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Gasboy 9800A Series Diagnostic Manual

Pumps and dispensers
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SERIES 9800A
PUMPS AND DISPENSERS
DIAGNOSTIC MANUAL
C35797
REV. 03/07/03
Copyright 2003 by Gasboy International LLC All rights reserved.
The information in this document is confidential and proprietary.
No further disclosure shall be made without
permission of Gasboy International LLC. Gasboy International LLC believes that the information in this document is
accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other
rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.
GASBOY INTERNATIONAL LLC LANSDALE, PA

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Summary of Contents for Gasboy 9800A Series

  • Page 1 No further disclosure shall be made without permission of Gasboy International LLC. Gasboy International LLC believes that the information in this document is accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other rights of third parties resulting from its use.
  • Page 2 Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or property, follow these listed warnings and other warnings and precautions outlined in this manual when installing, using, or working around this equipment. Check with GASBOY Technical Services for compatibility of liquids with pump materials.

  • Page 3: Table Of Contents

    CONTENTS Section 1: INTRODUCTION About this Book ..................Using the Troubleshooting Section ............Section 2: CHASSIS WIRING Junction Boxes..................AC Junction Box .................. DC Junction Box .................. 115VAC/60 Cycle Pump Wiring ..............115VAC/60 Cycle Dispenser Wiring ............230VAC/50 Cycle Pump Wiring ..............230VAC/50 Cycle Dispenser Wiring ............
  • Page 4 GASBOY Series 9800A Heater/Thermostat Cable Assembly ............3-22 Connector .................... 3-22 Power Bracket Assembly (C06436) ............3-23 Connectors................... 3-23 Section 4: TROUBLESHOOTING Using This Section ..................Section 5: REPLACEMENT INSTRUCTIONS General Information .................. Electronic Component Access ..............Replacing the Platform Assembly .............
  • Page 5 Contents Support Assembly ..................Float Assembly..................Float Assembly Breakdown ..............High Hose Retriever Parts ................ Internal Retriever Breakdown ..............9840A Manifold Assembly ............... 9840AX Manifold Assembly ..............9853AHC Pump Discharge............... 9853AHC Manifold ..................9853ATW1M Manifold Assembly.............. 9800AXTW1 Manifold Assembly .............. Mechanical Totalizer .................
  • Page 6 GASBOY Series 9800A 097335 230V, Canada-ATC 097434 ........... 9850AXS Discharge, Valve Pipe Assembly, 097321 115V, 097323 230V, Canada-ATC 097435 ........... 9850AXTW Discharge 097326 115V, 097329 230V, Canada-ATC 097428 98 9850AXTW Discharge 097348 115V, 097349 230V, Canada-ATC 097436 99 9852A, 9852AX Discharge - 097300 115V, 097301 230V, Canada-ATC 097418................

  • Page 7: Introduction

    A double line at the end of a problem sequence indicates the last of the checks for that problem. If your 9800A still is not working, recheck your symptoms and follow another problem sequence if necessary. If you encounter problems you cannot solve by using this manual, call GASBOY customer service at 1-800-444-5529.

  • Page 9: Chassis Wiring

    Section 2 CHASSIS WIRING JUNCTION BOXES All field wiring connections to the Series 9800A dispensing unit are made in the unit’s junction boxes. The 9800A wiring is split into two classifications, AC and DC. A junction box is provided for AC; a DC junction box is optional. AC and DC wiring must never be mixed in any common junction box, conduit, or trough.

  • Page 10: Dc Junction Box

    When the dispensing unit includes the optional RS-485 interface, RS-485 lines are provided. This interface allows the user to connect a GASBOY CFN Series System directly to the Series 9800A dispensing unit. These lines must be capped when not in use.

  • Page 11: 115Vac/60 Cycle Pump Wiring

    Chassis Wiring 115VAC/60 CYCLE PUMP WIRING 03/07/03 2- 3...

  • Page 12: 115Vac/60 Cycle Dispenser Wiring

    GASBOY Series 9800A 115VAC/60 CYCLE DISPENSER WIRING 03/07/03...

  • Page 13: 230Vac/50 Cycle Pump Wiring

    Chassis Wiring 230VAC/50 CYCLE PUMP WIRING 03/07/03 2- 5...

