Gasboy SERIES 9800Q Diagnostic Manual

SERIES 9800Q

PUMPS AND DISPENSERS

DIAGNOSTIC MANUAL

C36600

REV. 01/28/ 04

Copyright 2004 by Gasboy International LLC All rights reserved.
The information in this document is confidential and proprietary. No further disclosure shall be made without
permission of Gasboy International LLC. Gasboy International LLC believes that the information in this document is
accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other
rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.

GASBOY INTERNATIONAL LLC LANSDALE, PA

IMPORTANT WARNINGS AND SAFEGUARDS

Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or
property, follow these listed warnings and other warnings and precautions outlined in this manual when installing, using,
or working around this equipment. Check with GASBOY Technical Services for compatibility of liquids with pump
materials.

TURN OFF AND LOCK OUT ALL POWER TO PUMP BEFORE PERFORMING SERVICE, MAINTENANCE OR IN THE EVENT

All products must be installed by a
qualified installer and used in
conformance with all building, fire, and
environmental codes and other safety
requirements applicable to its
installation and use, including, but not
limited to, NFPA 30, NFPA 30A, NFPA
395 & NFPA 70. A qualified installer is
familiar with fuel systems installations
under the above stated building, fire,
and environmental codes and other
safety requirements for the particular
type of installation.

This product is only part of a fuel
dispensing system and additional
equipment and accessories, such as,
but not limited to, breakaway
connectors, shear valves, pressure
regulators, flow limiters, and other
safety devices may be necessary to
meet the applicable codes.

For maximum safety, we recommend
that all employees be trained as to the
location and procedure for turning off
power to t he en tire system. I nstru cti ons
regarding proper operation of the
equipment along with the appropriate
safety warnings should be posted in
plain view at the fuel island.

Before performing service or
maintenance (including changing of fuel
filters or strainers) or in the event of a
fuel spill, turn off and lock out all power
to the system. In battery-powered
pumps, disconnect power source. In
submersible pump applications, turn off
and lock out power at the master panel
and close any impact valves to the
submersible pump and any other
dispensers which use that submersible
pump. AC power can feed back into a
shut-off dispenser when dispensers
share a common submersible pump or
starter rel ay. Also block island s so no
vehicles can pull up to the dispenser
when the dispenser is being worked on.

DO NOT use Teflon tape for any pipe
threads in the product.

DO NOT use consumer pumps for
pumping fuel or additives into aircraft.

DO NOT use commercial pumps for
direct fueling of aircraft without filters
and separators necessary to ensure
product purity.

DO NOT use where sanitary design is
required (for food products for human
consumption) or with water-based
liquids.

DO NOT smoke near the pump or when
using the pump.

DO NOT use near open flame or
electrical equipment which may ignite
fumes.

DO NOT permit the dispensing of
gasoline or other petroleum products
into a vehicle with its motor running.

DO NOT permit the dispensing of
gasoline or other petroleum products
into unapproved containers or into
approved containers in or on vehicles
including trucks. All containers mu st be
filled on the ground to prevent static
discharge. Always use Approved and
Listed hoses and nozzles with electric
pumps and dispensers.

DO NOT block open the nozzle in any
manner. Nozzles shall conform to UL
and NFPA code requirements for
attended or unattended service.

DO ensure that the pump is equipped
with proper filters based on the product
being dispensed and its intended use.

DO wear safety goggles and protective
clothes when dispensing any liquid
which may be potentially harmful or
hazardous.

DO keep all parts of body and loose
clothing clear of belts, pulleys, and other
exposed moving parts at all times.

OF A FUEL SPILL.

DO require washing and changing of

clothes if fuel is spilled on a person or
his/her clothing. Keep away from open
flames, sparks, or people smoking.

DO provide a receptacle for catching
product from pump/meter when
servicing.

DO clean up product spills on the
driveway. Turn off and lock out all
power prior to cleanup.

DO insure pump is properly grounded.
DO insure hose is compatible with fluid

being dispensed.
DO inspect hose, nozzle, and pump on

a regular basis for wear, damage, or
other conditions which may create a
safety or environmental hazard.

DO make sure all pipe threads are
properly cut and the inside reamed to
remove burrs. Use UL classified
gasoline-resisting compound on all
joints of gasoline handling piping.
Sealing compound must also be
resistant to Gasohol (Ethanol and
Methanol). Use gasoline-resistant pipe
compound on male threads only; pipe
compound used on female threads can
be squeezed into the supply line where
it can enter the product stream and
become lodged in the pump or meter.

DO ensure that junction box covers are
in place and properly tightened. Mating
surfaces between the box and cover
must be free of dirt, nicks, and
scratches. All unused entries into the
junction box must be properly plugged.

035282 Rev. 1267

707 North Valley Forge Rd. Lansdale, PA, 19446 ● [phone] ● FAX: [phone]

GASBOY INTERNATIONAL LLC

CONTENTS

Section 1: INTRODUCTION

About this Book......................................................................................... 1-1

Using the Troubleshooting Section........................................................... 1-1

Section 2: CHASSIS WIRING

Junction Boxes.......................................................................................... 2-1

AC Junction Box .................................................................................. 2-1

115VAC/60 Cycle Pump Wiring................................................................ 2-3

115VAC/60 Cycle Dispenser Wiring......................................................... 2-4

230VAC/50 Cycle Pump Wiring................................................................ 2-5

230VAC/50 Cycle Dispenser Wiring......................................................... 2-6

115VAC/60 Cycle Front Load Option Pump Wiring.................................. 2-7

115VAC/60 Cycle Front Load Option Dispenser Wiring........................... 2-8

230VAC/50 Cycle Front Load Option Pump Wiring.................................. 2-9

230VAC/50 Cycle Front Load Option Dispenser Wiring........................... 2-10

Section 3: ELECTRONIC HEAD ASSEMBLY

Overall Layout........................................................................................... 3-1

CPU PCB.................................................................................................. 3-2

Connectors........................................................................................... 3-3

Jumpers............................................................................................... 3-5

LED Indicators ..................................................................................... 3-6

Test Points........................................................................................... 3-6

SW Switches........................................................................................ 3-6

Address Switches ................................................................................ 3-8

Pulser Output Rate Switches............................................................... 3-8

LCD Display PCB (C01373)...................................................................... 3-9

Connector ............................................................................................ 3-9

Jumpers............................................................................................... 3-10

Sale Backlight PCB (C06372)................................................................... 3-11

Connector ............................................................................................ 3-11

RS-485 Interface PCB (C06389) ............................................................. 3-12

Connectors........................................................................................... 3-12

LED Indicators ..................................................................................... 3-13

Pump Interface PCB (06425).................................................................... 3-14

Connectors........................................................................................... 3-15

LED Indicators ..................................................................................... 3-15

Power Supply PBC ................................................................................... 3-16

