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Pacific Service Manual 111661

1. In Direct Connect Pin 2 Ground Out Pin 3 Disconnect In Pin 4 Ground Out Pin 5 Pulsed D Lag In Pin 6 Ground Out Pin 7 Pulser D Lead In Pin 8 Ground Out Pin 9 Pulser C Lag In Pin 10 Pump Handle In Pin 11 Pulser C Lead In Pin 12 12vdc Out Pin 13 Pulser B Lag In Pin 14 12vdc Out Pin 15 Pulser B Lead In Pin 16 12vdc Out Pin 17 Pulser A Lag In Pin 18 12vdc Out Pin 19 Pulser A Lead In Pin 20 12vdc Out J1 Memory Board Not Used J13 J14 Loop Back Not Used C 12 CPU Board 111661 Rev B 02 09 CPU Board Jumper Settings The CPU board has a series of jumpers installed on the board The proper jumper configurations are shown below C 13 CPU Board 111661 Rev B 02 09 Proportional Valve Control The proportional valves are 24 volt valves The way the proportional valves handle a preset or a prepay is to modulate the proportional valves for the two gas products to slowly close off the valve at the end of a sale Also these valves are only 2 wire The way the blending action works is that you have two valves One on the output of the low grade product meter and one on the outlet of the high grade product meter The CPU controls the flow through these valves by modulating opening and closing them with 24 volt dc pulses The valves are modulated at a rate proportional to
2. TP1 TP2 G 9 Handle Switch Circuit 111661 Rev B 02 09 Connecting the Handle Switches The handle switch cable is a black red 2 wire cable that connects the barrier board for that side with the handle switch or handle switch chain for that side It comes from the barrier board passes through the same potted conduit as the ribbon cable for the pulsers see figure 8 and connects to the first handle for that side If there is more than one handle per side you have to connect the handle switches in a daisy chain see figure 9 The red wires go to the T3 and T4 terminals and the black wires go to the T1 and T2 terminals There are 4 terminals on this board marked T1 T4 If you look at the board with the Reed switch facing up then the top left terminal is T1 and T3 is below that The top right is T2 and below that is T4 Red to T3 or T4 Black to Even numbered terminals T1 or T2 Example A dispenser with 2 handles per side would connect in the following manner see figure 10 Step 1 The red black 2 wire coming from the barrier in the head would go to the A handle first and the red would connect to T3 and the Black would connect to T1 Step 2 The daisy chain cable to the next handle would go like this Red wire from T4 on the first handle switch to T3 on the next handle switch and the black from the first handle switch terminal T2 to the next handle switch T1 Figure 8 Handle and pulser cables from hea
3. Figure 10 Product Select Keypad Overlay Figure 11 Reverse side of the Product Select Board C 5 CPU Board 111661 Rev B 02 09 Communication with the Local Preset Bennett makes a Local Preset system that can be installed on the dispenser This system is used by Full Service attended locations for presetting the dispenser to pump a preset amount of volume or currency When this system is in place the Local Preset electronics communicates with the dispenser CPU so that the dispenser can open and close the valves properly for the preset amount of fuel This communication goes from connector J4 or J5 on the local preset through a multi conductor cable to the product select board J2 connector out of the product select board on J1 connector to the J2 connector side 1 of the CPU or J1 connector side 2 of the CPU Troubleshooting the Local Preset There is very little troubleshooting available with the Local Preset Board Under normal circumstances if this board fails replace it There are no Test Point references nor Diagnostics available to help troubleshoot any potential problems Display Contrast If the display is hard to view than you can adjust the contrast by removing the glue applied by the factory and using a small straight screwdriver adjust the RV1 until you have the desired contrast see figure 13 Once you have adjusted the contrast you must re seal RV1 with glue NOTE The contrast will adjust the letters num
4. s a 2 sided dispenser This display is used for the customer to view sales information as well as certain prompting messages This display gets its lighting from a backlight board When the handle is lifted the display may have a prompting message that says choose grade or push start When the customer begins fueling the pulser information is sent to the CPU board and there it is converted to display data and sent to the display The display board just keeps up with the CPU in real time This board also holds the switches S1 and S2 to recall the last sale if there is a power outage and to recall the electronic totals These switches are a reed switch that s normally opened As you hold a magnet provided over the switch then it will close and then the display will provide either the last sale during power outages or the electronic totals S1 is used for the Electronic Totals This switch is on the left side of the Main Display in line with the volume amount of the sale S2 is used to recall the last transaction during a power outage This switch is on the left side of the Main Display in line with the money amount of the sale To use this you simply hold the magnet up to the plastic overlay of the display around the vicinity of the switches Locate the switches on our board drawing above E 1 Display Board 111661 Rev B 02 09 Description of Controls There are no controls on this board LED s Other than the L
5. Pin 3 12vdc standby In 18 Ga Yellow Pin 4 12vdc standby In 18 Ga Yellow Pin 5 12vdc In 18 Ga Red Pin 6 12vdc In 18 Ga Red Pin 7 Ground In 18 Ga Black Pin 8 Ground In 18 Ga Black Pin 9 Ground In 18 Ga Black Pin 10 Ground In 18 Ga Black Pin 11 5vdc In 18 Ga Violet Pin 12 5vdc In 18 Ga Violet J8 Communication Ribbon Cable from Power Distribution Board Pin Signal Direction AWG amp Color Pin 1 Suicide Power Fail Out 16 Conductor Ribbon Cable Pin 2 VeriFone RS485 data Bi Directional Pin 3 Recall Previous Sale Out Pin 4 VeriFone RS485 Common Bi Directional Pin 5 Power Fail From power fail circuit In Pin 6 VeriFone RS485data Bi Directional Pin 7 N C Pin 8 N C Pin 9 Motor A 12Vdc relay control Out Pin 10 Dispenser com side 2 Bi Directional Pin 11 Motor B 12Vdc relay control Out Pin 12 Dispenser com side 2 Bi Directional Pin 13 Motor C 12 Vdc relay control Out Pin 14 Dispenser com side 1 Bi Directional Pin 15 Motor D 12 Vdc relay control Out Pin 16 Dispenser com side 1 Bi Directional C 11 CPU Board 111661 Rev B 02 09 J9 J10 Intrinsically safe Barrier Board connections J9 side 2 and J10 side 1 to the CPU These boards mount directly on the CPU and there is no cabling It is direct connect 20 position edge plug Pin Signal Direction AWG amp Color Pin 1 Pump Handle
6. 14 5 volts d c battery backup side 2 Yellow wire Pin 5 12 Volts d c Used for display board operator interface board local preset side 1 Red wire Pin 6 12 Volts d c Used for display board operator interface board local preset side 2 Red wire Pin 7 DCC Direct Current Common or Ground Reference Black wire Pin 8 DCC Direct Current Common or Ground Reference Black wire Pin 9 DCC Direct Current Common or Ground Reference Black wire Pin 11 5 Volts d c CPU logic power Violet wire side 1 Pin 12 5 Volts d c CPU logic power Violet wire side 2 J2 Battery Charging Circuit When main power is on the battery charging circuit provides 14 1 Volts d c to charge the battery When the battery is On the battery supplies 12 6 volts d c for the system Pin 1 14 1 volts battery charging 12 6 volts battery on Pin 2 Direct Current Common DCC or ground reference Pin 3 Not Used J3 Grey ribbon cable that connects the CPU to the Power Distribution Board This cable mainly handles the card reader communication and dispenser communication from the CPU to the Power Distribution Board Pin 1 identified by the red tracer Suicide signal The CPU uses this signal to turn off the battery after 30 seconds in case of power failure Normal reading is 5 volts d c Pin 2 RS 485 Card Reader communication with console Pin 3 Recall Used b
7. Barrier Circuit runs through a potted conduit between the upper portion electronics area high voltage section of the dispenser to the lower portion hydraulics area low voltage section of the dispenser Refer to the section on Pulsers to find out more about how the pulsers work The handle switch information for each side of the dispenser is carried on a 2 wire cable that connects from the J3 connector on the Barrier Circuit runs through the same potted conduit between the upper portion electronics area high voltage section of the dispenser to the lower portion hydraulic area low voltage section of the dispenser where it connects to the first handle switch If there is more than one handle switch per side a two wire cable is daisy chained to the next handle switch Refer to the section on handle switches in this manual Description of Controls There are no controls on this board LED s There are no LED s on this board Test Points There are no test points on this board Terminal Strips Connectors and Pinouts The following is a description of the connections to the terminal strips and pinouts of all the connections on the Barrier board J1 This connector connects to J10 side 1 on the bottom of the CPU to the Barrier Board It is a direct connection no cable This connection sends power and communication signals to the pulsers and handle switches Pin Signal Direction AWG amp Color Pin 1 Pump Handle Bi Directio
8. DC Voltage Reference B 7 Voltage Tolerances B 7 Testing Fuses B 7 Incoming Power B 8 Neutral to Ground Reading B 8 Terminal Strips Connectors and Pinouts B 9 TS1 Input Power B 9 TS2 Motor Power products A and B B 9 TS3 Motor Power products C and D B 9 TS4 Card Reader Communication B 9 TS5 Dispenser Communication B 10 J1 DC Voltages to the CPU Board B 10 J2 Battery Charging Circuit B 10 J4 DC Voltages to the Power Distribution Boards B 10 J3 Dispenser Card Reader Communications and Motors B 11 J5 Filtered AC Connection B 11 Power Supply B 12 Part Number B 12 Board Functions B 12 Description of Controls B 12 LED s B 12 Fuses B 12 Voltage Adjustments B 12 Taking Voltage Readings B 13 Color Coding B 13 24 Volts B 13 12 Volts B 13 5 Volts B 13 111661 Rev B 02 09 SECTION C ii SECTION D SECTION E SECTION F THE CPU BOARD Part Number C 1 Board Functions C 1 Theory of Operation C 2 Communication with the Point of Sale C 3 Communication with the Card Reader System C 4 Communication with the Handle Switches C 4 Communication with the Pulsers C 4 System Software C 4 System Memory C 5 On Board Battery C 5 Communication with the Product Select Panel C 5 Communication with the Local Preset C 6 Local Preset Troubleshooting C 6 Power Fail Circuit C 6 Power On Self Test C 6 Li
9. Michigan UNAUTHORIZED ALTERATION OF BENNETT PRODUCTS Bennett Pump Company products are designed to meet or exceed the standards of UL FCC and the National Institute of Standards and Technology These standards protect the operator and the consumer from personal injury and insure an accurate delivery of product Any deviation from the use of authorized replacement parts or alteration of a designed product configuration may cause personal injury death or the revocation of one or all of the above approvals The most frequently abused design alteration of Bennett products is the conversion of a self contained model pumping unit in the dispenser cabinet to a remote dispenser submerged pump in the storage tank This field practice has mainly occurred in an effort to overcome the problem of vapor lock Bennett Pump Company does not condone nor offer a kit or instructions for this type of conversion Bennett Pump Company strongly opposes this type of conversion Safety standards required by the agencies above are violated when unauthorized conversions are performed Bennett Pump Company recommends the replacement of a self contained model with a remote dispenser model to overcome the problem of vapor lock The Pacific Series does not offer a self contained model Bennett Pump Company will not assume responsibility or liability for any consequential injury or damage caused by the unauthorized alteration of its products NOTE Before performing any type of serv
10. Switch Alarm Enter a password TBD 82 Mesh Break Send unit back to VeriFone using the RMA process 83 Mesh and Case Switch Break Send unit back to VeriFone using the RMA process Any other error number Send unit back to VeriFone using the RMA process Error Codes H 7 Secure PumpPAY Card Reader Diagnostics 111661 Rev B 02 09 The LCD display unit s screen contrast is set during manufacture Ordinarily it should not require adjustment To adjust the LCD display unit s screen contrast 1 On the rear side of the unit break the seal under the COM2 port 2 Use a Phillips screwdriver to adjust the screen contrast as required Card Reader Over time oil oxides or other contaminants can accumulate on the card reader Use a suitable cleaning card in the card reader Keypad and or Front To ensure proper hygiene for customers and to ensure the correct functioning of the SECURE PUMPPAY unit keypad and front section of the unit must be inspected regularly because grease or other contaminants can accumulate from customer use of the unit To clean a unit s keypad front section complete the following steps 1 Use a dry clean cloth to remove any dust 2 Use a cloth and soapy water to remove any grease or other stubborn stains NOTE Do NOT direct a power hose at a unit NOTE Do NOT use any solvents or cleaning agents to clean a unit Battery A unit s battery powers its anti tamper circuitry when main power is not pr
11. The Auxiliary Display Board will display both prices if programmed This board receives its data from J7 of the Product Select Auxiliary Backlight Display Board via J1 There are no test points on this board PPV Displays Product Select Touch Pads Note that these are connected to the Product Select Auxiliary Backlight Display LEDs to help direct the customer where to select the desired product If the dispenser only has 1 2 or 3 products then the Overlay changes not the Auxiliary Display Board E 3 Display Board 111661 Rev B 02 09 E 4 Notes 111661 Rev B 02 09 Main Display Back Light Board Part Number 107334 Used to illuminate the Money Volume Display Theory of Operation There is a customer display board on each side of the dispenser if it s a 2 sided dispenser This display is used for the customer to view the sale information as well as certain prompting messages This display gets its lighting from a backlight board The backlight board is simply a board with numerous LED s mounted to it This board has no smart functions It is simply a light source so that the customer can read the display information The Backlight circuit is tied to the dispenser electronics and turns on whenever the dispenser has normal power The backlight gets it s main power from the display board through a small 2 wire connection This is 24 Vdc If the dispenser looses power or the main power drops belo
12. conductor cables are the Daisy Chain that connect all other parts of the dispenser through the product select board Pin Signal Direction AWG amp Color Pin 1 24vdc Out 18 Ga Orange Pin 2 24vdc Out 18 Ga Orange Pin 3 12vdc Out 18 Ga Red Pin 4 12vdc standby Battery Out 18 Ga Yell Pin 5 12vdc Reset Out 22 Ga Blue Pin 6 14vdc Recall In 22 Ga Violet Pin 7 0 volts Safety Stop In 22 Ga Grey Pin 8 Keypad RS 485 Data Bi Directional 22 Ga Black Pin 9 Keypad RS 485 Data Bi Directional 22 Ga Red Pin 10 VeriFone RS 485 Data Bi Directional 22 Ga Orange Pin 11 VeriFone RS 485 Data Common Bi Directional 22 Ga Brown Pin 12 VeriFone RS 485 Data Bi Directional 22 Ga White Pin 13 Display LOAD Out Pin 14 Display DATA Out Pin 15 Display CLOCK Out Pin 16 Ground Out 18 Ga Black Pin 17 Ground Out 18 Ga Black Pin 18 Ground Out 18 Ga Black J1 Internal LAN side 2 J2 Internal LAN side 1 J7 DC voltages from Power Board J8 Communication signals to Power Board J12 Valve Connection J9 Intrinsically Safe Barrier Board Side 2 J10 Intrinsically Safe Barrier Board Side 1 Figure 18 CPU Board Electronic Calibration Switch C 10 CPU Board 111661 Rev B 02 09 J3 J4 Not Used J7 DC Voltages from the Power Distribution Board Pin Signal Direction AWG amp Color Pin 1 24vdc In 18 Ga Orange Pin 2 24vdc In 18 Ga Orange
13. crankshaft see figure B 5 via the piston s connecting rod see figure B 6 When the distributor see figure B 2 is in a position that allows product to be ported from a piston chamber see figure B 4 there is greater product pressure applied to the inside of the piston than to its outer side The differential of pressure causes the piston to travel in an outward direction As the piston travels in an outward direction product is ported to the meter s top collector and to its outlet As a piston is forced in its outward direction a rotational force is applied to the crankshaft via the piston s connecting rod This rotational force of the crankshaft is then applied to adjacent pistons which offering zero resistance allows them to be pulled in their inner direction easily This allows product from the distributor to fill the piston chamber The above process is repeated by all four pistons A spring and pressurized countervalve see figure B 7 employing a diaphragm imparts a downward thrust on the rotating distributor to seal its surfaces and prevent internal leakages which would result in unmeasured product being delivered A 8 Overview of 708 Electronic Components 111661 Rev B 02 09 A 9 Notes 111661 Rev B 02 09 Power Distribution Board Assembly 110206 Board Functions Incoming A C voltage filter FIL1 Solid State Relay control for submerged pumps K1 K2 K3 K4 Fuse protection for the system F1 F
