bennett cng dispenser installation

120950 Rev B 08-2-13

READ THIS BOOK This book has important information for safe installation and operation of this equipment. Read and understand this book before applying power. Keep this book and tell all service personnel to read this book. If instructions are not followed then bodily injury, death or damage to the equipment could transpire.

For new books, visit our web page at: http://www.bennettpump.com

Bennett CNG Series CNG Series Remote Dispensers

Installation Manual Only Trained Personnel May Work on This Equipment

Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456 USA 800-235-7618 ~ Outside USA 231-798-1310

[email protected] ~ www.bennettpump.com

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Safety Instructions .................................................................................................................................... 3 Product Specifications .............................................................................................................................. 4 Power Requirements ......................................................................................................................... 4 Environmental Requirements ............................................................................................................. 4 Dimensions ........................................................................................................................................ 4 General Installation Information ............................................................................................................... 4 Underground Installation Requirements ................................................................................................... 4 CNG Dispenser DIN ................................................................................................................................. 5 Pipelines and Containment Sumps .......................................................................................................... 6 How to Lift & Transport ............................................................................................................................. 6 Base Dimension ....................................................................................................................................... 7 Mechanical Installation Requirements ...................................................................................................... 8 Pipeline Installation ................................................................................................................................... 8 (Purging System) Blower .......................................................................................................................... 9 Determining the number of wires needed ................................................................................................ 10 General Wiring Instructions ...................................................................................................................... 11 Beginning the Wiring Process ............................................................................................................ 11 Instructions for Earth Grounding the Equipment ...................................................................................... 12 AC Power Installation ............................................................................................................................... 12 Electronic Power Connections ........................................................................................................... 12 Rules to Ensure Proper Installation ................................................................................................... 12 Data Communication Wiring ..................................................................................................................... 13 Current Loop Fuel Wire Termination (1 Sided and 2 Sided) ............................................................. 13 RS-485 Fuel Wire Termination (White Terminal Block) ..................................................................... 13 RS-485 Card Reader Wire Termination (Power Distribution Board TS4) ......................................... 13 Battery ...................................................................................................................................................... 14 Installing the Wire Separator .................................................................................................................... 14 Dispenser Start-Up and Checklist ............................................................................................................ 15 Final Installation Checklist ........................................................................................................................ 16 Field Wiring and Communication Diagram - Current Loop ...................................................................... 17 Current Loop Notes ............................................................................................................................ 18 Field Wiring and Communication Diagram - RS-485 ............................................................................... 19 RS-485 Notes..................................................................................................................................... 20 How to Electronically Calibrate (E-Cal) the Dispenser ............................................................................. 21 Bennett Warranty ...................................................................................................................................... 22 Site Audit Form ......................................................................................................................................... 24

NOTICE

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interface, and (2) this device must accept in-terference received, including interference that may cause undesired operation. Not all equipment covered in this manual is listed by Underwriters Laboratories.

IMPORTANT

Examine the shipment immediately upon arrival to make certain there has been no damage or loss in transit. Bennett Pump Company, as shipper, is not liable for the hazards of transportation. Please make damage claims directly to the truck line.

Table of Contents

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CAUTION: Do not drill holes in dispensers. Holes can cause failure of the electronic

equipment. The warranty will become void. Use only adhesive backed sign mounting brackets.

READ AND UNDERSTAND ALL WARNING LABELS ATTACHED TO THE DISPENSER

Safety Instructions

DANGER: Fire, explosion, injury or death will occur if filters are changed by untrained personnel. Make sure only trained personnel change filters.

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.

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: Training is needed in the operation and programming of this dispenser before using it. READ THE OPERATORS MANUAL.

WARNING: The shut-off ball valve for the incoming CNG Line must be closed when service or maintenance is performed on this equipment.

WARNING: Electronic components are static sensitive. Use proper static precautions (static straps) before working on the equipment.

WARNING: To prevent electric shock, keep the electrical parts of the dispenser dry.

WARNING: Training is needed in the installation, service or maintenance of this equipment (dispenser, pump, console, control box) before working on it. Maintenance repairs must be done by authorized personnel only.