Connectors........................................................................................... 3-17

LED Indicators ..................................................................................... 3-17

Test Points........................................................................................... 3-17

Pump Relays............................................................................................. 3-18

Connectors........................................................................................... 3-19

Ballast Assembly....................................................................................... 3-20

Connectors........................................................................................... 3-20

Fluorescent Lamp Assembly (C06398), Fluorescent Lamp (033412)...... 3-21

Connector ............................................................................................ 3-21

01/28/04

Contents-1

GASBOY Series 9800Q

Heater/Thermostat Cable Assembly......................................................... 3-22

Connector ............................................................................................ 3-22

Power Bracket Assembly (C07707).......................................................... 3-23

Connectors........................................................................................... 3-23

Section 4: TROUBLESHOOTING

Using This Section.................................................................................... 4-1

Section 5: REPLACE MENT INSTRUCTIONS

General Information .................................................................................. 5-1

Electronic Component Acces s.................................................................. 5-2

Replacing the Platfor m Ass emb ly............................................................. 5-3

Replacing the CPU PCB ........................................................................... 5-5

Replacing the LCD Display PCB............................................................... 5-6

Replacing the Sale Backlight PCB............................................................ 5-7

Replacing the Power Supply PCB ............................................................ 5-8

Replacing the RS-485 or Pump I/F PCB .................................................. 5-9

Replacing the Ballast Cable Assembly..................................................... 5-10

Replacing the Heater Cable Assembly..................................................... 5-13

Contents-2 01/28/04

Section 1

INTRODUCTION

ABOUT THIS BOOK

This book was written to assist the authorized service representative (ASR) or technician in
troubleshooting the Series 9800Q. This manual contains:

• a functional description of each part

• wiring connections

• illustrations of the circuit boards and their indicators, connectors, jumpers, and switches

• diagnostic test proce dur e s

• a troubleshooting (Problems) section.

USING THE TROUBLESHOOTING SECTION

The Troubleshooting se ction lists common problems, probable causes, and cor rective action to
be taken. The probable causes and che cks for each problem ar e presented in logi cal sequence ,
allowing you to rule o ut one set of symptoms before going o n to the next. Thus, following the
procedures as listed sho uld help isolate your problem.

A double line at the end of a problem sequen ce indica tes the last o f the checks f or that problem.
If your 9800Q still i s not working, reche ck your s ympt o ms and fol lo w an other problem sequ en ce if
necessary. If you encounter problems you cannot solve by using this manual, call GASBOY
customer service at 1-800-444-5529.

Checks and correcti ve actions requiring voltage measurements assume famili arity with and are
done with a voltmeter unless noted that an oscilloscope or ohmmeter should be used.

01/28/04

1-1

Section 2

CHASSIS W IR ING

JUNCTION BOXES

All field wiring connections to the Series 98 00Q dispensing unit are mad e in the unit’s junction
boxes. The 9800Q wiring is split into two class ifications, AC and DC. A junction box is provided
for AC; a DC junction box is o ptional. AC and DC wiring must nev er be mixed in any common
junction box, co nduit, or tro ugh. S ee the Ser ies 980 0 Q Instal latio n/Oper atio n Ma nual for det ailed
instructions. The foll owing lists the wires that can be found in the junctio n boxes along with a
brief description of each. A more detailed description can be found in the Series 9800Q
Installation/Operation Manual.

AC Junction Box
AC Ground - Grounding for the Series 9800Q

Micro Feed - Hot side of power for the microprocessor register electronics.
Micro Neutral - Neutral side of power for the micro feed.
Control Pump Motor Feed - Hot side of power used to authorize the control line to the

dispensing unit. Two lines provided for twins. Also powers slow and fast flow valves, when
valves are used.

Neutral Feed - Neutral side of the power supplied on the Control/Pump Motor or
Control/Submersible Feed lines.

Control/Submersible Feed - Hot side of the power used to authorize the control line to the
dispensing unit. Pr ovides power to slow and fast flow va lves along w ith the swit ch detect si gnal.
Two lines provided for twins.

Submersible Starter Driv e - Controls Submersible Starter Relay. Two lines provided for twins.
Submersible Drive - Active only when submersible drive relays are provided. Controls

submersible starter relay or submersible pump. Two lines provided for twins.
Reset Complete (Switch Detect) /Slow Flow - For use w ith fuel manageme nt system, indi cates

reset process is complete and dispensing unit is ready to dispense product; if applicable, also
controls remote slow flow valve (satellite). Two lines provided for twins.

Fast Flow - Controls remote fa st flow valv e (sate llite). Use d only wi th two- stage solen oid v alve s.
May provide remote control or monitoring of fast flow. Two lines provided for twins.

Phase 2 Feed - Hot feed; opposite phase of pump motor feed.
Slow/Fast Satellite Returns - Us ed only with satellites in nonsimultaneous applicat ions. Four

lines are provided with twins.

Light Feed - Hot side of power for fluorescent lights.
Light Neutral - Neutral side of power for the light feed.
Pulser - When the dispensing unit includes the optional pulser interface, a pulser output is

provided. This pu lser o utput prov ides a D C output t o ind icate the q uantit y dispen sed. T his is a n
open collector outp ut. A DC ground line from the mo nitoring equipment should be connected t o
the DC ground line provided from the electronic register. This output can sink up to 100 milliamps

01/28/04 2-1

GASBOY Series 9800Q

DC at voltages up to 24 VDC. The pulse rate can b e configured by a sealable DIP switch for
rates of 1, 10, 100, 2 50, 500, or 1000 pulse s per unit (gallons) or 1 , 10, 100, or 250 puls es per
unit (liters). This output should only be used when monitoring of the dispenser’s operation is
desired. An additiona l output is provided f or a twin. Th ese lines must be cap ped when not in

use.

RS-485

When the dispensing unit includes the optional RS-485 interface, RS-485 lines are provided.
This interface allow s the user to connect a G ASBOY CFN Series System dir ectly to the Series
9800Q dispensing unit. These lines must be capped when not in use.

2-2 01/28/04

Chassis Wiri ng

115VAC/60 CYCLE PUMP WIRING

01/28/04

2-3

GASBOY Series 9800Q

115VAC/60 CYCLE DISPENSER WIRING

2-4 01/28/04

Chassis Wiri ng

230VAC/50 CYCLE PUMP WIRING

01/28/04

2-5

GASBOY Series 9800Q

230VAC/50 CYCLE DISPENSER WIRING

2-6 01/28/04

Chassis Wiri ng

115VAC/60 CYCLE FRONT LOAD OPTION PUMP WIRING

01/28/04

2-7

GASBOY Series 9800Q

115VAC/60 CYCLE FRONT LOAD OPTION DISPENSER WIRING

2-8 01/28/04

Chassis Wiri ng

230VAC/50 CYCLE FRONT LOAD OPTION PUMP WIRING

01/28/04

2-9

GASBOY Series 9800Q

230VAC/50 CYCLE FRONT LOAD OPTION DISPENSER WIRING

2-10 01/28/04

Section 3

ELECTRONIC HEAD ASSEMBLY

OVERALL LAYOUT

Use this drawing as a guide to identifying the components in a 9800Q electronic head assembly.

