Fuel Management System SentryGOLD Compact for Bennett Electronic Dispenser INSTALLATION MANUAL 2901 Crescent Drive Tallahassee, FL 32301 (850) 878-4585 office (850) 656-8265 fax www.trakeng.com support@trakeng.com Trak Engineering, Inc. - Page: 1 of 13
Compact Installation Manual Installing the Trak Compact Fleet Card System in Bennett 3000 Series Electronic Commercial Dispensers For 3700 Series Electronic Commercial Models with the following configuration drawing key numbers: -1, -2, -3, -4, -6, -9, -13, -16, -17, -18, -19, -20, -22, -25, -29, -32, -37, -38, -39, - 40, - 41, - 42, - 43, - 44, - 46, - 49, - 52, - 55, - 57, and - 58 DANGER means: If you do not follow the instructions, severe injury or death will occur. WARNING means: If you do not follow the instructions, severe injury or death can occur. CAUTION means: If you do not follow the instructions, damage can occur to the equipment. DANGER: Fire, explosion, injury or death will occur if fuel filters are changed by untrained personnel. Make sure only trained personnel change filters. DANGER: To prevent injury to you from vehicles and onlookers, always place a barrier around this equipment before performing service or maintenance. DANGER: Gasoline is flammable. NO SMOKING OR OPEN FLAME. WARNING: You must have training in the installation, service or maintenance of this equipment (dispenser, pump, console, control box or submerged pump) before working on it. Maintenance repairs must be done by authorized personnel only. Warranty work may only be performed by Bennett certified technicians. WARNING: To prevent electric shock, keep the electrical parts of the dispenser dry. WARNING: Electronic components are static sensitive. Use proper static precautions (static straps) before working on the equipment. CAUTION: Do not drill holes in fuel dispensers. Holes can cause failure of the electronic equipment. The warranty will become void. Use only adhesive backed sign mounting brackets. Trak Engineering, Inc. - Page: 2 of 13
A. Unloading, Unpacking, and Inspecting a New Compact The Trak Compact is shipped in a secure package surrounded by packing material. Before signing the freight delivery receipt, inspect the carton for any obvious signs of damage that may have damaged the compact. If any damage is found, instruct the delivery driver to make a notation on the delivery receipt before you sign. If possible, open the carton and inspect the compact before signing the delivery receipt. Trak Compacts are shipped F.O.B. This means that the title to the equipment passes to the purchaser at the time the equipment is loaded on the truck at our factory. Freight damage claims are the responsibility of the purchaser. Trak will assist you in preparing any damage claim by helping you identify and price any parts necessary to make needed re- pairs. Carefully open the carton. DO NOT DISCARD THE PACKAGING. Should the need arise to repackage the Compact; the cardboard packaging can be reused. Report any non-shipping related problems to Trak Customer Service: In USA, telephone (850) 878-4585 or via FAX to (850) 656-8265; or via email to: Trakeng.com B. Installing the Compact in the Bennett Dispenser The Compact is installed from the back side of the front electronic panel on the Bennett dispenser. To install, follow the procedure outlined below. 1. Unlock the two key locks on the front of the electronic panel. Lower the panel down. There will be 18 studs that hold the shipping cover in place. Remove the 18 nuts (reserve them for later use) and remove the panel. 2. There is a gasket between the shipping cover and the panel. Inspect the gasket carefully. There must not be any breaks, mars or other imperfections that will cause a water leak. ABSOLUTELY NO WATER MAY LEAK INTO THE BENNETT ELECTRONIC COMPARTMENT. If there is any question as to the integrity of the gasket, replace it before proceeding. Once the gasket is inspected, place the Compact face down and slide over the studs as shown below. The Compact electronic box should be closest to you standing in front of the cover. Once in place, replace all 18 nuts and tighten securely. Each nut should be loosely tightened until all are snug. Then securely tighten each one alternating opposite sides. DO NOT over tighten. A snug fit will be adequate. Excessive force will cause the studs to break and compromise the integrity of the gasket system. 3. With the Compact in place proceed to the next section for electrical connections. Trak Engineering, Inc. - Page: 3 of 13
C. Making the Electrical Connections in the Bennett Dispenser The Compact is connected to the Bennett dispenser in 2 places communication and power. 1. Electronic Power Connections: 1. Connect the White (Neutral) 20ga. wire in 115V circuits coming from the Compact Power Connector to terminal 1 of TS2on the CPU board. The CPU board is located on the upper electronics door. 2. Connect the Black (Hot) 20ga. wire to terminal 2 of TS2 on the CPU board. 2. Communications Connections: For the RS-485 communication wires, the Compact has 3 wires coming from the Comm. connector. Connect the RS485 communication wires to TS1 on the CPU as follows: 1. TS1-5 RS485 Negative (-) White 2. TS1-6 RS485 Common Blue 3. TS1-7 RS485 Positive (+) Green D. CPU Board Jumper Configuration The 3700 Series can operate in two different modes, Console or Stand Alone, which must be defined by jumper settings on the CPU board. Stand Alone Mode -Stand Alone mode allows the 3700 Series to operate without being connected to a console or control device. In this mode, when the handle is turned on the dispenser authorizes itself. This mode is not normally used when a Compact is installed in the dispenser but can be selected if there are any problems with the Compact. Console Mode - Console mode allows the 3700 Series to communicate with compatible consoles or control devices using a RS485 communication data loop. Trak Engineering, Inc. - Page: 4 of 13
