Atlas
®
DEF Operation, Diagnostics, and
Recommended Spare Parts
Manual
MDE-5044A
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
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
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac
Registered trademarks
ASTRA
®
Atlas
®
Fuel Point
®
Gasboy
®
Keytrol
®
Slimline
®
Non-registered trademarks
Consola
™
Infinity
™
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.
Federal Communications Commission (FCC) Warning
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be re quired to correct the inte rference at his own exp ense. Changes or modifications not expressly approved by
the manufacturer could void the user’s authority to operate this equipment.
Approvals
Trademarks
Additional US and foreign trademarks pending.
Other brand or product names shown may be trademarks or registered trademarks of their respective holders.
This document is subject to change without notice.
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com
2014 GASBOY. All Rights Reserved.
Table of Contents
Table of Contents
1 – Introduction 1-1
Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 – Important Safety Information 2-1
3 – Operation Modes 3-1
Fueling Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fueling at Idle State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Cold Weather DEF Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
DEF LED Functions - Cold Weather Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
9800 CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Coriolis Meter Interface Board . . . . . . . . . .
Temperature Control Board . . . . .
DEF Warm Weather Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
. . . . . . . . . . . . . . . . . . . . . . 3-2
. . . . . . . . 1-1
. . . . . . . . 1-1
. . . . . . 1-1
. . . . . 1-1
. . . . . 3-2
4 – Diagnostics, Calibration, and Troubleshooting 4-1
DEF Dispenser Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Diagnostics Procedure for Cold Weather Problems
Atlas 9862 DEF Dispenser Status/Error Codes.
Electronic Calibration (E-CAL) Adjust
Calibration and Accuracy Checks - DEF Dispensers. . . . . . . . . . . . . . . 4-9
ment for E-85/DEF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
. . . . . . . . . . . . . . . . . . 4-5
5 – Recommended Spare Parts 5-1
Electronic Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lower Hydraulic Section . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Index Index-1
MDE-5044A Atlas® DEF Operation, Diagnostic, and Recommended Spare Parts Manual · April 2014 Page i
Table of Contents
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Page ii MDE-5044A Atlas® DEF Operation, Diagnostic, and Recommended Spare Parts Manual · April 2014
Purpose Introduction
1 – Introduction
Purpose
This manual provides information on the operations, diagnostics, and recommended spare
parts for the Atlas
Intended Users
This manual is intended to assist the Authorized Service Representative (ASR) or technician
in troubleshooting, operating, and identifying the parts for the Atlas DEF dispenser.
Required Tools
®
Diesel Exhaust Fluid (DEF) dispensers.
Following tools are required for diagnosing and repairing the Atlas DEF dispenser:
• Digital Voltmeter
®
• Flat-blade and Phillips
Screwdrivers
• Set of Hydraulic Wrenches
• Rubber Mallet
• Magnetic Ring Tool (M10656B001) for units without M10257B002 Nozzle
Related Documents
Document
Number Title GOLD
FE-356 Field Wiring Diagram Atlas Retail, Commercial, E-85, and
DEF Dispenser
MDE-4331 Atlas
MDE-4334 Commercial and Retail Series Atlas St
Fuel Systems Installation Manual Gasboy Atlas Pumps/Dispensers
s with Electronic and Mechanical Displays
Abbreviations and Acronyms
Term Description
ASR Authorized Service Representative
CPU Central Processing Unit
DEF Diesel Exhaust Fluid
E-CAL Electronic Calibration
®
GOLD Gilbarco
I/O Input/Output
J-box Junction Box
LED Light Emitting Diode
Online Documentation
SM
Library
Gasboy® Parts List & Wiring Diagrams
art-up/Service Manual Gasboy Atlas Pumps/Dispensers
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 1-1
Introduction Abbreviations and Acronyms
Term Description
LSD Least Significant Digit
MSD Most Significant Digit
PCA Printed Circuit Assembly
PCB Printed Circuit Board
RAM Random Access Memory
ROM Read Only Memory
W&M Weights and Measures
Page 1-2 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
2 – 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 in formation 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).