01/28/04 3-1

GASBOY Series 9800Q

CPU PCB

Single Pump 115VAC (C06391), Twin Pump 115VAC (C06392)

Single Dispenser 115VAC (C06393), Twin Dispenser 115VAC (C06394)
Single Pump 230VAC (C06500), Twin Pump 230VAC (C06501)
Single Dispenser 230VAC (C06502), Twin Dispenser 230VAC (C06503)

The CPU PCB is the heart of the GASBOY Series 9800Q. This CPU PCB:

• processes and stores all 9800Q data

• contains a battery-ba cked RAM IC for transaction and totalizer data retention during power

failures

• controls the data sent to the display PCB’s

• controls the relays for each pump side

• monitors the dual-channel pulser inputs for each pump side

• monitors the handle switch for each pum p sid e

• monitors the electronic totalizer switch

• sends pulser data to an external control system via an optional pump interface PCB

• communicates on th e GASBOY RS-485 pump lo op via an optional RS-485 pump interface

PCB

• allows the user to configure the 9800 through dip switches

• provides diagnostic LED’s to monitor operation of the unit

Version shown is C06394

3-2 01/28/04

Electronic Head Assembly

Connectors

Connector P1 controls side 1 and P2 controls s ide 2. The AC IN and NEUT pins are used as a
pump authorization sig nal when SW1-6 is clo sed. The AC IN also feed s the SF, FF, and SUBM
relays. The SF a nd FF outputs can dir ectly power the sole noid valves. The S UBM output can
power a customer-supplied submersible starter relay. The starter relay’s coil current must not
exceed 300 mA.

P1 and P2 - AC Input, Valve, and Submersible Relay Outputs

P3 - Side 1 Pulser Input, P5 - Side 2 Pulser Input

P4 - Handle Switch Inputs

NOTE: Pin 2 and Pin 4 are not used on the Front Load option.

01/28/04

3-3

GASBOY Series 9800Q

P6 - Electronic Totalizer Switch

The electronic totalizer switch connects to P6.

P7 - Suction Pump/Submer si ble Pump R el ay Dri ve s

The suction pump/submersible pump (optional) relays connect to P7.

P8 - RS-485/Pump Interface

The optional RS-485 and Pump Interface PCB’s connect to P8.

3-4 01/28/04

Electronic Head Assembly

P9 – Front Load Option

P10 - Power Supply Input

P11 - LCD Display Interface

Jumpers

Jumper K1 is set according to the size of the RAM IC in
socket U19.

The 9800Q CPU PC B ca n ac com mo date two sizes of battery­backed RAM; 2K and 8K. At this time only the 2K size is
being used.

01/28/04

3-5

GASBOY Series 9800Q

LED Indicators

The LED indicators provided enable you to monitor 9800Q operations.

Test Points

Test points are provided for voltage measurements.

SW Switches

The 9800Q can be confi gured for variou s operating cond itions using the switches loca ted on the
CPU PCB. Check these s witches an d change the ir setti ngs if nece ssary. Swit ch settin gs shoul d
be changed with th e power OFF . The n ew set tings ar e read b y the CPU PCB when t he power i s
turned ON again.

SW1

SW1-1 Baud Rate

This switch is set to r e fle ct the co mmu nicat io n r ate of t he G A SBO Y R S­485 pump loop; open for 9600 baud or closed for 1200 baud. The
GASBOY CFN system communicates at 9600 baud.

SW1-2 Mode

This switch should be open for the 9800Q to communicate on the
GASBOY RS-485 pump loop (on-line) and closed for all other
applications (standalone).

3-6 01/28/04

Electronic Head Assembly

SW1-3, SW1-4 Delay Time

These two switches set the delay time used by
leak detectors in submersible pump applications.
The delay time is the period between activation of
the submersible pump and activation of the slow
flow valve. This t ime should be set according to
the type of leak detector installed on the
submersible pump to allow a normal leak test for
each transaction. The d elay t ime sho uld be set to
zero seconds for su ct ion pu mps .

SW1-5

Not used.

SW1-6 Authorization

This switch allows a ctivation or non-activation of th e unit through
an external source ( fuel management system) . When closed, a
115/230 VAC signal must b e present o n the Contr ol Feed ( pump
motor or subm) line for pu mp activ ation to occur (requir ed se tting
for Series 1000). When open, the 9800Q ignores the Control
Feed line (required setting for CFN System or no fuel
management system).

SW1-7 Totalizers

This switch sh ould be set to open for normal opera tion. When
closed, this switch enables the reset of the electronic totalizers.

SW1-8

Not used.

01/28/04

3-7

GASBOY Series 9800Q

SW2

This four-positio n sw itch pa ck ser ves a d ual pur pose : as an addr es s settin g whe n com munic ating
on the GASBOY RS-485 lo op or Series 9 00, or as a p ulser output rate selector w hen pul ser data
is sent to a fuel management system other than a GASBOY CFN or Series 900.

Address Switches

A unique address identifier must be s et when the
9800Q is connected to the GASBOY RS-485
pump loop via the 9800Q RS-485 I/F PCB.
Because there are 16 possible address
combinations, up to 1 6 units (single or twin) may
be connected to the pump loop. Addressing
should start at 1 an d cont in ue s equ entially through

16. The physical wiring order does not have to
correspond with the address order ; that is the first
unit on the RS-485 loop doesn’t have to be
address 1. The chart at right gives the switch
settings and addr ess selections. With t he Series
900 option, the address must be set to 1.

$GGUHVV

6:

1Closed
2

Open Closed
3Closed
4

Open
5Closed
6

Open
7Closed
8

Open
9

Closed ClosedClosed Open
10

Open ClosedClosed Open
11

Closed ClosedOpen Open
12

Open ClosedOpen Open

Closed

13

Open

14

Closed

15

Open

6: 6:

ClosedClosed
Closed
Open
Open
Closed
Closed
Open
Open

Closed
Closed Open Open
Open
Open Open Open16

Closed

Closed

Open

Open

Open

Open

Open

Open

6:

Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed

Open

Open

Pulser Output Rate Switches

When the 9800Q is connected to external
control equipment other than a GASBOY
CFN system (standalone) , t he pul ser signa ls
are sent out via the 9800Q Pump I/F PCB.
The pulse rate required by the monitoring
equipment can be config ured by setting the
switches as shown in the chart at right. The
pulse rate represents pulses per gallon
(PPG, domestic) or pulses per liter (PPL,
international). For dom estic units, the pul se
rate can be up to 500 PPG for 9840Q and
up to 1000 PPG for all other models. For
international units, the pulse rate can b e up
to 100 PPL for 9840Q and up to 25 0 P PL for
all other models. This switch may need to
be sealed by a Weights and Measures
paper seal if the 9800Q is used for the
resale of product.

