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Gasboy SERIES 9800Q, Diagnostic Manual

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Gasboy SERIES 9800Q Diagnostic Manual Download Page 41

 

01/28/04 

4-1 

Section 4    

TROUBLESHOOTING  

 
 
 

USING THIS SECTION

 

 
The Troubleshooting section lists common problems, probable causes, and corrective action to 
be taken.  The probable causes and checks for each problem are presented in logical sequence, 
allowing you to rule out one set of symptoms before going on to the next.  Thus, following the 
procedures as listed should help isolate your problem. 
 
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. 
 
Checks and corrective actions requiring voltage measurements assume familiarity with and are 
done with a voltmeter unless noted that an oscilloscope or ohmmeter should be used. 

Summary of Contents for SERIES 9800Q

Page 1: ... 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 ...

Page 2: ...r pumping fuel or additives into aircraft DO NOT use commercial pumps for direct fueling of aircraft without filters and separators necessary to ensure product purity DO NOT use where sanitary design is required for food products for human consumption or with water based liquids DO NOT smoke near the pump or when using the pump DO NOT use near open flame or electrical equipment which may ignite fu...

Page 3: ... Load Option Dispenser Wiring 2 10 Section 3 ELECTRONIC HEAD ASSEMBLY Overall Layout 3 1 CPU PCB 3 2 Connectors 3 3 Jumpers 3 5 LED Indicators 3 6 Test Points 3 6 SW Switches 3 6 Address Switches 3 8 Pulser Output Rate Switches 3 8 LCD Display PCB C01373 3 9 Connector 3 9 Jumpers 3 10 Sale Backlight PCB C06372 3 11 Connector 3 11 RS 485 Interface PCB C06389 3 12 Connectors 3 12 LED Indicators 3 13...

Page 4: ...n 4 1 Section 5 REPLACEMENT INSTRUCTIONS General Information 5 1 Electronic Component Access 5 2 Replacing the Platform Assembly 5 3 Replacing the CPU PCB 5 5 Replacing the LCD Display PCB 5 6 Replacing the Sale Backlight PCB 5 7 Replacing the Power Supply PCB 5 8 Replacing the RS 485 or Pump I F PCB 5 9 Replacing the Ballast Cable Assembly 5 10 Replacing the Heater Cable Assembly 5 13 ...

Page 5: ...to be taken The probable causes and checks for each problem are presented in logical sequence allowing you to rule out one set of symptoms before going on to the next Thus following the procedures as listed should help isolate your problem A double line at the end of a problem sequence indicates the last of the checks for that problem If your 9800Q still is not working recheck your symptoms and fo...

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Page 7: ...es power to slow and fast flow valves along with the switch detect signal Two lines provided for twins Submersible Starter Drive Controls Submersible Starter Relay Two lines provided for twins Submersible Drive Active only when submersible drive relays are provided Controls submersible starter relay or submersible pump Two lines provided for twins Reset Complete Switch Detect Slow Flow For use wit...

Page 8: ...is output should only be used when monitoring of the dispenser s operation is desired An additional output is provided for a twin These lines must be capped when not in use RS 485 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 9800Q dispensing unit These lines must...

Page 9: ...Chassis Wiring 01 28 04 2 3 115VAC 60 CYCLE PUMP WIRING ...

Page 10: ...GASBOY Series 9800Q 2 4 01 28 04 115VAC 60 CYCLE DISPENSER WIRING ...

Page 11: ...Chassis Wiring 01 28 04 2 5 230VAC 50 CYCLE PUMP WIRING ...

Page 12: ...GASBOY Series 9800Q 2 6 01 28 04 230VAC 50 CYCLE DISPENSER WIRING ...

Page 13: ...Chassis Wiring 01 28 04 2 7 115VAC 60 CYCLE FRONT LOAD OPTION PUMP WIRING ...

Page 14: ...GASBOY Series 9800Q 2 8 01 28 04 115VAC 60 CYCLE FRONT LOAD OPTION DISPENSER WIRING ...

Page 15: ...Chassis Wiring 01 28 04 2 9 230VAC 50 CYCLE FRONT LOAD OPTION PUMP WIRING ...

Page 16: ...GASBOY Series 9800Q 2 10 01 28 04 230VAC 50 CYCLE FRONT LOAD OPTION DISPENSER WIRING ...

Page 17: ...01 28 04 3 1 Section 3 ELECTRONIC HEAD ASSEMBLY OVERALL LAYOUT Use this drawing as a guide to identifying the components in a 9800Q electronic head assembly ...

