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Instructions

FLUID MANAGEMENT SYSTEMS

Used for bulk dispensing of petroleum and synthetic- based oils and antifreeze

to multiple service bays.

NOTE:

These instructions are for software version 1.05

308607J

Summary of Contents for Horizon Fluid Management Systems

Page 1: ...ructions in this manual Save these instructions Instructions FLUID MANAGEMENT SYSTEMS Used for bulk dispensing of petroleum and synthetic based oils and antifreeze to multiple service bays NOTE These...

Page 2: ...instructions for individual options begins on page 29 with Time and Date Setup Clear Setup Options 23 Print Setup Options 24 Update Tables Options 25 Diagnostics 26 ABOUT Screen 26 POWER UP Screen 26...

Page 3: ...83 System Configuration Examples 84 Horizon Forms 85 Examples 86 Blank Forms 97 System Dynamics And Design Factors 104 Pressure Relief Kit 104 Ability to Dispense Fluid During System Failure 104 Avoid...

Page 4: ...D Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in serious injury D This equipment is for professional use only D Read all instruction manuals tags a...

Page 5: ...MAT RIEL Toute mauvaise utilisation de l quipement peut occasionner la rupture un dysfonctionnement ou un d marrage inopin et provoquer des blessures graves D Ce mat riel est destin un usage uniquemen...

Page 6: ...he system prior to ordering it If this information cannot be located recreate it from the packing slip that came with the system Packing slip and Appendix pages 81 106 2 Verify that all the parts on t...

Page 7: ...lation Forms The completed forms will ease system setup by placing the information in the order the software will request the input To ease software setup keep the items in numerical order Pre instal...

Page 8: ...oor plan and page 13 Cable Routing and Connection n Installation Steps Reference 6 Route and connect the AC power to each control module Do not turn on the power yet Floor plan and page 14 7 Route the...

Page 9: ...Setup Page 23 18 Using the administrative keypad connected to the Master Control Module complete the System Setup Use the six forms that were filled out in the Pre installation Procedure refer to ste...

Page 10: ...intended for If the DIP switches are not set to the correct address the control module will not receive its information If two control modules have the same address both of them will receive the infor...

Page 11: ...30 ON ON ON ON ON OFF 31 OFF OFF OFF OFF OFF ON 32 ON OFF OFF OFF OFF ON 33 OFF ON OFF OFF OFF ON 34 ON ON OFF OFF OFF ON 35 OFF OFF ON OFF OFF ON 36 ON OFF ON OFF OFF ON 37 OFF ON ON OFF OFF ON 38 ON...

Page 12: ...308607 Fig 2 06652 110 VAC Connection 220 VAC Connection transformer wire nut 06897 transformer Wire Connector Color 1 black 2 white 5 black 6 white Wire Connector Color 1 black 2 white 5 black 6 whi...

Page 13: ...directed in the floor plan being sure to follow the cable length and other configuration requirements D The mounting surface must be able to support the weight of the control module 14 lbs 6 3 kg Use...

Page 14: ...up continuously during normal operation To ease system maintenance install a switch for turning off the power at each control module Locate the switches near each control module but out of reach from...

Page 15: ...Light Kit 238996 NOTE If existing Ready Light is used the bulb and lens must be replaced with bulb P N 113859 and lens 113857 Fluid Solenoid P N 218588 includes Ready Light 215487 or 512927 Air Solen...

Page 16: ...ry for the control modules to be able to com municate properly with each other across the network D Connect the control module s in the middle of the network chain as shown in Fig 10 with the termi na...

Page 17: ...e bottom of the printer as shown in Fig 12 Route and connect the printer cable between the printer and the Master Control Module connectors Use the printer cables shown in Fig 12 Computer Route and co...

Page 18: ...ings for Old Style Printer 113774 Printer serial port Printer cable with connector P N 191395 25 ft 7 6 m or 191396 50 ft 15 3 m Fig 12 green white red ground receive transmit ground receive transmit...

Page 19: ...his is the HOME screen It is the destination any time the HOME button on the keypad is pressed 1 Cursor is initially on RUN 2 Move the cursor to SETUP by pressing the or key NOTE The SETUP option can...

Page 20: ...ely new setup See page 22 CLEAR SETUP to clear particular setup options Choose CLEAR SETUP if this is the initial setup of a new system See page 23 PRINT SETUP to print out selected information about...

