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Gasboy atlas Service Manual

Commercial and retail series
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Commercial and Retail Series
Atlas
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MDE-4334C

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Summary of Contents for Gasboy atlas

  • Page 1 Commercial and Retail Series Atlas Start-up/Service Manual ™ MDE-4334C...
  • Page 2 Computer Programs and Documentation All Gasboy computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy. Such computer programs and documents may also contain trade secret information. The duplication, disclosure, modification, or unauthorized use of computer programs or documentation is strictly prohibited, unless otherwise licensed by Gasboy.

  • Page 3: Table Of Contents

    Serial Number Plate and Date Codes ......1-7 Atlas Model Number Table........1-9 Options Overview.
  • Page 4 Atlas 9800 PCAs ........
  • Page 5 Installing the Atlas 9800 Power Supply (M07588A00X) ........
  • Page 6 Solenoid Valve and Filter Manifold ......7-68 Solenoid Valves for 9x40, 9850 and 9x53 with Satellite Outlet Piping .7-70 Page iv MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 7 Atlas Hydraulics, Bezel and Door Configurations ........
  • Page 8 This page is intentionally left blank. Page vi MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 9: Read This First

    Sections of this manual combine to provide start-up and service information for Atlas pumps and dispensers. This manual is a general service guide and not a replacement for Gasboy Atlas Certified Training. Certified Training includes instructions in safety procedures, use of test equipment and common tools, wiring requirements, and electrical service procedures.

  • Page 10: Who Should Use This Manual

    Report (CSR) number, if previously assigned. Using Replacement Parts Use only genuine Gasboy Atlas replacement parts. Use of other parts will void warranty and could affect unit conformance to various national, local, or state codes. Whom to Contact at Gasboy...

  • Page 11: Related Documents

    RP400 PEI Recommended Procedures for Testing Electrical Continuity of Petroleum Dispensing Systems Note: In addition to these documents, Gasboy Atlas marketing and information sheets are also sources of information. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 1-3...

  • Page 12: Abbreviations And Acronyms

    Unit supplied by a Submerged Turbine Pump (STP) Dual Hose Same as Twin Hose Pump Unit that contains a self-contained pumping unit Two-wire Proprietary communication system for Atlas 8800 series units Page 1-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 13: Model Information

    Model Information Mechanical Retail Pump/Dispenser The following illustration displays the external components of a Gasboy pump/dispenser (Mechanical Retail Unit). Mechanical units have mechanical type displays as opposed to electronic digital type displays. In units that are Commercial instead of Retail, the external components are the same, with the exception that they do not have a Monetary Sale amount, a Price Per Unit (PPU) display, or Monetary Totalizer display.

  • Page 14: Electronic Retail Pump/Dispenser

    Model Information Electronic Retail Pump/Dispenser The following illustration displays the external components of a Gasboy pump/dispenser (Electronic Retail Unit). Electronic units have digital displays as opposed to mechanical displays. In units that are Electronic Commercial instead of Retail, the external components are the same, with the exception that they do not have a Monetary Sale amount, a PPU display, or Monetary Totalizer display.

  • Page 15: Serial Number Plate And Date Codes

    The serial number plate is located on the “A” side at the bottom of the unit attached to the inside of the frame. Refer to the following tables to determine the date code on a Gasboy pump or dispenser: Month Codes...
  • Page 16 Note: The flow rates shown are under ideal conditions and will vary depending upon the hanging hardware involved, Submerged Turbine Pump (STP) sizing, number of units dispensing at the same time, and inlet piping to the unit. These are not guaranteed flow rates. Page 1-8 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 17: Atlas Model Number Table

    Read this First Atlas Model Number Table The Atlas model number uses a series of four numbers and five letters stamped into the serial plate to denote the machine type and configuration. Refer to the following table to determine the dispenser/pump type that is denoted on the serial plate.

  • Page 18: Options Overview

    15". Internal Hose Retriever Internal Hose Retrievers are also available for all Atlas Pump models. Satellite Piping Satellite Piping is available on all remote dispensers and the 9850 pump. This option will provide the internal piping needed to connect to a 9215 or 9216 satellite dispenser.
  • Page 19 Factory installation as well as field retrofit kits will be available for all Pulse Output options. RS-485 Interface When connecting a 9800 model to a Gasboy Cash Flow Network (CFN) or TopKAT system, an RS-485 interface board must be installed in the unit. The interface can be ordered and installed at the factory.
  • Page 20 Read this First Model Information This page is intentionally left blank. Page 1-12 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 21: Important Safety Information

    Gasboy Authorized manual, where additional hazards and safety precautions for Service Contractor or call the Gasboy Service Center at 1- your task will be found. Fire, explosion, electrical shock or 800-444-5529. It is imperative to your safety and the safety of pressure release could occur and cause death or serious others to understand the procedures before beginning work.
  • Page 22 Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 1910.333 contains specific Lockout/ Tagout provision for electrical hazards. Page 2-2 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 23 • Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring. • Call emergency numbers. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 2-3...
  • Page 24 Important Safety Information This page is intentionally left blank. Page 2-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 25: Start-Up Procedures

    Introduction Purpose Gasboy Atlas units require this start-up process for pumps and dispensers that are installed in the United States. This procedure ensures that the equipment is installed and the warranty is registered properly. It is also recommended that you follow this procedure outside the United States.

  • Page 26: Start-Up Checklists

    Forms should be provided with each unit; if not, contact the Gasboy Atlas Distributor. Make a copy of the checklists for use in the field, in order to preserve originals for future use. This will ensure that you always have the original to copy and use in the future.
  • Page 27 STPs, Prep Manual station equipment motors, and other devices. All power wiring and circuit breakers to Gasboy Atlas equipment must be dedicated and not be shared with other equipment. All circuit breakers to Gasboy Atlas equipment must be clearly labeled and readily accessible.

  • Page 28: Meter Calibration

    7-11, to allow dispensing and calibration. Current production Gasboy Atlas pumps/dispensers are pre-calibrated to US gallons (calibration verification is still required) and programmed to default programming values. They may be operated and purged in normal mode after entering prices. Purging can be done for units eventually, to be converted to metric mode while the unit is in the gallon mode.

  • Page 29: Preventive Maintenance And Inspection

    Abbreviations and Acronyms Term Description Authorized Service Contractor Petroleum Equipment Institute Price Per Unit (PPU) of the associated grade MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 4-1...

  • Page 30: Common Terms Used

    Preventive Maintenance Maintenance Procedures and Parts Gasboy Atlas pumps and remote dispensers are designed for years of uninterrupted service. However, certain dispenser or pump parts will experience normal wear and therefore will require periodic inspections. For example, detecting fuel leaks that may occur, belt tension and belt condition, lubrication and strainer cleanliness, are all important to maintain safe and efficient unit operation.

  • Page 31: Maintenance Of Vendor Supplied Parts

    Certain parts of the dispenser/pump are produced by vendors for Gasboy (hoses, nozzles, and so on) and as such may have documentation different from the one that Gasboy supplies. In these cases, it will be necessary to consult the vendor documentation for service intervals and any adjustments, if required, for your dispenser/pump.
  • Page 32 The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service Gasboy Atlas pumps/dispensers yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/dispensers. Only Gasboy Atlas-trained ASCs should service a Gasboy Atlas unit.