14. disconnect and re connect the cable The dispenser will remain in the programming mode until the cable is disconnected It will not time out Replace the managers keypad back in the electronics head for safe keeping until the next time you have to program Programming can only be done from side 1 A layout of the manager keypad is shown in Figure 4 Refer to Pacific Operators Instructions for complete information on programming and diagnostic information D 3 Product Select Auxiliary Display Board 111661 Rev B 02 09 These electromechanical totalizers are not field replaceable If one totalizer fails you must replace the whole assembly There is only one assembly for all Pacific dispensers If this is a single or dual product dispenser then the extra totalizer s will not be used The assembly has a J1 connector that is plugged into J5 of the Product Select Auxiliary Backlight Display Board Totalizer Assembly 109407 D 4 Product Select Auxiliary Display Board 111661 Rev B 02 09 D 5 Notes 111661 Rev B 02 09 Main Display Board Part Number 107330 Displays Volume Currency and Price information Displays information for diagnostics and sales totals Recalls the last Sale if there is a power outage Recalls the electronic totals Provides power for the Main Display Backlight Board Theory of Operation There is a customer display board on each side of the dispenser if it
15. from both phases the system energizes the blender valve and fast flow is achieved Generally a retail dispenser in fast flow puts out a maximum of 10 12 gallons per minute maximum due to state and federal regulations Error checking The dual phase pulsers allow for error checking One phase is used to check the other For example after pumping 1 gallon of fuel the CPU should see approximately 1024 pulses from each phase There is a built in diagnostic where if the CPU sees more than 15 consecutive missing pulses from one or the other of the phases it will stop the sale and post an error message on the display of the side of the dispenser with the error Also on a blending dispenser if one or the other product going into the mix is dispensing too slowly an error will result We know this because we read the pulse output which tells us how much fuel is being pumped from each product Errors are stored in a diagnostic history file and any error that occurs can be cleared by removing and replacing the hose from the nozzle boot Also if the pulser is disconnected an error will result G 4 Pulser Circuit 111661 Rev B 02 09 The pulser information for each side of the dispenser is carried on a ribbon cable that daisy chains from one pulser to the next This ribbon cable connects from connector J2 of the Barrier Board runs through a potted conduit between the upper portion electronics area high voltage section of the dispenser to the lower por
16. it sit overnight then re connect It may continue to work for awhile Printer is jamming This is typically caused when the wrong paper is used at a Secure PumpPAY site The paper should be 2 5 16 wide Bennett s Part Number is 112028 The Secure PumpPAY unit displays Please Pay Inside E01 AND when the View is pressed on the POS it shows IN USE Fueling point may be stuck in Prepay Reserve state This can happen if the customer hits ENTER and CANCEL at the zip code prompt without entering any digits Have the cashier clear the pump in reserve may need to clear pumps on hold first then clear pump in reserve Or have the cashier go out to the fueling point lift the handle select a grade push start etc then replace the nozzle this will clear it back to IDLE state The display on the Secure PumpPAY unit is very dim or appears to not be working On the back of the Secure PumpPAY unit next to the Ethernet connection there is a small screw This is a brightness setting Turning the screw clockwise will add brightness and turning counter clockwise will decrease the brightness H 11 Secure PumpPAY Card Reader Troubleshooting 111661 Rev B 02 09 VeriFone Interface Board VIB2 111714 Board Functions Provides power for the printer Provides power for the Secure PumpPAY Provides power for the fan Communication for the Secure PumpPAY is routed through this board Data fo
17. open completing a circuit and sends an output voltage somewhere between 2 330 and 3 000 Vdc to the CPU Each handle produces a specific voltage that allows the CPU to identify which handle is on A or B by using the jumper configuration shown on the next page Then the CPU knows what product is being requested and sends the appropriate 12 volt dc signal to the appropriate relay to turn on the appropriate motor It also causes the CPU to send the proper price display to the correct price window on the display board When the handle is returned to the nozzle boot this signals that the sale is complete and the CPU sends this information to the Point of Sale device if there is one so that the sale may be collected The valve should close immediately less than 1 2 second after the handle is hung up The sale cannot be collected unless the handle switch is off The same theory of operation applies if you have a lift lever instead of a flapper nozzle boot There are LEDS on the CPU that can tell you if the handle switch has been lifted There are also diagnostics for the handle switch These topics will be covered later in this section and in Diagnostics Magnetic Pump Handle Assembly Part Number 111171 Signals the CPU that a customer is requesting product at a fueling point when the nozzle is removed from the boot or the lift lever is raised Signals the CPU to display the price for the chosen product Magnetic Handle Switch Board uses wire a
18. pump To clear an error message simply lower the handle or put the nozzle back in the boot and remove the nozzle again This should clear the error message If it doesn t try removing the nozzle or lifting the handle and replacing it once again A list of stored error codes is stored chronologically in diagnostic mode 2 Make sure you repair the problem that may have caused the error condition first and then clear the message For persistent error codes and their remedies contact Bennett Technical Support at 1 800 423 6638 I 1 Error Codes 111661 Rev B 02 09 I 2 Notes 111661 Rev B 02 09 Symptom Hose does not dispense fuel The dispenser isn t turned on Turn on the dispenser The submerged pump isn t turned on Turn on the submerged pump There isn t enough fuel in the tank Make sure there is adequate fuel in the tank Take a stick reading and make sure there is at least 12 inches of fuel Isolation valve is closed Open the isolation valve in the submerged pump manhole Electronic Leak Detector has disabled the submerged pump Follow the service procedures for the Leak Detector to re enable the submerged pump The valve isn t opening Check to make sure that the valve is opening by taking the voltage readings on the 24vdc circuit Refer to the section on CPU board The dispenser is not authorized If the dispenser is connected to the console is the console sending down authorization for
19. shear valve or impact valve must be closed when service or maintenance is performed on this equipment WARNING You must have training in the operation and programming of this dispenser before using it READ THE OPERATORS MANUAL WARNING Make sure this equipment is correctly grounded Failure to do will cause injury or damage equipment or improper operation Improper grounding voids the warranty WARNING When anchoring the dispenser always level the dispenser with shims before bolting to the island DO NOT shim just the middle of the dispenser and bolt down 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 111661 Rev B 02 09 Basic System Theory of Operation 110 230 Volts A C 50 or 60 cycle power comes into the dispenser through field wiring to the bottom of the Power Distribution Board terminal strip TS1 Power then passes through a 3 amp fuse and then is filtered for noise Any electrical noise is dampened out by this filter FIL1 The power is then passed from the Power Distribution Board to the Power Supply through connector J5 for Direct Current D C conversion There is only one Power Distribution Board and one Power Supply for the dispenser Power comes into the Power Supply assembly on connector J1 This power supply creates various D C Voltages for use throughout the system Specifica
20. the blend ratio that is programmed into the dispenser programming mode 7 when the blending function is turned on It is not enough that the CPU pulses the valves but it must receive feedback from the pulsers to make sure that the valves are opening to the right amount and if not the CPU can make adjustments This is why if you could monitor the output shaft of each meter you would see one meter spinning a little faster than the other and then the CPU makes and adjustment and the other meter starts spinning faster as the other slows down The CPU checks the output every gallon If there is an error due to too much of one product going into the mix an error will appear and the sale will stop You can program a range of blender error from 1 to 100 This setting also in mode 7 allows you to set a point at which you can trip an error and shut down the dispenser The blend ratio can be set in mode 7 as previously mentioned A Bennett pump does not blend octane it blends volume In other words if you have a low grade with a certain octane rating and a high grade with a certain octane rating then you must contact the company that supplies that fuel and ask them how much of the low grade should we blended with the high grade to reach a certain octane level The maximum blend ratio you can set is 80 20 the first number always refers to the amount of the low grade that goes into the mix Also the blend ratio can only be set at the dispenser an
21. the different handles are as follows Handles Off side 2 3 00vdc Handle A 2 790vdc Handle B 2 730vdc There is a potentiometer that can be used to adjust the bias set point voltage to 3 000vdc if necessary This is not normally done in the field The potentiometer is RV2 for TP2 This is done with all handles hung up for that side Test Point TP3 3 000vdc WARNING Do not attempt to adjust these voltages in the field unless instructed to do this by Technical Support Test Point TP4 1 889vdc Test Point TP6 Direct Current Common or DCC ground Test Point TP7 CPU Logic Voltage 5 0vdc C 8 CPU Board 111661 Rev B 02 09 Mixer Allocation Limit No Flow Timeout Blend Ratio Blend Error Band Slow Flow Amount Fleet PPV Dash PPV Flash Cross Multiply Money Push to Start Console Stand Alone Blender Truncate Round Sale RAM Clear Procedure Sometimes it may be necessary to per form a RAM Clear procedure This is a procedure that should only be done after all other logical troubleshooting steps have been exhausted It is used sometimes if the dispenser software stops operating Or if the main memory gets corrupted or invalid This procedure will clear the memory Caution Some dispenser programming may be lost after the RAM clear and system reprogramming will be required Caution This procedure will zero out electronic pump tot
22. the power distribution board Card reader information comes from the IC Box through twisted pair wiring 3 wires and connects to terminal strip TS4 This is RS485 protocol This information follows the same path through the power distribution board as the dispenser communication that is it exits the power distribution board through the same ribbon cable over to the CPU on connector J8 The CPU board The CPU board is the heart of the system It runs the software has the memory communicates with Point of Sale sends control signals to the solid state relays sends display signals to the display boards communicates with the product select touch panel interfaces with the handles and pulsers through the Intrinsically Safe Barrier Boards controls the proportional valves through a wiring harness It performs the blending functions and stores historical data for sales and diagnostics It receives power from the Power Distribution Board It also routes power to the card reader system It also communicates with and sends signals from the Vapor Recovery system There is one CPU board per dispenser and it can be accessed easily by opening the electronics enclosure door The CPU board is mounted vertically and has various cables and harnesses connected to it The CPU receives dc voltages from the power distribution board on connector J7 The wiring harness is color coded and uses the following color scheme 1 Orange 24 volts dc Valve printer display an
23. the pump to turn on Refer to the Point of Sale reference manual Put the pump in stand alone and test Blown fuse on the Power Distribution board due to cross phasing of the dispensers Refer to the section on the Power Distribution Board for service instructions Bad Valve Replace with a known good valve CPU is locked up Power down the dispenser and bypass the battery Power the dispenser back up and re try Meter is not turning Check to see if the meter turns If not replace the meter Shear valve is closed Open the shear valve for that product at the base of the dispenser The maximum allocation is set to zero Change the setting in programming to a higher number Example 50 Nozzle is broken Replace the nozzle Hose does not dispense fuel The hoses are hung up in the wrong nozzle boots Make sure that the correct hoses are in the correct nozzle boots T h e D i s p e n s e r constantly calls in Bad Handle Switch Replace handle switch Card Reader Payment Key Stuck Lubricate Key with silicon lubricant The prices are not showing up in the correct PPUV windows The Point of Sale needs to be programmed correctly The Pacific puts the Diesel product as the first product instead of the 4th product Possible Cause Corrective Action J 1 Troubleshooting Breakdown 111661 Rev B 02 09 Symptom The Display is blank Dispenser is turned off Check the power switch inside th
24. to the Power Supply Pin 1 Earth Ground Green wire Pin 3 Neutral White wire Pin 5 110 230 volts A C 50 60 cycle Black wire J6 Non filtered A C 110 230 volts A C 50 60 cycle Note that this is switched Pin 1 Earth Ground Pin 2 Neutral Pin 3 Hot top J4 D C Voltages created by the Power Supply and sent to the Power Distribution Board Pin 1 5 volts d c Logic Power for the CPU Violet wire Pin 2 5 volts d c Logic Power for the CPU Violet wire Pins 3 6 Direct Current Common DCC Ground Reference Black wires Pin 7 12 volts d c Power for display board operator interface board local preset side 1 Red wire Pin 8 12 volts d c Power for display board operator interface board local preset side 2 Red wire Pin 9 24 Volts d c Used for Backlights Printer and Valve Control side 1 Orange wire Pin 10 24 Volts d c Used for Backlights Printer and Valve Control side 2 Orange wire B 11 Power Distribution Board 111661 Rev B 02 09 Power Supply Assembly Part Number 105512 Board Functions Creates Direct Current DC voltages from Alternating Current AC voltages Power Supply Assembly Theory of Operation AC power 110 230 volts AC 50 60 cycle comes from the Power Distribution board on Power Supply Assembly connector J1 The purpose of the power supply is to take incoming AC and convert it to various DC voltages f
25. 111661 Rev B 02 09 Bennett Pacific Series 1000 Series Remote Dispensers Electronic Service Manual Only Trained Personnel May Work on This Equipment READ THIS BOOK This book has important information for safely servicing of this equipment Read and understand this book before attempting troubleshooting Keep this book and tell all service personnel to read this book If you do not follow the instructions you can cause bodily injury death or damage to the equipment For new books FAX to BENNETT MARKETING SERVICES 231 799 6202 Or visit our web page at http www BennettPump com Bennett 1218 E Pontaluna Road Spring Lake MI 49456 USA 800 235 7618 Outside USA 231 798 1310 sales bennettpump com www bennettpump com 111661 Rev B 02 09 This page was intentionally left blank 111661 Rev B 02 09 Table of Contents SECTION A SECTION B i INTRODUCTION A 1 SERVICE SAFETY INSTRUCTIONS A 2 BASIC SYSTEM THEORY OF OPERATION A 3 THE POWER DISTRIBUTION BOARD Part Number B 1 Board Functions B 1 Theory of Operation B 2 Battery Backup B 3 Description Of Controls B 4 Switch 2 On Off B 4 Switch 1 Battery Kill B 4 PAD Jumpers B 5 Relays B 5 Fuses B 6 Standard B 6 Pico B 6 Light Emitting Diodes LED s B 6 System Battery B 6 Powering Down the Dispenser for Service B 6 Turning the Dispenser On B 6 Taking Voltage Readings B 7 AC Voltage Reference B 7
26. 2 J2 Pulser Ribbon Cable Connection G 3 J3 Pump Handle Cable Connection G 3 Pulser Board Part Number G 4 Theory of Operation Pulsers G 4 Error Checking G 4 J2 Ribbon Cable on Pulser Connection G 5 J3 Ribbon Cable to Next Pulser Connection G 5 Connecting Pulsers G 6 Test Points G 6 LED s G 6 Handle Switch Circuit Part Number G 7 Theory of Operation Handle Switches G 7 Handle Switch Location G 8 Setting the Jumper on the Handle Switch Board G 8 Test Points G 9 Connecting the Handle Switches G 10 LED s for the Handles G 11 SECURE PUMP PAY Serial Numbers H 1 Diagnostics H 2 Keypad H 4 Printer H 4 Display H 4 Card Reader H 5 Dukpt Encryption H 5 Menu2 Option H 6 Ping H 6 Error Codes H 7 Preventive Maintenance Tips H 8 LCD Display Contrast H 8 Troubleshooting Chart H 9 VIB2 Board H 12 Part Number H 12 Description Controls H 12 LED s H 12 Connectors amp Pinouts H 13 ERROR CODES List of Error Codes I 1 Clearing Error Messages I 1 TROUBLESHOOTING BREAKDOWN J 1 DIAGNOSTICS K 1 Table of Contents 111661 Rev B 02 09 This manual covers service information for the electronic components of Bennett pumps It covers the Pacific Series with 708 electronics Information is correct at time of publication For more information please contact the Bennett Customer Response Department at Bennett Pump in Spring Lake
27. 2 F3 F4 7 D C voltage distribution J1 Battery charging circuit J2 Connection to field wiring for motor out card reader communication and dispenser communication TS2 3 4 amp 5 Provides a switch for the main power S2 Provides a switch for the battery override S3 B 1 Power Distribution Board 111661 Rev B 02 09 Power Distribution Board Theory of Operation The Power Distribution board is located in the center of the dispenser in the electronics cabinet This board is covered by a metal cover to protect anyone working inside the equipment from receiving an electrical shock This cover is removed for service It must also be replaced when service is complete WARNING Always replace the metal cover when you have completed service Failure to do so poses a potential for electrical shock 110 230 Volts A C 50 or 60 cycle power comes into the dispenser through field wiring to the bottom of the Power Distribution Board terminal strip TS1 1 Power then passes through a 3 amp fuse and then is filtered for noise Any electrical noise is dampened out by this filter FIL1 The power is then passed from the Power Distribution Board to the Power Supply through connector J5 for Direct Current D C conversion Incoming A C voltage is also routed through fuse F1 1 amp for submerged pump control If power to the dispensers are cross phased this fuse will blow to protect the dispenser from damage
