SERIES 9800A

PUMPS AND DISPENSERS

DIAGNOSTIC MANUAL
C35797

REV. 03/07/03

Copyright 2003 by Gasboy International LLC All rights reserved.

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

GASBOY INTERNATIONAL LLC LANSDALE, PA

 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
OF A FUEL SPILL.

All products must be installed by a DO NOT use Teflon tape for any pipe DO require washing and changing of
qualified installer and used in threads in the product. clothes if fuel is spilled on a person or
conformance with all building, fire, and his/her clothing. Keep away from open
environmental codes and other safety DO NOT use consumer pumps for flames, sparks, or people smoking.
requirements applicable to its pumping fuel or additives into aircraft.
installation and use, including, but not DO provide a receptacle for catching
DO NOT use commercial pumps for product from pump/meter when
limited to, NFPA 30, NFPA 30A, NFPA direct fueling of aircraft without filters
395 & NFPA 70. A qualified installer is servicing.
and separators necessary to ensure
familiar with fuel systems installations product purity. DO clean up product spills on the
under the above stated building, fire, driveway. Turn off and lock out all
and environmental codes and other DO NOT use where sanitary design is power prior to cleanup.
safety requirements for the particular required (for food products for human
type of installation. consumption) or with water-based DO insure pump is properly grounded.
liquids.
This product is only part of a fuel DO insure hose is compatible with fluid
dispensing system and additional DO NOT smoke near the pump or when being dispensed.
equipment and accessories, such as, using the pump.
DO inspect hose, nozzle, and pump on
but not limited to, breakaway
DO NOT use near open flame or a regular basis for wear, damage, or
connectors, shear valves, pressure
electrical equipment which may ignite other conditions which may create a
regulators, flow limiters, and other
fumes. safety or environmental hazard.
safety devices may be necessary to
meet the applicable codes. DO NOT permit the dispensing of DO make sure all pipe threads are
gasoline or other petroleum products properly cut and the inside reamed to
For maximum safety, we recommend
into a vehicle with its motor running. remove burrs. Use UL classified
that all employees be trained as to the
gasoline-resisting compound on all
location and procedure for turning off DO NOT permit the dispensing of joints of gasoline handling piping.
power to the entire system. Instructions gasoline or other petroleum products Sealing compound must also be
regarding proper operation of the into unapproved containers or into resistant to Gasohol (Ethanol and
equipment along with the appropriate approved containers in or on vehicles Methanol). Use gasoline-resistant pipe
safety warnings should be posted in including trucks. All containers must be compound on male threads only; pipe
plain view at the fuel island. filled on the ground to prevent static compound used on female threads can
discharge. Always use Approved and be squeezed into the supply line where
Before performing service or
Listed hoses and nozzles with electric it can enter the product stream and
maintenance (including changing of fuel
pumps and dispensers. become lodged in the pump or meter.
filters or strainers) or in the event of a
fuel spill, turn off and lock out all power DO NOT block open the nozzle in any
to the system. In battery-powered manner. Nozzles shall conform to UL DO ensure that junction box covers are
pumps, disconnect power source. In and NFPA code requirements for in place and properly tightened. Mating
submersible pump applications, turn off attended or unattended service. surfaces between the box and cover
and lock out power at the master panel must be free of dirt, nicks, and
and close any impact valves to the DO ensure that the pump is equipped scratches. All unused entries into the
submersible pump and any other with proper filters based on the product junction box must be properly plugged.
dispensers which use that submersible being dispensed and its intended use.
pump. AC power can feed back into a DO wear safety goggles and protective
shut-off dispenser when dispensers clothes when dispensing any liquid
share a common submersible pump or which may be potentially harmful or
starter relay. Also block islands so no hazardous.
vehicles can pull up to the dispenser
when the dispenser is being worked on. DO keep all parts of body and loose
clothing clear of belts, pulleys, and other
exposed moving parts at all times.

035282 Rev. 1267

GASBOY INTERNATIONAL LLC

707 North Valley Forge Rd. Lansdale, PA, 19446 ● (215) 855-4631 ● FAX: (215) 855-0341
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
DC 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

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GASBOY Series 9800A

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

Connector ............................................................................................ 3-22
Power Bracket Assembly (C06436) .......................................................... 3-23
Connectors........................................................................................... 3-23

Section 4: TROUBLESHOOTING
Using This Section .................................................................................... 4-1

Section 5: REPLACEMENT INSTRUCTIONS

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

Appendix: PARTS LIST

Using This Parts List ................................................................................. 1

9800A Single Assembly – Front View....................................................... 2

9800A Single Assembly –Side View ......................................................... 4
9800A Twin Assembly –Front View .......................................................... 6
9800A Twin Assembly –Side View ........................................................... 8
9840A Assembly – Front View.................................................................. 10
9840A Assembly –Side View .................................................................... 12
9840A Chassis .......................................................................................... 14
9840AX Chassis........................................................................................ 16
9850AS Chassis........................................................................................ 18
9850AXS Chassis ..................................................................................... 20
9850AXTW1 Chassis ................................................................................ 22
9850AXTW2 Chassis ................................................................................ 24
9852A, 9853A Chassis ............................................................................. 26
9853AHC Chassis..................................................................................... 28
9852AX, 9853AX Chassis......................................................................... 30
9852ATW1 Chassis Assembly.................................................................. 32
9853ATW1M Chassis Assembly............................................................... 34
9852AXTW1, 9853XTW1 Chassis Assembly ........................................... 36
9852ATW2, 9853ATW2 Chassis Assembly ............................................. 38
9852AXTW2, 9853AXTW2 Chassis Assembly......................................... 40

