Sentry VI INSTALLATION MANUAL

Transcription

1 FUEL MANAGEMENT SYSTEM Sentry VI INSTALLATION MANUAL Trak Engineering, Inc Crescent Drive Tallahassee, FL Phone:(850) FAX:(850) Web Site: 1

2 IMPORTANT The Sentry VI and associated equipment will be installed in close proximity to combustible fuel dispensers. For the safety of all concerned, it is essential that you read and understand the instructions in this manual before proceeding. ****** CAUTION ****** TURN OFF ALL POWER TO THE ISLAND BEFORE BEGINNING INSTALLATION. THE SENTRY VI SYSTEM SHALL BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NFPA NO. 70), THE AUTOMOTIVE AND MARINE SERVICE STATION CODE (NFPA NO. 30A) AND LOCAL ORDINANCES. DO NOT INSTALL THE SENTRY VI SYSTEM IN A LOCATION THAT DOES NOT MEET THE REQUIRED STANDARDS AS LISTED ABOVE. QUALIFIED LICENSED ELECTRICIANS ARE REQUIRED TO PERFORM ANY MODIFICATIONS OR ALTERATIONS TO THE ELECTRICAL CIRCUITS AT THE INSTALLATION SITE. ALL PARTS USED TO INSTALL THE SENTRY VI SYSTEM INSIDE A DISPENSER, THAT ARE NOT PART OF THE INSTALLATION PACKAGE, SHALL BE LABORATORY TESTED FOR USE IN CLASS 1, GROUP D HAZARDOUS LOCATIONS. ALL INSTALLATIONS SHALL ALSO COMPLY WITH OSHA SAFETY STANDARDS. FAILURE TO COMPLY WITH THE LISTED CAUTIONS MAY RESULT IN SERIOUS PERSONAL INJURIES, PROPERTY LOSS AND/OR EQUIPMENT DAMAGE. 2

3 TABLE OF CONTENTS TALLAHASSEE, FL SECTION 1.0 OVERVIEW PRODUCT DESCRIPTION INSTALLATION OVERVIEW SITE CRITERIA PRE-INSTALLATION INSTRUCTIONS... 6 SECTION 2.0 SENTRY MOUNTING LOCATION... 7 SENTRY MOUNTING... 8 SECTION 3.0 SYSTEMS POWER UNIT INSTALLATION GENERAL... 9 SECTION 4.0 PUMP CONTROL MODULE INSTALLATION INSTALLATION WIRING CONNECTIONS WIRING CONNECTIONS (CONTINUED) FIBER OPTIC SPLICING FIBER OPTIC SPLICING (CONTINUED) SECTION 5.0 PULSER INSTALLATION PULSER INSTALLATION PULSER POWER UNIT INSTALLATION (NON-AUTOMATED) PULSER POWER UNIT INSTALLATION (FULLY AUTOMATED) NOZZLE PICKUP (FULLY AUTOMATED) NOZZLE PICKUP (FULLY AUTOMATED) (CONTINUED) PROGRAMMING THE RADIO NOZZLE PICKUP INSTALLATION OF RADIO NOZZLE PICKUP INSTALLATION OF FULLY AUTOMATED RADIO RECEIVER SECTION 6.0 SENTRY HARDWARE SETUP INTERNAL SETUP OVERVIEW BOARD POSITIONING BARRIER CONNECTION KEY READER INSTALL KEY READER INSTALL (CONTINUED) FIBER OPTIC CONTROL CABLE INSTALLATION FIBER OPTIC CONTROL CABLE INSTALLATION (CONTINUED) TRIP SHIELD PLACEMENT TRIP SHIELD PLACEMENT (CONTINUED) CLOSING THE SENTRY

4 6.7 CLOSING THE SENTRY (CONTINUED) SECTION 7.0 ADDITIONAL DISPENSER HOOKUP STANDARD INSTALLATION OFF ISLAND PLACEMENT SECTION 8.0 COMMUNICATION OPTIONS OVERVIEW FIBER OPTIC INSTALLATION FIBER OPTIC INSTALLATION (CONTINUED) HARD WIRE INSTALLATION SECTION 9.0 F CODES ENTERING THE F CODE SECTION SETTING COMMUNICATION PARAMETERS F CODE LIST F CODE LIST (CONTINUED) F CODE LIST (CONTINUED) F CODE LIST (CONTINUED) SPECIAL F CODES (RESTRICTED)

5 Section 1.0 Overview The object of this document is to provide a standard for the installation of the TRAK Sentry VI Fuel Management System (FMS). Installation of this system shall ONLY be performed by qualified service personnel. 1.1 Product Description The Sentry VI System installation consists of three primary groups: The Sentry VI Pedestal Dispenser Interface Communication Interface 1.2 Installation Overview The instructions contained in this manual are intended as guidelines. They will not describe all possible variations that may occur. If the person installing the Sentry VI is not thoroughly knowledgeable in all aspects of this type installation, it is strongly recommended that assistance be requested from Trak Customer Support at (850) before proceeding. The installer will mount the Sentry VI on, or near, Fuel Dispensers, connect power and control lines from the Sentry VI Control Panel to the Dispensers and mount and test the communication links. One Sentry VI Control Panel will control up to 8 hoses. The Block Diagram below demonstrates an average system configuration. PCM Power Pulsar Unit Pulsar Serial Port Adapter Control Panel Assembly BARRIER PCM Power Unit Power Pulsar Unit Pulsar Sentry 6 Fuel Sentry Figure 1 Sentry VI Block Diagram 5

