser containment pan consistent with all national and
local electrical codes.

Twisted-pair Cable
Gilbarco-specified cable must be used to permit issuance of a Certificate of Conformance 
and/or warranty. Use of cables of other types may also create a hazardous situation.

WARNING
Petroleum vapors may migrate inside the cable insulation between conductors
and sheathing of various cables, including twisted-pair cables. Vapors may
ignite, leading to serious injury or death.

Use only twisted-pair cables specified by Gilbarco.

Cable Ordering Information

Refer to the following table for cable ordering information:
Type Comments
Q13221-02 Wire - 600V Stranded, Annealed Copper Tinned with PVC Insulation
~OR~
Type TFFN or NTW, 18 AWG UL-approved Gasoline and Oil-resistant, Wire with 10-12 twists per foot

Page 9-6 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Electrical Requirements Reference Information

Ethernet Cable
Gilbarco requires use of 10 Base-T or Category 5E (CAT5E) Cable as specified in this
document.

Ethernet Cable Installation Personnel and Procedures

IMPORTANT INFORMATION
A copy of the ANSI/TIA/EIA TSB 67 Certification of Conformance from the wiring
personnel must be provided to the ASC before the site can be commissioned. The
certificate is part of the documentation that must be on the file at the installation site.
A certification of the field test will be required at equipment start-up. For any questions
regarding this procedure, contact Gilbarco.

Ethernet Cables must be installed by certified telecommunications technicians in accordance

with ANSI/TIA/EIA 568-A Commercial Building Telecommunication Cabling Standards (and
Amendments). The installing technician must read and understand the following:
Document Title
ANSI/IEEE 142-1991 Recommended Practice for Grounding of Industrial and Commercial Power Systems
(IEEE Green Book).
ANSI/IEEE 1100 Recommended Practice for Powering and Grounding Sensitive Electronic Equipment
(IEEE Emerald Book).
ANSI/TIA/EIATSB67 Transmission Performance Specification for Field Testing of Unshielded Twisted-pair
Cabling Systems.
ANSI/TIA/EIA568-A Commercial Building Telecommunication Cabling Standards (with amendments).

The following are the two ways to connect high-speed data to the dispenser:
a An Ethernet or Category 5 (CAT5) cable installation.
b FlexPay Connect
• POS controls CRIND on dedicated twisted-pair
• POS controls CRIND with pump data on same wire
• Applause on dedicated twisted-pair
• Applause with pump data on same wire

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-7
Reference Information Electrical Requirements

Ethernet or CAT5 Cable Installation

Note: An Ethernet or CAT5E cable cannot be installed in power conduit as the maximum
cable length is 300 feet.

IMPORTANT INFORMATION
Petroleum vapors may migrate inside the cable insulation between conductors
and sheathing of various cables, including 10 Base-T or CAT5 E Cable. Vapors
may ignite, leading to serious injury or death.

It is crucial that the installer follow NECs, article 501 requirements by removing
the outer jacket and spreading the wire pairs at the seal-off points of the CAT5E
Cable, so that a good vapor seal is achieved. This is required because all 
CAT5E Cables will conduct vapors inside their outer jacket.

Use gas-oil resistant CAT5 or CAT5E. For example, Belden® 7928a.

Conduit seal-offs required as per National Electric Code, section 514.9. As the outer
jacket defeats the seal-off, the jacket must be removed and the conductor pairs
separated to allow a good seal (see Figure 9-2).

For non-US installations, consult local regulations.

Figure 9-2: Low-voltage Conduit

Seal-off

Low-voltage Conduit

Sealing Compound
Poured here

Outer Jacket Extending

into Seal-off

Separated Pairs

Close-up View of Seal-off

Note: Jacketed and/or Shielded Cable must have the jackets and shielding removed where
the wire passes through the seal-off material.

Page 9-8 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Electrical Requirements Reference Information

Grounding
Grounding requirements are as follows:
• NFPA 70 requires connecting the following to the system ground:
- Consoles - Relay control boxes
- Pumps and dispensers - Circuit breaker panel
- Submerged turbine pumps - Electronic leak detectors
• Gilbarco requires connecting each pump/dispenser to an equipment grounding conductor
(see Figure 9-3) located in the conduit per NFPA 70, Article 250. The following applies to
ground conductor:
- Use of wire no smaller than 12 AWG.
- Use of wire with green or green and yellow striped insulation.
- Connection to green grounding screw in the J-box.
- Grounding the providing power under NFPA 70, Article 250.
- Bonding the neutral bus to an approved grounding electrode.