DANGER: Disconnect all power and relieve pressure to this equipment and associated pump during installation, service or any maintenance, i.e., changing filters.

DANGER: CNG is flammable. NO SMOKING OR OPEN FLAME.

DANGER: To prevent injury from vehicles and onlookers, always place a barrier around this equipment before performing service or maintenance.

WARNING ADVERTISSEMENT ADVERTENCIA For the safe installation of this equipment, read and understand all warning and cautions. Look for these warnings:

DANGER means: If instructions are not followed, severe injury or death will occur. WARNING means: If instructions are not followed, severe injury or death can occur. CAUTION means: If instructions are not followed, damage can occur to the equipment.

WARNING: Vehicle engine must be turned off while dispensing product.

WARNING: No ignition source can be within 10 feet of the dispenser.

WARNING: A portable fire extinguisher with a rating of no less than 20-B:C must be provided in the dispensing area.

WARNING: If the breakaway is not provided then one must be installed that will disengage at 150lbs.

WARNING: There must be a message near the dispensers that says, Natural Gas Vehicle Fuel Cylinders shall be periodically inspected (normally every 3 years) to ensure safe operation of the vehicle. Contact vehicle or cylinder manufacture.

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POWER REQUIREMENTS AC Power Input, Electronic.......................................................................115VAC, 60HZ @ 660W. DC Power Supply Outputs...................................................................................+5VDC @ 5.0 Amps Max. .........................................................................................................................+12VDC @ 1.75 Amps Max. .........................................................................................................................+24VDC @ 2.75 Amps Max. Lead-Acid Battery Output..................................................................................+12VDC @ 2.0 Amps Max. Nickel-Cadmium Battery Output..................................................................+3.6VDC @ 40 Milliamps Max. ENVIRONMENTAL REQUIREMENTS Operating Temperature Range...........................................................................................-20C to +40C. Humidity..................................................................................................................0-95% non-condensing. DIMENSIONS CNG Series Maximum.....................................................................*49 Wide x 22 Deep 93 3/8 High. CNG Series Base...............43 1/2 Wide x 19 1/4 Deep. *Without Valance.

Product Specifications

General Installation Information Examine the shipment immediately upon arrival to make certain there has been no damage or loss in transit. Bennett Pump Company, as shipper, is not liable for the hazards of transportation. Please make damage claims directly to the truck line. Examine the dispensers cabinet and chassis for any loose or missing fasteners that may have become loose during transit. Examine all fittings in the dispensers hydraulics for any connections that may have become loose dur-ing transit. Read these instructions carefully and read all tags attached to the dispenser before starting installation. A dispenser that is not properly installed will not perform properly and will void the limited warranty.

Underground Installation Requirements All installation specifications may vary from different locations. In all cases the installation must be in accordance with all National Electrical Codes, State and Local Codes. All installations must be performed by a technician who is trained and licensed in accordance to all codes, standards and regulations. Installation of the Bennett product and all accessories (i.e. Nozzles, Hoses and Breakaways) must be performed by a technician who is trained and licensed in accordance to all codes, standards and regula-tions.

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CNG Dispenser DIN

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It is extremely important to ensure that all wiring and conduits are in accordance with all local, state and federal regulations, including, but not limited to, the National Electrical Code (NFPA 70), NFPA 30, NFPA 30A and NFPA 52. NOTE: U.L. requires that all electrical connections to the dispenser be made with threaded, rigid conduit and properly sealed conductors. All dispensers and electrical connection boxes must be grounded per NFPA 70.

PIPELINES AND CONTAINMENT SUMPS

THE ONLY FACTORY APPROVED METHOD FOR LIFTING THE CNG SERIES

How to Lift & Transport

Figure 1 - Transporting the Dispenser

* There are eyebolts included in the unit that need to be installed for transportation. To transport the dispenser remove the bolts and install the eyebolts. Once completed re-install the bolts.

*

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Base Dimensions

Figure 2 - Dispenser Footprint

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The dispenser must be mounted on a concrete foundation. Anchor the dispenser to the island with four (minimum 1/2) anchor bolts through the base frame. WHEN ANCHORING THE DISPENSER, always level the dispenser with metal shims before bolting to the island. Place the metal shims at the location of the anchor bolts so the dispenser frame is not distorted when the anchor bolts are tightened down. The dispenser must be bolted to the island. Do not skip this step.