6 1.3 Site Criteria The Sentry will control virtually any dispenser on any island configuration. It may be placed in almost any environment. However, there are several environmental restrictions that must be followed for both safety and functionality: DO NOT locate the Sentry where the temperature is consistently above +130 F or below -20 F DO NOT locate the Sentry where it will put the user at risk from the local traffic. DO NOT locate the Sentry more than 200 feet from the communication point. 1.4 Pre-Installation Instructions The Sentry VI Fuel Management System will accommodate either single or dual hose dispensers. It may be installed in either a remote or a self-contained dispenser. Before installation, it must be determined that there is sufficient space in the dispenser junction box to install the required equipment. There must be sufficient space for the Pump Control Module to be installed without interfering with the operation of the dispenser or the access required for maintenance or service. A. Each dispenser junction box must have one available opening, which can be used to connect the PCM. (Any dispenser that will contain the System Power Unit must have two openings available.) B. Open the junction box. Determine if there is sufficient space to safely make the additional connections that will be required. If the box appears to be full, have an electrician trim the existing wiring to provide the necessary space. When connecting to a dispenser, in which the SPU will be contained, the amount of space required to include the PCM is 20 cubic inches. The volume of the junction box, in cubic inches, is usually stamped on the inside. If not, you can measure the length, width and depth of the box to calculate the available space. Estimate the amount of available space currently taken up by the wires in the box. This will give you an approximate value for the remaining space. For example, if a junction box that is 30 cubic inches in size is one third full, there will be 20 cubic inches remaining. C. If the dispenser already has a pulser unit attached, it will have to be removed. ONLY TRAK APPROVED PULSERS AND PULSER POWER UNITS MAY BE USED AND ONLY ONES CONNECTED TO THE VEEDERROOT MECHANICAL REGISTERS. Check to make sure that the pulser is compatible with the register and dispenser and that its wires can be safely routed to the bottom of the dispenser. The PCM and SPU can be used if, and only if, all of the above conditions are satisfied. If for any reason these criteria cannot be met, contact TRAK for alternate methods of installation. 6

7 Section 2.0 Sentry Mounting The first installation shall be the Fuel Sentry. As mentioned earlier, there are many different fuel island configurations. The following example should be used as a guideline and adapted to your specific needs. 2.1 Location The Sentry, shown below, is designed to be mounted within a few feet of the dispenser. As a minimum, it must be mounted no closer than 18 inches of any nozzle opening. Site conditions permitting; place the Sentry 3 to 5 feet from the dispenser. P.N. # PART PART # QTY 1 Sentry 6 CP Trip Shield TS Concrete Fastener Pulsar Power Unit PPU 1 5 SPU SPU PCM PCM-1 1 Figure 2 Sentry System Keep in mind that the Sentry will have a low voltage power cable running between the SPU and the Barrier, as well as several Fiber Optic (FO) cables. They will run underneath the protective trip shield. In many cases, existing conduit may already be installed somewhere near the dispenser. The Sentry may be bolted down over the existing conduit. In such cases, the trip shield will not be required. Remember that power must be delivered to the Sentry and control cables must run from the Sentry to the dispenser. Exactly how this is accomplished is not critical, but, must comply with all required codes. 7

8 Sentry Mounting Using the template located in the back of this manual, layout the proper bolt pattern for the Sentry. As shown below, the Sentry is attached to two mounting brackets that are, in turn, attached to the concrete fuel island via four anchor bolts. P.N.# Part Part # Q uantity 1 R ear M ount B rkt M ounting Screw Front M ount B rkt A nchor B olt A nchor W asher A nchor Sleeve Figure 3 Sentry Housing 1. Locate the position of the Sentry. Remove the template from the back of this manual and place it on the ground. Carefully mark the centerline of each concrete anchor hole. 2. Remove the template and drill four holes as marked, with a 3/8 inch concrete bit. Drill each hole three inches deep. Remove excess dust from each hole. 3. Remove the front and rear mounting brackets and place the brackets over the four holes, as shown. Insert the four Anchor Sleeves (Item 6) into the four holes. Place the Anchor Washers (Item 5) on the Anchor Bolts (Item 4) and screw them into the Anchor Sleeves. Tighten by hand (finger-tight only). 4. Place the Sentry down over the two mounting brackets and insert and tighten the four mounting screws. Remove the four mounting screws and carefully lift the Sentry straight up and off. Using a wrench, tighten the four anchor bolts. Be careful not to move the bracket s position. Now the Sentry may be replaced or removed, as necessary, by the four mounting screws. ALTERNATIVE: If two 24 inch ratchet extensions are available, the mounting brackets may be attached to the Sentry housing and then the Sentry can be placed over the four concrete bolts. Reach down through the housing and tighten the four concrete nuts with the two ratchet extensions used together. 8

9 Section 3.0 Systems Power Unit Installation The SPU is designed to convert a 120 VAC power source to an intrinsically safe low voltage that allows the wires to be run without the need to be encased in a conduit. (The SPU shall always be used in conjunction with a TRAK Barrier.) 3.1 General The SPU is designed to attach to the nearest dispenser to the Sentry. The maximum distance between the two may not exceed 10 feet. The unit is supplied with a 15 foot power cable, which attaches from the SPU and to the Barrier, under the Sentry Control Panel. As described in Section 1, the Dispenser Junction Box must have sufficient room to allow attachment of the SPU. The SPU is a small explosion proof box with two 3/4 inch pipe nipples projecting from two sides. One contains two black wires and the other has a 5 pin watertight connector. The nipple with the two black wires shall be screwed into an available opening of the dispenser junction box. Remove the junction box cover plate, mount the SPU, and connect the two black wires to power. Power can be found within the dispenser junction box. Connect one black wire to 120 VAC hot, and the other to neutral. This SPU is designed, for 120 VAC 60 Hz ONLY. Figure 4 SPU Installation WARNING: DO NOT connect to 220 VAC or higher. The 15 foot, Low Voltage Power Cable (male connector) shall be connected to 5 pin connector in the other nipple. The female end attaches to the Barrier in the Sentry housing. This cable is labeled intrinsically safe. DO NOT install this cable along with, or near, power wires or other cables not intended for intrinsically safe operation. Failure to do so can compromise the intrinsically safe nature of this installation. To connect the Power Cable to the SPU, turn the male connector until the keys match up and insert. Twist the shell cw to lock in place. BARRIER END (IN SENTRY HOUSING) 14 FEET SPU END (IN DESPENSER) Figure 5 SPU Power Cable 9