Figure 9-3: Grounding Plan

Gilbarco Console
Metal Conduit Conduit
Isolated Ground
Main Circuit Pump/Dispenser Power Outlet
Breaker Panel Circuit Breaker Panel (Hubbel IG5261t)

Insulated Switched Neutral

Grounding Circuit Breaker

Conductor

Neutral Bus

Ground Bus
Neutral Bus

Ground Bus Encore Unit

Motor*
Pump/Dispenser J-box
Ground Screw
Grounding 12AWG Green Ground Wire
Electrode
White Neutral Wire

*The motor is internally grounded

to the motor frame.
Notes:
Rigid Metal Conduit
= Ground
Bond
Refer to NEC Ground Surface
and/or local Conduit
codes for
appropriate 2 Feet
conduit
requirements. Rigid Metal Conduit
Adapter

Grounding Plan (Typical)

Note: For Frontier units without the J-box, connect the ground wire using UL-listed wire nut to the lead
provided in the cabinet from the grounding terminal.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-9
Reference Information Electrical Requirements

Sealing ‘Y’ Fittings

‘Y’ seals are installed in the conduit runs to minimize passage of vapors, gases, or flames from
one portion of the electrical installation to another through the conduit. Fittings must be
installed in accordance with Articles 501-5 and 502-5 of the NEC and fitting manufacturer’s
instructions.

Gilbarco uses Killark type EY fittings and recommends them or their equivalent for vertical
conduit runs. The following sealing directions are for Killark fittings only, and instructions
may vary for other manufacturer’s fittings. Read and understand all instructions completely
before you begin.

To seal ‘Y’ fittings, proceed as follows:

1 Remove the close-up plug (see Figure 9-4).

Figure 9-4: Typical ‘Y’ Sealing

Conduit Wires

Close-up Plug

Sealing Compound

Fill to Bottom of Threads

Floor Dam

Conduit

2 Separate conductors and fill the conduit in and around conductors using Killark type “PF”
packing fiber to make a floor dam to hold the fluid sealing compound.
Note: Floor dam must be even with the conduit stop in the lower hub of the fitting. Ensure that
the conductor insulation is not damaged. Force pack between conductors and hubs,
pushing any shreds of packing fiber away from conductors to prevent leakage path.

3 Use only Killark type “SC” sealing compound with Killark fittings, and do the following:
a Use a clean mixing vessel for every batch of sealant.
b Mix the compound at the rate of three parts compound to one part water by volume.
c Sprinkle the compound in water while stirring, until a thick paste is formed.
d Do not mix more compound than can be used in 15 minutes.
e Continue mixing for at least three minutes, until consistency is just fluid enough to pour
slowly, like thick gravy (not watery).

Page 9-10 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Plumbing Requirements Reference Information

4 Slowly pour the fluid compound till it fills the bottom of the Close-up plug threads.
Note: Be careful to pour slowly, to avoid trapping air bubbles in the seal.

5 Immediately wipe off any spilled compound and close the seal with a close-up plug.
Note: Initial setting of the sealing compound will occur within 30 minutes. Compound requires
a minimum of eight hours above 32 °F (0 °C) to develop sufficient strength to withstand
explosion pressures.

Plumbing Requirements

Pipe Installation
For Installation of underground liquid storage systems (Chapter 9), refer to Petroleum
Equipment Institute (PEI) publication RP100 Recommended Practices and for installation of
above-ground storage systems for motor vehicle fueling, refer to PEI publication RP200
Recommended Practices.

Product inlet pipes and vapor pipes for Gilbarco pumps/dispensers vary in location between
models. Product piping order differs from blenders to previous Advantage Series models. See 
model-specific footprint before installing pipes.
• Check national, state, and local regulations for installation of the pipe system.
• Use containment system as required by national, state, and local regulations.
• Below the unit, use UL and code-approved flexible pipe (constructed of UL-approved
pipe material and UL-approved fittings).
Note: Some local regulatory agencies do not allow the use of a galvanized piping
component when diesel is involved. Consult local regulators. Also, galvanized
piping is not usable for certain Alternative fuels, such as E25 and E85 or Biodiesel.

IMPORTANT INFORMATION
Gilbarco supplies galvanized Tubing (not pipe). However, no zinc or galvanizing is
present on the inner circumference of any tubing or piping supplied by Gilbarco.

• Use 1-1/2-inches pipe for riser-to-pump or dispenser.

• Alternative fuels such as E25 and E85 may require special piping materials or
components. Consult the manufacturer to determine whether the piping material is
compatible with the fluid being used.
• Use 2-inches risers on Frontier units which use a 2-inches shear valve.
• Leak detectors may not detect leaks reliably in plumbing between master and satellite
Frontier units. Secondary containment and likely specialized leak detection equipment is
required. Consult codes.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-11
Reference Information Plumbing Requirements

Pipe Size
The required pipe size depends on the number of units sharing lines, size of the STPs
(dispensers only), and length of the run. The following guidelines must be followed:

Pumps (Standard Flow)

Use new pipes of 2, 2-1/2, or 3 inches.
• Pipe of 2 inches for runs up to 50 feet to a single pump
• Pipe of 2-1/2 or 3 inches for longer runs up to 75 feet to a single pump with maximum lift
condition
Note: A dedicated line is recommended to supply each self-contained pump.