  • Page 33: Replacements And Adjustments

    Improperly installed or maintained equipment can create a hazard. Improperly installed or maintained equipment could cause a fire, explosion, or electrical shock. For any component not supplied by Gasboy Atlas (for example, hoses and nozzles), consult and follow the installation and maintenance instructions provided by the manufacturer.

  • Page 34: Preserving The Finish

    As a result, it is necessary to give the finish a reasonable amount of care if an attractive appearance is to be maintained. The finish on Gasboy Atlas pump housings is a high-heat baked synthetic enamel, similar to that used on automobiles. The life of this finish can be lengthened several years if the painted surfaces are thoroughly cleaned with a high grade automobile polish and then protected with a coat of paste wax at regular intervals.

  • Page 35: Preventive Maintenance Table

    WARNING The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service the Gasboy Atlas pump/dispenser yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/dispensers.
  • Page 36 WARNING The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service the Gasboy Atlas pump/dispenser yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/ dispensers.
  • Page 37 WARNING (continued) The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service the Gasboy Atlas pump/dispenser yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/dispensers.
  • Page 38 Refer to Petroleum Equipment Institute PEI publication PR-500. Use only approved methods and instruments. Do not allow untrained personnel to service the Gasboy Atlas pumps/dispensers. Only Gasboy Atlas- trained ASCs should service a Gasboy Atlas unit. Leaks, internal...
  • Page 39 WARNING The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service the Gasboy Atlas pump/dispenser yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/ dispensers.
  • Page 40 WARNING The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service the Gasboy Atlas pump/dispenser yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/dispensers.
  • Page 41 WARNING The pump/dispenser contains pressurized flammable fuel and lethal voltages. Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death. Do not attempt to service the Gasboy Atlas pump/dispenser yourself, and do not allow untrained personnel to service Gasboy Atlas pumps/dispensers.
  • Page 42 Do not wax textured surfaces. CAUTION The main and PPU displays of Gasboy Atlas pumps/dispensers can become difficult to read if waxed. Waxing the main and PPU displays may impede a customer’s ability to read the display because the display may appear hazy.

  • Page 43: Pump Programming

    Introduction Purpose This section provides instructions for programming and changing settings in Gasboy Atlas 9800, 8800, and 8700 series pumps and dispensers. Programming and settings for each series will be explained separately. Depending on the series, units will have electronic or mechanical means to display the fuel dispensed.

  • Page 44: Common Terms Used

    Electronic Commercial Units (9800 Series) The 9800 Gasboy Atlas Series unit contains a volume display (money display is omitted). The unit can operate in Standalone or Online mode, when connected to various Fleet Fueling Systems such as the Gasboy Series 1000, Gasboy CFN, or TopKAT Fuel Control System.

  • Page 45: Electronic Retail Units

    Point of Sale (POS)/controllers as manufactured by Gasboy, Gilbarco, Ruby Verifone, Allied, and other manufacturers. Interface devices for communication such as a Gilbarco PAM 1000 can also be used to convert the two-wire communication to a usable format for other POS manufacturers who cannot connect directly to the two-wire system.

  • Page 46: Mechanical Commercial Units

    CPU PCA when power is restored. To change the switch and jump jack (if applicable) settings, access the CPU board by removing the front panel, then remove the screws shown in Figure 5-4 page Page 5-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 47 Figure 5-4: Access to CPU Board Note: Display unit will swing forward and down Loosen and remove screws. after screws are removed. Keep for reinstallation. Figure 5-5: Previous Atlas 9800K CPU (M05346A00X, C06391-C06394, C06500-C06503) MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 5-5...

  • Page 48: Configuration Steps

    Figure 5-6: Current Atlas 9800 CPU (M06333KXXXX) Configuration Steps Baud Rate (JP1 on M06333KXXXX CPU and SW1-1 on Previous CPU) This jumper/switch selects the baud rate for the RS-485 communications. The Gasboy CFN System and TopKAT Electronic System communicate at 9600 baud. Baud Rate JP1/SW1-1...
  • Page 49 Control Feed/AUTH line (refer to the wiring diagram for your model pump/dispenser) for pump activation to occur (required setting for Gasboy Series 1000, TopKAT Mechanical and all non-Gasboy systems). When open, the Control Feed line signal is ignored (normal setting for Online mode communicating via an RS-485 I/F [TopKAT Electronic System, CFN System] or Standalone mode).
  • Page 50 485 communications for a protocol break character. When received, any transition in progress will be halted and then completed. This setting should only be used when the pump/dispenser is communicating to a Gasboy CFN system. When communicating to a Gasboy TopKAT ™...
  • Page 51 When the pump/dispenser is connected to an external controlling equipment other than CFN System or TopKAT Electronic System, that requires pulse output signals (for example, Pulse- out I/F configuration interfacing with Gasboy Series 1000 and non-Gasboy systems), the pulse signals are sent via the Pulse-out interface board. Setting switches SW2-1 through SW2-3 configures the Pulse-out rate required by the monitoring equipment.
  • Page 52 (“On”), it enables the pump/dispenser to drive electro-mechanical totalizers used on some K pump models. On A and Q models, this switch is ignored. EM Totalizer SW2-7 Enabled Closed Disabled Open Page 5-10 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 53: Atc Setup

    When any of these digits are displayed, it indicates the following: • 8 = Temperature probe fault is detected • 4 = Pulser error occurred • 2 = Exceptional reset was detected MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 5-11...

  • Page 54: Error Codes

    Standalone mode. When the 9800 series unit is in the Online mode, connected to a CFN or TopKAT, transaction error codes are transmitted back to the system with the completed transaction data. Page 5-12 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 55: Programming 8800 Series Units

    Figure 5-7 page 5-14 shows a PCA of the Gasboy 8800 Electronic System. For proper service, the technician must be knowledgeable of the functions of components and how they relate to the system.
  • Page 56 P201 AT_PumpPCA_controller P205 P202 P204 P203 Manager Keypad Details Figure 5-8: Manager Keypad Layout 1 2 3 4 5 6 7 8 9 TOTAL VOL. CLEAR ENTER TOTAL S0000304 Page 5-14 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 57: Display Conventions

    Clear key – Used to clear the last keypad entry, and exit the Money and Volume Totals mode. Programming Errors The following table shows the currently allocated security and command codes that have been assigned for Atlas. These codes can be modified by the user by the use of command codes. Programming Level Default Security Code...

  • Page 58: Programming Steps For 8800 Series Units

    Reset will, in many cases hide problems that are being alerted by these troubleshooting aids by resetting the pump/dispenser processor. If multiple or repetitive resets are required, investigate a hardware or software issue. Page 5-16 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 59: Level 1 Programming

    Select the Price Level and then press Enter. Enter the new PPU and then press Enter. Note: Repeat the above steps for the other Side, Grade, and Price Level. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 5-17...
  • Page 60 Press the option code and then press Enter, where: 0 = No 5 Button Preset or Programmable Pump Preset (PPP) installed 1 = Money Preset 2 = Volume Preset 3 = Incremental Preset Page 5-18 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 61 It can only be performed after performing a Master Reset, CC7, or for new units. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 5-19...

