120526 Instr. DEF 400 Series Retrofit Rev B 03 23

120526 Instr. DEF 400 Series Retrofit Rev B 03 23
Bennett Big Blue DEF Retrofit Kit
400 Series for Diesel Exhaust Fluid Dispensers
Installation Instructions
READ THIS MANUAL
This manual has important information for safe installation and operation of this equipment. Read and
understand this manual before applying power. Keep this manual and tell all service personnel to read
this book. If these instructions are not followed, bodily injury, death, or damage to the equipment
may occur.
Instr. 120526 Rev B 3-23-16
Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456
USA 800-235-7618 Outside USA 231-798-1310 [email protected]
www.bennettpump.com
Table of Contents
Safety Instructions ...................................................................................................................................... 3
Product Specifications ................................................................................................................................ 4
Unloading, Unpacking, Inspection, and Proper Storage ............................................................................ 5
Dispenser Identification Number (DIN)....................................................................................................... 6
Kit Contents and Required Tools ............................................................................................................... 7
Preparing the Existing 3K Chassis ............................................................................................................. 8
Preparing the DEF Unit for Installation ..................................................................................................... 10
Lifting Instructions..................................................................................................................................... 11
Attaching the DEF Unit to Existing 3K ...................................................................................................... 12
Mechanical and Plumbing Notes .............................................................................................................. 13
DEF 400 - DH Series Footprint ................................................................................................................ 14
Electrical Field Wiring ............................................................................................................................... 15
•
Current Loop with 1028 Electronics Wiring Diagram .................................................................. 17
•
RS485 with1028 Electronics Wiring Diagram.............................................................................. 18
1028 CPU Connection Diagram .............................................................................................................. 19
Wiring the DEF Retrofit ........................................................................................................................... 20
Dressing the DEF Retrofit ....................................................................................................................... 24
Recommended Literature ........................................................................................................................ 26
Bennett Limited Warranty ........................................................................................................................ 27
The material included in this installation manual is accurate at the date of publication. The intent of this
manual is to assist. If further assistance is required, please contact the Bennett Technical Service Department at 1-800-423-6638.
Bennett Marketing Services can be contacted by mail, facsimile, telephone or e-mail at the locations
specified below:
Bennett Pump Company
Marketing Services
1218 East Pontaluna Road
Spring Lake, MI 49456
Telephone from USA 1-800-235-7618
Telephone from outside USA 231-798-1310, Extension 287 or 269
Facsimile: 231-799-6200
Email: [email protected] or [email protected]
Website: www.bennettpump.com
2
Instr. 120526 Rev B 3-23-16
Safety Instructions
For the safe installation of this equipment, read and understand all warning and cautions. Look for these warnings:
Red and White “DANGER” means: If you do not follow the instructions, severe injury or death will occur.
Orange and Black “WARNING” means: If you do not follow the instructions, severe injury or death can occur.
Yellow and Black “CAUTION” means: If you do not follow the instructions, damage can occur to the
equipment.
DANGER
PELIGRO
DANGER
•
FIRE, EXPLOSION, INJURY, OR DEATH WILL OCCUR IF FUEL FILTERS ARE CHANGED
BY UNTRAINED PERSONNEL. MAKE SURE, ONLY TRAINED PERSONNEL CHANGE
FILTERS.
•
TO PREVENT INJURY TO YOU FROM VEHICLES AND ONLOOKERS, ALWAYS PLACE A
BARRIER AROUND THIS EQUIPMENT BEFORE PERFORMING SERVICE OR
MAINTENANCE.
•
DISCONNECT ALL POWER TO THIS EQUIPMENT AND ASSOCIATED SUBMERGED
PUMP(S) DURING INSTALLATION, SERVICE, OR ANY MAINTENANCE I.E., CHANGING
FILTERS.
WARNING
ADVERTENCIA
MISE EN GARDE
•
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.
•
To prevent electric shock, keep the electrical parts of the dispenser dry.
•
Electronic components are static sensitive. Use proper static precautions (static
straps) before working on the equipment.
•
The emergency shut-off valve (also called the fire valve, shear valve, or impact valve)
must be closed when service or maintenance is performed on this equipment.
•
You must have training in the operation and programming of this dispenser before
using it. READ THE OPERATORS MANUAL.