  • Page 14: 230Vac/50 Cycle Dispenser Wiring

    GASBOY Series 9800A 230VAC/50 CYCLE DISPENSER WIRING 03/07/03...

  • Page 15: 115Vac/60 Cycle Front Load Option Pump Wiring

    Chassis Wiring 115VAC/60 CYCLE FRONT LOAD OPTION PUMP WIRING 03/07/03 2- 7...

  • Page 16: 115Vac/60 Cycle Front Load Option Dispenser Wiring

    GASBOY Series 9800A 115VAC/60 CYCLE FRONT LOAD OPTION DISPENSER WIRING 03/07/03...

  • Page 17: 230Vac/50 Cycle Front Load Option Pump Wiring

    Chassis Wiring 230VAC/50 CYCLE FRONT LOAD OPTION PUMP WIRING 03/07/03 2- 9...

  • Page 18: 230Vac/50 Cycle Front Load Option Dispenser Wiring

    GASBOY Series 9800A 230VAC/50 CYCLE FRONT LOAD OPTION DISPENSER WIRING 2-10 03/07/03...
  • Page 19 Chassis Wiring 03/07/03 2- 11...

  • Page 21: Electronic Head Assembly

    Section 3 ELECTRONIC HEAD ASSEMBLY OVERALL LAYOUT Use this drawing as a guide to identifying the components in a 9800A electronic head assembly. 03/07/03...

  • Page 22: Cpu Pcb

    Single Dispenser 115VAC (C06393), Twin Dispenser 115VAC (C06394) Single Pump 230VAC (C06500), Twin Pump 230VAC (C06501) Single Dispenser 230VAC (C06502), Twin Dispenser 230VAC (C06503) The CPU PCB is the heart of the GASBOY Series 9800A. This CPU PCB: • processes and stores all 9800A data •...

  • Page 23: Connectors

    Electronic Head Assembly Connectors Connector P1 controls side 1 and P2 controls side 2. The AC IN and NEUT pins are used as a pump authorization signal when SW1-6 is closed. The AC IN also feeds the SF, FF, and SUBM relays.
  • Page 24 GASBOY Series 9800A P6 - Electronic Totalizer Switch The electronic totalizer switch connects to P6. P7 - Suction Pump/Submersible Pump Relay Drives The suction pump/submersible pump (optional) relays connect to P7. P8 - RS-485/Pump Interface The optional RS-485 and Pump Interface PCB’s connect to P8.

  • Page 25: Jumpers

    Electronic Head Assembly P9 – Front Load Option P10 - Power Supply Input P11 - LCD Display Interface Jumpers Jumper K1 is set according to the size of the RAM IC in socket U19. The 9800A CPU PCB can accommodate two sizes of battery- backed RAM;...

  • Page 26: Led Indicators

    ON again. SW1-1 Baud Rate This switch is set to reflect the communication rate of the GASBOY RS- 485 pump loop; open for 9600 baud or closed for 1200 baud. The GASBOY CFN system communicates at 9600 baud.
  • Page 27 Electronic Head Assembly SW1-3, SW1-4 Delay Time These two switches set the delay time used by leak detectors in submersible pump applications. The delay time is the period between activation of the submersible pump and activation of the slow flow valve. This time should be set according to the type of leak detector installed on the submersible pump to allow a normal leak test for each transaction.

  • Page 28: Address Switches

    This four-position switch pack serves a dual purpose: as an address setting when communicating on the GASBOY RS-485 loop or Series 900, or as a pulser output rate selector when pulser data is sent to a fuel management system other than a GASBOY CFN or Series 900.

  • Page 29: Lcd Display Pcb (C01373)

    Electronic Head Assembly LCD DISPLAY PCB (C01373) The LCD Display PCB contains the quantity display viewed by the user. This PCB: • displays the quantity per sale, totalizer data, and diagnostic information Connector P1 - CPU PCB Interface 03/07/03 3- 9...

  • Page 30: Jumpers

    GASBOY Series 9800A Jumpers The LCD Display PCB must be addressed to display the pump data for the hose (side) that is closest to it. This means that two of the PCB’s are addressed as hose outlet #1 and two are addressed as hose outlet #2 (in a twin).

  • Page 31: Sale Backlight Pcb (C06372)

    Electronic Head Assembly SALE BACKLIGHT PCB (C06372) The backlight PCB illuminates the LCD display for night viewing. This PCB: • attaches to the 9800A LCD display PCB • combines long-life, super-bright LED’s with a reflector for increased surface illumination Connector P1 - Power Input Connector 03/07/03 3- 11...

