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Page 3

Table of Contents

Cover

..........................................................1

General Safety Information............................................2

Table of Contents ..........................................................3

Overview

..........................................................4

Purpose of equipment ............................................4

Limits of intended use ............................................4

Specifi cations

.......................................................5-7

System

Specifi cations ............................................5

Compatible

Fluids...................................................5

Component

Descriptions

.....................................6-7

Confi guration Planning

..........................................8-11

Planning Worksheet & Instructions .....................8-9

Planning Worksheet: Worked Examples .........10-11

Installation

...................................................12-23

Required tools

....................................................12

Installation 41-Step Procedure

.....................12-15

Mechanical Detail Illustrations .........................16-17

Pump/meter

Installation

(fi g 20) ....................16

Smart

Controller

Installation (fi g 21) ..........16

Hose Reel/Ready Light mount (fi g 22) ..........17

Fluid Valve Installation (fi g 23) ......................17

Wiring

Illustrations

...........................................18-23

Complete

System

(fi g 24)..............................18

Console

(fi g 25) .............................................19

Smart

Controller

(fi g 26) .............................20

Wire End Detail (fi g 27) .................................21

Valves and Ready Lights (fi g 28,29) .............21

Ground Level Set-up (fi g 30) .........................22

Impulse

Meter

(fi g 31) ...................................23

Basic Operating Procedures (BP)

.......................24-35

Overview of PIN codes .........................................24

Guide to Basic Procedures...................................25

Special Methods and Suggestions .......................26

BP1:

Normal Power Up ........................................27

BP2:

New Dispense Job ......................................28

BP3:

Job Status Review ......................................29

BP4:

Queue Jumping ...........................................30

BP5:

Job Deletion ................................................31

BP6:

Tank Refi lling ...............................................32

BP7:

Inventory Status ..........................................33

BP8:

Dispense Log ..............................................34

BP9:

PIN entry/revision ........................................35

Special Console Procedures (SP)

.......................36-46

SP1:

Console Initialization ...................................36

SP2:

Fluid Identifi cation ..................................37-38

SP3:

SC Identifi cation .....................................39-40

SP4:

Comm Port Selection ..................................41

SP5:

Set Time/Date..............................................42

SP6:

System Confi guration [save/read] ..............43

SP7:

System Log .................................................44

SP8:

Test All SC’s ................................................45

SP9:

SC Comm Test ............................................46

Problem Diagnostics and Correction

.................47-56

Guide to Diagnostics

.........................................47

Error Diagnosis / Action Tables

...................48-56

Repair Procedures (RP)

.......................................57-65

RP1:

Replacing Console ......................................57

RP2:

Replacing Impulse Meter ............................57

RP3:

Replacing Air or Fluid Valve ........................58

RP4:

Replace Ready Light ...................................58

RP5:

Replace Smart Controller ............................59

RP6:

Replace Ticket Printer .................................59

RP7:

Add One or More Stations ...........................59

RP8:

Add Another Fluid to System .......................60

RP9:

Verifi cation of Comm/Power Wiring.............61

RP10:

Verifi cation of Valve Port Wiring ................61

RP11:

Verifi cation of Inactive Port Setup .............62

RP12:

Troubleshooting SC Problems ..................62

RP13:

Ground Level SC Identifi cation .................63

RP14:

Setting up for Future Expansion................63

RP15:

System Restore from Error .......................64

RP16:

Troubleshooting SC Magnetic Polling .......64

RP17:

Troubleshooting Oil Quantity Errors ..........65

RP18:

Assuring a Suitable Power Supply ............65

Cable Substitutions......................................................66

PIN Code Record Form ...............................................67

Warranty

........................................................68

Содержание Spectrum 100 3110-006P

Страница 1: ...nsoleTM Model 3120 030 Smart ControllerTM Model 3120 031 Ready Light Model 3120 032 Fluid Solenoid Valve Model 3120 033 Air Solenoid Valve Model 3120 036 Power Adapter Operation Installation Maintenan...

Страница 2: ...configuration 3 Relieve pressures built up in the system before any service or repair is begun See pressure relief procedure this page 4 Never alter or modify any parts of this product doing so may c...

Страница 3: ...g 30 BP5 Job Deletion 31 BP6 Tank Refilling 32 BP7 Inventory Status 33 BP8 Dispense Log 34 BP9 PIN entry revision 35 Special Console Procedures SP 36 46 SP1 Console Initialization 36 SP2 Fluid Identif...

Страница 4: ...wer from sources with surge protection and ground fault interrupt protection To secure fluid inventory against theft or misuse use the PIN code protection system provided in SpectrumTM software Specif...