10 Section 4.0 Pump Control Module Installation The PCM is a single 3/4 x 4 inch pipe nipple that is capable of controlling a Dispenser Valve or Pump Motor. The PCM will control up to a 3/4 horsepower 120 VAC Pump Motor or Dispenser Valve. The PCM shall always be attached to the Dispenser Junction Box. 4.1 Installation The PCM consists of a.75 x 3.5 inch pipe nipple that contains a solid state switch operated by a signal from the Sentry through an FO cable. The solid state switch controls the Dispenser Valve or Pump Motor. The PCM has a capped end and an uncapped end. Two FO cables extend from each end. The uncapped end, in addition to the FO cables, will have two black wires, a red wire and a yellow wire extending from it. The two black wires are the switch legs for the ON/OFF (PCM) control. PCM The uncapped end of the PCM (with the multiple wires) will be Figure 6 PCM Installation screwed into an available opening in the Dispenser Junction Box. This can be done directly or through a fitting, such as a union. Power and the fiber optic connections are to be made inside the Dispenser Junction Box when conduit is used to route the cables to the dispenser. The FO cable must be spliced to the matching FO cable from the Sentry. (See par. 4.3 for splicing procedure.) That cable may be placed under the trip shield. 4.2 Wiring Connections The two black wires are connected to the solid state switch (within the PCM) and will turn the Dispenser Valve or Pump Motor ON or OFF. Locate the hot wire that supplies power to the valve or motor. Cut that wire with enough length to splice to the black wires. Strip both ends of the wire and splice one end to either one of the black wires and the other end to the remaining black wire. Although the schematic on the next page shows the PCM controlling a Dispenser Valve, the PCM may also be wired to control the Pump Motor. In some cases the PCM may be wired to control the Reset Motor, when two dispensers are not on the same submersible pump. The Fuel Sentry is supplied with one PCM. This unit can be controlled from either side, (internally or externally) of the junction box. There are two fiber optic cables connected between the dispenser and the Sentry. If the fiber optic is contained in conduit and comes into the dispenser through the electrical box (internal), the control line is the capped FO cable on the same end as the black wires. When the fiber optic cable terminates outside of the electrical box (external), then the control line is the capped line on the outside of the junction box. The second FO cable uses the PCM as a barrier. It is used in the internal application to connect through the junction box to the pulser power module. 10

11 4.2 Wiring Connections (continued) RESET HOUSING RESET MOTOR PULSER HANDLE SWITCH MOTOR SWITCH VALVE PULSE POWER MODULE FIBER OPTIC CABLE TO SENTRY PUMP JUNCTION BOX PUMP CONTROL MODULE (PCM) FIBER OPTIC CABLE TO SENTRY (INTERNAL PCM) RED YELLOW BLACK BLACK 4.3 Fiber Optic Splicing FIBER OPTIC CABLE TO SENTRY (EXTERNAL PCM) MOTOR HOT 115 VAC Figure 7 PCM Electrical Connection TO PUMP NEUTRAL MOTOR OR REMOTE PUMP RELAY The FO cables from the PCM are not long enough to reach the Sentry Control Panel. These cables will have to be spliced to extend their length. Note that the PCM has two fiber optic cables. One simply passes through the PCM from one end to the other. This feed through cable is used with the Internal PCM. Normally it is not used with an External PCM. The other FO cable exits from both ends and terminates within the PCM at the same point. It will allow for internal connection to the PCM or external. This cable will need to be spliced. 1. Calculate the length of fiber optic cable required to run between the PCM and the top of the Sentry column. Add an extra foot to your length to ensure reasonable slack. 2. Using a wire stripper, carefully remove about 3/8 inch of the gray outer covering. Be very careful not to nick or cut the black inner covering. Do this to both ends. 3. Each end of the fiber optic cable will need to be a SQUARE CLEAN CUT. The best way is to use a single edge razor blade. Place the cable on a rigid surface and hold the razor blade on top TAP LIGHTLY WITH HAMMER HERE Figure 8 Cut Fiber Optic Cable 11

12 of the cable perpendicular to it. Tap the razor blade firmly to produce a clean right angle cut. 4.3 Fiber Optic Splicing (continued) 4. Now insert one of the ends into a fiber optic crimp and crimp firmly. Crimping is best accomplished using a special crimp tool. It provides a uniform crimp. If you do not have one, one may be purchased for a nominal fee from TRAK Engineering. Now insert the other end, ensuring the two ends butt against each other in the center, and crimp the other side. This cable will now be placed under the trip shield. To install Pump Control Modules in other dispensers, see Section 7. DIRECT BURIED FIBER OPTIC CABLES FIBER OPTIC CRIMP EXTERNAL PCM STRIP 3/8" PCV COVERING FROM EACH END BEFORE INSERTING INTO CRIMP CRIMP CONNECTIONS 12

