Gasboy Atlas Start-up User Manual

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Commercial and Retail Series

Atlas

™

Start-up/Service Manual

MDE-4334D

Computer Programs and Documentation

Gasboy, Greensboro, is an ISO 9001:2000 registered facility. Underwriters Laboratories (UL):

UL File# Products listed with UL

MH4314

All dispensers and self-contained pumping units

MH6418

Power operated Transfer Pump Models 25, 25C, 26, 27, 28, 72, 72S, 72SP , 72X, 73 and 1820

MH7404

Hand operated Transfer Pump Models 1230 Series, 1243 Series, 1520 and 1720 Series

MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s

Card reader terminals, Models 1000, 1000P Site controller, Model 2000S CFN Series Data entry terminals, Model TPK-900 Series Fuel Point Reader System

National Conference of Weights and Measures (NCWM) - Certificate of Compliance (CoC):

Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:

CoC# Product Model # CoC# Product Model # CoC# Product Model #

95-179 Dispenser

9100 Retail Series, 8700 Series, 9700 Series

91-019 Dispenser

9100 Commercial Series

05-002 Atlas

8700K, 8800K, 9100K, 9200K, 9800K

95-136 Dispenser 9800 Series 91-057 Controller

1000 Series FMS, 2000S-CFN Series

New York City Fire Department (NYFD):

NYFD C of A # Product

4823 9100A, 9140A, 9152A, 9153A,

9800A, 9840A, 9850A, 9852A,

9853A, 9140 4997 9822A, 9823A 5046 9100Q, 9140Q, 9152Q, 9153Q,

9800Q, 9840Q, 9852Q, 9853Q 5087 8753K, 8853K, 9153K, 9853K

(restricted to diesel and non-

retail gasoline sales) 5091 8752K, 9152K 5129 9122K, 9123K, 9822K, 9823K

California Air Resources Board (CARB):

Executive Order # Product

G-70-52-AM Balance Vapor Recovery G-70-150-AE VaporVac

Registered trademarks

ASTRA

Fuel Point

Gasboy

Keytrol

Slimline

Additional US and foreign trademarks pending.

Other brand or product names shown may be trademarks or registered trademarks of their respective holders.

Non-registered trademarks

Atlas™ Consola™ Infinity™

Federal Communications Commission (FCC) Warning

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.

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

Approvals

Trademarks

Table of Contents

1 – Read This First 1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Topics in This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Who Must Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Service Protocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Common Terms Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

DEF Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting DEF Freeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

If DEF Freezes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Important Requirements for

Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E85 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Mechanical Retail Pump/Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Electronic Retail Pump/Dispenser . . . . . . . .

Serial Number Plate and Date Codes . . . . .

Atlas Model Number Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Options Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

. . . . . . . . . . . . . . . . . . . . 1-11

. . . . . . . . . . . . . . . . . . . . 1-12

. . . . . 1-6

. . . . . . . 1-10

2 – Important Safety Information 2-1

3 – Start-up Procedures 3-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Topics in This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

How to Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Certificate of Conformance (CoC) Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Start-up Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Checklists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Meter Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gasboy Atlas (Gallon Unit of Measure) . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

. . . . . . . . 3-2

. . . . . . . . 3-4

4 – Pump Programming 4-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Programming Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9800 Series Electronic Commercial Units . . . . . . . . . . . . . . . . . . . . . . . 4-1

8800 Series Electronic Retail Units . . . . . .

Mechanical Commercial Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Configuring 9800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Configuration Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Configuration Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

ATC Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

. . . . . . . . . . . . . . . . . . . . . . 4-2

. . . . . 4-1

. . . . . . 4-3

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page i

Table of Contents

Programming 8800 Series Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

General Programming Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Display Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Programming Steps for 8800 Series Units . . . . . . . . . . . . . . . . . . . . . .4-15

Level 1 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Level 2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Level 3 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Option and Miscellaneous Programming/Data Acquisition. . . . . . . . . .4-24

Displaying Pump Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Error Codes and Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Programming 8700 Series Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Programming Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Programming Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

. .4 -27

5 – Electronic and Electrical Components 5-1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Important Information About Releases . . . . .

Topics in This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

How to Use This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Electronics Highlights. . . . . . . . . . . . . . . . . . . . . . .

Retail Parts by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Retail Parts by Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Commercial Parts by Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

8800 Series Electronic Retail Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

System and Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

About Service Procedures . . . .

Working on Electronic and Electrical Components. . . . . . . . .

Component Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PCAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Atlas 9800 Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessing Electronic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Atlas 9800 Power Supply

Installing Atlas 9800 CPU Board (M06333KXXXX) . . . . . . . . . . .

Installing Atlas 9800 Pulse-out I/F with EM Totaliz

Atlas 8800 Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Preparing for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Preventing ESD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Hazardous Materials . . . .

Atlas 9800 PCAs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Atlas 9800 CPU Board (M06333KXXXX) . . . . . . . . . . . . . . . . . . . . . . .5-25

Atlas 9800 Power Supply (M07588A00X). . . . . . . . . . . . . . . . . . . . . . .5-28

Atlas 9800 Serial EEPROM Board (M06656K00X). . . . . . . . . . . . . . . .5-29

Atlas 9800 Pulse-out I/F Board with 

EM Totalizer Drive (M06587A001) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

K-pump RS-485 with Totalizer (M06725A001) . . . . . . . . . . . . . . . . . . .5-31

(M07588A00X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32

Jumpers JP1, JP2, and JP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34

Jumpers JP4 and JP5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

Pump Interface PCA [T18994 (Atlas 8800 Only)] . . . . . . . . . . . . . . . . .5-37

Pump Controller PCA [T20092 (Atlas 8800 Only)] . . . . . . . . . . . . . . . .5-38

ATC Component Overview (Atlas 8800 Only). . . . . . . . . . . . . . . . . . . .5-40

Manager Keypad [T17549-G1 (Atlas 8800 Only)]

Display Backlight PCA (0.6-inch) [T17622-G9 (Atlas 8800 Only)] . . . .5-43

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

. . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

er Drive Board (M06587A001). . . . . . . . . . . . . . .5-34

. . . . . . . . . . . . . . . . . . . . .5-1

. . . . . .5-11

. . . . . . . . . . .5-12

. . . . . . .5-25

.5-31

. . . . . . .5-37

. . . . . . . . . . . . . . . . .5-42

Page ii MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Table of Contents

LCD Display (0.6-inch) [T17701-G1 (Atlas 8800 Only)]. . . . . . . . . . . . 5-44

LCD Display (0.6-inch) [T18981-G1 (Atlas 8800 Only)]. . . . . . . . . . . . 5-45

Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Main Power Supply (T19868-G1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

I.S Barrier Assembly ATC (T19428-G1). . . . . .

Q10131-03 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Electro-mechanical Registers and Totalizers . . . . . . . . . . .

About Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Pulsers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Standard Pulsers . . . . . . . . . . . . . . .

Testing Pulsers and I.S Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Pulser Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

About Ultra-Hi Pulsers . . . . . . . . . . . . . . . .

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEF Heating System (Commercial Cold W Coriolis Meter Interface Board (M10030A001).

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

. . . . . . . . . . . . . . . . . . 5-50

. . . . . . . . . . . . . . . . . . . . . 5-53

. . . . . . . . . . . . . . . . . . . . . 5-55

eather DEF Units Only) . . 5-55

. . . . . . . . . . . . . . . . . . 5-57

. . . . . . . 5-46

. . . . . . . . . . 5-53

. . . . . . . . . . 5-55

6 – Hydraulic/Mechanical Components 6-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Topics in This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

How to Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Hydraulic and Mechanical Highlights. . . . . . . . . . . . . . .

2-stage Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

General Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working on Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Servicing Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Servicing Seals, O-rings, and Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Pipes and Hydraulic Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Purging Air from System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Purging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Purging Product Lines (New Installations). . . .

Purging Pumps and Dispensers (with Fuel in Product Lines) . . . . . . . 6-11

Purging Air in DEF Systems. . . . . . . . . . . .

Measuring Flow Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring Pressure and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Pressure Measuring Locations on Unit . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Measuring Pressure Drop for Pumps and Dispensers

Analyzing Pressure Drop for Pumps

Measuring Vacuum for Pump. . . . . . . . . . . .

About Vacuum Readings . . . . . . . . . . . . . .

Measuring Dry Vacuum for Pump . . . . . . . .

Measuring Wet Vacuum and Pressure for Pump

Meter Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Calibrating Meters . . . . . . . . . . . . . .

CFT Meter Calibration Adjustment for

Super-Hi™ Models (All Models Excluding 9850K and 9850KX) . . . . . 6-23

LC Meter Calibration Adjustment for Ultra-Hi 

Models 9850K and 9850KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Calibration Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

. . . . . 6-4

. . . . . . 6-9

. . . . . . . . . . . . . . . . . . 6-10

. . . . . . . . . . . . . . . . . . . . . 6-12

. . . . . 6-13

6-14

. . . . . . . . . . . . . 6-16

and Dispensers . . . . . . . . . . . . . 6-17

. . . . . . . . . . . . . . . . . . . . 6-19

. . . . . . . . . . . . . . . . . . . . . 6-19

. . . . . . . . . . . . . . . . . . . . 6-19

. . . . . . . . . . . . . . . . . 6-20

. . . . . . . 6-22

. . . . . . . . . . . . . . . . . . . . . 6-22

Standard, Hi-Flow, and 

for E85/DEF Units 

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page iii

Table of Contents

[Electronic Calibration (ECAL)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .6-26

About Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

CFT/E85 Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

Repairing CFT/E85 Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

Replacing Cylinder Cover and Gasket (Cy

Replacing O-rings (Body and Cover Leaks) . . . .

linder Cover Leaks) . . . . . .6-29

. . . . . . . . . . . . . . . . .6-30

Calibrating Wheel Parts Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

Replacing Piston Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

Removing/Replacing Shaft Seal and Gasket (Upper Seal Leaks) . . . .6-33

LC Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

Removing/Replacing LC Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Filters and Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .6-37

About Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Servicing Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

About Strainers . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

DEF Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

Servicing Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

Hanging Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Hanging Hardware . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

. . . . . . .6-41

Hoses and Flow Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

Breakaway Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44

Testing Hose and Hanging Hardware Continuity . . . . . . . . . . . . . . . . .6-46

Internal Hose Retrievers

Pumping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

and Clamps. . . . . . . . . . . . . . . . . . . . . . . . . .6-48

. . . . . . . . .6-50

GPU Pumping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50

Servicing Strainer Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52

Servicing Pressure Control Valve (PCV) Servicing Bypass/Pressure Relief Servicing Rotor and Shaft Assembly

. . . . . . . . . . . . . . . . . . . . . . . .6-54

Valve (PRV) . . . . . . . . . . . . . . . . . .6-55

. . . . . . . . . . . . . . . . . . . . . . . . . . .6-57

XU2A Pumping Unit for 9850K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58

Sump for 9850K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61

Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Electric Motor for Self-contained Pump Units

. . . . . . . . . . . . . . .6-62

. . . . . . . . .6-62

Belts and Pulleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-63

Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-64

Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .6-65

Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65

Solenoid Valve and Filter Manifold . . . . . . . .

. . . . . . . . . . . . . . . . . . . .6-67

Solenoid Valves for 9 X 40, 9850 and 9 X 53 with 

Satellite Outlet Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-68

Meter Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69

Shear Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-70

T-52A Pressure Regulator Valve Option. . . . . . . . . . . . . . . . . . . . . . . .6-72

Vapor Recovery Stage 2 Balance Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-73

Mechanical Computers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEF Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .6-73

. . . . . . . . .6-74

Nozzle Door Mechanism (Cold Weather Units Only) . . . . . . . . . . . . . .6-74

-72

Page iv MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Table of Contents

7 – Troubleshooting Tables 7-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Topics in This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Troubleshooting Tables (Commercial Electronic and Retail Elec

Sample Troubleshooting Form. . . . . . . . . . .

Priority Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Table 1: Communications to Console . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Table 2: Fuel Delivery (All Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Table 3: Electronic Displays, Electric Reset,

Table 4: Error Codes 10-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Table 5: Handle Responses, Leaks, Noise, and

Table 6: Repeated Problems and STPs. . . . . . . . . . . . . . . . . . . . . . . . 7-10

tronic Units) . . . . . . . . . . . . . . . . . . 7-2

. . . . . . . . . . . . . . . . . . . . . 7-3

and Calibration . . . . . . . . 7-6

Presets (All Units) . . . 7-9

8 – Wiring and Configuration 8-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Topics in This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Cable Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Block Diagram Atlas Commercial (Including DEF and 

E85 Models) M05193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Atlas Hydraulics, Bezel, and Door Configurat

ions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

. . . . . . 8-1

9 – Preventive Maintenance and Inspection 9-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Important Information About Releases. . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Topics in This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

How to Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures and Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Maintenance of Vendor Supplied Parts . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Performing Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Replacements and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Strainer Replacement . . .

Adjusting Belts (Suction Pumps Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Preserving Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preserving Finish of Fueling Equipment . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Preventive Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

. . . . . . 9-1

. . . . . . 9-2

. . . 9-4

. . . . . . . . 9-5

. . . 9-6

Index Index-1

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page v

Table of Contents

This page is intentionally left blank.

Page vi MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Introduction Read This First

1 – Read This First

Introduction

Purpose

This section contains a general introduction, service protocol, safety, and model number information.

Sections of this manual provide start-up and service information for dispensers. This manual is a general service guide and not a replacement for Gasboy certified training. Certified training includes instructions on safety procedures, use of test equipment and common tools, wiring requirements, and electrical service procedures. The sections in this manual cover the following topics:

Topics Page

Read This F Important Safety Information 2-1 Start-up Procedures 3-1 Pump Programming 4-1 Electronic and Electrical Components 5-1 Hydraulic/Mechanical Components 6-1 Troubleshooting Tables 7-1 Wiring and Configuration 8-1 Preventive Maintenance and Inspection 9-1

irst 1-1

Important Information About Releases

Sections of this manual may be released or updated independently to supply the most current data. Information about release date and version for independently released sections will be included in the section title and footer of the document. For the latest updates, refer to Gilbarco Online Documentation (GOLD

Atlas™ pumps and

Atlas

This section was last updated

in July 2013.

Topics in This Section

Topic Page

DEF Special Considerations 1-6

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-1

Read This First Introduction

Who Must Use This Manual

This manual is intended for Gasboy Atlas Authorized Service Contractors (ASCs) who have been trained and certified by attending Gasboy certified training classes. These ASCs must be aware of the safety requirements and basic troubleshooting techniques, such as reading a  volt/ohmmeter, reading pressure, and so on, and understanding the differences

between

various Gasboy Atlas products, options, and functionalities.

If you have not attended the Gasboy training, contact the Gasboy Training Department. For contact information, refer to “

Gasboy Contact Information”.

Service Protocol

A Service Technician requesting technical assistance must do the following:

1 Be available at the site.

2 When placing the call, ensure that the following are available:

• Unit model and serial number

• Site name and telephone number

• Your technician number

• Problem description and history

• All required recommended spare parts

• Manuals available for reference

3 Call the Technical Support Department at 1-800-444-5529. Refer to the Customer Service

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.

Gasboy

Information Required Contact Details

Schedule training Gasboy Training Department

Technical assistance, customer service, and warr

Explanation of Gasboy’s warranty policy For assistance, contact your local Ga T

echnical literature, parts manuals, and other

documents

Contact Information

anty service

TechnicalTraining@gilbarco.com

Gasboy Technical Support at 1-800-444-5529

Helpdesk@gasboy.com

sboy Distributor

y Literature Department at (336) 547-5661

Gasbo

Page 1-2 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Introduction Read This First

Abbreviations and Acronyms

Term Description

API Application Programming Interface ASC Authorized Service Contractor ATC Automatic Temperature Compensation CFN Cash Flow Network CFR Code of Federal Regulations CFT Meter Center Flow Through Meter CPU Central Processing Unit DEF Diesel Exhaust Fluid EC Error Code - a number that identifies an error condition reported by the software ESD Electrostatic Discharge FMS Fuel Management System GOLD Gilbarco Online Documentation GPM Gallons Per Minute GPU Global Pumping Unit I.S Intrinsic Safety LAN Local Area Network LC Liquid Control LCD Liquid C rystal Display LED Light Emitting Diode MOC Major Oil Company NEC National Electrical Code NFPA National Fire Protection Association OSHA Occupational Safety and Health Administration PAM Pump Access Module PCA Printed Circuit Assembly PCB Printed Circuit Board (may be used interchangeably with PCA) PCV Pressure Control Valve PEI Petroleum Equipment Institute PIN Personal Identification Number POS Point of Sale PPG Pulse Per Gallon, of the associated grade PPL Pulse Per Liter, of the associated grade PPP Programmable Pump Preset PPU Price Per Unit (that is, price per gallon or liter) PRV Pressure Relief (Bypass) Valve PSI Pounds (of Pressure) per Square Inch RAM Random Access Memory SAE Society of Automotive Engineers STP Submersible Turbine Pump TCP Transmission Control Protocol

UL UST Underground Storage Tank W&M Weights and Measures

Underwriters’ Laboratories

Page 1-4 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Introduction Read This First

Common Terms Used

Term Description

Allocation Maximum amount of fuel that can be dispensed from a nozzle for a g Cold Start Clears pump and configuration data. Command Code Listing under Command Level for setting software parameters. Command Level A level of programming accessed by PIN(s).

Turbine Pump (STP) in the storage tank to

Dispenser A dispensing unit that relies on an Submer

Diesel Exhaust Fluid (DEF)

Dual Hose Same as Twin Hose. E85 Gasoline ethanol blend with 85% ethanol. Five Button Preset This is a keypad that cont ains five buttons on which the customer

Function Code One or more procedures within a Command Code. Grade Indicates the fuel grade available at the nozzle. In case of blen

Manager Keypad Device within the dispenser for setting programming parameters. Money Display A display that shows the total value of the pro Option Code A choice that is available on entering a Function Code. Product Indicates the base fuel grade available in the stor

Prover Can A calibrated container used by W&M officials and calibrating technicians to accur

Pump Refers to a dispensing unit that has a self-con Side 1 Indicates the electrical acce

Two-wire Proprietary communication system for Atlas 8800 series units Variator The variator section of the computer register(s Volume Display A six-digit display that shows the total volume of prod

send fuel to the dispenser.

clear, colorless, non-toxic, non-flammable, non-combustible liquid. It is made up of 32.5%

A urea with the balance distilled or de-ionized water. Urea and water are completely miscible and do not separate in storage. DEF is mildly corrosive.

value and/or increment or decrement in the selected sale or volume value, before fueling.

created by blending products.

however, in a non-blending environment, a grade is the same as a product.

or calibr

ate meters in a fuel dispenser.

Side 1 of the dispenser.

ss side of the dispenser. The Manager Keypad is accessed from

sible

duct d

ispensed during normal operation.

age t

ank. Not to be confused with “Grade”;

ained suction pump in the unit’s cabinet.

) is exposed to allow for price changes.

uct dispensed during normal operation.

iven transaction.

can enter a predetermined

der dispensers, a grade is

ately check

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-5

Read This First DEF Special Considerations

DEF Special Considerations

Several important considerations exist for DEF. The service technician must be aware of the following when servicing or supporting DEF units:

• DEF is non-flammable or explosive.

• The fluid is slightly corrosive and can damage tools or equipme steel or plastic. It can also damage the electronic components.

• DEF spills can be cleaned with water and a damp rag. may result in corrosive damage to components or metals.

• DEF can cause serious eye injury if sprayed in t skin. Wear protective gloves and eye protection, as required. Flush eyes i mmed iately with water, if sprayed.

• DEF freezes at approximately 11.3 °F (-11.5 °C). If it freezes may permanently damage the meters, valves, breakaways, and possibly other devices. It is extremely important that DEF fluid in the dispenser does not fall below that temperature.