Leading zeros are always sup pressed in the
hundreds and ten s po sitions to the left of th e
decimal point. When in standalone mode,
positions to the right of the decimal point are
displayed based on the pulse rate selected
as shown in the table at right.

Pulse Rate SW2-1 SW2-2 SW2-3

1 Closed Closed Closed

10 Open Closed Closed
100 Closed Open Closed
250 Open Open Closed
500 Closed Closed Open

1000 Open Closed Open
None Closed Open Open
None Open Open Open

Pulse Rate Display

1:1 XXX.

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

1000:1 XXX.XXX

Timeout Switch

When the 9800Q is in st andalone mode, it will t urn off an active
hose if it doesn’t detect pulse s for 4 minutes, 15 seco nds. This
timeout feature can be disabled by setting switch SW2-4 to
Open.

Timeout SW2-4

Enabled Closed
Disabled Open

3-8 01/28/04

Electronic Head Assembly

LCD DISPLAY PCB (C01373)

The LCD Display PCB contains the quantity display viewed by the user. This PCB:

• displays the quantity per sale, totalizer data, and diagnostic information

Connector

P1 - CPU PCB Interface

01/28/04

3-9

GASBOY Series 9800Q

Jumpers

The LCD Display PCB must be addressed to display the
pump data for the hose (side) that is closest to it. This
means that two of the PCB’s are addressed a s hose outlet
#1 and two are addressed as hose outlet #2 (in a twin).
Jumper K1 selects the d ispl a y address.

The LCD Display PCB can be configured to
display whole units, tenths, hundredths, or
thousandths. Presently all domestic 9800Q’s
are shipped displa ying t hou sandth s of a g allon;
all internationa l 98 00Q ’s are shipped displa ying
hundredths. Jumper K2, K4, and K6 s elect the
units and their pins should be jumpered as
shown. Presently there is no software or
firmware to support whole units or tenths.

3-10 01/28/04

Electronic Head Assembly

SALE BACKLIGHT PCB (C06372)

The backlight PCB illuminates the LCD display for night viewing. This PCB:

• attaches to the 9800Q LCD display PCB

• combines long-life, super-bright LED’s with a reflector for increased surface illumination

Connector

P1 - Power Input Connector

01/28/04

3-11

GASBOY Series 9800Q

RS-485 INTERFACE PCB (C06389)

The RS-485 Interface PCB allows the 9800Q to communicate on the GASBOY RS-485 loop.
This PCB:

• provides protection a gainst noi se and damagi ng voltage tran sients that m ay be induced onto

the RS-485 lines

• contains diagnostic LED’s to monitor operation of the RS-485 lines.

Connectors

P1 - RS-485 Unprotected from DC Junction Box

P2 - RS-485 Protected to CPU PCB

3-12 01/28/04

Electronic Head Assembly

LED Indicators
LED indicators are provided to
allow you to monitor the RS-485
communication lines.

01/28/04

3-13

GASBOY Series 9800Q

PUMP INTERFACE PCB (C06425)

The Pump Interface PCB sends the p ulser signa l to extern al monitoring equipment th at does not
support the GASBOY RS-485 electronic pump loop. This PCB:

• provides a pulser signal for each pump side, up to 100 mA at 24 VDC. The current and

voltage are determined by the external equipment.

• contains diagnostic LEDs to monitor the pulser output lines

Connectors

P1 - Pulser Output

3-14 01/28/04

Electronic Head Assembly

P2 - CPU PCB Interface

LED Indicators
LED indicators are provide d to allow you to monitor
the pulser output lines.

01/28/04

3-15

GASBOY Series 9800Q

POWER SUPPLY PCB

115 VAC (C06396)
Battery-Backed 115 VAC (C06397)
230 VAC (C06488)
Battery-Backed 230 VAC (C06489)

The power supply PCB provides:

• +5VDC logic power and +7.5VDC LED backlight power

• diagnostic LED’s to monitor DC voltages

• a signal to warn the microprocessor of an impending power failure

• rechargeable battery-backup to display last trans act io n for a mi ni mum of 15 mi nut es ( C 063 97

and C06489 versions).

Version shown is C06397.

3-16 01/28/04

Electronic Head Assembly

Connectors

P1 - CPU Power Output

P2 - Backlight Power Output

P3 - AC Input

LED Indicators

LED indicators are provided to allow you to monitor the DC voltages.

Test Points

Test points are provided for voltage measurement.

01/28/04

3-17

GASBOY Series 9800Q

PUMP RELAYS

The pump relays ar e alwa ys u sed for s uctio n pump s a nd may b e used for subm ersi ble pum ps up
to and including 1-1/2 HP at 230 VAC. These relays:

• control the motor that drives the suction or submersible pump (one each side)

• are controlled by the CPU PCB

3-18 01/28/04

Electronic Head Assembly

Connectors

Relay Drive

Pump Mot or Power

01/28/04

3-19

GASBOY Series 9800Q

BALLAST ASSEMBLY

115 VAC (C06473)
230 VAC (C06476)

The ballast assembly provides power for the fluorescent lights.

Connectors

Front and Rear Lamps

Input Power

3-20 01/28/04

Electronic Head Assembly

FLUORESCENT LAMP ASSEMBLY (C06398)
FLUORESCENT LAMP (033412)

The fluorescent lamp assemblies illuminate the brand panels.

OR

FLUORESCENT LAMP ASSEMBLY (C07117)
FLUORESCENT LAMP (033412)

Connector

Input Power - from ballast assembly

01/28/04

3-21

GASBOY Series 9800Q

HEATER/THERMOSTAT CABLE ASSEMBLY

115 VAC (C06450)
230 VAC (C06490)

The heater assembly is used to warm the power supply battery in extreme temperatures and
conditions. It:

• contains a 25W heater strip

• contains a thermostat to regulate temperature

Connector

Input Power

3-22 01/28/04

Electronic Head Assembly

POWER BRACKET ASSEMBLY (C06436)

The Power Bracket Assembly contains the switch, fuse, and AC connectors.

Connectors

Micro Power Input - Connects to AC power from conduit assembly.

Heater Power - Supplies AC power to optional heater. Connector is standard on all models.

01/28/04

3-23

GASBOY Series 9800Q

ELECTRONIC TOTALIZER CABLE ASSEMBLY

Front (Standard) C06434
Rear (Optional) C06819

The electronic totalizer assembly contains a sensor that, when activated, shows the pump’s
totalizer data on the sale displays. A rear extension cable allows the totalizer to be activated from
both sides of the unit.