28. 661 Rev B 02 09 How to perform a Card Reader Diagnostics Test 1 Select the soft key next to Card Reader to run the card reader test see figure 15 Card Reader Test Insert Card fully CAN to return Figure 15 2 Insert a card see figure 16 Card Reader Test Remove Card CAN to return Figure 16 3 Remove the card The screen displays information about the card see figure 17 mag1 63 mag2 36 mag3 No Data Figure 17 4 To return to the test menu press CANCEL How to perform a DUKPT Encryption Diagnostics Test Select the soft key next to IKSN see figure 18 Initializing DUKPT Figure 18 If the test is successful a screen similar to the following is displayed see figure 19 KSN FFFF12345678 Figure 19 H 5 Secure PumpPAY Card Reader Diagnostics 111661 Rev B 02 09 If the test fails the following screen is displayed see figure 20 bDUK_get_KSN error Figure 20 When you are finished with the diagnostics MENU1 press the Back soft key see figure 8 page H 3 How to advance to MENU2 Option Use the top right soft key to display the MENU2 option see figure 21 DIAG MENU2 lt ACCEPT gt Figure 21 How to perform a Pin Diagnostics Test This test is used to allow you to ping the back office from the Secure PumpPAY 1 Press ENTER to display the list of MENU2 tests see figure 22 Ping is currently the only option Ping Back Figure 22 2 Press the menu
29. CEL button twice to exit Diagnostics Error 99 Figure 7 dIAg 3 Diagnostic Code 4 RAM Test To enter this test enter diagnostics and press the 4 button on the keypad and the ENTER button This test is used to test the system RAM The CPU performs a RAM test to determine if RAM is good or corrupted If the RAM failure is detected by the RAM test the displays flash the message in figure 8a If a RAM failure is not detected by the RAM test the displays flash the message in figure 8b Press the CANCEL button to exit this test Press the CANCEL button twice to exit Diagnostics Error 2 Figure 8a dIAg 4 dAtA G00d Figure 8b dIAg 4 Diagnostics K 4 111661 Rev B 02 09 Diagnostic Code 5 Pump Handle Test To enter this test enter diagnostics and press the 5 button on the keypad and the ENTER button This test checks the status of the pump handles on the dispenser The CPU reads the pump handle switches and writes the status of each handle to the display When all handles are off the display appears as in figure 9a When a handle is turned on an A or b should appear See figure 9b for an example of the A pump handle raised Turn each pump handle on individually or all at once to test the status Press CANCEL button to exit this test Press the CANCEL button twice to exit Diagnostics HAndLE Figure 9a dIAg 5 Diagnostic Code 6 Power Failure Counter This code is used to investigate
30. Card Reader System Bennett installs the card reader in the electronic head of the dispenser There is one card reader and printer per side The dispenser provides power for the card reader and printer and routes card reader communication from the card reader to the CPU board and then through the Power Distribution Board to the terminal strip on the Power Distribution board TS4 Here on TS4 is the 3 terminal connector that connects the dispenser card reader channel with the Bennett IC box in the store using RS485 twisted pair field wiring communication And from the IC box to the POS using RS232 communication The communication for the card readers between the CPU and the Power Distribution Board is through the same ribbon cable as the dispenser communication It exits the CPU on connector J8 and enters the Power Distribution Board on J3 It exits the board on Terminal Strip TS4 Communication with the Handle Switches When the customer removes the nozzle from the nozzle boot a small electronic circuit is activated sending a signal through the Intrinsically Safe Barrier to the CPU This signal is dependent on the jumper setting on the circuit board The CPU interprets this voltage as the identifier for the handle That is it sees it as Handle A or B If the jumper setting is wrong then the handle switch will not call in correctly Communication with the Pulsers The dual phase pulsers put out two phases of pulses 90 degrees out of p
31. EPROM s Loose cable in the electronics Check the cables going to the Display Board Refer to the Display Board section for trouble shooting Backlight doesn t come on Dispenser is in power fail Once main power returns to the dispenser the light should come back on Cable came loose from the Display Board to the Backlight board Check the small power cable for lighting that connects the Display Board to the Backlight Board Possible Cause Corrective Action J 2 Troubleshooting Breakdown 111661 Rev B 02 09 Symptom Managers Keypad does not get into the programming mode The keypad cable is plugged into the wrong side of the dispenser Plug the Manager Keypad into J4 of the Product select Auxiliary Backlight Display Board on side 1 of the dispenser A handle switch has been activated Make sure all the handles are hung up The system cannot enter Managers mode if a handle is removed Dispenser does not stop at preset amount Attendant waiting longer than 60 seconds between the time he presets the pump and actually starts pumping fuel The pump is timing out Teach the attendant that he only has 60 seconds after setting the preset before it times out and will over run the preset amount Dispenser does not stop at Pre pay amount Valve not closing in time Extend the slow flow offset Or change out the valve with a known good one Ghost Sales Ruby sending prices on a pre authorized
32. If this fuse blows check for cross phasing If a cross phasing condition exists correct the problem before attempting to replace the fuse Power from the power distribution board comes into the Power Supply assembly on connector J1 This power supply creates various D C Voltages for use throughout the system Specifically the power supply takes the 110 230volt A C input to create the following voltages 1 24 Volts DC 2 12 Volts DC 3 5 Volts DC These voltages have tolerances of 10 There are no adjustments for any of these voltages but there are test points The DC voltages are fed back to the Power Distribution board connector J4 through a multi pin conductor connected to J2 of the Power Supply Figure 1 Power Distribution Board with the protective cover on Figure 2 Incoming power on terminal TS1 is line voltage It passes thru fuse protection and a easy Off On switch Then it is filtered and sent over to the power supply Figure 3 DC voltages returns from the power supply to the power distribution board on connector J4 B 2 Power Distribution Board 111661 Rev B 02 09 There is fuse protection on the Power Distribution Board for both power coming into the system and also fuse protection for power traveling internal to the system From there the DC voltages are sent over to the CPU board through another multi pin conductor from connector J1 of the Power Distribution Board to connector J7 on the CPU b
33. aces follow this procedure 1 Wash the dispenser in a solution of warm water and a mild detergent that removes grease and oil 2 Rinse thoroughly with clean water 3 Dry all surfaces with a clean cloth 4 If the surface is dull due to oxidation apply a cleaner specially formulated to remove oxidation to the clean surface This will restore luster to the painted surface WARNING Do not use strong detergents petroleum solvents abrasive cleaners or steel wool to clean the dispenser To clean stainless steel anodized aluminum or chrome plated panels follow this procedure 1 Wash the dispenser in a solution of warm water and a mild detergent that removes grease and oil 2 Rinse thoroughly with clean water 3 Dry all surfaces with a clean cloth 4 Apply a coat of non abrasive paste wax to protect the panels from corrosion NOTE To remove tree resin or sap from dispensers use turpentine Maintenance K 9 111661 Rev B 02 09 Notes K 10 111661 Rev B 02 09 Bennett 1218 E Pontaluna Road Spring Lake MI 49456 USA 800 235 7618 Outside USA 231 798 1310 sales bennettpump com www bennettpump com
34. ader information comes from the IC Box through twisted pair wiring 3 wires and connects to terminal strip TS4 This is RS485 protocol This information follows the same path through the power distribution board as the dispenser communication that is it exits the power distribution board through the same ribbon cable over to the CPU on connector J8 Description of Power Control Warning The only option that you have for removing power from the dispenser is by turning off the S2 switch from the Power Distribution Board Switch 3 S3 Located on the bottom right hand side of the board is the Battery Over ride Switch This switch can be used to override the 30 second battery if primary power is lost at the dispenser or if incoming power drops below 74 volts A C This switch Stays in the up position by a spring To kill the power you must press down momentarily and then release Once the switch is closed and the display goes blank remove your finger from the switch See figure 8 Figure 7 TS4 is the Dispenser Card Terminal Connection to the IC Box in the building and TS5 is the Fuel Communication to the 515 box Figure 8 S3 is a switch which is normally opened Always turn off the battery when attempting to service the Pacific dispenser B 4 Power Distribution Board 111661 Rev B 02 09 PAD Jumpers There are a series of PAD jumpers located below the solid state relays These PAD jumpers should not change in the Pac
35. als CLEAr dAtA 0 Figure 17 COdE 49 Caution Do not show your customer how to do this procedure This procedure should only be performed by factory trained personnel Note RAM clear procedure is not a warranted procedure unless Technical Support is contacted and recommends it To perform a RAM clear Please refer to the Pacific s Operator s manual for the procedure Menu Code 49 will RAM Clear the dispenser see figure 17 Note An indication of a successful RAM clear will be when you turn the dispenser back on and all zeros are displayed for the last sale Note Clearing the RAM does NOT change all the programming to the factory default settings You may notice some programming remaining the same and other settings changing It is best to review your program settings before performing the RAM Clear so that you know how to reset them after the RAM Clear Some things the RAM clear resets is A Default password back to 2218 B Resets non reset able electronic totals C Sets prices to zero The following options are NOT affected by performing a RAM Clear Gallon Liter Imperial Gallons Volume Resolution Flag Decimal Mode Number of Grades Pre charge Time Number of Hoses Beeper Number of Tiers C 9 CPU Board 111661 Rev B 02 09 J1 J2 Internal Local Area Network LAN Product Select Keypad Connectors 18 Position AMP Mini Universal Header sides 1 amp 2 These multi colored
36. arness is also used for the CPU to send power and talk to other components such as the display board and backlight board farther down the line The product select board includes the Price Per Volume Displays Main Display The main display is used for the customer to view the currency and volume amount of the sale The display gets its information from the CPU through the product select board Electromechanical Totalizer Board The dispenser is equipped with an Electro mechanical totalizer for each hose which records the volume dispensed for each sale The volume recorded is an accumulative total that cannot be reset The total is cumulative and reads in whole unit gallon or liter increments Main Display Backlighting Board The dispenser does not use lights or ballasts To light the display it uses a backlight board using a series of 1 5 volt Light Emitting Diodes LED s By using this type of lighting it eliminates the need to replace burnt out light bulbs and ballasts These LED s are powered from 24 volts it receives from the main display Local Preset Option Another option that is available is the Local Preset This option is generally for attended fueling sites where the attendant can select the money or volume of the transaction The dispenser stops at the preset amount A receipt printer is available The local preset electronics is mounted the same place that the card reader would be mounted in the dispenser electronics Therefore the lo
37. as to be set to identify which handle it is i e A or B Please see section on Handle switches This cable connects to the Barrier Board on J3 runs through the same potted conduit as the pulser ribbon cable and then down to the first handle switch in the chain Refer to the section on handle switches to find out how the cable connections work Pin Signal Direction AWG amp Color Pin 1 Pump Handle Bi Directional Red Pin 2 Pump Handle Bi Directional Black PD1 Chassis ground connection Must always be connected to insure the Intrinsically Safe Barrier Board is functioning correctly DANGER A disconnected ground wire can allow uncontrolled amounts of energy to enter the hydraulic area creating a spark with sufficient energy to cause an explosion of the gasoline vapors G 3 Intrinsically Safe Barrier Board 111661 Rev B 02 09 Pulser Board Assembly Part Number 107927 Pulser provides two separate channels or phases of square wave pulse information that represents the amount of fuel passing through the meter One dual phase pulser is mounted to the top of each meter Theory of Operation Dual Phase Pulsers Pacific pulsers are dual phase electronics pulsers that pulse at a rate of 1024 pulses per gallon The Dual Phase design is to prevent tampering These pulsers are physically mounted to the output shaft of the meter As fuel flows through the meter the output shaft rotates and turns the pu
38. bers on the screen not the backlighting Power Fail circuit The CPU also detects when power has been removed from the system or when the voltage input has dropped below 75 volts A C At that point the CPU enables the power fail circuit turns off the dispenser lights and sends a message to the display of PFAIL This turns on the battery which provides 30 seconds worth of power to the display until it times out Power On Self Test When the dispenser is turned on the CPU runs a diagnostic routine This is why all of the solid state relays cycle on and off momentarily every time you turn on power to the dispenser Description of controls There are no controls on this board Figure 12 Local Preset is an option that is purchased for Full Service locations It gets its power and data from the dispenser It connects to the dispenser CPU through a daisy chain multi colored cable thru the product select Figure 13 RV1 is used to adjust the contrast of the letters numbers on the screen for the Local Preset display not the backlight C 6 CPU Board 111661 Rev B 02 09 Light Emitting Diodes Handle Switch LED s Located towards the lower left of the CPU board LED D18 Pump Handle side 1 product A This LED is lit when the handle is hung up Unlit when the handle is lifted LED D19 Pump Handle side 1 product B This LED is lit when the handle is hung up Unlit when the handle is lifted LED D20 Pump Han
39. cal preset and the card reader system cannot co exist in the same dispenser The local preset is programmed using a standard PC ASCII keyboard with an OS2 connection There are 2 languages to choose from You can also program receipt header footer information A 6 Overview of 708 Electronic Components 111661 Rev B 02 09 Normal fueling transaction at the dispenser When a customer wants fuel they lift the nozzle from the nozzle boot That signals the CPU that the customer wants fuel They are then prompted by the display to select a grade or octane Once the product is selected and if the dispenser is in stand alone the dispenser shows all 8888 s in the display segment check sends out the appropriate motor control signal If the dispenser is in Console control it waits until authorization has been received from the console Then the appropriate valve is opened after the programmed delay time expires for the leak detectors Fuel begins to flow Liquid flow through the dispenser The dispenser sends a 120vac signal to the relay used to control the submerged pump As the signal energizes the coil it closes the contacts sending the proper voltage to the motor As the motor turns on it pressurizes the product line to approximately 28 P S I Once the product begins to flow it goes through the normally opened shear valve and enters the product inlet of the dispenser see figure A 1 From here the product gets purified through the filte
40. connector J3 on the Power Distribution Board to connector J8 of the CPU board There are LED s on the CPU board for this channel that are marked Receive and Transmit These LED s will normally blink if the CPU is talking to the POS The dispenser will only talk to the POS if it is in Console mode If it is in Standalone or Programming mode it will halt communication and you will see the LED s stop blinking Dispenser communication with the console is on a speak when spoken to arrangement The POS always initiates the communication with the dispenser Also only one dispenser communicates with the POS at a time The POS polls each fueling point individually one at a time and then moves to the next fueling point After it talks to the last fueling point it starts over again Solid State Relay Motor Control The CPU sends the 12volt DC signals to the solid state relays that are located on the Power Distribution Board through this same ribbon cable Figure 4 Current Loop wires connects the 515 POS to the pump These signals are routed to the CPU board Figure 5 Console com comes in on the ribbon cable There are LEDs right next to the connector to indicated side 1 and side 2 transmit and receive with the console Figure 5A Motor control between the CPU and the Power Distribution board is also through this ribbon cable C 3 CPU Board 111661 Rev B 02 09 Communication with the