• DEF must not be contaminated with dies Such contamination can cause serious damage to vehicle’s catalytic converters.

• A dedicated stainless steel calibration prover (with SS with DEF to avoid contamination of the product with diesel fuel or gasoline. No exceptions are allowed.

• DEF can be returned to the storage tank only if it is not conta must be disposed of in an environmentally safe manner. Do not dump DEF in storm sewers or any location, where the fluid or its constituents may enter a waterway.

• DEF must never be introduced into diese engine may occur. Only dispense DEF into vehicle tanks dedicated for DEF.

• DEF when stored at temperatures above 100 °F (37.7 °C) may break down into ammonia ga

s over a time. Take care when opening the cabinets, tank vaults, or other areas, where

DEF may have leaked or been spilt to avoid inhaling any toxic ammonia vapors.

• When exposed to air, the water in DEF will evapora crystals. Crystals may be fine and sharp. They will dissolve in water.

• DEF is much heavier than fuels such as gasoline. Be heavier Prover Cans and so on, by following proper safe lifting techniques.

el fuel, contaminants or other fluids or materials.

l fuel tanks or serious damage to the vehicle’s

Failure to thoroughly clean spills

he eyes or may affect those with sensitive

valve, if equipped) must be used

te and result in development of urea

careful to avoid injury when lifting

nt that are not stainless

in hydraulic components, it

minated. Contaminated DEF

Page 1-6 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

DEF Special Considerations Read This First

CAUTION

WARNING

Applicable during Installation and Operation of the Dispenser: DEF freezes at approximately 11 °F (-11.5 °C). Power to the dispenser and heater must always remain ON in cold weather. If power is lost and the temperature drops below this point, the system must be inspected for freeze damage before restart. For sites that experience occasional power losses or for sites that are located in very cold climates, it is recommended that a back up power generator be used to maintain constant power to the dispenser. Do not use any additives to lower the freezing point of DEF. Additives of any type must not be used in DEF.

Prolonged storage at temperatures above 77 °F (25 °C) can impair the quality of DEF and reduce its shelf life.

CAUTION

DEF is mildly corrosive. It can corrode components that are made from incompatible material(s) and reduce their integrity. The use of incompatible material(s) may lead to leaks and spills, and can contaminate and degrade the DEF. When dispensing DEF, verify with the manufacturer if the material of all plumbing components are compatible with the DEF being dispensed.

CAUTION

Do not use Prover Cans meant for engine fuel with DEF or vice versa. Use stainless steel Prover Cans for DEF. DEF and engine fuel must not be mixed with each other or be contaminated by each other. Else, damage to a vehicle’s engine or pollution control devices could occur. DEF crystallizes as its water base evaporates. Pouring out liquid will not guarantee that no corrosive DEF remains in the Prover Can. DEF must not be contaminated with diesel fuel, contaminants, or other fluids or materials. Such contamination can cause serious damage to vehicle catalytic converters.

Troubleshooting DEF Freeze

DEF freezes at approximately 11.3 °F (-1 1.5 °C). If it freezes in hydraulic components, it may permanently damage the meters, valves, breakaways and possibly other devices. It is extremely important that DEF fluid in the dispenser does not fall below that temperature.

If the unit experiences a freeze, it will be required to thaw all components and repair the damage that may have occurred. Units can be thawed using directed exhaust from a vehicle (if no electronic boards are in the area being thawed). Although DEF is non-flammable, diesel fuel is flammable. Therefore, other close proximity heating devices that are non-explosion proof cannot be used. However, before using electrical heating devices with heat extension ducting, ensure that such devices or their power cords are not in hazardous vicinity near diesel, gasoline, other fueling equipment, or hazardous vapors or liquids. To determine any hazard zone involved, consult the installation or service manuals for other equipment. As other damage either missed or not detected may exist, very closely monitor the equipment looking for leaks when the lines are pressurized. Wear eye protection.

• Conventional fluid handling precautions are also applicable to DEF.

• Avoid contact with eyes, skin, and clothing. Ensure that showers are close to the work location.

eyewash stations and safety

• DEF is mildly corrosive and non-flammable.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-7

• Clean the DEF spill with water and dry the area wit contain metallic parts. Spilt DEF can be slippery and will corrode certain types of metallic parts. Wear eye protection and rubber gloves during any cleanup activity.

• DEF is heavier than gasoline. Be aware that Pr so on will be considerably heavier than gasoline.

h clean rags, especially areas that

over Cans, containers filled with DEF, and

Read This First DEF Special Considerations

CAUTION

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

nozzles dispensing E85 fuel and DEF must not be used to dispense any other type of fuel such as Gasoline.

Leaks and potential environmental hazards can result or components may fail prematurely. To avoid these issues, follow the guidelines for dispensing E85 fuel and DEF in this manual.

If DEF Freezes

If DEF freezes, proceed as follows:

1 Remove power to the pump and dispenser.

2 Check for any damage to breakaways, nozzles, hoses/hanging hardware, and meter. Perform

required repairs. Valve damage can often be detected by looking for seals slightly protruding from the valve body (compared to the new valve). Hose breakawa ys may only partially separate.

3 Correct the issue that is causing the loss of heat.

4 Thaw components of the dispenser . Dispenser units can be thawed using directed exhaust from

a vehicle, as long as electronic boards or connections are not present in the area. They can also be thawed using a non-flame heating device.

Notes: 1) Electronic bo ards or connections must not be present in the area wher e you thaw th e

componen electronics.

2) Electrical cords or the heating device mu hazardous area around any fueling pump or dispenser. To identify the designated hazardous area, refer to MDE-4331 Atlas Fuel Systems Installation Manual.

ts of the dispenser, as any resulting condensation may damage the

st not be used within a designated

5 Check for leaks. Some leaks can be significant. You may be required to turn off the unit

immediately.

6 Check if there is any damage to the above ground tank system or heated above ground

plumbing. For assistance, consult the tank manufacturer.

7 For more details on the significance and impact of freezing in DEF, refer to “DEF Heating

System (Commercial Cold We

ather DEF Units Only)” on page 5-55.

Page 1-8 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Important Requirements for E85 Units Read This First

CAUTION

Leaks and potential environmental hazards can result or components may fail prematurely. To avoid these issues, follow the guidelines in this section.

Important Requirements for E85 Units

Following equipment and materials are required to properly install E85 units:

UL-listed E85 Hose (Q13486)

• Veyance

Note: Extended reach hoses are not available for E85 applications.

UL-listed E85 Nozzle (M11298)

21GE

OPW

Note: Approved for use with E85 dispen

UL-listed E85 Swivel (N23748-04)

OPW 241 TPS-0492

Note: Approved for use with E85 dispen

UL-listed E85 Shear Valve (T19695-23)

OPW 10P-0152E85

Note: Approved for use with E85 dispens

Flexsteel™ Futura® Ethan-All for E85

Flexsteel Futura for E25

sers, as required under UL 87A.

ers,

as required under UL 87A.

UL-listed E85 Breakaway (N23010-10)

OPW 66V-0492

Note: Approved for use with E85 dispensers,

as required under UL 87A.

Filter Use only filters specifically marked for use with E85.

UL-listed Pipe Sealant

Use only UL-listed TPS PTFE Pipe Sealant manufactured by

UL-listed Teflon

Tape

SAF-T-LOC International Corp.

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

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

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-9

Read This First Model Information

Boot Area

Total Monetary  Sale Display

Volume Dispensed  Display

Access Door

Door Lock

Nozzle and Pump Handle

On/Off Lever Control

Warning Labels

PPU Display

Monetary Totalizer

Volume Totalizer

Mechanical Retail Unit

Model Information

Mechanical Retail Pump/Dispenser

The external components of a Gasboy pump/dispenser (Mechanical Retail unit) are shown in

Figure 1-1. Mechanical units have mechanical type displays as opposed to electronic di

type displays. In units that

are Commercial instead of Retail, the external components are the same, except that they do not have a Monetary Sale amount, a Price Per Unit (PPU) display, or Monetary Totalizer display.

Figure 1-1: Atlas Mechanical Retail Unit

gital

Page 1-10 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Model Information Read This First

Boot Area

Digital Main Display

PPU

Warning Label

Door Lock

Access Door

Nozzle and Pump Handle

Electro-mechanical Totalizer

Electronic Retail Unit

Volume Dispensed Display

On/Off Lever Control

Electronic Retail Pump/Dispenser

The external components of a Gasboy pump/dispenser (Electronic Retail unit) are shown in

Figure 1-2. Electronic units have digital displays as opposed to mechanical dis

that are Electronic Commercial instead of Retail, the

external components are the same, except

that they do not have a Monetary Sale amount, a PPU display, or Monetary Totalizer display.

Figure 1-2: Atlas Electronic Retail Unit

plays. In units

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-11

Read This First Model Information

Serial Number

Model Number

Serial Number Plate and Date Codes

A two-letter date code is stamped on the serial number plate before the serial number. This code shows the month and year of manufacture. For warranty purposes, refer to the date code to determine the age of the equipment. The serial number plate is locate d on the “A” side at the bottom of the unit attached to the inside of the frame.

To determine the date code on a Gasboy pump or dispenser, refer to the following tables:

Month Codes

A = January E = May J = September B = February F = June K = October C = March G = July L = November D = April H = August M = December

Year Codes

P = 2005 U = 2009 R = 2006 W = 2010 S = 2007 X = 2011 T = 2008 Y = 2012

Figure 1-3: Serial Number/Model Identification

For example, a serial number plate stamped “BP AT000199” contains the following information:

• Date code [BP] - This unit was manufactured in B = February, P = 2005.

• Serial Number [AT000199]

Page 1-12 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Model Information Read This First

Model Series

Series Description

9100K Mechanical Commercial Pumps and Dispensers 9800K Electronic Commercial Pumps and Dispensers 8700K Mechanical Retail Pumps and Dispensers 8800K Electronic Retail Pumps and Dispensers 9860KX Electronic DEF Dispensers Only 9870KX Electronic Commercial Dispensers for Alternative Fuels (E85)

Model Flow Rates

Series Designation (Digits 1 and 2) Flow Rate Designation (Digits 3, 4, and 5) Flow Rate Quantity

91/98/87/88 52K 15 GPM (57 LPM) 91/98/87/88 53K 22 GPM (83 LPM) 91/98/87/88 40K 40 GPM (151 LPM) 98 50K 50 GPM (190 LPM) 98 60K (DEF Only) 10 GPM (38 LPM) 98 72K 15 GPM (57 LPM)

Note: The flow rates shown are under ideal conditions a

involved, Submersible Turbine Pump (STP) sizing, number of units dispensing at the same time, and inlet piping to the unit. These are not guaranteed flow rates.

nd will va

ry depending on the hanging hardware

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. To determine the pump/dispenser type that is denoted on the serial plate, refer to the following table:

Gasboy Atlas Model Code

Retail Model Code Breakdown

8 X X X X X X X X 9 X X X X X X X X

Product Name ATLAS 8 ATLAS 9 Product Series: Product Series:

- Retail, Mechanical

- Retail, Electronic 8 - Satellite 2 Type: - Commercial

- Full Size Cabinet 5 Type: Flow Rates: - Narrow 1

- Ultra-Hi Gallonage (40 to 50 gpm)

- Not used 1 - Full Size Cabinet 4

- Std Gallonage  (10 to 15 gpm)

: Product Name:

7 - Commercial,

™

0 - Compact Cabinet 2

2 - Full Size Cabinet 5

Commercial Model Code Breakdown

Mechanical  Non-computing

onic

Elect

6 7

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-13

Read This First Model Information

Gasboy Atlas Model Code

- Hi Gallonage (18 to 22 gpm)

Hydraulic Series - Ultra-Hi Gallonage

- Murray A - Not used 1

- Gasboy Hydraulics with Gibar

co C meter

- Gilbarco Hydraulics with Center

Flow Through (CFT) Meter

- Tokheim Hydraulics

Pump or Dispenser

- Pump Blank Hydraulics Series:

- Dispenser X - Murray A Hydraulic

Configurat

- 1 Grade, 1 Hose Blank Blank Blank - Improved Gasboy K

- 1 Grade, 2 Hose T W 1 - Tokheim

- 2 Grades, 2 Hoses

- Combo T W 3 - Pump 0

ion

3 Flow Rates:

(

40 to 50 gpm)

Q - Std Gallonage 10

K - Hi Gallonage 18 to

E 215 Standard or

T W 2 Pump or Dispenser

to 15 gpm)

pm)

22 g

High Speed Satellite

- 216 Super or Ultra

-Hi Speed

Satellite

- Gasboy Q

Hydr

aulics

- Dispenser X Hydraulic

nfiguration

- 1 Grade, 1 Hose Blank Blank Blank

- 1 Grade, 2 Hoses T W 1

- 2 Grades, 2 Hoses T W 2

- Combo T W 3

Listing of Atlas Model Suffixes

For information on options that are available for a particular unit, refer to “Atlas Model

Number Table” on page 1-13. Following is a list of some of the opt

some models:

• B - Display Battery Backup

• CX - 10:1 Pulser, Quantity

• CC - 100:1 Pulser, Quantity

• CM - 100:1 Pulser, Money

• D5 - TopKAT PLUS Mounting Kit

• D9 - TopKAT Mounting Kit

• EK - Electric Keytrol

• F - Internal Filter Adapter

• I - Internal Hose Retrievers

• J - Manual Reset (Export Only)

Page 1-14 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

ions that are available on

Model Information Read This First

•K - Hand Crank

• L - Lighted Display Panel

• PP - Slowdown Valve

• PPS - Satellite Internal Piping - 9850K

• R - Liters Registration

• S - Internal Satellite Piping

• SS - Stainless Steel - All Panels

• SSA - Stainless Steel - Front and Back

• SSTS - Stainless Steel - Top and Sides

• TW1 - Dual Hose Single Product

• TW2 - Dual Hose Dual Product

• TW3 - Satellite Combo Unit

• V - Vapor Recovery Complete

• WW - Warm Weather (DEF Units Only)

• X - Remote Dispenser

• Y - Vapor Recovery Ready

• Z - Front Load Nozzle Boot

• 25 - 230 VAC, 50 Hz

• 35 - 380 VAC, 50 Hz

• 36 - 380 VAC, 60 Hz

Options Overview

This section provides an overview of the options available in Atlas dispensers.

TopKAT

The TopKAT Fuel Management System (FMS) can be ordered factory mounted on any 9800 unit except Atlas DEF dispenser. TopKAT PLUS FMS can be ordered factory mounted on any 9800 unit. This Plug and Play option increases the ease of installation and provides customers with a user-friendly fuel reporting system. The TopKAT system is also available as a pedestal mounted unit and for use with Mechanical pumps.

Electric Keytrol (EK)

The Electric Keytrol can be ordered factory mounted on the 9100 series. The EK provides each customer with a personal key slot and totalizer to record their fueling amounts. Configurations are available for both single and twin units.

Vapor Recovery

Balanced Vapor Recovery kits are available for all the K pump units except Atlas DEF and E85 dispensers. Following two kits are available:

• Vapor Recovery Complete

•Vapor Recovery

The Vapor Recovery Complete k the high hose retriever to the splitter, all the way to the nozzle.

it provides everything required for a balanced system from

The Vapor Recovery kit i s a retrofit kit used when p roviding your own vapor recovery system. This kit will provide a new nozzle boot and hook to allow a stage two nozzle to be mounted on the dispenser.

High Hose Retriever

High Hose Retrievers are also available for standard hoses. Hose clamps are available for a variety of hose sizes, up to lengths of 15 inches.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 1-15

Read This First Model Information

Internal Hose Retriever

Internal Hose Retrievers are also available for all Atlas pump models. The Atlas DEF cold weather unit has a built-in hose reel.

Satellite Piping

Satellite Piping is available on the 9850 pump and all remote dispensers except Atlas DEF and E85 dispensers. This option will provide the internal piping required to connect to a 9215 or 9216 satellite dispenser.

Hand Crank

Hand Cranks are available for installations in locations, where power availability is a concern. This option is only available for suction pumps.

Solenoid Valve

A two-stage slow down valve is available for units in retail applications. This option is standard on all remote dispensers.

Pulse Output

Pulse output is available for all the 9800 pump models and some 8800 models. The pulse

output board for the 8800 model will be different from the 9800 model. Veeder-Root will be provided for mechanical units, when specified. An additional pulse output board must be ordered when connecting an Electronic unit to an FMS requiring mechanical type pulses. Factory installation as well as field retrofit kits will be available for all pulse output options.

pulsers

RS-485 Interface

When connecting a 9800 model to a Gasboy Cash Flow Network (CFN), TopKAT PLUS or T opKAT system, an RS-485 Interface Board must be installed in the unit. The interface can be ordered and installed at the factory. Field installation kits are also available.

Note: The RS-485 Interface Board is not

available for the 8800 model.

Local Area Network (LAN) Interface

When a T op KAT PLUS is mounted on the 9800 model, a LAN cable is factory installed with a LAN jack at the end in the Junction Box (J-box) for Transmission Control Protocol/Internet Protocol (TCP/IP) communications.

Battery-backed Power Supply

Until summer of 2012, a battery-backed power supply was an option for all the 9800 models. This option was required for units used in a Retail application. If power was lost to the unit, the battery allowed the last transaction amount to remain on the display to meet Weights and Measures (W&M) requirements. The 8800 series and current 9800 series displays are backed up by a super cap that performs this function at the display.

Manual Reset

Manual resets are available for mechanical units and export orders only.

Page 1-16 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

2 – Important Safety Information

The EMERGENCY STOP, ALL STOP, and PUMP STOP buttons at the cashier ’s station WILL NOT shut off electrical power to the  pump/dispenser. This means that even if you activate these stops, fuel may continue to flow uncontrolled.

You must use the TOTAL ELECTRICAL  SHUT-OFF in th e cas e of an emerge nc y a nd not the console’s ALL STOP and PUMP STOP or similar keys.

WARNING

Important Safety Information

Notes: 1) Save this Important Safety Information section

in a readily accessible location.

2) Although DEF is non-flammable, diesel is flammable. Therefore, for DEF cabine ts that are attached to diesel dispensers, follow all the notes in this section that pertain to flammable fuels.

This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death o r serious injury, if these safe service procedures are not followed.

Preliminary Precautions

You are working in a potentially dangerous environment of flammable fuels, vapors, and high voltage or pressures. Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment.

Emergency Total Electrical Shut-Off

The first and most important information you must know is how to stop all fuel flow to the pump/dispenser and island. Locate the switch or circuit breakers that shut off all power to all fueling equipment, dispensing devices, and Submerged Turbine Pumps (STPs).

Read the Manual

Read, understand and follow this manua l and any other labels or related materials supplied with this equipment. If you do not understand a procedure, call a Gasboy Authorized Serv ice Contractor or call the Gasboy Support Center at  1-800-444-5529. It is imperative to your safety and the safe ty of othe

rs to understand the procedures before beginning wo rk.

Follow the Regulations

Applicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Fuel Dispensing

Facilities and Repair Garages, NFPA 70; National Electrical Code (NEC), Occupatio nal Safety and Health Administration

(OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gasboy replacement p art s and re trofit kits on your pump/dispenser. Using parts other than genuine Gasboy replacement parts could create a safe ty hazard and violate local regulations.

Safety Symbols and Warning Words

This section provides important information about warning symbols and boxes.

Alert Symbol

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical component s or the electronics of the dispenser requires total electrical shut off of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gasboy equipment.

Evacuating, Barricading and Shutting Off

Any procedure that requires access to the pump/dispenser or STPs requires the following actions:

• An evacuation of all unauthorized persons and vehicles from the work area

• Use of safety tape, cones or barricades at the affected unit(s)

• A total electrical shut-off of the affected unit(s)

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 2-1

This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prev safety directives that follow this symbol to avoid possib le inj ury or death.

ent potential personal safety hazards. Obey

Signal Words

These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions below must be followed to prevent death, injury or damage to the equipment:

DANGER: Alerts y

which will result in death or serious injury.