Mechanical Installation Requirements

All piping must be clean of foreign debris, such as: oil, grease and shavings. All connections must be tight to prevent leaks. The use of a 3/4 and 1/2 Swagelok gap inspection gauge will be required to test field connections. The Inlet (3/4) and Return (3/4) lines use a Swagelok fitting that must be installed with the following guidelines: WARNING: Do not bleed system by loosening fitting nut or fitting plug. Do not assemble and tighten fittings when system is pressur-

ized. Make sure that the tubing rests firmly on the shoulder of the

tube fitting body before tightening the nut. Use the correct Swagelok gap inspection gauge to ensure suffi-

cient pull-up upon initial installation. Always use proper thread sealants on tapered pipe threads. Do not mix materials or fitting components from various manu-

facturerstubing, ferrules, nuts, and fitting bodies. Never turn fitting body. Instead, hold fitting body and turn nut. Avoid unnecessary disassembly of unused fittings. Use only long reducers in female Swagelok end connections. Swagelok Installation: 1. Fully insert the tube into the fitting and against the shoulder; rotate

the nut finger-tight. Further tighten the nut until the tube will not turn by hand or move axially in the fitting (see figure 3).

2. Mark the nut at the 6 oclock position (see figure 4). 3. While holding the fitting body steady, tighten the nut one and one-

quarter turns to the 9 oclock position (see figure 5). On initial installation, the Swagelok gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tightened. Position the Swagelok gap inspection gauge next to the gap between the nut and body. If the gauge will not enter the gap, the fitting is suffi-

ciently tightened. If the gauge will enter the gap, additional tightening is re-quired (see figure 6).

Pipeline Installation

Figure 3 - Swagelok tube

Figure 4 - Mark Nut

Figure 5 - Tighten Nut

Figure 6 - Swagelok gap inspection gauge (see Swageloks An Installers Pocket Guide for Swagelok Tube Fittings, MS-13-151 manual for further instructions.)

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It is required for the electronic enclosure of the dispenser to maintain a minimum pressure differential of 0.1 inches of water at all times. To achieve this a blower with a minimum of 65CFM air supply capability must be installed and attached to the port at the bottom of the vapor barrier (see figure 7). When the blower is in operation it will insure that the enclosure is purged with four volumes of air before the dis-penser is powered and will maintain positive pressure in the enclosure. The blower must be installed at least 5 feet away from the dispenser in an unclassified area (CNG Only). To connect the blower to the dispenser use the 2 PVC nipple from the footprint of the dispenser to the port at the bottom of the flame deck. There is a switch, relay, timer and gauge (see figures 8 and 9) used to control the power of the dis-penser. If the switch detects less than 0.1 inches of water in the electronic enclosure then the power will be removed from the dispenser until the pressure differential returns to 0.1 inches of water.

Figure 9 - Switch & Gauge

Switch

Gauge

Figure 7 - Blower Port

Blower Port

Swagelok Reassembly: You may disassemble and reassemble Swagelok tube fittings many times. 1. Prior to disassembly, mark the tube at the back of the nut; mark a line along the nut and fitting body

flats. Use these marks to ensure that you return the nut to the previously pulled-up position. 2. Insert the tube with pre-swaged ferrules into the fitting body. 3. While holding the fitting body steady, rotate the nut with a wrench to the previously pulled-up posi-

tion, as indicated by the marks on the tube and flats. At this point you will feel a significant increase in resistance. Tighten the nut slightly.

WARNING: Do not use the Swagelok gap inspection gauge with reassembled fittings.