  • Page 32: Rs-485 Interface Pcb (C06389)

    GASBOY Series 9800A RS-485 INTERFACE PCB (C06389) The RS-485 Interface PCB allows the 9800A to communicate on the GASBOY RS-485 loop. This PCB: • provides protection against noise and damaging voltage transients that may be induced onto the RS-485 lines •...

  • Page 33: Led Indicators

    Electronic Head Assembly LED Indicators LED indicators are provided to allow you to monitor the RS-485 communication lines. 03/07/03 3- 13...

  • Page 34: Pump Interface Pcb (06425)

    PUMP INTERFACE PCB (C06425) The Pump Interface PCB sends the pulser signal to external monitoring equipment that does not support the GASBOY RS-485 electronic pump loop. This PCB: • provides a pulser signal for each pump side, up to 100 mA at 24 VDC. The current and voltage are determined by the external equipment.

  • Page 35: Led Indicators

    Electronic Head Assembly P2 - CPU PCB Interface LED Indicators LED indicators are provided to allow you to monitor the pulser output lines. 03/07/03 3- 15...

  • Page 36: Power Supply Pbc

    GASBOY Series 9800A POWER SUPPLY PCB 115 VAC (C06396) Battery-Backed 115 VAC (C06397) 230 VAC (C06488) Battery-Backed 230 VAC (C06489) The power supply PCB provides: • +5VDC logic power and +7.5VDC LED backlight power • diagnostic LED’s to monitor DC voltages •...

  • Page 37: Connectors

    Electronic Head Assembly Connectors P1 - CPU Power Output P2 - Backlight Power Output P3 - AC Input LED Indicators LED indicators are provided to allow you to monitor the DC voltages. Test Points Test points are provided for voltage measurement. 03/07/03 3- 17...

  • Page 38: Pump Relays

    GASBOY Series 9800A PUMP RELAYS The pump relays are always used for suction pumps and may be used for submersible pumps up to and including 1-1/2 HP at 230 VAC. These relays: • control the motor that drives the suction or submersible pump (one each side) •...

  • Page 39: Connectors

    Electronic Head Assembly Connectors Relay Drive Pump Motor Power 03/07/03 3- 19...

  • Page 40: Ballast Assembly

    GASBOY Series 9800A BALLAST ASSEMBLY 115 VAC (C06473) 230 VAC (C06476) The ballast assembly provides power for the fluorescent lights. Connectors Front and Rear Lamps Input Power 3-20 03/07/03...

  • Page 41: Fluorescent Lamp Assembly (C06398), Fluorescent Lamp (033412)

    Electronic Head Assembly FLUORESCENT LAMP ASSEMBLY (C06398) FLUORESCENT LAMP (033412) The fluorescent lamp assemblies illuminate the brand panels. FLUORESCENT LAMP ASSEMBLY (C07117) FLUORESCENT LAMP (033412) Connector Input Power - from ballast assembly 03/07/03 3- 21...

  • Page 42: Heater/Thermostat Cable Assembly

    GASBOY Series 9800A HEATER/THERMOSTAT CABLE ASSEMBLY 115 VAC (C06450) 230 VAC (C06490) The heater assembly is used to warm the power supply battery in extreme temperatures and conditions. It: • contains a 25W heater strip • contains a thermostat to regulate temperature...

  • Page 43: Power Bracket Assembly (C06436)

    Electronic Head Assembly POWER BRACKET ASSEMBLY (C06436) The Power Bracket Assembly contains the switch, fuse, and AC connectors. Connectors Micro Power Input - Connects to AC power from conduit assembly. Heater Power - Supplies AC power to optional heater. Connector is standard on all models. 03/07/03 3- 23...
  • Page 44 GASBOY Series 9800A ELECTRONIC TOTALIZER CABLE ASSEMBLY Front (Standard) C06434 Rear (Optional) C06819 The electronic totalizer assembly contains a sensor that, when activated, shows the pump’s totalizer data on the sale displays. A rear extension cable allows the totalizer to be activated from both sides of the unit.