Assembly Breakdowns
Air Separator Assembly ............................................................................ 42
Barrier, Intrinsically Safe (IS), Front Load Nozzle Option ......................... 43
Check Valves ............................................................................................ 44
9800A Single Dial Enclosure .................................................................... 45
9800A Twin Dial Enclosure....................................................................... 46
9840A, 9840AX Dial Enclosure................................................................. 47
Flange Assembly....................................................................................... 48
Motor Mount .............................................................................................. 48

Contents-2 03/07/03
 Contents

Support Assembly ..................................................................................... 48

Float Assembly.......................................................................................... 49
Float Assembly Breakdown ...................................................................... 50
High Hose Retriever Parts ........................................................................ 51
Internal Retriever Breakdown ................................................................... 52
9840A Manifold Assembly ....................................................................... 53
9840AX Manifold Assembly ...................................................................... 53
9853AHC Pump Discharge....................................................................... 54
9853AHC Manifold .................................................................................... 54
9853ATW1M Manifold Assembly.............................................................. 55
9800AXTW1 Manifold Assembly .............................................................. 55
Mechanical Totalizer ................................................................................. 56
9850A, 9850AX, 9850AXTW Meter Assembly ......................................... 57
Liquid Controls Meter Cover Assembly Breakdown (9850A) .................. 58
Liquid Controls Meter Housing Assembly Breakdown (9850A)............... 60
9840A, 9852A,9853A, 9853AHC, 9852ATW1, 9852ATW2, 9853ATW2,
9853ATW1M Meter Assembly ............................................................. 62
9852AXTW1, 9853AXTW1, 9840AX Meter Assembly ............................. 63
9852AXTW2, 9853AXTW2 Meter Assembly ............................................ 64
9800A Meter Assembly Breakdown.......................................................... 66
9840A Motor.............................................................................................. 68
9850A Motor.............................................................................................. 69
9852A, 9853A Motor ................................................................................. 70
9853AHC Motor ........................................................................................ 71
9852ATW1 Motor ...................................................................................... 72
9852TW2, 9853ATW2, 9853ATW1M Motor ............................................. 73
9853ATW2, 9853ATW1M Motor, 380V .................................................... 74
Nozzle Boot, Front Load Option................................................................ 75
9840 Pumping Unit Assembly................................................................... 76
9850A Pump and Platform Assembly ....................................................... 77
9852A, 9853A Pumping Unit Assembly .................................................... 78
9853AHC Pumping Unit Assembly ........................................................... 79
9852ATW1 Pumping Unit Assembly......................................................... 80
9853ATW1M Pumping Unit Assembly...................................................... 81
9852ATW2, 9853ATW2 Pumping Unit Assembly..................................... 82
Pumping Unit Assembly Breakdown......................................................... 84
Blackmer XU2A Pump and Platform Assembly Breakdown ..................... 86
Reset......................................................................................................... 88
Strainer Body/Check Valve Assembly ...................................................... 88

Discharge Assemblies
9840A Discharge – 097230 ...................................................................... 89
9840A Discharge, Canada-ATC 097264 .................................................. 89
9840A Valve Discharge - 097239 115V, 097240 230V ............................ 90
9840AX Discharge - 097241 115V, 097242 230V.................................... 91
9840AX Discharge – Canada-ATC 097415.............................................. 92
9840AX Filter Discharge - 097243 115V, 097244 230V........................... 93
9840AX Satellite Discharge - 097245 115V, 097246 230V,
Canada-ATC 097416........................................................................... 94
9850A, 9850AX Discharge Valve Assembly 097305 115V,
097311 230V, Canada-ATC 097426 ................................................... 95
9850A Discharge Assembly - 097302, Canada-ATC 070087 .................. 95
9850AS Discharge, Satellite Pipe Assembly 097308 115V,

0069 Contents-3
GASBOY Series 9800A

097335 230V, Canada-ATC 097434 ................................................... 96

9850AXS Discharge, Valve Pipe Assembly, 097321 115V,
097323 230V, Canada-ATC 097435 ................................................... 97
9850AXTW Discharge 097326 115V, 097329 230V, Canada-ATC 097428 98
9850AXTW Discharge 097348 115V, 097349 230V, Canada-ATC 097436 99
9852A, 9852AX Discharge - 097300 115V, 097301 230V,
Canada-ATC 097418........................................................................... 100
9852ATW1, 9852AXTW Discharge - 097324 115V, 097325 230V,
Canada-ATC 097419 .......................................................................... 100
9852ATW2 Discharge - 097352 115V, 097353 230V,
Canada-ATC 097420........................................................................... 100
9852A, 9852AX Filter Discharge - 097306 115V, 097307 230V,
Canada-ATC 097424........................................................................... 101
9852ATW1, 9800AXTW Filter Discharge - 097333 115V, 097334 230V,
Canada-ATC 097425........................................................................... 101
9852AX Satellite Discharge - 097303 115V, 097304 230V,
Canada-ATC 097429........................................................................... 102
9800AXTW Satellite Discharge - 097327 115V, 097328 230V,
Canada-ATC 097430........................................................................... 102
9852AX Filter, Satellite Discharge - 097309 115V, 097310 230V............ 103
9852AXTW Filter, Satellite Discharge - 097336 115V, 097337 230V ...... 103
9852A Discharge – 097188; Canada-ATC 097273 .................................. 104
9852A Filter Discharge – 097359, Canada-ATC 097338 ........................ 104
9852ATW2 Discharge Assembly – 097209; Canada-ATC 097417.......... 105
9852ATW2 Filter Discharge Assembly – 097208; Canada-ATC 097417. 105
9853A, 9853AX, 9853AHC Discharge - 097312 115V, 097313, 230V,
Canada-ATC 097421........................................................................... 106
9853AXTW Discharge - 097339 115V, 097340 230V,
Canada-ATC 097422........................................................................... 106
9853ATW2, 9853ATW1M Discharge - 097355 115V, 097356 230V;
Canada-ATC 097423........................................................................... 106
9853A, 9853AX Filter Discharge - 097316 115V, 097317 230V .............. 107
9853AXTW Filter Discharge - 097343 115V, 097344 230V ..................... 107
9853A, 9853AHC Discharge Assembly – 097171, Canada-ATC 097269 108
9853A Filter Discharge Assembly - 097361 ............................................. 108
9853ATW1M, 9853ATW2 Discharge Assembly – 097155,
Canada-ATC 097266........................................................................... 109
9853AX Satellite Discharge - 097314 115V, 097315 230V,
Canada-ATC 097431........................................................................... 110
9853AXTW Satellite Discharge - 097341 115V, 097342 230V,
Canada-ATC 097432........................................................................... 110
9853AX Filter, Satellite Discharge - 097318 115V, 097319 230V............ 111
9853AXTW Filter, Satellite Discharge - 097345 115V, 097346 230V ...... 111
9853ATW2F Discharge Assembly – 097205; Canada-ATC 097433........ 112