13 Section 5.0 Pulser Installation The pulser is a small mechanical device that converts the rotation of the mechanical fuel quantity counter into a light pulse for every tenth of a gallon pumped. There are two devices involved: the mechanical pulser and the Pulser Power Unit (PPU). 5.1 Pulser Installation The pulser attaches to the tenths wheel of a VeederRoot counter. It consists of a small gear that engages the larger gear of the tenths wheel. As the tenths wheel rotates, the pulser gear rotates which in turn opens and closes an electrical switch. The switch is connected to a PPU or FAPPU. 1. Unscrew the white pointer tab on the side of the register. 2. Position the pulser so the pulser gear meshes with the tenths wheel gear. It may be helpful to place a small dab of silicone rubber glue between the pulser plate and the side of the register. This will help prevent the pulser from slipping out of place. 3. Replace the white pointer with the supplied screw so the pulser is secured in place. 4. Pull the pulser wires out of the way of any moving parts. Secure the wire in place with a tie wrap. 5. The pulser is now ready to be attached to the PPU TENTH WHEEL PULSER GEAR PULSER SCREW PULSER WIRES PULSER ASSEMBLY PULSER PULSER WIRES PPU WIRES PULSER POWER UNIT PPU FIBER OPTIC CABLE UNLEADED 13

14 5.2 Pulser Power Unit Installation (Non-Automated) The PPU is a self-contained power module that supplies electrical power to the pulser and a light signal to be transmitted through the fiber optic cable. It has over a 10 year life cycle under normal conditions and will operate to the same temperature extremes as the Sentry. It should be mounted as near the pulser as possible. 1. Find a location that will accommodate the PPU. It should be located as close as possible to the pulser without interfering with any moving parts. 2. Once a suitable location has been found, clean off the mounting surface. Attach the Velcro sticker to the PPU. Remove the protective backing from the exposed side of the Velcro and then press the PPU in place. It may be additionally secured with tie wraps if necessary. 3. Connect the two wires from the pulser to the two wires from the PPU. There is no polarity so the order in which they are connected does not matter. 4. Measure the length of fiber optic cable that will run between the PPU and the Sentry Control Panel. Add one foot to that length and cut a piece of fiber optic cable. FIBER OPTIC CRIMP FIBER OPTIC CABLE STRAIN RELIEF FO CABLE 3/4" FLUSH FO CRIMP CRIMP AREA 5. Strip the end of the fiber optic cable. Remove 3/4 of an inch of the protective coating and insert the cable into the crimp so the end is flush with the crimp. Now crimp the end on. It is recommended that a short length of black electrical tape be tightly wrapped around the junction between the end of the crimp and the gray outer covering of the fiber optic cable and strain relief be added ½ inch from the open end of the crimp. 6. Insert the end into the PPU and tighten the screw. The rest of the fiber optic cable should be routed through the dispenser being careful to secure it away from any moving parts or where it may be damaged during maintenance. Lay the remainder of the cable under the trip shield to the Sentry. To install pulser in other dispensers, see Section 7. 14

15 5.3 Pulser Power Unit Installation (Fully Automated) The Fully Automated System is comprised of three units: a Radio Nozzle Pickup, a Receiver and a Fully Automated Pulse Power Unit (FAPPU). The Nozzle Pickup is attached to the fueling nozzle. The Receiver is installed on the top of the dispenser and connected to the FAPPU. The FAPPU is a self-contained module that receives communication signals, and produces a light signal to be transmitted through the fiber optic cable. It has over a 10 year life cycle under normal conditions and will operate to the same temperature extremes as the Sentry. It should be mounted as near the pulser as possible. 1. Find a location that will accommodate the FAPPU. It should be located as close as possible to the pulser without interfering with any moving parts. 2. Once a suitable location has been found, clean off the mounting surface. Attach the Velcro sticker to the FAPPU. Remove the protective backing from the exposed side of the Velcro and then press the FAPPU in place. It may be additionally secured with tie wraps if necessary. 3. Connect the two wires from the pulser to outside two connections of the three terminal connections at the FAPPU. There is no polarity so the order in which they are connected does not matter. 4. Measure the length of fiber optic cable that will run between the FAPPU and the Sentry Control Panel. Add one foot to that length and cut a piece of fiber optic cable. 5. Strip the end of the fiber optic cable. Remove 3/4" of the protective coating and insert the cable into the crimp so the end is flush with the crimp. Now crimp the end on. It is recommended that a short length of black electrical tape be tightly wrapped around the junction between the end of the crimp and the gray outer covering of the fiber optic cable. 6. Insert the end into the FAPPU and tighten the screw. The rest of the fiber optic cable should be routed through the dispenser, being careful to secure it away from any moving parts or where it could be damaged due to maintenance. Lay the remainder of the cable under the trip shield to the Sentry. To install pulsers in other dispensers, see Section Nozzle Pickup (Fully Automated) The Radio Nozzle Pickup and Receiver contain both a Radio Receiver and a Transmitter, a Microcontroller. The Nozzle Pickup also contains a Tilt Switch and Batteries. When the nozzle is removed from the dispenser, the Tilt Switch detects the movement and turns the Micro-controller on. The Micro-controller listens for information (via the Receiver) being transmitted from the vehicle via the Vtag or Ring around the fill pipe. When a signal is detected, it stores the entire message and then re-transmits the message to the Receiver on the dispenser. 15