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
!
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical component s or
the electronics of the dispenser requires total elect rical 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)
Read the Manual
Read, understand and follow this manual 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
oth
e
rs to understand the procedures before beginning work .
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 lea d to leg al citation s
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 safety hazard and violate
local regulations.
Safety Symbols and Warning Words
This section provides important information about wa rn ing
symbols and boxes.
Alert Symbol
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
ent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible injury
or death.
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 followe d to prevent death, injury or
damage to the equipment:
DANGER: Al
erts yo
u to a hazard or unsafe practice
which will result in death or serious injury.
WARNING: Alerts
you to a hazard or unsafe practice
that could result in death or serious injury.
CAUTION with Alert symbol: Designates a hazard or
un
safe practice which may result in minor injury.
CAUTION w
i
thout Alert symbol: Designates a hazard or
unsafe practice which may result in property or
equipment damage.
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, expl
osion and fire safety
warnings do not apply to DEF fluid lines.
!
!
!
Important Safety Information
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 2-1
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
!
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 burn s.
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 and their vapors.
No Sparks - No Smoking
Sparks from starting vehicles, starting or using power tools,
burning cigarettes, cigars or pipes can also ig nite 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 capab l e of
rendering first aid be present during servicing. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods, if
you work with or around high voltages. This informa tion is
available from the American Red Cross. Always 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:
• Location of accident (for example, address, front/back of
building, and so on)
• Nature of accident (for example, possible heart attack, run
over by car, burns, and so on)
• Age of victim (for example, baby, teenager, middle-age,
elderly)
• Whether or not victim has received first aid (for example,
stopped bleeding by pressure, and so on)
• Whether or not a victim has vomited (for example, if
swallowed or inhaled something, and so on)
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 complete ly 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-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
IMPORTANT: Oxyg en may be needed at scene if gasoline has
been ingested or inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/Tagout covers servicin g and maintenance of machines
and equipment in which the unexpecte d energization or sta rt-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 electric al haz ards.
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 circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 2-3
Important Safety Information
This page is intentionally left blank.
Page 2-4 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Fueling Process Operation Modes
The DEF nozzle with the blue cover requires a magnetic actuator to dispense the
product. The DEF nozzle with the black cover does not require a magnetic actuator.
IMPORTANT INFORMATION
3 – Operation Modes
Fueling Process
Fueling at Idle State
When the dispenser is at idle state, the following will occur while fueling:
• Electronic head-assembly displa
• Dispenser is in the prime state and urea is at the i
(M02321A005).
• The nozzle is removed from a cold weather dispenser or
weather dispenser.
• Display resets and shows all 8s, then 0s with decimal point.
• Solenoid valve opens (with an audible click).
• Nozzle is inserted into the tank labeled for urea.
• Nozzle is squeezed and product is dispensed.
• Display shows the amount of product being dispensed.
• Nozzle is turned off and product stops
• Nozzle is returned to the cradle or
• Solenoid valve closes and the fueling transaction is terminated.
• Display shows the total amount of product dispensed.
y shows the last sale or a decimal point.
ntake of the Solenoid Valve
handle is turned on a warm
dispensing.
the handle is turned off.
Cold Weather DEF Dispenser
Following will occur in cold weather DEF unit while fueling:
• The dispenser is primed and the product is at the intake of the sol
• When the nozzle is removed, sensor switch sends signal to 9800 Central Proc
(CPU) Board (M06333KECAL):
- Side 1 “Handle” Light Emitting Diode (LED) lights.
- Customer display shows all 8s, then 0s with decimal point.
- Side 1 “Fast”, “Slow”,
- Submersible motor activates in the tank.
- 9800 CPU board sends the AC hot signal to the solenoid valve.
- Solenoid valve opens.
• The product flows and enters into the Coriolis
then to the nozzle (hose jumps).
• When the nozzle is opened, product starts to flow.