•
Make sure this equipment is correctly grounded. Failure to do will cause injury or
damage equipment or improper operation. Improper grounding voids the warranty.
CAUTION
PRECAUCIÓN
MISE EN GARDE
•
Do not operate this equipment as a dispenser unless it is completely assembled.
•
Do not drill holes in DEF dispensers. Holes can cause failure of the electronic
equipment. THE WARRANTY WILL BECOME VOID. Use only adhesive backed sign
mounting brackets.
Product freeze may cause damage to the dispenser/ AUS-32 (DEF) fluid should not
reach temperatures below 12°F or -11°C. The warranty will become void. If a power
failure occurs, necessary means should be taken to prevent freezing.
•
!! READ AND UNDERSTAND ALL WARNING LABELS ATTACHED TO THE DISPENSER !!
3
Instr. 120526 Rev B 3-23-16
Product Specifications
POWER REQUIREMENTS
AC Power Input, Electronic ............................................................. Input 120 or 230 Volts A.C. 50/60 Hz.
DC Power Supply Outputs .......................................................................................... +5VDC 100mA Max.
.................................................................................................................................. +12 VDC 100mA Max.
DC Power Supply Outputs ...................................... +24 VDC 1.0 Amps Max.,+5VDC Isolated 50mA Max.
Lead - Acid Battery Output .................................................................................. +12 VDC, 1.2 Amp Hours
ENVIRONMENTAL REQUIREMENTS
Electronics Operating Temperature Range ......................................................................... -20°C to +40°C
Humidity .........................................................................................................................0-95% Condensing
AUS-32 (DEF) Fluid......................................................................................... Follow ISO Standard 22241
DIMENSIONS
400 Series Retrofit .................................................................................................... 60” H x 19” W x 20” D
4
Instr. 120526 Rev B 3-23-16
Unloading, Unpacking, Inspection, and Proper Storage
Bennett dispensers are bolted to a pallet and then carefully packaged with cardboard/Styrofoam liners
and a cardboard exterior carton. The entire package is then securely wrapped with plastic shrink-wrap.
Use a forklift to transport the dispenser while it is still on the pallet.
Before signing the freight delivery receipt, inspect the carton and pallet for any obvious signs of damage
to the dispenser. If any damage is found, instruct the delivery driver to make a notation on the delivery
receipt before signing. If possible, open the carton and inspect the dispenser before signing the delivery
receipt.
Bennett dispensers are shipped Ex Works (Spring Lake, Michigan, USA). This means that the title to the
equipment passes to the purchaser at the time the equipment is loaded on the truck at our factory.
Freight damage claims are the responsibility of the purchaser. Bennett will assist in preparing any
damage claim, by helping to identify and price any parts necessary to make needed repairs.
Carefully remove the plastic shrink-wrap from the carton. Then carefully remove the cardboard
container and any inside liners. DO NOT DISCARD THE PACKAGING. Should the need arise to
repackage the dispenser; the cardboard packaging can be reused. Plastic shrink-wrap can be
purchased at office supply stores or industrial packaging stores.
Examine the exterior panels for any signs of freight damage. If shipping damage has occurred after
signing for delivery, call the freight carrier immediately and request an inspection. DO NOT DISCARD
THE PACKAGING; the inspector will want to examine it.
If there is no freight damage to the exterior of the dispenser, use the door key that is wire tied to the
nozzle hook to unlock the upper door.
1. Remove the lower panel from the dispenser.
2. Visually examine the interior of the dispenser for shipping damage. Note: Although, the dispenser is
extremely sturdy, a dispenser that has been dropped can suffer damage internally even while it
appears normal on the exterior.
3. Read the model/serial plate of the dispenser and check to confirm that the hydraulic configuration is
what your order specified.
Report any non-shipping related problems to:
Bennett Customer Service
USA - (800) 423-6638 | International - (231) 798-1310 | Fax - (231) 799-6202
Email - [email protected] or contact us using the following address:
Bennett Pump Company
1218 E. Pontaluna Road
Spring Lake, Michigan, USA 49456
After freight inspection, it is extremely important to store the new dispensers in a heated building prior to
installation. Bennett factory test all units with deionized water prior to shipment. If stored in an
environment that is below freezing (+32°F/0°C), internal components will freeze or crystallize. This will
cause damage to the internal hydraulics at startup if these guidelines are not followed. Any damages
related to improper storage are not covered under the Bennett Limited Warranty for DEF dispensers.