16 5.4 Nozzle Pickup (Fully Automated) (continued) The FAPPU contains an FO Transmitter. The Receiver detects the transmission from the nozzle. The FAPPU then re-transmits to the Sentry via the Fiber Optics. The Receiver has a range of approximately 30 feet. Normally, the nozzle is within 5 to 10 feet of the dispenser. The system should be tested with the hose at its greatest extension. 5.5 Programming the Radio Nozzle Pickup The FAPPU must be installed and operating before the Radio Nozzle Pickup can be installed. For a new installation or replacement, the Nozzle Pickup must be programmed before it is installed. IMPORTANT: Any Nozzle Pickups other than the unit to be programmed must be move to a point more than 30 feet (The further the better). Make absolutely sure that any FAPPUs in the immediate area are asleep. To insure this, wait at least two (2) minutes without any fueling operations, before programming the Nozzle Pickup. Once you are sure that all FAPPUs are asleep, you may continue. 1. Remove the FO cable from the FAPPU. 2. Place a magnet on the FAPPU in the area next to the large terminal block as shown. 3. If it is placed in the correct position, it will stick there. 4. While observing the LED on the FAPPU, wake the Nozzle Pickup by rocking it gently 5. The FAPPU LED should flutter then turn on all the time 6. After several seconds the LED should turn off. If it does the unit is programmed and ready for installation. If the LED does NOT turn on all the time, and continues to flutter until it turns off, the unit is defective. Repeat the procedure again to be sure the unit not operating. 7. After the unit has been successfully programmed, it may be installed. Reinsert the FO cable into the FAPPU VINYL BOOT 5.6 Installation of Radio Nozzle Pickup RADIO NOZZLE PICKUP 1. To install Nozzle Pickup, mount the unit on the top of the nozzle as shown. Make sure the end with the word COIL on it is toward the nozzle not the handle. Use large black Tie-wraps to attach the unit as shown. It should be placed as far to the front of the nozzle as TIE WRAP 16

17 practicable. The Tie-wraps should be placed through the slotted openings. The slotted openings should be placed against the nozzle boot. CAUTION: DO NOT put the Tie-wrap around the Trigger Lever. WARNING: When installing the Nozzle Pickup on a Vapor Recovery Nozzle, DO NOT allow the installation to interfere with the operation of the Vapor Recovery Boot. 5.7 Installation of Fully Automated Radio Receiver 1. The Radio Receiver is mounted via two sheet metal screws on top of the dispenser. An additional hose must be drilled to accommodate the wire. 2. The FAPPU is installed inside the dispenser. The pulser wires and Radio Receiver wires are connected as shown below. The Sentry fiber optic cable should be connected to the FO port. DIP SWITCH WHITE BLACK FIBER OPTIC CABLE PULSER WIRES MAGNET TARGET AREA BROWN RED BLACK GREEN BLUE RECEIVER WIRES 17

18 Section 6.0 Sentry Hardware Setup Now that all the hardware has been installed, the Sentry must be electrically connected to the low voltage power lines and fiber optic control lines. If there are additional dispensers to be connected, follow the instructions in Section 7 before completing this section. 6.1 Internal Setup Overview The Sentry has several components that all must be properly connected to the unit to function. As the above drawing shows, there are several components to be connected. The Barrier must be connected to the Systems Power Unit. It must also be connected to the Control Panel. The Key Reader must be inserted into the front of the housing and connected to the Control Panel. The dispenser controls lines (not shown) must also be connected to the Control Panel. 6.2 Board Positioning Shim Key Reader S6 Control Panel Barrier Velcro Housing The Sentry Control Panel is designed for easy connection of all external lines. To aid in setup, grasp the panel from both sides and slide down over the rear of the housing. The panel has two brackets that fit the housing and will allow the panel to remain in an upright position for easy access. The board may rest in this position while connections are being made. 18

19 6.3 Barrier Connection The Barrier is affixed to the inside of the Sentry housing using Velcro (recommended) or silicone adhesive. The bottom of the Barrier has a 5-pin twist lock receptacle. The connector is keyed. Align the keys and insert the Power Cable female plug from the Systems Power Unit into the 5-pin socket. Twist the connector 1/2 turn clockwise, this locks the connector in position. TO BOARD FROM SPU At the opposite end of the Barrier there is a one-foot cable that attaches to the Control Panel circuit board. There are two, four pin connectors on the end on the cable. The black snap lock connector will connect to all Sentry VI Control Panels. The brown connector is to accommodate the earlier Sentry V Control Panels that may still be in service. The black connector has a tab on one side that mates with the circuit board connector. It can only be connected one way. FROM BARRIER GREEN BLACK RED WHITE 6.4 Key Reader Install The Key Reader is a small rectangular black plastic block that is inserted into the front of the housing. The multicolored ribbon cable, attached to the Key Reader, shall be fed through the housing from the outside and is attached to the circuit board. The Key Reader is secured in place with a U shaped shim. 1. Feed the ribbon cable through the Key Reader opening in the front of the housing. Push the Key Reader into place with the notched end facing up. 2. Once the Key Reader has been inserted into the housing, place the U shaped shim into the slot of the Key Reader inside the housing. This will secure the Key Reader in place. 19

20 6.4 Key Reader Install (continued) 3. The Key Reader cable terminates into a dual in-line plug. This plug is inserted into the Key Reader connector on the circuit board. Position the plug over the circuit board connector with the ribbon cable going away from the Control Panel. Push the plug into the connector. The two clamps on either side of the connector will lock down over the plug and hold it into place. 4. The Key Reader cable is plugged into the Key Reader connector. CARD READER KEY READER 6.5 Fiber Optic Control Cable Installation The Sentry is designed to control up to 8 hoses. The Sentry has 8 fiber optic outputs labeled R1 through R8 and 8 Pulser inputs labeled P1 through P8. As shown in Section 1.2, each hose has two fiber optic control lines - R1 that connects the Sentry board to the PCM and P1 that connects the Sentry board to the PPU. The following table shows the connections for each hose. Hose # PPU PCM Hose # PPU PCM Hose 1 P R1 Hose 5 P R5 Hose 2 P R2 Hose 6 P R6 Hose 3 P R3 Hose 7 P R7 Hose 4 P R4 Hose 8 P R8 At this point, both the PCM and PPU should have been installed in the dispenser with their respective fiber optic cables terminated inside the Sentry housing. All cables, regardless of whether they are for the PCM or the PPU, are connected to the Sentry board in the same manner. 1. Each fiber optic cable should have been terminated with a fiber optic crimp. Pull the fiber optic cable up from the housing and measure the length to ensure that it will reach comfortably to the top of the Sentry board. Add an extra foot and cut the cable using the techniques shown in Section Strip the end of the cable and attach a crimp using the same method shown in Section 5.2 on page