WARNING: Alert

that could result in death or serious injury.

CAUTION with Alert symbol: Designates a hazard or

safe practice which may result in minor injury. CAUTION wi unsafe practice which may result in property or equipment damage.

ou to a hazard or unsafe practice

you to a hazard or unsafe practice

thout Alert symbol: Designates a ha zard or

Working With Fuels and Electrical Energy

Prevent Explosions and Fires

Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island.

DEF is non-flammable. Therefore, explos warnings do not apply to DEF fluid lines.

ion and fire safety

Important Safety Information

The pump/dispenser contains a chemical known to the State of California to cause cancer.

WARNING

The pump/dispenser contains a chemical known to the State of California to ca use birth defects or other reproductive harm.

WARNING

Gasoline/DEF ingested may cause unconsciousness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately.

DEF generates ammonia gas at high er temperatures. When opening enclosed panels, allow the unit to air out to avoid breathing vapors. If respiratory difficulties develop, move victim away from source of exposure and into fresh air. If symptoms persist, seek medical attention.

WARNING

Gasoline inhaled may cause unconsciousness and burns to lips, mouth and lungs. Keep airway open. Seek medical advice immediately.

WARNING

Gasoline/DEF spilled in eyes may cause burns to eye tissue. Irrigate eyes with water for approximately  15 minutes. Seek medical advice immediately.

WARNING

Gasoline/DEF spilled on skin may cause burns. Wash area thoroughly with clear water. Seek medical advice immediately.

WARNING

DEF is mildly corrosive. Avoid cont act with eyes , skin, and clothing. Ensure that eyewash stations and safety showers are close to the work location. Seek medical advice/recommended treatment if DEF spills into eyes.

WARNING

No Open Fire

Open flames from matches, lighters, welding torches or

other sources can ignite fuels an

d their vapors.

No Sparks - No Smoking

Sparks from st arting vehicles, starting or using power tools, burning cigarettes, cigars or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic charge on your body, can cause a spark sufficient to ignite fuel vapors. Every time you get out of a vehicle, touch the metal of your vehicle, to discharge any electrostatic charge before you approach the dispenser island.

Working Alone

It is highly recommended that someone who is capable of rendering first aid be present during servicing. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages. This information is available from the American Red Cross . Alw ay s advise the station personnel about where you will be working, and caution them not to activate power while you are working on the equipment. Use the OSHA Lockout/Tagout procedures. If you are not familiar with this requirement, refer to this information in the service manual and OSHA documentation.

In an Emergency

Inform Emergency Personnel

Compile the following information and inform emergency personnel:

ple,

• Location of accident (for exam building, and so on)

• Nature of accident (for example over by car, burn s, and so on)

• Age of victim (for example, baby, teenager, middle-age,

derly)

• Whether or not victim has received first aid (for example,

opped bleeding by pressure, and so on)

• Whether or not a victim has vomited (for example, if

lowed or inhaled something, and so on)

address, front/back of

possible heart attack, run

Working With Electricity Safely

Ensure that you use safe and established practices in working with electrical devices. Poorly wired devices may cause a fire, explosion or electrical shock. Ensure that grounding connections are properly made. Take care that sealing devices and compounds are in place. Ensure that you do not pinch wires when replacing covers. Follow OSHA Lockout/Tagout requirements. Station employees and service contractors need to understand and comply with this program completely to ensure safety while the equipment is down.

Hazardous Materials

Some materials present inside electronic enclosures may present a health hazard if not handled correctly . Ensure that you clean hands after handling equipment. Do not place any equipment in the mouth.

Page 2-2 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or st art-up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. Lockout/Tagout applies to all mechanical, hydraulic, chemical, or other energy, but does not cover electrical hazards. Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 1910.333 contains specific Lockout/Tagout provision for electrical hazards.

Hazards and Actions

WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a serious hazard. Fire or explosion may result, causing serious injury or death. Follow established emergency procedures.

DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.

Collision of a Vehicle with Unit Fire at Island Fuel Spill

The following actions are recommended regarding these hazards:

Important Safety Information

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

• Use station EMERGENCY CUTOFF immediately. Turn off all system

• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not remove

• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow open flames, smoking or power tools in the area.

• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.

• Call emergency numbers.

AC power and do not always stop product flow.

circuit breakers to the island(s).

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 2-3

Important Safety Information

This page is intentionally left blank.

Page 2-4 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Introduction Start-up Procedures

3 – 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 warranty is registered properly. It is also recommended that you follow this procedure outside the United States.

The start-up process and checklists are used to ensure that the unit( properly.

Important Information About Releases

This section was last updated

in July 2013.

Topics in This Section

Topic Page

Certificate of Conformance (CoC) Numbers 3-1 Start-up Checklists 3-2 Meter Calibration 3-4

How to Use This Section

Make copies of the installation checklist found in MDE-4331 Atlas Fuel Systems Installation Manual to ensure that all units have been installed correctly and function properly.

s) are installed and function

Certificate of Conformance (CoC) Numbers

CoC numbers are required during installation and start-up of new sites. You may be asked for these numbers by a W&M official. For information on CoC numbers, refer to the cover page of this document.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 3-1

Start-up Procedures Start-up Checklists

Start-up Checklists

Installation Checklists

To ensure proper and safe operation of all equipment and to maintain warranty coverage, it is required that the checklist be completed at this time. Many of the items on the list must have been checked by the electrician already . Forms must be provided with each unit; if not, contact the Gasboy Atlas Distributor. Make copies of the checklists for use in the field, to preserve originals for future use.

Mechanical and Hydraulic Related Items Checklist

Item Procedure Refer To Checked

1 Shear valves must be installed as per the va

recommendations. Shear point is ±0.75-inch of grade and properly mounted.

2 Flexible pipes must not be used within the dispenser

flexible pipes meeting local and state pump/dispenser, when allowed by regulatory authorities.

3 Pumps (self-contained units) must have a vacuum actuated pressure

eve

regulating valve to pr

used with above ground tanks. 4 Pumps require a check valve. MDE-4333 Atlas Fuel Systems Site Prep Manual 5 Hose breakaways must be used and installed as per the

recommendations. For units with retrievers, breakaways, and whip

hoses, hose breakaways must be attached to the nozzle end. For units

without retrievers, the hose breakaway is attached to the dispenser end. 6 The unit must be anchored to the island properly. 7 Vapor recovery piping at the pump/dispenser must have no traps or

sag 8 Verify if there are correct nozzles, piping, and brand p

grade. 9 All code, regulatory agency, or customer specified safety warning signs,

lab

els, or decals have been installed.

10 Long hose lengths beyond Gasboy Atlas recommendations must not be

used without special retr

6 inches of hose length may rest on the ground when nozzle is resting in

r balance vapor recovery, no portion of the hose may be on the

boot. Fo

ground. 11 The unit is mounted using the proper quantity, size, and strength

mounting hard 12 The unit must pump fuel, as calibrated. All displays show

calibrated parameters must be accurate. 13 The pump must have a vertical lift of no more than 11 feet to deliver the

fuel. 14 The conduit used in the pump to deliver fuel must be of appropriate

eter.

dia 15 The distance of the pump from the under ground tank must not exceed

50 feet.

nt positive pressure at the pump base, when

ievers; for VaporVac

are.

lve manufacturer’s

. However, 

codes can be used below the

manufacturer’s

anels for each

hoses, no more than 

ing the

MDE-4333 Atlas Fuel Systems Site Prep Manual

Manufacturer’s specifications

Unit order specific

As provided with and for unit

NFPA 30A

Page 3-2 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Start-up Checklists Start-up Procedures

Electrical Related Items Checklist

Item Procedure Refer To Checked

1 Equipment must be installed in conjunction with an

emergency p

ower cut-off to shut off all power from the

equipment in case of an emergency.

2 STP isolation relays are required for all dispensers.

res as specified for

3 Re tail 8800 only: Use twisted-pair w

i two-wire communication for new installations or where new wire is pulled. Do not use a shielded wire.

4 All wir ing must be stranded copper of the gauge and

insulation casing specified.

5 All grounds must be properly connected as per the

allation manual req

inst

uirements as well as state, local,

and national codes.

6 Co nduit must be approved for hazardous locations and

properly size

d for the wiring involved.

7 Properly size all circuit breakers for the units/unit options

involved.

8 All pump/dispenser wiring must be properly spaced and

ated from wiring for electrically noisy devices such as

isol variable speed STPs, station equipment motors, and other devices.

tlas

9 All po wer wiring and circuit breakers to Gasboy

A equipment must be dedicated and not be shared with other equipment.

10 At temperatures below 15 °F (-9.44 °C) for DEF units filled

must b

with fluid, power

e supplied to the DEF heater as

well as for external plumbing.

11 All circuit breakers to Gasboy Atlas equipment must be

arly labeled and readily accessible.

cle

12 All D

showing the pu

istribution Boxes (D-Boxes) must be clear

mp/dispenser number connections.

ly labeled

13 All pumps/dispensers must be wired to the same phase of

electrical powe

14 New site wiring must be Megger

tested. Old site wiring

must be continuity and short-tested with a digital meter.

15 Wiring color must be coded or tagged, sized for distance

application

and

, and resistant to gas and oil.

16 Remove all tie-wraps securing pulsers and ensure that the

ble to

pulser is a

float (pumps).

17 Confirm proper wiring, if used with a Gasboy FMS (using

the appropr

iate FMS installation manual).

• MDE-4333 Atlas Fuel Systems Site Prep Manual

• FE-356 Atlas Pump and Dispenser Field Wiring

• FE-357 Atlas Pump Retail/Commercial Field Wiring

MDE-4331 Atlas Fuel Systems Installation Manual

• NFPA 30A

•NFPA 70

• UL 87

•NEC NEC and local codes

MDE-4333 Atlas Fuel Systems Site Prep Manual

• MDE-4811 Islander PLUS and ICR PLUS Installation Manual

• MDE-4298 CFN Series Site Controller III Installation Manual

• MDE-4319 TopKAT Fuel Management System

allation Manual

Inst

• MDE-4813

CFN Plus Installation Manual

• For Atlas units with the D5 TopKAT PLUS option, refer to

13 T

MDE-50

opKAT PLUS Installation Manual.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 3-3

Start-up Procedures Meter Calibration

Meter Calibration

Calibrate all the units before their use by customers. For instructions on calibrating units, refer to “Hydraulic/Mechanica

DEF and E85 units are electronically calibrated. For calibrating DEF/E85 units (ECAL procedure), refer

to MDE-4331 Atlas Fuel Systems Installation Manual.

l Components” on page 6-1.

Note: DEF units must be purged properly befor

Incomplete purging of air can result in inaccurate calibration or errors in calibration verification testing. Improper purging can cause damage to meters and shorten their life. DEF units create special difficulties regarding purging, especially because of the ability of the fluid to hold air and commonly the pumps used with the devices have no air separation capability. Overhead plumbing is especially troublesome.

Gasboy Atlas (Gallon Unit of Measure)

For Gasboy Retail unit, temporary pricing must have already been entered into the unit as outlined in “Purging Air from System” on page 6-9 to allow dispensing and calibration.

Current production Gasboy Atlas pumps/dispensers, excluding units desig ned for DEF or E85 are tested using US gallons default programming values. Retail units may be operated and purged in normal mode after entering prices. On retail units, purging can be done for units eventually, to be converted to metric mode while the unit is in gallon mode.

(calibration verification is still required) and programmed to

e calibration or calibration verification.

Page 3-4 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Introduction Pump Programming

Atlas

TURN OFF ENGINE

4 – 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. Retail units may also show the cost of the fuel dispensed.

Important Information About Releases

This section was last updated

in July 2013.

Programming Overview

The purpose of this overview is to show the display characteristics that allow visual reference for identifying each series of pumps and dispensers. This is accompanied by a brief description of the programming methods. For detailed information, refer to “Configuring 9800 Series” on

page 4-3, “Programming 8800 Series Units” on page 4-1 1, and “Programming 8700 Series Units” on page 4-27.

9800 Series Electronic Commercial Units

9800 Gasboy Atlas series Electronic Commercial 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 Fleet Plus, Gasboy CFN, or TopKAT Fuel Control System. Configuring 9800 series units is done by selecting switch and jump jack (if applicable) settings on the Central Processing Unit (CPU) Board. These switches control the operation mode, timeout control, addressing, and pulse rates. The type of display associated with the 9800 series units is shown in Figure 4-1.

Figure 4-1: Electronic Commercial Display

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-1

Pump Programming Programming Overview

Atlas

TURN OFF ENGINE

Total Sale

Gallons

Total Sale

Gallons

8800 Series Electronic Retail Units

The 8800 series Electronic Retail units perform with options such as sale control, totals maintenance, preset, Automatic Temperature Compensation (ATC) functions,  electro-mechanical totalizers, and so on. External communication two-wire communication system, which

is used or can be used by a host of Point of Sale (POS)/controllers as manufactured by Gasboy, Gilbarco, Ruby Verifone 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.

utilizes a proprietary 

, Allied, and other

Programming of the Electronic Retail units is accomplis

hed using three levels of command

codes:

• Level 1 codes are potentially used by station pers

onnel but also useful at times, during

service.

• Level 2 codes are higher level codes typically intended for

the ASC in programming the

unit for desired operation.

• Level 3 codes are the highest level reserved for un

it configuration and changing Personal Identification Number (PIN) codes. All levels require entry of a PIN code before access. These codes can be changed for station security. However, losing the codes will require a master reset of the unit and reprogramming. Most codes have a default setting.

Figure 4-2: Electronic Retail Display

Page 4-2 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Configuring 9800 Series Pump Programming

Atlas

TURN OFF ENGINE

Total Sale

Gallons

Total Sale

Gallons

Mechanical Commercial Units

The 9100 and 8700 series units use a mechanical computing device. On 8700 series, prices are set on the mechanical units by adjusting the Variator. Besides the instructions in this manual, there are instructions on the base of the Variator assembly also.

Figure 4-3: Mechanical Commercial Display

Configuring 9800 Series

The 9800 series (Electronic Commercial) can be configured for various operating conditions by setting the switch(es) and jump jacks (if applicable) located on the CPU Printed Circuit Assembly (PCA).

General Configuration Details

The 9800 series units can be configured for various operating conditions using the switch(es) and jump jacks (if applicable) located on the CPU PCA. Check these switch(es) and jump jacks (if applicable) and change their settings, if required. Switch and jump jack (if applicable) settings must be changed only when power is shut off. The new settings are read by the CPU PCA when power is restored.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-3

Pump Programming Configuring 9800 Series

Loosen and remove the screws. Keep for reinstallation.

Note: Display unit will swing forward and down after screws are removed.

To change the switch and jump jack (if applicable) settings, access the CPU Board by removing the front panel and then remove the screws shown in Figure 4-4.

Figure 4-4: Access to CPU Board

Figure 4-5: Previous Atlas 9800K CPU (M053 46A00X, C06391-C06394, and 

C06500-C06503)

Page 4-4 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Configuring 9800 Series Pump Programming

Figure 4-6: Current Atlas 9800 CPU (M06333KXXXX)

Configuration Steps

This section provides steps for configuring the 9800 series (Electronic Commercial) for various operating conditions.

Baud Rate (JP1 on M06333KXXXX CPU and SW1-1 on Previous CPU)

This jumper/switch selects the baud rate for RS-485 communications. The Gasboy CFN System and TopKAT Electronic System communicate at 9600 baud.

Baud Rate JP1/SW1-1

1200 Jumpered/Closed 9600 Open

Mode (JP2 on M06333KXXXX CPU and SW1-2 on Previous CPU)

This jumper/switch selects the mode in which the pump/dispenser operates. Set the mode to “Online” if the pump/dispenser communicates through a RS-485 I/F (for example, to a controlling Gasboy CFN, TopKAT Electronic System). Set the mode to “Standalone” for all others including Pulse-out I/F configurations (for example, Pulse-out to a Gasboy Series 1000 FMS or TopKAT Mechanical System or non-Gasboy systems) or no controlling system.

Mode JP2/SW1-2

Standalone Jumpered/Closed Online Open

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-5

Pump Programming Configuring 9800 Series

Leak Detect Delay (JP3, JP4 on M06333KXXXX CPU and SW1-3, SW1-4 on Previous CPU)

These jumpers/switches select the delay time used by leak detectors in submersible pump applications. The delay time is the period between the activation of the submersible pump and activation of the slow flow valve. The delay time must be set according to the type of leak detector installed on the submersible pump to allow a normal leak test for each transaction. The delay time must be set to 0 seconds for suction pumps.

Delay Time JP3/SW1-3 JP4/SW1-4

0 seconds Jumpered/Closed Jumpered/Closed 4 seconds Jumpered/Closed Open 5 seconds Open Jumpered/Closed 6 seconds Open Open

Hose Pressurization (JP5 on M06333KXXXX CPU and SW1-5 on Previous CPU)

For US Gallons (always in Hose Pressurization mode), this jumper/switch is ignored. This  jumper/switch is used to determine if hose pressurization is used. If enabled, the slow flow valve is opened before reset is complete, dispensing begins.

to allow the hose to be pressurized before fuel

Pressurization JP5/SW1-5

Enabled Jumpered/Closed Disabled Open

Authorization (JP6 on M06333KXXXX CPU and SW1-6 on Previous CPU)

This jumper/switch allows activation or non-activation of the pump/dispenser from an external source (for example, Pulse-out I/F configurations). When jumpered (closed), a 115/230 VAC signal must be present on the Control Feed/AUTH line (for your model pump/dispenser, refer to the wiring diagram) for pump activation to occur (required setting for Gasboy Series 1000, T opKAT Mechanical and all non-Gasboy systems). When open, the Control Feed line signal is ignored [normal setting for online mode communicating through an RS-485 I/F (TopKAT Electronic System, CFN System) or standalone mode].

Authorization JP6/SW1-6

Enabled Jumpered/Closed Disabled Open

Note: For JP6 authorization, in standalone mode, the Auth Signal mu st be p resent to activate

the pump.

Page 4-6 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Configuring 9800 Series Pump Programming

Electronic Totalizers (JP7 on M06333KXXXX CPU and SW1-7 on Previous CPU)

This jumper/switch must be open for normal operation (electronic totals protected). When jumpered (closed), this allows the electronic totals to be reset.

Totalizers JP7/SW1-7

Reset Jumpered/Closed Normal Open

Pump Disable Detection (JP8 on M06333KXXXX CPU SW1-8 on Previous CPU)

This jumper/switch allows the pump/dispenser to detect or ignore a pump disable (RS-485 protocol break character). When detection is enabled, the pump/dispenser will monitor the  RS-485 communications for a protocol break character progress will be halted and then completed. This setting must only be used when the  pump/dispenser is communicating to a Gasboy CFN system. When Gasboy TopKAT or Fleet Plus system, or when in standalone mode including Pulse-out I/F configurations, the setting must be disabled as shown in the following table:

Detection JP8/SW1-8

Disabled Jumpered/Closed Enabled Open

. When received, any transaction in

communicating to a

JP9 (Only on M06333KXXXX CPU)

JP9 is a spare jump jack and is not used. The M06333KXXXX CPU Board can also be configured for

various operating conditions using the switch positions SW2-1 through SW2-10. The previous CPU only uses SW2-1 through SW2-4. Check these switches and change, if required. Switch settings must be changed with the power to the pump/dispenser “Off”. The CPU Board only reads new switch settings during power-up.

Note: A switch in the Closed position indicates that the switch i

“On” (towards the center of

the CPU Board).