Page 18: ...ransaction and totalizer data retention during power failures controls the data sent to the display PCB s controls the relays for each pump side monitors the dual channel pulser inputs for each pump side monitors the handle switch for each pump side monitors the electronic totalizer switch sends pulser data to an external control system via an optional pump interface PCB communicates on the GASBOY...

Page 19: ...eeds the SF FF and SUBM relays The SF and FF outputs can directly power the solenoid valves The SUBM output can power a customer supplied submersible starter relay The starter relay s coil current must not exceed 300 mA P1 and P2 AC Input Valve and Submersible Relay Outputs P3 Side 1 Pulser Input P5 Side 2 Pulser Input P4 Handle Switch Inputs NOTE Pin 2 and Pin 4 are not used on the Front Load opt...

Page 20: ...lizer 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 21: ...d 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 9800Q CPU PCB can accommodate two sizes of battery backed RAM 2K and 8K At this time only the 2K size is being used ...

Page 22: ...nd change their settings if necessary Switch settings should be changed with the power OFF The new settings are read by the CPU PCB when the power is turned ON again SW1 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 SW1 2 Mode This switch should be open f...

Page 23: ... time should be set to zero seconds for suction pumps SW1 5 Not used SW1 6 Authorization This switch allows activation or non activation of the unit through an external source fuel management system When closed a 115 230 VAC signal must be present on the Control Feed pump motor or subm line for pump activation to occur required setting for Series 1000 When open the 9800Q ignores the Control Feed l...

Page 24: ...Pulser Output Rate Switches When the 9800Q is connected to external control equipment other than a GASBOY CFN system standalone the pulser signals are sent out via the 9800Q Pump I F PCB The pulse rate required by the monitoring equipment can be configured by setting the switches as shown in the chart at right The pulse rate represents pulses per gallon PPG domestic or pulses per liter PPL interna...

Page 25: ...mbly 01 28 04 3 9 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 ...

Page 26: ...tlet 2 in a twin Jumper K1 selects the display address The LCD Display PCB can be configured to display whole units tenths hundredths or thousandths Presently all domestic 9800Q s are shipped displaying thousandths of a gallon all international 9800Q s are shipped displaying hundredths Jumper K2 K4 and K6 select the units and their pins should be jumpered as shown Presently there is no software or...

Page 27: ...IGHT PCB C06372 The backlight PCB illuminates the LCD display for night viewing This PCB attaches to the 9800Q LCD display PCB combines long life super bright LED s with a reflector for increased surface illumination Connector P1 Power Input Connector ...

Page 28: ... 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 contains diagnostic LED s to monitor operation of the RS 485 lines Connectors P1 RS 485 Unprotected from DC Junction Box P2 RS 485 Protected to CPU PCB ...

Page 29: ...Electronic Head Assembly 01 28 04 3 13 LED Indicators LED indicators are provided to allow you to monitor the RS 485 communication lines ...

Page 30: ...rnal 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 contains diagnostic LEDs to monitor the pulser output lines Connectors P1 Pulser Output ...

Page 31: ...Electronic Head Assembly 01 28 04 3 15 P2 CPU PCB Interface LED Indicators LED indicators are provided to allow you to monitor the pulser output lines ...

Page 32: ... VAC C06489 The power supply PCB provides 5VDC logic power and 7 5VDC LED backlight power diagnostic LED s to monitor DC voltages a signal to warn the microprocessor of an impending power failure rechargeable battery backup to display last transaction for a minimum of 15 minutes C06397 and C06489 versions Version shown is C06397 ...

Page 33: ...01 28 04 3 17 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 ...

Page 34: ... 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 are controlled by the CPU PCB ...

Page 35: ...Electronic Head Assembly 01 28 04 3 19 Connectors Relay Drive Pump Motor Power ...

Page 36: ...GASBOY Series 9800Q 3 20 01 28 04 BALLAST ASSEMBLY 115 VAC C06473 230 VAC C06476 The ballast assembly provides power for the fluorescent lights Connectors Front and Rear Lamps Input Power ...

Page 37: ...8 04 3 21 FLUORESCENT LAMP ASSEMBLY C06398 FLUORESCENT LAMP 033412 The fluorescent lamp assemblies illuminate the brand panels OR FLUORESCENT LAMP ASSEMBLY C07117 FLUORESCENT LAMP 033412 Connector Input Power from ballast assembly ...

Page 38: ...STAT 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 Connector Input Power ...

Page 39: ...ACKET 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 ...

Page 40: ... 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 Front Cable Rear Cable ELECTRONIC TOTALIZER ACTUATOR C01342 The electronic totalizer actuator is a permanent magnet that causes the 9800Q displays to show totalizer data when placed in close proximity to the totalizer sensor ...