  • Page 62: Level 2 Programming

    Command Code 10: System Configuration This multi-purpose code contains several sub codes called Function Codes (FC). Not all codes are used for the Atlas. If accessible, do not change other codes from their default values or the unit may not work properly.
  • Page 63 Programming 8800 Series Units Pump Programming Press Configuration #. Function Code 1: Unit Type Defines the unit. It should always be set to 1 for Atlas. 1 = 1 product 2 = 2 product Function Code 2: Money Decimal Point Defines the money display format.
  • Page 64 1 = 5 seconds 2 = 15 seconds 3 = 30 seconds 4 = 45 seconds 5 = 60 seconds 6 = 75 seconds 7 = 90 seconds 8 = 120 seconds Page 5-22 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 65 Assigning Grades. Normally not used, as grades should be programmed using the POS. Command Code 12: Pump Program This is also a multi-purpose code with sub-codes. Not all codes are used for the Atlas. If accessible, do not change other codes from their default value or the pump/dispenser may not work properly.

  • Page 66: Level 3 Programming

    To change the PIN code, proceed as follows: Enter 13. Enter Level #1, 2 or 3. Enter the new PIN Code. Note: The unit returns to Command Input Mode. Page 5-24 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 67 4 = 4.0 (Default) 5 = 17.0 ms 6 = 19.0 ms 7 = 26.0 ms Function Code 4 = Volume Suppression 1 = 0.030 (Default) 2 = 0.009 3 = 0.000 MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 5-25...

  • Page 68: Option And Miscellaneous Programming/Data Acquisition

    The firmware sequence will sequence through each fueling position. Select the fuel type for each position (Diesel or Gasoline). Turn the programming switch on the ATC controller board to Off. Press F2 to exit the ATC Programming mode. Page 5-26 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 69: Displaying Pump Totals

    Press Vol Total. The volume total will display for the grade selected. Select the grade. Read volume totals for grade selected. To view Side 2 totals, press Enter. Press Clear to exit. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 5-27...

  • Page 70: Error Codes And Descriptions

    PIN Code 1 Changed PIN Code 2 Changed Cast/Credit Option Changed Master Reset Jumper in Place Side Exists Option Changed PPU Options Changed Not Used Pump Handle Up at Power-up Page 5-28 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 71: Programming 8700 Series Units

    Programming Steps Setting Calibration Gasboy Atlas pumps and dispensers are adjusted for accurate measure at the factory. It is the responsibility of the installer to check the unit for accuracy and make the necessary adjustments. Where required, it is the owner’s responsibility to report this device to the local Weights and Measures authority for inspection before putting the unit in service.
  • Page 72 When re-attaching the bezel to the dispensing unit, ensure that the top inner edge of the bezel assembly slides into the “U” shaped channel located on the upper edge of the dispensing unit. Page 5-30 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 73: Electronic And Electrical Components

    How to Use this Section Refer to Topics in this Section for the location and listings of topics contained in this section. Use the table to find information on specific components. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-1...

  • Page 74: Abbreviations And Acronyms

    Submerged Turbine Pump Electronics Highlights Atlas 8800 Electronic Retail units will communicate with various POS devices using the Gilbarco two-wire current loop proprietary communication protocol. Atlas 9800 Series Commercial units will communicate with various POS devices using the Gasboy PAC Data Protocol.

  • Page 75: Retail Parts By Name

    Cable # R20412-G3 Cable from T20092-G1 (Pump Controller PCA) P208 (3) (2 wire) to FE wiring sheet 1> P402A(2) Cable # R20412-G3 from T19428-G1 IS Barrier > JIS (10) to P201 (10) T19405 G3 Filter # Q10895-07 MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-3...
  • Page 76 Varistor PCA # T17448-G1 (115 VAC) in Main Junction Box Varistor PCA # T17448-G3 (220/230/240 VAC) in Main Junction Box Note: ATC is available as an option in units for the Canadian market. Page 6-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 77: Retail And Commercial Parts By Number

    M06333KXXXX Commercial ONLY Atlas 9800 CPU Board 115/230 VAC Note: M06333KXXXX requires M07588A00X Power Supply. M06587A001 Commercial ONLY Atlas 9800 Pulse-out I/F Board with EM Totalizer Drive (see page 6-19 for Where Used information) M06656K00X Commercial ONLY Atlas 9800 Serial EEPROM Board...
  • Page 78 T19405-G3 T-Meter Module Automatic Temperature Controller T19428-G1 Intrinsically Safe Barrier Assembly T19868-G1 Main Power Supply T20092-G1 Pump Controller PCA T20569-G1 Optimum Automatic Temperature Controller Control PCA W199 Probe Assembly Page 6-6 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 79: 8800 Series Retail Electronics

    Electronic and Electrical Components 8800 Series Retail Electronics The Atlas 8800 Series Electronics Cabinet is discussed in this section. The electronic parts are listed in the previous page. The electronics manages all the common functions for a low hose compact dispenser, such as sales control, maintenance, preset Automatic Temperature Controller (ATC) functions, electro-mechanical totalizers, and other options.

  • Page 80: About Service Procedures

    About Service Procedures Figure 6-1 shows an example of a Front-load and Side-load Atlas 8800 Retail Unit. The nozzle boot is located either on the front or side of the unit. Figure 6-1: Atlas 8800 Retail Pumps: Side and Front-load...

  • Page 81: Working On Electronic And Electrical Components

    Preventing ESD WARNING Ground Wrist Strap is required Use Integrated Circuit (IC) extractor PCAs and Integrated Circuits (ICs) are sensitive to ESD. ESD can damage electronic parts. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-9...

  • Page 82: Hazardous Materials

    • Test point labels indicate an acceptable electrical range, an example being: 4.8 - 5.2 VDC • Light Emitting Diode (LED) Status Code: Refer to the LED Status description included with PCA information Page 6-10 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 83: Component Overview

    Component Overview Figure 6-2 illustrates the electronic components found in the Atlas 8800 Retail unit. It is a typical Atlas 8800 Electronic System. For proper service, the technician must possess knowledge of the functions of components and how they relate to the system.

  • Page 84: Pcas

    Figure 6-3: Atlas 9800 Series Block Diagram Atlas 9800 Power Supply Board M07588A001 115 VAC with backup battery Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board M07588A002 115 VAC without backup battery (M06587A001) or K-Pump Pulse-out with Totalizer Boards (M05158A00X)
  • Page 85 Electronic and Electrical Components Figure 6-4 contains information regarding LEDs, hose information, switch locations, and Random Access Memory (RAM) connections for previous Atlas 9800K CPUs. M05346A002 (Dual, 115 VAC) and M05346A004 (Dual, 230 VAC): Used on Models 9852K, 9853K, 9840K...
  • Page 86 LEDs, hose information, switch locations, and jump jack locations on the current Atlas 9800 CPU. Notes:1) M06333KXXXX requires an Atlas 9800 Power Supply M07588A00X. 2) M06333KXXXX requires ATC Kit M08218K001 for Models 9850A/Q, 9850K, 9852A/Q, 9853A/Q, 9840A/Q where ATC is present.
  • Page 87 M06333K9840AQ M06656K005* 9840A/Q) *Atlas 9800 Serial EEPROM boards (M06656K00X) used for reprogramming M06333KXXXX CPU boards. Software kit M06656K100 contains parts M06656K001 - K005 (one of each). Figure 6-6 shows the M07588A00X Atlas 9800 Power Supply board that connects to the CPU.
  • Page 88 Electronic and Electrical Components PCAs Figure 6-7 shows the Previous Atlas 9800K CPU. Figure 6-7: M05346A002 (115 VAC) and M05346A004 (230 VAC) (Previous Atlas 9800K CPUs) P8 (RS-485/Pulser I/F) P7 (Relay Drive) P6 (Totalizer) P10 (Power Input) P9 (ISB PWR/GND)
  • Page 89 C06387 2 P1 side A and 2 P1 side B P1 (26) Switch 1 (8) Switch 2 (4) Figure 6-9: M05248A001 - K-Pump RS-485 with Totalizer P802 P804 P803 Note: For cable block diagram, refer to M05193. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-17...
  • Page 90 2 connections side A P1 (3) 2 connections side B M07588A00X P2 (3) Figure 6-10: C06425, C06746 - 9800 Pump I/F Figure 6-11: M05158A001/2/3 - K-Pump Pulse-out with Totalizer P802 P804 P803 Page 6-18 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 91 EM Totalizer, no Pulse-out I/F. Note: Models 9850A/Q/K can only use M06587A001, C06425 or C06746. Figure 6-12: M06587A001 Atlas 9800 Pulse-out I/F with EM Totalizer Board Notes:1) To be used with models 9850A/Q/K and models calling out for Dual Channel, Dual Hose Pulse-out I/F (not available on 9850 Dual Hose).