Front Cable

Rear Cable

ELECTRONIC TOTALIZER ACTUATOR C01342

The electronic totalizer actuator is a permanent magnet that causes the
9800Q displays to show totalizer data when pla ced in close proximity to the
totalizer sensor.

3-24 01/28/04

Section 4

TROUBLESHOOTING

USING THIS SECTION

The Troubleshooting se ction lists common problems, probable causes, and cor rective action to
be taken. The probable causes and che cks for each problem ar e presented in logi cal sequence ,
allowing you to rule o ut one set of symptoms before going o n to the next. Thus, following the
procedures as listed sho uld help isolate your problem.

A double line at the end of a problem sequen ce indica tes the last o f the checks f or that problem.
If your unit still is no t working, recheck your sympt oms and follow another problem s equence if
necessary. If you encounter problems you cannot solve by using this manual, call GASBOY
Technical Service at 1-800-444-5529.

Checks and correcti ve actions requiring voltage measurements assume famili arity with and are
done with a voltmeter unless noted that an oscilloscope or ohmmeter should be used.

01/28/04 4-1

GASBOY Series 9800Q

9800Q is dead. Displ ays are blan k, including de cimal points. Unable to ac tivate side 1 o r
side 2.

Possible Cause Checks Corrective Action

No 115/230AC feed to 9800Q
for micro power.

Check if circuit breaker is off
or tripped.

Check if 115/230VAC is being
switched through circuit
breaker.

Check if 115/230VAC is
measured at the micro

Turn breaker on, if off.

Replace circuit breaker if
115/230VAC is not measured.

Correct wiring problems if

115/230VAC is not measured.
connector on the power
bracket.

AC power fuse is blown. Check the fuse in power

Replace fuse, if blown.
bracket.

Blown power supply (PICO)
fuse(s) or defective power
supply.

Using a voltmeter, measure
between the GND test point
and each side of F1 and F2 on
the power supply.

Replace F1 if 5VDC is

measured on one side but not

the other.

Replace F2 if 7.5VDC is

measured on one side but not

the other.

Replace the power supply if

0VDC is measured on both

sides of F1 or F2.

Defective CPU PCB. None Replace the PCU PCB if

+5VDC is measured betwe en

the GND and +5VDC test

points on the CPU PCB but

the 9800Q is still dead.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

4-2

01/28/04

Troubleshooting

9800Q won’t activate in stan dalone mode. When the pu mp handle is thrown, the d isplays
do not go through reset sequence.

Possible Cause Checks Corrective Action

System controlling 9800Q not
functioning properly.

AUTH signal not getting to
CPU PCB.

If the 9800Q is controlled by a
fuel management system
other than CFN, verify proper
operation of system.
If the 9800Q is controlled by a
fuel management system
other than CFN, an AC
authorization (AUTH) signal is
required for pump activation.
On the 9800Q CPU PCB,
check if L1 (side 1) or L5 (side

2) light when the fuel system
tries to activate the pump.

Repair fuel management

system if necessary. Refer to

fuel management system

manuals for further assistance.

f L1 and/or L5 don’t light, use

an AC voltmeter to measure

between pins 1 and 6 of

connectors P1 (side 1) and P2

(side 2) of the CPU PCB. If

115/230 VAC is measured but

L1 and/or L5 don’t light,

replace the CPU PCB. If

115/230VAC is not measured,

trace the wiring back to the

fuel management system a nd

correct the problem.

Mode switch on CPU PCB set
incorrectly.

Check switch SW 1-2 o n CPU
PCB.

Close switch, if open. Turn

power off, then on after

changing switch settings.

9800Q is running on battery
power (Skip this section if y our

9800Q is not equipped with a
battery back-up power supply).

Check if micro circu it bre ak er
is off or tripped.

Check if 115/230VAC is being
switched through circuit
breaker.

Check if 115/230VAC is
measured in 9800Q AC
junction box.

Check the MICRO power
switch.

Check the fuse in the power

Turn breaker on, if off.

Replace circuit breaker if

115/230VAC is not being

switched.

Correct wiring problems if

115/230VAC is not measured.

Turn on, if off.

Replace fuse if blown.
bracket.

Defective handle switch. Using a DC voltmeter,

measure between the
common (COM) and normally

Replace the handle switch if

proper voltages are not

measured.
open (N.O.) terminals on the
handle switch. +5VDC sho uld
be measured. Turn the handle
on. 0VDC should be
measured.

Defective AC power fail
circuitry.

Using a DC voltmeter,
measure between ground
(TP2) and pin 3 of connector
P10 (violet wire) on the CPU

Replace the power supply

PCB if +5VDC is not

measured between GND and

the violet wire.
PCB.

continued

01/28/04

4-3

GASBOY Series 9800Q

Possible Cause Checks Corrective Action

Defective CPU PCB. None. Replace the CPU PCB if the

9800Q still will not activate.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

4-4

01/28/04

Troubleshooting

9800Q won’t activate in on-line mo de. When the pump h andle is thrown, the displa ys do
not go through reset sequence.

Possible Cause Checks Corrective Action

9800Q is not communicating
to the GASBOY CFN system.

Verify that the 9800Q is
communicating.

Perform actions listed under

9800Q is not communicating

to the GASBOY CFN System.

9800Q won’t activate in
standalone mode.

Verify that the 9800Q works in
standalone mode..

Close SW1-2 on the CPU

PCB, turn the power off and

on, then perform the actions

listed under 9800Q won’t

activate in standalone mod e.

Open SW1-2, then turn the

power off and on before

returning to this page.

CFN system data loaded
incorrectly.

Verify that all CFN system
data is loaded correctly

Reload system data, if

incorrect.
(authorization code s, produ ct
codes, pump table, etc.)

01/28/04

4-5

GASBOY Series 9800Q

9800Q is not communicating to the GASBOY CFN system.

Possible Cause Checks Corrective Action

CFN system is not functioning
properly.

Verify proper operation of the
CFN system.

Repair CFN system, if

necessary. Refer to CFN

manuals for further assistance.

CFN system not configured
properly.

Verify that the device types
and pump addresses are
configured corre ct ly.

Make sure the pump type is 2

with no options for the Site

Controller II or type 64 for the

Site Controller I.

Incorrect swit ch set t in gs on
9800Q CPU PCB.

Verify that the SW1 switches
are set as follows: 1=OPEN,
2=OPEN, 6=OPEN. Verify
that the SW2 switches match

Change switch settings if

necessary. Turn the power

off, then on after changing

switch settings.
the CFN system.

Defective RS-485 PCB. None. Replace RS-485 PCB.
Defective CPU PCB. None. Replace CPU PCB.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

4-6

01/28/04

Troubleshooting

9800Q resets but does not dispense fuel – Pump.