SW2-1 Through SW2-4 (Identical for M06333KXXXX CPU and Previous CPU)

These four switches serve a dual purpose: as an address setting when communicating through  RS-485 I/F (for example, Online mode with CFN systems, To Fleet Plus system, or Islander II system), or as a pulser output rate selector when in Pul I/F configuration (for example, Gasboy Series 1000 FMS).

Address Switches (If JP2 on M06333KXXXX CPU or SW1-2 on Previous CPU is Open)

A unique address identifier must be set when the pump/dispenser is communicat the

RS-485 interface. The unique address must correspond to the address of a unique PCU of a Gasboy CFN, Islander II, Fleet Plus, or TopKAT Electronic system. There are 16 possible address combinations; up to 16 pumps (single or twin) can be connected through RS-485 interface. Addressing must start at 1 and continue sequentially through 16. The physical wiring order does not have to correspond with the address order, that is, the first  pump/dispenser on the RS-485 does not have to be address 1.

pKAT Electronic system, 

se-out

ing through

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-7

Pump Programming Configuring 9800 Series

Address SW2-1 SW2-2 SW2-3 SW2-4

1 Closed Closed Closed Closed 2 Open Closed Closed Closed 3 Closed Open Closed Closed 4 Open Open Closed Closed 5 Closed Closed Open Closed 6 Open Closed Open Closed 7 Closed Open Open Closed 8 Open Open Open Closed 9 Closed Closed Closed Open 10 Open Closed Closed Open 11 Closed Open Closed Open 12 Open Open Closed Open 13 Closed Closed Open Open 14 Open Closed Open Open 15 Closed Open Open Open 16 Open Open Open Open

Pulse Output Rate Switches (If JP2 on M06333KXXXX CPU is Jumpered or SW1-2 on Previous CPU is Closed)

When the pump/dispenser is connected to an external controlling equipment other than CFN System, Fleet Plus 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 through the Pulse-out Interface Board. Setting

es SW2-1 through SW2-3 configures the Pulse-out rate required by the monitoring

switch equipment. The Pulse-out rate represents the pulses per unit (gallon, liter, or imperial gallon). SW2 may require to be sealed by a W&M paper seal if the unit is used for resale of the product.

Pulse Rate SW2-1 SW2-2 SW2-3

1:1 Closed Closed Closed 10:1 Open Closed Closed 100:1 Closed Open Closed 250:1 Open Open Closed 500:1 Closed Closed Open None Open Closed Open None Closed Open Open None Open Open Open

The maximum pulse output rate that can be achieved depends on the model of the pump/dispenser and the unit of measure. Pulse output rate o

f 1000:1 is not supported.

Page 4-8 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Configuring 9800 Series Pump Programming

Note: 9800 refers to models 9852, 9853, 9822, and 9823.

Unit of Measure 9800 Models 9840A/Q Models 9840K Models 9850 Models

US Gallons 500:1 500:1 500:1 100:1 Liters 100:1 100:1 10:1 10:1 Imperial Gallons 500:1 500:1 500:1 100:1

Note: If a valid Pulse-out rate is not selected, the M06333KXXXX CPU will not output pulses.

Leading zeros are always suppressed in the tens an

d hundreds place to the left of the decimal point. In the Standalone mode, positions to the right of the decimal point are displayed based on the pulse output rate and unit of measure selected as shown in the following table:

Pulse Rate Gallons - US or Imperial Liters and/or 9850

1:1 10:1 100:1 XXX.XX XXXX.XX 250:1 XXX.XXX XXXX.XX 500:1 XXX.XXX XXXX.XX

XXX. XXXX. XXX.X XXXX.X

Timeout Switch (If JP2 on M06333KXXXX CPU is Jumpered or SW1-2 on Previous CPU is Closed)

When the pump/dispenser is in the standalone mode including Pulse-out

I/F configurat

ions, it will turn off an active hose outlet if it does not detect input pulses for 4 minutes and 15 seconds.

Timeout SW2-4

Enabled Closed Disabled Open

SW2-5 and SW2-6 - Unit of Measure Selection (Only on M06333KXXXX CPU)

These two switches set the unit of measure (US gallons, liters, or Imperial gallons) that the pump/dispenser will be using to meter fuel.

Unit of Measure SW2-5 SW2-6

US Gallons Closed Closed Liters Open Closed Imperial Gallons Closed Open NOT USED (default US Gallons) Open Open

SW2-7 - Electro-mechanical Totalizer Enable (Only on M06333KXXXX CPU)

This switch is only used on K model pumps/dispensers (excluding the 9850K model). When closed (“On”), it enables the pump/dispenser to drive electro-mechanical totalizers used on some K model pump. On A and Q models, this switch is ignored.

EM Totalizer SW2-7

Enabled Closed Disabled Open

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-9

Pump Programming Configuring 9800 Series

SW2-8 - Background Debug Module (BDM) Enable (Only on M06333KXXXX CPU)

This switch must be OPEN for normal operation.

SW2-9 - Software Load Enable (Only on M06333KXXXX CPU)

This switch must be OPEN for normal operation. When this switch is closed, it enables lo ading the new M06333KXXXX CPU software.

SW2-10 (Only on M06333KXXXX CPU)

This switch is not used. Set to the Open position.

ATC Setup

When you activate the magnet located at the opposite side of the totalizer, following items appear on the display:

Display Name Example Display Description

Volume 0023043 Uncompensated volume Probe Temperature 023.2 Probe temperature in Celsius only Flow Rate 189.2 Flow rate (in LPM only) Software Version 1.30 Software version number ATC Status 842.2 Automatic Temperature Compensation

On the status display, the rightmost digit (2) indicates whether the temperature compensation is enabled or not, and if so, the product that is being dispensed. Following digits indicate the settings that have been enabled:

• 0 = Temperature compensation enabled

• 1 = Product is gasoline and compensation is enabled

• 2 = Product is diesel and compensation is enabled

On the status display, the leftmost digits (842) a

re error indicators, which are blank when the corresponding error condition is not active. 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

Setting DIP Switches

DIP Switch Settings

Switch

er Switch Function Settings for Existing and Model 9850K

Numb

1 Product 1 ON for Diesel, OFF for Gasoline ON for Diesel, OFF for

2 Product 2 ON for Diesel, OFF for Gasoline ON for Diesel, OFF for

3 Not Used N/A N/A 4 Unit of Measure N/A ON for Liters, OFF for Gallons 5 Pulser Multiplier ON for 9850 and 9850K, OFF for 9852/9853 N/A 6 Number of Probes ON for two (2) probes, OFF for one (1) probe ON for two (2) probes, OFF for

Settings for Models 9840K, 9852K, 9853K

Gasol

Gasoli

e (1)

probe

Page 4-10 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

DIP Switch Settings

Switch Number Switch Function Settings for Existing and Model 9850K

7 Pulser Adder ON for 9840 ON for 9840K 8 ATC ON for ATC ON, OFF for ATC OFF ON for ATC ON, OFF for ATC

Settings for Models 9840K, 9852K, 9853K

Error Codes

When operating the pump/dispenser, the 9800 series unit shows a two or three digit error transaction code on the LCD display when transactions are terminated abnormally (that is, other than turning the pump handle off).

The error codes are displayed for two seconds at the left of the LCD window, alternating with a five-second display of the l new transaction begins. When an error occurs, note the error code and relay the information to the system administrator.

Code Condition

RAM failure

01 02 ROM failure 55 Power failure 56 Pulser error 57 Timed out 58 Limit cutoff 59 Flow error meter 1 (9840 only) 60 Flow error meter 2 (9840 only) 99 Frozen error (9860 only) 993 Calibration error (9860 or 9870 only)

ast sale amount. The display alternates between the two until a

The error codes are displayed for two seconds at the left of the LCD window, alternating with a five second display of the last sale amount. The display alternates between the two until a new transaction begins. In case of a 993 error, a new transaction will NOT start until the error is cleared. 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.

Note: Error Codes for the Atlas DEF units can be

found in MDE-4331 Atlas Fuel Systems

Installation Manual.

Programming 8800 Series Units

For 8800 series units, the programming mode can only be entered when both sides of the dispenser are in an idle mode, using the Manager Keypad. The nozzles must be in the nozzle boots. Dispenser programming results in the unit being placed offline with regard to external communications. Dispenser programming is started by pressing F1 on the Manager Keypad. Following sub-sections describe general dispenser operation while in programming mode.

At each level, the PIN code must be entered. A any programming process.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-11

fter you are in the third level, you can access

Pump Programming Programming 8800 Series Units

AT_PumpPCA_controller

P206

P207

P208

P201

P204

P203

P202

P205

JP1

General Programming Details

Action Cash Display LSD in Volume Display

F1 1 2222 0000 1 ENTER

Repeats for Level 2 10 10 ENTER 2 1503 0000 2 ENTER

Repeats for Level 3 17 17 ENTER 3 1309 0000 3 ENTER 88888 Flashing

Notes: 1) It is important to note that each programming level utilizes a unique set of

programming codes. The reason for this is to allow room for future expansion of programming features. Function codes within a command code begin at 1.

88888 Flashing

2) After the highest level security code has been enter

Entry into a command code will present data in either the

ed, you can access all levels.

DEFAULT format or last programmed values for that command code. Only one command code and function  code/parameter may be programmed/changed at a time.

Figure 4-7 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.

Figure 4-7: Pump Controller (T20092)

Page 4-12 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

123

456 789

ENTER

TOTAL

VOL.

TOTAL

CLEAR

S0000304

Manager Keypad Details

Figure 4-8 shows the Manager keypad details.

Figure 4-8: Manager Keypad Layout

Manager Keypad Key Definitions and Use

Key(s) Definition/Use

0-9 Numeric Values

F1 Function 1 – Used to start dispenser programming

codes. In general, each depression of F1 will take you back to a previous programming function selection. Pressing F1 from the normal dispenser state will always initiate the Programming mode.

Note that displays are always activated during the Programming mode. F2 Function 2 – Used to exit the programming mode and return to normal mode. $Totals Money Tot als – Used to display money tot

code. Clear is used to exit the Money Totals mode. Vol. Total Volume Totals – Used to display volume totals by side and grade. This key does not require a

ENTER Value entry keys – Sends the entered value to the pump. CLEAR Clear key – Used to clear the last keypad entry, and exit the Money and Volume Totals mode.

ty code. Clear key is used to exit the Volume Totals mode.

secur

als by side and grade. Th

nd sequence among programming and function

is key does not require a security

Programming Errors

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

Level 1 2222 Level 2 1503 Level 3 1309 -

Default Security Code

Level Primarily Used by

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-13

Pump Programming Programming 8800 Series Units

Display Conventions

The programming digit positions for the main money and volume displays are shown in 

Figure 4-9. This applies even in cases where more than s

display purposes. Information will be di restricted to digits 4 through 1, unless otherwise noted.

Figure 4-9: Location of Data on Displays at Power Up

splayed on all grade PPUs when required and will be

ix display digits are available for

During programming, the command code is always shown left justified in the main money display, starting at digit position 6. Other display information will be dependent on specific programming command codes and function codes within the command code.

Flashing fields indicate a selected parameter where data may be entered or simply inspected.

Programming parameters are shown in LCD displays as soon as the parameter selection key is pressed. Parameters are entered into the pump control system only after Enter is pressed.

Totals Examples

T o toggle between the grade and side selection for both $ Total and Vol Total key , press Enter as found on the Manager Keypad.

Non-resettable Money and Volume Totals

The dispenser maintains a set of non-resettable totals for each dispensed fuel grade. These totals reflect the total value of money and volume of fuel, since the dispenser was installed.

Money and Volume Totals

$ Total is used to retrieve money totals for each fuel grade. This key does not require a security code. Clear is used to exit Money Totals mode. 1 displayed in the leftmost $ Total display indicates that this total is a non-resettable money total. The Vol Total key displays the volume for the grade selected. Volume for both sides of the unit can be viewed. Clear is used to exit the Volume Total mode. This convention comes from The Advantage Series product line and is maintained here for ASC and Site Manager familiarity.

Page 4-14 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

Programming Steps for 8800 Series Units

This section provides the programming steps for 8800 Series units.

Master Reset/Warmstart

A Master Reset removes all programming, unit configuration, and dispenser memory in addition to resetting the internal processor to an initial state. It is frequently referred to as a Cold Start. A Warmstart (power-down and up of the unit) only resets the processor to an initial state.

Master Resets are generally required:

• When changing the software

• To temporarily or permanently fix a locked dispe

nser or unusual dispenser response

A Master Reset is a powerful service tool. Howeve

r, when troubleshooting a non-responsive pump, avoid performing a Master Reset as the first step in troubleshooting. First observe the symptoms, observe the diagnostic LEDs, and check the voltage, as appropriate. In many cases, a Master Reset will 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.

To perform a Master Reset, proceed as follows:

1 Record all totals and programming. Isolate the unit at the D-Box.

2 Turn off power to the unit.

3 Install a jump jack on JP-1B on the A side main display (J-box opening side).

4 Restore power to the unit and wait for Error Code 40.

5 Remove the jump jack.

6 Reprogram the unit.

7 Bring the unit back on line at the D-Box.

Level 1 Programming

Following information gives specific programming steps for Level 1 commands. All this information is entered on the Manager Keypad. Ensure that you follow the following steps. The side with the J-box opening is Side 1 while the other side is Side 2. Power-up and Command Code 8 will display the current software version.

For Level 1 programming, proceed as follows:

1 Press Fl.

2 Enter the 4-digit ID (default 2222) and then press Enter.

3 Press F1 to exit any command code.

4 Press F2 to return to normal operation.

You may enter any command code directly from Level 1 after entering the PIN code.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-15

Pump Programming Programming 8800 Series Units

Command Code 1: Program PPU

Manual programming of PPU, unit pricing. Pricing can also be downloaded through the  two-wire communication using the POS device.

To program the PPU, proceed as follows:

1 Press 1 and then press Enter. 2 Select the Side (1 or 2) and then press Enter. 3 Select the Grade and then press Enter. 4 Select the Price Level and then press Enter. 5 Enter the new PPU and then press Enter.

Note: Repeat steps 1 to 5 for the other Side, Grade, and Price Level.

Command Code 2: Program Two-wire/Standalone

T o set the operation to Standalone mode (isolates sale control from the POS) or two-wire (unit control through the POS), proceed as follows:

1 Press 2 and then press Enter.

2 Press the configuration number and then press Enter, where:

• 0 = Standalone mode

•1 = Two-wire mode

• 2 = Pulse-out mode

Command Code 3: Program Allocation

Programming Volume Allocation basically sets the maximum sale size in units of measure (for example, gallons).

To program the Volume Allocation, procee

1 Press 3 and then press Enter.

2 Select the Side (1 or 2) and then press Enter.

3 Select the Hose/Grade and then press Enter.

4 Select the Allocation amount and then press Enter.

Note: Repeat steps 1 to 4 for the other Side, Hose, and Grade.

d as follows:

Page 4-16 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

Command Code 4: Program Manual Blank Display Cash/Volume Preset Select

The Manual Blank and Five-button Preset is a dual use code that allows turning off displays manually or is used to activate different preset modes depending on the options included with the unit.

To program Manual Blank Display Cash/Volume P

1 Press 4 and then press Enter. 2 Select the Function Code (1 or 2) and then press Enter, where:

reset Select, proceed as follows:

Function Code 1: Manual Blank Displays Press the option code and then press En

ter, where:

0 = Display Off 1 = Display On

Function Code 2: Cash/Volume Preset Select

Press the option code and then press En 0 = No Five-button Preset or Programmable Pump Preset

ter, where:

(PPP) installed 1 = Money Preset 2 = Volume Preset 3 = Incremental Preset

Command Code 5: Test Customer Programmable Preset

T est Programmable Customer Preset is a code that is used to initiate testing for the Five-button Preset option if used.

To program the Test Programmable Customer Preset, proceed as follows:

1 Press 5 and then press Enter. 2 Select the Configuration and then press Enter, where:

0 = STOP Test/Program 1 = START Test/Program

Depending on the preset option, the type testing will convey the following when you press the pre

set buttons:

Five-button Preset (Non-customer Pr

Press Enter

after making selections, where:

ogrammable Preset)

1 = Program Button 1 (Default 1) 2 = Program Button 2 (Default 5) 3 = Program Button 3 (Default 10) 4 = Program Button 4 (Default 15) Incremental Preset (Non-customer Programmable Preset) Press Enter

after making selections, where: 1 = Program Button 1 (Default 1) Money 2 = Program Button 2 (Default 5) Money 3 = Program Button 3 (Default 10) Money 4 = Program Button 1 (Default 1) Volume 5 = Program Button 2 (Default 5) Volume 6 = Program Button 3 (Default 10) Volume

After the test is complete, follow

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-17

programming steps to setup.

Pump Programming Programming 8800 Series Units

Command Code 6: Memory Clear for Error Code 31 or 35

The Memory Clear code is only useful to clear a unit displaying an Error Code (EC) 31 Totals Data Error) or EC 35 Configuration Data Error.

To program the Memory Clear code, proceed as follows:

1 Press 6 and then press Enter.

2 Press 1 and then press Enter.

Command Code 7: Program Totals Input

The Setting T otals Input code allows setting of non zero totals. It is useful for new installations or service when the station does not want to restart totals for its dispensers at zero, when old dispensers are replaced, or receive certain types of service. It can only be performed after performing a Master Reset, CC7, or for new units.

To program Totals Input, proceed as follows:

1 Press 7 and then press Enter. 2 Select the Side (1 or 2) and then press Enter. 3 Select the Grade # and then press Enter. 4 Press $ Total. 5 Enter the money total and then press Enter.

Note: Repeat steps 1 to 5 for the other side and grade.

6 Press Volume Total and repeat the above procedure for volume totals.

Command Code 8: Display Version Number

To display the Pump Controller Firmware Version, proceed as follows:

1 Press 8 and then press Enter. 2 Select the Software Option and then press Enter, where:

1 = Pump Controller 3 = Customer Programmable Preset

Level 2 Programming

Following information gives specific programming steps for Level 2 commands. All this information is entered on the Manager Keypad. Ensure that you follow the following steps. The side with the J-box opening is Side 1 while the other side is Side 2.

Note: *Indicates the default value.

PIN Code Entry

You must enter Level 1 before accessing Level 2 commands.

• Level 1- Press

• Level 2- Fro (default 1503), and then press Enter. Press F1 to exit any command code. Press F2 to return to normal operation.

Page 4-18 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Fl, enter the 4-digit ID (default 2222) and then press Enter.

m Level 1, enter any Level 2 Command Code (10-12), enter the 4-digit ID

Programming 8800 Series Units Pump Programming

Command Code 10: System Configuration

This multi-purpose code contains several sub codes called Function Codes (FC). Not all codes are used for Atlas. If accessible, do not change other codes from their default values or the unit may not work properly.

1 Press Enter after making selections. 2 Press 10. 3 Press Function #. 4 Press Configuration #.

Function Code 1: Unit Type

Defines the unit. It must be always set to 1 for 1 = 1 product 2 = 2 product

Function Code 2: Money Decimal Point

Defines the money display format. 1 = xxxxx 2 = xxxx.x 3 = xxx.xx 4 = xxx.xxx

Atlas.

Function Code 3: Calculation PPU Decimal Poin Defines the PPU decimal point. Must use number 4

for US (required in U.S. as per W&M). 1 = xxxx 2 = xxx.x 3 = xx.xx 4 = x.xxx

Function Code 4: Displayed PP

Configures the default value. N

U Decimal Point

ormally select 4 for US. If the displayed decimal point and

calculated decimal point are different, program FC 3 first. 1 = xxxx 2 = xxx.x 3 = xx.xx 4 = x.xxx

Function Code 5: STP Pre-start

Set to On for mechanical leak de

tectors or set to Off for most electronic line leak detectors.