  • Page 92: Atlas 9800 Parts

    Atlas 9800 Parts Atlas 9800 CPU Board (M06333KXXXX) The features of the Atlas 9800 Central Processing Unit (CPU) board are as follows: • Accepts either 115 or 230 VAC on AUTH line inputs. • Compatible with models 9852K, 9853K, 9850K, 9840K, 9852A/Q, 9853A/Q, 9850A/Q, 9840A/Q, 9822A/Q, 9823A/Q/K.
  • Page 93 Disconnect AC power to the pump/dispenser. Remove the DC cable from the P1 connector on the power supply. Set Switch SW2-9 to the closed (“On”) position. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-21...
  • Page 94 Electronic and Electrical Components Atlas 9800 Parts Select the appropriate Atlas 9800 Serial EEPROM board (M06656K00X) for the software type you want to load (refer to Atlas 9800 Serial EEPROM Board (M06656K00X) page 6-24). Ensure that JP1 is not jumpered on the Serial EEPROM Board Assembly (M06656K00X).

  • Page 95: Atlas 9800 Power Supply (M07588A00X)

    Atlas 9800 Parts Electronic and Electrical Components Atlas 9800 Power Supply (M07588A00X) The features of the Atlas 9800 Power Supply (M07588A00X) are as follows: • Required for M06333KXXXX CPU board (see Figure 6-15 page 6-21). • Compatible with models 9852K, 9853K, 9850K, 9840K, 9852A/Q, 9853A/Q, 9850A/Q, 9840A/Q, 9822A/Q, 9823A/Q/K.

  • Page 96: Atlas 9800 Serial Eeprom Board (M06656K00X)

    Electronic and Electrical Components Atlas 9800 Parts Atlas 9800 Serial EEPROM Board (M06656K00X) The features of the Atlas 9800 Serial Electronically Erasable Programmable Read Only Memory (EEPROM) Board are as follows: • Used to reprogram software on Atlas 9800 CPU board (M06333KXXXX, see...

  • Page 97: Atlas 9800 Pulse-Out I/F Board With Em Totalizer Drive (M06587A001)

    Atlas 9800 Pulse-out I/F Board with EM Totalizer Drive (M06587A001) The features of the Atlas 9800 Pulse-out I/F Board with EM Totalizer Drive are as follows: • To be used with 9850A/Q/K models and models calling out for Dual Channel, Dual Hose Pulse-out I/F (not available on 9850 Dual Hose).

  • Page 98: K-Pump Rs-485 With Totalizer (M05248A001)

    • Compatible with 9800 CPU Boards (C06391, C06392, C06393, C06394, C06500, C06501, C06502, C06503, M05346A001, M05346A002, M05346A003, M05346A004, M06333KXXXX). • Can be used in place of previous 9800 RS-485 I/F Board C06389. Figure 6-19: K-Pump RS-485 with Totalizer (M05248A001) Page 6-26 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 99: Accessing The Electronic Components

    Loosen the two screws that secure the display panel, remove them if necessary, and pivot the display panel down. Installing the Atlas 9800 Power Supply (M07588A00X) To install the Atlas 9800 Power Supply (M07588A00X), proceed as follows: WARNING Always remove AC power from the pump/dispenser before servicing the unit. Failure to turn off the unit before servicing may result in serious injury or death.

  • Page 100: Installing The Atlas 9800 Cpu Board (M06333Kxxxx)

    • Display Backlight to the P2 connector. • CPU DC to the P1 connector. Installing the Atlas 9800 CPU Board (M06333KXXXX) To install the Atlas 9800 CPU board, proceed as follows: WARNING Always remove AC power from the pump/dispenser before servicing the unit. Failure to turn off the unit before servicing may result in serious injury or death.
  • Page 101 “9850“ Corresponds to all 9850 Software: 9850A, 9850Q, 9850K Re-assemble the pump/dispenser by proceeding to Accessing the Electronic Components page 6-27 and follow the steps in the reverse order. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-29...

  • Page 102: Installing The Atlas 9800 Pulse-Out I/F With Em Totalizer Drive Board (M06587A001)

    Electronic and Electrical Components Installing the Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board Installing the Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board (M06587A001) Jumpers JP1, JP2, and JP3 This board assembly can be configured for use in one of the following pump/dispenser configurations: •...

  • Page 103: Configurations

    Installing the Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board (M06587A001) Electronic and Electrical Configurations Figure 6-20: Dual Channel, Single Hose Pulse-out I/F Side 1A Output Pulse Side 1 Side 1A Return Side 1B Output Side 1A Return Figure 6-21: Single Channel, Dual/Single Hose Pulse-out I/F...

  • Page 104: Atlas 8800 Parts

    Pump Controller PCA and supplies 120 VAC for the valve and STP signals. Figure 6-23 shows the STP PCA layout that contains components related to the hydraulic interface, T18994 G1 Pump Interface PCA. Figure 6-23: T18994 Pump Interface PCA (Atlas 8800 only) P306 P307 P406...

  • Page 105: T20092 Pump Controller Pca (Atlas 8800 Only)

    • Totals memory • Programming storage Figure 6-24 shows the PCA of the Atlas Retail Electronic System. For proper service, the technician must possess knowledge of the functions of components and how they relate to the system. Figure 6-24: T20092 Pump Controller (Atlas 8800 only)
  • Page 106 The board receives +14 VDC from the Hydraulic Interface PCA. Customer programmable and 5-button preset as well as the Manager Keypad (except for ATC) are connected directly to this PCA. It supplies +5 VDC to the Hydraulic Interface PCA. Page 6-34 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 107: Atc Component Overview (Atlas 8800 Only)

    Intrinsically Safe (IS) barrier is used at the junction box between the T-meter Module PCA and the ATC PCA. Figure 6-26: T20569 ATC PCA (Atlas 8800 only) P307 P308 P304 P204A P405 P303A P301 AT_ATC_GR4 P415 P303 P305 MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-35...