Possible Cause Checks Corrective Action

No 115/230VAC feed to pump. Check if circuit breaker is off

or tripped.
Check if 115/230VAC is being

switched through circuit
breaker.

Check if 115/230VAC is
measured in the junction box.

Turn breaker on, if off.

Replace circuit breaker if

115/230VAC is not being

switched.

Correct wiring problems if

115/230VAC is not being

measured.

Defective CPU PCB. Using a DC voltmeter,

measure between ground
(CPU PCB test point TP2) and
screw terminal #4 (blue wire
for side 1, violet wire for side

2) of the pump relay. The
voltage should be 0VDC.

If equipped with an optional
solenoid valve, measure
between screw terminals 1
and 3 of terminal block SOL1
and SOL2, using an AC
voltmeter.

Replace the CPU PCB if

+5VDC is measured betwe en

ground and the blue or violet

wires.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

Replace the CPU PCB if

115/230VAC is not measured

between screw terminal 1 and

3.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

Defective pump relay. Using an AC voltmeter,

measure between AC neutral
and screw terminals #1 and #2
of the pump relay.

Defective optional solenoid
valve.

Solenoid valve shoul d cl ic k
after reset.

Defective pump motor. Motor should turn when

115/230VAC is measured in

Replace the relay if

115/230VAC is measured at

screw terminal #1 but not at

#2.

Replace valve if click is not

heard after reset.

Replace pump motor if

115/230VAC is not measured.
junction box.

Out of fuel. Check fuel level in tank. Order fuel if tank empty.
Pump will not prime or loses
prime.

Dirty strainer .

Loose V-belt.

Air leak in suction line,
excessive lift, bypa s s valve
stuck on open, air separator

Remove strainer cap and

clean strainer.

If belt is loose, tighten

according to

Installation/Operation Manual

instructions.

Call qualified service

personnel if any of these

conditions exist..
float stuck open, float chamber
valve open.

01/28/04

4-7

GASBOY Series 9800Q

9800Q resets but does not dispense fuel – Dispenser.

Possible Cause Checks Corrective Action

No 115/230VAC feed to
dispenser.

Defective CPU PCB. If the submersible pump is

Check if circuit breaker is off
or tripped.

Check if 115/230VAC is being
switched through circuit
breaker.

Check if 115/230VAC is
measured in junction box.

powered by the optional solid
state relay mounted in the
pump head, follow this check,
otherwise skip to next check.
Using a DC voltmeter,
measure between ground
(CPU PCB test point TP2) and
screw terminal #4 (blue wire
for side 1, violet wire for side

2). The voltage should be
0VDC.

Using a DC voltmeter,
measure between neutral and
both sides of fuse F1 (side 1)
or F2 (side 2).

Using an AC voltmeter,
measure between screw
terminals 1 and 3 of terminal
SOL1 or SOL2.

Turn breaker on, if off.

Replace circuit breaker if

115/230VAC is not being

switched.

Correct wiring problems if

115/230VAC is not measured.

Replace the CPU PCB if

+5VDC is measured betwe en

ground and the blue or violet

wires.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

If 115/230VAC is not

measured on either side of the

fuses, replace the CPU PCB.

If 115/230VAC is measured on

one side of the fuse but not on

the other, replace the fuse.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

Replace the CPU PCB if

115/230VAC is not measured

between screw terminal 1 and

3.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

Defective pump relay. Using an AC voltmeter,

Defective submersible starter
relay.

Out of fuel Check fuel level in tank. Order fuel if tank empty.

4-8

01/28/04

measure between AC neutral
and screw terminals #1 and #2
of the pump relay.
Measure across coil of starter
relay.

Replace the relay if

115/230VAC is measured at

screw terminal #1 but not at

#2.

Replace starter relay if

115/230VAC is measured

across coil, but relay does not

close.

Troubleshooting

Possible Cause Checks Corrective Action

Leak detector did not open. Check the settings of switches

SW1-3 and SW1-4 to
determine the selected delay
time.

Leak in supply line or piping.

Shear valve tripped. Try to determine cause (loose

mounting to island, cabinet
had been hit, etc.)

Select a longer delay time if

needed.

Replace defective leak

detector if it does not open.

Repair leak.

Reset, or if necessary, replace

shear valve if it is tripped.

Correct cause of valve

tripping.

Defective submersible motor. Repair or replace motor.

01/28/04

4-9

GASBOY Series 9800Q

Product is dispensed, but no quantity shows on the 9800Q display.

Possible Cause Checks Corrective Action

Broken or damaged couplin g. Broken or damaged couplin g. Repair or replace coupling i f

damaged.

Defective pulser or defective
CPU PCB.

While dispensing fuel slowly,
measure between GND (TP2)
and pins 1 and 2 of connector
P3 (side 1) or P5 (side 2) on
the CPU PCB using an
oscilloscope.

Replace the pulser if a +5VDC

square wave is not measured

between GND and pin 1 and

between GND and pin 2 of the

appropriate connector.

Replace the CPU PCB if a

+5VDC square wave is

measured but the displays still

show no quantity.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

4-10

01/28/04

Troubleshooting

Quantity shows on 9800 Q displays but f uel management system records i ncorrect or zero
quantity. This problem pertains only to 9800Q’s connected to non-CFN fuel management
systems.

Possible Cause Checks Corrective Action

Pulser output rate switches
don’t match system pulser
rate.

Check the settings of SW2-1
through SW1-4 on the CPU
PCB.

Change the CPU PCB switch

settings or change the fuel

management system pulser

rate accordingly.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

Fuel management system
pulser input circuitry not
compatible.

The 9800Q requires the fuel
management system to "pull
up" the pulser signal to a DC

Call GASBOY Technical

Service for assistance.
voltage between 5VDC and

24VDC.

Defective CPU PCB. Using an oscilloscope, check

the signal between GND (TP2)
and the following pins of P2 on
the pump I/F PCB.:

Pin 5-Side 1 1000:1;
250:1, international
Pin 6-Side 2 1000:1;
250:1, international

Replace the CPU PCB if a

+5VDC square wave signal is

not measured on the

appropriate pins.

NOTE: Replacing the CPU

PCB may require replacement

of your Weights and Measures

seal.

Pin 10-Side 1 below 1000:1;
below 250:1 international
Pin 11-Side 2 below 1000:1;
below 250:1 international

Defective Pump I/F PCB. Using an oscilloscope, check

the signal between GND (TP2)
and P1 pin 1 (side 1) or P1 pin
2 (side 2) on the pump I/F
PCB.

Replace the Pump I/F PCB if

the pulser signal is not

measured on the appropriate

pins.

Replace the power supply if

0VDC is measured on both

sides of F1 or F2.

01/28/04

4-11

GASBOY Series 9800Q

The 9800Q does not disp lay t he last tran saction d uring an AC pow er failu re. This prob lem
pertains only to 9800Q’s equipped with a battery back-up power supply.