Pumps (High Flow)

Use new pipes of 3, 3-1/2, or 4 inches.
• Pipe of 3 inches for runs up to 50 feet to a single pump
• Pipe of 3-1/2 or 4 inches for longer runs up to 75 feet to a single pump with maximum lift
condition
Note: A dedicated line is recommended to supply each self-contained pump.

Dispensers (Standard Flow)

Use new pipes of 2, 2-1/2, or 3 inches.
Notes: 1) If the distance from the STP to the farthest dispenser is 200 feet or less, use a pipe 
of 2 inches.
2) If the distance exceeds 200 feet, use a pipe of 2-1/2 or 3 inches to the first dispenser
and a pipe of 2 inches along the rest of the way. Trunk lines supplying multiple
dispensers must be larger and must be sized to provide low pressure drops for an
anticipated flow rate. Use of smaller size pipes may result in lower flow rates than
normally accepted.

Dispensers (High Flow)

Use new pipes of 3, 3-1/2, or 4 inches.
Notes: 1) If the distance from the STP to the farthest dispenser is 200 feet or less, use a pipe 
of 3 inches.
2) If the distance exceeds 200 feet, use a pipe of 3-1/2 or 4 inches to the first dispenser
and a pipe of 3 inches along the rest of the way. Trunk lines supplying multiple
dispensers must be larger and must be sized to provide low pressure drops for an
anticipated flow rate.

Dispensers (Frontier High Gallon)

Use new 3- or 4-inch pipe.
Notes: 1) If the distance from the STP to the farthest dispenser is 75 feet or less, use a pipe 
of 3 inches.
2) If the distance exceeds 75 feet, use a pipe of 4 inches to the first dispenser and a pipe 
of 3 inches along the rest of the way. Trunk lines supplying multiple dispensers must
be larger and must be sized to provide low pressure drops for an anticipated flow
rate.

Page 9-12 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
Plumbing Requirements Reference Information

Check Valves (Used on Pumps and Frontier Units only)

For information on installing the check valves for pumps, refer to PEI publication RP100 and
manufacturer’s installation instructions. Install the check valve as close as practically possible
to the suction unit. It must be gravity-activated with minimal, or no spring load. Check valves
for use internal to the pumping unit are available from Gilbarco as an order entry item.

Ensure that there is only one check valve in each dedicated line (preferred method). Use of
multiple check valves can restrict flow and cause cavitation, resulting in significant flow rate
reductions. If installation necessitates placing more than one unit on a single dedicated product
line, then check valves must be placed at each pumping unit. Check valves must be accessible
for service.

The inlet check valve for Frontier units is required for accuracy in metering fuel. Use a
factory-installed option or installation-installed check valve of low pressure drop.
Note: Components must be compatible with the fluid type being dispensed. For more
information, consult the concerned manufacturer.

Shear Valves (Generally Used on Dispensers Only)

Note: For some locations, shear valves are required for pumps.

For installation of underground liquid storage systems (Chapter 9), refer to PEI publication
RP100 Recommended Practices and for installation of above-ground storage systems for motor
vehicle fueling refer to PEI publication RP200 Recommended Practices. A shear valve 
(see Figure 5-17 on page 5-21) is an NFPA 30A required safety device. It closes automatically
to stop product flow during a fire or if the dispenser gets knocked off the island. It also
provides a means of manually closing inlet pipes.

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page 9-13
Reference Information Plumbing Requirements

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Page 9-14 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix A: Elevation Diagrams

Appendix A: Elevation Diagrams

Figure A-1: Elevation Details

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page A-1
Appendix A: Elevation Diagrams

Figure A-2: Main Cabinet Conduit Knockouts

16 3/4

20 1/4

8 3/8
1 5/8
13/16

1 5/8
11 7/8
23 3/4

Notes: 1) Only two conduits per plate can be field-installed at diagonal knockouts.
2) Not used for field connection for pumping units.
3) Dimensions are in inches.