Electronic Assembly
Electronic Platform Assembly ................................................................... 114
Electronic Platform Options ...................................................................... 116

9800A Kits and Accessories .................................................................. 118

Contents-4 03/07/03
Section 1

INTRODUCTION

ABOUT THIS BOOK

This book was written to assist the authorized service representative (ASR) or technician in
troubleshooting the Series 9800A. 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 procedures
• a troubleshooting (Problems) section.

USING THE TROUBLESHOOTING SECTION

The Troubleshooting section lists common problems, probable causes, and corrective action to
be taken. The probable causes and checks for each problem are presented in logical sequence,
allowing you to rule out one set of symptoms before going on to the next. Thus, following the
procedures as listed should help isolate your problem.

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

Checks and corrective actions requiring voltage measurements assume familiarity with and are
done with a voltmeter unless noted that an oscilloscope or ohmmeter should be used.

03/07/03 1-1
Section 2

CHASSIS WIRING

JUNCTION BOXES
All field wiring connections to the Series 9800A dispensing unit are made in the unit’s junction
boxes. The 9800A wiring is split into two classifications, AC and DC. A junction box is provided
for AC; a DC junction box is optional. AC and DC wiring must never be mixed in any common
junction box, conduit, or trough. See the Series 9800A Installation/Operation Manual for detailed
instructions. The following lists the wires that can be found in the junction boxes along with a
brief description of each. A more detailed description can be found in the Series 9800A
Installation/Operation Manual.

AC Junction Box

AC Ground - Grounding for the Series 9800A

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. Provides power to slow and fast flow valves along with the switch detect signal.
Two lines provided for twins.
Submersible Starter Drive - Controls Submersible Starter Relay. Two lines provided for twins.
Submersible Drive - Active only when submersible drive relays are provided. Controls
submersible starter relay or submersible pump. Two lines provided for twins.
Reset Complete (Switch Detect)/Slow Flow - For use with fuel management system, indicates
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 fast flow valve (satellite). Used only with two-stage solenoid valves.
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 - Used only with satellites in nonsimultaneous applications. 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.

03/07/03 2-1
GASBOY Series 9800A

DC Junction Box

Pulser - When the dispensing unit includes the optional pulser interface, a pulser output is
provided. This pulser output provides a DC output to indicate the quantity dispensed. This is an
open collector output. A DC ground line from the monitoring equipment should be connected to
the DC ground line provided from the electronic register. This output can sink up to 100 milliamps
DC at voltages up to 24 VDC. The pulse rate can be configured by a sealable DIP switch for
rates of 1, 10, 100, 250, 500, or 1000 pulses per unit (gallons) or 1, 10, 100, or 250 pulses per
unit (liters). This output should only be used when monitoring of the dispenser’s operation is
desired. An additional output is provided for a twin. These lines must be capped when not in
use.

RS-485

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

2-2 03/07/03
 Chassis Wiring

115VAC/60 CYCLE PUMP WIRING

03/07/03 2-3
GASBOY Series 9800A

115VAC/60 CYCLE DISPENSER WIRING

2-4 03/07/03
 Chassis Wiring

230VAC/50 CYCLE PUMP WIRING

03/07/03 2-5
GASBOY Series 9800A

230VAC/50 CYCLE DISPENSER WIRING

2-6 03/07/03
 Chassis Wiring

115VAC/60 CYCLE FRONT LOAD OPTION PUMP WIRING

03/07/03 2-7
GASBOY Series 9800A

115VAC/60 CYCLE FRONT LOAD OPTION DISPENSER WIRING

2-8 03/07/03
 Chassis Wiring

230VAC/50 CYCLE FRONT LOAD OPTION PUMP WIRING

03/07/03 2-9
GASBOY Series 9800A

230VAC/50 CYCLE FRONT LOAD OPTION DISPENSER WIRING

2-10 03/07/03
 Chassis Wiring

03/07/03 2-11
Section 3

ELECTRONIC HEAD ASSEMBLY

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

03/07/03 3-1
GASBOY Series 9800A

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 9800A. This CPU PCB:

• processes and stores all 9800A data

• contains a battery-backed 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 pump side
• monitors the electronic totalizer switch
• sends pulser data to an external control system via an optional pump interface PCB
• communicates on the GASBOY RS-485 pump loop 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 03/07/03
 Electronic Head Assembly

Connectors

Connector P1 controls side 1 and P2 controls side 2. The AC IN and NEUT pins are used as a
pump authorization signal when SW1-6 is closed. The AC IN also feeds the SF, FF, and SUBM
relays. The SF and FF outputs can directly power the solenoid valves. The SUBM output can
power a customer-supplied submersible starter relay. The starter relay’s coil current must not
exceed 300 mA.