Possible Cause Checks Corrective Action

Battery not fully charged or
defective power supply PC B.

If the 9800Q had been off for a
very long time, the battery
probably isn’t fully charged.

Replace the power supply if

charging did not fix the

problem.
After AC power is restored,
allow the 9800Q to run for 24
to 36 hours, then turn AC
power off and make sure the
last transaction is displayed for
15 minutes minimum.

9800Q does not display electronic totalizer data.

Possible Cause Checks Corrective Action

Pump Handles are on. Check if pump handles are on. Turn pump handles off, if on.

Possible misalig nment of

Check alignment. Realign if needed.

totalizer switch and magnet.
Defective actuator. None. Replace actuator.
Defective totalizer sensor or
defective CPU PCB.

Remove the totalizer cable
assembly from P6 of the CPU
PCB. Short the two pins
together on P6 of the CPU
PCB.

Replace the totalizer cable

assembly if shorting P6

causes totalizer data to

display.

Replace the CPU PCB if

shorting P6 does not cause

totalizer data to display.

NOTE: Changing the pulser

rate switches may require

replacement of your Weights

and Measures seal.

Electronic totalizer data looks scrambled after a power failure.

Possible Cause Checks Corrective Action

RAM memory IC not retaining

None. Replace RAM memory IC.

data.

4-12

01/28/04

Troubleshooting

The flourescent lights don’t turn on.

Possible Cause Checks Corrective Action

No 115/230VAC feed to
9800Q for light power.

Check if circuit breaker is off
or tripped.

Check if 115/230VAC is being
switched through circuit
breaker.

Check if 115/230VAC is
measured at the LIGHTS

Turn breaker on, if off.

Replace circuit breaker if

115/230VAC is not being

switched.

Correct wiring problems if

115/230VAC is not measured.
connector on the power
bracket.

Loose, burnt out, or damaged
bulb.

Check bulb for damage or
burn marks.

Tighten, if loose. Replace if

burnt out or damaged.

Defective ballast None. Replace ballast.

All displays on 9800Q show 01 at the far left of the display.

Possible Cause Checks Corrective Action

RAM failure. None. Replace RAM IC U19 on CPU

PCB. Replace CPU PCB if

replacing U19 did not fix

problem.

All displays on 9800Q show 02 at the far left of the display.

Possible Cause Checks Corrective Action

ROM failure. None. Replace ROM IC U18 on CPU

PCB. Replace CPU PCB if

replacing U18 did not fix

problem.

STANDALONE MODE ERROR HANDLING

When operating the pump/dispenser in standalone mode (not connected to a fuel management system), the
9800Q displays two-digit error transaction codes on the LCD displays when transactions are terminated
abnormally (by a means other than turning off the pump handle).

There are four possible error conditions that may be displayed:

Code Condition

55 Power failure
56 Pulser error
57 Timed out
58 Limit cutoff

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.
When an error occurs, the user should note the error code and relay the information to the system
administrator.

Transaction error codes are displayed only when the pump/dispenser is operating in standalone mode.
When connected to a fuel management system, (on-line mode), transaction error codes are transmitted
back to the fuel management system with the completed transaction data.

01/28/04

4-13

GASBOY Series 9800Q

With the 9800Q in standalone mode, one or more displays flash 55 at the far left of the
display.

Possible Cause Checks Corrective Action

9800Q is running on battery
power (Skip this Possible
Cause if your 9800Q is not
equipped with a battery back­up power supply).

Check if the breaker supply ing
power to the MICRO circuit is
off or tripped.

Check if 115/230 VAC is being
switched through circuit
breaker.

Check if 115/230 VAC is
measured in 9800Q junction
box.

Check the MICRO power
switch.

Check the fuse in the power

Turn breaker on, if off.

Replace circuit breaker if

115/230 VAC is not being

switched.

Correct wiring problems if

115/230 VAC is not measured.

Turn on, if off.

Replace fuse if blown.
bracket.

Defective AC power fail circ uit. Usi ng a DC voltm eter ,

measure between ground
(TP2) and pin 3 of connector
P10 (violet wire) on the CPU

Replace the power supply

PCB if +5VDC is not

measured between ground

and the violet wire.
PCB.

With the 9800Q in standalone mode, one or more displays flash 56 at the far left of the
display.

Possible Cause Checks Corrective Action

Bad pulser or CPU PCB. With the pump handle in the

off position (nozzle hung up),
observe the pulser lamp
indicators on the CPU PCB,

If both lamps do not flash,

replace the pulser. If both

lamps flash, replace the CPU

PCB.
while slowly turning the pulser
shaft. Both lamps (PULA and
PULB) should flash on and off.

4-14

01/28/04

Troubleshooting

With the 9800Q in standalone mode, one or more displays flash 57 at the far left of the
display.

Possible Cause Checks Corrective Action

No fuel is dispensed. None.

Go to the problem 9800Q

resets but does not

dispense fuel.

Pulser doesn’t turn. Check if the pulser couplin g is

broken or damaged.

The operator filled the vehicle,

Check if the handle is still on. None.

Repair or replace coupling if

damaged.

but never turned off the pump
handle.

9800 timeout feature is
enabled.

Check the position of swit c h
SW2-4 on the 9800 CPU PCB.

If the switch is closed, the

9800 will timeout if it doesn’t

detect pulses for 4 minutes, 15

seconds. To set the 9800 to

never timout, open SW2-4.

With the 9800Q in standalone mode, one or more displays flash 58 at the far left of the
display.

Possible Cause Checks Corrective Action

The maximum quantity limit for
a single transaction was
pumped. The limits are:
9800 gallons = 990.000
9840 gallons = 990.000
9800 liters = 9990.00
9840 liters = 9990.00

Verify that the display’ s la st
sale shows the limit from the
Possible Cause column for
the applicable 9800 model.

The 9800 cannot dispense

more than the maximum

quantity shown in the

Possible Cause colu mn in a

single transaction. Run

additional transactions until

fueling is completed.

01/28/04

4-15

Section 5

REPLACEMENT INSTRUCTIONS

GENERAL INFORMATION

WARNING:

This unit should be serviced only by qualified service personnel.
To reduce the risk of electrical shock when servicing, turn off all power to the

pump/dispenser. S imply turning off the pow er switch in the electro nic head will
not remove all power from the unit! All breakers that feed the unit should be
turned off. In submersibl e pump applications, turn off power to the submer sible
pump and any other dispenser s which use that submersible pump. AC power
can feed back i nto a shut-off d ispenser wh en other dispe nsers share a common
submersible pump or st arte r rela y.

All replacement proce dures are written with the understan ding that the Series 9800Q has be en
opened for servicing. Electronic component access is detailed on the next page.

The numbers found in brackets [1] in the text can b e used to find t he associ ated balloo n number
in the reference drawings.