Also, for self-contained pumping units, set to Off. 0 = Off 1 = On

Function Code 6: Beeper Option

Activates the beeper. 0 = Off 1 = On

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-19

Pump Programming Programming 8800 Series Units

Function Code 8: Two-wire Display Blank Option

Activation of this code allows entering of a specific prese

t amount to be turned off on the display at the dispenser using a remote POS device. 0 = Off 1 = On

Function Code 9: 5- or 6-digit Cash Display

Programs 5 or 6 digits of cash. POS must be set to the same. 0 = 5 Digit Money 1 = 6 Digit Money

Function Code 10: Decimal/Comma Mode

Programs display format. 0 = Decimal point 1 = Decimal point, comma

Function Code 11: Pre-select Timeout

The customer must make a decision (other than the default

) within the programmed time or the

unit will be de-authorized.

Function Coda 12: Pump Timeout

After you begin dispensing of fuel, if the idle time exce

eds the programmed time, the unit will terminate the sale. 0 = None 1 = 5 seconds 2 = 15 seconds 3 = 30 seconds 4 = 45 seconds 5 = 60 seconds 6 = 75 seconds 7 = 90 seconds 8 = 120 seconds

Function Code 13: Slowdown

This determines the time for which the

unit will be in a slowdown mode during a preset sale. Setting it for too short time will result in you missing the target sale. Setting it for too long will increase the time of completion the sale. This code is useful for preset problems. 0 = .070 gallons (.264 liters) 1 = .120 gallons (.454 liters) 2 = .170 gallons (.643 liters) 3 = .220 gallons (.833 liters) 4 = .270 gallons (1.02 liters) 5 = .320 gallons (1.21 liters) 6 = .370 gallons (1.40 liters) 7 = .420 gallons (1.59 liters) 8 = .470 gallons (1.78 liters) 9 = .520 gallons (1.97 liters)

Function Code 15: Zero PPU Pricing Option Enable

Allows dispensing of fuel with a “zero” PPU. 0 = Disabled 1 = Enabled

Page 4-20 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

Function Code 16: Beeper Timeout

Used in conjunction with FC 12 to turn beeper of

f after a programmed period of time. 0 = None 1 = 5 seconds 2 = 15 seconds 3 = 30 seconds 4 = 45 seconds 5 = 60 seconds 6 = 75 seconds 7 = 90 seconds 8 = 120 seconds

Function Code 17: Stop Control Turns off one or both sides of the unit if the St

op option is pressed.

0 = Stop controls one side 1 = Stop controls two sides

Function Code 18: Zero Previous Transaction After P

Resets the last transaction after the pump handle is raise

ump Handle Operation

d and the unit is authorized (required for New Jersey, US). 0 = Zero after lamp test 1 = Zero before lamp test (Required for New Jersey)

Function Code 19: Lamp Test (Leak Detector Test)

It is not actually a lamp test; but it programs the amount of time

the dispenser valves take to open, after the handle is raised. Primarily used for dispensers with mechanical STP leak detectors to allow the leak detector enough time to run its test. 1 = 1 second 2 = 2 seconds 3 = 3 seconds 4 = 4 seconds 5 = 5 seconds 6 = 6 seconds 7 = 7 seconds 8 = 8 seconds 9 = 9 seconds

Function Code 20: Programmable Pump Preset Value

Set to 1 for use with

six-digit cash programming. 0 = Value X 1 1 = Value X 10

Function Code 21: PPU Blinking Option

0 = No PPU Blinking 1 = PPU Blinking

Function Code 22: Volume Decimal Point

0 = xxx.xxx 1 = xxxx. xx (export only)

Function Code 23: Program STP Control

0 = Off 1 = On

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-21

Pump Programming Programming 8800 Series Units

Command Code 11: Grade Assignment (Perform this at Console)

Assigning Grades. Normally not used as grades must 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 Atlas. If accessible, do not change other codes from their default value or the pump/dispenser may not work properly.

To program the pump, proceed as follows:

1 Press 12. 2 Enter the Side #, where 1 = Side A, 2 = Side B. 3 Enter the Function Code (1-4). 4 Enter the Configuration Code.

Function Code 1: Two-wire Pump ID

Sets the two-wire ID that the POS uses for the pump/dispenser involved. Pre making selections. 1-16 = Choose a number between 1-16

ss Enter after

Function Code 2: Cash/Credit at Pump

0 = No 2 = Yes

Function Code 3: Side Exists

0 = Does not exist 1 = Exists

Function Code 4: PPU Options

0 = Level 1 price bar displays the level sent by console 1 = Normal

Level 3 Programming

You must enter Level 1 and 2 before accessing Level 3 commands.

• Level 1 - Press Fl, ente

• Level 2 - From (default 1503), and then press Enter.

• Level 3 - From (default 1309), and then press Enter. Press F1 to exit any command code. Press F2 to return to normal operation.

Command Code 13: PIN Code Change

Change PIN code. To change the PIN code, proceed as follows:

r the 4-digit ID (default 2222), and then press Enter.

Level 1, enter any Level 2 Command Code (10-12), enter the 4-digit ID

Level 2, enter any Level 3 Command Code (13-17), enter the 4-digit ID

1 Enter 13.

2 Enter Level #1, 2, or 3.

3 Enter the new PIN code.

Note: The unit returns to Command Input Mode.

Page 4-22 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

Command Code 17 - Conversion Factor and Master Reset Select Function

The Conversion Factors/Performing Master Resets function is normally used during the setup of a unit, to program the unit of measure and provide a means to do a firmware initiated Master Reset.

Function Code 1: Conversion Factor

0 = No conversion factor* 1 = US. Gallons 2 = Imperial Gallons 3 = Liters 4 = 1012 Pulses per gallon

Function Code 2: Master Reset

0 = No Master Reset 1 = Master Reset

Command Code 18 - To Program Various Options Under Pulse Output

Function Code 1 = Volume Pulses per Unit

1 = 1 2 = 10 (Default) 3 = 50 4 = 100 5 = 1000

Function Code 2 = Volume Output Pulse Width

1 = 0.5 ms 2 = 1.0 ms 3 = 2.0 ms 4 = 4.0 (Default) 5 = 17.0 ms 6 = 19.0 ms 7 = 26.0 ms 8 = 150.0 ms

Function Code 3 = Money Output Pulse Width

1 = 0.5 ms 2 = 1.0 ms 3 = 2.0 ms 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

Function Code 5 = Quadrature Pulse Output

0 = Disabled (Default) 1 = Enabled

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-23

Pump Programming Programming 8800 Series Units

Function Code 6 = Authorize After Stop

0 = Disabled (Default) 1 = Enabled

Function Code 7 = PRC Restore Option Programming

0 = Disabled (Default) 1 = Enabled

Command Code 2 - To Program the Unit to the Pulse Output Mode

Function Code 0 = Standard Mode Function Code 1 = Two-wire Mode Function Code 2 = Pulse Output Mode

Option and Miscellaneous Programming/Data Acquisition

Special programming is involved in ATC and displaying Totals.

ATC Programming

At power-up, the units programmed with the ATC option will flash 104 before displaying normal information. Units with the option, but not programmed for ATC will flash 100. To program the ATC option, proceed as follows:

1 Turn On the programming switch on the ATC Controller Board.

Note: The dispenser must not be used during this programming and all pump handles must be

down or

2 Press 100 on the keypad and then press Enter.

• The money position showing fueling positi

• The volume position showing the

inactive.

on selected will display 1.

fuel type selected will display 1, where:

1 = Gasoline 2 = Diesel

• The PPU position showing fuel density selected will display 730, where: 740 = Gasoline 840 = Diesel 730 = Default

3 Select the fuel type and press Enter.

4 The firmware sequence will sequence through each fueling position. Select the fuel type for

each position (diesel or gasoline).

5 Turn the programming switch on the ATC controller board to Off.

6 Press F2 to exit the ATC Programming mode.

Page 4-24 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8800 Series Units Pump Programming

ATC Inspection Mode

Inspection of the ATC states and data collection can be obtained following a similar procedure as outlined for ATC Programming above. Instead of pressing 100, other codes can be used as described in the following table:

ATC Inspection Modes

On the Manager Keypad, press the ATC following function code, when the unit is idle. Note that all pump handles must be down or inactive. Press Enter, meter number if appropriate, and then press Enter. Exit by pressing F1.

Function

de D

300 Audit Last Transaction Gross Volume Net Volume Average Temperature 301 Display Volume

302 Display Fuel Density Meter Number 730 Gas

303 Display Temperature Meter Number Current Temperature

escription Main Display Volume Display PPU Display

rrection Factor

Meter Number Volume Correction

Factor.

840 Diesel

304 Display Gross Totals Gross Volume (most

500 Display Software

ersion Number

200 Real-Time Transaction

Mode

Displaying Pump Totals

During service, it is often required to access pump totals. This can be done at the POS or at the pump/dispenser. Access is simple and is through the Manager Keypad.

To view Side 1 totals, proceed as follows:

1 Press $ Total. The combined cash and credit total will display for grade 1, side 1.

2 Select the grade. Read $ Total for each grade selected.

3 Press Vol Total. The volume total will display for the grade selected.

4 Select the grade. Read volume totals for grade selected .

5 To view Side 2 totals, press Enter.

significant)

C Version

oss Volume Net Volume Current Temperature

6 Press Clear to exit.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-25

Pump Programming Programming 8800 Series Units

Error Codes and Descriptions

Following list describes error codes/states that you may observe. These codes are useful when troubleshooting a problem. Side A is the J-box opening side and Side B is th e opposite side.

Error Code Description

20 Pulser Fail 21 Non existent Memory 22 Not used 23 Grade Assignment Changed 24 Conversion Factor Changed/ Not Programmed 25 Two-wire/Standalone Mode Changed 26 No Conversion Factor, Tape 27 Side A Two-wire ID Changed 28 Side B Two-wire ID Changed 29 Pump Time-out Error 30 Not Used 31 Totals Data Error 32 Pulser Count Error 33 Push-to-stop Button Activated 34 Not Used 35 Configuration Data Error 36 Unit Type Configuration Code Changed 37 PIN Code 1 Changed 38 PIN Code 2 Changed 39 Cast/Credit Option Changed 40 Master Reset Jumper in Place 41 Side Exists Option Changed 42 PPU Options Changed 43 Not Used 44 Pump Handle Up at Power-up

Page 4-26 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Programming 8700 Series Units Pump Programming

Totalizers

Note: The unit shown to the left is

an example of one type of Totalizer. The example shown is a Mechanical T otalizer and is used only in mechanical units.

Curved Panel Ends

Dollars/Cents

Gallons/Liters PPU

Programming 8700 Series Units

General Programming Details

The mechanical computer can be set for the price range and PPU (gallon/liter) dispensed. Adjustments for volume of the product dispensed is accomplished at the meter calibration adjustment wheel.

Note: 9100 series units do not require programming.

Figure 4-10: Variator Assembly for Mechanical Units

Programming Steps

This section provides the programming steps for the 8700 Series unit.

Setting Calibration

Gasboy Atlas pumps and dispensers are tested for accurate measure at the factory. It is the responsibility of the installer to check the unit for accuracy and make the required adjustments. It is the owner’s responsibility to report this device to the local W&M authority for inspection before putting the unit in service. For setting the calibration, refer to “Meter Calibration” on

page 6-22.

Setting Prices

To set the prices, proceed as follows:

1 Unlock and remove the front panel. Repeat this procedure for the other side.

2 The variator section of the computer register(s) is exposed to allow for price changes. Slide the

variator cover of the computer register apart to expose the price range arms.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 4-27

Pump Programming Programming 8700 Series Units

Range Arm

Range Arm Locator

3 There are three range arms located in the variator section. One sets the tenths of a cent

position, one sets the one cent position, and the last one sets the ten cents position. To change the setting, grasp a range arm and raise it to clear the range arm locator, and relocate the range arm to the desired setting. Ensure that the range arm is totally bottomed on its setting. Repeat this for all range arm settings, if required.

Figure 4-11: Range Arm Setting

4 To change the money unit setting, locate the lever control that is located above the variator

section on the same level as the price display. There are three available positions: 0.00, 1.00, and 2.00. Remove the cotter pin, grasp the lever, and raise it slightly to clear the position locators. Position the lever to the desired setting and release. Reinsert the cotter pin through the lever and plate.

Note: If the lever does not move to the r

equired position, rotate the right hand money wheel

until the lever is free to move.

Figure 4-12: Insert Cotter Pin

5 If you have difficulty reaching the money shift lever when changing prices, remove the two

cap screws located over the tabs of the bezel assembly. Lift the bezel assembly upward and remove it from the unit. When reattaching 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 4-28 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Introduction Electronic and Electrical Components

5 – Electronic and Electrical Components

Introduction

Purpose

This section provides information regarding the electronics and electrical components within pumps and dispensers. This information consists of applicable data on connections, settings, test points, and functional descriptions. PCAs control the hydraulics, monitors fuel delivery, computes, displays, and stores transactional information. These electronic components interface with the POS devices and support payment options. The term PCA and Printed Circuit Boards (PCBs) are used interchangeably in this document.

Important Information About Releases

This section was last updated

Topics in This Section

Topic Page

Electronics Highlights 5-1 About Service Procedures 5-8 Working on Electronic and Electrical C Component Overview 5-11 PCAs 5-12 Power Supplies 5-46 Electro-mechanical Registers and Totalizers 5-50 Pulsers 5-53

How to Use This Section

For location and listings of topics contained in this section, refer to “Topics in This Section”. To find information on specific components, use the above table.

Electronics Highlights

in July 2013.

omponent

s 5-9

Atlas 8800 Electronic Retail units communicates 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.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-1

Electronic and Electrical Component s Electronics Highlights

Retail Parts by Name

Retail Parts

Retail Parts for Gasboy Atlas 8800 Series

ATC # T19405-G3 T-Meter Module Automatic Temperature Controller (Optional)

™

ATC, Optimum Backlight # T17622-G9 0.6-inch Main Display PCA Ballast # M03154B001 Instant Start Barrier, Intrinsically Safe # T19428-G1 Assembly ATC (Optional) Buzzer # Q11763-01 Cable # M02739A001 from T20092-G1 (Pump Controller PCA) P205 (16) and 207 (10) to T20569-G1 OP ATC

ol PCA P405 (34) and P301 (20) and 305 (34)

Contr Cable # M04658A001 from T18994-G1 P405 (20) to Q11763-01 Buzzer to Q12514-10 switch A1 PH (B1) (4) and

B1 PH (A1) Cable # M04658A001 from T18994-G1 P406 (5) to J922A (4)

and J922B (4) > M00455A003 Grade 2 side Electronic Totalizer B Cable # M04659A001_2_3 to relay Cable # M04850A002 Cable # M04889A001 from T18994-G1 P405 (20) to Q11763-01 Buzzer to Q12514-10 switch A1 PH (B1) (4) and

B1 PH (A1) Cable # M04890A001 from Main J-box Cable # R196677-G1 from T20092-G1 (Pump Controller PCA) P204

P304 (34) Cable # R18944-G1 from T17331-G1 (Pump Preset PCA) P412 (3

P612 (34) Cable # R18944-G1from T17331-G1 (Pump Preset PCA) P413 (34

P612 (34) Cable # R19072-G1 from J921A to T18350-G3 Pulser Cable # R19527-G1 from T20569-G1 {OP ATC Control PCA (Optional)} P204A

Display Cable # R19936-G1 from T20092-G1 (Pump Controller PCA) P201 (

(34) Cable # R19939-G1 from T20092-G1 (Pump Controller PCA) P206 (

(5) Cable # R19951-G1 Cable from T20092-G1 (Pump Controlle

P901A (10) Cable # R19951-G1 Cable from T20092-G1 (Pump Controlle Cable # R19951-G1 Cable from T20569-G1 {Optimum ATC Contro

(Manager Keypad) P901A (10) Cable # R19952-G1 Cable from T20092-G1 (Pump Controller PCA) P205 (16) to T18994-G1 (Pump Interface PCA)

P305 (1 Cable # R20128-G1 Cable from T20569-G1 {OP ATC Contr Cable # R20146-G1 Cable from T20092-G1 (Pump Controlle

PCA) P303 (10) Cable # R20148-G3 Cable from T19405-G3 (T-Meter Module) P200 (16) to Probe 2 PTP2 (16) Cable # R20148-G3 Cable from T19405-G3 (T-Meter Module) P202 (16) to Probe 1 PTP1 (16) Cable # R20412-G3 Cable from T20092-G1 (Pump Controlle

Wiring Cable # R20412-G3 Cable from T20092-G1 (Pump Controller PCA) P208

P402A (2) Cable # R20412-G3 from T19428-G1 I.S Barrier > JIS (10) to P201 (10) T19405-G3

# T20569-G1 Optimum Automatic Temperature Controller Control PCA (Optional)

(4) to J921B and J921A to J1 (3) to P1 Relays

> M00455A003 Grade 1 Electronic Totalizer Side A

(4) to J921B and J921A to J1 (3) to P1 Relays

(34) to T20569-G1 (OP ATC Control PCA)

4) to T17328-G1 Pump Preset Display PCA

) to T17328-G1 Pump Preset Display PCA 

(34) to P204A (34) J204 LCD Main

10) to T17331-G1 (Pump Preset PCA) P411

5) to T18994-G1 (Pump Interface PCA) P306

r PCA) P203 (10) to T17549-G1 (Manager Keypad)

r PCA) P207 (10) toT18994-G1 P307 (10)

ller PCA (Optional)} P303A (10) to T17549-G1

ol PCA (Optional)} P307 (4) to Main J-box

r PCA) P203 (10) to T20569-G1 (OP ATC Control

r PCA) P208 (two-wire) to P402A (2) to J402 FE

[3 (two-wire)] to FE wiring sheet 1>

Page 5-2 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Electronics Highlights Electronic and Electrical Components

Retail Parts

Filter # Q10895-07 Fuse # Q10131-03 Key Pad # T17549-G1 Manager LCD # T17701-G1 or T18981-G1 Main Display PCA 0.6-inch Power Supply # T19868-G1 Main Pulser # T18350-G3 Assembly Pump Controller # T20092-G1 PCA Switch # Q12514-10 Pump Handle SW Totalizer # M00455A003 Electronic Varistor PCA # T17448-G1 (115 VAC) in Main J-box Varistor PCA # T17448-G3 (220/230/240 VAC) in Main J-box

Note: ATC is available as an option in units for the Canadian market.