Page 21: ...E CAN Change to DISABLE CAN if the system has only one control module or if programming the Master Control Module off the customer site 4 Press ENTER on the keypad when the cursor is at the desired op...

Page 22: ...bration D Inventory D Comm on CM 1 D Run options D System time outs On Master Control Module only _ _ _ _ _ _ _ _ _ _ SETUP A_ _ _ _ _ _ _ _ _ _ ENABLE DISABLE CAN MODIFY SETUP NEW SETUP MODIFY SETUP...

Page 23: ...hen the cursor is at the desired option 6 The CLEAR verification screen will appear with the cursor on NO If ENTER is pressed with NO se lected the screen will return to CLEAR OPTIONS screen 7 Scroll...

Page 24: ...ppear Press any key to exit after DONE appears on the screen 6 Press BACK key to return to SETUP screen The information that can be printed in PRINT SETUP include D All memory D Operator pass words D...

Page 25: ...return to UPDATE TABLES screen 7 Scroll to YES by pressing the or key 8 Press ENTER on the keypad The selected table will be cleared and the UPDATING screen will appear Press any key to return to the...

Page 26: ...AUTION When activating solenoids fluid may be dispensed You are only testing the solenoids that are con nected to the control module the keypad is con nected to LO indicates the solenoid is off To tur...

Page 27: ...are using right now ADMIN ENHANCED or BASIC are the two choices 11 The DIP SWITCHES screen shows the dip switch setting for the control module the keypad is con nected to CM ID 1 in the screen exampl...

Page 28: ...odule and can be used to test the printer or computer connection A confirmation screen will appear If YES is selected the transac tion table fills with test data which prints out in computer or printe...

Page 29: ...eld type in four letters and or numbers for the operator s password 4 Press ENTER on the keypad 5 With the cursor in the ACCESS field scroll to the correct access level using the or key RUN SETUP or I...

Page 30: ...rification screen will appear with the cursor on NO D If modifying the setup pressing ENTER with NO selected will return to the SETUP OP TIONS screen without saving D If entering a new setup pressing...

Page 31: ...odules 1 Cursor is in the CM field 2 The control module number will automatically increment up by 1 as you add modules or you can type the number identification NOTE The control module number must cor...

Page 32: ...DER number field The order number determines the order that fluids are dis played during RUN operations The default setting is to display the fluids in the order of the fluid numbers 11 Type in the or...

Page 33: ...ere entered 8 Leave the N if fluid 1 is not available at this dis pense area Scroll to Y by pressing the or key if the fluid is available at this dispense area 9 Press ENTER on the keypad to ENTER the...

Page 34: ...ress ENTER on the keypad 14 Cursor moves to the MTR field 15 Type the number of the meter for this dispense point Assign the meters consecutive numbers starting with number 1 The meters you enter will...

Page 35: ...for the calibration factor D P N 238618 Oil Meter has a nominal calibra tion factor of 200 pulses per quart 211 pulses per liter D P N 215474 Meter for antifreeze and washer fluid has a nominal factor...

Page 36: ...he ENABLE DISABLE field DISABLE is the default setting Press the or key to scroll to ENABLE 2 Press ENTER to confirm the setting and go to the next screen 3 Cursor is in the fluid number FL 01 field 4...

Page 37: ...put is formatted in a column that can be sent to either a printer or a computer COMPUTER output is a text file that can be used to create reports with a computer and additional software such as Excelr...

Page 38: ...ssword press ENTER with the cursor on NO 5 Continue to set either YES or NO in the JOB NUMBER VEHICLE ID REQUEST PRESET AND CUSTOM INPUT fields 6 If YES is selected for CUSTOM INPUT the cursor will mo...

Page 39: ...ENTER TO CONT Dispense Time out NOTE Dispense time out cannot be set to zero it is always enabled The time out that is set will apply to the entire system Dispense time out provides a way to close a j...

Page 40: ...40 308607 Printer and Computer Output Printer Output Format as Viewed on a Computer Screen Job Report Inventory Report...

Page 41: ...reens provide you with the layout of the text file Horizon produces The user will need to have the expertise to use it with existing soft ware or consult with a vendor to modify their software to use...

Page 42: ...42 308607 Inventory Report Checksum computer can use to validate transmission Units for Inventory gallons or liters Amount currently in tank Fluid number I indicates an inventory report...