Page 41: ...dures as listed should help isolate your problem 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 Checks and corrective actions requiri...

Page 42: ... 115 230VAC is not measured AC power fuse is blown Check the fuse in power bracket Replace fuse if blown Blown power supply PICO fuse s or defective power supply Using a voltmeter measure between the GND test point and each side of F1 and F2 on the power supply Replace F1 if 5VDC is measured on one side but not the other Replace F2 if 7 5VDC is measured on one side but not the other Replace the po...

Page 43: ...nagement system and correct the problem Mode switch on CPU PCB set incorrectly Check switch SW1 2 on CPU PCB Close switch if open Turn power off then on after changing switch settings 9800Q is running on battery power Skip this section if your 9800Q is not equipped with a battery back up power supply Check if micro circuit breaker is off or tripped Check if 115 230VAC is being switched through cir...

Page 44: ...01 28 04 Possible Cause Checks Corrective Action Defective CPU PCB None Replace the CPU PCB if the 9800Q still will not activate NOTE Changing the pulser rate switches may require replacement of your Weights and Measures seal ...

Page 45: ...00Q is not communicating to the GASBOY CFN System 9800Q won t activate in standalone mode Verify that the 9800Q works in standalone mode Close SW1 2 on the CPU PCB turn the power off and on then perform the actions listed under 9800Q won t activate in standalone mode Open SW1 2 then turn the power off and on before returning to this page CFN system data loaded incorrectly Verify that all CFN syste...

Page 46: ...e configured correctly Make sure the pump type is 2 with no options for the Site Controller II or type 64 for the Site Controller I Incorrect switch settings on 9800Q CPU PCB Verify that the SW1 switches are set as follows 1 OPEN 2 OPEN 6 OPEN Verify that the SW2 switches match the CFN system Change switch settings if necessary Turn the power off then on after changing switch settings Defective RS...

Page 47: ...re replacement of your Weights and Measures seal Replace the CPU PCB if 115 230VAC is not measured between screw terminal 1 and 3 NOTE Changing the pulser rate switches may require replacement of your Weights and Measures seal Defective pump relay Using an AC voltmeter measure between AC neutral and screw terminals 1 and 2 of the pump relay Replace the relay if 115 230VAC is measured at screw term...

Page 48: ...ween screw terminals 1 and 3 of terminal SOL1 or SOL2 Replace the CPU PCB if 5VDC is measured between ground and the blue or violet wires NOTE Changing the pulser rate switches may require replacement of your Weights and Measures seal If 115 230VAC is not measured on either side of the fuses replace the CPU PCB If 115 230VAC is measured on one side of the fuse but not on the other replace the fuse...

Page 49: ...ay time Leak in supply line or piping Select a longer delay time if needed Replace defective leak detector if it does not open Repair leak Shear valve tripped Try to determine cause loose mounting to island cabinet had been hit etc Reset or if necessary replace shear valve if it is tripped Correct cause of valve tripping Defective submersible motor Repair or replace motor ...

Page 50: ... While dispensing fuel slowly measure between GND TP2 and pins 1 and 2 of connector P3 side 1 or P5 side 2 on the CPU PCB using an oscilloscope Replace the pulser if a 5VDC square wave is not measured between GND and pin 1 and between GND and pin 2 of the appropriate connector Replace the CPU PCB if a 5VDC square wave is measured but the displays still show no quantity NOTE Changing the pulser rat...

Page 51: ...the pulser signal to a DC voltage between 5VDC and 24VDC Call GASBOY Technical Service for assistance Defective CPU PCB Using an oscilloscope check the signal between GND TP2 and the following pins of P2 on the pump I F PCB Pin 5 Side 1 1000 1 250 1 international Pin 6 Side 2 1000 1 250 1 international Pin 10 Side 1 below 1000 1 below 250 1 international Pin 11 Side 2 below 1000 1 below 250 1 inte...

Page 52: ...otalizer data Possible Cause Checks Corrective Action Pump Handles are on Check if pump handles are on Turn pump handles off if on Possible misalignment of totalizer switch and magnet Check alignment Realign if needed Defective actuator None Replace actuator Defective totalizer sensor or defective CPU PCB Remove the totalizer cable assembly from P6 of the CPU PCB Short the two pins together on P6 ...

Page 53: ...ction ROM failure None Replace ROM IC U18 on CPU PCB Replace CPU PCB if replacing U18 did not fix problem STANDALONE MODE ERROR HANDLING When operating the pump dispenser in standalone mode not connected to a fuel management system the 9800Q displays two digit error transaction codes on the LCD displays when transactions are terminated abnormally by a means other than turning off the pump handle T...