  • Page 108: T19405-G3 Atc T-Meter Module Pca (Atlas 8800 Only)

    PCA T20092-G1. The ATC T-meter Module PCA T19405-G3 (optional) interface PCA modifies the pulser-count to account for the ambient temperature change. The adjusted pulser-count is supplied to the Pump Controller PCA. Page 6-36 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 109: T17549-G1 Manager Keypad (Atlas 8800 Only)

    Probe 1 PTP5 (16) T17549-G1 Manager Keypad (Atlas 8800 only) Figure 6-28 shows the Manager Keypad used in Atlas 8800 units to display pump transaction information in two locations. The Manager Keypad relates to PCA T20092-G1, shown in Figure 6-24 page 6-33.

  • Page 110: T17622-G9 (.6 Inch) Display Backlight Pca (Atlas 8800 Only)

    T17701-G1 LCD Display (.6 inch) (Atlas 8800 only) Figure 6-30 shows the T17701-G1 LCD Display (.6 inch). It is used in Gasboy Atlas Retail units to help display pump transaction information. The LCD is at the pump and displays information to the customer.

  • Page 111: Power Supplies

    Figure 6-31 shows the ATC retail Atlas Cable # M02739A001 from T20092-G1 Pump Controller (PCA) P205 (16) and 207 (10) to T20569 G1 OP ATC PCA P405 (34) and P301 (20) and 305 (34).
  • Page 112 R19072-G1 to T18350-G3 A-side M04658A001 R19072-G1 to T18350-G3 B-side T18994-G1 M04658A001 Q11763-01 Buzzer (3) J405 (20) M04658A001 Q12514-10 PH-SW B1 (4) M04658A001 Q12514-10 PH-SW A1 (4) M04658A001 P1 Relay (3) Page 6-40 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 113: T19868-G1 Main Power Supply

    J601 (3) J604 T19868-G1 Main Power Supply T19983 Cable P604 (4) J302 T19868-G1 Main Power Supply T19868 Cable P302 (6) J308 T19868-G1 Main Power Supply T18994-G1 Pump Interface P308 (2) MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-41...
  • Page 114 Electronic and Electrical Components Power Supplies Figure 6-34 shows Atlas relays related to single and dual pumps. Figure 6-34: M04956A001 and 2 Relays Retail Commercial Relays M04956A001_2 For this Voltage Use this Plug 115/230 VAC P1 M04956A001 Single Retail Relay Assembly P1 (3)

  • Page 115: T19428-G1 Is Barrier Assembly Atc

    Electro-mechanical Registers and Totalizers About Displays Depending on the configuration, Atlas units may have electronic or mechanical registers or totalizers. Totalizers provide a cumulative total similar to the odometer reading on a vehicle. The display provides the customer with information about the total cost and total volume of the fuel dispensed.

  • Page 116: Electronic Totalizer Display

    Electro-mechanical Totalizer M00455A003. In the electronic layout of Atlas pumps, there are two electronic totalizers, one each on side A and side B. The sides are connected by cable M04889A001 through 4-pin connectors J922A and J922B.
  • Page 117 Connector # Electronic Totalizer M00455A003 Grade 1 J922A Side A M04889A001 J922A Electronic Totalizer M00455A003 Grade 2 J922B Side B M04889A001 J922B J406 M04889A001 T18994 G1 P406 (5) MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-45...

  • Page 118: Electro-Mechanical Totalizer Assembly

    Read and follow all safety precautions in Read this First page 1-1. Warnings and cautions appear throughout this section and must be regarded with utmost vigilance. Follow OSHA Lock-Out and Tag-Out Procedures. Page 6-46 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 119: Pulsers

    Program the unit to scale pulses for specific applications. For example, standard gallonage units use 1000 pulses per gallon. See Pump Programming page 5-1 of this manual for other conversion factors. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 6-47...

  • Page 120: Testing Pulsers And Is Barriers

    Module Brown or Black Brown (Ground) Pulser Data Chassis Ground +75VDC +5VDC for Optimum only All measurements are made to point A or B at the respective I.S. Barrier. Page 6-48 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 121: Pulser Drive Assembly

    20, 5047, 5049 and 5050. Pulser locations are designated by ePulserX. Refer to the following table to determine the location of the pulser. Note: Event Logs are available only for Atlas 8800 units. Pulser Name Side of Unit...
  • Page 122 Electronic and Electrical Components Pulsers This page is intentionally left blank. Page 6-50 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 123: Hydraulic/Mechanical Components

    7 – Hydraulic/Mechanical Components Introduction Purpose This section provides information regarding hydraulic systems and fuel handling mechanical components contained within Gasboy Atlas units. It includes specific safety information, typical testing procedures, information on related components and common service procedures. Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data.

  • Page 124: How To Use This Section

    Above ground equipment that measures and dispenses fuel received under pressure from an STP or other external pump. Pump Unit contains motor and pumping device to draw product from storage tank (also known as a self-contained unit) Page 7-2 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 125: Hydraulic And Mechanical Highlights

    Solenoid Valve/Filter Manifold 2-stage Solenoid Valve The new Gasboy Atlas Pump has a standardized 1" 2-stage solenoid valve. If the valve hydraulics require service, the service technician can remove the diaphragm without removing the coil or conduit connections. The valve and filter adapter are built into the manifold.

  • Page 126: Meter

    The kit provides materials and instructions for the complete change-out of all seals as a major rebuild. 3. MDE-2188 provides information on how to install the K35222 Kit. The kit contains enough top seals to service ten (10) meters. Page 7-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 127 1 Per Grade Air Gap (Electronic Units only) The air gap is a new concept for Gasboy Atlas units. The air gap is located between the hydraulics and electronics of the unit. This air gap removes fumes before getting into the electronics and lowers the classification of the electronic platform area.

  • Page 128: General Service Procedures

    Lock-Out and Tag-Out Procedures. Working on Hydraulic Components Gasboy Atlas dispensers receive pressurized fuel from an STP while pumps generate pressure using a self-contained pumping unit. The potential hazard of fluid spray or leak exists when working on the hydraulic system. Ensure that proper service procedures and safety precautions are followed.

  • Page 129: About Servicing Hydraulic Components

    Purging Air from the System page 7-11. Verify if the unit is operating properly. Record Totals after the service and provide the Totals (before and after) to the station, if fuel was dispensed. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-7...

  • Page 130: Servicing Seals, O-Rings, And Gaskets

    OK, check for plumbing obstructions. • Always use sealants suitable for the fuel involved. Some fuels, especially diesel, may wash away general purpose sealants. Page 7-8 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 131: Torque Specifications

    1/4 inch NPT 22-25 29.8-33.9 3/8 inch NPT 30-35 40.7-47.5 1/2 inch NPT 35-40 47.5-54.2 3/4 inch NPT 45-55 61.0-74.5 1 inch NPT 70-80 94.9-108.4 1-1/2 inch NPT 150-180 203-244 MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-9...
  • Page 132 25 ± 5 0.30 ± 0.06 Lower bearing housing 75 ± 10 0.90 ± 0.12 Packing retainer 20 ± 5 0.25 ± 0.06 Body cover 130 ± 10 1.50 ± 0.12 Page 7-10 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 133: Purging Air From The System

    Use an appropriately-sized prover can. Pump this Amount Start-ups (installing new systems) 35 gallons (132.5 liters) per hose Figure 7-4: Typical Shear Valve and Test Port Test Port MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-11...