Page 43: ...time the terminal program is started up 1 Open Accessories in your Program Manager 2 Open Terminal 3 Pull down the Settings menu and select Commu nications 4 Set as shown below Baud Rate 9600 Data Bi...

Page 44: ...nsfers menu and select Receive Text File 2 Type in the desired File Name 3 Make sure the Save Files of Type is set to Text Files TXT 4 Select the desired Drive and Directory where you want the Horizon...

Page 45: ...Horizon Data 3 Enter a Name select an Icon and select OK 4 A screen for the HyperTerminal you just created will appear It will take you through each setup screen 5 Pull down the menu for Connect usin...

Page 46: ...trol None then select OK 7 Pull down the terminal File menu and select Save As 8 Type in the desired File Name example HORIZON TRM 9 Make sure the Save Files of Type is set to Termi nal Files TRM 10 S...

Page 47: ...T If the job records are not saved they will scroll off the terminal program screen and the information will be lost 1 When you want to save data from the Horizon system to the computer disk pull down...

Page 48: ...pad HOME Screen _ _ _ _ _ _ _ _ _ _ HOME A_ _ _ _ _ _ _ _ _ _ RUN SETUP INVNT 2 Enter Password The password is optional and is determined by what is entered during setup Get your password from your sy...

Page 49: ...s to the VEHICLE ID field f Type the vehicle ID number g Press ENTER on the keypad h Cursor moves to the custom input field In this example MILES has been entered during set up to record the odometer...

Page 50: ...displayed after the fluid number b Display the fluid to be dispensed either by en tering the fluid number or by pressing the or key to scroll through the options c Press ENTER on the keypad to select...

Page 51: ...preset amount when using free flow dispense the job will remain open until the set time out period is reached a The PRESET AMOUNT field appears with the cursor on YES a Press the or key to scroll to...

Page 52: ...TED STATUS WAITING means that there is a utilization conflict which has placed the job in the waiting queue The job will start as soon as the conflict is elimi nated ENTRY REJECTED STATUS SYSTEM FULL...

Page 53: ...r the operator activates the dispense device The job will end when the preset time out period is reached see page 39 e After the job ends it will be reported on the printer or computer if the system i...

Page 54: ...from the active queue and will not appear on the screen D 12 01 in line one of the Active Job is the time the job was entered JOE is the identification of the operator D The second line shows the req...

Page 55: ...ppears with the cursor in the DATE field b Type in the date you want the report to start with c Press ENTER on the keypad The cursor will move to the TIME field d Type in the time you want the report...

Page 56: ...on the keypad b Press ENTER on the keypad HOME Screen _ _ _ _ _ _ _ _ _ _ HOME A_ _ _ _ _ _ _ _ _ _ RUN SETUP INVNT 2 Enter Password NOTE Inventory mode cannot be accessed without a password Get your...

Page 57: ...nge to YES if you are adding fluid to your tanks Press ENTER and an amount field will appear Follow the instructions in step 3 below D Entering NO will move the cursor to MORE Follow the instructions...

Page 58: ...and second HH MM DD and the month day and year MM DD YY when the level was reset Note that the Horizon has a 24 hour clock d Entering NO will move the cursor to MORE Follow the instructions in step 4...

Page 59: ...b Wait for the PRINT INVENTORY FINISHED screen before pressing another key NOTE The length of time it takes to print is dependant on how many fluids are being con figured on the system c The printout...

Page 60: ...l return you to the INVENTORY screen without saving 2 Scroll to YES by pressing the or key 3 Press ENTER on the keypad to save the inventory option 4 A screen will appear to notify you that your save...

Page 61: ...ly confusing information System Components and Installation Overview Control Module Check each control module prior to mounting it on the wall 1 Modify a power cord so it has a plug on one end and str...

Page 62: ...r data entries will be preserved However the rest of the network will clear and be ready to receive the system map from the Master Control Module 3 Use the password 1111 to enter Setup Move the cursor...

Page 63: ...ssful and should be done again a Check the condition of the CAN cable and ensure that the CAN is enabled on all the control module See page 64 Problem Net work communication is not operating pro perly...

Page 64: ...ns on the solenoids attached to that Control Module With the solenoids on verify the wiring to the solenoids and ready lights flush out the plumbing lines and allow fluid to flow to check the meter pu...

Page 65: ...ers under DIAGNOSTICS refer to the ports the meters are attached to on that control module 7 12 not to meter numbers assigned in the programming steps k Make sure that the pulses are showing up at the...