21 6.5 Fiber Optic Control Cable Installation (continued) SET SCREW FIBER OPTIC CABLE INSERT STRAIGHT IN 3. Insert each cable into the corresponding fiber optic cavity in the FO Receiver Block. The drawing above shows the proper method of installation. 4. Tighten the setscrew located on the side of the fiber optic cavity to hold the cable in place. Be careful not to over tighten the screws or you may strip the threads. This completes the installation of the hardware with the exception of the communication circuit. The next chapter describes the various communication options and how they are installed. Before closing the Sentry (Section 6.7), select the communication option that is appropriate for the installation and connect that system. When complete, refer back to this section. 6.6 Trip Shield Placement The trip shield is designed to protect the cables that pass through it, as well as prevent personnel from tripping over the cables. The Sentry uses a low voltage intrinsically safe cable. The cable is connected in the Dispenser to the Systems Power Unit. It passes under the trip shield to the Sentry, and is connected to the Barrier at the Sentry. Because of the intrinsically safe nature of the cable, it is not necessary to enclose the cable in a conduit. For this reason, it may be run on top of the island and is protected from wear and abuse by the trip shield. (It may be run through conduit if conduit is the preferred method of installation.) To install the trip shield: 1. Carefully measure the distance from the Sentry base to the dispenser base. Add 1 inch to the measurement. Cut the trip shield, with a hacksaw, to the calculated length. 2. Determine the point at which the trip shield will meet the dispenser base. You must either chisel under the base of the dispenser to allow passage of the wires, or drill a hole through the base of the dispenser. 21

22 6.6 Trip Shield Placement (continued) 3. Lay the power wire and fiber optic cables on the island where the trip shield will be placed. Place the trip shield over the cables being careful to ensure the Sentry end of the trip shield is under the Sentry and the other is butted against the dispenser housing. 4. Use as many concrete nails as required. Center them in the pre-drilled holes and hammer them into the concrete island with a heavy hammer. Be careful not to damage any wires under the trip shield. If necessary, use cable ties or tape to prevent movement of the wires. If other dispensers must be connected, the same method will apply. Additional dispensers will only require the two fiber optic cables per hose. If there is not a flat continuous surface between the Sentry and the initial dispenser or other dispenser, the trip shield will not be feasible. In these cases, the fiber optic cable and the power cable may be directly buried (such as in a saw cut) or pulled through conduit. The fiber optic cable is also labeled intrinsically safe and may be installed by any method used for ordinary wiring without regard to explosion proof requirements. If the power line (120 VAC) is to be routed into the Sentry housing, it must adhere to all requirements for Class 1, Group D Hazardous Locations requirements. The Systems Power Unit within the pedestal may be installed no lower than 18 inches above the island surface. 6.7 Closing the Sentry Once all connections have been made, the Sentry Control Panel may be replaced into the operating position on top of the housing. The Control Panel is designed to be inserted straight down onto the housing. The back of the Control Panel has slots cut into each edge. The top edge of the housing will fit firmly into these slots. To close, lift the Control Panel up off the resting hooks and rotate the Control Panel toward you so the top faces you at the same angle as the housing top. Make sure all attached cables are away from the top edge of the housing. Now gently lower the Control Panel onto the housing being careful not to allow the circuit board to contact the housing. 22

23 6.7 Closing the Sentry (continued) Once the Control Panel Assembly is placed on top of the housing, you may need to gently rock the Control Panel Assembly for it to seat fully onto the housing. With it fully in place, turn the external key located on the rear of the housing, this locks the Control Panel Assembly in place. Check to ensure that it is locked by trying to lift the Control Panel. If properly locked, it should remain in place. 23

24 Section 7.0 Additional Dispenser Hookup Once all connections have been made to the first dispenser (generally the one you take power from), connections must be made to any additional dispensers. In general, PCM and Pulser installations are the same as described in Sections 4 and 5. However, placement of the fiber optic control lines from the dispenser to the Sentry may vary. Described below are several options for the fiber optic line installation. 7.1 Standard Installation As described in prior sections, the quickest and easiest way to run the fiber optic control lines is under a trip shield. If the Sentry is positioned between two dispensers, the trip shield may be run from the second dispenser to the Sentry just like the first one. If the Sentry is positioned on the end of the island, the trip shield can be run between the two dispensers with the fiber optic cable passing through the intermediate dispenser. This option should be laid out before any trip shield placement has been made. 7.2 Off Island Placement In some cases the dispenser will not be located on the same island as the Sentry. In such cases, it is not practical to run the trip shield. DO NOT locate the trip shield where vehicular traffic would run over it. It will not support the weight of a vehicle. In situations where the fiber optic cable must be run between islands, the cable can either be installed in buried conduit or a saw cut can be made with the cable placed directly in the saw cut. The cut must be backfilled after the cable is laid. These methods are not described in detail. The installer should be familiar with such techniques. 24