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

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

P4 - Handle Switch Inputs

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

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GASBOY Series 9800A

P6 - Electronic Totalizer Switch

The electronic totalizer switch connects to P6.

P7 - Suction Pump/Submersible Pump Relay Drives

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

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

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 Electronic Head Assembly

P9 – Front Load Option

P10 - Power Supply Input

P11 - LCD Display Interface

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

The 9800A CPU PCB can accommodate two sizes of battery-

backed RAM; 2K and 8K. At this time only the 2K size is
being used.

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GASBOY Series 9800A

LED Indicators
The LED indicators provided enable you to monitor 9800A operations.

Test Points
Test points are provided for voltage measurements.

SW Switches

The 9800A can be configured for various operating conditions using the switches located on the
CPU PCB. Check these switches and change their settings if necessary. Switch settings should
be changed with the power switch OFF. The new settings are read by the CPU PCB when the
power is turned ON again.

SW1
SW1-1 Baud Rate
This switch is set to reflect the communication rate of the GASBOY RS-
485 pump loop; open for 9600 baud or closed for 1200 baud. The
GASBOY CFN system communicates at 9600 baud.

SW1-2 Mode
This switch should be open for the 9800A to communicate on the
GASBOY RS-485 pump loop (on-line) and closed for all other
applications (standalone).

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 Electronic Head Assembly

SW1-3, SW1-4 Delay Time

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

SW1-5
Not used.

SW1-6 Authorization
This switch allows activation or non-activation of the unit through
an external source (fuel management system). When closed, a
115/230 VAC signal must be present on the Control Feed (pump
motor or subm) line for pump activation to occur (required setting
for Series 1000). When open, the 9800A ignores the Control
Feed line (required setting for CFN System or no fuel
management system).

SW1-7 Totalizers
This switch should be set to open for normal operation. When
closed, this switch enables the reset of the electronic totalizers.

SW1-8
Not used.

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GASBOY Series 9800A

SW2
This four-position switch pack serves a dual purpose: as an address setting when communicating
on the GASBOY RS-485 loop or Series 900, or as a pulser output rate selector when pulser data
is sent to a fuel management system other than a GASBOY CFN or Series 900.

Address Switches
A unique address identifier must be set when the $GGUHVV 6: 6: 6: 6:
9800A is connected to the GASBOY RS-485 1 Closed Closed Closed Closed
pump loop via the 9800A RS-485 I/F PCB. 2 Open Closed Closed Closed
Because there are 16 possible address 3 Closed Open Closed Closed
combinations, up to 16 units (single or twin) may 4 Open Open Closed Closed
be connected to the pump loop. Addressing 5 Closed Closed Open Closed
should start at 1 and continue sequentially through 6 Open Closed Open Closed
16. The physical wiring order does not have to 7 Closed Open Open Closed
correspond with the address order; that is the first 8 Open Open Open Closed
unit on the RS-485 loop doesn’t have to be 9 Closed Closed Closed Open
address 1. The chart at right gives the switch 10 Open Closed Closed Open
settings and address selections. With the Series 11 Closed Open Closed Open
900 option, the address must be set to 1. 12 Open Open Closed Open
13 Closed Closed Open Open
14 Open Closed Open Open
15 Closed Open Open Open
16 Open Open Open Open
Pulser Output Rate Switches
When the 9800A is connected to external
control equipment other than a GASBOY Pulse Rate SW2-1 SW2-2 SW2-3
CFN system (standalone), the pulser signals 1 Closed Closed Closed
are sent out via the 9800A Pump I/F PCB. 10 Open Closed Closed
The pulse rate required by the monitoring 100 Closed Open Closed
equipment can be configured by setting the 250 Open Open Closed
switches as shown in the chart at right. The 500 Closed Closed Open
pulse rate represents pulses per gallon 1000 Open Closed Open
None Closed Open Open
(PPG, domestic) or pulses per liter (PPL,
None Open Open Open
international). For domestic units, the pulse
rate can be up to 500 PPG for 9840A, 250
PPG for 9850A and up to 1000 PPG for all
other models. For international units, the
pulse rate can be up to 100 PPL for 9840A,
10 PPL for 9850A, and up to 250 PPL for all
other models. This switch may need to be
sealed by a Weights and Measures paper
seal if the 9800A is used for the resale of
product.
Pulse Rate Display
Leading zeros are always suppressed in the 1:1 XXX.
hundreds and tens positions to the left of the 10:1 XXX.X
decimal point. When in standalone mode, 100:1 XXX.XX
positions to the right of the decimal point are 250:1 XXX.XXX
displayed based on the pulse rate selected 500:1 XXX.XXX
as shown in the table at right. 1000:1 XXX.XXX

Timeout Switch
When the 9800A is in standalone mode, it will turn off an active Timeout SW2-4
hose if it doesn’t detect pulses for 4 minutes, 15 seconds. This Enabled Closed
timeout feature can be disabled by setting switch SW2-4 to Disabled Open
Open.