  • Page 134: Purging Pumps And Dispensers (With Fuel In Product Lines)

    Purging through a fully open nozzle on a unit with air in product lines can damage the meter due to overspeed. Damage resulting from overspeed is not covered by warranty. Page 7-12 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 135 Prover Return the nozzle to the nozzle boot. Empty the approved container into the appropriate product tank. Note: The purged amount will not be reflected in the electronic Totals. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-13...

  • Page 136: Measuring The Flow Rate

    Clean up any spills promptly. To calculate gallons or liters per minute, multiply the volume dispensed by four. For example: 5 gallons x 4 = 20 gallons per minute. Page 7-14 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 137: Measuring Pressure And Vacuum

    • Use gauges that have appropriate scales for reading in Pounds Per Square Inch (psi) (scale 0-100 psi) for pressure and 0-30 Hg (inches of mercury) for vacuum. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-15...

  • Page 138: Pressure Measuring Locations On Unit

    Note: The pressure at the dispenser inlet will reduce when the dispenser is dispensing fuel. Pressure drop of more than a few psi may indicate an inadequately sized STP, underground restrictions, inadequately sized plumbing, or a defective STP. Page 7-16 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 139: Measuring Pressure Drop For Pumps And Dispensers

    Activate the nozzle and pump fuel at full flow into an approved container. Measure the flow rate and read and record the psi reading on both gauges. Return the pump handle to the Off position. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-17...

  • Page 140: Analyzing Pressure Drop For Dispensers And Pumps

    Determine the dispenser pressure at the inlet and flow rate with the nozzle wide open. Note: If the pressure at the base of the dispenser is substantially lower, it indicates that the dispenser is functioning correctly. Page 7-18 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 141 • Use less restrictive hoses and nozzles • Reduce the maximum lift of product from the tank • For a pump, reduce the maximum lift of product from the tank and minimize feed line lengths MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-19...

  • Page 142: Measuring Vacuum For Pump

    Use this test to determine the priming ability of a self-contained pumping unit (only run the test if priming problems exist). Always follow all safety Warnings and Cautions. Figure 7-10: Vacuum Gauge Port on Global Pumping Unit (GPU) Vacuum Gauge and Extenuation Pipe Page 7-20 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 143: Measuring Wet Vacuum And Pressure For Pump

    Record the vacuum pressure with the nozzle opened fully, and then the nozzle closed. Record the flow rate with the nozzle opened fully. Compare readings with the Acceptable Range Tables page 7-22. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-21...
  • Page 144 • Filter dirty • Bypass valve defective or sticking • Regulator or check relief valve defective or sticking • Solenoid valve defective • Meter check valve defective or sticking Page 7-22 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 145: Meter Calibration

    (flow produced in one minute with the nozzle wide open). Note: Calibrating with a small can causes inaccurate test results. Never use an under- sized prover can for calibration purposes. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-23...

  • Page 146: Cft Meter Calibration Adjustment For Standard, Hi-Flow, And Super-Hi Models (All Models Excluding 9850K And 9850Kx)

    Life of the meters can be negatively affected if this is not done. For electronic units, pricing (temporary or permanent) must be entered into the unit as outlined in the purging section to allow dispensing and calibration. Page 7-24 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 147 Check the calibration. If the calibration is not correct, repeat steps through 5. If the calibration is correct, proceed to step 7. After the calibration is complete, reinstall the locking pin and secure with a seal wire. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-25...

  • Page 148: Lc Meter Calibration Adjustment For Ultra-Hi Models 9850K And 9850Kx

    Hydraulic/Mechanical Components Meter Calibration Atlas (Gallon Unit of Measure) All Atlas meters must be checked for calibration before placing them in service or upon service replacement. Air-purging of new units or serviced meters is required before calibration. Causes of known Calibration Problems •...

  • Page 149: Meters

    • Test and close the shear valves involved. Shut off power to the unit. • Remove parts slowly. Collect fuel in approved containers. • Clean up all spills promptly. About Meters The Gasboy Atlas CFT meter is used on standard units (refer to CFT Meters page 7-28).

  • Page 150: Cft Meters

    • Inspect all gaskets when the unit is Off during repairs. Replace meters, as needed. • Some meter bolts are difficult to access. A 13 mm universal socket makes installation and removal easier. • For calibration procedures, refer to Meter Calibration page 7-23. Page 7-28 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 151: Repairing Cft Meters

    Remove meter bracket bolts. Remove the meter. Perform necessary service on the meter. Inspect and clean the manifold or inlet and discharge line mounting surfaces. Install new inlet and discharge flange O-Rings. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-29...

  • Page 152: Replacing Cylinder Cover And Gasket (Cylinder Cover Leaks)

    Torque all bolts in sequence, as shown below. Figure 7-14: Replacing Cylinder Cover and Gasket Cylinder Cover Gasket Cylinder Cover Follow the steps in After Repairing Meters page 7-30. Page 7-30 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 153: Replacing O-Rings (Body And Cover Leaks)

    Install the cover(s). Torque all meter bolts. Follow the steps in After Repairing Meters page 7-30. Figure 7-15: Replacing O-Rings Inlet/Discharge Flange O-Ring Body Cover O-Ring Lower Bearing Housing O-Ring MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-31...

  • Page 154: Calibrating Wheel Parts Repair

    Cylinder Cover and Gasket (Cylinder Cover Leaks) page 7-30. Examine the cylinder liner for scoring. If it is scored, replace the meter. Remove the piston head screws, and then remove the piston head and cup. Page 7-32 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 155 Follow the steps in After Repairing Meters page 7-30. Figure 7-17: Replacing Piston Cups Cylinder Liner Piston Cup Cylinder Cover Bolt Piston Head Piston Head Screws Cylinder Cover Cylinder Cover Gasket MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-33...

  • Page 156: Removing/Replacing The Shaft Seal And Gasket (Upper Seal Leaks)

    Install the new gasket with the seal cap. Torque all screws (locking screws is recommended). Follow the steps in After Repairing Meters page 7-30. Page 7-34 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 157: Lc Meters

    Meters Hydraulic/Mechanical Components LC Meters LC meters are used in Atlas Ultra-Hi Master or Ultra-Hi Combo series units 9X50 and 9X50TW3. Figure 7-19: LC Meter and Pulser Assembly Pulser Meter Inlet Meter Discharge Service Tips • Remove and replace meters using metric tools.

  • Page 158: Removing/Replacing Lc Meters

    Install the new inlet and discharge gaskets. Replace the meter. Bolt the meter to the inlet. Bolt the meter to the discharge casting. Reconnect the pulser. Follow the steps in After Repairing Meters page 7-30. Page 7-36 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 159: Filters And Strainers

    2) Conversions from non-alcohol to alcohol-enhanced fuels typically results in frequent filter changes due to the cleansing effect of alcohol in tanks and piping. Always use Gasboy-recommended filters (standard, water alert, and high capacity). Filter Description Gasboy Part Number...

  • Page 160: Servicing Filters

    Shut off the operating handle. Shut off the associated STP circuit breakers (dispensers only). Multiple STP disconnects may be required. Shut off the dispenser circuit breaker. Shut off all power to the unit. Page 7-38 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 161 • Clean up all spills promptly Use an approved container to collect the residual fuel. Use gasoline/fuel-approved absorbent materials to mop up the spilled fuel. Use Gasboy-approved fuel collectors, if applicable. Be careful of any residual fuel. Always follow all safety warnings and cautions.