01/28/04 5-1

GASBOY Series 9800Q

ELECTRONIC COMPONENT ACCESS

Before attempting to start- up the 9800Q, it is important to become familiar with the location of
some key components as well as the various switch-selectable operating modes.

1. Unlock and remove the front panel.

2. Remove the two bolts lo cated over the tab s of the bezel assem bly. Lift the beze l assembly
upwards and out to remove. If the model inclu des the front load no zzle, remove the n ozzle
boot plastic shroud (two screws) before removing the bezel assembly.

3. Loosen, and remove i f necessary, the two screws located on t he left and righ t door support
brackets and pivot display panel down.

5-2 01/28/04

Replacement Instructions

REPLACING THE PLATFORM ASSEMBLY

1. Disconnect the LIGHTS and MICRO connectors [1] from the power bracket.

2. Disconnect the AC, pulser, handle, and DC [2] cables from the CPU PCB and RS-485 or
Pump I/F PCB. Push the cables down through the holes in the platform.

3. Disconnect the rear lamp cable from the ballast cable [3].

4. Remove the rear ground braid and its retaining hardware [4] from the platform.

5. Disconne ct the ca bl es [5] from the rear door PC B’s.

6. Remove the hardware [6] securing one of the support brackets. Be careful not to let the
door fall off while removing the screws. Slide the door away from the remaining support
bracket and pull the door out of the cabinet.

7. Remove the four nuts, washers, and lock washers securing the platform assembly to the
chassis.

8. Go to the front of the chassis (the side with the door still installed) and lift the platform up and
out toward you.

9. Reverse Steps 1 through 9 to replace the platform assembly.

01/28/04 5-3

GASBOY Series 9800Q

5-4 01/28/04

Replacement Instructions

REPLACING THE CPU PCB

1. Disconnect all cables [1] from the CPU PCB.

2. If an optional RS-485 or Pump I/F PCB is installed, r emove the two Phillip s screws [2]. Pu ll
the optional PCB off of the CPU PCB.

3. Remove the screws from the CPU PCB and unsnap PCB from standoffs.

4. Remove the program IC from socket U1 8 [3] and the memory IC from socket U19 [4] of the
defective CPU PCB by gently prying with a slotted screwdriver.

5. Install the old program IC and memor y IC into sockets U18 and U19 on the new CPU PC B.
Be careful to observe proper pin orientation.

6. Reverse Steps 1 through 3 to install the new CPU PCB.

7. Verify that the switch settings on the new CPU PC B are correct. See the switch sett ings in
Section 3, Electronic Head Assembly for verification.

01/28/04 5-5

GASBOY Series 9800Q

REPLACING THE LCD DISPLAY PCB

1. Disconnect the cable [1] from the Sale Backlight PCB.

2. Disconnect the ribbon cable [2] from the LCD Display PCB.

3. Unsnap the LCD display PCB from standoffs [3].

4. Remove the two Phillips screws [4] and washers securing the Sale Backlight PCB to the
LCD Display PCB.

5. Reverse Steps 1 through 4 to install the new LCD Display PCB.

6. Verify that the jumper settings o n the new LCD Di splay PC B match the j umper setti ngs from
the defective LCD Display PCB. See the jumper settings in Section 3, Electronic Head
Assembly for verification.

5-6 01/28/04

Replacement Instructions

REPLACING THE SALE BACKLIGHT PCB

1. Disconnect the cable [1] from the Sale Backlight PCB.

2. Remove the two Phillips screws [2] and washers securing the Sale Backlight PCB to the
LCD Display PCB.

3. Unsnap and remove the two plastic buttons [3] securing the Sale Backlight PCB to the
reflector.

4. Reverse Steps 1 through 3 to install the new Sale Backlight PCB.

01/28/04 5-7

GASBOY Series 9800Q

REPLACING THE POWER SUPPLY PCB

1. Disconne ct the ca bl es [1] from th e Power Su ppl y PCB.

2. Remove the two screws [2] from the Power Supply PCB and then unsnap PCB from
standoffs [3].

3. Reverse Steps 1 and 2 to install the new Power Supply PCB.

5-8 01/28/04

Replacement Instructions

REPLACING THE RS-485 OR PUMP I/F PCB

1. Disconnect the connector [1] from the RS-485 or Pump I/F PCB.

2. Remove the two Phillips screws [2] from the RS-485 or Pump I/F PCB.

3. Pull the RS-485 or Pump I/F PCB from the CPU PCB.

4. Reverse Steps 1 through 3 to install the new RS-485 or Pump I/F PCB.

NOTE: Older units may have a 5-position cable from DC conduit. New pump and RS-485 PCBs
have a 4-position connector. When installing the new PCB, make sure that pin 1 of the cable (red
wire) matches up with pin 1 of the PCB connector.

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GASBOY Series 9800Q

REPLACING THE BALLAST CABLE ASSEMBLY

1. The platform assembly must be removed in order to replace the ballast cable assembly.
See Replacing the Platform Assembly earlier in this section. Proceed to Step 2 once
platform assembly is rem ov ed.

2. Usi ng a slotted screwdriver , apply pressure to the r etaining tab on one si de of the LIGHTS
connector [1] on the power bracket, then push the connector in through bracket.

3. Disco nnect the lamp cable ass emblies [2] from the ballast cab le assembly on the front and
rear of the platform.

4. Usi ng a slotted screwdriver , apply pressure to the ret aining tab on one side of each b allast
connector [3], then push the connectors down through the platform.

5-10 01/28/04

Replacement Instructions

01/28/04 5-11

GASBOY Series 9800Q

6. On the underside of the platform assembly, remove the two screws and washers [5]
holding the ballast to the platform; on older units two nuts must be removed.

7. Reverse Steps 2 through 6 to install the new b allast cable assembly. Be s ure to install a
new tie strap or push-in w ire twist standoff to keep t he cable wiring awa y from the optional
heater strip. See Replacing the Platform Assembly earli er in this section to c omplete the
procedure.

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Replacement Instructions

REPLACING THE HEATER CABLE ASSEMBLY

1. The platform asse mbly must be r emoved i n order to
replace the heater ca ble assem bly. Se e Replacing
the Platform Assembly earlier in this section.
Proceed to Step 2 once platform assembly is
removed.

2. Remove the two Phillips screws [1] securing the
thermostat to the platform. Push the thermostat
through the bushing.

3. Disconnect the HEATER connector [2] from the power bracket.

4. Remove the two Phillips screws [3] and fiber washers retaining the heater strip.

5. Peel the heater strip [4] from the platform.

6. Remove bac king fro m the new heat er s trip an d sec ure it to the platfor m i n the same p osition
as the old heater.

7. Reverse Steps 2 throu gh 4 to install the new heater cable assemb ly. See Replacing the
Platform Assembly earlier in this section to complete the procedure.

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