Страница 5: ...adding machine paper tape rolls The printer is capable of printing a record of each dispense job and associated data as well as daily and monthly historic dispense log reports Specifications Product S...

Страница 6: ...ports Solenoid is rated for 24 VDC service Order one per dispense point Figure 8 Model 3120 033 Air Solenoid Valve Valve Dimensions 1 3 4 x 2 x 4 1 2 Rated 200 psi working pressure For on off control...

Страница 7: ...ady Light Mounts directly in 500 diameter hole now provided on all Bal crank hose reels Bright green LED lamp Operates on 24 VDC Order one per fluid solenoid valve Figure 16 Models 3121 xxx Cable Comm...

Страница 8: ...a ticket printer If a quick lube bay is to be used identify the designated quick lube bay 14 All systems are factory pre programmed and will be shipped with a copy of your completed planning sheet wit...

Страница 9: ...00TM Configuration Planning Sheet User User City State Balcrank Distributor Distributor PO No F5192 Rev A 7 04 for factory entry only 3 4 Pump Room Parts Counter SC 00 Air Balcrank Sales Order No Pre...

Страница 10: ...1 2 SC00 Air Service Area Blocks Fluid Type Fluid Type Balcrank Spectrum 100TM Configuration Planning Sheet User User City State Balcrank Distributor Distributor PO No for factory entry only 3 4 Pump...

Страница 11: ...7 04 for factory entry only 3 4 Pump Room Parts Counter SC 00 Air Texas Pump Service Austin TX Car City 81339 10 W 30 522 500 100 417 ATF 518 275 80 210 Balcrank Sales Order No Pre programming Date C...

Страница 12: ...toff valves pressure relief kits pump outlet shutoff valves and suction air eliminators See PUMP INSTALLATION DIAGRAM Figure 20 page 16 4Install in line Impulse Meters model 3120 103 at each pump as f...

Страница 13: ...the terminal plugs using the jeweler s screwdriver Refer to WIRING DETAIL SMART CONTROLLERS Figure 26 page 20 1 3 At the parts counter strip ends of the Comm Power Cable model 3121 xxx from the pump...

Страница 14: ...21 Refer also to WIRING DETAIL SMART CONTROLLERS Figure 26 page 20 Attach wires at the valve end using crimp connectors or screw caps Be sure to include Ready Light wires in the valve end connections...

Страница 15: ...ner Authorize and dispense 1 0 gallons of fluid 1 using the procedure NEW DISPENSE JOB Procedure BP2 page 28 Observe for correct operation of the Ready Light Check to be sure the correct fluid is disp...

Страница 16: ...103 Electronic Impulse Meter Pressure Relief Kit See page 6 for selection 1 2 NPS fluid line and fittings Model 3120 003 Air Line Hand Shutoff Valve Fluid Line Hand Shut off Valve and outlet check va...

Страница 17: ...ight presses into 0 500 dia hole located as shown Note Ready light and solenoid valve wiring secured to the reel with cable ties Premium Reels Fluid Solenoid Valve connects to hose reel swivel using 1...

Страница 18: ...on 3123 xxx Solenoid Cable 12 Sections 3120 034 Digital Impulse Meter 3 Req d 3110 006 Queuing Console 1 Req d 3121 xxx Power Signal Cable 4 Sections 3120 030 Smart Controller 4 Req d Illustrations Sy...

Страница 19: ...Model 3121 xxx to SC 00 Smart Controller Air Power Signal Cable Model 3121 xxx to SC 01 Smart Controller Station 1 Impulse Meter Cable Model 3122 xxx to Impulse Meters M M M M M M M M C C P P S C C P...

Страница 20: ...xxx to next Smart Controller PORT 1 PORT 2 PORT 3 PORT 4 IN OUT Smart Controller Model 3120 030 Power Power BLUE WHITE WHITE BLUE BARE WIRE WHITE BLACK S S BLUE WHITE WHITE BLUE BARE WIRE WHITE BLACK...

Страница 21: ...033 Trim insulation on individual wires to this distance Trim cable cover to here If shielded remove excess metal cloth from the cable shield but leave bare shield wire intact Trim back unused wires...

Страница 22: ...installed at fluid ports Port to Port On each output port Fluid Smart Controller Attach controllers one at a time initialize them affix an I D label then replace with the next controller and repeat th...

Страница 23: ...wn meter wire to colored cable wire Fluid 1 red Fluid 2 white Fluid 3 green Fluid 4 blue Close up view Digital Impulse Meter Model 3120 103 Two wires from Impulse Meter Cable One to Two Impulse Meters...