  • Page 162: About Strainers

    The strainer helps to prolong filter life by preventing premature filter clogging. Strainers can also help reduce the frequency of filter change, resulting from fungus and slime conditions. Always reinstall or replace the strainer. Page 7-40 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 163: Servicing Strainers

    • Test and close the shear valves involved. Shut off power to the unit. • Remove parts slowly. Collect fuel in approved containers. • Clean up all spills promptly. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-41...

  • Page 164: About The Hanging Hardware

    Do not use soft-wall hoses. They can cause the unit to register with the nozzle closed when the nozzle hook is first raised. Always use UL-approved hoses designed for the fuel being dispensed. Read and follow all safety precautions. Follow OSHA Lock-Out and Tag-Out procedures. Page 7-42 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 165 Do not overtighten. Note: Install padded or contoured plastic hose clamps and retractor cables properly. In all instances, do not install hose retractor clamps downstream of the breakaway. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-43...

  • Page 166: Breakaway Valves

    Always use UL-listed breakaways. • For proper operation of the breakaway, always bolt the dispenser or pump securely to the island. See Gasboy Atlas installation instructions for pumps and dispensers. • Some breakaway manufacturer’s require testing of dispensers or pumps for pull strength before installing the device.
  • Page 167 Purge the system of air. See Purging Air from the System page 7-11 for more information. Perform a hose continuity test. See Testing Hose and Hanging Hardware Continuity page 7-47. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-45...
  • Page 168 • Consult the manufacturer for the maximum number of times you can reset a breakaway. Some breakaways cannot be reset. • A protective sleeve supplied by the manufacturer is recommended to avoid damage to the dispenser and to improve appearance. Page 7-46 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 169: Testing Hose And Hanging Hardware Continuity

    Ensure that there is no liquid fuel or flammable vapor present. Clean up, as necessary. Lift the nozzle hook and authorize the unit to pressurize the hose. Lower the nozzle hook, shutting the unit off. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-47...
  • Page 170 • Wear insulating gloves if the hanging hardware component is handheld during test, or use an insulated device to support the nozzle. Refer to PEI/RP400-02 for additional information. Page 7-48 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 171: Internal Hose Retrievers And Clamps

    If retriever reel does not have the cable, connect the cable to the reel. Load the retriever reel to the desired spring force. Assemble the reel to the reel hanger. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-49...

  • Page 172: Pumping Unit

    • Fire and explosion could result in severe injury or death. • Shut off power to the unit. • Remove parts slowly. Collect fuel in approved containers. • Clean up all spills promptly. Page 7-50 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 173 Pumping Unit Hydraulic/Mechanical Components About the GPU Self-contained Gasboy Atlas pumping units use the Bennett GPU. The case is made of aluminum and sealing surfaces may be damaged while working on an inappropriate surface. Figure 7-25: GPU (Four Views) Front View...
  • Page 174 After the pumping unit is drained, replace all plugs using a non-hardening UL-approved pipe sealant suitable for the type of fluids being used. Note: Do not use Teflon tape. Page 7-52 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 175: Servicing The Strainer Check Valve

    Note: Removing the plug allows air to enter. See Figure 7-27. Remove the strainer cover. Inspect the gasket for damage. If the gasket is damaged, discard the gasket and replace it with a new gasket. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-53...
  • Page 176 • It is a good service practice to replace the strainer cover gasket when servicing the strainer or check valve. This will help avoid subsequent leaks. Page 7-54 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 177: Servicing The Pressure Control Valve (Pcv)

    Note: The cover is held on by bolts and not screwed in. Remove the spring and valve. Use needle nose pliers to remove the valve from the bore. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-55...

  • Page 178: Servicing The Bypass/Pressure Relief Valve (Prv)

    • Test and close the shear valves involved. Shut off power to the unit. • Remove parts slowly. Collect fuel in approved containers. • Clean up all spills promptly. Page 7-56 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 179 Adjust the screw to obtain amperage just below the maximum setting noted on the motor faceplate. Replace the adjustment cap. Disconnect the amp probe and replace the junction box cover. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-57...

  • Page 180: Servicing The Rotor And Shaft Assembly

    • A shot of clean oil in the bore after replacing the pumping elements will aid in priming and initial start-up. • Excessive belt tension may cause failure of the pumping elements or bearings. Page 7-58 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 181: Xu2A Pumping Unit For 9850K

    Adjustment Cap Grease Relief Fittings About the XU2A Self-contained Gasboy Atlas 9850K models use the Blackmer XU2A pumping unit. Note: For additional maintenance, servicing and troubleshooting information of the XU2A, refer to MDE-4320 Gasboy UHF Pump Blackmer XU2A Rebuild Kit Installation Manual.
  • Page 182 PCV and necessary bypass piping back to the storage tank. A system PCV is also recommended while operating for extended periods (more than a minute) against a closed discharge valve. Page 7-60 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 183 Recommended Grease Exxon - Ronnex MP Grease ® Mobil - Mobilith AW-2 (64353-6) Grease, or equivalent ® MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-61...

  • Page 184: Sump For 9850K

    Above ground tanks must have a pressure regulator valve installed at the base of the pump. Installation at other locations can cause flow or sump overflow problems. Ask Gasboy for the valve type and follow the manufacturer’s instructions completely for installation.

  • Page 185: Pump Motor

    • Check the line voltage during operation with the nozzle closed, and then with the nozzle open. Low or high voltages (greater than +/- 10%) can cause overheating or premature failure. • NFPA requires explosion-proof motors. Only use an Atlas-specified explosion-proof motor for replacement. Service Tips •...

  • Page 186: Belts And Pulleys

    Do not run the motor to install the belt. The belt is tight during assembly. Some belts have arrows marked on them to show the direction of rotation. While replacing belts, ensure that the arrows point in the direction of rotation. Page 7-64 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 187: Belt Adjustment

    The Expansion Union will permit upward or downward adjustment with the conduit attached. Once you have achieved the proper belt tension, tighten the two upper screws, and then the bottom shoulder bolts. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-65...

  • Page 188: Valves

    7-27. All Atlas models that can have internal piping for feeding a satellite use a solenoid valve in the discharge piping line. These models are 9140, 9840, 9850, and 9152/53 or 9852/53 with a “S” suffix. Read this section for repair or replacement of these valves.
  • Page 189 Labor cost for your area may determine your service philosophy. High labor costs favor parts replacement. The difficult removal of a part from a unit favors a partial rebuild in the unit. Gasboy recommends the following services for average or lower than average labor costs. For Valves...

  • Page 190: Solenoid Valve And Filter Manifold

    1” 2-stage solenoid valve. Filters should be selected and changed as per the section Filters and Strainers page 7-37. The valve diaphragm and coil are the serviceable parts. Use Gasboy recommended kits for valve repair. Follow the instructions provided with the kit. Recommended Solenoid Valve Repair Kits Kit Description Kit No.
  • Page 191 Valve and Filter Manifold Models 8700, 8800, 9152/53, 9852/53 Service Tips While reinstalling the strainer, always install it with tabs pointing downwards. Hand-tighten the filter and do not use a wrench. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-69...