41. d the ground are at the same potential B 8 Power Distribution Board 111661 Rev B 02 09 Terminal Strips Connectors and Pinouts The following is a description of the connections to the terminal strips and pinouts of all the connections on the Power Distribution Board Note Voltage readings can be taken right on the terminal strip connector pins Terminal Strip 1 TS1 Dispenser Input Power Pin 1 Earth Ground Pin 2 Neutral Pin 3 Incoming Line Voltage 110v 230 v AC 50 or 60 Hz Terminal Strip 2 TS2 Motor Power Products A and B Pin 4 Not used Pin 5 Not used Pin 6 Not used Pin 7 Submerged pump relay control product A Pin 8 Not used Pin 9 Not used Pin 10 Not used Pin 11 Submerged pump relay control product B Terminal Strip 3 TS3 Motor Power Products C Pin 12 Not used Pin 13 Not used Pin 14 Not used Pin 15 Submerged pump relay control product C Pin 16 Not used Pin 17 Not used Pin 18 Not used Pin 19 Not used Terminal Strip 4 TS4 Dispenser Card Reader Terminal DCT RS 485 Communication Pin 20 Data RS485 for card reader terminal from dispenser to IC Box terminal Pin 21 Data Common from dispenser to IC Box Common terminal Pin 22 Data RS485 for card reader terminal from dispenser to IC Box terminal Term
42. d to hydraulic area Red Red Black Black Figure 10 Example of how to hook up handle switch wires Magnetic Switch Figure 9 Example of how two Pump Handle Switches are wired G 10 Handle Switch Circuit 111661 Rev B 02 09 Light Emitting Diodes The CPU board contains a series of LED s that indicate the status of the handle switches for side 1 and 2 They can be viewed on side 2 of the dispenser and are located on the lower left side of the CPU board If the LED is ON the handle is hung up If the light goes out the handle is on Example Figure 11 shows All LED s illuminated The top row are Handles A B C not used and D not used for side 2 from left to right and the bottom row shows side 1 Figure 12 shows what would happen if side 2 handle A were lifted Handle Switch LED s LED D18 Pump Handle side 1 product A This LED is lit when the handle is hung up Unlit when the handle is lifted LED D19 Pump Handle side 1 product B This LED is lit when the handle is hung up Unlit when the handle is lifted LED D20 not used Pump Handle side 1 product C This LED is lit when the handle is hung up Unlit when the handle is lifted LED D21 not used Pump Handle side 1 product D This LED is lit when the handle is hung up Unlit when the handle is lifted LED D22 Pump Handle side 2 product A This LED is lit when the handle is hung up Unlit when the handle is lif
43. d backlighting 2 Yellow 14 volts dc Battery charging circuit 3 Red 12 volts dc Product select Card reader Pulsers Handles Display and Solid State Relays 4 Black DC Ground Reference for all DC voltages 5 Violet 5 volts dc System logic voltage used by the CPU The CPU board is physically mounted to the Intrinsically safe barrier modules A 4 Overview of 708 Electronic Components 111661 Rev B 02 09 Intrinsically Safe Barrier Modules The Intrinsically safe barrier modules provide protection to the handle and pulser circuits located in the lower half of the dispenser in the hydraulic area These circuits are designed with fuses and zener diodes to prevent any potential energy from entering the hydraulic area so that under no condition will there be enough energy to create an electrical spark This way there can be no explosion if there are vapors There is one ISB for side 1 and one for side 2 The boards are identical The fuses on these boards cannot be replaced in the field as a UL requirement These boards are covered with a metal cover to protect the circuits from an inadvertent short and the covers should always be in place when the dispenser is in operation The ISB s do not have any discreet or smart components There are two ISB modules for a two sided dispenser they are identical and interchangeable Dual Phase Pulsers Pacific pulsers are dual phase electronics pulsers that pulse at a rate of 1024 puls
44. d not the POS This is to prevent fraud These proportional valves are modulated to deliver the correct amount of the blended product based on the blend ratio programmed in mode 7 If a straight grade is selected the other straight grade valve remains closed The proportional valve contains a plunger a spring and a diaphragm See figure 20 Figure 20 Components of a propor tional valve C 14 Valve Control 111661 Rev B 02 09 Outlet Manifold The outlet manifold is just a housing for a series of check valves You would normally have multiple steel tubes product lines connected to it The check valves only allow product to flow one way The mixer valve uses the same check valve that is used in the product inlet casting at the base of the pump There is also a functional element that will relieve back pressure below 50 p s i An example of the mixer valve is shown in figures 21 22 and 23 Service Tip Leaking Check Valve in the Mixer If one of these check valves is leaking the product which has already been counted can leak thru to the other side and out the other sides nozzle if it is in use Figure 21 Outlet Manifold is a housing for check valves Figure 22 The check valve can be removed and cleaned Figure 23 Functional element center re lieves pressure below 50 p s i C 15 Valve Control 111661 Rev B 02 09 Electronic Calibration Switch Board Part Number 111663 Board Functions Enables Di
45. dispenser Install version 5 00 00 or greater in the 515 interface box No communication with console Installation Wiring Make all wiring in accordance with Installation Manual 105894 Point of Sale Console not set up properly Ensure the Point of Sale has been set up properly 515 box turned off Turn on the 515 box Dispenser in Stand Alone mode Program the dispenser for console control in mode 21 Bad cable from 515 to VeriFone Point of Sale Swap cable with a known good one Maximum length has been exceeded Make sure that there is no more than 1000 feet between the dispenser and the 515 box Bad Power Distribution Board Replace Power Distribution Board with a known good one Bad CPU Board Replace CPU with a known good one Ribbon Cable between CPU Board and Power Distribution Board Make sure that the connections are snug Replace Ribbon Cable Valve or valves are not opening Loss of 24vdc Troubleshoot the 24vdc signal Is it one side or both sides Call Technical Support Bad Valve Replace Valve with a known good one Bad diaphragm Replace valve with a known good one Decimal place is wrong Programming problem Check modes 8 and 99 D i s p e n s e r s t o p s pumping after several seconds Handle switch magnet loosing magnetism Replace the handle switch board Possible Cause Corrective Action J 3 Troubleshooting Breakdown 111661 Rev B 02 09 Symptom The Main Dis
46. dle side 1 product C This LED is lit when the handle is hung up Unlit when the handle is lifted Not Used should remain on at all times LED D21 Pump Handle side 1 product D This LED is lit when the handle is hung up Unlit when the handle is lifted Not Used should remain on at all times LED D22 Pump Handle side 2 product A This LED is lit when the handle is hung up Unlit when the handle is lifted LED D23 Pump Handle side 2 product B This LED is lit when the handle is hung up Unlit when the handle is lifted LED D24 Pump Handle side 2 product C This LED is lit when the handle is hung up Unlit when the handle is lifted Not Used should remain on at all times LED D25 Pump Handle side 2 product D This LED is lit when the handle is hung up Unlit when the handle is lifted Not Used should remain on at all times Communication LED s These LED s are located on the right side middle of the CPU board LED D28 Dispenser communication receive for side 1 Communication with the Point of Sale LED D29 Dispenser communication transmit for side 1 Communication with the Point of Sale LED D30 Dispenser communication receive for side 2 Communication with the Point of Sale LED D31 Dispenser communication transmit for side 2 Communication with the Point of Sale If it is communicating with the console these LED s are constantly blinking If not communicat
47. e dispenser Turn it on Blown Fuse Check the system fuse on the Power Distribution Board Refer to the Power Distribution Board section Dispenser has been turned off from the main power panel Turn on the breaker for this dispenser inside the building Bad Display Board Replace the Display Board with a known good one Bad CPU Replace the CPU with a known good one The dispenser does not call in The dispenser is in stand alone Program mode 21 to put the dispenser in console control The handle switch is not working properly Make sure the handle switch is working properly by running diagnostics mode 5 If not the handle switch handle switch cable barrier board or CPU could be the problem Troubleshoot as needed Bad Intrinsically Safe Barrier Board or loose cable Check to make sure the handle switch cable is making good contact with the connector Replace ISB if necessary with a known good one T h e 5 1 5 b o x h a s l o s t communication Reset the 515 controller by power cycling it for 15 seconds Check the Point of Sale system for proper programming Is the Point of Sale set up for Handle up Calling The segments in the display don t look right The display board is broken Run diagnostics on the display Do all the segments light up If not replace the display board The EPROM s have a bent pins Remove the EPROM s and check for bent pins Re install the
48. e display shows the dispenser is in Diagnostics Level 0 2 The current level of software installed in the dispenser is displayed which will change from version to version Press ENTER to move to the next level of Diagnostic Code 0 0 3 Software I D Number The display shown in figure 4 appears The price display shows the dispenser is in Diagnostics Level 0 3 This field is a number that identifies the software revision level This will change from software version to software version At this point if ENTER is pressed the Design Type is redisplayed Continue to press ENTER to move from one level to another of Diagnostics Code 0 Press the CANCEL button to exit this code Press the CANCEL button twice to exit Diagnostics dESIGn Type 4 Figure 2 dIAG 0 1 SOFt rEL 0 22 Figure 3 dIAG 0 2 SOFt Id P 0022 Figure 4 dIAG 0 3 Diagnostics K 2 111661 Rev B 02 09 Diagnostic Code 1 Display Segment Test This test is used to identify failed segments in the main sales displays or the individual price per volume IPPV displays To enter this test enter diagnostics and press the 1 button on the keypad and the ENTER button The main sales display window will instruct you the press the ENTER button to begin see figure 5a Each time you hit the ENTER button a new set of segments will be displayed see figure 5b Press the CANCEL button to exit this code Press the CANCEL button twice to exit Diagnost
49. e nozzle removed the spring loaded lever moves the magnet encased in the lever away from the proximity of the reed switch on the pc board This opens the switch and tells the CPU Board that the nozzle has been lifted The Pump Handle Lever Operation The pump handles are located on the front of the dispenser To operate the dispenser remove the nozzle from the holder and lift the pump handle up for the ON position Push the pump handle down for the OFF position These are referred to as lift to start nozzle boots Push to Start Operation The Push to Start nozzle boots turn on the dispenser as soon as the nozzle is removed from the nozzle boot also referred to as Auto On With this style of operation the customer is required to select the desired product by pressing the appropriate product select switch Note that the same Nozzle Boot can either be a Lever Operated or Push to Start Operated boot How to Adjust the Pump Handle for Lever Operation or Push to Start Auto On Operation Figure C shows the back side of a Nozzle Boot set up for the Lift to Start option Notice that the cross bar is inserted in the first two notches on the black flapper With this configuration the spring presses against the flapper at an angle that forces it to stay closed even with the nozzle removed To convert this into an Auto On operation you will press down on the cross board and slide it into the second set of notches See figure D With this c
50. e the board must be sent back to the factory for repair If you try to field repair this board injury or death could result due to an explosion or fire at the pump The Pulser Barrier Boards need are covered by a metal cover Always replace the metal cover after servicing the equipment G 1 Intrinsically Safe Barrier Board 111661 Rev B 02 09 Theory of Operation The Intrinsically safe barrier modules provide intrinsic safety protection to the handle and pulser circuits located in the lower half of the dispenser in the hydraulic area These circuits are designed with fuses and zener diodes to prevent any potential energy from entering the hydraulic area so that under no condition will there be enough energy to create an electrical spark hot enough to ignite gasoline vapors There is one Intrinsically Safe Board ISB for side 1 and one for side 2 The boards are identical The fuses on these boards cannot be replaced in the field as a UL requirement These boards are covered with a metal cover to protect the circuits from an inadvertent short and the covers should always be in place when the dispenser is in operation The ISB s do not have any discreet or smart components There are two ISB s on a two sided dispenser they are identical and are interchangeable The pulser information for each side of the dispenser is carried on a ribbon cable that daisy chains from one pulser to the next This ribbon cable connects from connector J2 of the
51. es This button is the button below the number 9 button on the numeric keypad This button will be used as the ACCEPT button This button is below the 7 button on the numeric keypad This button will be used to backup in maneuvering through the modes Top Right Soft Key Top Left Soft Key ACCEPT Button Backup Button Figure 1 Continued on next page Address Mode Clear to exit Figure 2 Enter Password Figure 3 2 Press the key and 1 almost simultaneously again If a password has been set the following screen is displayed Note that this screen does not display the first time you enter Manager s Mode see figure 3 How to get into Diagnostics 1 At the main welcome screen press the key and 1 almost simultaneously pressing the key first and then quickly pressing the 1 key see figure 2 H 2 Secure PumpPAY Card Reader 111661 Rev B 02 09 DCR 02 Press ENT key Mode DEBIT SET Printer CUSTOM ENC 3DES DUKPT Printer Speed 115200 Min Max poll 10 1270 IP 169 254 196 189 Ver v10010 23 Apr 2008 Figure 4 FUNCTION CONFIG lt ACCEPT gt Figure 5 3 Enter the password and press ENTER The screen displays the current settings see figure 4 4 From the Settings screen press the ENTER key again to display the Function screen see figure 5 FUNCTION DIAG lt ACCEPT gt Figure 6 5 Use the top right soft key to di
52. es per gallon These pulsers are physically mounted to the output shaft of the meter As fuel flows through the meter the output shaft rotates and turns the pulser Approximately 8 rotations of the meter represents 1 gallon of fuel The pulser is an optically coupled device and outputs 2 separate phases of square wave pulses through a ribbon cable connection in a daisy chain fashion where it connects through the flame deck to the ISB for that side The pulsers operate off a regulated 5volt dc signal that was created from a 12volt supply When the valves are closed and there is no fuel flow there should be no pulses output from the pulser The pulser only generates pulses as it is turning As it turns and generates pulses it sends these pulses to the CPU board through the ISB for that side The CPU counts the pulses and performs the mathematical computations to covert this information to a display readout that shows the volume and it s computed currency value on the main display The CPU and the pulser works in conjunction with one and another For example when the CPU receives it s first 9 pulses it opens up the proportional valves At this point it is making sure that both phases are working If one of the phases of the pulser is not working the dispenser will never come out of slow flow Generally a retail dispenser in fast flow puts out a maximum of 10 12 gallons per minute maximum due to state and federal regulations There is one pulser
53. esent Each battery should have a working life of at least 5 years A unit s battery replacement date is printed on a label on the rear side of the unit Ordinarily a unit s battery should be replaced during each scheduled service of the unit or during any corrective repair of the unit The battery is mounted in the card reader housing To replace a battery 1 Open the cover on the card reader housing 2 Find the two extension cables one is connected to the existing battery the other is a spare extension cable 3 Connect the new battery to the spare extension cable 4 Detach the old battery from its extension cable 5 Remove the old battery Dispose of the battery at a suitable disposal site 6 Put the new battery into the space that used to be occupied by the old battery 7 Tuck both extension cables into the housing 8 Close the cover on the card reader housing 9 Update replace the label that states the battery s replacement date Adjusting the LCD Display Contrast H 8 Secure PumpPAY Card Reader Preventative Maintenance Tips 111661 Rev B 02 09 Symptom Possible Cause Resolution The POS Controller does not see ANY Secure PumpPAY units DCR Polling Errors Check cable on the back of the POS Controller com 9 should be securely seated Check the I O Configuration on the POS Controller to ensure the correct Edits in GemStall were selected for the Secure PumpPAY Check the B amp B Connector Ensure the s