Mechanical Mode Not used with the Compact The 3700 series dispensers are programmed using jumpers or shunts. The jumper header JP1 is a 9 position header and is located on the top right corner on the back of the CPU/Board. This jumper header is used to program the dispenser. Jumper configuration changes may be required on the CPU circuit board at the site. See the chart below for a quick reference of what the jumpers do. See the next page for an explanation of each jumper setting. JP1-1 through JP1-4 - Fueling Point Address. See Next Page. JP1-5 - Console or Stand Alone Mode CPU Jumpers on JP1 JP1-6 - Suction Pump Motor Delay JP1-7 - Leak Detector Pre-charge JP1-8 - Imperial Gallons JP1-9 - Units Jumper Header JP1 is located on the top right of the back of the CPU / Control board. This board is mounted to the upper door. It has 9 positions. Jumpers should be set with dispenser power off. The jumper settings are only read on power up. Trak Engineering, Inc. - Page: 5 of 13
Console Mode Sending Jumpers The 3700 Series is shipped from the factory configured for the console mode of operation. In the Console mode, the 3700 electronic commercial dispenser will communicate with the Trak Compact using RS485 communication. When in the Console mode, after the handle is lifted, the dispenser must receive the authorization command from the Compact before the dispenser resets and begins the sale. Jumper Header JP1 is a 9 position jumper header. Position 5 is for setting the dispenser in the Console or Stand Alone mode. Placing the jumper across the pins on position 5 puts the dispenser in Console mode. This jumper configures the CPU for RS485 output on TS1 (Field wire connection to the Console). TS1-5 = DATA ( ) TS1-6 = DATA (Common) TS1-7 = Data (+) Circuit Board Jumper Configuration Stand Alone Mode - Setting Jumpers In the Stand Alone mode, the dispenser does not require an outside authorization signal from any console or control unit. When the handle is lifted, the dispenser authorizes itself and the dispenser resets and the sale begins. Jumper Header JP1 is a 9 pin jumper header. Position 5 is for putting the dispenser in the Stand Alone or Console mode. Removing the jumper from JP1 position 5 puts the dispenser in the Stand Alone mode. Setting the Jumpers - The jumpers should be set with power off and are only read at bootup (power up). WARNING - DO NOT SET OR REMOVE JUMPERS WITH DISPENSER POWER TURNED ON! DAMAGE TO THE DISPENSER MAY RESULT. ALWAYS MAKE SURE DISPENSER POWER IS OFF WHEN ADDING OR RE- MOVING JUMPERS! The 9 position Jumper Header is located on the CPU board. It is used to set the hose position address and to program the dispenser. Trak Engineering, Inc. - Page: 6 of 13
Jumper position 1 4 - (Fueling Point Address - Up to 16 fueling position addresses). Use jumper positions 1 through 4 to set the dispenser address. Normally, Bennett pumps do not need an address set when using current loop communications, but, with this RS 485 style communication, an address must be set for the Trak Compact to know which fueling point it is talking to. The first four rows of pins (on jumper header JP1) represent a binary number whose greatest value is 16 (or 0-15 if you prefer). The fueling point address must be set to identify each hose position / fueling point using these jumpers. See the chart on the next page for details on how to set the address for a specific fueling point number using the jumpers on the first four rows of jumper header JP-1. Jumper position 5 - Console or Stand Alone mode In - Console Out - Stand Alone Jumper Position 6 - Motor delay (suction pumps without valves). This function allows a 2 second delay preventing the dispenser from turning on immediately when the pump handle is lifted. This would be used on a dispenser with self contained pumps and no valves. You would set the dispenser for the two second delay so that the motor does not come on immediately when the handle is thrown allowing the dispenser to pump through a hose without a valve before the dispenser resets. In- 2 second delay Out- No Delay Jumper Position 7 - Leak Detector Pre-charge This function allows the system to energize the submerged pump pressurizing the line to check for leaks before the valve opens. The jumper should be out in most cases unless the leak detectors routinely trip (very slow flow from the nozzle then use 9 seconds). In- 9 seconds Out- 2 seconds Jumper Position 8 - Imperial Gallons In- Imperial Gallons Out- US Gallons Position 8 Position 9 Imperial Gallons In Out Jumper Position 9 - Units In- Liters Out- Gallons Gallons Out Out Liters Out In Trak Engineering, Inc. - Page: 7 of 13
Jumper Header JP1 on the CPU board is used to program the dispenser and to set the hose position address. The first 4 rows are used to set the hose position address. Addresses from 1 16 are available. Here is how to set the address using the first four rows of the Jumper Header. Trak Engineering, Inc. - Page: 8 of 13