Страница 24: ...h job transaction data and printed on job ticket reports Configuration Level 3 Maximum Protection Uniform Authority Level System PIN protection barriers and PIN entry steps are used for Conditions A B...

Страница 25: ...time the status of all authorized undispensed jobs may be reviewed Press the STATUS key to access the job summary quick view screens which are organized by fluid type Right scroll to see jobs in queu...

Страница 26: ...until all dispense jobs are completed or discontinued using the procedure JOB DELETION Procedure BP5 page 31 6 Turn OFF console power at night Turning off the console at the end of a workday assures t...

Страница 27: ...ole is now ready for dispense operations SPECTRUM 100 IDLE PIN 9000 2 If you have set up PIN code security in the system the display will prompt for a PIN number before continuing immedi ately after p...

Страница 28: ...fter selection the fluid type such as 5W20 will appear on line 2 You can still edit the selection by pressing another fluid key Or press ENTER to continue 5 The prompt will ask for a fluid batch amoun...

Страница 29: ...BE CAREFUL Do NOT press ENTER while reviewing job screens 4 If you scroll left instead of right from Q0 the display will allow review of job his tory data completed jobs designated by the label P xx...

Страница 30: ...BUSY display DO NOT press ENTER if you wish to escape from the queue jump subroutine 1 Begin with the program at home posi tion SPECTRUM 100 BUSY or IDLE Press the STATUS key to begin the queue jump p...

Страница 31: ...Then press ENTER to continue 3 The next display shows status details for dispense jobs The first line shows the fluid type and job number The second line shows a queue indicator Q01234 in which the hi...

Страница 32: ...5W20 ENTER AMOUNT BEING ADDED 0050 GA ENTER EDIT VALUE ADD 0050 GA TO 5W20 YES no ENTER SCROLL YES NO AMT IN TANK IS 0537 GA STICK TANK TO VERIFY ENTER SCROLL TANK REFILL SET UP INVENTORY STATUS DISPE...

Страница 33: ...100 IDLE 3 The display will then prompt INVEN TORY STATUS FLUID Select the fluid to be checked by using one of the four fluid selector keys on the console After selection the fluid type such as 5W20...

Страница 34: ...ENSE LOG FLUID Select the fluid to be checked by using one of the four fluid selec tor keys on the console After selection the fluid type such as 5W20 will appear on line 2 You can still edit the sele...

Страница 35: ...lect PIN then press ENTER 4 The next prompt will ask you to select a PIN protection configuration Scroll to select configuration 1 2 3 or 4 Then press ENTER to make the selection Refer to page 24 for...

Страница 36: ...l change to CLEAR ALL PARAMETERS YES Press ENTER to continue 5 The display will change to INITIALIZED on the first line Cycle the power switch OFF and then ON 7 On restoring power the system will dis...

Страница 37: ...fluids to be used Use number keys to place or edit the correct numerical value which corresponds to the number of Spec trum impulse meters to be used in the pump room then press ENTER to continue 6 Ne...

Страница 38: ...ed unit of measure for the selected fluid SCROLL to high light the correct choice pint quart liter gallon Then press ENTER to continue 10Next enter the fluid capacity in gallons or liters of the tank...

Страница 39: ...number by text editing the number on line 2 This should be 00 for a new system and 00 must be the SC used for the air solenoids Then press ENTER to continue 5 Next identify the final fluid controller...

Страница 40: ...ication is success fully made the second line of the display will read SC00 SC INITIALIZED for 3 seconds Then the program will move to the next bay number and will repeat the magnetic identifi cation...

Страница 41: ...y SCROLL to highlight SET UP then press ENTER 3 The next prompt will ask you to select a type of set up activity SCROLL to high light COMM PORT SELECT then press ENTER 4 The display will then show two...

Страница 42: ...0 IDLE Press the three key simultaneous entry for management rou tines NEW ENTER STATUS 2 The next prompt will ask you to choose the required management activity SCROLL to highlight SET UP then press...

Страница 43: ...next prompt will ask you to select a type of set up activity SCROLL to highlight SYSTEM CONFIGURATION then press ENTER 4 The display will then display SAVE READ PARAMETERS on the first line and select...

Страница 44: ...next prompt will ask you to choose the required management activity SCROLL to highlight SET UP then press ENTER 3 The next prompt will ask you to select a type of set up activity SCROLL to high light...

Страница 45: ...nning 3 The next prompt will ask you to select a type of system test SCROLL to the right to highlight TEST ALL SC S then press ENTER 5 The system will now run continuous func tional tests to verify pr...