Page 66: ...f the dispense point hardware typically a ball valve or check valve and check each component to deter mine where the problem is 2 A different ready light comes on than the one expected and fluid flows...

Page 67: ...ew jobs This is indicated by a mes sage stating SYSTEM FULL This situation is related to problem 5 Use the RUN VIEW CURRENT JOBS screen see page 54 to check if there are a number of jobs in the active...

Page 68: ...luid level 3 Use Diagnostics Solenoids to turn on the appropriate air solenoid if there is no air check wiring and replace solenoid if needed 4 Repeat step 3 above for the appropriate fluid solenoid 5...

Page 69: ...sconnect the cable from the pulse meter taking note of the wiring polarity 3 Remove the old pulse meter and install the new one following the original wiring polarity To Replace the Electronic Pulse M...

Page 70: ...ly closed but foreign matter could hold the valve open preventing it from stopping the fluid flow Clean the valve as instructed below 1 Follow the Shutdown Procedure on page 69 Be sure to open the dis...

Page 71: ...ft cloth and wipe the keypad clean Do not allow the cleaner or any other fluid to get under the front panel To Install New Software 1 Turn off the electrical power to the Horizon system 2 Remove the c...

Page 72: ...oller Area Network which is the network that interconnects the control modules in a larger system D It provides the printer and or computer interface D It continuously tracks the time and date Control...

Page 73: ...re turned on 5 Solenoid Cable Connectors Use to connect solenoid cable wires to the control module 6 Power Supply Converts AC input power for use by control module 7 Power Supply Connector Connects in...

Page 74: ...on that requires the entry of letters cannot be input with this keypad Operator PIN personal identification number numbers must contain only numbers If the operator is required to input data to the Jo...

Page 75: ...asional system configuration changes Another option is for the distributor or installer to keep this keypad to maintain multiple installations Administrative Keypad 06520 Keypad Specifications D There...

Page 76: ...Eaglet and Fire Ballr Part No 512926 Air Solenoid Valve High Flow For higher flow pump models such as the Presidentr Technical Data Category Data Type 3 way solenoid operated air valve normally close...

Page 77: ...ure proper reading of the pulses During the setup of the Horizon software each pulse meter is defined including the number of pulses per unit of fluid This pulse constant can be input for differ ent u...

Page 78: ...to control modules They are available in 25 and 50 ft 7 6 and 15 3 m lengths with 9 pin RS 232 connectors Keypads can be no further than 50 ft 15 3 m from the control module Computer Cables with conn...

Page 79: ...ch is available in bulk spools of 500 or 1000 ft 152 5 or 305 m There is no distance requirement between control modules pro vided the overall length of the network is not greater than 2000 ft 610 m 0...

Page 80: ...40 Column Thermal Printer Part No 113774 Thermal Printer Order power supply and paper separately See below Part No 514037 Printer Paper Printer Replacement Paper 1 roll Printer Power Supply Part No De...

Page 81: ...308607 81 Appendix...

Page 82: ...the Administrators Keypad in order to use the setup and diagnostic screens Fluid Supply Monitoring The Inventory setup allows the user to monitor the level of each tank on the system A level can be se...

Page 83: ...floor plan will be used to position Horizon components many of which are sensitive to cable lengths NOTE See the Technical Data on page 107 for the system specifications 3 Place the fluid system compo...

Page 84: ...mensions of the facility are too large the 50 ft 15 3 m maxi mum for cables may require the installation of addition al control modules Example 1 Parts List Qty Component 1 Master Control Module 1 Sla...

Page 85: ...noids and 9 meters could be handled by 2 control modules 6 ports on each for solenoids and six ports on each for me ters but each control module has only one port for attaching a keypad Example 2 Part...

Page 86: ...ss Level ACCESS LEVEL check one Name on System PIN Number Run Run Invt User Name 4 characters max 4 characters max Run Inventory Setup John Doe J O H N 1 2 3 4 X Bob Smith B O B S 3 3 3 3 X Tim Willia...

Page 87: ...cess to run level and SETUP which gives access to all levels Press the ENTER key when the proper access level is displayed 4 After entering the access level the cursor will move to ADD on the bottom l...

Page 88: ...cation 10 Characters max Master Near Office Pumps 1 O F F I C E At Service Bay 1 2 B A Y 1 At Service Bay 2 3 B A Y 2 At Service Bay 3 4 B A Y 3 5 6 7 8 9 10 11 12 13 14 15 16 17 Fluid Fluid Name in S...