5
Instr. 120526 Rev B 3-23-16
Dispenser Identification Number (DIN)
6
Instr. 120526 Rev B 3-23-16
Kit Contents and Required Tools
Required Parts:
Kit P/N 118347 should include:
Quantity
Part Number
Description
1
117841
Conduit / Wire Assembly, Heater
2
H033301
Slip Joint Assembly
2
118178
Elbow, 1/2” Male x 1/2” Female
6
J771501
Conduit Nut, 1/2 x 1-11/32 x 1-1/4
6
N886801
Washer-Conduit, .88 ID - 1.25 OD
1
118348
Thermostat Conduit Assembly
1
118084
Base Thermostat Mounting DEF Extension
4
A631901
Screw - Fil, M4 - .7 x 10mm, Stainless Steel
1
118085
Cover, Thermostat
1
118176
Conduit Assembly, Valve
1
108542
Wire Assembly, Barrier BS to Barrier Board
1
108544
Wire Assembly, 10 Conductor Ribbon Cable 30”
1
117658
Barrier Wire Assembly, DEF Pulser - Handle
4
A519401
Metal Standoff, #6-32 Male-Female .375 LG
4
A425901
Screw, Phillips Pan Hd, #8-32 x 1/4”
1
107576
Circuit Board Assembly, Intrinsically Safe Barrier
1
109604
Cover, Intrinsically Safe Barrier Board
4
A393201
Screw, Recessed #6-32 x 3/8”
4
109854
Screw, Phillips Pan Hd, #6-32x1/2 SS Self Tap
4
101601
Butt Splice Connector, 14-16 AWG Insulated
12
A586901
Hex Bolt,M6-1.0x20mm
12
107724
Nut-Self Locking, M6x1 Nylon Insert
1
113672
Grommet-Rubber .875 ID (Thermostat)
Required Tools:
•
•
•
•
•
•
•
•
Metric Wrench and Socket Set
Standard SAE Wrench and Socket Set
Phillips Screw Driver
Precision Flat Head Screwdriver
Wire Cutter, Wire Crimp, and Wire Strippers
Pipe Wrench(s)
Adjustable Wrench
7/8” Step Bit
7
Instr. 120526 Rev B 3-23-16
Preparing the Existing 3K Chassis
REMOVE AC POWER
NOTE:
IF INSTALLING A NEW 3K DISPENSER, PLEASE REFER TO THE 3K SPEC. 100
INSTALLATION MANUAL (P/N 120001) FOR COMPLETE INSTALLATION OF THE 3000
SERIES.
Step 1 - Remove the lower door from the side of the 3K that will have the DEF Retrofit installed.
Disconnect the black and red handle switch wires. With a fully extended lower door, lift the door
straight up so that the pins slide out from the hinge. Set door aside. Remove the hinges from
the 3K by removing the 6 Phillips pan head screws (#6-32x1/2 SS Self Tap). Set aside. Refer
to Figure 1.
Step 2 - Remove the top cover from the dispenser by removing the 6 Phillips pan head screws
(#6-32x1/2 SS Self Tap). Set aside. Refer to Figure 1.
Step 3 - Remove the end panel from the side where the DEF Retrofit will be installed. Remove the
remaining Phillips pan head screws (#6-32x1/2 SS Self Tap) as shown in Figure 1. Note: A
large metal putty knife is recommended to remove the end panel.
Figure 1
8
Instr. 120526 Rev B 3-23-16
Preparing the Existing 3K Chassis
Step 4 - Using the 7/8” Step Bit, drill holes in the 3K vapor deck for the DEF valve, heater, and
thermostat. Deburr the edges so sealing washers properly seat. Note: Holes are pre-drilled on
new combination units and The hole pattern will vary depending on pump model. Refer to
Figure 2 (Conduit Hole Placement Diagram) below.
Conduit Placement Diagram
Valve Conduit
Thermostat Conduit
Heater Conduit
Barrier Conduits
(Will vary depending on pump model)
Figure 2
9
Instr. 120526 Rev B 3-23-16
Preparing the DEF Unit for Installation
Step 5 - Remove the two side panels from the DEF Retrofit by removing the 10 Phillips pan head
screws (#6-32x1/2 SS Self Tap). Set aside. Refer to Figure 3.