Page 54: ...breaker if 115 230 VAC is not being switched Correct wiring problems if 115 230 VAC is not measured Turn on if off Replace fuse if blown Defective AC power fail circuit Using a DC voltmeter measure between ground TP2 and pin 3 of connector P10 violet wire on the CPU PCB Replace the power supply PCB if 5VDC is not measured between ground and the violet wire With the 9800Q in standalone mode one or ...

Page 55: ...he 9800 CPU PCB If the switch is closed the 9800 will timeout if it doesn t detect pulses for 4 minutes 15 seconds To set the 9800 to never timout open SW2 4 With the 9800Q in standalone mode one or more displays flash 58 at the far left of the display Possible Cause Checks Corrective Action The maximum quantity limit for a single transaction was pumped The limits are 9800 gallons 990 000 9840 gal...

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Page 57: ...nit should be turned off In submersible pump applications turn off power to the submersible pump and any other dispensers which use that submersible pump AC power can feed back into a shut off dispenser when other dispensers share a common submersible pump or starter relay All replacement procedures are written with the understanding that the Series 9800Q has been opened for servicing Electronic c...

Page 58: ...rating modes 1 Unlock and remove the front panel 2 Remove the two bolts located over the tabs of the bezel assembly Lift the bezel assembly upwards and out to remove If the model includes the front load nozzle remove the nozzle boot plastic shroud two screws before removing the bezel assembly 3 Loosen and remove if necessary the two screws located on the left and right door support brackets and pi...

Page 59: ...its retaining hardware 4 from the platform 5 Disconnect the cables 5 from the rear door PCB s 6 Remove the hardware 6 securing one of the support brackets Be careful not to let the door fall off while removing the screws Slide the door away from the remaining support bracket and pull the door out of the cabinet 7 Remove the four nuts washers and lock washers securing the platform assembly to the c...

Page 60: ...GASBOY Series 9800Q 5 4 01 28 04 ...

Page 61: ... standoffs 4 Remove the program IC from socket U18 3 and the memory IC from socket U19 4 of the defective CPU PCB by gently prying with a slotted screwdriver 5 Install the old program IC and memory IC into sockets U18 and U19 on the new CPU PCB Be careful to observe proper pin orientation 6 Reverse Steps 1 through 3 to install the new CPU PCB 7 Verify that the switch settings on the new CPU PCB ar...

Page 62: ...isplay PCB from standoffs 3 4 Remove the two Phillips screws 4 and washers securing the Sale Backlight PCB to the LCD Display PCB 5 Reverse Steps 1 through 4 to install the new LCD Display PCB 6 Verify that the jumper settings on the new LCD Display PCB match the jumper settings from the defective LCD Display PCB See the jumper settings in Section 3 Electronic Head Assembly for verification ...

Page 63: ...e 1 from the Sale Backlight PCB 2 Remove the two Phillips screws 2 and washers securing the Sale Backlight PCB to the LCD Display PCB 3 Unsnap and remove the two plastic buttons 3 securing the Sale Backlight PCB to the reflector 4 Reverse Steps 1 through 3 to install the new Sale Backlight PCB ...

Page 64: ...4 REPLACING THE POWER SUPPLY PCB 1 Disconnect the cables 1 from the Power Supply PCB 2 Remove the two screws 2 from the Power Supply PCB and then unsnap PCB from standoffs 3 3 Reverse Steps 1 and 2 to install the new Power Supply PCB ...

Page 65: ... the RS 485 or Pump I F PCB 3 Pull the RS 485 or Pump I F PCB from the CPU PCB 4 Reverse Steps 1 through 3 to install the new RS 485 or Pump I F PCB NOTE Older units may have a 5 position cable from DC conduit New pump and RS 485 PCBs have a 4 position connector When installing the new PCB make sure that pin 1 of the cable red wire matches up with pin 1 of the PCB connector ...

Page 66: ...sembly is removed 2 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 3 Disconnect the lamp cable assemblies 2 from the ballast cable assembly on the front and rear of the platform 4 Using a slotted screwdriver apply pressure to the retaining tab on one side of each ballast connector...

Page 67: ...Replacement Instructions 01 28 04 5 11 ...

Page 68: ...o the platform on older units two nuts must be removed 7 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 See Replacing the Platform Assembly earlier in this section to complete the procedure ...

Page 69: ...he thermostat to the platform Push the thermostat through the bushing 3 Disconnect the HEATER connector 2 from the power bracket 4 Remove the two Phillips screws 3 and fiber washers retaining the heater strip 5 Peel the heater strip 4 from the platform 6 Remove backing from the new heater strip and secure it to the platform in the same position as the old heater 7 Reverse Steps 2 through 4 to inst...

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