3-8 03/07/03
 Electronic Head Assembly

LCD DISPLAY PCB (C01373)

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

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

Connector
P1 - CPU PCB Interface

03/07/03 3-9
GASBOY Series 9800A

Jumpers

The LCD Display PCB must be addressed to display the

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

The LCD Display PCB can be configured to

display whole units, tenths, hundredths, or
thousandths. Presently all domestic 9800A’s,
except 9850A, are shipped displaying
thousandths of a gallon; all international
9800A’s are shipped displaying hundredths.
9850A units are shipped displaying
hundredths. The 9850A liter software will
blank the hundredths location and display
tenths only. Jumper K2, K4, and K6 select 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 03/07/03
 Electronic Head Assembly

SALE BACKLIGHT PCB (C06372)

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

• attaches to the 9800A LCD display PCB

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

Connector

P1 - Power Input Connector

03/07/03 3-11
GASBOY Series 9800A

RS-485 INTERFACE PCB (C06389)

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

• provides protection against noise and damaging voltage transients that may be induced onto
the RS-485 lines
• 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 03/07/03
 Electronic Head Assembly

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

03/07/03 3-13
GASBOY Series 9800A

PUMP INTERFACE PCB (C06425)

The Pump Interface PCB sends the pulser signal to external monitoring equipment that does not
support the GASBOY RS-485 electronic pump loop. This PCB:

• provides a pulser signal for each pump side, up to 100 mA at 24 VDC. The current and
voltage are determined by the external equipment.
• contains diagnostic LEDs to monitor the pulser output lines

Connectors

P1 - Pulser Output

3-14 03/07/03
 Electronic Head Assembly

P2 - CPU PCB Interface

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

03/07/03 3-15
GASBOY Series 9800A

POWER SUPPLY PCB

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

The power supply PCB provides:

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

• diagnostic LED’s to monitor DC voltages
• a signal to warn the microprocessor of an impending power failure
• rechargeable battery-backup to display last transaction for a minimum of 15 minutes (C06397
and C06489 versions).

Version shown is C06397.

3-16 03/07/03
 Electronic Head Assembly

Connectors
P1 - CPU Power Output

P2 - Backlight Power Output

P3 - AC Input

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

Test Points
Test points are provided for voltage measurement.

03/07/03 3-17
GASBOY Series 9800A

PUMP RELAYS

The pump relays are always used for suction pumps and may be used for submersible pumps up
to and including 1-1/2 HP at 230 VAC. These relays:

• control the motor that drives the suction or submersible pump (one each side)
• are controlled by the CPU PCB

3-18 03/07/03
 Electronic Head Assembly

Connectors
Relay Drive

Pump Motor Power

03/07/03 3-19
GASBOY Series 9800A

BALLAST ASSEMBLY
115 VAC (C06473)
230 VAC (C06476)

The ballast assembly provides power for the fluorescent lights.

Connectors
Front and Rear Lamps

Input Power

3-20 03/07/03
 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

03/07/03 3-21
GASBOY Series 9800A

HEATER/THERMOSTAT CABLE ASSEMBLY

115 VAC (C06450)
230 VAC (C06490)

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

• contains a 25W heater strip

• contains a thermostat to regulate temperature

Connector
Input Power

3-22 03/07/03
 Electronic Head Assembly

POWER BRACKET ASSEMBLY (C06436)

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

Connectors

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

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

03/07/03 3-23
GASBOY Series 9800A

ELECTRONIC TOTALIZER CABLE ASSEMBLY

Front (Standard) C06434
Rear (Optional) C06819

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

Front Cable

Rear Cable

ELECTRONIC TOTALIZER ACTUATOR C01342

The electronic totalizer actuator is a permanent magnet that causes the

9800A displays to show totalizer data when placed in close proximity to the
totalizer sensor.

3-24 03/07/03
Section 4

TROUBLESHOOTING

USING THIS SECTION

The Troubleshooting section lists common problems, probable causes, and corrective action to
be taken. The probable causes and checks for each problem are presented in logical sequence,
allowing you to rule out one set of symptoms before going on to the next. Thus, following the
procedures as listed should help isolate your problem.

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

Checks and corrective actions requiring voltage measurements assume familiarity with and are
done with a voltmeter unless noted that an oscilloscope or ohmmeter should be used.

03/07/03 4-1
GASBOY Series 9800A

9800A is dead. Displays are blank, including decimal points. Unable to activate side 1 or
side 2.

Possible Cause Checks Corrective Action

No 115/230AC feed to 9800A Check if circuit breaker is off Turn breaker on, if off.
for micro power. or tripped.

Check if 115/230VAC is being Replace circuit breaker if

switched through circuit 115/230VAC is not measured.
breaker.

Check if 115/230VAC is Correct wiring problems if

measured at the micro 115/230VAC is not measured.
connector on the power
bracket.
Power switch is off. Check the power switch. Turn on, if off.
AC power fuse is blown. Check the fuse in power Replace fuse, if blown.
bracket.
Blown power supply (PICO) Using a voltmeter, measure Replace F1 if 5VDC is
fuse(s) or defective power between the GND test point measured on one side but not
supply. and each side of F1 and F2 on the other.
the power supply.
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 between
the GND and +5VDC test
points on the CPU PCB but
the 9800A is still dead.

NOTE: Changing the pulser

rate switches may require
replacement of your Weights
and Measures seal.

4-2 03/07/03
 Troubleshooting

9800A won’t activate in standalone mode. When the pump handle is thrown, the displays
do not go through reset sequence.

Possible Cause Checks Corrective Action

System controlling 9800A not If the 9800A is controlled by a Repair fuel management
functioning properly. fuel management system system if necessary. Refer to
other than CFN, verify proper fuel management system
operation of system. manuals for further assistance.
AUTH signal not getting to If the 9800A is controlled by a f L1 and/or L5 don’t light, use
CPU PCB. fuel management system an AC voltmeter to measure
other than CFN, an AC between pins 1 and 6 of
authorization (AUTH) signal is connectors P1 (side 1) and P2
required for pump activation. (side 2) of the CPU PCB. If
On the 9800A CPU PCB, 115/230 VAC is measured but
check if L1 (side 1) or L5 (side L1 and/or L5 don’t light,
2) light when the fuel system replace the CPU PCB. If
tries to activate the pump. 115/230VAC is not measured,
trace the wiring back to the
fuel management system and
correct the problem.
Mode switch on CPU PCB set Check switch SW1-2 on CPU Close switch, if open. Turn
incorrectly. PCB. power switch off, then on after
changing switch settings.
9800A is running on battery Check if micro circuit breaker Turn breaker on, if off.
power (Skip this section if your is off or tripped.
9800A is not equipped with a
battery back-up power supply). Check if 115/230VAC is being Replace circuit breaker if
switched through circuit 115/230VAC is not being
breaker. switched.