Step 6 - Locate the small brackets that are mounted to the DEF frame. Remove the nylon nuts (6-32)
from the brackets to disassemble prior to installation. Refer to Figure 3.
Small Brackets
Figure 3
10
Instr. 120526 Rev B 3-23-16
Lifting Instructions
Step 7 - Using a lift truck, position the forks on the bottom side of the factory supplied lift brackets.
They are located in the head of the dispenser. Carefully set the DEF unit onto the island next
to the existing 3K unit. Refer to Figures 4 and 5.
Lift Brackets
Figure 4
Figure 5
11
Instr. 120526 Rev B 3-23-16
Attaching the DEF Unit to Existing 3K
Step 8 - Install and secure two bolts (M6-1.0x20mm) and 2 lock nuts (M6x1) through each of the
four lower brackets between the frame and DEF Retrofit. Install and secure one bolt
(M6-1.0x20mm) and lock nut (M6x1) through each of the upper two brackets. Refer to
Figure 6.
Figure 6
12
Instr. 120526 Rev B 3-23-16
Mechanical and Plumbing Notes
General Information:
The dispenser must be mounted on a concrete foundation. Do not pour concrete around the product
pipes or electrical conduit.
All piping, hoses, thread sealants, and any fluid handling fittings must be approved materials compatible
with DEF.
Make sure all local and national codes are followed during installation of the Bennett equipment.
Installation must be in accordance with the Class 1, Division 1, Group D National Fire Protection Agency
NFPA 70: National Electrical Code (NEC), NFPA 30A: Code for Motor Fuel Dispensing Facilities and
Repair Garages, NFPA 30: Flammable and Combustible Liquids Code, NFPA 31 Installation of OilBurning Equipment Standard, International Fire Code (IFC), and all state and local codes.
Follow all installation instructions provided by the piping and component manufacturers.
For complete instructions for storage and dispensing of Diesel Exhaust Fluid (DEF), order PEI/RP1100
“Recommended Practices for the Storage and Dispensing of Diesel Exhaust Fluid (DEF)” from the Petroleum Equipment Institute, P.O. Box 2380, Tulsa, OK 74101 or at http://www.pei.org.
Note:
All piping must be clean of foreign debris such as oil, grease, and shavings. All connections
must be liquid tight with gasoline-resistant tape compound to prevent leaks before it is put into
service. All Fluid handling components must be cleaned with de-ionized water per ISO standard
22241.
Note:
All piping, hoses, and any fluid handling fittings must be approved materials compatible with
Urea DEF (Diesel Exhaust Fluid) AUS-32, and meet ASME B31 - American Society of Mechanical Engineers Standards.
Note:
AUS-32 (DEF) is classified as non-hazardous material.
13
Instr. 120526 Rev B 3-23-16
DEF 400 - DH Series Footprint
14
Instr. 120526 Rev B 3-23-16
Electrical Field Wiring
General Information
NOTE:
PLEASE REFER TO THE 3K SPEC. 100 INSTALLATION MANUAL (P/N 120001) FOR
COMPLETE INSTALLATION OF THE 3000 SERIES.
Find the wiring diagram specific to the dispenser model for the dispenser that is being installed in the
Wiring Diagrams section. Read and follow all directions including supplemental notes contained on the
drawing.
The dispenser’s field wiring connections are in the upper electronics head (electrical enclosure) of the
dispenser or the dispenser may have been ordered with the optional explosion proof junction box
located in the lower area of the dispenser. Using the door keys shipped with the dispenser, (on side 1)
unlock the two locks on the upper electronics enclosure and open the door to access the wiring terminal
on the CPU/ Control board. If there is a junction box wire to the terminal strip and flying leads in the
junction box. Refer to the instructions for wiring to the junction box under the “Wiring Diagrams” section
of this manual.
All field wiring must be stranded copper, oil and gas resistant (THHN) color coded, with a 600 volt
insulation rating. See wiring diagrams section for proper wire sizes. Pull 72 inches extra wire to reach
the top of the dispenser. Do not use wire nuts. The ends of the wires should be clean and free from
oxidation.