(Purging System) Blower

Figure 5 - Timer & Relay

Timer / Relay

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AC Power Wires (115VAC) 1 x 12ga. Wire for Ground 1 x 14ga. Wire for Hot 1 x 14ga. Wire for Neutral Card Reader Communication Wires - RS485 1 x 18ga. Wire for communication (+) 1 x 18ga. Wire for communication (common 1 x 18ga. Wire for communication (-) Fuel Communication Wires - Units - RS485 1 x 18ga. Wire for communication (+) 1 x 18ga. Wire for communication (common) 1 x 18ga. Wire for communication (-)

Fuel Communication Wires - Current Loop (1 sided) 1 x 18ga. Wire for communication (+) 1 x 18ga. Wire for communication (-) Fuel Communication Wires - Current Loop (2 sided) 2 x 18ga. Wire for communication (+) 2 x 18ga. Wire for communication (-)

(Purging System) Blower

Determining the Number of Wires Needed

Note: Prior to performing work the environment must be cleared of any hazardous gases.

Timer Board Battery Bypass At start up the timer board will not allow the dispenser to power up until 3 minutes after a purge pressure of .1 inches of water is reached. This is required for a complete air change in the dispenser enclosure to eliminate any explosive gasses.

The timer board relies on a charged battery for proper operation. If the battery is discharged, the timer will have to be bypassed via the bypass push button on the timer board. The switch will have to be held until the battery reaches a suitable charge level. This could take several minutes. The dispenser enclo-sure must also be closed and have a purge pressure of at least .1 inches of water for proper battery charging.

Figure 10.4 Timer Board

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Wiring Notes: These notes are must do requirements to ensure a successful installation that meets Bennetts limited warranty requirements. 1. Check with Federal, State and Local Codes for conduit use in locations area. Bennett recommends

rigid metal conduit. 2. Use only stranded wire with listed gas and oil resistant insulation. Do not use wire smaller than

listed on the Bennett wiring diagrams. For long runs increase wire size accordingly. 3. DO NOT USE WIRE NUTS ON DATA LINES. DO NOT SPLICE DATA WIRES. THEY MUST BE

DIRECT RUNS. 4. When the dispenser data wires are pulled through the underground conduit they must be terminated

at the Junction Box. 5. The wire separator (supplied with the pump) must be installed on the wires as they exit the pump

conduit before the wires are terminated to the power board. The wire separator is needed to properly seal the conduit in the last step of installation.

6. Electronic power must be on a separate dedicated circuit breaker. Up to two dispensers may be placed on (1) 15 amp circuit breaker.

7. WARNING: DO NOT CROSS PHASE THE DISPENSERS OR DAMAGE WILL OCCUR. This means that the electronic power for all dispensers at the site must be on the same phase.

8. The maximum distance from the breaker panel to the dispenser is 500 feet (150m). Beginning the Wiring Process All dispenser wiring will be terminated directly to the Junction Box (see figure 10) and not pulled into the electronic enclosure. The Neutral Wire must be terminated onto terminal 1 of the Timer Board and the Hot Wire must be terminated onto terminal 2 of the Timer Board. All data wires will be terminated onto the terminal strip. See pages 16 - 19 for wire placement.

General Wiring Instructions

Figure 10 - Junction Box

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WARNING: Failure to properly ground the equipment can cause injury or damage to the equipment and will void the Bennett limited warranty.

This product must be properly grounded. Each dispenser requires a 12-gauge earth ground wire. Grounding provides a path of least resistance for electric current to reduce the risk of electric shock. Grounding is required to protect the dispensers computer from external electrical noise generating de-vices. The ground wire connection must provide 1 ohm (or less) resistance to earth ground. To estab-lish a good earth ground, follow this procedure: 1. Connect a 12-gauge (minimum), green stranded wire to the green wire in the Junction Box. 2. Pull the wire through the rigid metal conduit and connect it directly to the ground bar of the main

electrical service panel, not a sub-panel. Do NOT rely on the metal conduit as a ground. DO NOT USE WIRE NUTS ON GROUND WIRES. USE COMPRESSION FITTINGS ONLY!

3. Do not daisy-chain ground wires. All ground circuits must be dedicated wires connected directly to the ground bar in the main electrical panel. A direct connection to the sites ground rod must be connected to the ground bar in the main electrical panel.

4. Ensure that a 14-gauge minimum ground wire is connected between the dispenser ground lug and the Power Distribution Board TS1, terminal 1. This wire must be connected for proper operation to occur.

Each remote dispenser uses one 115V 60 Hz circuit for dispenser power. Make sure the power source has the correct frequency and voltage. Connect the electrical circuit to the terminal strip on the power supply board.