• The coriolis meter senses and monitors the product flow and
Coriolis Meter Interface Board (M10030A001) and then to the 9800 CPU board.
• The pulse A LED flashes for pump #1 on the 9800 CPU board.
• If the optional Dual Pulse Input/Outp
9800 CPU board, the two pulsar LEDs will flash when product flow is detected.
• When fueling stops, pulsar LEDs on the 9800 CPU board and optional dual pulse I/O
board stop flashing.
• Customer display shows the total amoun
• Nozzle is placed back into the cradle, dispense
• The fast, slow, and sub LEDs on the 9800 CPU board
TRANSACTION.
enoid valve.
essing Unit
“Sub” LEDs light.
Meter/Pulsar Assembly (M10006B501) and
sends the pulse signal to the
ut (I/O) Board (M06587A001) is attached to the
t of product dispensed in gallons.
r motor stops, and the solenoid valve closes.
are now OFF. END OF
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 3-1
Operation Modes DEF LED Functions - Cold Weather Units
DEF LED Functions - Cold Weather Units
9800 CPU Board
Following table shows the LEDs on the 9800 CPU board:
LED LED Status Condition
Pump Handle On Nozzle out
Pulsar On (Flashing) Product flowing
+5 VDC On Always
Slow LED
On Nozzle out and authorizedFast LED
Sub LED
Coriolis Meter Interface Board
Following table shows the LEDs on the coriolis meter interface board:
LED LED Status Condition
CR 1 On +24 VDC power supply enabled
CR 2 - CR 3 On Meter side ‘A’ enabled with the pump handle
CR 4 On +5 VDC power supply enabled
CR 5 Off Pump not in frozen state
Temperature Control Board
Following table shows the LEDs on the temperature control board:
LED LED Status Condition
CR 1 On Power supplied to the fan
CR 2 On Power supplied to the heater
Note: Both CR 1 and CR 2 will activate together when the thermostats
ature o
detect a temper
f 43 °F (6.1 °C) in the cabinet.
DEF Warm Weather Units
DEF warm weather units operate and function the same as the DEF cold weather units without
the functions of the heater/fan assembly, thermostats, and temperature control board, as these
items are not included in the DEF warm weather unit.
Page 3-2 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Diagnostics, Calibration, and Tr oubleshooting DEF Dispenser Problems
An intermitting or bad 9800 power supply can cause the symptoms mentioned in
“Problem 1: Entire unit is down/dead.”, always with the exception of AC power (+5 VDC)
present in the unit.
IMPORTANT INFORMATION
4 – Diagnostics, Calibration, and Troubleshooting
DEF Dispenser Problems
Following section is provided to guide you through possible DEF dispenser problems. For
more information, refer to MDE-4331 Atlas Fuel Systems Installation Manual, MDE-4334
Commercial and Retail Series Atlas Start-up/Service Manual, and FE-356 Field Wiring
Diagram Atlas Retail, Commercial, E-85, and DEF Dispensers with Electronic and
Mechanical Displays.
Before beginning any troubleshooting session, it is advisa
• Perform a visual inspection of the dispenser to ensure that
ble to follow these steps:
it is installed according to
MDE-4331 Atlas Fuel Systems Installation Manual.
• Ensure that all cables and switch settings are connected and set
properly according to
MDE-4331 Atlas Fuel Systems Installation Manual and MDE-4334 Commercial and
Retail Series Atlas Start-up/Service Manual.
• Measure the DC power supply output voltages to
ensure that they are proper operating
tolerances.
• Observe all the LEDs on all the Printed Circuit Boards (PCBs) to ensure that proper s
is present.
• Observe the customer display and verify if any error messages are present.
• Verify if this is a new start-up or an existing unit,
and for how long has it been in
operation.
Note: Before beginning any troubleshooting
session, it is helpful to use the “Flow Chart” on
page 4-3 and the “Atlas DEF Block Diagram” on page 4-4.
Following table shows possible symptoms,
Problem 1: Entire unit is down/dead.
Symptoms • No customer display.
• Display is blank.
• Unable to reset unit.