Retail Parts by Number

Part Number Description

M00455A003 Electro-mechanical Totalizer M02739A001 Cable from T20092-G1 (Pump Controller PCA) P205 (16) and 207 (10) to T20569-G1 OP ATC

M03154B001 Instant Start Ballast M04011B001 Cable Pulser Assembly M04658A001 Cable from T18994-G1 P405 (20) to Q11763-01 Buzzer to Q12514-10 switch A1 PH (B1) (4) and

M04658A001 Cable from T18994-G1 P406 (5) to J922A (4) >

M04659A001 M04659A002 M04659A003

M04850A006 Main Conduit M04889A001 Cable from T18994-G1 P405 (20) to Q11763-01 Buzzer to Q12514 10 switch A1 PH (B1) (4) and

M04890A001 Ballast and 2-lamp assembly M04956A006

M04956A007 Q10131-03 Fuse, 3 A, 250 V SLO-BLO Q10895-07 Filter Q11763-01 Buzzer Q12514-10 Pump Handle Switch R12667-G1 Cable from T20092-G1 (Pump Controller PCA) P204 (34) to T20569-G1 (OP ATC Control PCA)

R18944-G1 Cable from T17331-G1 (Pump Preset PCA) P412 (34) to T17328-G1 Pump Preset Display PCA

R19072-G1 Cable from J921A to T18350-G3 Pulser R19527-G1 Cable from T20569-G1 (OP ATC Control PCA) P204A (34) to P204A (34) J204 LCD Main

R19936-G1 Cable from T20092-G1 (Pump Controller PCA) P201 (10) to T17331-G1 (Pump Preset PCA)

R19939-G1 Cable from T20092-G1 (Pump Controller PCA) P206 (5) to T18994-G1 (Pump Interface PCA)

ol PCA P405 (34) and P301 (20) and 305 (34)

Contr

B1 PH (A1)

and J922B (4) > M00455A003 Grade 2 Side Electronic Totalizer B Cable to relay

B1 PH(A1)

Relay Single, A007 Dual

P304 (34

P612 (34

Display

P41

P306 (5)

(4) to J921B and J921A to J1 (3) to P1 Relays

M00455A003 Grade 1 Electronic T otalizer Side A

(4) to J921B and J921A to J1 (3) to P1 Relays

)

1 (34)

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-3

Electronic and Electrical Component s Electronics Highlights

Part Number Description

R19951-G1 Cable from T20092-G1 (Pump Controller PCA) P203 (10) to T17549-G1 (Manager Keypad)

P901A (10) R19951-G1 Cable from T20092-G1 (Pump Controller PCA) P207 (10) toT18994-G1 P307 (10) R19951-G1 Cable from T20569-G1 (Optimum ATC Controller

Keypad) P901A (10) R19952-G1 Cable from T20092-G1 (Pump Controller PCA) P205 (16) to T18994-G1 (Pump Interface PCA)

R20128-G1 Cable from T20569-G1 (OP ATC Control PCA) P307 (4) to Main J-box R20146-G1 Cable from T20092-G1 (Pump Controller PCA) P203 (10) to T20569-G1 (OP ATC Control PCA)

R20148-G3 Cable from T19405-G3 (T-Meter Module) P200 (16) to Probe 2 PTP2 (16) R20148-G3 Cable from T19405-G3 (T-Meter Module) P202 (16) to Probe 1 PTP1 (16) R20412-G3 Cable from T20092-G1 (Pump Controller PCA) P208 ( R20412-G3 Cable from T19428-G1 I.S Barrier > JIS (10) to P201 (10) T19405 G3 R20412-G3 Cable from T20092-G1 (Pump Controller PCA) P208 (3) (2 wire) to FE wiring sheet 1> P402A (2) T17448-G1 Varistor PCA (115 VAC) in Main J-box T17448-G3 Varistor PCA (220/230/240 VAC) in Main J-box T17549-G1 Manager Keypad T17701-G1 

~ OR ~ T18981-G1

T17897-01 Membrane Switch, Pump Reset Display T18350-G3 Assembly Pulser T18679-G1 Main Display Backlight PCA T18994-G1 Pump, Hydraulic Interface PCA 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

P305 (16

P303 (10

Main Display PCA LCD

)

PCA) P303A (10) to T17549-G1 (Manager

2 wire) to P402A (2)to J402 FE Wiring

Commercial Parts by Number

Part Number Description

140941824 Cable Pump Handle Switch, Cold Weather DEF Only C02824 Fuse, Pico 3 A, 125 V, QB

C04044 Q10131-29

C04243 Sensor, Front Load Nozzle Boot C06372 Display Backlight Board (Used only with C06387, M12158A002, or M12158A004) C06387 LCD Display PCA (Replaced by M12158A002 or M12158A004) C06455 Cable, Display Ribbon, Single C06518 Cable/Bracket Assembly, Solenoid to CPU, Ultra-Hi Only, Dual C06519 Cable Backlight PWR, Single Front Load, Ultra-Hi Only C06574 Cable, Display Ribbon, Front load, Single, Ultra-Hi Only

Page 5-4 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

1 A, 250 VAC Slow-blow Fuse

Electronics Highlights Electronic and Electrical Components

Part Number Description

C06766 Barrier, I.S, Front Load C09071 Fuse, Pico 1A, 125 V, QB C09546 Fuse Holder M00150A003 Cable Assembly, ECAL Switch DEF Only M00150A004 Cable Assembly, ECAL Switches E85 Only M00455A002 Electro-mechanical Totalizer M02367A004 Cable, AC to Filter, DEF Only M02958A002 Valve Coil Assembly, E85 Only M03154B001 Instant Start Ballast M04011B001 Cable Pulser Assembly M04114A007 Conduit/Cable Assembly, Cold Weather DEF Only M04114A008 Cable, Meter Interface, Warm Weather DEF Only M04161B005 Power Supply, +24 VDC, DEF and E85 Only M04193A001 Cable/Bracket Assembly, Solenoid to CPU, Ultra-Hi Only, Single M04659A004

M04659A005 M04659A007

M04659A008 M04850A008 Conduit, Main AC M04850A010 Conduit, Main AC, E85 Only M04890A001 Ballast and 2-lamp Assembly M04956A008

M04956A009 M04956A010

M04956A011 M05105A002 Cable Pump Handle Switch M05105A003 Cable Pump Handle Switch, Front Load Warm Weather DEF Only M05107A001 Cable, Power Supply to CPU, DC M05107A002 Cable, Power Supply to CPU, DC, E85 Only M05108A001 Cable Backlight PWR M05109A001 Cable, Display Ribbon, Dual M05110A001 AC Bracket Assembly M05110A002 AC Bracket Assembly, DEF Only M05119A001 Cable, Sensor, K-pump M05120A001 Cable 115 VAC Heater M05120A002 Cable 230 VAC Heater M05158A00X K-pump Pulse-out I/F Board with Totalizer Drive (Replaced by M06587A001) M05189A002 Conduit Pulse-out to Main J-box, Standard M05189A006 Conduit DC, Dispenser-mount TopKAT M05189A008 Conduit DC, Dispenser-mount TopKAT PLUS M05201A001 Cable Pulser to CPU M05248A001 RS-485 I/F Board with Electro-mechanical Totalizer Drive (Replaced by M06725A001)

Cable to Relay

Cable to Relay, E85 Only

Relay Single, A009 Dual

Relay Single, A011 Dual, E85 Only

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-5

Electronic and Electrical Component s Electronics Highlights

Part Number Description

M05683A002 Conduit, DC Dispenser-mount TopKAT, Ultra-Hi Only M05683A004 Conduit, DC Standard, Ultra-Hi Only M05683A006 Conduit DC, Dispenser-mount TopKAT PLUS M05684A002 Conduit, Main AC, Ultra-Hi Single Dispenser M05685A002 Conduit, Main AC, Ultra-Hi Single Pump M05686A002 Conduit, AC, Valve and Micro, Ultra-Hi TW2 Only M05686A003 Conduit, AC, Valve and Micro, Ultra-Hi TW1 Only M05692A002 Conduit, AC, Valve and Lights, Ultra-Hi TW2 Only M05692A002 Conduit, AC, Valve and Lights, Ultra-Hi TW1 Only M05819K001 Kit, ATC Single Non-Ultra-Hi M05819K002 Kit, ATC Dual Non-Ultra-Hi M05819K003 Kit, ATC Single Ultra-Hi M05819K004 Kit, ATC Dual Ultra-Hi M05839B002 Cable Pulser Assembly, E85 Only M06031A001 Valve Controller Board, E85 Only M06333KXXXX Atlas 9800 CPU Board 115/230 VAC

Note: M06333KXXXX requires M07588A00X Power Supply.

M06525A001 RS-485 I/F Board with Electro-mechanical Totalizer Drive (Replaces M05248A001) M06587A001 Atlas 9800 Pulse-out I/F Board with EM Totalizer Drive (Replaces M05158A00X) M06656K00X Atlas 9800 Serial EEPROM Board M06783A001 E2 Temperature Control Board, DEF Only M07141A003 Cable, DC to Coriolis Interface, DEF and E85 Only M07233A003 Cable, Heater Adapter, Cold Weather DEF Only M07275A002 Conduit, Satellite AC, Ultra-Hi Pump Combo Only M07275A004 Conduit, Satellite AC, Ultra-Hi Dispenser Combo Only M07366A001 Satellite Control Board, 115 VAC, Ultra-Hi Combo Only M07366A002 Satellite Control Board, 230 VAC, Ultra-Hi Combo Only M07588A001 Atlas 9800 Power Supply AC-DC with Battery 115 VAC (Replaced by M12421K00X Kit) M07588A002 Atlas 9800 Power Supply AC-DC Without Battery 115 VAC M07588A003 Atlas 9800 Power Supply AC-DC with Battery 230 VAC (Replaced by M12422K00X Kit) M07588A004 Atlas 9800 Power Supply AC-DC Without Battery 230 VAC M08121A002 Cable, AC from Filter to PS, DEF Only M09958A001 Cable, Heater AC to J-box, DEF Only M10006A001 Coriolis Meter, DEF Only M10030A001 Coriolis Interface Board, DEF Only M10059A002 Cable, DC PWR to Meter Interface Board, DEF Only M10060A001 Cable, Pulser to Meter Interface Board, DEF Only M10092A001 Cable, Coriolis Meter, DEF Only M10131A006 Cable, Heater Sensor, Cold Weather DEF Only M10131A008 Cable, Frozen Sensor, Cold Weather DEF Only M11277A001 Cable, Main AC to J-box, DEF Only

Page 5-6 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Electronics Highlights Electronic and Electrical Components

Part Number Description

M11277A002 Cable, DC to J-box, DEF Only M11480A001 Valve Interface Board, E85 Only M11714A002 Display, LCD PCA, Super Cap M11715A001 Cable, AC to Filter, E85 Only M11716A001 Cable, AC from Filter to PS, E85 Only M11717A001 Cable, Valve Adapter, E85 Only M12019A001 Backlight PCA, Use with M11714A001 or M11714A002 Only M12201A001 Cable, Pump Handle, Cold Weather DEF Only M12202A001 Cable, AC Splitter Heater, Cold Weather DEF Only M12260A001 Heater/Fan Assembly 230 W, Cold Weather DEF Only M12261A001 Cable, AC Heater Relay Extension, Cold Weather DEF Only M12262A001 Cable, DC to Heater, Cold Weather DEF Only M12263A001 Cable, AC PWR Extension, Cold Weather DEF Only M12264A001 Cable, DC Heater Relay Extension, Ribbon, Cold Weather DEF Only Q10362-02 AC filter, DEF and E85 Only Q10557-01 Fluorescent Bulb Q11008-01 Relay, Solid State, 40 A Q11008-02 Relay, Solid State, 25 A, Cold Weather DEF Only Q11781-01 Fuse Holder, E85 Only Q12514-10 Sensor, Pump Handle, Side Load Q13070-07 Fuse, Pico 1 A, 250 V, QB Q13254-03 Heater/Fan Assembly 750 W, Cold Weather DEF Only T17448-G1 Varistor PCA (115 VAC) in Main J-box T17448-G3 Varistor PCA (220/230/240 VAC) in Main J-box

8800 Series Electronic Retail Units

Atlas 8800 series Electronic Retail unit is discussed in this section. The electronic parts are listed in the “Retail Parts by Name” on page 5-2. The electronics manages all the common functions for a low hose compact dispenser such functions, electro-mechanical totalizers, and other options. External communications utilize a proprietary two-wire communication system used by a number of POS controller manufacturers. Interface devices for communications such as a Pump Access Module (PAM) 1000 can be used to convert two-wire communications to a usable format for other POS manufacturers who cannot connect directly to the two-wire system.

Note: T o interface to the Gasboy CFN Site Controller Systems, a Current Loop (ISL2, SC2) or

PC Inter

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-7

face Package (SC3) is used in place of the PAM.

as sales control, maintenance, preset ATC

Electronic and Electrical Components About Service Procedures

Front-load Unit

Side-load Unit

System and Component Overview

In this section, cautions and warnings for electronic components will be addressed. Extreme care must be taken while using explosive vapors or liquids, which may be present around the dispensing equipment. These vapors can be ignited by flames, electrical arcs, or static electricity discharges. An electrical shock hazard exists when working with this equipment. An electrical discharge can cause injury, ignite vapors, or damage sensitive electronic components. All safety precautions and requirements must be strictly followed.

About Service Procedures

Figure 5-1 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 5-1: Atlas 8800 Retail Pumps - Side and Front-load

Page 5-8 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Working on Electronic and Electrical Components Electronic and Electrical Components

WARNING

Read and follow all precautions and requirements before performing any inspection and/or maintenance in a potential ly dang erous environment of flammable fuels, vapors, and high voltage.

Fire, explosion or electrical shock could result in severe injury or death if safety procedures are not strictly followed.

Do not smoke and prevent open flames in the pump area. Promptly clean up spills or debris in the pump area.

Use IC extractor

Ground wrist strap is required

WARNING

Working on Electronic and Electrical Components

Explosive vapors or liquids are present in and around the fuel dispensing equipment, which can be ignited by open flames, electrical arcs, or static electricity discharges.

A potential shock hazard exists when working with this equipment. Electricity discharges can cause injury and damage sensitive electronic components. Follow all precautions and requirements.

Preparing for Service

To prepare for service, perform the following:

• Barricade the working area.

• Shut off all power from units with electronic components to be serviced. Shut off power from the assoc required.

• Use extreme caution during any observation or testing procedure applied to the unit.

• To prevent damage from Electrostatic Discharg ignition of flammable fuels or vapors, follow all precautions and requirements.

Preventing ESD

iated connected devices, for example, STP. Multiple disconnects may be

that requires power to be

e (ESD) to electronic components or

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-9

Electronic and Electrical Components Working on Electronic and Electrical Components

The area contains a chemical known to the State of California to cause cancer.

WARNING

The area contains a chemical known to the State of California to cause birth defects or other reproductive harm.

WARNING

There is danger of explosion if batteries are incorrectly replaced. Only replace batteries with the same or equivalent type of batteries recommended. Dispose of the used batteries as per battery manufacturer’s instructions. Ensure that you replace the batteries in the correct polarity position to avoid damage to the equipment.

WARNING

To ensure equipment protection and maintenance of safe operation, always use the correct replacement fuse. Using an incorrectly sized or type fuse may cause equipment damage. The type of fuse is also very important. Some fuses even with the same amperage rating are designed to respond differently to over current and so on.

CAUTION

PCAs and ICs are sensitive to ESD. ESD can damage electronic parts.

While removing PCAs or handling ESD sensitive parts:

• Touch an unpainted metal surface to discharge any static electricity build-up.

• Use a wrist strap connected to a grounded metal frame or chassis.

• Place the removed PCAs or ICs on a grounded anti-static mat.

• Use an IC extractor tool to remove the under

• Place all PCAs you plan to return for credit or

girded circuits.

repair in anti-static bags.

Hazardous Materials

Some components inside electronic enclosures may present a health hazard if not handled correctly. Always clean your hands after handling the equipment. Do not hold or place any equipment in your mouth.

Replaceable Batteries

Some PCBs contain replaceable batteries. Insert all the batteries correctly.

Replacing Fuses

Helpful Service Information

Some boards include information that helps in correct or faster servicing. Be aware of the following found on many boards:

• Cable connectors are labeled with the destination of the cable.

• Test points are clearly labeled and recessed to faci

• Test point labels indicate an acceptable elec

• LED Status Code: Refer to the LED Status description incl

litate the use of meter probes.

trical range. For example, 4.8-5.2 VDC.

uded with PCA information.

Page 5-10 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Component Overview Electronic and Electrical Components

Pulser (T18350-G3)

Main Display (T18981-G1) 2 Locations

Graphics Overlay (T17549-G1)

P204 Display Data

P205

P203 Manager’s Keypad

Pump Controller (T20092-G1)

P206

P207

P208

P-307 STP and Valve Signals from the Pump Controller Board

P406 Driver Signals to the Totalizers

P309 AC Signals to the Valves and  STP/Motor Relays

P305 Handle Switch, Pulser Data to the Pump Controller Board and +5 VDC from the Pump Controller Board

P308 24 VAC from the Power Supply

Valve Feed and Transformer Assembly

Two-wire Data

P306 +14 VDC to the Pump Controller board.

P405 Handle Switch and Pulser Data

Main Power Supply (T19868-G1)

110 VAC to Valves and STPs 

4.7 VAC to Display Backlights

Component Overview

Figure 5-2 shows the electronic components found in Atlas 8800 Retail unit. It is a typical

Atlas 8800 electronic system. For proper service, the functions of components and how they relate to the system.

Part Number Description

T18350-G3 Pulser Assembly T18994-G1 Hydraulic Interface PCA T19868-G1 Main Power Supply T20092-G1 Pump Controller PCA T17701-G1

~ OR ~ T18981-G1

LCD Main Display PCA

While learning to operate the system, use a copy of this illustration for reference until you are completely familiar with the system. This information is supplied with the Service Launch Package. The prime functions of boards, devices, and service details are covered in

“Hydraulic/Mechanical Components” on page 5-1.

the technician must possess knowledge of

Figure 5-2: Atlas 8800 Electronics Retail Unit

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-11

Electronic and Electrical Components PCAs

M07588A002 115 VAC without backup battery

M07588A001 115 VAC with backup battery

Atlas 9800

Power Supply Board

P3 - AC Input

C06387 LCD Display Board M12158A00X LCD/Backlight Assembly.

P1: +5 VDC Power Fail Battery and Ground to CPU

K-Pump RS-485 Board M06725A001 with Totalizer output M05248A001 with Totalizer output C06389 Standard

(M06587A001) or K-Pump Pulse-out with Totalizer Boards (M05158A00X)

(M06333KXXXX)

Atlas 9800 CPU Board

P14: Serial Peripheral I/F

P9: ISB PWR/GND

JP1-JP9

P11: Display Power and Data

P10: DC Power Input

shows the interface that relates assemblies and components for the main display

SW2

P1 - Hose 1 Valves and STP

P2 - Hose 2 Valves and STP

P3 - Pulser 1

P5 - Pulser 2

P4 - Handle switches

P2: +7.5 VDC Power to display Back lights and Electromechanical Totalizers

P8 RS-485 I/F or Pulse-out I/F

P6 - Totalizer Sensor Intput

P7 Relay Drive

Connection to the CPU bd.

Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board

M07588A003 230 VAC with backup battery M07588A004 230 VAC without backup battery

PCAs

This section provides information specific to PCAs.

Atlas 9800 PCAs

PCAs control the hydraulics and monitor the fuel delivery, compute, and display store transaction information, interface with FMS. The term PCA and PCB may be interchanged suitably.

Note: For proper service of PCAs, the technician must possess knowledge of the

components and how they relate to the system.

functions of

Figure 5-3 shows the interface that relates assemblies and c

omponents for the main display

PCA [see Figure 5-2 (on page 5-11) and Figure 5-32 (on page 5-39)].

Figure 5-3: Atlas 9800 Series Block Diagram

Page 5-12 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

PCAs Electronic and Electrical Components

U8 Programmed IC (Software)

Figure 5-4 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.

C06394 (Dual, 115 VAC) and C06503 (Dual, 230 VAC):

Used on Models 9850K, 9850A/Q, 9852A/Q, 98

53A/Q, 9840A/Q, 9822A/Q, 9823A/Q/K.