54. f the orange wires measure for 24 volts dc There are 2 orange wires one for side 1 and one for side 2 Both should have 24 volts 5 14 volts Putting your black negative lead on any of the black wires and your red positive lead on either of the yellow wires measure for 14 volts dc There are 2 yellow wires one for side 1 and one for side 2 Both should have 14 volts 5 12 volts Putting your black negative lead on any of the black wires and your red positive lead on either of the red wires measure for 12 volts dc There are 2 red wires one for side 1 and one for side 2 Both should have 12 volts 5 5 volts Putting your black negative lead on any of the black wires and your red positive lead on the violet wire measure for 5 volts dc There is 1 violet wire It should read 5 volts 5 If any of these voltages are out of range you may experience erratic performance and it may be necessary to replace the Power Supply Call Technical Support for assistance 1 800 423 6638 B 13 Power Supply 111661 Rev B 02 09 B 14 Notes 111661 Rev B 02 09 CPU Board Assembly Part Number 110185 Board Functions Runs Software Contains Memory RAM Communicates with the Point of Sale Controls the Solid State Relays Sends display signals to the Display Board Interfaces with the Handles and Pulsers Controls all the Blending Functions Valve Control Stores hi
55. fold The outlet manifold for the right hose contains a check valve for each product being delivered The same check valves are used here and in the inlet manifold The left hose is only used for the non blended fuel which does not require a check valve System Memory A 3 3 volt dc on board battery is provided on the CPU board for maintaining system programming in the Random Access Memory RAM during a power outage or anytime the system is turned off This battery is not replaceable This battery is designed to outlast the longest of power outages System software The dispenser operating program is provided by use of two 32 pin EPROMS These EPROMS determine the functions that are available on the dispenser Product Select The product select board is where the customer can either press a start button or select an octane or grade at the beginning of the fuel transaction The product select is similar to a standard keypad but is not a standard dry contact type keypad Instead the keys on this board are activated using the principle of capacitance The customer removes the nozzle and makes either a grade selection or presses a start key on the product select The customer should hear a beep when pressing any key The product select is activated by human touch There are diagnostics built in to test these keys on the product select board The product select is connected to the CPU by means of a wiring harness This wiring h
56. for every meter Error checking The dual phase pulsers allow for error checking One phase is used to check the other For example after pumping 1 gallon of fuel the CPU should see approximately 1024 pulses from each phase There is a built in diagnostic where if the CPU sees more than 26 consecutive missing pulses from one or the other of the phases it will stop the sale and post an error message on the display of the side of the dispenser with the error Also on the blended product if one or the other product going into the mix is dispensing too slowly an error will result Errors are stored in a diagnostic history file and any error that occurs can be cleared by removing and replacing the nozzle from the nozzle boot or lifting and lowering the lever if it is set up in the Lever Option see page G 8 Nozzle Boot Handle switches allow the system to know what product the customer wants to dispense and signals the CPU to turn on the proper pump motor The handle switch uses a magnetic proximity switch to signal when the nozzle has been removed from the boot and the lever lifted On the nozzle boot there is a spring loaded lever Attached to the lever is a magnetic When the nozzle is removed from the nozzle boot and the lever rises auto on or the lever is lifted lift to start it moves the magnet away from the proximity switch on the handle circuit board When this happens the switch is opened and sends a signal to the CPU The CPU reads this signa
57. getting written to and erased For information on clearing the RAM see section later in this chapter On Board Battery There is a 3 6 volt dc Ni cad battery that is used by the RAM chip to store all of the programming information if the dispenser is programmed and looses power This battery is soldered right onto the CPU board It should maintain programming for extended and prolonged periods of power outage If the dispenser looses programming during a power outage then the battery is bad The CPU board must be replaced You cannot replace just the battery Communication with the touch panel customer keypad The Pacific dispenser uses a capacitive type customer product select switch This is not a normal dry contact normally open series of switches like most of the competitors have historically used This keypad is used as the start button or a grade select button The CPU contains the buffer address information for this product select keypad The keypad uses capacitive technology and has no dry contact type switches That is when the customers finger gets in proximity to the sensor the key is triggered The addressing information of the keypad is kept by the CPU Diagnostics can be run to show what the function of all buttons on the keypad are for Figure 9 CPU battery is a 3 6 volt battery This battery maintains programming if power is lost It cannot be replaced If the battery goes bad the CPU board must be replaced
58. ght Emitting Diodes C 7 Communication LED s C 7 Test Points C 8 RAM Clear Procedure C 9 Terminal Strips Connectors and Pinouts C 10 J1 J2 Internal Local Area Network C 10 J7 DC Voltages from the Power Distribution Board C 11 J8 Communication Ribbon Cable C 11 J9 J10 Intrinsically Safe Barrier Board Connections C 12 CPU Jumpers C 13 Valve Control Proportional Valve Control C 14 Mixer Valve C 15 Electronic Calibration Switch Board C 16 THE PRODUCT SELECT AUXILIARY BACKLIGHT DISPLAY BOARD Part Number D 1 Theory of Operation D 1 Block Diagram D 2 How to Prepare the Dispenser for Programming D 3 The Electromechanical Totalizers D 4 THE DISPLAY BOARDS Main Display Part Number E 1 Main Display Theory of Operation E 1 Main Display Terminal Strips Connectors and Pinouts E 2 Auxiliary Display Part Number E 2 Auxiliary Display Theory of Operation E 3 THE BACKLIGHT BOARD Part Number F 1 Theory of Operation F 1 Description of Controls F 1 LED s F 1 Test Points F 1 Terminal Strips Connectors and Pinouts F 1 Table of Contents 111661 Rev B 02 09 SECTION G SECTION J SECTION I iii SECTION H SECTION K THE INTRINSICALLY SAFE BARRIER BOARD Part Number G 1 Theory of Operation G 2 Description of Controls G 2 LED s G 2 Test Points G 2 Terminal Strips Connectors and Pinouts G 2 J1 connector to the CPU G
59. ground for measuring AC voltages B 7 Power Distribution Board 111661 Rev B 02 09 Important voltage tests A couple of important voltage tests that our Technical Support Department may want to have you check are as follows Incoming power Measure for A C Voltage between terminal 3 and terminal 2 Hot to Neutral The measurement should be recorded before calling Technical Support see figure 13 Also measure between the ground and the neutral with your meter on the A C scale You should see approximately zero volts see figure 14 Neutral to Ground Also an important reading is to make sure that the resistance from the neutral to the ground is less than 1 ohm Take this measurement with the multi meter on the ohms scale and with the field wires disconnected from the board Notice that the field wires connect to quick disconnect type terminals see figure 15 Note Make sure the dispenser power circuit Breaker Panel has been turned off before taking this measurement It is important to mark this measurement down on your Audit Report for each installation Figure 13 This example shows measuring incoming power of 120 volts A C to the dispenser Figure 14 Measuring for stray voltage between Neutral and Ground Should be zero volts Figure 15 With the field wires disconnected from the board measure the resistance between neutral and ground It should be 1 ohm or less This means that the neutral an
60. hase with one another 1024 pulses counted by the CPU equals one United States Gallon As the pulser outputs pulses those signals are sent through a daisy chained ribbon cable to all other pulsers for that side and up and through the Intrinsically Safe Barrier module to the CPU The CPU performs the mathematical calculations to convert pulses to volume and then from volume to currency and send the volume and currency information to the Display Board on a real time basis System Software Two system Programmable Read Only Memory EPROM s chips run the dispenser operating program These chips are located in slots U25 and U30 The chips have markings on them that describe the software revision level which can also be seen in diagnostics the Bennett Part Numbers and the Day Code of the chips These are replaceable chips but should not be replaced by untrained personnel Figure 6 Card reader communication comes in from the IC box on TS4 It then goes to the CPU board on the same ribbon cable as the console communication Figure 7 Ribbon cable handles DCT and console com information Figure 8 System software 2 EPROM s located in slots U25 and U30 RAM C 4 CPU Board 111661 Rev B 02 09 System Memory RAM The CPU board contains 128K of non volatile RAM The RAM is the area of the microprocessor that does all of the calculations It is sometimes referred to as the scratch pad or chalk board because it keeps
61. he battery override switch is located on the right hand side of the Power Distribution board It is used to bypass the 30 second battery On time If the system is on battery and you want to override it push down on switch F1 It will disconnect the battery circuit Note Always make sure the battery has been bypassed when servicing the equipment Powering down the dispenser for Service To remove power from the dispenser for service follow this procedure Power down the dispenser by turning off S2 from the Power Distribution board The display lights should go off and a message on the display should read PFAIL This message will blink for 30 seconds OR until the battery override switch is closed S3 on the Power Distribution Board Turning the dispenser back on Turn on S2 from the Power Distribution Board Note Always replace the metal cover for the Power Distribution Board after finishing your service work This will help protect any un trained store personnel from voltages if they open the electronic head of the dispenser B 6 Power Distribution Board 111661 Rev B 02 09 Taking Voltage Readings When taking voltage readings it is important to have a good voltage reference Without a good reference the voltage reading that you measure may be wrong There is a difference between an AC voltage reference and a DC voltage reference AC Voltage reference When measuring an A C voltage the best voltage reference that you ca
62. ice to the dispensers be sure to shut off all electrical supplies and secure them in the OFF position Close all valves in incoming piping Also to prevent the risk of electrical shock from sub pump feed back make sure you disconnect the field wiring from the power distribution board by using the quick disconnect terminals provided at the bottom of the power distri bution board Maintenance must be performed by trained personnel ONLY BEFORE SERVICING A BENNETT DISPENSER CHECK THE FOLLOWING 1 Make sure all dispensers are correctly grounded with 12 gauge wire 2 Make sure input voltages are within operating level 120VAC 96 to 135VAC or 240VAC 192 to 276VAC 3 There are no more than two units operating on a clean and dedicated 120 240VAC voltage sources 4 There are RC networks installed across the coil of the motor relay and contacts of remote submerged pumps IF ANY DEVIATION FROM THE ABOVE IS FOUND CORRECT THE PROBLEM BEFORE PROCEEDING A 1 Introduction 111661 Rev B 02 09 READ AND UNDERSTAND ALL WARNING LABELS ATTACHED TO THE DISPENSER NOTICE This device complies with part 15 of the FCC rules Operation is subject to the following 2 conditions 1 This device may not cause harmful interference and 2 this device must accept interference received including interference that may cause undesired operation A 2 WARNING ADVERTISSEMENT ADVERTENCIA For the safe installation of this equipment read and understand all wa
63. ics Diagnostic Code 2 Error History The error log file provides 40 entries total The latest 40 errors are included in the error log file The errors are displayed for the selected side If the latest 40 errors were all on side 2 then no errors would be displayed on side 1 and 40 errors would be displayed on side 2 see figure 6 To enter this test enter diagnostics and press the 1 button on the keypad and the ENTER button Press the Enter button to view the data in descending chronological order Press the CANCEL button to exit this code Press the CANCEL button twice to exit Diagnostics PrESS EntEr Figure 5a Figure 5b dAtA 2 Figure 6 0000 00 00 Diagnostics K 3 111661 Rev B 02 09 Diagnostic Code 3 CPU Test This test deliberately introduces a fault into the arithmetic unit of the CPU The display must then read ERROR 99 indicating the system has detected the fault If the message is not displayed the test has failed To enter this test enter diagnostics and press the 3 button on the keypad and the ENTER button A typical test appears as in figure 7 The 99 error will clear when the CANCEL button is pushed to exit Diagnostics Press the CANCEL button to exit this test Press the CAN
64. ific dispenser If these PAD jumpers are not set correctly improper system operation will result and you may possibly blow fuse F1 For proper operation connect the PAD jumpers as follows For submerged pumps Product A PAD 4 connected to T1 Product B PAD 3 connected to T3 Product C PAD 2 connected to T5 Product D PAD 1 connected to T7 Relays Relays are controlled with 12 volt D C control signals from the CPU Relay K1 Product A LED D15 Relay K2 Product B LED D16 Relay K3 Product C LED D9 Relay K4 Product D LED D6 Note Anytime you see a relay LED lit you can assume the relay is turned on Figure 9 PAD jumpers are set for remote submerged pumps They are connected to the top row of pads Figure 10 Do Not Change the PAD jumper This is for Self Contained pumps which is Not an option with the Pacific dispenser Figure 11 LED Lit means the CPU is telling the relay to turn on B 5 Power Distribution Board 111661 Rev B 02 09 Fuses A series of fuses are located on the Power Distribution Board There are two types standard and Pico The standard fuses are located in standard fuse mounts whereas the Pico fuses are soldered onto the board The fuses are used as follows Standard Fuses F1 3 amp standard blow for system power F2 1 amp standard blow for submerged pump control F3 1 amp for battery charging circuit Pico Fuses F4 F5 3 25 amp 24 volt D C circuit side 1 a
65. ignal to the proper relay turning it On and routing the line voltage the proper terminal on the terminal strips located at the bottom of the Power Distribution Board This line voltage is connected to the STP relay inside the building by field wiring When the CPU wants to turn Off a motor it removes the 12volt dc signal which opens that relay In the case of the blended product more than one relay is activated at one time Figure 4 Pico fuses and standard replaceable fuses are located in the upper right of the Power Distribution Board Also connector J1 sends power over to the CPU Figure 5 External battery for maintaining display after loss of primary power This battery is re chargeable and takes several hours to charge on a brand new dispenser Figure 6 Solid state relays provide motor control for the STP s or the Self Contained Motors 12volts DC is used to turn them on B 3 Power Distribution Board 111661 Rev B 02 09 Dispenser communication with a Point of Sale and Card Reader communication is also routed through the power distribution board Dispenser communication comes in from the model 515 box to the power distribution board terminal strip TS5 This is the current loop communication signal that passes through the Power Distribution Board on connector J3 through a ribbon cable to the CPU board connector J8 Card reader communication also is routed through the power distribution board Card re
66. inal Strip 5 TS5 Dispenser Communication Current Loop Signals There are 2 Current Loop wires per SIDE of a dispenser On a two sided dispenser side 1 communication is on terminals 23 and 24 and side 2 communication is on terminals 25 and 26 These wires are pulled from the model 515 box inside the building and are connected to the dispenser here Pay attention to polarity Make sure to connect the in the dispenser to the in the 515 etc Notice that the first terminal in the dispenser is data for side 1 Pin 23 Data side 1 out to model 515 box for the first Fueling Point Pin 24 Data side 1 out to model 515 box for the first Fueling Point Pin 25 Data side 2 out to model 515 box for the second Fueling Point Pin 26 Data side 2 out to model 515 box for the Second Fueling Point B 9 Power Distribution Board 111661 Rev B 02 09 Terminal Strip 6 TS6 Constant 120 AC Connection Note that this is a constant 120vac Pin 1 Neutral top Pin 2 Incoming Line Voltage 110v 230 v AC 50 or 60 Hz J1 DC voltages from the Power Distribution Board to the CPU board Multi colored cable Pin 1 24 Volts d c Used for Backlights Printer and Valve Control side 1 Orange wire Pin 2 24 Volts d c Used for Baclkights Printer and Valve Control side 2 Orange wire Pin 3 Standby 14 5 volts d c battery backup side 1 Yellow wire Pin 4 Standby
67. ing with the POS then the Transmit LED for that side will be on constantly and the Receive LED will be off Figure 14 Handle switch LEDs tell you if the CPU recognizes the handle switch If a handle is lifted the light goes out See below Figure 15 The LEDs right next to the com cable are green The top 2 are transmit and the bottom two are receive side 1 2 They should blink if dispenser is talking to the POS C 7 CPU Board 111661 Rev B 02 09 Test Points Test Point TP1 This is the voltage for the handle circuit side 1 Depending on what handle is lifted will be a different voltage for the handle detect circuit The expected voltages for the different handles are as follows Handles Off side 1 3 00vdc Handle A 2 790vdc Handle B 2 730vdc Figure 16 Test Point 1 4 Glue There is a potentiometer that can be used to adjust the bias set point voltage to 3 000vdc if necessary This is not normally done in the field The potentiometer is RV1for TP1 This is done with all handles hung up for that side Note It should never be necessary to adjust the potentiometer for the voltage for the handle switches Contact Technical Support before making any adjustments on this potentiometer 1 800 423 6638 Test Point TP2 This is the voltage for the handle circuit side 2 Depending on what handle is lifted will be a different voltage for the handle detect circuit The expected voltages for