Electronic Power Connections: 1. Connect the White 14ga. wire in 115V circuits to Terminal 1 of the Timer Board. 2. Connect the Black 14ga. wire to the black wire to Terminal 2 of the Timer Board. 3. Electronic power must be connected to a dedicated 15 amp. circuit breaker. The dispenser is facto-

ry wired for 115V operation and may not be changed in the field. (If this is done, the warranty is voided.) Electronic power for all dispensers at an installation must be wired to the same AC line phase.

Rules to ensure proper operation: 1. Each dispenser uses one 115V 60 Hz circuit for dispenser power. Put no more than two (2) CNG

dispensers on a circuit breaker (for Electronic Power). 2. Do not connect any other devices or motors to these circuits. 3. Put the pump wiring in a separate conduit. Do not put non-pump related wires, such as price signs

or intercoms, in the same conduit as pump wiring. 4. Use only 14-gauge stranded gas and oil resistant THHN wire. 5. Do not use wire nuts within the dispenser or the wire run from the breaker panel to the dispenser. WARNING: All Dispenser AC Power circuits must be on the same phase or damage could result to the dispenser power board.

Instructions for Earth Grounding the Equipment

AC Power Installation

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Data wires are required for operation of each fueling position with a control console or controller. The data wires can be put in the same conduit as the other pump wiring. Refer to the wiring diagram section for additional information. Side 1 Current Loop Fuel Wire Termination: (Power Distribution Board TS5) 1. Connect 1 Yellow 18ga. wire to the Power Distribution Board terminal 23 for side 1 negative

connection. Connect the other end to the 515 or control console position 1 negative. 2. Connect 1 Orange 18ga. wire to Power Distribution Board terminal 24 for side 1 positive connection.

Connect the other end to the 515 or control console position 1 positive. Side 2 (if applicable) Current Loop Fuel Wire Termination: (Power Distribution Board TS5) 1. Connect 1 Yellow 18ga. wire to the Power Distribution Board terminal 25 for side 2 negative

connection. Connect the other end to the 515 or control console position 2 negative. 2. Connect 1 Orange 18ga. wire to Power Distribution Board terminal 26 for side 2 positive connection.

Connect the other end to the 515 or control console position 2 positive. RS485 Fuel Wire Termination: (White Terminal Block) 1. Connect 1 Orange 18ga. wire to the + (positive) connection on the white terminal block located

above the CPU. Connect the other end to the Dual Fan Out Box (Interconnection Box) 1 positive. 2. Connect 1 Black 18ga. wire to the common connection on the white terminal block located above

the CPU. Connect the other end to the Dual Fan Out Box (Interconnection Box) 1 Ground. 3. Connect 1 Brown 18ga. wire to the - (negative) connection on the white terminal block located above

the CPU. Connect the other end to the Dual Fan Out Box (Interconnection Box) 1 negative. RS485 Card Reader Wire Termination: (Power Distribution Board TS4) 1. Connect 1 Violet 18ga. wire to the power distribution board terminal 20 for the positive connection.

Connect the other end to the Interconnection Box positive. 2. Connect 1 Gray 18ga. wire to the power distribution board terminal 21 for the common connection.

Connect the other end to the Interconnection Box Gnd (Ground) connection. 3. Connect 1 Blue 18ga. wire to power supply board terminal 22 for the negative connection. Connect

the other end to the Interconnection Box negative.

Data Communication Wiring

RS485 Wires should be twisted together at 3 turns per foot to reduce the effects of electrical noise on the communication circuit. Due to the risk of noise causing possible problems with communication,

Bennett highly recommends the use of twisted wires, but does not require it.

Note: Belden Shielded Cable is accepted, but the drain must not be terminated.

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Installing the Wire Separator A safe installation requires that a wire separator be installed on the wires as they are routed through the conduit and into the dispensers electronic enclosure. The wire separator holds the wires apart to ensure that the seal off compound fully seals around each wire. Apply the potting compound during the last step of installation. This will prevent flammable vapors from working their way into the electronic enclosure. The wire separator is supplied in the plastic bag located inside the electronic enclosure attached to the side wall. CAUTION: Data wires (two 18-gauge per fueling position) are dedicated to a particular fueling position. To prevent damage to the electronic circuit boards, do not mix the data wires or connect them to any other data wires! CAUTION: DO NOT USE WIRE NUTS OR SPLICES ON DATA WIRES. FAILURE OF THE SYSTEM WILL OCCUR! 1. Wrap some CHICO X fiber around wires and push into

conduit assembly to prevent potting from running down the length of the conduit (see figure 13).