Check if 115/230VAC is Correct wiring problems if

measured in 9800A AC 115/230VAC is not measured.
junction box.

Check the MICRO power Turn on, if off.

switch.

Check the fuse in the power Replace fuse if blown.

bracket.
Defective handle switch. Using a DC voltmeter, Replace the handle switch if
measure between the proper voltages are not
common (COM) and normally measured.
open (N.O.) terminals on the
handle switch. +5VDC should
be measured. Turn the handle
on. 0VDC should be
measured.
Defective AC power fail Using a DC voltmeter, Replace the power supply
circuitry. measure between ground PCB if +5VDC is not
(TP2) and pin 3 of connector measured between GND and
P10 (violet wire) on the CPU the violet wire.
PCB.
continued

03/07/03 4-3
GASBOY Series 9800A

Possible Cause Checks Corrective Action

Defective CPU PCB. None. Replace the CPU PCB if the
9800A still will not activate.

NOTE: Changing the pulser

rate switches may require
replacement of your Weights
and Measures seal.

4-4 03/07/03
 Troubleshooting

9800A won’t activate in on-line mode. When the pump handle is thrown, the displays do
not go through reset sequence.

Possible Cause Checks Corrective Action

9800A is not communicating to Verify that the 9800A is Perform actions listed under
the GASBOY CFN system. communicating. 9800A is not communicating to
the GASBOY CFN System.
9800A won’t activate in Verify that the 9800A works in Close SW1-2 on the CPU
standalone mode. standalone mode.. PCB, turn the power switch off
and on, then perform the
actions listed under 9800A
won’t activate in standalone
mode. Open SW1-2, then turn
the power switch off and on
before returning to this page.
CFN system data loaded Verify that all CFN system Reload system data, if
incorrectly. data is loaded correctly incorrect.
(authorization codes, product
codes, pump table, etc.)

03/07/03 4-5
GASBOY Series 9800A

9800A is not communicating to the GASBOY CFN system.

Possible Cause Checks Corrective Action

CFN system is not functioning Verify proper operation of the Repair CFN system, if
properly. CFN system. necessary. Refer to CFN
manuals for further assistance.
CFN system not configured Verify that the device types Make sure the pump type is 2
properly. and pump addresses are with no options for the Site
configured correctly. Controller II or type 64 for the
Site Controller I.
Incorrect switch settings on Verify that the SW1 switches Change switch settings if
9800A CPU PCB. are set as follows: 1=OPEN, necessary. Turn the power
2=OPEN, 6=OPEN. Verify switch off, then on after
that the SW2 switches match 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 03/07/03
 Troubleshooting

9800A resets but does not dispense fuel – Pump.

Possible Cause Checks Corrective Action

No 115/230VAC feed to pump. Check if circuit breaker is off Turn breaker on, if off.
or tripped.

Check if 115/230VAC is being Replace circuit breaker if

switched through circuit 115/230VAC is not being
breaker. switched.

Check if 115/230VAC is Correct wiring problems if

measured in the junction box. 115/230VAC is not being
measured.
Defective CPU PCB. Using a DC voltmeter, Replace the CPU PCB if
measure between ground +5VDC is measured between
(CPU PCB test point TP2) and ground and the blue or violet
screw terminal #4 (blue wire wires.
for side 1, violet wire for side NOTE: Changing the pulser
2) of the pump relay. The rate switches may require
voltage should be 0VDC. replacement of your Weights
and Measures seal.

If equipped with an optional Replace the CPU PCB if

solenoid valve, measure 115/230VAC is not measured
between screw terminals 1 between screw terminal 1 and
and 3 of terminal block SOL1 3.
and SOL2, using an AC NOTE: Changing the pulser
voltmeter. rate switches may require
replacement of your Weights
and Measures seal.
Defective pump relay. Using an AC voltmeter, Replace the relay if
measure between AC neutral 115/230VAC is measured at
and screw terminals #1 and #2 screw terminal #1 but not at
of the pump relay. #2.
Defective optional solenoid Solenoid valve should click Replace valve if click is not
valve. after reset. heard after reset.
Defective pump motor. Motor should turn when Replace pump motor if
115/230VAC is measured in 115/230VAC is not measured.
AC junction box.
Out of fuel. Check fuel level in tank. Order fuel if tank empty.
Pump will not prime or loses Dirty strainer. Remove strainer cap and
prime. clean strainer.

Loose V-belt. If belt is loose, tighten

according to
Installation/Operation Manual
instructions.

Air leak in suction line, Call qualified service

excessive lift, bypass valve personnel if any of these
stuck on open, air separator conditions exist..
float stuck open, float chamber
valve open.

03/07/03 4-7
GASBOY Series 9800A

9800A resets but does not dispense fuel – Dispenser.

Possible Cause Checks Corrective Action

No 115/230VAC feed to Check if circuit breaker is off Turn breaker on, if off.
dispenser. or tripped.

Check if 115/230VAC is being Replace circuit breaker if

switched through circuit 115/230VAC is not being
breaker. switched.