25 Section 8.0 Communication Options To complete the installation of the Sentry VI, a means by which the Central Controller may communicate with the Sentry must be provided. Communications will be accomplished by connecting the Sentry to a Data Converter. This may be done in one of two ways. 1. Fiber Optic (FO) (maximum cable length 200 feet) 2. Hard Wire (copper) (maximum cable length 1,000 feet) The standard Sentry VI installation provides FO cable. It is capable of communicating up to 200 feet total cable length between the Sentry and the Data Converter. If FO cable is not practical, the second option, hard wire, may be used up to 1,000 feet total cable length. 8.1 Overview TRAK recommends the use of FO cable wherever possible. This will ensure absolute reliability, integrity and immunity from electromagnetic interference (EMI). The FO cable must be run between the Sentry and the Data Converter. Because of the intrinsically safe nature of the FO cable, it may be run through existing conduit or buried. FO cable is limited to 200 feet of total cable length. Because of the indirect paths in which conduit is often laid, the actual line-of-site distance will always be less than the total cable length. DATA CONVERTER If the above method is not practical, the use of hard wire is required. Hard wire is capable of communicating over 1,000 feet. But, it may be susceptible to electromagnetic noise including near lightning strikes. This wire may be buried but, may not share conduits with other power wiring. 8.2 Fiber Optic Installation The Sentry may be connected to the Data Converter using FO cable. Two FO cables are required between each Sentry and the Data Converter. These cables are limited to 200 feet in total length. The FO cables will be connected to the Sentry Control Panel TX and RX receptacles. The other end will connect to a Data Converter. The Data Converted is capable of connecting to two Sentries. The first Sentry will be connected to TX 1 and RX 1 receptacles. (If there is a second Sentry, it will be connected to TX 2 and RX 2) 25

26 8.2 Fiber Optic Installation (continued) The FO cables may be buried, installed in conduit with other power lines, or installed in conduit with any other communication line or intrinsically safe lines. Follow these steps to install the FO cable: 1. Determine the length of FO cable required. Keep in mind that vertical distances must be included. Cut two pieces of FO cable the length required. It is best to cut the cable a little longer than needed. Some extra will be needed to trim the ends. 2. Install the cables from the Sentry to the Data Converter. Be aware that if the FO cable is to be pulled through conduit, excessive tension will stretch the cable and result in poor or no communications. Any lengths pulled over 50 feet should be taped every 5 feet to a 14 gauge wire and then the wire used as a pull wire. Be careful not to bend the FO cable into a sharp (90 degree) angle. Always allow at least a 3 inch radius. 3. Terminate the FO cables at the Sentry end, as described in Section 5.2. Insert one into RX and the other into TX as shown in Section 6.5. Tighten the Set Screws enough to hold the FO cables snugly. Over tightening the Set Screws will deform the terminations and compromise the connection. 4. At the Data Converter end, terminate the two FO cables as described in Section The FO cable that was inserted into the RX port on the Sentry Control Panel should be placed into the TX 1 port of the Data Converter. The FO cable that was inserted into the TX port on the Sentry Control Panel should be placed into the RX 1 port of the Data Converter. Tighten the Set Screws enough to hold the FO cables snugly. Over tightening the Set Screws will deform the terminations and compromise the connection. 6. The Data Converter also has a wall plug-in transformer that must be plugged into a wall socket. 7. Finally plug the cable from the computer port on the Data Converter into a serial port on the Central Controller. 26

27 8.3 Hard Wire Installation The Sentry may also communicate with the Data Converter using hard wire (two pair twisted copper) cable. Only one hard wire cable is required between the Sentry and the Data Converter. This cable is limited up to 1000 feet in length. If you choose to use Hard Wire, it may be purchased from TRAK Engineering. The hard wire cable will connect to the Sentry Control Panel on one end and to a Data Converter at the other end. The hard wire cable may be buried or installed in conduit. It is not recommended that hard wire be installed in conduit containing power cables. It may be installed in conduit with other communication lines. Follow the steps below to install the hard wire cable: 1. Determine the length cable required. Keep in mind that vertical distances must be included. Cut one piece to the length required. It is best to cut the cable a little longer than needed. Some extra cable will be needed to trim the ends. 2. Install the cable from the Sentry to the Data Converter. 3. The cable at the Sentry end will be terminated into a 6 pin plug. Crimp on the terminals provided and insert into the plug in the order shown. The plug will be inserted into the LOCAL jack. The connector is keyed to mate with the circuit board connector. Ensure that the connector is plugged in properly. The diagram shows the board in the position that it would normally be in when set on top of the housing. TX RX RADIO LOCAL R1 R2 R3 R4 R5 R6 R7 WHITE BLACK GREEN RED 4. At the Data Converter end, the cable must be terminated into a four-pin plug, which will also be plugged into the LOCAL jack. Crimp the terminals provided and insert into the plug in the order shown. 5. Insert the cable plug into the LOCAL jack on the Data Converter. The connector is keyed to mate with the circuit board connector. Ensure that the connector is plugged in properly. 6. The Data Converter requires the use of an AC Converter, which must be plugged into a 115V 60Hz outlet. 27

28 8.3 Hard Wire Installation (continued) 7. Finally, if the Sentry is local to the Central Converter, plug the cable from the computer port on the Data Converter into a serial port on the Central Controller. If the Sentry is a remote site, connect the phone line into the Data Converter. DATA CONVERTER 28

29 Section 9.0 F Codes The Sentry VI has a computer on the board that controls all fueling operations at the fuel island. In order to communicate, the Sentry must be configured to correspond to the setup of the Central Controller. These parameters may be setup at the Sentry using Function Codes (F Codes). Most of the F Codes are transmitted to the Sentry from the Central Controller, each time it is polled. Two (2) parameters MUST and can only be setup at the Sentry. These are the Sentry Address and the Baud Rate. Please familiarize yourself with the following F Codes and their functions. Some of the F Codes, as indicated should only be used with assistance from the Technical Support Department of TRAK Engineering, Inc. 9.1 Entering the F Code Section A Sentry that has not been in use for a period of time may display the following: 07/24/09 12:53 PRESS [ENTER] TO BEGIN If the Sentry has been in use or if you have pressed [ENTER], the Sentry will display the User prompt: ENTER YOUR MILEAGE, PRESS [ENTER] 1. At the prompt, enter the Access Code and Press [Enter] (the factory default is 1010). This will exit the User mode and enter the Operations mode. The Access Code may be changed in the WINCC program in the Computer Setup section. (See WINCC Fuel Management System User s Guide, Section V, for additional information). If an incorrect Access Code is entered, the Sentry will display, INCORRECT ACCESS CODE. Wait for the User prompt to return and try again. When the F Codes have been accessed the following will appear. ENTER F & CODE 2. Please note: Once you have entered an F Code section, you must respond to every parameter in that section. To change a parameter, enter the desired information and press [ENTER]. If you wish to accept a parameter without changing it, just press [ENTER]. In like manner, continue through all the parameters in a section. When the last parameter has been entered, it will return to the initial prompt shown above. You must be at that prompt before entering any other F Code section. Sentry VI will automatically return to the user prompt if no key is pressed within one minute. 29