  • Page 45: Troubleshooting

    A double line at the end of a problem sequence indicates the last of the checks for that problem. If your unit still is not working, recheck your symptoms and follow another problem sequence if necessary. If you encounter problems you cannot solve by using this manual, call GASBOY Technical Service at 1-800-444-5529.
  • Page 46 GASBOY Series 9800A 9800A is dead. Displays are blank, including decimal points. Unable to activate side 1 or side 2. Possible Cause Checks Corrective Action No 115/230AC feed to 9800A Check if circuit breaker is off Turn breaker on, if off.
  • Page 47 Troubleshooting 9800A won’t activate in standalone mode. When the pump handle is thrown, the displays do not go through reset sequence. Possible Cause Checks Corrective Action System controlling 9800A not If the 9800A is controlled by a Repair fuel management functioning properly.
  • Page 48 GASBOY Series 9800A Possible Cause Checks Corrective Action Defective CPU PCB. None. Replace the CPU PCB if the 9800A still will not activate. NOTE: Changing the pulser rate switches may require replacement of your Weights and Measures seal. 03/07/03...
  • Page 49 Checks Corrective Action 9800A is not communicating to Verify that the 9800A is Perform actions listed under the GASBOY CFN system. communicating. 9800A is not communicating to the GASBOY CFN System. 9800A won’t activate in Verify that the 9800A works in Close SW1-2 on the CPU standalone mode.
  • Page 50 GASBOY Series 9800A 9800A is not communicating to the GASBOY CFN system. Possible Cause Checks Corrective Action CFN system is not functioning Verify proper operation of the Repair CFN system, if properly. CFN system. necessary. Refer to CFN manuals for further assistance.
  • Page 51 Troubleshooting 9800A resets but does not dispense fuel – Pump. Possible Cause Checks Corrective Action No 115/230VAC feed to pump. Check if circuit breaker is off Turn breaker on, if off. or tripped. Check if 115/230VAC is being Replace circuit breaker if switched through circuit 115/230VAC is not being breaker.
  • Page 52 GASBOY Series 9800A 9800A resets but does not dispense fuel – Dispenser. Possible Cause Checks Corrective Action No 115/230VAC feed to Check if circuit breaker is off Turn breaker on, if off. dispenser. or tripped. Check if 115/230VAC is being...
  • Page 53 Troubleshooting Possible Cause Checks Corrective Action Leak detector did not open. Check the settings of switches Select a longer delay time if SW1-3 and SW1-4 to needed. determine the selected delay time. Replace defective leak detector if it does not open. Leak in supply line or piping.
  • Page 54 GASBOY Series 9800A Product is dispensed, but no quantity shows on the 9800A display. Possible Cause Checks Corrective Action Broken or damaged coupling. Broken or damaged coupling. Repair or replace coupling if damaged. Defective pulser or defective While dispensing fuel slowly, Replace the pulser if a +5VDC CPU PCB.
  • Page 55 Weights and Measures seal. Fuel management system The 9800A requires the fuel Call GASBOY Technical pulser input circuitry not management system to "pull Service for assistance. compatible. up" the pulser signal to a DC voltage between 5VDC and 24VDC.
  • Page 56 GASBOY Series 9800A The 9800A does not display the last transaction during an AC power failure. This problem pertains only to 9800A’s equipped with a battery back-up power supply. Possible Cause Checks Corrective Action Battery not fully charged or If the 9800A had been off for a Replace the power supply if defective power supply PCB.
  • Page 57 Troubleshooting The flourescent lights don’t turn on. Possible Cause Checks Corrective Action No 115/230VAC feed to Check if circuit breaker is off Turn breaker on, if off. 9800A for light power. or tripped. Check if 115/230VAC is being Replace circuit breaker if switched through circuit 115/230VAC is not being breaker.
  • Page 58 GASBOY Series 9800A With the 9800A in standalone mode, one or more displays flash 55 at the far left of the display. Possible Cause Checks Corrective Action 9800A is running on battery Check if the breaker supplying Turn breaker on, if off.
  • Page 59 Troubleshooting With the 9800A in standalone mode, one or more displays flash 57 at the far left of the display. Possible Cause Checks Corrective Action No fuel is dispensed. None. Go to the problem 9800A resets but does not dispense fuel. Pulser doesn’t turn.