Note: This PCA is only used for 9800 serie

Figure 5-4: Previous Atlas 9800K CPU (M05346A00X, C06391-C06394, C06500-C06503)

s Commercial pumps.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-13

Electronic and Electrical Components PCAs

Fuses (13070-07)

Hose 1

Hose 2

Valve and STP Relays  (Non-replaceable)

Authorization and Relay LEDs

+3.3 V LED

+5 V LED

TP4, TP5 and TP6 (DC Voltage Test Points)

Pulser and Handle LEDS

Fuses (13070-07)

Previous Atlas 9800K CPU Software Kits

Dispenser or Pump Type Conversion Factor PCB Used On Software

Standard 9800K Gallons M05346A001 -

M05346A004 CPUs

C06500 -

C06503

Electronic Commercial Uni

Standard 9800K Liters M03946K002 Standard 9800K Imperial Gallons M03946K003 Super-Hi 9840K Gallons M03946K004

Super-Hi 9840K Liters M03946K005 Super-Hi 9840K Imperial Gallons M03946K006 Ultra-Hi 9850K Gallons C06391 - C06394, Ultra-Hi 9850K Liters C06426K9850L Ultra-Hi 9850K Imperial Gallons C06426K9850M

Figure 5-5 contains information regarding 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.

M03946K001

C06426K98

50G



M06333KXXXX (Dual, 115/230 VAC)

Used on Models 9852K, 9853K, 9850K, 9840K, 9852A/Q, 9853A/Q, 9850 A/Q, 9840A/Q, 9822A/Q, 9823A/Q/K

Figure 5-5: Current Atlas 9800 CPU (M06333KXXXX)

Page 5-14 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

PCAs Electronic and Electrical Components

P2 - +7.5 VDC Power to Display Backlights and Electro-mechanical Totalizers

TP3

TP2

TP1

P1 - +5 VDC Power Fail Battery and Ground to CPU

P3 - AC Input

Current Atlas 9800 CPU Software Kits

Conversion

Dispenser or Pump Type

Standard 9800K (Models: 9852K, 9853K)

Ultra-Hi 9850 (Models: 9850A/Q, 9850K)

Electronic Commercial Unit

*Atlas 9800 Serial EEPROM Boards (M06656K00X) are used for reprogramming CPU Boards (M06333KXXXX).

tware Kit (M06656K100) contains parts M06656K001 - M06656K006 (one of each).

Sof

Super-Hi 9840K (Model:

9840K) Standard 9800Q

(Models: 9852A/Q,  9853A/Q, 9822A/Q,  9823A/Q/K)

Super-Hi 9840Q (Model: 9840A/Q)

Standard 9860 and 9870 (Models: 9862KX, 9872KX)

Figure 5-6 shows the Atlas 9800 Power Supply Board (M07588A00X) that connects to the

CPU.

Factor PC

Selectable at M06333KXXXX CPU

M06333K9800K CPU M06656K001*

M06333K9850 CPU M06656K002*

M06333K9840K CPU M06656K003*

M06333K9800AQ CPU

M06333K9840AQ CPU

M06333KECAL M06656K006*

B Used On Software

M06656K004*

M06656K005*

Figure 5-6: Atlas 9800 Power Supply (M07588A00X)

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-15

Electronic and Electrical Components PCAs

TP1

P6 (Totalizer)

P7 (Relay Drive)

P8 (RS-485/Pulser I/F)

P10 (Power Input)

P11 (LCD Display)

Switch 1

Switch 2

TP2

P1 (Hose 1 AC)

P2 (Hose 2 AC)

P3 (Pulser 1)

P4 (Handles)

P5 (Pulser 2)

P9 (ISB PWR/GND)

P10

P11

P14 (Serial Peripheral I/F)

JP 1-9

SW2, 1-10

P12 (Not Used)

TP4 (+3.3 V)

TP5 (GND)

TP6 (+5 V)

P18

Figure 5-7 shows the previous Atlas 9800K CPU.

Figure 5-7: M05346A002 (115 VAC) and M05346A004 [230 VAC (Previous Atlas 9800K

CPUs)]

Figure 5-8: Current Atlas 9800 CPU (M06333KXXXX)

Note: For cable block diagram, refer to M05193.

Page 5-16 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

PCAs Electronic and Electrical Components

P802

P804

P803

P802

P804

P803

M05248A001

M06725A001

PCA Connections and Cables

Connector # Through Cabl e To Assembly At Connector #

P1 (6) P/O M04850A008 P2 (6) P/O M04850A008 P3 (4) Pulser 1 P5 (4) Pulser 2 Pulser Side B

P4 (4) M05105A001

P6 (2) M05119A001 Q12514-13 Sensor P7 (3) Relay K1 (3) and (4)/Relay K2 (3) and (4) P8 (14) M06725A001 P2 (14) CPU P9 (6) Not Used P10 (3) M05107A001 M07588A00X Atlas 9800 Power Supply

P11 (26) M05109A001 C06387 or M12158A00X P1 Side A and

P18 (3) M00150A003 or M00150A004 ECAL Security Switches (DEF or E85

M05201A001(Cable) Pulser (8) M04011B001 (cable)

Q12514-10 Pump Handle Switch A1 PH (B1) (4) Q12514-10 Pump Handle Switch B1 PH (A1) (4)

AC-DC

P1 Side B

)

Only

Pulser Side A

P1 (5)

P1 (26)

Figure 5-9: K-pump RS-485 with Totalizer

Note: For cable block diagram, refer to M05193.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-17

Electronic and Electrical Components PCAs

P802

P804

P803

PCA Connections and Cables

Connector # Through Cable To Assembly At Connector #

P1 (4) M05189A002 Field Wiring Main J-box P2 (14) Direct Connect M05346A002 (115 VAC) or

230 V

M05346A004 (

M06333KXXXX (115/230 VAC) P802 (2) M00455A002 Side A P803 (2) M00455A002 Side B

P804 (3) M05108A001

C06372 or M12019A001

2 Connections Side A

2 Connections Side B

M07588A00X P2 (3)

AC) or

Figure 5-10: C06425, C06746 - 9800 Pump I/F

P8 (14)

P1 (3)

Figure 5-11: M05158A001/2/3 - K-pump Pulse-out with Totalizer

Page 5-18 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

PCAs Electronic and Electrical Components

Part Number Where Used

M05158A001 T

M05158A002 To be used with all models (except 9850A/Q/K) calling out for Dual

M05158A003 T o be used with all models (except 9850A/Q/K) requiring only EM Totalizer ,

Note: Models 9850A/Q/K can only use M06587A001, C06425, or C06746.

o be used with all models (except 9850A/Q/K) calling out for Single

Channel, Dual/Single Hose Pulse-out I/F (see Figure 5-27 on page 5-36).

Channel, Single Hose Pulse-out I/F (see Figure 5-26 on page 5-35).

no Pulse-out I/F.

Figure 5-12: Atlas 9800 Pulse-out I/F with EM Totalizer Board (M06587A001)

Notes: 1) To be used with models calling out for Dual Channel, Dual Hose Pulse-out I/F (9850

Dual Hose requires M05683A004 Revision B or later).

2) M06587A001 Pulse-out I/F replaces the following 9800 Pump I/F Boards:

• Single Channel, Dual/Single Hose Puls

e-out I/F Board, C06425.

• Dual Channel, Single Hose Pulse-out I/F Board, C06746.

3) For cable block diagram, refer to M05193.

PCA Connections and Cables

Connector # Through Cable To Assembly At Connector #

P1 (4) M05189A002 Field Wiring Main J-box P2 (14) Direct Connect M05346A002 (115 VAC) or

P802 (2) M00455A002 Side A P803 (2) M00455A002 Side B P804 (3) M05108A001 C06372 or M12019A001

46A004 (23

M053 M06333KXXXX

2 Connections Side A 2 Connections Side B

M07588A00X P2 (3)

0 VAC) or

P8 (14)

P1 (3)

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-19

Electronic and Electrical Components PCAs

Figure 5-13 shows the C06372 Backlight for the main LCD Display Board.

Figure 5-13: C06372 Main Display Backlight (Atlas 9800 Only)

Figure 5-14 shows the new Main Display Backlight Board (M12019A001).

Figure 5-14: New Main Display Backlight (Atlas 9800 Only)

Figure 5-15 shows C06387 LCD Display Board. In Figure 5-3 on page 5-12, the C06387 LCD

Display Board has been shown to connect to the CPU.

Figure 5-15: C06387 Atlas 9800 LCD Display Board

Page 5-20 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

PCAs Electronic and Electrical Components

K2, K4, K5, K6, K7 Decimal Point/Comma Jumpers

K1 - Side Select Jumper

Hose/Side 1 - Jumper Pins 1 and 2 Hose/Side 2 - Jumper Pins 2 and 3

Figure 5-16 shows the new Super Cap Main Display Board (M11714A00X).

Figure 5-16: New Super Cap Main Display (Atlas 9800 Only)

Display K2 K4 K5 K6 K7

000000 OFF OFF OFF OFF OFF

00000.0 ON OFF OFF OFF OFF

0000.00 OFF ON OFF OFF OFF 0000,00 OFF ON ON OFF OFF

000.000 OFF OFF OFF ON OFF 000,000 OFF OFF OFF ON ON

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-21

Electronic and Electrical Components PCAs

P1401

P1405B

P2402

P1405AP1400

CR1 +24 V

CR5 Frozen

CR3 No Fault A

CR2 No Fault B

P2110

CR4 +5 V

P2112

Figure 5-17 shows Coriolis Interface Board (M10030A001).

Figure 5-17: Coriolis Interface Board [M10030A001 (At las DEF Only)]

PCA Connections and Cables (Cold Weather DEF)

Connector # Through Cable To Assembly At Connector #

P1400 (6) M04114A007 Temperature Sensor (Frozen) (M10131A008) PTRMF (3)

P1401 (3) M04114A007 to

2264A001

M1 P1405A (6) M04114A007 Coriolis Meter (M10006A003) J1501A/B (6) P1405B (6) Not used P2110 (7) M1 0059A002 Atlas CPU (M06333A002) P9 (6) P2112 (8) M1 0060A001 to

5201A001

M0 P2402 (2) M07141A003 +24 V Power Supply (M04161B005) Red - (+)

2 Temperature Control Board (M06783A001) P1301A (10)

tlas CPU (M06333A002) P3 and P5 (4)

PCA Connections and Cables (Warm Weather DEF)

Connector # Through Cable To Assembly At Connector #

P1400 (6) Jumper Pins 5 and 6 P1401 (3) Not used P1405A (6) M04114A008 Coriolis Meter (M10006A003) J1501A/B (6) P1405B (6) Not used P2110 (7) M10059A002 Atlas CPU (M06333A002) P9 (6) P2112 (8) M10060A001 to

P2402 (2) M07141A003 +24 V Power Supply (M04161B005) Red - ( +)

M05201A001

Atlas CPU (M06333A002) P3 and P5 (4)

Black - (-)

Page 5-22 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

PCAs Electronic and Electrical Components

CR1 Fan Active

CR2 Heater Active

P1301A

Figure 5-18 shows E2 Temperature Control Board (M06783A001).

Figure 5-18: E2 Temperature Control Board [M06783A001 (Atlas Cold Weather DEF

Only)]

PCA Connections and Cables (Cold Weather DEF)

Connector # Through Cable To Assembly At Connector #

P2 (4) M12261A001 to

P3 (3) M12263A001 to

P1301A (6) M12264A001 to

M12202A001 to M07233A003

M09958A003

M04114A007

This assembly mounts directly to a Solid-state Relay (Q11008-02).

ater/Fan Assembly (Q13254-03) P2082 (6)

AC Power Input AC J-box (3)

Coriolis Interface (M10030A001) J1401 (3) Temperature Sensor (M10131A006) PTRMH (3)

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-23

Electronic and Electrical Components PCAs

D3 SLOW1

JJ1, JJ2, JJ3

P2402

D1 +24 V

D4 FAST1

D5 SLOW2

D2 +5 V

JJ4, JJ5, JJ6

D6 FAST2

P7105

Component Side

Solder Side

Figure 5-19 shows Valve Interface Board (M11480A001).

Figure 5-19: Valve Interface Board [M11480A001 (Atlas E85 Only)]

PCA Connections and Cables (Atlas E85 Only)

Connector # Through Cable To Assembly At Connector #

P1 (4) M04850A010 Atlas CPU (M06333A002) P1 (6) P2 (4) M04850A010 Atlas CPU (M06333A002) P2 (6) P2402 (2) M07141A003 +24 V Power Supply (M04161B005) Red - (+)

P7105 (26) Cable on M06031A001 Valve Controller (M06031A001) P6105 (26)

Due to different tolerances in components and proportional valve coils, jump jacks JJ1 through JJ6 (JJ1 through JJ3 affect side 1, JJ4 through JJ6 affect side 2) were added to allow adjusting the SLOW flow rate. If the SLOW flow rate is too slow , add ing a jumper on one of these jump jacks will increase the valve drive output in SLOW flow mode. Each jumper added increases the drive output (maximum 3 per hose outlet). They do not affect FAST (or full) flow. If jumpers have been added and the SLOW flow is too fast (for example, over run of presets), removing a jumper will decrease the drive output in SLOW flow mode.

Black - (-)

Page 5-24 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Atlas 9800 Parts Electronic and Electrical Components

CR15 Valve One Active

P6101

P6103

P6102

P6104

CR17 Valve Two Active

P6105

Figure 5-20 shows Valve Controller Board (M06031A001).

Figure 5-20: Valve Controller Board [M06031A001 (Atlas E85 Only)]

PCA Connections and Cables (Atlas E85 Only)

Connector # Through Cable To Assembly At Connector #

P6101 (4) M11717A001 M02958A002 Valve Coil (Side 1)

Atlas 9800 Parts

Atlas 9800 CPU Board (M06333KXXXX)

P6102 (4) M11717A001 M02958A002 Valve Coil (Side 2) P6103 (4) Not used P6104 (4) Not used P6105 (4) Cable on M06031A001 M11480A001 Valve Interface P7105 (26)

The features of the Atlas 9800 CPU Board are as follows:

• Accepts either 115 or 230 VAC on AUTH line inputs.

• Compatible with models 9852K, 9853K, 9850K, 98 9840A/Q, 9822A/Q, 9823A/Q/K, 9862KX, 9872KX.

• Compatible with all RS-485 I/F Boards (C06389, M05248A001, M06725A001).

• Compatible with all Pulse-out I/F Boards (C06425, C06746, M05158A001,

58A002, M05158A003, M06587A001).

M051

• Replaces 9800 CPU Boards: C06391, C06392, C06393, C06394, C06500, C06501, C0650

2, C06503, M05346A001, M05346A002, M05346A003, M05346A004.

40K, 9852A/Q, 9853A/Q, 9850A/Q,

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-25

Electronic and Electrical Components Atlas 9800 Parts

The ON position (Closed) of the switch is towards the center of the board.

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.

WARNING

• Requires new power supply M07588A00X (refer to “Atlas 9800 Power Supply

(M07588A00X)” on pa

ge 5-28).

• Requires ATC Kit (M08218K0 01), for models 9850A/Q, 9850K, 985 2A/Q, 9853A/Q, and 9840A/Q, where AT

Figure 5-21: Atlas 9800 CPU Board (M06333KXXXX)

C is present.

CPU Boards Software Type Pump Type

M06333K9800K 9800K 9852K, 9853K M06333K9850 9850 9850A, 9850Q, 9850K M06333K9840K 9840K 9840K M06333K9800AQ 9800Q 9852A/Q, 9853A/Q, 9822A/Q, 9823A/Q/K M06333K9840AQ 9840Q 9840A, 9840Q M06333KECAL 9800K ECAL 9862KX, 9872KX

Note: The above software types can be loaded on any one of the M06333KXXXX

using the appropriate M06656K00X Serial EEPROM Board.

CPU Boards b

Loading New CPU Software (M06333KXXXX)

The CPU Board is configured and programmed before shipping from the factory. In the event the software requires to be changed, proceed as follows:

1 Disconnect AC power to the pump/dispenser . Remove the DC ca ble from t he P1 conn ecto r on

the power supply .

2 Set Switch SW2-9 to the closed (“On”) position. 3 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)” on 

ge 5-29).

Page 5-26 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Atlas 9800 Parts Electronic and Electrical Components

4 Ensure that JP1 is not jumpered on the Serial EEPROM Board Assembly (M06656K00X).

Carefully insert into the P14 connector located in the middle of the CPU Board.

5 Connect the DC cable to the P1 connector on the power supply. Connect AC power to the

pump/dispenser.

6 At this point, on the Serial EEPROM Board Assembly , the green “PWR” and yellow “BUSY”

LEDs will illuminate. A few seconds later, the yellow “BUSY” LED will go off and green “OK” LED must illuminate, indicating download is OK. Ensure that the “OK” LED is lit before proceeding. If the red “NOT OK” LED illuminates, repeat steps 1 (on page 5-26) to 6. If the “NOT OK” LED illuminates after a second attempt, call your service represe

ntative or

contact Gasboy Technical Service.

7 Disconnect AC power to the pump/dispenser . Remove the DC ca ble from t he P1 conn ecto r on

the power supply.

8 Set Switch SW2-9 to the Open position.

Note: If SW2-9 is left in the Closed position, the unit wi

ll not display software version,

software type, and firmware version during power-up.

9 Carefully remove the Serial EEPROM Board assembly from the P14 connector.

10 Connect the DC cable to the P1 connector on the power supply.

11 Connect AC power to the pump/dispenser.

Ensure that the displayed software type is correct for the pump/dispenser model that the CPU is installed in (refer to the following table):

Displayed Software Type Corresponding Pump Type

“9800 1” Corresponds to the 9800Q Software:

“9800 2” Corresponds to the 9800K Software:

“9840 1” Corresponds to the 9840Q Software:

“9840 2” Corresponds to the 9840K Software:

“9850” Corresponds to all 9850 Software:

9852A/Q, 9853A/Q, 9822A/Q, 9823A/Q/K

9852K, 9853K, 9862KX, 9872KX

9840A, 9840Q

9840K

9850A, 9850Q, 9850K

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-27

Electronic and Electrical Components Atlas 9800 Parts

Power Supply Without Battery Backup

(M07588A002)

Power Supply with Battery Backup

(M07588A001)

Atlas 9800 Power Supply (M07588A00X)

The features of the Atlas 9800 Power Supply (M07588A00X) are as follows:

• Required for M06333KXXXX CPU Board (see Figure 5-21 on page 5-26).

• Compatible with models 9852K, 9853K, 9850K, 98 9840A/Q, 9822A/Q, 9823A/Q/K, 9862KX, 9872KX.

• Compatible with the following 9800 CPU Boards: C06391, C06392, C06393, C06394, C0650

0, C06501, C06502, C06503, M05346A001, M05346A002, M05346A003,

M05346A004, and M06333KXXXX.

• Replaces previous 9800 power supplies as shown in the

Description Old Power Supply Part Number Replacement Power Supply Part Number

115 VAC with Battery C06397 M07588A001 (see Note 1 below) 115 VAC Without Battery C06396 M07588A002 230 VAC with Battery C06489 M07588A003 (see Note 2 below) 230 VAC Without Battery C06488 M07588A004

Figure 5-22: Atlas 9800 Power Supply (M07588A00X)

40K, 9852A/Q, 9853A/Q, 9850A/Q,

following table:

Notes: 1) This supply can no longer be manufactured. Replacement kits are available. For



115 VAC units, the kits are as follows:

Number of Displays per Unit Kit Number

1 M12421K001 2 M12421K002 4 M12421K003

2) This supply can no longer be manufactured. Replacement kits are available. For



230 VAC units, the kits are as follows:

Number of Displays per Unit Kit Number

1 M12422K001 2 M12422K002 4 M12422K003

Page 5-28 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Atlas 9800 Parts Electronic and Electrical Components

Atlas 9800 Serial EEPROM Board (M06656K00X)

The features of the Atlas 9800 Serial EEPROM Board are as follows:

• Used to reprogram software on Atlas 9800 CPU Board [M06333KXXX (see Figure 5-21 on page 5-26)].