• Unable to dispense product.
• No LEDs light on any PCBs.
Possible Causes • No 115 VAC feed to dispenser.
• Dispenser’s circuit breaker is off.
• Blown system fuse.
• Loose or disconnected AC wiring in Junction Box (J-box).
Corrective Action • Turn on AC breaker for the dispenser, if off.
• Ensure 115 VAC at all power supplies input.
• Check system fuse if AC is not present in the power supply.
• Check and measure the AC voltage in the J-box, if all of the above fails.
causes, and corrective actions:
ignal
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 4-1
DEF Dispenser Problems Diagnostics, Calibration, and Troubleshooting
Problem 2: No product dispenses/flows.
Symptoms • Dispenser electronically resets.
Possible Causes • Solenoid valve does not activate.
Corrective Action • Ensure to hear the solenoid valve opening.
• Display shows all 0s.
• No error messages.
• No product dispenses.
• 9800 CPU board does not send the AC signal to the solenoid valve or submersible motor in the tank.
• Bad submersible motor in the product’s tank.
• Bad coriolis meter interface board (possibly due to the coriolis meter).
• Bad nozzle.
• Check valve is stuck at the closed position.
• Feel the hose jump.
• Observe fast, slow, and sub LEDs on the 9800 CPU board.
• Check fast and slow fuses on the 9800 CPU board, replace if open.
• If the solenoid valve activates, check for proper AC signal at the sub fuse on the 9800 CPU board.
• Replace the fuse, if open. If the fuse is OK but there is no sub LED, replace the 9800 CPU board.
• If the 9800 CPU board displays a proper AC signal, open the inlet line to verify if the product flows when the
unit is on.
• Replace the submersible motor, if there is no product flow at the inlet.
• Verify if the check valve is not stuck at the closed position by loosening the inlet cap. Also, verify if the
product is present.
Problem 3: Dispenser does not calibrate.
Symptoms • Display shows error code 993 on DEF unit.
Possible Causes • Air in product line needs to be purged.
Corrective Action • Verify that the tank is not low in product, request a delivery if the product level is low.
Problem 4: DEF unit dispenses product very slowly, slow flow.
Symptoms • No error messages appear, but the product dispenses very slowly as in slow flow mode.
Possible Causes • Dirty filter, product contamination.
Corrective Action • Remove inlet filter and replace, if dirty.
• No product can be dispensed.
• Product leak in the plumbing.
• Bad 9800 CPU board or program.
• Very low product level in the tank.
• Product contamination.
• Recalibrate the DEF unit by performing the calibration procedure described in MDE-4331 Atlas Fuel
Systems Installation Manual and MDE-4334 Commercial and Retail Series Atlas Start-up/Service Manual.
• Dispense product until there is no visual evidence of air in the product (may take two to three prover cans).
• Check for any product leaks in all the product lines and the internal plumbing. Correct the leaks, if visible.
• Verify that the filter is clean and free of debris.
• Change the 9800 CPU board, if all of the above fails.
• Check valve not opening completely.
• Defective solenoid valve.
• Defective 9800 CPU board.
• Defective submersible motor in tank.
• Defective nozzle filter or the nozzle.
• On the 9800 CPU board, measure for 115 VAC on both sides of the fast flow fuse (F2).
• If AC is not present, perform a continuity test across the F2 fuse. Replace the fuse, if open.
• If the F2 fuse is not open, replace the 9800 CPU board.
• If 115 VAC is present on the blue and black wire on the two stage solenoid valve, replace the solenoid
valve.
• Check the submersible motor to see if the running is at full speed due to low voltage or defective motor.
• DEF nozzle could restrict the flow (remote possibility), replace the nozzle and retry dispensing the product.
Page 4-2 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
STOP
Below
Operating
Temperature
Specs.