  • Page 61: Replacement Instructions

    Section 5 REPLACEMENT INSTRUCTIONS GENERAL INFORMATION WARNING: This unit should be serviced only by qualified service personnel. To reduce the risk of electrical shock when servicing, turn off all power to the pump/dispenser. Simply turning off the power switch in the electronic head will not remove all power from the unit! All breakers that feed the unit should be turned off.

  • Page 62: Electronic Component Access

    GASBOY Series 9800A ELECTRONIC COMPONENT ACCESS Before attempting to start-up the 9800A, it is important to become familiar with the location of some key components as well as the various switch-selectable operating modes. DIESEL UNLEADED GALLONS GALLONS UNLOCK Unlock and remove the front panel.
  • Page 63 Replacement Instructions HEATER LIGHTS MICRO POWER 1 AMP SB POWER LOOSEN 03/07/03...

  • Page 64: Replacing The Platform Assembly

    GASBOY Series 9800A REPLACING THE PLATFORM ASSEMBLY Disconnect the LIGHTS and MICRO connectors [1] from the power bracket. Disconnect the AC, pulser, handle, and DC [2] cables from the CPU PCB and RS-485 or Pump I/F PCB. Push the cables down through the holes in the platform.
  • Page 65 Replacement Instructions 03/07/03...

  • Page 66: Replacing The Cpu Pcb

    GASBOY Series 9800A REPLACING THE CPU PCB Disconnect all cables [1] from the CPU PCB. If an optional RS-485 or Pump I/F PCB is installed, remove the two Phillips screws [2]. Pull the optional PCB off of the CPU PCB.

  • Page 67: Replacing The Lcd Display Pcb

    Replacement Instructions REPLACING THE LCD DISPLAY PCB Disconnect the cable [1] from the Sale Backlight PCB. Disconnect the ribbon cable [2] from the LCD Display PCB. Unsnap the LCD display PCB from standoffs [3]. Remove the two Phillips screws [4] and washers securing the Sale Backlight PCB to the LCD Display PCB.

  • Page 68: Replacing The Sale Backlight Pcb

    GASBOY Series 9800A REPLACING THE SALE BACKLIGHT PCB Disconnect the cable [1] from the Sale Backlight PCB. Remove the two Phillips screws [2] and washers securing the Sale Backlight PCB to the LCD Display PCB. Unsnap and remove the two plastic buttons [3] securing the Sale Backlight PCB to the reflector.

  • Page 69: Replacing The Power Supply Pcb

    Replacement Instructions REPLACING THE POWER SUPPLY PCB Disconnect the cables [1] from the Power Supply PCB. Remove the two screws [2] from the Power Supply PCB and then unsnap PCB from standoffs [3]. Reverse Steps 1 and 2 to install the new Power Supply PCB. 03/07/03...

  • Page 70: Replacing The Rs-485 Or Pump I/F Pcb

    GASBOY Series 9800A REPLACING THE RS-485 OR PUMP I/F PCB Disconnect the connector [1] from the RS-485 or Pump I/F PCB. Remove the two Phillips screws [2] from the RS-485 or Pump I/F PCB. Pull the RS-485 or Pump I/F PCB from the CPU PCB.

  • Page 71: Replacing The Ballast Cable Assembly

    Replacement Instructions REPLACING THE BALLAST CABLE ASSEMBLY The platform assembly must be removed in order to replace the ballast cable assembly. See Replacing the Platform Assembly earlier in this section. Proceed to Step 2 once platform assembly is removed. Using a slotted screwdriver, apply pressure to the retaining tab on one side of the LIGHTS connector [1] on the power bracket, then push the connector in through bracket.
  • Page 72 GASBOY Series 9800A 5-12 03/07/03...
  • Page 73 Replacement Instructions On the underside of the platform assembly, remove the two screws and washers [5] holding the ballast to the platform; on older units two nuts must be removed. Reverse Steps 2 through 6 to install the new ballast cable assembly. Be sure to install a new tie strap or push-in wire twist standoff to keep the cable wiring away from the optional heater strip.

  • Page 74: Replacing The Heater Cable Assembly

    GASBOY Series 9800A REPLACING THE HEATER CABLE ASSEMBLY The platform assembly must be removed in order to replace the heater cable assembly. See Replacing the Platform Assembly earlier in this section. Proceed to Step 2 once platform assembly is removed.

  • Page 76: Appendix

    APPENDIX PARTS LIST...

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