Check if 115/230VAC is Correct wiring problems if

measured in junction box. 115/230VAC is not measured.
Defective CPU PCB. If the submersible pump is Replace the CPU PCB if
powered by the optional solid +5VDC is measured between
state relay mounted in the ground and the blue or violet
pump head, follow this check, wires.
otherwise skip to next check. NOTE: Changing the pulser
Using a DC voltmeter, rate switches may require
measure between ground replacement of your Weights
(CPU PCB test point TP2) and and Measures seal.
screw terminal #4 (blue wire
for side 1, violet wire for side
f 115/230VAC is not measured
2). The voltage should be
on either side of the fuses,
0VDC.
replace the CPU PCB. If
115/230VAC is measured on
Using a DC voltmeter, one side of the fuse but not on
measure between neutral and the other, replace the fuse.
both sides of fuse F1 (side 1) NOTE: Changing the pulser
or F2 (side 2). rate switches may require
replacement of your Weights
and Measures seal.
Using an AC voltmeter,
measure between screw Replace the CPU PCB if
terminals 1 and 3 of terminal 115/230VAC is not measured
SOL1 or SOL2. 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, Replace the relay if
measure between AC neutral 115/230VAC is measured at
and screw terminals #1 and #2 screw terminal #1 but not at
of the pump relay. #2.
Defective submersible starter Measure across coil of starter Replace starter relay if
relay. relay. 115/230VAC is measured
across coil, but relay does not
close.
Out of fuel Check fuel level in tank. Order fuel if tank empty.

4-8 03/07/03
 Troubleshooting

Possible Cause Checks Corrective Action

Leak detector did not open. Check the settings of switches Select a longer delay time if
SW1-3 and SW1-4 to needed.
determine the selected delay
time. Replace defective leak
detector if it does not open.

Leak in supply line or piping. Repair leak.

Shear valve tripped. Try to determine cause (loose Reset, or if necessary, replace
mounting to island, cabinet shear valve if it is tripped.
had been hit, etc.) Correct cause of valve
tripping.
Defective submersible motor. Repair or replace motor.

03/07/03 4-9
GASBOY Series 9800A

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

Possible Cause Checks Corrective Action

Broken or damaged coupling. Broken or damaged coupling. Repair or replace coupling if
damaged.
Defective pulser or defective While dispensing fuel slowly, Replace the pulser if a +5VDC
CPU PCB. measure between GND (TP2) square wave is not measured
and pins 1 and 2 of connector between GND and pin 1 and
P3 (side 1) or P5 (side 2) on between GND and pin 2 of the
the CPU PCB using an appropriate connector.
oscilloscope.
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 03/07/03
 Troubleshooting

Quantity shows on 9800A displays but fuel management system records incorrect or zero
quantity. This problem pertains only to 9800A’s connected to non-CFN fuel management
systems.

Possible Cause Checks Corrective Action

Pulser output rate switches Check the settings of SW2-1 Change the CPU PCB switch
don’t match system pulser through SW1-4 on the CPU settings or change the fuel
rate. PCB. management system pulser
rate accordingly.

NOTE: Changing the pulser

rate switches may require
replacement of your Weights
and Measures seal.
Fuel management system The 9800A requires the fuel Call GASBOY Technical
pulser input circuitry not management system to "pull Service for assistance.
compatible. up" the pulser signal to a DC
voltage between 5VDC and
24VDC.
Defective CPU PCB. Using an oscilloscope, check Replace the CPU PCB if a
the signal between GND (TP2) +5VDC square wave signal is
and the following pins of P2 on not measured on the
the pump I/F PCB.: appropriate pins.

Pin 5-Side 1 1000:1; NOTE: Replacing the CPU

250:1, international PCB may require replacement
Pin 6-Side 2 1000:1; of your Weights and Measures
250:1, international 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 Replace the Pump I/F PCB if
the signal between GND (TP2) the pulser signal is not
and P1 pin 1 (side 1) or P1 pin measured on the appropriate
2 (side 2) on the pump I/F pins.
PCB. Replace the power supply if
0VDC is measured on both
sides of F1 or F2.

03/07/03 4-11
GASBOY Series 9800A

The 9800A does not display the last transaction during an AC power failure. This problem
pertains only to 9800A’s equipped with a battery back-up power supply.

Possible Cause Checks Corrective Action

Battery not fully charged or If the 9800A had been off for a Replace the power supply if
defective power supply PCB. very long time, the battery charging did not fix the
probably isn’t fully charged. problem.
After AC power is restored,
allow the 9800A to run for 24
to 36 hours, then turn AC
power off and make sure the
last transaction is displayed for
15 minutes minimum.

9800A 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 misalignment of Check alignment. Realign if needed.

totalizer switch and magnet.
Defective actuator. None. Replace actuator.
Defective totalizer sensor or Remove the totalizer cable Replace the totalizer cable
defective CPU PCB. assembly from P6 of the CPU assembly if shorting P6
PCB. Short the two pins causes totalizer data to
together on P6 of the CPU display.
PCB.
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 03/07/03
 Troubleshooting

The flourescent lights don’t turn on.

Possible Cause Checks Corrective Action

No 115/230VAC feed to Check if circuit breaker is off Turn breaker on, if off.
9800A for light power. or tripped.

Check if 115/230VAC is being Replace circuit breaker if

switched through circuit 115/230VAC is not being
breaker. switched.

Check if 115/230VAC is Correct wiring problems if

measured at the LIGHTS 115/230VAC is not measured.
connector on the power
bracket.
Loose, burnt out, or damaged Check bulb for damage or Tighten, if loose. Replace if
bulb. burn marks. burnt out or damaged.
Defective ballast None. Replace ballast.

All displays on 9800A 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 9800A 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
9800A 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.