68. intermittent problems with power The counters keep track of the number of times a power failure occurs To enter this test enter diagnostics and press the 6 button on the keypad and the ENTER button 6 1 Power The display shown in figure 10a appears The Price display shows the dispenser is in Diagnostics Level 6 1 The number of power failures that have occurred since the system was reset cold start appears on the second line of the main display Press ENTER to advance to the next counter HAndLE A Figure 9b dIAg 5 PFAILS 0 Figure 10a dIAg 6 1 Diagnostics K 5 111661 Rev B 02 09 rUArtF 0 Figure 10b dIAg 6 2 Press ENTER to advance to the next counter Cold Start Counter This code is used to tell the technician how many times a Cold Start has been performed on the dispenser 6 3 Cold Start The display shown in figure 10c appears The Price display shows the dispenser is in Diagnostics Level 6 2 The number of Cold Starts that have occurred appears on the second line of the main display Other Failure Counters 6 4 y9Err 1 6 5 y9Err 2 6 6 y9tOt 1 6 7 y9tOt 2 These counters are used for Engineering and not to be used in the field Press the CANCEL button to exit this test Press the CANCEL button twice to exit Diagnostics CStArt 0 Figure 10c dIAg 6 3 Communications Failure Counter This code is used to investigate intermittent problems with communications The c
69. iquid Crystal Display LCD there are no LED s The LCD is not field replaceable Test Points There are no test points on this board Terminal Strips Connectors and Pinouts The following is a description of the connections to the terminal strips of all the connections on the main display board JP 1 Communication Ribbon Cable from Product Select Auxiliary Backlight Board JP 2 Power for the Main Display Backlight Board The display board for each model Pacific is the same Therefore all you need to stock is one display board to service all the models Auxiliary Display Board Part Number 107332 Controls up to four product prices Supports 2 Tier Pricing Provides LED s for the Grade Select Touch Pads E 2 Display Board 111661 Rev B 02 09 Theory of Operation There is an auxiliary display board on each side of the dispenser if it s a 2 sided dispenser This display is used for the customer to view pricing information This display gets its lighting from a backlight board as well as provides lighting for the product select touch pads As the customer selects the product the un used product prices will either dash or blank out depending on programming You can also program the Price Per Volume to either flash while not in use or stay on continually This board can support up to four products It s the same board on all dispensers so it is interchangeable The Pacific dispenser is able to control 2 Tier pricing
70. ition can be displayed by pressing the i button Press the ENTER button to move forward through the log When all logged transitions have been viewed the display flashes the message shown in figure 12c Press the CANCEL button to exit this test Press the CANCEL button twice to exit Diagnostics End oF StAtES Figure 12c 0000 00 00 Table 1 State Descriptions xx State Code nnnnnn State Name Description ee Event Code Event Name 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 IdLE Auth HANdLE rEAdy FLO SUSPNd CollCt PENDNg AttNdt Error ErCLCt AtCLCt totALS bLANcd FLOdNE STANd Idle Arm Handle Ready Flow Suspend Collect Pending Attendant Error Error Collect Attendant Collect Totals Blanked Flow Done Stand Alone 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Handle Active Handle Idle Set Arm Clear Arm Flow Active Set Paid Attendant Key On Attendant Key Off Blank Display Fault Noflow Timeout Power Failure Totals Active Totals Idle Sale Done Error Sale Done Warm Start Self Arm Setup Change Emergency stop Active Emergency stop Idle Diagnostics K 8 111661 Rev B 02 09 WARNING Do not use a high pressure washer to clean the dispenser Liquid under pressure can enter the dispenser cabinet and damage electronic components Keep the dispenser clean and protected It will keep a new pump appearance longer To clean painted surf
71. key next to Ping to enter the IP address you want to ping see figure 23 Press Back to return to the previous menu IP ADDRESS 0 0 0 0 Figure 23 3 Use the keypad and the and keys to enter the IP address Press to move the cursor to the left press to move it to the left see figure 24 IP ADDRESS 169 254 196 200_ Figure 24 H 6 Secure PumpPAY Card Reader Diagnostics 111661 Rev B 02 09 4 Use the keypad and the and keys to enter the IP address Press to move the cursor to the left press to move it to the left see figure 24 IP ADDRESS 169 254 196 200_ Figure 24 If the ping is successful the screen displays a message similar to figure 25 Press any key to return to the Ping menu Ping 169 254 196 200 pkt1 rsp time 10 0 ms pkt2 rsp time 0 0 ms pkt3 rsp time 0 0 ms Stats 0 packet loss rtt min 0 0 ms rtt avg 3 3 ms rtt max 10 0 ms Figure 25 If the ping is unsuccessful the screen briefly displays the following error message and returns to the Ping menu see figure 26 Ping 169 254 196 200 56 data bytes sent Ping Error Figure 26 5 Press the Back soft key to return to the Diagnostics menu see figure 21 page H 6 How to Exit Diagnostics 1 Press to leave the Diagnostics Function 2 Press twice to exit the Configuration Function and finish loading the SECURE PUMPPAY software Error Number Error Description Action 22 Service
72. l and determines if it is handle A or B and then turns on the appropriate relay to turn on the remote motor When the handle is returned to the nozzle boot this signals that the sale is complete and the CPU sends this information to the Point of Sale device if there is one There is a handle switch for every nozzle boot Proportional Valve control The CPU also controls the valves The valves are there to control product flowing through a hose They prevent the unauthorized dispensing from a hose that isn t authorized They are also used to slow down the flow towards the end of a pre pay or preset sale These proportional valve operates off 24 volts dc The CPU pulses or modulates the valve with pulses based on the rate of what is programmed in for the blend ratio through the dispenser programming For example if the dispenser is set for a 60 40 blend it will modulate the first product for a 60 mixture and the second product to produce 40 It checks the output pulses of the respective meters to see if it is A 5 Overview of 708 Electronic Components 111661 Rev B 02 09 blending properly or if it has to modulate one or the other valve more or less If the mixture does not meet the blend ratio setting within a programmable tolerance then an error will result and the sale will stop The maximum blend ratio that can be set is 95 5 or 5 95 The error tolerance can be set from 1 to 99 We recommend setting this for 10 Outlet Mani
73. lly the power supply takes the 110 230volt A C input to create the following voltages 1 24 Volts DC 2 12 Volts DC 3 5 Volts DC These voltages have tolerances of 5 There are no adjustments for any of these voltages but there are test points The DC voltages are fed back to the Power Distribution board connector J4 through a multi pin conductor connected to J2 of the Power Supply There is fuse protection on the Power Distribution Board for both power coming into the system and also fuse protection for power traveling internal to the system From there the DC voltages are sent over to the CPU board through another multi pin conductor from connector J1 of the Power Distribution Board to connector J7 on the CPU board From this point the voltages are distributed to all other parts of the system A 3 Overview of 708 Electronic Components 111661 Rev B 02 09 Battery Backup A separate rechargeable 12volt battery is connected to the Power Distribution Board When the dispenser is in normal operation the battery is not used and is charged by the 14 volt D C battery charging circuit located on the Power Distribution Board When main incoming power is removed from the system or when the system incoming AC voltage drops below 74 volts AC the CPU detects this and the dispenser goes into Power Fail condition At this point the battery supplies 12 volts DC for 30 seconds to the system or unless you use the magnet provided to close
74. lser Eight rotations of the meter represents one gallon of fuel The pulser is an optically coupled device with a spinning disk with two infrared beams and outputs 2 separate phases of square wave pulses 90 degrees out of phase with each other We call these two phases phase 1 and phase 2 or Leading and Lagging phases These signals are routed through a ribbon cable connection in a daisy chain fashion where it connects through the vapor barrier to the barrier board for that side There it connects to the CPU board for processing The pulsers operate off a regulated 5volt dc signal that was created from a 12volt supply When the valves are closed and there is no fuel flow there should be no pulses output from the pulser The pulser only generates pulses as it is turning As it is turned by the output meter shaft it generates pulses and sends these pulses to the CPU board through the ISB for that side The CPU counts the pulses and performs the mathematical computations to covert this information to a display readout that shows the volume and it s corresponding computed currency value on the main display The CPU and the pulser works in conjunction with one and another For example the CPU first opens the blender valve for slow delivery At this point the CPU is making sure that both phases are working If one of the phases of the pulser is not working the dispenser will never come out of the slow flow state After 9 good pulses are received
75. n use is the incoming ground wire connected to terminal one on TS1 on the lower left edge of the Power Distribution Board on side 1 of the dispenser see figure 12 DC Voltage reference When measuring D C Voltages rather than looking to hook your test lead up to a board component a good place to put your black lead on any black wire connection on the multi pin multi colored connector J3 on the upper right side of the Power Distribution Board Voltage Tolerances When taking voltage readings the tolerance of any reading is 5 There are no adjustments that can be made on any voltages from the Power Supply If the voltage is out of range replace the power supply Measuring fuses There are two ways to see if a fuse is good Either visually or by measuring it using a multi meter To measure the fuse put your meter on the ohms scale or continuity If the fuse is good you should hear a beep when you put your leads across the fuse This means the fuse is good If it reads anything other than 0 ohms or continuity the fuse is probably bad and needs to be replaced This test works for replaceable fuses and Pico fuses as well Note Always measure fuses with the dispenser power off Note When replacing a fuse always replace with the same type and size The rating of the fuse is written on the fuse If in doubt about the rating of any fuse in the system call Bennett Technical Support Figure 12 Using incoming
76. nal Direct Connection Pin 2 Gnd Pin 3 Interrupt Out Pin 4 Gnd Pin 5 Pulser D Lag phase 2 Bi Directional Pin 6 Gnd Pin 7 Pulser D Lead phase 1 Bi Directional Pin 8 Gnd Pin 9 Pulser C Lag phase 2 Bi Directional Pin 10 Gnd Pin 11 Pulser C Lead phase 1 Bi Directional Continued on next page G 2 Intrinsically Safe Barrier Board 111661 Rev B 02 09 J1 Continued Pin Signal Direction AWG amp Color Pin 12 12 Vdc Pin 13 Pulser B Lag phase 2 Bi Directional Direct Connection Pin 14 12 Vdc Pin 15 Pulser B Lead phase 1 Bi Directional Pin 16 12 Vdc Pin 17 Pulser A Lag phase 2 Bi Directional Pin 18 12 Vdc Pin 19 Pulser A Lead phase 1 Bi Directional Pin 20 12 Vdc J2 Pulser Ribbon Cable Connection Pin Signal Direction AWG amp Color Pin 1 5 Vdc Out Ribbon Cable Pin 2 5 Vdc Out Pin 3 Gnd Pin 4 Gnd Pin 5 Pulser A Lead phase 1 In Pin 6 Pulser A Lag phase 2 In Pin 7 Pulser B Lead phase 1 In Pin 8 Pulser B Lag phase 2 In Pin 9 Pulser C Lead phase 1 In Pin 10 Pulser C Lag phase 2 In Pin 11 Pulser D Lead phase 1 In Pin 12 Pulser D Lag phase 2 In Pin 13 Interrupt Out Pin 14 Interrupt Out J3 Pump Handle Connection This is a two wire connection that communicates between the handles and the Barrier Board Each handle switch has an electronic PC board with a jumper that h
77. nd barrel connectors Programming remains the same for either board type Magnetic Switch Setting the barrel connections on the handle switch board Each handle switch has an electronic pc board This board has several electronic components including a wire and barrel plugs You set the address of the handle by how you set this connections The barrel plugs should be set as follows Wire across P5 amp P6 for product A see figure 1 Wire across P4 amp P6 for product B see figure 2 Figure 1 Figure 2 Continued on next page G 7 Handle Switch Circuit 111661 Rev B 02 09 Magnetic Handle Switch Board Figure 3 Magnet Figure 4 General rule for setting connections on handle switch boards From the side of the dispenser that you are standing on the left most handle is always A to the right of that one is B The connection should be set up accordingly It doesn t matter what side you are on If in doubt call Technical Support at 1 800 423 6638 Handle Switch Location The handle switch is located on the back of the Nozzle Boot near the bottom see figure 3 If the dispenser has two nozzle boots on one side then the electronics are the same on both and so is the cabling When the nozzle is hung up the spring loaded lever moves towards magnet and closes the reed switch signaling the CPU Board that the handle has been hung up There is a magnet located in the lever see figure 4 With th
78. nd side 2 F6 3 25 amp 14 volt D C battery charging circuit F7 3 25 amp 12 volt D C circuit side 1 and side 2 F8 3 25 amp 5 volt D C logic power Note Contact Technical Support before replacing a Pico fuse Light Emitting Diodes There are several LED s located on this board They are described as follows LED D15 Motor A power If illuminated means the solid state relay for the A submerged pump motor is energized LED D12 Motor B power If illuminated means the solid state relay for the B submerged pump motor is energized LED D 9 Motor C power If illuminated means the solid state relay for the C submerged pump motor is energized LED D 6 Motor D power If illuminated means the solid state relay for the D submerged pump motor is energized LED D 7 Recall If illuminated means that the Recall button has been activated LED D14 Power Fail If illuminated means that the system has lost primary power or that incoming power has dropped below 75 volts A C System Battery P N 105908 A 12 volt rechargeable battery is supplied with the dispenser The battery has a charging circuit and must be charged for several hours before it has a full charge The battery is used to supply DC voltage 12volt D C to the dispenser if the dispenser looses primary power or if primary power drops below 75 volts D C The battery when in use provides power for 30 seconds and then times out T
79. nector J2 The rear connector in figure 3 to the right is the output connector to the next pulser or if it is the last pulser in the chain will have a jumper across the last row of pins This connector is J3 Caution When connecting a pulser NEVER connect a pulser or disconnect a pulser without turning off the dispenser power and battery Damage to the pulser or the Intrinsically Safe Barrier circuit will occur if power is left on Test Points There are no test points in the pulser circuit LED s There are no LED s in the pulser circuit Figure 2 Ribbon cable daisy chain Figure 1 Ribbon cable for each side from electronics section Figure 3 Ribbon cable connection Jumper across pins 13 14 on last pulser J2 Center J3 Rear G 6 Pulser Circuit 111661 Rev B 02 09 Theory of Operation Handle Switches Handle switches allow the system to know what product the customer wants to dispense and signals the CPU to turn on the proper pump motor The handle switch uses a reed style proximity switch in conjunction with a magnet to signal when the nozzle has been removed from the boot or when the handle has been lifted lift lever In the nozzle boot there is a spring loaded lever Behind the lever is a magnetic pickup When the nozzle is removed from the nozzle boot the spring loaded lever moves the magnet away from the proximity of a reed switch on the handle circuit board When this happens the reed switch is pulled
80. o be able to program if need be All programming of the dispenser is done from side 1 Side 1 is identified as the side with the serial plate attached to the base plate Programming is done first for side one and then for side two Note Most programming functions are copied to side two after side one is programmed but not all Always check side two after programming side one Locate the managers keypad and ribbon cable by removing it from the plastic bag that came in the electronics head With all handles hung up in their nozzle boots and with the dispenser turned on and with side 1 upper door opened and lowered connect the other end of the cable to the J4 connector on the Product Select Auxiliary Display Backlight Board The plug receptacle is marked as Keyboard and is located on the right hand side as you are looking at it Plug the managers keypad into the receptacle observing the proper plug polarity You can unplug and plug in the keypad with the power on Figure 2 Connect the Manager Keypad to the Product Select Auxiliary Display Back light Board connector J4 Manager s Keypad Figure 4 Layout of the Managers Keypad 0 When the managers keypad is properly connected the dispenser will automatically enter into the Managers Mode and you should hear a Beep and see Enter Side 1 on the display Press the Enter key to program the dispenser If the Enter Side 1 message does not appear