Page 89: ...a 1 The cursor will be in the fluid number FL01 field The fluid number will automatically increment up by 1 as you add fluids or you can type the number manually 2 Press ENTER on the keypad to move th...

Page 90: ...i A N N b Dispense Area Names Numbers DA Dispense Area Name in Software Map Dispense Area Location 10 Characters max Service Bay 1 1 B A Y 1 Service Bay 2 2 B A Y 2 Service Bay 3 3 B A Y 3 4 5 6 7 8 9...

Page 91: ...e in the FLUID DATA screens 5 Leave the N if fluid 1 is not available at this dis pense area Scroll to Y by pressing the or key if the fluid is available at this dispense area 6 Press ENTER on the key...

Page 92: ...id Solenoid CM3 1 CM3 2 CM3 3 Meter Number 4 5 6 Air Solenoid CM1 1 CM1 2 CM1 3 3 Bay 3 Fluid Solenoid CM4 1 CM4 2 CM4 3 Meter Number 7 8 9 Air Solenoid 4 Fluid Solenoid Meter Number Air Solenoid 5 Fl...

Page 93: ...In this exam ple the entry would be PORT1 taken from CM2 1 on Form 4 10 Type the port number and press ENTER on the keypad 11 Cursor moves to the Meter Number MTR field 12 Type the number of the mete...

Page 94: ...30 Oil 3 7 200 QT 5 Bay 2 10 30 Oil 3 8 200 QT 6 Bay 2 ATF 3 9 100 PT 7 Bay 3 5 30 Oil 4 7 200 QT 8 Bay 3 10 30 Oil 4 8 200 QT 9 Bay 3 ATF 4 9 100 PT 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...

Page 95: ...on at 100 pulses per pint 200 pulses per quart 800 pulses per gallon or 211 pulses per liter D If using P N 215474 Meter for antifreeze and washer fluid set calibration at 5 pulses per pint 10 pulses...

Page 96: ...1 Y 3 Y 1 Y 0 N 3 Y 3 Y 9 Y 9 Y 0 N 4 System Software Identification Checkout check if when completed Run Options Configured Passwords Yes Job Yes Vehicle ID Yes Optional Field Yes Miles Presets Yes...

Page 97: ...308607 97 Blank Forms...

Page 98: ...7 Horizon Form 1 Graco Inc Horizon t Horizon User Name PIN Number and Access Level ACCESS LEVEL check one Name on System PIN Number Run Run Invt User Name 4 characters max 4 characters max Run Invento...

Page 99: ...on C l M d l Fl id N N b Control Module Fluid Names Numbers CM CM Name in Software Map Control Module Location 10 Characters max 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Fluid Fluid Name in Software...

Page 100: ...Inc Graco Inc Horizon t Horizon Di A N N b Dispense Area Names Numbers DA Dispense Area Name in Software Map Dispense Area Location 10 Characters max 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2...

Page 101: ...Meter Number Air Solenoid 3 Fluid Solenoid Meter Number Air Solenoid 4 Fluid Solenoid Meter Number Air Solenoid 5 Fluid Solenoid D Meter Number I 6 Air Solenoid S 6 Fluid Solenoid P Meter Number E Ai...

Page 102: ...zon Form 5 Graco Inc Horizon t Horizon Meter Calibration Chart No Location Fluid CM Port Pulses Per Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35...

Page 103: ...fied 4 System Software Identification Checkout check if when completed Run Options Configured Passwords Job Vehicle ID Optional Field Presets Output Options Configured Printer Computer 5 Attachments M...

Page 104: ...ypass near the fluid solenoid B If the control module that drives that fluid solenoid fails or the power fails in that area of the shop the bypass can be used to keep fluid available Fluid cannot be d...

Page 105: ...izon system Cap the connector that is not being used D In some cases such as in mining applications a design may be required that allows fluid to be dis pensed regardless of the state of operation of...

Page 106: ...erators open and close their valves and the pump operates As this fluid moves back and forth through the pulse meter G the meter generates pulses which the system interprets as actual dispensing Check...

Page 107: ...Solenoid Ports per Control Module 6 Pulse Meter Ports per Control Module 1 Port for Keypad per Control Module 1 Port for printer or computer per Master Control Module 1 Bar code reader per control mo...

Page 108: ...ot limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of war...

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