YES
NO
Wait Until Local
Temperature
Increases
and Warms
Test 9800
CPU
Board
PROBLEM 1
Hear Fan ON
Feel Heat in Lower Cabinet
Feel Heaters
YES
Verify
Solenoid
Valve is
Open
NO
NO
Coriolis
Interface
CR1 and
CR2 ON
YES
NO
Replace
Coriolis
Meter
M10006A003
Temperature Control Board
CR1 and CR2 is ON
Replace
Power
Supply
M04151B005
YES
Test Fuse on
Heater/Fan
Assembly
Replace
Heater and
Fan
Assembly if
Fuse is good
NO
YES
NO
YES YES
YES
YES
NO
NO
NO
NO
NO
Verify
110 VAC
is on P3 AC
Input
Connector
Temperature
Control Board
Mearure for
+5 VDC
at TP1 and TP2
Temperature
Control Board
Mearure
+5 VDC
on P130 Pin 1
Measure
110 VAC
at P1301A at Pins
1 and 4
Replace
Temperature
Control
Board
Replace
Bottom
Temperature
Sensor
Verify
110 VAC
is Measured
at J-box
Check Power
Cable
Connection to
Temperature
Control
Board
Coriolis
Interface
Board
Measure
+5 VDC at
J1401 Pins
1 and 3
Check Circuit
Breaker is ON
9800 CPU Board
Measure +5 VDC at
P9 Pins 1 and 6
No or Low
Voltage
Measured
YES
Is
Outside
Temperature
Below - 30
DISPLAY
999
No Product
Frozen Condition: The coriolis interface board monitors the temperature at the
solenoid valve using the temperature sensor known as the frozen thermostat. The
purpose is to remove power to signal the 9800 CPU board not to active the solenoid
valve on the coriolis meter. This prevents the solenoid valve to potentially leak and
also prevent damage to the coriolis meter.
The CR5 LED on the coriolis interface board will light when a freeze condition
exists, which is normally caused by other component failure, causing the heaters
not to turn on as shown Figure 4-1.
Calibration Test: When the freeze problem has been
corrected and the heater/fans are working, to keep the inside
cabinet temperature in 30° F (-1.1° C) range or higher, you
need to recalibrate the unit to remove the error message 999
displayed.
Symptoms: In very cold weather conditions, the display shows 999 and is unable to dispense product.
Diagnostics, Calibration, and Tr oubleshooting Diagnostics Procedure for Cold Weather Problems
Diagnostics Procedure for Cold Weather Problems
Figure 4-1 shows the flow chart of diagnostics procedure for cold weather problems for Atlas
9862 DEF units.
Figure 4-1: Flow Chart
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 4-3
Diagnostics Procedure for Cold Weather Pro bl ems Diagnostics, Calibration, and Troubles hooting
P2112
P2110
P1401
P1405A
P2402
P1400
J-3 AC IN
CR2
Heater ON
CR1
Fan ON
P-2
P-3
P1301A
P1
P2
P3
P4
P5
Atlas®9862 DEF Block Diagram
+5 VDC
+5 VDC
110 VA C
+5 VDC
P9
Nozzle Boot
Switch
(M06600K001)
Frozen
Thermostat
(M10131A008)
Two Stage
Valve
(M02321A005)
Heater
Thermostat
(M10131A006)
Coriolis Meter [M10006A001
(Complete Assembly)]
[M10006B501 (Electronics)]
Fan/Heater Assembly
(M12260A001) for Nozzle
Fan and Heater Assembly
(Q13254-03)
Motor
Relay
40 Amp
(Q11008-02)
Switching Power Supply
(M04161B005)
24 VDC
IN
Atlas 9862
CPU
M06783A001
Temperature Control Board
M10030
Coriolis Interface
Figure 4-2: Atlas DEF Block Diagram
Page 4-4 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Diagnostics, Calibration, and Tr oubleshooting Diagnostics Procedure for Cold Weather Problems
The DEF nozzle with the blue cover requires a magnetic actuator to dispense the
product. The DEF nozzle with the black cover does not require a magnetic actuator.