81. o the parameter change it back to the correct setting save the change then Initialize that DCR to see if it corrected the issue H 9 Secure PumpPAY Card Reader Troubleshooting 111661 Rev B 02 09 Symptom Possible Cause Resolution The Secure PumpPAY reboots intermittently More than likely it is a power issue check the VIB2 After replacing the VIB2 and if the problem still persists it may be the Secure PumpPAY Replace the VIB2 first to see if the problem is corrected Check and make sure that there is less than 1 ohm resistance between Neutral and Earth Ground for the dispenser s power source When testing credit and debit cards the Secure PumpPAY does not respond to the first press of the CREDIT or DEBIT key The unit flashes and simply redraws the screen May respond like this when the key is pressed a second time Ensure there are no Poll Errors on the POS Re configure the Secure PumpPAY including the debit key and then try again Secure PumpPAY may need to be replaced When testing cards the printer prints Try Again repeatedly This is caused by a DCR assignment error The DCR assignment has been duplicated You will need to determine which DCR assignment was duplicated correctly configure both units and then reboot Secure PumpPAY does not light up Check power to dispenser Check power to the VIB2 If dispenser has power but VIB2 does not then replace the VIB2 If there is no powe
82. oard From this point the voltages are distributed to all other parts of the system Battery Backup A separate rechargeable 12volt battery is connected to the Power Distribution Board When the dispenser is in normal operation the battery is not used and is charged by the 14 volt D C battery charging circuit located on the Power Distribution Board When main incoming power is removed from the system or when the system incoming AC voltage drops below 74 volts AC the CPU detects this and the dispenser goes into Power Fail condition At this point the battery supplies 12 volts DC for 30 seconds to the system or unless the battery override switch is closed This battery over ride switch allows the technician to eliminate the 30 second wait if he has to service the equipment The battery itself is connected at the factory but requires several hours to charge This battery has nothing to do with maintaining system programming in the event of a power outage Make sure the battery is connected because the battery will eliminate the effect of momentary power sags thus making the dispenser more reliable The Power distribution board has other functions as well This board houses four relays that are used to route incoming line voltage as Motor Out signals to turn on remote submerged pump relays These relays are controlled by 12 volt DC signals from the CPU board When the CPU board wants to turn on a submerged pump it sends a 12 volt dc s
83. oltage used by the CPU The CPU board is physically mounted to the Intrinsically safe barrier modules The CPU must be removed to remove either of the Intrinsically Safe Barriers Figure 2 CPU Board plugged in Figure 3 The DC power comes from the Power Distribution board to connector J7 of the CPU Figure 1 CPU Board C 2 CPU Board 111661 Rev B 02 09 Communication with the Point of Sale Current Loop communication is routed from the Point of Sale through the Bennett model 515 box From the model 515 box the dispenser communication channel is connected by two field wires for each side of the dispenser So a dual sided dispenser will have 4 field wires connected between the dispenser communication channel connector TS 5 on the Power Distribution Board and the terminal strip of the 515 This communication allows the dispenser to talk to the Point of Sale device The Point of Sale POS must be able to talk to each fueling point to gather data so that the POS can download prices authorize the dispenser find out what state the dispenser is in handle down idle handle up calling dispensing total sale amount etc The current loop connection on TS5 is polarity sensitive so make sure the and the go to the proper terminals Terminal 23 is side 1 24 is side 1 25 is side 2 and 26 is side 2 From the Power Distribution Board the communication signals are routed through a ribbon cable on
84. on AWG amp Color Pin 1 5 Vdc In Ribbon Cable Pin 2 5 Vdc In Pin 3 Gnd In Pin 4 Gnd In Pin 5 Pulser A phase 1 Bi Directional Pin 6 Pulser A phase 2 Bi Directional Pin 7 Pulser B phase 1 Bi Directional Pin 8 Pulser B phase 2 Bi Directional Pin 9 Pulser C phase 1 Bi Directional Pin 10 Pulser C phase 2 Bi Directional Pin 11 Not Used Bi Directional Pin 12 Not Used Bi Directional Pin 13 Connection Verification Bi Directional Pin 14 Connection Verification Bi Directional G 5 Pulser Circuit 111661 Rev B 02 09 Connecting Pulsers The pulsers connect to the Intrinsically safe Barrier Board through a ribbon cable in a daisy chain fashion There are 2 Barrier boards one for side 1 and one for side 2 All of the pulsers for side 1 connect to the barrier for side 1 and all of the pulsers for side 2 connect to the barrier for side 2 The ribbon cable from the barrier board comes through the vapor barrier and connects to the first product pulser usually A product and then if there is more than 1 pulser another ribbon cable daisy chains to the next pulser See Figures 1 and 2 The ribbon cable has notches so that the cable cannot be put on backwards If you look at figure 3 you will notice that there are 2 connectors on the pulser The one in the center is the input connection from the barrier if it s the first pulser or the input from the previous pulser This is con
85. onfiguration the spring presses against the flapper at an angle that forces it open as you lift the nozzle Figure 5 Figure 6 G 8 Handle Switch Circuit 111661 Rev B 02 09 Test Points You can measure for proper handle switch voltages on the CPU board on TP1 side 1 and TP2 side 2 Warning Do not attempt to adjust these voltages in the field Test Point TP1 This is the voltage for the handle circuit side 1 Depending on what handle is lifted will be a different voltage for the handle detect circuit The expected voltages for the different handles are as follows Handles Off side 1 3 00 volts dc Handle A 2 790 volts dc Handle B 2 730 volts dc Handle C 2 620 volts dc not used Handle D 2 330 volts dc not used Test Point TP2 This is the voltage for the handle circuit side 1 Depending on what handle is lifted will be a different voltage for the handle detect circuit The expected voltages for the different handles are as follows Handles Off side 2 3 00 volts dc Handle A 2 790 volts dc Handle B 2 730 volts dc Handle C 2 620 volts dc not used Handle D 2 330 volts dc not used Test Point TP3 3 000 volts dc The blue potentiometers located on the lower left of the CPU board will be sealed from the factory If these seals are broken the Warranty will be voided Figure 7 Potentiometers RV1 and RV2 are sealed and must not be adjusted in the field
86. or use throughout the system After creating these voltages it sends them to the Power Distribution Board for distribution throughout the system The DC voltages created are 24 volts DC for use with the valves the receipt printer power the display and the backlighting 12 volts DC for use with the Product select board Card Reader power Pulser and Handle circuitry and the solid state relays 5 volts DC for the CPU logic voltage Description of Controls There are no controls on the Power Supply Assembly LED s There are no LED s on this assembly Fuses There are no fuses on this assembly Voltage Adjustments There are no voltage adjustments on this assembly If the output voltages are not within 10 of the rated voltage replace the power supply Power Supply Assembly B 12 Power Supply 111661 Rev B 02 09 Taking voltage readings Continued Next you can measure power from the Power Distribution Board to the CPU board You can measure using the same technique Note Color Coding In the 708 electronics most of the voltages and wires are color coded but not always In most cases the colors are as follows Orange 24 Volts DC Red 12 Volts DC Violet 5 Volts DC Black DC Common With the dispenser power on locate connector J1 on the top right vertical of the Power Distribution Board 24 volts Putting your black negative lead on any of the black wires and your red positive lead on either o
87. ounters keep track of the number of times a communications UART failure occurs 6 2 Communication The display shown in figure 10b appears The Price display shows the dispenser is in Diagnostics Level 6 2 The number of communications failures that have occurred since the system was reset cold start appears on the second line of the main display To zero the counter press the following buttons on the manager s keypad in the sequence listed Press Press Press NOTE After this three button sequence is entered the counter displayed is cleared Diagnostics K 6 111661 Rev B 02 09 n n n n n n E E x x Figure 12b dddd hh mm Diagnostic Code 7 Keyboard Switch and Beeper Test To enter this test enter diagnostics and press the 7 button on the keypad and the ENTER button The display shown in figure 11 appears This code is used to test the switches for the product buttons During this test the dispenser emits a tone when each product key is pressed The name of the button appears in the top line of the display If no tone is heard the button or key failed the test The main display shows the name of the last button pressed Press the CANCEL button twice to exit this test Press the CANCEL three times to exit Diagnostics Diagnostic Code 8 State Transition History This test is used to view the state transition log maintained by the CPU board It stores a history of all state transitions which occur du
88. pecs H 13 Secure PumpPAY Card Reader VIB2 Board 111661 Rev B 02 09 H 14 Notes 111661 Rev B 02 09 Error Code 00 No Error 02 RAM Error The RAM initialization string does not match that in ROM 13 Pulser A Error The pulser interface generated an error output while pulser A was active 23 Pulser B Error The pulser interface generated an error output while pulser B was active 33 Pulser C Error The pulser interface generated an error output while pulser C was active 43 Pulser D Error The pulser interface generated an error output while pulser D was active 51 Grade A Low Product A exceeded the error band 52 Grade B Low product B exceeded the error band 60 Mailbox Overflow Internal Error 70 Not Calibrated or Bad Checksum The calibration values are not initialized or the EPROM checksum is invalid 71 Ecal constant out of range error The ecal adjustment is outside the allowable calibration range 72 Vapor Recovery Error The vapor recovery device generated an error 74 Electronic Calibration Switch is in Calibrate Mode 83 Pulser Disconnected The pulser circuit is disconnected 93 Pulser Circuitry Error This is the pulser error catch 99 CPU Failure addition error Problem Clearing Error Messages In the event of an error a message will be displayed on the side of the dispenser where the error occurred Any error message will shut down the sale but not disable the
89. play flashing a Pulser Error Message There has been a diagnostic failure the pump locked up Run diagnostics CPU test Reset the pump and test The pulser is defective Swap the pulser with a know good one and retest There is a bad connection Check the ribbon cable from the pulser make sure it s connected properly Make sure the daisy chain ribbon cable is connected to the proper pulsers and in the right order The jumper is missing or set incorrectly on the last pulser in the chain Set the jumper across pins 13 and 14 on the last pulser in the chain Dispenser pumps in slow flow all the time Pulser Problem The dispenser not seeing 9 pulses from both phases and is never coming out of slow flow Replace the pulser Valve problem The fast flow valve is not opening Check for proper voltages and replace valve with known good one if necessary Leak Detector Problem Could have a possible leak in the piping Dispenser electronic head is wet on the inside Door locks are not closed properly Close and lock the doors properly Water getting in some other way Call Bennett Technical Support The display amount is different from the console amount for that sale Incorrect setting for rounding in the dispenser Check the dispenser programming to see how it is set Is it set to cross multiplication rounding or truncating Dispenser seems to be pumping slowly Clogged filter Clean or change filte
90. r Some type of restriction in the line Diagnose accordingly Pumps usually pump 10 gallons per minute Low pressure Install a pressure gauge on the inlet Normal pressure should be about 28 PSI on a 3 4 H P pump Call Technical Support Possible Cause Corrective Action J 4 Troubleshooting Breakdown 111661 Rev B 02 09 J 5 Notes 111661 Rev B 02 09 How to Use Diagnostics Menu Code 0 To enter Diagnostics the manager s keypad must be connected to the dispenser to place the dispenser into the manager s mode See page 18 for instructions on how to attach the manager s keyboard Make sure the A C Reset switch is in the ON position and the pump handles are all in the OFF position These instructions will not be repeated for each Menu Code Diagnostic tests have been programmed into the dispenser software to help the operator and service technician troubleshoot failures of the dispenser The dispenser can run several levels of self diagnostic tests to determine where the failure has occurred The levels that will be discussed here are By performing a diagnostic test the operator or manager can inform the service technician of the problem before coming to the site The service technician can then anticipate which repair parts to bring To enter Diagnostics follow this procedure After the correct number 1 or 2 has been entered for the side to be viewed press the 0 button and then the MODE button on the keypad The main di
91. r see figure A 2 and then passes the check valve not present The check valve is located in the same manifold as the filter on the opposite side Once it goes through the check valve it enters the meter see figure A 3 When the product leaves the meter the flow is controlled by the proportional valve see figure A 4 If the blended grade is selected then the CPU Board will modulate a 24vdc signal to both valves to create the blend ratio programmed in the dispenser From this point the product goes through a 3 4 steel tube see figure A 5 The product travels through this tube at approximately 10 12 G P M up the side of the dispenser into the outlet manifold From here the product is dispensed through the hose and nozzle of the dispenser 1 2 3 4 5 Figure A A 7 Overview of 708 Electronic Components 111661 Rev B 02 09 Figure B Product enters at the bottom inlet see figure B 1 and fills the inner cavity of the meter As the meter body fills product passes around the crankshaft and up to the top throat of the meter body From the top throat product flows to the distributor B 2 which either ports product to or from each of the four piston chambers When the distributor see figure B 2 is in a position that allows product to be ported to a piston chamber see figure B 3 equal pressure is applied across both sides of the piston Equal pressure applied across a piston offers zero resistance to the
92. r the printer is routed through this board Contains the thermostat for the fan Communication for the SPP Installer is routed through this board Power switch SW1 for the power to the Secure PumpPAY LED s D5 red RS 232 communications to the Secure PumpPAY Receive D7 green RS 232 communications from the Secure PumpPAY Transmit H 12 Secure PumpPAY Card Reader VIB2 Board 111661 Rev B 02 09 J1 Printer Power Pin 1 24vdc Pin 2 vcc Pin 3 common F1 3A F2 3A J2 Auxiliary Power Pin 1 24vdc Pin 2 12vdc Pin 3 vcc Pin 4 24vdc printer Pin 5 common Pin 6 common J3 Fan Power Pin 1 12vdc Pin 2 common Pin 3 N C J4 Pacific LAN Pin 1 24vdc Pin 2 12vdc Pin 3 N C Pin 4 Data Pin 5 Data Return Pin 6 Data Pin 7 common Pin 8 common Pin 9 common J5 Secure PumpPAY COM1 F3 3A J6 Secure PumpPAY LAN J7 PC Download J8 Heater Relay Pin 1 12vdc Pin 2 common TS1 Retrofit LAN Connection Terminal 1 Data Terminal 2 Data Return Terminal 3 Data PC Download J7 Secure PumpPAY COM1 J5 Printer Power J1 Auxiliary Power J2 Retrofit LAN Connection TS1 Pacific LAN J4 Secure PumpPAY LAN J6 Heater Relay J8 Fan Power J3 Power Switch Up On Down Off Board S
93. r to the VIB2 and the Secure PumpPAY does not light up then check the cable connections from the Power Distribution Board to Secure PumpPAY The OP4100 displays Hardware Error This is caused by the Secure PumpPAY being tampered with The Secure PumpPAY will need to be replaced Printer text prints on the edge of the receipt This is typically caused when the wrong paper is used at a Secure PumpPAY site The paper should be 2 5 16 wide Bennett s Part Number is 112028 Printer is non responsive Check to ensure the printer cables are securely seated and not pinched in the door Replace the cables and if the printer still does not work then replace the printer If the replacement printer is not immediately available unplug the printer both power and data cable and let it sit overnight then re connect It may continue to work for awhile H 10 Secure PumpPAY Card Reader Troubleshooting 111661 Rev B 02 09 Symptom Possible Cause Resolution Printer was having issues and when the Printer Diagnostics was completed the message was 1 No status received or 2 Printer Not Responding The printer has power and you can feed paper Check to ensure the printer cables are securely seated and not pinched in the door Replace the cables and if the printer still does not work then replace the printer If the replacement printer is not immediately available unplug the printer both power and data cable and let