The wire separator (supplied with the pump) must be installed on the wires as they exit the conduit
located in the electrical enclosure before the wires are terminated in the electronics enclosure. The wire
separator is needed to properly seal the conduit in the last step of installation.
Underground conduit for the field wiring must be 3/4 inches, rigid metal, and continuous. The use of
PVC conduit is not allowed. All conduit between the building and each dispenser should be a separate
conduit run.
For Remote dispensers Bennett requires the installation of RC networks across the coil and contactors
of the sub-pump relays for proper operation of the dispenser. Failure to install the RC networks will void
Bennett’s Limited Warranty.
Intercom wiring must be in a separate conduit from the dispenser conduit. DO NOT install intercom
wiring in the same conduit as the dispenser wiring or else the Bennett Warranty will be voided
and improper system operation will result.
Dispenser Electronic Power must be on a separate dedicated circuit breaker. Do not put submerged
pump or self-contained pump power on this circuit breaker. One heated DEF combo may be
placed on (1) 15 amp circuit breaker. All dispensers at the station must be on the same phase of power.
All dispenser field wiring between the building and the dispenser for power, neutral and ground wire
conductors must not be spliced, wire nutted or shared with any other equipment. Doing so would void
the Bennett Limited Warranty. All power, neutral and ground conductors shall be run from the dispenser
to the Main Service Panel.
Follow all local, state and federal requirements for installation of vapor seals.
Electrical contractors must pull 72 inches of wire above the grade level to reach through the
dispenser’s conduit and into the electrical area at the top of the dispenser. Read and follow all
instructions on the wiring diagrams and observe all national and local electrical codes.
15
Instr. 120526 Rev B 3-23-16
Electrical Field Wiring
General Information (Cont’d)
In instances where new dispensers are replacing old dispensers, Bennett recommends that new wiring
be pulled to each dispenser. The maximum distance from the breaker panel to the dispenser is 500
feet.
WARNING:
DO NOT CROSS PHASE THE DISPENSERS OR DAMAGE WILL OCCUR.
When installing more than one dispenser the remote sub-pump relay
control wire from each dispenser must be on the same phase of power or
cross phasing will occur at the sub-pump relay. This means that the
electronic power for all dispensers at the site must be on the same phase.
Electrical Conduits - Make sure that each dispenser has its own electrical underground conduit. Wiring
from multiple dispensers in a single conduit is not allowed. All underground conduit should be rigid metal
and drawn up tight. The use of PVC (plastic) conduit is not allowed and may void the Bennett Warranty.
Make sure that vapor “seal offs” are properly installed on all conduits at and from each dispenser. Make
sure any intercom wiring is not run with dispenser field wiring. A separate (second) conduit must be run
if using an intercom at the dispenser.
16
Instr. 120526 Rev B 3-23-16
P3271 Sheet 1
Current Loop with 1028 Electronics
Wiring Diagram
17
Instr. 120526 Rev B 3-23-16
P3271 Sheet 3
RS485 with 1028 Electronics
Wiring Diagram
18
Instr. 120526 Rev B 3-23-16
1028 CPU Connection Diagram
Calibration Switch
Side 1 Main Display
Side 2 Main Display
Aux. Price Display
Product 2 Manager
Keypad
(Local Preset Only)
(Local Preset Only)
1028 CPU Board
P/N 118171
Product 2 Barrier
Board
Side 1 Manager Keypad
Side 1 Barrier
Board
Side 2 Valve
Side 1 Valve
Side 2 Satellite
Board
Side 1 Satellite Board
Side 1 Fuel Communication
1-RS485 +
2-RS485 Common
3-RS485 4-Current Loop +
5-Current Loop -
Bypass Float (Suction)
Side 2 Fuel Communication
1-RS485 +
2-RS485 Common
3-RS485 4-Current Loop +
5-Current Loop -
Door Alarm (Mexico)
Backlight Power
Side 2 Pulse Output
Side 1 Pulse Output
External Battery
Micro-Processor Programmer
3A Fused
Accessory Pwr.
Side 1 Motor Contact
Side 2 Motor Contact
Un-Fused
Accessory Pwr.