Serial EEPROM Board Software Type Pump Type

M06656K001* 9800K 9852K, 9853K M06656K002* 9850 9850A, 9850Q, 9850K M06656K003* 9840K 9840K M06656K004* 9800Q 9852A/Q, 9853A/Q,

9822A/Q, 9823A/Q/K M06656K005* 9840Q 9840A, 9840Q M06656K006* 9800K ECAL 9862KX, 9872KX

*A kit of the latest versions of all of these boards is also available as p

art nu

mber M06656K100.

• Provides LED indicators to monitor software transfer (Download OK and Download Not OK).

X, 

Figure 5-23: LED Indicators

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-29

Electronic and Electrical Components Atlas 9800 Parts

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:

• T o be used with models calling out for Hose requires M05683A004 Revision B or later).

• This board assembly can be configured for use in one of the following pump/dispenser config

urations:

- Dual Channel, Single Hose Pulse-out I/F (see Figure 5

- Single Channel, Dual/Single Hose Pulse-out I/F (see Figure 5-27 on page 5-36).

- Dual Channel, Dual Hose Pulse-out I/F (see Figure 5-28 on page 5-36).

• Compatible with models 9852K, 9853K, 9850K, 98 9840A/Q, 9822A/Q, 9823A/Q/K, 9862KX, 9872KX.

• Compatible with 9800 CPU Boards (C06391, C06392, C06393, C06394, C06500, C065

01, C06502, C06503, M05346A001, M05346A002, M05346A003, M05346A004,

M06333KXXXX).

• Can be used in place of previous 9800 Pump I/F Pulse-out I/F (C06746).

• Can be used in place of previous 9800 Pump I/F Board with Single Channel, Dual/S Hose Pulse-out I/F (C06425).

Note: 9850A/Q/K models cannot use M05158A00X Boards. They can use M06587A001,

25, and C06746 Boards only.

C064

Dual Channel, Dual Hose Pulse-out I/F (9850 Dual

-26 on page 5-35).

40K, 9852A/Q, 9853A/Q, 9850A/Q,

Board with Dual Channel, Single Hose

ingle

Figure 5-24: Atlas 9800 Pulse-out I/F Board with EM Totalizer Drive (M06587A001)

Page 5-30 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Accessing Electronic Components Electronic and Electrical Components

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.

WARNING

K-pump RS-485 with Totalizer (M06725A001)

The features of K-pump RS-485 with Totalizer Board are as follows:

• Allows RS-485 communications between 9800 and a CFN system, TopKAT, or TopKAT PLUS Electronic

• Compatible with 9852K, 9853K, 9850K, 9840 9822A/Q, 9823A/Q/K, 9862KX, 9872KX.

• Compatible with 9800 CPU Boards (C06391, C06392, C06393, C06394, C06500,

01, C06502, C06503, M05346A001, M05346A002, M05346A003, M05346A004,

C065 M06333KXXXX).

• Can be used in place of previous 9800 RS-485 I/F Board C06389 and M05248A001.

Figure 5-25: K-pump RS-485 with Tot alizer (M06725A001)

system.

K, 9852A/Q, 9853A/Q, 9840A/Q, 

Accessing Electronic Components

To access the electronic components, proceed as follows:

1 Unlock and remove the front panel on the pump/dispenser.

2 Remove the two bolts/screws located over the tabs of the bezel assembly. Lift the bezel

assembly upwards and out to remove.

Note: For A and Q models with front load nozzle,

screws) before removing the bezel assembly.

3 Loosen the two screws that secure the display panel and remove them, if required, and pivot

the display panel down.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-31

remove the nozzle boot plastic shroud (two

Electronic and Electrical Components Installing Atlas 9800 Power Supply (M07588A00X)

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.

WARNING

Installing Atlas 9800 Power Supply (M07588A00X)

To install the Atlas 9800 Power Supply (M07588A00X), proceed as follows:

1 Check the existing power supply. For the correct replacement part number, refer to 

“Atlas 9800 Power Supply (M07588A00X)” on page 5-28.

2 Ensure that the AC power to the pump/dispenser has been disconnected.

3 Disconnect the AC power cable from the P3 connector. Disconnect the DC cables from the P2

and P1 connectors.

4 Unscrew and remove all screws that hold the power supply . Retain the screws for installing the

new power supply.

5 Remove the power supply. For models with plastic standoffs, after the screws have been

removed, carefully unsnap the power supply from the standoffs and remove it. Remove any standoffs that may have remained on the power supply and place them back into the plate where the power supply was mounted.

6 Install the new power supply on the standoffs. Ensure that the P1 connector is closest to the

CPU Board and P3 connector is away from the CPU. If the pump model is 9822 or 9823, the P1 connector is closest to the pump handle assembly.

7 Reinstall the screws removed in step 4. For models with plastic standoffs, carefully push the

power supply onto the plastic standoffs before

8 Reconnect the following:

installing the screws.

• Cables and AC power to the P3 connector.

• Display Backlight to the P2 connector.

• CPU DC to the P1 connector.

Page 5-32 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Installing Atlas 9800 CPU Board (M06333KXXXX) Electronic and Electrical Components

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.

WARNING

Installing Atlas 9800 CPU Board (M06333KXXXX)

To install the Atlas 9800 CPU Board, proceed as follows:

1 Check the existing power supply. If the existing supply is not a M07588A00X Assembly, it

must be replaced. For additional information, refer to “Installing Atlas 9800 Power Supply

(M07588A00X)” on page 5-32.

2 Ensure that the AC power to the pump/dispenser has been disconnected. Remove the DC cable

from the P1 connector on the power supply.

3 If the pump/dispenser does not have ATC installed, proceed to step 4. If the model of the

pump/dispenser is one of the following - 985 0A/Q, 9850K, 9852 A/Q, 9853A/Q, 9840A/Q, the AT

C support bracket (that holds the ATC black box) must be replaced. Use the kit

M08218K001 to install the new bracket.

4 If the pump/dispenser has an RS-485 or Pulse-out Interface Board, remove the screws that

secure the interface board and disconnect it from the existing CPU Board.

5 Disconnect all cables going to the connectors on the CPU Board. Ensure that you take note of

connectors and cables so that they can be reconnected to the correct connector.

6 Unscrew and remove all the screws holding the CPU Board. Retain the screws for installing

the M06333KXXXX CPU Board.

7 Remove the CPU Board. For models with plastic standoffs, carefully unsnap the CPU Board

from the standoffs and remove it. Remove any standoffs that may have remained on the CPU Board and place them back into the plate where the board was mounted.

8 The M06333KXXXX CPU Board can be configured for various operating conditions using

the jumpers JP1 to JP9 and Switch SW2. Check these jumpers and switch settings and change, if required. Jumper settings must be changed with the power to the pump/dispenser “Off”. The M06333KXXXX CPU Board only reads new jumper settings during power-up. For detailed information on Jumper and Switch Settings for the M06333KXXXX CPU, refer to

“Configuration Steps” on page 4-5.

9 Set the new CPU Board on the standoffs. Reinstall screws removed in step 6. For models with

plastic standoffs, en sure that the metal st andoffs

are under the mounting holes located between P2 and P3, and the outside corner next to P5. Carefully push the new CPU Board onto the standoffs before installing the screws.

10 Reconnect all the cables, P1 to P9, and P11, if applicable. Reconnect the DC cable to P10 of

the power supply.

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-33

Electronic and Electrical Components Installing Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board (M06587A001)

11 Apply power to the pump/dispenser and take note of the display(s). The first set of numbers

displayed will be the software version (for example, 06013), second set is the software type (for example, 9800 1), and third set is the firmware version (for example, 01008).

Ensure that the displayed software type is correct for

the pump/dispenser model that the CPU is installed in (refer to the following table). If it is, proceed to step 12. If not, proceed to

“Loading New CPU Software (M06333KXXXX)” on page 5-26.

Displayed Software Type Corresponding Pump/Dispenser Model

“9800 1” Corresponds to the 9800Q Software:

“9800 2” Corresponds to the 9800K Software:

“9840 1” Corresponds to the 9840Q Software:

“9840 2” Corresponds to the 9840K Software:

“9850” Corresponds to all 9850 Software:

12 Reassemble the pump/dispenser by proceeding to “Accessing Electronic Components” on

9852A/Q, 9853A/Q, 9822A/Q, 9823A/Q/K

9852K, 9853K, 9862KX, 9872KX

9840A, 9840Q

9840K

9850A, 9850Q, 9850K

page 5-31 and follow the steps in the reverse order.

Installing 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:

• Dual Channel, Single Hose Pulse-out I/F (see Figure 5-26 on page 5-35).

• Single Channel, Dual/Single Hose Pulse-out I/F (see Figure 5-27 on page 5-36).

• Dual Channel, Dual Hose Pulse-out I/F (see Figure 5-28 on page 5-36).

Following chart shows the jumper settings and wires to c configuration.

Check JP1 - JP3 jumpers and change them, if required. The jumper settings must be changed only when the power to the pump/dispenser is removed, to protect the circuit that they are connected to.

The default configuration is Single Channel, Dual/Single Hose Pulse-out I/F. When configured for Dual Channel, Single Hose Pulse-out I/F, or Single Channel, Dual/Single Hose Pulse-out  I/F, the P3 connector is not connected.

onnect to in the J-box, based on the

Page 5-34 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Installing Atlas 9800 Pulse-out I/F with EM Totalizer Drive Board (M06587A001) Electronic and Electrical Components

Pulse Side 1

Side 1B Output (Green)

Side 1A Output (Red)

Side 1A Return (Black)

Side 1A Return (White)

When configured for Dual Channel, Dual Hose Pulse-out I/F, the P3 connector is used.

Jumper Settings

Single Channel, Dual/Single Hose Pulse-out I/F (Default Setting)

Wire Color JP1 Position 1

JP2 Position 1 JP3 Open

Black No Connection Side 1B Return Side B Return Blue** No Conn ection No Connection Pulse Out Side 2A* Brown No Connection No Connection Pulse out Side 2A Gray No Connection No Connection Side 2B Return Green Pulse out Side 2 Pulse out Side 1B Pulse out Side 1B Amber No Connection No Connection Pulse out Side 2B Red Pulse out Side 1 Pulse out Side 1A Pulse out Side 1A Violet** No Connection No Connection Pulse Out Side 2B* White Common Return Side 1A Return Side A Return Yellow No Connection No Connection Side 2A Return

*Requires DC conduit M05683A004 Revision B or later. **9850K models only.

Dual Channel, Single Hose Pulse-out I/F

JP1 Position 2 JP2 Position 2 JP3 Open

Dual Channel, Dual Hose Pulse-out I/F

JP1 Position 2 JP2 Position 2 JP3 Jumpered

Jumpers JP4 and JP5

When this board is used in a model A or Q pump/dispenser or 9850K, jumpers JP4 and JP5 are set to the Q/A position. When this board is used for all other K models except 9850K, these jumpers must be in the K position.

Configurations

Refer to Figure 5-26 through Figure 5-29 on page 5-36 for different configurations.

Figure 5-26: Dual Channel, Single Hose Pulse-out I/F

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-35

Electronic and Electrical Components

Pulse Side 1

Pulse Side 2

Side 1 Output (Red)

Side 2 Output (Green)

Common Return (White)

Pulse Side 1

Side 1A Output (Red)

Side 1B Output (Green)

Side 1A Return (White)

Side 1B Return (Black)

Pulse Side 2

Side 2A Output (Brown)

Side 2B Output (Amber)

Side 2A Return (Yellow)

Side 2B Return (Gray)

Pulse Side 1

Side 1A Output (Red)

Side 1B Output (Green)

Pulse Side 2

Side 2A Output (Blue)

Side 2B Output (Violet)

Side A Return (White)

Side B Return (Black)

Figure 5-27: Single Channel, Dual/Single Hose Pulse-out I/F

Figure 5-28: Dual Channel, Dual Hose Pulse-out I/F

Installing Atlas 9800 Pulse-out I/F with EM Totalizer

Drive Board (M06587A001)

Figure 5-29: Dual Channel, Dual Hose Pulse-out I/F on 9850KX Ultra-Hi

Page 5-36 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Atlas 8800 Parts

AT_PumpPCA_interface

P306

P307 P406 P405

P309 P308 P305

Atlas 8800 Parts

Pump Interface PCA [T18994 (Atlas 8800 Only)]

Pump Interface PCA (T18994) connects with the pump controller and pulsers, pump handle switches, valves, STP signal relays, and electro-mechanical totalizers. Normally , this interface is with the Pump Controller PCA. However, when an ATC Controller Board is used, the Pump Controller Interface sends pulser information to the ATC Controller PCA. The Hydraulic Interface (T18994) also converts the 24 VAC it receives from the power supply to 14 VDC for the pump handle feed and 150 VDC for pulsers. The interface receives +5 VDC from the Pump Controller PCA and supplies 120 VAC for the valve and STP signals.

Figure 5-30 shows the STP P

Interface, Pump Interface PCA (T18994-G1).

Figure 5-30: Pump Interface PCA [T18994 (Atlas 8800 Only)]

A layout that contains components related to the Hydraulic

Electronic and Electrical Components

PCA Connections and Cables

Connector # Through Cable To Assembly At Connector #

P305 (20) R19952-G1 T20092-G1 P205 (16) P306 (5) R19939-G1 T20092-G1 P206 (5) P307 (10) R19951-G1 T20092-G1 P207 (10) P308 (2) 24 VAC R20333-G1

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-37

P309 (12) T19983 T19983-G1 P604 (4) P601 (3) P401

)

M04658A001 Q12514-10 (A1)/Q12514-10 (B1) PH (A1) (4), PH (B1) (4)

P405 (2

P406 (5) M04889A001

R19072-G1 T18350-G3 (A) T18350-G3 (B) J921B (4), J921A (4) M04658A001 Q11763-01 (+) (C) (-)

M00455A003 Grade 1 J922A (4) M00455A003 Grade 1 J922B (4)

Electronic and Electrical Components Atlas 8800 Parts

P206

P207

P208

P201

P204

P203

P202

P205

JP1

AT_PumpPCA_controller

P206

P207

P208

P201

P204

P203

P202

P205

JP1

Pump Controller PCA [T20092 (Atlas 8800 Only)]

This PCA provides computation for the operation of the unit. It provides instructions to the other boards for:

• Control of valves

• Displayed information

• Sale progression

• Sale calculations

•Totals memory

• Programming storage

Figure 5-31 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 5-31: Pump Controller [T20092 (Atlas 8800 Only)]

T20092 Connections and Cables (with ATC)

Connector # Through Cable To Assembly At Connector #

P201 (10) (Not used)

P202 (13) (Not used)

P203 (10) R201461-G1 T20569-G1 P303 (10) P204 (34) R19667-G1 T20569-G1 P304 (34) P205 (16)

P207 (10)

P206 R19939-G1 T18994-G1 P306 (5)

Page 5-38 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

M02739A001 T20569 P405 (34)

P301 (20) P305 (34)

Atlas 8800 Parts Electronic and Electrical Components

CR-2 Blink = Transmitting Data

CR-1 ON = Two-wire Reversed

CR-4 Blink = Receiving Data

CR-3 ON = CPU Running

JP-1 Jumper On at  Power Up = Master Reset

Figure 5-32 shows the Hydraulic Interface that contains assemblies and components related to

customer information on the Pump Controller PCA (T20092-G1).

Figure 5-32: Atlas 8800 Pump Controller (T20092)

PCA Connections and Cables

Connector # Through Cable To Assembly At Connector #

P201 (10-pin) N/A N/A N/A P202 (13-pin) N/A N/A N/A P203 (10-pin) R19951-G1 T17549-G1 P901A (10) P204 (34-pin) T17768-G1 T17701-G1 or T18981-G1,

P205 (16-pin) R19952-G1 T18994-G1 P305 (16) P206 (5-pin) R19939-G1 T18994-G1 P306 (5) P207 (10-pin) R19951-G1 T18994-G1 P307 (10) P208 (3-pin) R20412-G3 J402 Field Wiring P402A (2)

This PCA contains a firmware chip that holds base instructions for the operation of the unit. LEDs are provided to alert the technician during diagnostics, regarding POS problems, processor function, or reversed polarity of the two-wire system feed wires.

The board receives +14 VDC from th e Hydraulic Interface PCA. Cus tomer 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.

andard LCD Display

P801 (34) (Side A)  (2 places) and (Side B)  (2 places)

P402 (3)

MDE-4334D Atlas™ Start-up and Service Manual · July 2013 Page 5-39

Electronic and Electrical Components Atlas 8800 Parts

AT_ATC_GR4

P307

TP1

P405

P301

P305 S1

P415

P303

P303A

P304

P308

P204A

JP1

ATC Component Overview (Atlas 8800 Only)

The ATC PCA (T20569) and T-Meter Module ATC (T19405) are optional electronic components. Examples of probes and meters used for temperature control are primarily for the Canadian market. The ATC option measures the temperature of the dispensed products and compensates for changes in the product volume due to changes in the ambient temperature.

The T-Meter Module PCA links the thermal probe in

the meter cover with t

he ATC PCA. An Intrinsically Safe (I.S) barrier is used at the J-box between the T-Meter Module PCA and ATC PCA.

115/230/380 VAC Single/Dual Unit with ATC PCA (T20569) and

Programmable Pump Preset (Option)

The ATC PCA (T20569) records the temperature-related input from the T-Meter Module Hydraulic Interface PCA, which then modifies the pulser-count to regulate the temperature change. The adjusted pulser-count is supplied to the Pump Controller PCA. Components for the firmware are located near the center of the board at U5 and U11, which also contains the battery-backed RAM. The PCA receives +5 VDC from the Pump Controller PCA and

14.5 VDC from the Pump Interface PCA. The ATC PCA also receives Keypad before the Pump Controller PCA, which allows information to be entered through the keypad for programming and testing purposes, when the ATC is us ed.

Figure 5-33: ATC PCA [T20569 (Atlas 8800 Only)]

data from the Manager

Page 5-40 MDE-4334D Atlas™ Start-up and Service Manual · July 2013

Gasboy Atlas Start-up User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 – Read This First

Introduction

Purpose

Important Information About Releases

Topics in This Section

Who Must Use This Manual

Service Protocol

Related Documents

Abbreviations and Acronyms

Common Terms Used

DEF Special Considerations

Troubleshooting DEF Freeze

If DEF Freezes

Important Requirements for E85 Units

Model Information

Mechanical Retail Pump/Dispenser

Electronic Retail Pump/Dispenser

Serial Number Plate and Date Codes

Atlas Model Number Table

Options Overview

2 – Important Safety Information

3 – Start-up Procedures

Introduction

Purpose

Important Information About Releases

Topics in This Section

How to Use This Section

Certificate of Conformance (CoC) Numbers

Start-up Checklists

Installation Checklists

Meter Calibration

Gasboy Atlas (Gallon Unit of Measure)

4 – Pump Programming

Introduction

Purpose

Important Information About Releases

Programming Overview

9800 Series Electronic Commercial Units

8800 Series Electronic Retail Units

Mechanical Commercial Units

Configuring 9800 Series

General Configuration Details

Configuration Steps

ATC Setup

Error Codes

Programming 8800 Series Units

General Programming Details

Display Conventions

Programming Steps for 8800 Series Units

Level 1 Programming

Level 2 Programming

Level 3 Programming

Option and Miscellaneous Programming/Data Acquisition

Displaying Pump Totals

Error Codes and Descriptions

Programming 8700 Series Units

General Programming Details

Programming Steps

5 – Electronic and Electrical Components

Introduction

Purpose

Important Information About Releases

Topics in This Section

How to Use This Section

Electronics Highlights

Retail Parts by Name

Retail Parts by Number

Commercial Parts by Number

8800 Series Electronic Retail Units

System and Component Overview

About Service Procedures

Working on Electronic and Electrical Components

Preparing for Service

Preventing ESD

Hazardous Materials