E. Operator Setup The Compact must be configured with certain setup parameters. These are accessed in an operator section that is accessible only through a concealed code. To access this section, the Compact must be up and running. The front splash screen will vary from customer to customer but the method remains the same. You must press the upper right corner and then within 2 seconds you must press the lower right corner as shown in the picture below. This will bring up a screen as shown below that requires you to enter an access code to proceed any further. Any failure to enter a proper access code within 30 seconds will cause the system to return to the splash screen. The access code will display as * as you type. The access code is a 4- digit number and is set at the factory at 2901. Trak Engineering, Inc. - Page: 9 of 13
The main menu, shown below, has 7 selections: 1. Sentry Settings 2. TRAK Options 3. Auto Detect Hoses 4. Set Date / Time 5. Sentry Status 6. Test Pumps 7. Manual Override Each screen is explained below. 1. Sentry Settings These are the base setup parameters that determine the pump timings, systems numbers and baud rate. Most selections bring up a number entry screen that allows the user to enter a new number. Simply press the change button to modify the setting. Sentry Number This is the number of the Sentry in the system and should be unique to each Sentry. It is selectable from 000 to 999. Do not use 000. This is reserved for testing purposes. Baud Rate This is selectable from 1200 baud to 115,200 baud. Baud rate is largely determined from site communication hardware and telephone or IP sustainable baud rates. This selection utilizes a drop down menu selection. Customer This is a unique 3-digit number that identifies your system as unique from anyone else. This number is assigned by Trak. Pump Time On This is the amount of time the customer has from selecting the pump until pumping begins. Should the user fail to start pumping within this time, the Sentry will terminate the transaction. Pump Time Off - This is the amount of time the customer has to release the pump handle and then re-squeeze before the pump shuts off. Should they squeeze the handle before this timer expires, they may continue pumping. Mileage Retries These are the number of attempts the user has to enter the correct mileage before the Sentry accepts the number entered. Trak Engineering, Inc. - Page: 10 of 13
2. Trak Options This selection allows you to perform certain operational tests. Set Sentry CommPort This is used to allow the Sentry to automatically detect the external communication port the Compact is connected to. Reset Printer Sends a reset and setup commands to the internal transaction printer. Export Txtns to Flash This forces the Compact to write all the transactions to an external flash memory key. The key port is accessed through the external access hole in the side of the box. Auto run on Boot This can be either turned on or off by pressing the appropriate button. If auto run is turned on, when the system reboots from power loss, the application program will automatically reload. If this option is turned off, Windows CE will boot but the application will wait for human intervention to start. Test Communication to Data Converter This sends a test message to the Data Converter to test the communication run. Open Explorer This will allow Windows CE explorer to run and be accessible while the application is running. 3. Auto Detect Hoses This option will automatically detect the hose number the Bennett pump is configured to. In general most hoses will be set to either 1 or 2. This process will take several seconds. If your communication is properly set up, it will display the hose number. See Circuit Board Jumper Configuration to set the Bennett pump to the proper hose number. Trak Engineering, Inc. - Page: 11 of 13
4. Set Date and Time The Sentry maintains a 24 hour clock so all transactions can be logged with the proper date and time. This setting allows you to set the date and time without having to enter into Explorer. To use, simply select the pull down menu and select the proper entry. Press Save to exit. 5. Sentry Status This is an information screen only. When selected it shows the following information: Device Type type of Sentry system Number of vehicle stored in the system Number of personnel numbers stored in the system Number of transaction stored in the system Number of key lockouts stored in the system 6. Test Pumps This allows the pumps (dispensers) to be tested while observing the pulse count. When the pump number is selected, the Sentry will automatically turn the dispenser on and then display the actual pulse count on the bottom Trak Engineering, Inc. - Page: 12 of 13
left of the screen. Pump selections are 1 through 12. The pulse count is the raw pulse count number. It is not corrected back to 10 pulses per gallon. 8. Manual Override This selection allows the dispenser to be placed in manual override by individual hose. To make the selection, simply press the button adjacent to the hose number. The selection will change from OFF to ON. This will remain in this condition until the button is pressed again. Be careful. Even if you exit this section, the hose will remain in the last condition that was selected. No further caution or warning is provided. To turn the hose OFF, simply press the button again. Trak Engineering, Inc. - Page: 13 of 13