Programming Jumper
On-Run Mode
Off-Program Mode
Electronics Power
1-Ground
2-Neutral
3-Line Voltage
Motor Contact
(Remote)
1-Not Used
2-Motor Control 1
3-Not Used
4-Motor Control 2
19
Motor Contact
(Self Contained)
1-Motor 1 Line Voltage In
2-Motor 1 Line Voltage Out
3-Motor 2 Line Voltage In
4-Motor 2 Line Voltage Out
Instr. 120526 Rev B 3-23-16
Wiring the DEF Retrofit
Step 9 - Install the heater conduit through the DEF insulation panel and 3K vapor deck. Refer to the
conduit placement diagram on page 9, and Figure 7 below. Note: The DEF insulation panel
has “pre-cut” holes that are labeled from the factory.
Step 10 - Thread the elbow and slip joint to the lower end of the heater conduit. Route the heater wires
and provided wire bundle through the conduit. Thread the slip joint to the top portion of the
explosion proof junction box on the heater. Refer to Figure 8. Note: Heater conduit assembly
will come pre-assembled on new combination units.
Step 11 - Using the “butt splice” connectors provided, crimp the heater wires as followed, and press
them into the explosion proof junction box.
• Blue to White (Neutral)
• Brown to Black (Hot)
• Green/Yellow to Green (Ground)
Step 12 - Replace and tighten explosion proof junction box cover. Tighten all vapor barrier nuts /
washers. Refer to Figure 9.
Heater Conduit
Figure 8
Heater Conduit
Vapor Deck
Heater
Figure 9
Figure 7
20
Instr. 120526 Rev B 3-23-16
Wiring the DEF Retrofit
Step 13 - Install the valve conduit through the DEF insulation panel and 3K vapor deck. Refer to the
conduit placement diagram on page 9, and Figure 10 below. Note: The DEF insulation panel
has “pre-cut” holes that are labeled from the factory.
Step 14 - Thread the elbow and slip joint to the lower end of the valve conduit. Route the valve wires
through the conduit. Thread the slip joint to the explosion proof junction box. Refer to Figure
10.
Step 15 - Connect the universal valve connectors as followed, and press them into the explosion
proof junction box.
• Red to Red (Neutral)
• Yellow to Yellow (Slow Flow)
• Black to Black (Fast Flow)
Step 16 - Replace and tighten explosion proof junction box cover. Tighten all vapor barrier nuts /
washers. Refer to Figure 11.
Step 17 - Plug the top universal valve connector into J15 on the 1028 CPU Board. Refer to the 1028
diagram on page 19.
Plug into J15
Explosion Proof Valve J-Box
Slip Joint
Universal
Connectors
Valve Conduit
Vapor Deck
Figure 11
Figure 10
21
Instr. 120526 Rev B 3-23-16
Wiring the DEF Retrofit
Step 18 - Install the thermostat conduit assembly through the 3K vapor deck. Refer to the
conduit placement diagram on page 9, and Figures 12 and 13 below.
Step 19 - Replace and tighten explosion proof junction box cover. Tighten all vapor barrier
nuts / washers. Refer to Figure 15.
Step 20 - Route the bulb and capillary through the insulation, and along the back corner of the DEF
hydraulics cavity to the lowest point. Secure the bulb to one of the holes on the hose reel with
the provided cable tie. Refer to Figure 14 below.
IMPORTANT! Do not kink the copper capillary and bulb. Incorrect heater operation will occur.
Step 21 - Connect the black wire from the heater to “TAB 1” on the thermostat and attach the white
heater wire to the incoming AC white power wire.
Step 22 - Splice into the main AC power wire and connect to tab “P” on the thermostat. Refer to the
wiring diagram on pages 17 and 18.
Step 23 - Attach the cover to the support bracket using two M4 screws.
Cover
Figure 12
Capillary
Thermostat
Bulb
Secure Bulb with
Cable Tie
Short Conduit
Support Bracket
Figure 14
Support Bracket
Vapor Deck
Figure 13
Figure 15
22
Instr. 120526 Rev B 3-23-16
Wiring the DEF Retrofit
Step 24 - Thread the supplied barrier board standoffs into the four threaded inserts on the 3K
vapor deck. Depending on the pump model, location may vary. See conduit hole placement
diagram on Page 9 and Figure 16 below. Note: New combo units will have the barrier board
pre-installed.