03/07/03 4-13
GASBOY Series 9800A

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

Possible Cause Checks Corrective Action

9800A is running on battery Check if the breaker supplying Turn breaker on, if off.
power (Skip this Possible power to the MICRO circuit is
Cause if your 9800A is not off or tripped.
equipped with a battery back-
up power supply). Check if 115/230 VAC is being Replace circuit breaker if
switched through circuit 115/230 VAC is not being
breaker. switched.

Check if 115/230 VAC is Correct wiring problems if

measured in 9800A AC 115/230 VAC is not measured.
junction box.

Check the MICRO power Turn on, if off.

switch.

Check the fuse in the power Replace fuse if blown.

bracket.
Defective AC power fail circuit. Using a DC voltmeter, Replace the power supply
measure between ground PCB if +5VDC is not
(TP2) and pin 3 of connector measured between ground
P10 (violet wire) on the CPU and the violet wire.
PCB.

With the 9800A 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 If both lamps do not flash,
off position (nozzle hung up), replace the pulser. If both
observe the pulser lamp lamps flash, replace the CPU
indicators on the CPU PCB, PCB.
while slowly turning the pulser
shaft. Both lamps (PULA and
PULB) should flash on and off.

4-14 03/07/03
 Troubleshooting

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

Possible Cause Checks Corrective Action

No fuel is dispensed. None. Go to the problem 9800A
resets but does not
dispense fuel.
Pulser doesn’t turn. Check if the pulser coupling is Repair or replace coupling if
broken or damaged. damaged.
The operator filled the vehicle, Check if the handle is still on. None.
but never turned off the pump
handle.
9800 timeout feature is Check the position of switch If the switch is closed, the
enabled. SW2-4 on the 9800 CPU PCB. 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 9800A 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 Verify that the display’s last The 9800 cannot dispense
a single transaction was sale shows the limit from the more than the maximum
pumped. The limits are: Possible Cause column for quantity shown in the
9800 gallons = 990.000 the applicable 9800 model. Possible Cause column in a
9840 gallons = 990.000 single transaction. Run
9850 gallons = 9990.00 additional transactions until
9800 liters = 9990.00 fueling is completed.
9840 liters = 9990.00
9850 liters = 9990.0

03/07/03 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. Simply turning off the power switch in the electronic head will
not remove all power from the unit! All breakers that feed the unit should be
turned off. In submersible pump applications, turn off power to the submersible
pump and any other dispensers which use that submersible pump. AC power
can feed back into a shut-off dispenser when other dispensers share a common
submersible pump or starter relay.

All replacement procedures are written with the understanding that the Series 9800A has been
opened for servicing. Electronic component access is detailed on the next page.

The numbers found in brackets [1] in the text can be used to find the associated balloon number
in the reference drawings.

03/07/03 5-1
GASBOY Series 9800A

ELECTRONIC COMPONENT ACCESS

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

DIESEL UNLEADED

GALLONS GALLONS

UNLOCK

1. Unlock and remove the front panel.

2. Remove the two bolts located over the tabs of the bezel assembly. Lift the bezel assembly
upwards and out to remove. If the model includes the front load nozzle, remove the nozzle

DIESEL UNLEADED

GALLONS GALLONS

REMOVE

boot plastic shroud (two screws) before removing the bezel assembly.

3. Loosen, and remove if necessary, the two screws located on the left and right door support
brackets and pivot display panel down.

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 Replacement Instructions

USE

F
USE

HEATER LIGHTS MICRO POWER 1 AMP SB OFF POWER ON

LOOSEN

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GASBOY Series 9800A

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. Disconnect the cables [5] from the rear door PCB’s.

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

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

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 Replacement Instructions

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GASBOY Series 9800A

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, remove the two Phillips screws [2]. Pull
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 U18 [3] and the memory IC from socket U19 [4] of the
defective CPU PCB by gently prying with a slotted screwdriver.

5. Install the old program IC and memory IC into sockets U18 and U19 on the new CPU PCB.
Be careful to observe proper pin orientation.

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

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

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 Replacement Instructions

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 on the new LCD Display PCB match the jumper settings from
the defective LCD Display PCB. See the jumper settings in Section 3, Electronic Head
Assembly for verification.

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GASBOY Series 9800A

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.

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 Replacement Instructions

REPLACING THE POWER SUPPLY PCB

1. Disconnect the cables [1] from the Power Supply PCB.

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

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

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GASBOY Series 9800A

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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 Replacement Instructions

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 removed.

2. Using a slotted screwdriver, apply pressure to the retaining tab on one side of the LIGHTS
connector [1] on the power bracket, then push the connector in through bracket.

3. Disconnect the lamp cable assemblies [2] from the ballast cable assembly on the front and
rear of the platform.

4. Using a slotted screwdriver, apply pressure to the retaining tab on one side of each ballast
connector [3], then push the connectors down through the platform.

4. With older units, on the base of the platform assembly (top side) cut the tie strap [4] using
wire cutters.

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GASBOY Series 9800A

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 Replacement Instructions

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 ballast cable assembly. Be sure to install a
new tie strap or push-in wire twist standoff to keep the cable wiring away from the optional
heater strip. See Replacing the Platform Assembly earlier in this section to complete the
procedure.

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GASBOY Series 9800A

REPLACING THE HEATER CABLE ASSEMBLY

1. The platform assembly must be removed in order to

replace the heater cable assembly. See Replacing
the Platform Assembly earlier in this section.
Proceed to Step 2 once platform assembly is
removed.

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 backing from the new heater strip and secure it to the platform in the same position
as the old heater.

7. Reverse Steps 2 through 4 to install the new heater cable assembly. See Replacing the
Platform Assembly earlier in this section to complete the procedure.

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APPENDIX

PARTS LIST