IMPORTANT INFORMATION
Atlas 9862 DEF Dispenser Status/Error Codes
Code Status
01 Random Access Memory (RAM) failure
02 Read Only Memory (ROM) failure
55 Power failure
56 Pulsar error
57 Timed out
58 Limit cutoff
59 Flow error meter 1
60 Flow error meter 2
99 Product unavailable
554 Power failure (calibration mode)*
564 Pulsar failure (calibration mode)*
574 Timed out (calibration mode)*
584 Limit cutoff (calibration mode)*
993 Invalid calibration factor*
994 Invalid calibration transaction
*During calibration testing.
Customer Display
Code Definition
7 Calibration switch on
5, 10, 15, 20, 50 Prover can sizes
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 4-5
Electronic Calibration (E-CAL) Adjustment for E-85/DEF Unit Diagnostics, Calibration, and Troubleshooting
Calibration Switch
(i)
(ii)
Electronic Calibration (E-CAL) Adjustment for E-85/DEF Unit
The E-85/DEF unit must be calibrated electronically. To calibrate the unit, proceed as follows:
Notes: 1) If the unit is two-sided, then the calibra
individually on each side.
2) The calibration switch is located on the J-box side of all thr
(see Figure 4-3).
Figure 4-3: Calibration Switch and J-box
tion procedure must be performed
ee E-85 unit types
1 Slide the back cover and turn the calibration switch to “Calibrate” position (up).
a Locate the calibration assembly, slide the Weights and Measures (W&M) seal metal cover
toward the exterior of the unit.
b Locate the inside switch for side B or the outside switch for side A. Place the switch in the
up position to activate the calibration procedure.
Number “7” appears in the Most Significant Digit (MSD), left-most digit of the pump display
and will remain throughout the procedure (see Figure 4-4).
Figure 4-4: Turning on Calibration Switch
Page 4-6 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Diagnostics, Calibration, and Troubl eshooting Electronic Calibration (E-CAL) Adjustment for E-85/DEF Unit
After five seconds, the prover can size appears in the two Least Significant Digits (LSD),
right-most digit of the pump display (see Figure 4-5). The can size will appear for five seconds
before advancing to the next can size. The display will continue to scroll through can sizes
until the nozzle is removed and pump handle is switched on.
Note: If the nozzle is not removed within 10 minutes of turning the switch to calibrate position,
error code 574 appears (57 indicates time out and 4 indicates calibration mode error).
Turn the calibration switch to off position (down) to clear the error.
Figure 4-5: Displaying Can Size
2 After the required can size appears on the display, remove the nozzle and switch on the pump
handle. This selects the can size for calibration.
Note: If the pump handle is switched on for an inap
propriate can size and if the dispensing
has not started, switch off the pump handle. Scrolling will resume. If dispensing has
begun, switch off the pump handle, turn the calibration switch to off position, and
restart calibration from step 1 on page 4-6.
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 4-7
Electronic Calibration (E-CAL) Adjustment for E-85/DEF Unit Diagnostics, Calibration, and Troubleshooting
DEF fluid tends to dissipate air much slower than for gasoline or diesel fuel. Wait for
three minutes and gently tap the prover can with a rubber mallet to ensure entrapped air
is dissipated and an accurate reading can be taken.
IMPORTANT INFORMATION
3
Dispense fuel into the prover can exactly to the zero mark. The uncalibrated volume appears.
Notes: 1) If the fuel/DEF is not dispensed within four minutes (about) of switching on the
pump handl
e (or within the time period set by the contr oller for pulsar time out), the
error code 574 appears indicating that the pump handle must be switched off to
clear the error. Scrolling will resume after you replace the nozzle.
2) If the fuel/DEF dispensing has started but stopped and the pump times out, the
calibra
as shown in Figure 4-6 (99 indicates that the pr oduct is
the product is not calibrated). The procedure must then be restarted from step 1
tion switch must be turned to off position. Otherwise, error code 993 appears
not available and 3 indicates
on page 4-6.