30 9.2 Setting Communication Parameters Before integrating a Sentry into the fueling system, two F Codes must be set to match the parameters in the WINCC software. They are the Sentry Address and Baud Rate. These parameters MUST be set correctly at the Sentry and ONLY at the Sentry. If these communications parameters at the Sentry do not match the settings in WINCC, it will not be able to communicate with the Sentry. NOTE: Perform the following at the Sentry Baud Rate Parameters 1. The Baud Rate is the speed at which the Sentry communicates. The Baud Rate for the Sentry must be exactly the same as set in WINCC. (See WINCC Fuel Management System Users Guide, Section V, for additional information). 1. Access the Sentry F Codes. At the prompt, enter [F][2][2] to access the Baud Rate of the Sentry. The following prompt will be displayed: BAUD RATE= The current Baud Rate setting will be displayed. Valid Baud Rates are 1200, 2400, 4800, and This Baud Rate must match the Baud Rate of the Central Controller or it will not communicate. FMS SENTRY Slowest 1200 Slow 2400 Fast 4800 Fastest (Standard) Enter the desired Baud Rate and press [ENTER], or just press [Enter] to accept the current value. The Sentry will return to the F Code prompt Sentry Address The TRAK FMS is capable of controlling multiple Sentries. Each Sentry must have a unique Address for WINCC to identify it. No two Sentries shall have the same Address. The Sentry s Address must always be the same as that Sentry s Address in WINCC. During the installation of WINCC, each Sentry is assigned a unique Address. That Address shall also be set in the Sentry. It is recommended, after assigning the Sentry numbers in WINCC, to print a Sentry list as a reference for the installation of each Sentry. 30

31 9.2.2 Sentry Address (continued) 1. At the F Code prompt, enter [F][6] to access the Sentry s Address. The following prompt will display: SENTRY = 1 2. Enter the correct Sentry Address, if it must be changed. Remember that this number must be the same as the Sentry number in WINCC. Press [ENTER] to store the changes. To accept the number displayed, just press [ENTER]. 9.3 F Code List F Codes will allow the user to change the settings on the Sentry. Among the settings that may be altered at the Sentry, are the System Information, Time, Date, Pump and Product Information, and others. It also allows access to the F Codes to reset transactions, reset the Sentry, and turn on special trouble shooting tools. The F Codes currently used in Sentry VI are listed below. Be careful not to change any F Codes without direction from TRAK or your dealer. You may exit the F Code at anytime by entering [F][1][4] at the F Code prompt. F1 SYSTEM PARAMETERS will allow the user to change the F Code Access Code, System Number, Mileage Retries, Mileage Window and a second System Number. Prompt 1 ACCESS CODE the factory default setting is 1010 and can be changed here or in the WINCC program. Prompt 2 SYSTEM NUMBER the factory default setting is 10. It is a unique number assigned by TRAK to each customer to identify their system. The number must correspond to the System Number assigned in WINCC. Prompt 3 MILEAGE RETRIES the factory default setting is 0. It is the number of times a user will be prompted to re-enter the mileage, if the entry does not fall within the Mileage Window. The transaction will be flagged to indicate mileage override. Prompt 4 MILEAGE WINDOW the factory default setting is It is the number of miles allowed between fueling. If the entry does not fall within the Mileage Window, the transaction will be flagged to indicate mileage override. Prompt 5 SYSTEM NUMBER 2 the factory default setting is 0. If a second System Number is used, it will allow vehicles from the indicated system, to use the pumps. 31

32 9.3 F Code List (continued) F2 SYSTEM CLOCK AND CONTROL TIMERS Prompt 1 YEAR the last two digits of the year. Prompt 2 MONTH the two digits of the month. Prompt 3 DAY the two digits of the day of the month. Prompt 4 HOUR the two digits of the hour of the day (24 hour format). Prompt 5 MINUTES the two digits of the minutes of the hour. Prompt 6 KEY TIMEOUT the number of seconds the user is allowed between keypad entries before the Sentry will reset. Prompt 7 PUMP TIME ON the number of seconds the user is allowed between selection of the pump and the start of fueling. Prompt 8 PUMP TIME OFF the number of seconds the user is allowed between stop fueling and the Sentry reset. NOTE: No timer setting shall not exceed 59 F3 TEST DISPLAY Enter [Y] or [N]. Y will turn the display mode ON. N will turn it OFF. When ON, it will display eight (8) sets of quantities and allow the user to observe the amount of fuel being pumped during fueling. This is used for test purposes only. F4 DISPLAY CLOCK AND SENTRY VERSION (For display only) the current Sentry time and date, the Version and Version Date of the Sentry program is displayed on the screen for two seconds. F5 PUMP/PRODUCT Each fuel type is assigned a Product Code number in WINCC. The user shall assign a Product Code for each Hose in use corresponding to the fuel, as indicated in WINCC for that Hose. (Max. - eight Hoses) F6 SENTRY ADDRESS the user must enter the unique Sentry Number, which the Central Controller Software has assigned to that Sentry. 32