  • Page 192: Solenoid Valves For 9X40, 9850 And 9X53 With Satellite Outlet Piping

    Rebuilding or Replacing Labor cost for your area may determine your service philosophy. High labor costs favor replacement. Difficult removal from unit favors partial rebuild in the unit. Gasboy recommends the following services for average or lower than average labor costs.

  • Page 193: Meter Check Valve

    • Wear eye protection while replacing any check valve. To service valves, proceed as follows: Close and test shear valves for dispensers. Shut off power to the unit and any involved STPs. Use OSHA Lock-out/Tag-out procedures. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 7-71...

  • Page 194: Shear Valves

    Lubricate the linkage with SAE 10W motor oil. • Gasboy highly recommends that you always use the double-poppet shear valve instead of single-poppet when replacing valves. Use of double-poppet shear valves may require some internal plumbing changes in older units.
  • Page 195 Hydraulic/Mechanical Components Model 9850KXTW1 Shear Valve Configuration The Atlas Ultra-Hi with Twin Inlet Manifold requires a special inlet configuration because of the limited base to manifold distance. Gasboy recommends the Marrison Bros. 2 inch 636F shear valve with a union attached at the bottom of the valve, to connect to the service system piping.

  • Page 196: T-52A Pressure Regulator Valve Option

    • Vapor Recovery hoses must never touch the ground when nozzle is at rest in the dispenser. • Promptly replace damaged hoses, nozzle bellows or face seals. • Inspect parts daily. Page 7-74 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 197: Troubleshooting

    • Defective Venturi or Co-Vent Mechanical Computers Although the mechanical computers used in Gasboy pumps are carefully adjusted and lubricated at the factory before shipment, they require (as do all mechanical parts) occasional cleaning and lubrication when in service. The intervals at which this should be done vary with conditions of operation.
  • Page 198 Hydraulic/Mechanical Components Mechanical Computers This page is intentionally left blank. Page 7-76 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 199: Troubleshooting Tables

    Identify the symptoms: Is there no display on one side of the pump/can the valves be heard opening and is the fuel being delivered? Investigate for other symptoms and conditions. MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 8-1...

  • Page 200: Troubleshooting Tables (Commercial Electronic And Retail Electronic Units)

    • History of problem including the attempts that have been made to solve the problem Troubleshooting Tables (Commercial Electronic and Retail Electronic Units) Gasboy recommends that you make a copy of this page for your reference and use it for all service calls. For Problems with...

  • Page 201: Sample Troubleshooting Form

    Likeliness Priority Code Highly likely or easy to check Likely Possible, some locations only Not likely Remote No entry Not previously reported MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 8-3...

  • Page 202: Table 1: Communications To The Console

    Troubleshooting Tables (Commercial Electronic and Retail Electronic Units) Table 1: Communications to the Console Communications 501 503 504 204 904 False calls at console No communication with controller: multiple units One unit Pulser Output Incorrect (missing) Page 8-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 203: Table 2: Fuel Delivery (All Units)

    D E D hose) No flow with reset (all hoses same grade at station) Slow-flow with reset (all hoses, same Device) Flow stall at slow C B B speed MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 8-5...

  • Page 204: Table 3: Electronic Displays, Electric Reset And Calibration

    No reset Reset motor runs, no return to zero Reset OK, valves/motor not on Resets continually Calibration Calibration does not hold (repeat tests) Calibration does not hold (few months) Page 8-6 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 205: Table 4: Error Codes 10-44

    PIN code 2 changed Cash/credit option changed Side exists option changed PPU options changed Pump handle on at power-up Commercial Electronic Units RAM Failure ROM Failure Power Failure Timed Out Limit Cutoff MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 8-7...

  • Page 206: Table 5: Handle Responses, Leaks, Noise, And Presets (All Units)

    7 10 14 16 19 28 29 39 50 51 52 55 58 61 62 66 68 75 77 79 84 89 90 97 101 106 108 113 Missed presets (complete miss) Small over-run Small under-run Page 8-8 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 207: Table 6: Repeated Problems And Stps

    7 10 14 15 31 32 39 43 49 52 62 76 77 84 87 90 93 97 100 111 113 114 STP not activated (multiple units) STP not activated (one hose) STP not activated (one unit) STP stays on (multiple) STP stays on (one) Wrong STP turns on MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 8-9...
  • Page 208 Troubleshooting Tables Troubleshooting Tables (Commercial Electronic and Retail Electronic Units) This page is intentionally left blank. Page 8-10 MDE-4334C Atlas Start-up and Service Manual · April 2008...

  • Page 209: Wiring And Configuration

    This section was last updated in January 2007. Topics in this Section Topic Page Cable Block Diagrams Atlas Hydraulics, Bezel and Door Configurations Cable Block Diagrams Block Diagram K-Pump Retail M04885 Block Diagram K-Pump Commercial M05193 MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 9-1...

  • Page 210: Atlas Hydraulics, Bezel And Door Configurations

    Figure 9-2: Electronic Single Side-load facing Junction Box Totalizer this Side Display both Sides Air Gap Grille Air Gap Grille Electronic Single Side-load Electronic Single Side-load opposite Junction Box Side facing Junction Box Page 9-2 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 211 Electronic Single Front-load Electronic Single Front-load facing Junction Box opposite Junction Box Side Figure 9-4: Mechanical 1 Grade-2 Hose facing Junction Box Totalizer this Side Hose 2 Display Hose 1 Display MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 9-3...
  • Page 212 Hose 1 Display Air Gap Grille Figure 9-6: Electronic 1 Grade-2 Hose Front-load facing Junction Box Hose 2 Display (Hose 1 Opposite Side) Totalizer this Side Air Gap Grille Page 9-4 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 213 (GR2 Opposite Side) GR1 Display Figure 9-8: Electronic 2 Grade-2 Hose Side-load facing Junction Box GR1 Totalizer this Side (GR2 Opposite Side) GR2 Display GR1 Display Air Gap Grille MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 9-5...
  • Page 214 Figure 9-9: Electronic 2 Grade-2 Hose Front-load facing Junction Box GR2 Display (GR1 Opposite Side) GR2 Totalizer this Side (GR1 Opposite Side) Air Gap Grille Figure 9-10: Mechanical Super-Hi facing Junction Box Totalizer this Side Display both Sides Page 9-6 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 215 Figure 9-12: Electronic Super-Hi Front-load facing Junction Box Totalizer this Side Display this Side Blank Bezel Air Gap Grille Air Gap Grille Electronic Super-Hi Front-load facing Electronic Super-Hi Front-load Junction Box opposite Junction Box Side MDE-4334C Atlas Start-up and Service Manual · April 2008 Page 9-7...
  • Page 216 Figure 9-13: Combo Unit facing Junction Box Master Totalizer Blank Bezel Master Display Air Gap Grille Air Gap Grille Satellite Inlet Master Inlet Combo Unit facing Junction Box Combo Unit opposite Junction Box Side Page 9-8 MDE-4334C Atlas Start-up and Service Manual · April 2008...
  • Page 218 Underwriters Laboratories Inc. © 2008 GASBOY 7300 West Friendly Avenue · Post Office Box 22087 Greensboro, North Carolina 27420 Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A. MDE-4334C Atlas Start-up and Service Manual · April 2008...

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