Figure 4-6: Displaying Error Code
4 Switch off the pump handle and return nozzle to boot. After three seconds, the calibration
factor appears on the display for three seconds and then zeros are displayed indicating that the
meter is now calibrated. No further transactions will be allowed until the calibration switch is
turned to off position.
Note: If an additional transaction is attempted, err
or code 994 appears (99 indicates product
not available and 4 indicates calibration mode err or). Turn the calibration switch to off
position and switch off the pump handle to clear the error. The error code 993 appears
indicating that the calibration procedure must be restarted from step 1 on page 4-6.
5 Turn the calibration switch to off position and slide the switch cover back over the switch.
Page 4-8 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Diagnostics, Calibration, and Troubl eshooting Electronic Calibration (E-CAL) Adjustment for E-85/DEF Unit
The settling time for freshly dispensed DEF is longer than for gasoline or diesel.
Therefore, a three-minute wait time between dispensing the DEF into the prover can
and taking the reading from the sight glass is recommended.
IMPORTANT INFORMATION
Units must be properly purged before calibration or calibration verification. Incomplete
purging of air can result in inaccurate calibration or errors in calibration verification
testing.
IMPORTANT INFORMATION
A stainless steel prover can must be used to calibrate DEF. Do not use a can that has
been used for other fluids. Contaminated DEF can cause damage to vehicle engines,
contaminated fuel can corrode dispenser material(s), vehicle catalytic converter(s), or
damage vehicle engines.
CAUTION
Calibration and Accuracy Checks - DEF Dispensers
An ELAFIX 40 Magnetic Adapter (M10656B001) must be pushed over the spout when you
dispense DEF into the prover can during calibration or service.
Each time a meter is calibrated, a volume of DEF is generated. This DEF must be properly
managed and cannot be discarded into the storm drain or where it can possibly reach surface
water or groundwater. If the DEF is to be returned to the supplier, store it in a closed
leak-proof container.
Avoid dispersal of spilled material and runoff. Ensure that DEF does not come in contact wi th
soil, waterways, drains, and sewers. Inform the relevant authorities if the product has caused
environmental pollution (sewers, waterways, soil, or air).
DEF poured back into the tank must be kept clean. Do not allow DEF to become contaminated
during handling.
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 4-9
Electronic Calibration (E-CAL) Adjustment for E-85/DEF Unit Diagnostics, Calibration, and Troubleshooting
This page is intentionally left blank.
Page 4-10 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Electronic Head Assembly Recommended Spare Parts
5 – Recommended Spare Parts
Electronic Head Assembly
Following table lists the recommended spare parts for the electronic head assembly of the
Atlas DEF dispenser:
Part Number Part Description
M10030A001 Coriolis Interface Printed Circuit
M06783A001* E2 Temperature Control PCA
M06333A002 Atlas 9800 CPU PCA
M05110A001 AC Bracket Cable
M10203A001* Temperature Sensor PCA
M12260A001* Fan/Heater Assembly for Nozzle
M10131A008 Frozen Thermostat
M04161B005 Switching Power Supply
M07588A002 9800 Power Supply PCA
Q11008-02* Solid State Relay
M12158A003 Main Display and Backligh
*Parts not used in warm weather units.
Assembly (PCA)
s Atlas Assembly
t
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 5-1
Recommended Spare Parts Electronic Head Assembly
Coriolis Interface PCA
(M10030A001)
Main Display and Backlights Atlas Assembly
(M12158A003)
9800 Power Supply PCA
(M07588A002)
Switching Power Supply
(M04161B005)
Line Filter (Q10362-02)
Atlas 9800 CPU PCA
(M06333A002)
E2 Temperature Control PCA
(M06783A001)
Solid State Relay
(Q11008-02)
J1400
Figure 5-1: Electronic Head Assembly
Page 5-2 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Lower Hydraulic Section Recommended Spare Parts
Lower Hydraulic Section
Following table lists the recommended spare parts for the lower hydraulic section of the Atlas
DEF dispenser:
Part Number Part Description
M10006A003 Coriolis Meter
M10006B501 Meter, Electronics Module
M10164B001 Flange Seal
M10258B001 Swivel SST DEF Breakaway
M10257B001 DEF Nozzle with Misfiling Option
M10257B002 DEF Nozzle Without Misfiling Option
M10170B002 Check Valve, 3/4” - 14 NPT
M10131A006* Heater Thermostat
M10226B101 DEF Outlet Hose
M10820A001 Y-Strainer (Thread End)
M10820B002 Replacement Strainer
M02321B005 Valve/Coil
M06600K001 Nozzle Boot Switch
*Parts not used in warm weather units.