Step 25 - Break the plastic edge piece off of the barrier board cover in the kit (Use snips or
scissors if necessary). Slide the edge piece over the two standoffs closest to the barrier
conduit. Make sure the edge piece is flush with the vapor deck. See Figure 16 below.
Step 26 - Place and align the barrier board on top of the standoffs.
Step 27 - Attach the barrier board ground strap to the vapor deck using a #8 screw.
Step 28 - Route the barrier conduit assembly through the vapor deck. Tighten all vapor barrier nuts and
washers. Refer to conduit hole placement diagram on Page 9 and Figure 16 below.
Step 29 - Plug the barrier assembly ribbon cable into J2 on the barrier board. Plug the 10
conductor ribbon cable into J1 on the barrier board, and plug the remaining end into J12 on
the 1028 CPU. Note: Refer to the 1028 Diagram on Page 19.
Step 30 - Place and align the barrier board cover on top of the barrier board. Secure the cover and
barrier board to the standoffs with four Phillips screws provided in the kit (#6-32 x 3/8).
Phillips Screws
Barrier Board Cover
Edge Piece
Intrinsically Safe Barrier
Board
Barrier Harness Assembly
Standoffs
Threaded Inserts
23
Figure 16
Instr. 120526 Rev B 3-23-16
Dressing the DEF Retrofit
Step 31 - Install the front panel that fits around the nozzle door. Align the panel pins with the
slots on the DEF unit and wrap the side corner around the frame of the 3K unit. Re-install the
3K door hinges and secure panel with the Phillips screws provided in the kit
(#6-32x1/2 SS Self Tap). Refer to Figure 17.
Step 32 - Install the back panel by aligning the pins with the slots on the DEF unit. Wrap the side
corner around the frame of the 3K unit. Secure the back panel to the 3K frame by installing
the Phillips screws (#6-32x1/2 SS Self Tap) provided in the kit. Refer to Figure 18.
Figure 17 - Front Panel
Figure 18 - Back Panel
24
Instr. 120526 Rev B 3-23-16
Dressing the DEF Retrofit
Step 33 - Install the short end panel above the DEF unit and secure to the 3K frame using four
Phillips screws (#6-32x1/2 SS Self Tap). Refer to Figure 19.
Step 34 - Re-install and secure the top cover on the 3K by installing six Phillips screws
(#6-32x1/2 SS Self Tap). Refer to Figure 19.
Step 35 - Remove the nozzle boot from the existing 3K door assembly and re-install on the new 3K
door provided in the kit. Note: The nozzle boot orientation is moving from the right to left
side. Refer to Figure 19.
Step 36 - Re-install the lower doors and re-connect the handle switch wires.
Figure 19
25
Instr. 120526 Rev B 3-23-16
Dressing the Ad-On
Recommended Literature
END OF PROCEDURE
Please refer to the following literature for installation of 3K peripherals.
If additional help or information is needed, please call Bennett Technical Support at
1-800-423-6638.
Part No.
Description
120001
3000 Series Electronic Installation Manual
108795
3000 Series Electronic Operator's Manual - Commercial
108796
Electronic Operator's Manual - Retail
117742
3000 Series Electronic Parts Manual (SPEC. 100)
107932
3000 Series Electronic Service Manual - Commercial
107933
Electronic Service Manual - Retail
116029
Monochrome SPM Credit / Debit Module Programming, Service, and Parts Manual
118601
Black / White SPM Credit / Debit Module Programming, Service and Parts Manual
118602
Color SPM Credit / Debit Module Programming, Service, and Parts Manual
124184
Simple Secure Payment PCI 3.1 (SSP Color) Programming, Service, and Parts Manual
126535
Guide Quick Reference SSP-Hengstler 3K
117429
Quick Reference, 3K & DEF Communication Notes
117439
Quick Reference, 3K SPM Install Notes
126304
DEF 400 Retrofit Kit 1028 Operator’s Manual - Retail
109766
Product ID Installation Instructions
**Note: Most literature is found on the CD and/or USB provided with the dispenser.
26
Instr. 120526 Rev B 3-23-16
Bennett Limited Warranty
for Products Installed in the United States
27
Instr. 120526 Rev B 3-23-16
28
Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456
USA 800-235-7618 Outside USA 231-798-1310 [email protected]
Instr. 120526 Rev B 3-23-16
www.bennettpump.com
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