Page A-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Appendix B: Wiring Diagrams

Figure B-1: Frontier Mono 1 Phase Suction Wiring Diagram

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-1
Appendix B: Wiring Diagrams

Figure B-2:Frontier 1 PRD MPD Dispenser Model Wiring Diagram

Page B-2 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-3:Frontier Duo Dispenser Model Wiring Diagram

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-3
Appendix B: Wiring Diagrams

Figure B-4:Frontier Mono Dispenser Model

Page B-4 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-5:Frontier Mono 3 Phase Suction Model Wiring Diagram

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-5
Appendix B: Wiring Diagrams

Figure B-6:Frontier 1P MPD 3 Phase Suction Model Wiring Diagram

Page B-6 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-7:Frontier Duo 3 Phase Suction Model Wiring Diagram

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-7
Appendix B: Wiring Diagrams

Figure B-8:Frontier 1P MPD 1 Phase Suction Model Wiring Diagram

Page B-8 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-9:Frontier Duo 1 Phase Suction Model Wiring Diagram

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-9
Appendix B: Wiring Diagrams

Figure B-10:Frontier QPD Dispenser Model - 1

Page B-10 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-11:Frontier QPD Dispenser Model - 2

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-11
Appendix B: Wiring Diagrams

Figure B-12:Frontier QPD Dispenser Model - 3

Page B-12 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-13:Frontier QPD 1 Phase Suction Model - 1

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-13
Appendix B: Wiring Diagrams

Figure B-14:Frontier QPD 1 Phase Suction Model - 2

Page B-14 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-15:Frontier QPD 1 Phase Suction Model - 3

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-15
Appendix B: Wiring Diagrams

Figure B-16: Frontier Vapor Recovery Mono Three-phase Suction and One-Phase Pressure

Page B-16 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-17: Frontier Vapor Recovery Mono One-phase Suction

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-17
Appendix B: Wiring Diagrams

Figure B-18: Frontier Vapor Recovery Duo Three-phase Suction and Pressure

Page B-18 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Appendix B: Wiring Diagrams

Figure B-19: Frontier Vapor Recovery Duo One-phase Suction

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Page B-19
Appendix B: Wiring Diagrams

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Page B-20 MDE-5341F Frontier Single and Dual Installation Manual · December 2021
 Index

Index
A J
Air, Purging From System 8-4–8-6 J-Box 9-2
Anchoring
Pump/Dispenser 5-11
L
ASC 8-1, 8-4, 8-7
Lifting Encore Units 5-1

C M
Calibration 9-3
Mounting the Unit 4-4, 5-1
CAUTION 5-6, 5-7, 5-8, 8-5
Pit Box 4-5
Changing Fuel Types 4-1
Plumbing Requirements 4-5
Alternative fuels 4-1
Conduit Installation 4-6
Vapor Barrier 6-3 P
Conduit, electrical 9-4 Pipe 9-11
Pipe, plumbing 5-10, 9-11, 9-12
Piping Layout 9-2
D
Plumb 9-11
DANGER 9-6
Potting Discs 6-4
Purging
E Underground Lines 8-4
Electric, Electrical, Electricity 9-3 Purging Air From The System 8-4–8-6
Electrician 9-3
Electronics Cabinet 9-3
S
Wiring 9-3
Service Procedures
Encore Cabinet 4-4
Purging Air 8-4–8-6
Epoxy Sealing 6-14
Setting PPU 8-7
Ethernet Cable 9-7
Shear Valve 9-13
Shutoff Operation 8-6
F SMART Meter 1-2
For New and Existing Pumps and STP 4-3, 5-10
Existing Dispensers With Fuel
In Lines 8-5
T
For New Dispensers 8-4
The Advantage Series
Installation differences 9-2
G TLS Console 6-15
Ground 9-5, 9-9
Ground Fault Interrupt 4-6
V
Grounding 9-9
Vapor Return Line 5-11

H W
Hazardous Locations 3-1
WARNING 5-1, 5-8, 5-12, 6-2, 6-3, 
6-6, 6-12, 7-2, 8-1
I Wiring 9-5
IMPORTANT 4-5, 5-5, 6-2, 8-7 Field Wiring 6-10
Inlet Pipes 5-5 Operating Environment 6-5
Installation Checklists
Hydraulic Related 8-2
Mechanical 8-2
Installing Units
Flexible fuels 5-5

MDE-5341F Frontier Single and Dual Installation Manual · December 2021 Index-1
The Advantage® Series, CRIND®, Gilbarco®, G-SITE®, Infoscreen®, and Transac® are registered trademarks of Gilbarco Inc. CIM™,
SMARTConnect™, and SMART Meter™ are trademarks of Gilbarco Inc.

All product names, logos, and brands are the property of their respective owners and are for identification purposes only. Use of these names,
logos, and brands does not imply endorsement.

© 2021 Gilbarco Inc.

7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone (336) 547-5000 · http://www.gilbarco.com · Printed in the U.S.A.
MDE-5341F Frontier Single and Dual Installation Manual · December 2021