Note: Magnetic Ring T ool (M10656B001) is requir ed for each technician servicing DEF units
except when a M10257B002 Nozzle is used.
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014 Page 5-3
Recommended Spare Parts Lower Hydraulic Section
Fan/Heater Assembly
(M12260A001) for Nozzle
Heater Fan Assembly
(Q13254-03)
Check Valve, 3/4” - 14 NPT
(M10170B002)
Freezing Sensor
(M10131A008)
M02321B005 Valve
M010820A001
Strainer
M11270B002 Swivel
Hose Reel Assembly
Figure 5-2: Atlas DEF Dispenser Hydraulics
Page 5-4 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
Index
Index
Numerics
9800 CPU Board 3-2
9800 CPU board 4-3
A
Atlas 9862 DEF Dispenser Status/Error
Codes 4-5
C
Calibration and Accuracy Checks 4-9
Cold Weather DEF Dispenser 3-1
Coriolis Meter Interface Board 3-2
CR5 LED 4-3
D
DEF Dispenser Problems 4-1
DEF LED Functions - Cold Weather
Units 3-2
DEF Warm Weather Units 3-2
Diagnostics Procedure for Cold Weather
Problems 4-3
Diagnostics, Calibration and
Troubleshooting 4-1
E
E-85 4-6
Electronic Calibration (E-CAL)
Adjustment 4-6
Electronic Head Assembly 5-1
F
F2 4-2
Fueling at Idle State 3-1
I
Important Safety Information 2-1
Intended Users 1-1
Introduction 1-1
L
Lower Hydraulic Section 5-3
M
M04161B005 5-1
M05110A001 5-1
M06333A002 5-1
M06600K001 5-3
M06783A001 5-1
M07588A002 5-1
M10006A003 5-3
M10006B501 5-3
M10030A001 5-1
M10131A006 5-3
M10131A008 5-1
M10164B001 5-3
M10170B002 5-3
M10203A001 5-1
M10226B101 5-3
M10257B001 5-3
M10257B002 5-3
M10258B001 5-3
M10656B001 4-9
M10820A001 5-3
M10820B002 5-3
M12158A001 5-1
Mode 3-1
P
Possible symptoms, causes, and
corrective actions 4-1
Problem 1
Entire unit is down/dead 4-1
Problem 2
No product dispenses/flows. 4-2
Problem 3
Dispenser does not Calibrate. 4-2
Problem 4
DEF unit dispenses product very
slowly, slow flow 4-2
Prover can 4-5, 4-2, 4-7, 4-8, 4-9
Purpose 1-1
Q
Q11008 5-1
Q13254-03 5-1
R
Recommended Spare Parts 5-1
Related Documents 1-1
Required Tools 1-1
S
sewers 4-9
soil 4-9
storm drain 4-9
T
Temperature Control Board 3-2
V
vehicle catalytic converter 4-9
W
W&M 4-6
waterways 4-9
Z
zero mark 4-8
MDE-5044A Atlas® DEF Operation, Diagnostic, and Illustrated Parts Manual · April 2014 Index-1
Gilbarco® is a registered trademark of Gilbarco Inc. GOLDSM is a service mark of Gilbarco Inc. Phillips® is a registered trademark of Phillips
Screw Company. UL
®
is a registered trademark of Underwriters’ Laboratories Inc.
© 2014 GASBOY
7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A.
MDE-5044A Atlas® DEF Operation, Diagnostic, and Illustrated Parts Manual · April 2014
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