Страница 46: ...test to verify proper operation of the selected Smart Controller electronics and their communications to from the con sole When it completes a round of tests it will repeat the procedure until you pre...

Страница 47: ...immediately after a problem occurs Status codes are always displayed in the form STXX where XX is a status code number Status codes are also recorded in memory as part of the SYSTEM HISTORY LOG This l...

Страница 48: ...tep 1 Not an error remedial action is not required Diagnostic Non Fault Codes and Messsages Dispense Log Message Code Code 06 Job Time Out Interpretation The dispense job has been deleted due to the 9...

Страница 49: ...ta message from the specified Smart Controller Step 1 Complete the Procedure Verifi cation of Communication Power Wiring Procedure RP9 page 61 Step 2 Restore operation If the error repeats then replac...

Страница 50: ...during a job Possibly caused by transient electrical noise Step 1 Cycle console system power on off and observe the start up test for detection of errors If a start up error message is displayed use t...

Страница 51: ...ole received a garbled data message from the specified Smart Controller This fault may be caused by transient electrical noise Step 1 Apply Procedure Assuring a Suit able System Power Supply Proce dur...

Страница 52: ...39 No Response to Valve Command Interpretation Console did not get confirmation after turning OFF a valve Step 1 Go to the Smart Controller at the identified station At that location apply procedure V...

Страница 53: ...system Error Message and Code Code 43 Valve Did Not Activate Interpretation Console detects that a valve did not activate on command Smart Control ler replacement is appropriate Step 2 Replace the val...

Страница 54: ...o Code System Checksum Error Interpretation Console reports a checksum error due to interruption of a data transfer cycle Step 1 Complete all steps of the procedure System Restore from Error Pro cedur...

Страница 55: ...p 2 Complete the procedure Verifi cation of Communication Power Wiring Procedure RP8 page 60 Error Message and Code No Code Param Checksum Error Interpretation Usually caused when power is lost to the...

Страница 56: ...itch OFF ON Step 2 If problem is not corrected replace console per Procedure Replace Model 3110 006 Queuing Console Procedure RP1 page 57 Observed Symptom Incorrect Amount of Fluid is Dis pensed Inter...

Страница 57: ...en download system setup param eters from the Air Smart Controller using the PRO CEDURE SYSTEM CONFIGURATION Procedure SP6 Page 43 1 0 Referring to the PIN code list created in step 2 reload all PIN c...

Страница 58: ...At the queuing console conclude or cancel all dispenses in queue Then cycle the power switch on the back of the console OFF ON and allow the self test routine to cycle The display should then show SP...

Страница 59: ...llation of the new smart controller confirm correct dispensing by authorizing a 1 qt sample to EACH dispense point Observe ready light then cancel each job 9 Remove the alternate dispensing method for...

Страница 60: ...roller confirm correct dispensing by authorizing a 1 qt sample to EACH dispense point Observe ready light then cancel each job 1 3 Remove the alternate dispensing method for temporary use prepared in...

Страница 61: ...the Com munications Power Cables to assure that wires are attached to the correct terminal position per Wiring Detail Smart Controller Figure 26 Page 20 Similarly review wire attachments at the conso...

Страница 62: ...pair Procedures RP System Repair or Expansion 6 At the queuing console turn the power switch on the back of the console OFF and then ON The display will show SPECTRUM 100 IDLE after complet ing a self...

Страница 63: ...ID labels from the Queuing Console box apply the label SC01 to the center front potted face of the controller Set aside SC01 for later installation mounting 7 Install the second fluid Smart Controlle...

Страница 64: ...shown in Figure 26 Page 20 Keep the head of the magnet very close to the face of the controller Make multiple passes back and forth until the controller s center LED blinks twice 3 Failure of Smart C...

Страница 65: ...audit the placement of solenoid wiring fluid 1 to port 1 fluid 2 to port 2 etc Be sure wire ends are properly stripped and attached to terminations Be sure the correct black ground wire is used as cab...

Страница 66: ...er Cable console to meter run one cable per impulse meter 18 gage 2 conductor unshielded stranded copper wire 300 V 80 deg C color code black red 30 mil PVC wire cover 30 mil PVC grey cable jacket UV...

Страница 67: ...make a written record of PIN code assignments for your Spectrum System After completing the sheet tear out and save in a secure location for future reference DO NOT LOSE YOUR PIN CODES It is very dif...

Страница 68: ...Rev 2 5 E 12 05 Software Rev 2 6 F 3 07 Added Caution Page 2 regarding jobs left in queue G 12 08 Updated warranty statement H 5 12 Change to new impulse meter p n 800000 Balcrank Corporation Weavervi...

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