94. rial Number contains 1 The unique serial number of the unit 2 The number of the production batch to which the unit belongs 3 A revision number 4 A latest replacement date for the unit s battery H 1 Secure PumpPAY Card Reader 111661 Rev B 02 09 Like the Dispenser the Debit Credit Terminal has a Diagnostic Mode to verify where a problem may exist The following instructions explain how to get to the Card Reader s Diagnostic Mode and how to perform each test You will find that there is little repair work that is required on these units Under normal circumstances you can fix problems before they happen with preventive maintenance The two most important ways to keep up with the preventive maintenance on these units are to keep the keys clean and by cleaning the card reader periodically The unit has three different types of diagnostics that you can use in the field Keypad Card Reader and Printer Understanding the keys on the Secure PumpPAY Unit To maneuver through the Diagnostics you will use four buttons most of the time see figure 1 Top Right Soft Key This button is referring to the top right button along the right side of the Display This button will be used to move right while maneuvering through the modes Top Left Soft Key This button is referring to the top left button along the left side of the Display This button will be used to move left while maneuvering through the mod
95. ring the operation of the dispenser It is capable of storing the last 40 state transitions and events that have occurred since the last cold start zeroing the RAM Enter this code to display the states that have been stored in the dispenser memory If no changes in state have been recorded the display flashes the message in figure 12a To enter this test enter diagnostics and press the 8 button and the ENTER button If there are states recorded the display is read as in figure 12b See explanation below nnnnnn Is the six character name of the state See Table 1 for a list of all possible state names ee Is the event code for the event that caused the state transition See Table 1 for a list of all possible event codes xx Is the next state code for the transition See Table 1 for the list of all possible next state codes dddd Is the number of elapsed days from cold start that the displayed state occurred Push volume to see the sec onds hh Is the hours portion of the elapsed time since the displayed state occurred mm Is the minutes portion of the elapsed time since the displayed state occurred State Definitions StArt StAtES Figure 12a 0000 00 00 PrESS Prod Figure 11 dIAg 7 Diagnostics K 7 111661 Rev B 02 09 Press the ENTER button to view the next transition in the state transitions log Each time the ENTER button is pressed the next logged transition is displayed The previous trans
96. rning and cautions Look for these warnings 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 Safety Instructions 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 DANGER Disconnect all power to this equipment and associated submerged pump s during installation service or any maintenance i e changing filters 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 WARNING The emergency shut off valve also called the fire valve
97. sables Electronic Calibration functions of the dispenser The Electronic Calibration Board is soldered onto the CPU Board on the J11 connection There is a stud provided to prevent anyone from moving the switch into the Calibration Mode This stud must be sealed in to restrict tampering with the calibration settings Mode 27 cannot be accessed with the switch in operate mode If the customer attempts to fuel with the switch in the calibrate position then an error 74 will be displayed C 16 Valve Control 111661 Rev B 02 09 C 17 Notes 111661 Rev B 02 09 Product Select Auxiliary Display Backlight Board 107336 Used by the customer to select the grade of fuel or as the dispenser start button The Manager Keypad plugs into this board to program the dispenser The Electromechanical Totalizers are plugged into this board The Main Display Board is plugged into this board The Auxiliary Display Board is plugged into this board The Local Preset or Card Readers are routed through this board The Auxiliary Display Board is illuminated by the LED s mounted on this board Theory of operation The product select auxiliary display backlight board controls the product select touch pads J3 These pads are used for the Grade Selection or the Press to Start These touch pads are similar in function to a standard dry contact normally open switch type keypad but it has a different operating principle These work
98. splay appears as in figure 1 The price shows the Side being read From this point any test can be entered by pressing the number of the test and the ENTER button To exit a diagnostic test press the CANCEL button Diagnostic Code Description 0 1 Design Type 0 2 Software Release Number 0 3 Software I D Number CKsum 1 Display Segment Test 4 RAM Test Diagnostic Code Description 6 2 Uart Failure Counter 6 3 Cold Start Counter 6 4 Reserved 6 5 Reserved 7 Keyboard Switch Beeper Test 6 1 Power Failure Counter 2 Fault History 6 6 Reserved 3 CPU Test Error 99 6 7 Reserved 5 Pump Handle Test 8 State Transition History dIAg COdE 0 Figure 1 SidE 1 Diagnostics K 1 111661 Rev B 02 09 Diagnostic Code 0 This test is used to display the design type software revision level and the software identification or checksum of this software To enter this test enter diagnostics and press the 0 button on the keypad and the ENTER button If you have just entered diagnostics press ENTER to see the first level of Test 0 0 1 Design Type The display shown in figure 2 appears The price display shows the dispenser is in Diagnostics Level 0 1 The number 6 is the default It means the dispenser is a 708 CPU design computer Press ENTER to move to the next level of Diagnostic Code 0 0 2 Software Release Number The display shown in figure 3 appears The pric
99. splay the diagnostics option see figure 6 6 Press ENTER to display the diagnostics menu and use the top right soft key to display MENU1 see figure 7 DIAG MENU1 lt ACCEPT gt Figure 7 7 Press ENTER to display the diagnostics tests you can run see figure 8 Keypad IKSN Printer Display Card Reader Back Figure 8 H 3 Secure PumpPAY Card Reader Diagnostics 111661 Rev B 02 09 How to perform a Keypad Diagnostics Test Select the soft key next to Keypad to run the keypad test As you press keys on the keypad the screen changes to reflect the key presses Check to make sure the key you press is correctly displayed on the screen Press CANCEL to return to the screen with the test list see figure 9 Key 4 Press any key CAN to return Figure 9 How to perform a Printer Diagnostics Test Select the soft key next to Printer to run the printer test You will see figure 10 and then figure 11 After the printer prints a receipt remove it from the printer see figure 12 If you do not remove the receipt and try the printer test again you will get an error message see figure 13 Launching Printer Test Figure 10 Printer is Normal Figure 11 Figure 12 Ticket out sensor busy Figure 13 How to perform a Display Diagnostics Test Select the soft key next to Display to run the display test see figure 14 Figure 14 H 4 Secure PumpPAY Card Reader Diagnostics 111
100. storical data for sales and diagnostics Contains back up battery for programming information C 1 CPU Board 111661 Rev B 02 09 Theory of Operation The CPU board is the heart of the system It runs the software has the memory communicates with Point of Sale sends control signals to the solid state relays sends display signals to the display boards communicates with the touch pad interfaces with the handles and pulsers through the Intrinsically Safe Barrier Boards controls the blend valves through a wiring harness It performs the blending functions and stores historical data for sales and diagnostics It receives power from the Power Distribution Board and also routes power to the card reader system It also communicates with and sends and receives signals from the Vapor Recovery system It also contains backup battery for maintaining programming in the RAM during power outages There is one CPU board per dispenser The CPU board is mounted vertically and has various cables and harnesses connected to it The CPU board receives dc voltages from the power distribution board on connector J7 The wiring harness is color coded and uses the following color scheme 1 Orange 24vdc Valve printer display and backlighting 2 Yellow 14vdc Battery charging circuit 3 Red 12 Product select Card reader Pulsers Handles and Solid State Relays 4 Black dcc Reference for all DC voltages 5 Violet 5vdc System logic v
101. ted LED D23 Pump Handle side 2 product B This LED is lit when the handle is hung up Unlit when the handle is lifted LED D24 not used Pump Handle side 2 product C This LED is lit when the handle is hung up Unlit when the handle is lifted LED D25 not used Pump Handle side 2 product D This LED is lit when the handle is hung up Unlit when the handle is lifted Figure 11 All handles hung up for both sides Side 2 Upper Side 1 Lower Figure 12 Side 2 handle A removed Extinguished G 11 Handle Switch Circuit 111661 Rev B 02 09 G 12 Notes 111661 Rev B 02 09 Secure PumpPAY Card Reader Assembly IMPORTANT NOTICE It is extremely important NOT to install any Secure PumpPAY Terminals positioned in a way that may be viewed copied or recorded by any devices such as a Security Camera installed at the location This section is intended for the technicians installing and or maintaining Secure PumpPAY units in the Pacific Dispenser This section describes how to integrate an Secure PumpPAY unit which is an EMV approved Chip amp PIN processing unit into a Pacific Dispenser The Secure PumpPAY unit offers Soft Keys Keypad Card Reader COM Ports LAN Communication Port and Battery the battery supplies power to the unit s tamper proof circuit SERIAL NUMBER Each Secure PumpPAY unit is supplied with a Serial Number This serial number is on the rear of the unit The Se
102. the battery kill reed switch This battery kill switch allows the technician to eliminate the 30 second wait if he has to service the equipment The battery itself is connected at the factory but requires several hours to charge This battery has nothing to do with maintaining system programming in the event of a power outage The Power distribution board has other functions as well This board houses four solid state relays that are used to route incoming power as Motor Out signals to turn on remote submerged pump relays These relays are controlled by 12 volt DC signals from the CPU board When the CPU board wants to turn on a submerged pump it sends a 12 volt dc signal to the proper relay pulling in the coil and routing the power to the proper terminal on the terminal strips located at the bottom of the Power Distribution Board When the CPU wants to turn Off a motor it removes the 12volt dc signal which opens that relay In the case of blended products more than one relay is activated at one time Dispenser communication with a Point of Sale and Card Reader communication is also routed through the power distribution board Dispenser communication comes in from the model 515 box to the power distribution board terminal strip TS5 This is the current loop communication signal that passes through the Power Distribution Board on connector J3 through a ribbon cable to the CPU board connector J8 Card reader communication also is routed through
103. tion hydraulics area low voltage section of the dispenser This ribbon cable connects to pulser connector J2 to the first pulser in the loop Usually this is the A product If there is more than one product pulser then another ribbon cable connects from the first pulser J3 back connector to the next pulser J2 front connector And it works like this for the remaining pulsers except for the last pulser for that side in the loop On the last pulser a jumper must be placed across the last set of pins on J3 to identify that pulser as the last pulser in the loop See figure on previous page J1 Pulser Connection Not Used J2 Connector 14 Pin ribbon cable connection This ribbon cable contains 5 Vdc power and communication signals for up to four dual phase pulsers Pin Signal Direction AWG amp Color Pin 1 5 Vdc In Ribbon Cable Pin 2 5 Vdc In Pin 3 Gnd In Pin 4 Gnd In Pin 5 Pulser A phase 1 Bi Directional Pin 6 Pulser A phase 2 Bi Directional Pin 7 Pulser B phase 1 Bi Directional Pin 8 Pulser B phase 2 Bi Directional Pin 9 Pulser C phase 1 Bi Directional Pin 10 Pulser C phase 2 Bi Directional Pin 11 Pulser D phase 1 Bi Directional Pin 12 Pulser D phase 2 Bi Directional Pin 13 Connection Verification Bi Directional Pin 14 Connection Verification Bi Directional J3 Connector 14 Pin ribbon cable connection to the next pulser J2 connector Pin Signal Directi
104. using electrical capacitance In other words when the customer places their finger within proximity of a pad the electrical capacitance of the pad circuit changes and the system recognizes this as a key press There are no moving parts on this keypad so it doesn t suffer so much from wear and tear The system can be programmed to give a beep when any key is pressed The keys are not programmable This board is also used to route data for the Main Display J6 and to the Auxiliary PPG Display J7 The data for the electromechanical totalizers are also routed through this board J5 The electromechanical totalizer is a mechanical counter that tracks meter totals mechanically and in a Non Re settable grand total fashion There is one Product Select Auxiliary Display Backlight Board per side they are identical and interchangeable This board is where you plug the Manager s Keypad for programming the dispenser J4 D 1 Product Select Auxiliary Display Board 111661 Rev B 02 09 on CPU Board on CPU Board 110185 110792 D 2 Product Select Auxiliary Display Board 111661 Rev B 02 09 How to Prepare the dispenser for Programming Programming of the dispenser is easy with the use of the Manager Keypad One Managers keypad is shipped with each Pacific dispenser along with a ribbon cable After use it is recommended that the managers keypad and cable be stored back inside the electronics head for the next person t
105. w approximately 75 Volts AC then the Power Fail circuit takes over and the backlight board is turned off There is also a diffuser plastic piece mounted in between the display and the backlight board A series of studs holds the boards in place Description of Controls There are no controls on this board LED s Numerous LED s are on this board but they serve no function other than as a light source Test Points There are no test points on this board Terminal Strips Connectors and Pinouts The following is a description of the connections to the terminal strips and pinouts of all the connections on the display board J1 Power to the Backlight Board PD 1 24Vdc PD 2 Ground F 1 Backlight Board 111661 Rev B 02 09 F 2 Notes 111661 Rev B 02 09 Intrinsically Safe Barrier ISB Board Assembly Part Number 105660 Provides an intrinsically safe barrier between the CPU and the Pump Handles and the Pulsers Contains fuses and zener diodes that Short any high voltages and electrical current away from the handles and pulsers in the hydraulic area of the pump Routes handle and pulser signals to the CPU board There is one Barrier Module for side 1 and 1 for side 2 They are identical interchangeable and have the same part numbers WARNING The Intrinsically Safe Barrier module has special fuses that are soldered onto the board and CANNOT BE REPLACED in the field If a barrier board has blown a fus
106. witch is set for Wayne Check to ensure there is power at the Dispenser and that each Secure PumpPAY is lit Check to ensure there are no error messages appearing on the Secure PumpPAY devices The Secure PumpPAY will work with credit cards but not with debit Check the Secure PumpPAY configuration to ensure Debit was selected The Secure PumpPAY displays please pay inside E01 The DCR Secure PumpPAY is not loading properly Check the following Run the Debit Encryption test in diagnostics mode on the Secure PumpPAY Check the POS Controller to ensure the correct parameters were set up for Debit and Dukpt The Secure PumpPAY displays loading messages containing a lot of strange characters This is caused by a DCR assignment error The DCR assignment has been duplicated You will need to determine which DCR assignment was duplicated correctly configure on the units and then reboot both units Com 9 on the POS Controller is securely seated for DCRs If it is more than one DCR reboot the POS Controller Change out the VIB2 and or the Secure PumpPAY unit Check the DCR parameters to ensure the unit s were set up correctly Check the Power Distribution Board communication wiring for TS3 The wires must be in the correct terminals and securely fastened Go into the DCR parameters change a parameter on one of the Secure PumpPAY units that is displaying the E01 error save the change then go back int
107. y the CPU Product Select Keypad to turn on dispenser buttons to read totals Normal reading is 5volts d c Pin 4 RS485 Common Card Reader communication with console common Pin 5 Power Fail Signal from power distribution board indicating loss of power or less than 75 volts A C Normal reading is 5 volts d c Pin 6 RS485 Card Reader communication with console Pin 7 Ground Pin 8 Ground Pin 9 Motor A Motor relay control signal 12vdc represents motor on Ovdc represents motor off Pin 10 Current Loop side 2 Fuel channel communication with the 515 interface box Pin 11 Motor B Motor relay control signal 12vdc represents motor on Ovdc represents motor off Pin 12 Current Loop side 2 Fuel channel communication with the 515 interface box Pin 13 Motor C Motor relay control signal 12vdc represents motor on Ovdc represents motor off Pin 14 Current Loop side 1 Fuel channel communication with the 515 interface box Pin 15 Motor C Motor relay control signal 12vdc represents motor on Ovdc represents motor off Pin 16 Current Loop side 1 Fuel channel communication with the 515 interface box B 10 Power Distribution Board 111661 Rev B 02 09 J5 Filtered A C 110 230 volts A C 50 60 cycle from power distribution board from Power distribution

Pacific Service Manual 111661

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