2. Using the wire separator provided, install one wire in each hole until all wires are separated.

3. Push wire separator at least 3/4 into conduit. 4. Prepare potting compound according to directions. NOTE:

Use CHICO potting compound for sealing fittings in hazardous locations.

5. Using a funnel, pour potting into conduit, be sure to get potting in between each wire.

6. Let stand until firm.

Figure 13 - Sealing Electrical Conduit

Finishing the Dispenser Wiring Installation

Battery The 12-volt battery will be disconnected from the factory (see figure 11). Prior to powering up the dispenser the battery must be plugged into J2 on the Power Distribution Board (see figure 12). At start up the timer board will not allow the dispenser to power up until three minutes after a purge pressure of .1 inches of water is reached. This is required for a complete air change in the dispenser enclosure to eliminate any explosive gasses. The timer board relies on a charged battery for proper operation. If the battery is discharged, the timer will have to be bypassed via the bypass push button on the timer board. The switch will have to be held until the battery reaches a suitable charge level. This could take several minutes. The dispenser enclosure must also be closed and have a purge pressure of at least .1 inches of water for proper battery charging.

Figure 11 - Battery Disconnected

Figure 12 - Battery Connected

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DANGER: Fire, explosion, injury or death will occur if fuel vapors are present. Make sure there are no vapors present before starting this procedure. CAUTION: To prevent damage to the dispenser, follow the proper start-up procedures. Before applying AC power to the dispenser, follow this procedure: 1. Open the upper and lower cabinet doors using the keys that were shipped with the unit. 2. Check to make sure:

The boards and other components have not come loose. LCD display boards are not cracked or damaged. The cables are properly connected to the boards. There are no torn cables or stranded harnesses. Both leads to the 12-volt battery are attached. Put the AC switch on the power supply board in the OFF position.

3. Make sure the inlet shut-off ball valve is closed. 4. Turn off all pump circuit breakers and all other circuit breakers to the dispenser.

Make sure the 12-gauge Ground wire is properly terminated in the Junction Box and in the dispenser ground terminal. This ground connection must measure 1 ohm (or less) resistance to earth ground at the Junction Box. Prior to using a compression fitting to tie the Ground and Neutral to the dispenser measure the ground resistance using an Ohm meter connected between the Ground and the Neutral wire in the Junction box. After measurement connect the wires with the compression fitting Note: this measurement method only works on 115VAC circuits. Make sure all the screws on the terminal strip are tight and that the terminal strip is fully pressed onto the circuit board and snapped in place.

Make sure the wiring (AC and DC) agrees with the wiring diagrams. DANGER: There must be no hazardous gases present before powering up the dispenser. Turn on 115 Volts circuit breaker to supply AC electronic power to the unit: 1. Use a voltmeter to verify 115 Volts AC on TS1 of the Power Distribution Board. TS1, terminal 2 is

Neutral. This AC circuit provides power to the electronic boards. Use a voltmeter to verify there is no AC power on any other terminals or wires at this point.

2. Turn on the switch on the Power Distribution Board and make sure displays are operating normally. 3. To charge the battery the override button on the Timer Board must be pressed and held for a few

seconds until the battery is charged. Once the battery begins to charge release the override button.

FINISHING THE WIRING INSTALLATION - REPLACE THE SAFETY COVERS Now that the pump is completely wired and tested replace the safety covers. Replace the Power Distribution Board cover removed at the start of the wiring process and be sure

that all 4 screws are installed and properly tightened. Perform this operation with the dispenser power off.

Check that the Intrinsically Safe Barrier cover is properly installed and the screws are tight. Check that the Power Supply cover on the back of the computer module is in place and the screws

are properly tightened. Close and lock all dispenser doors and covers. Open inlet shut-off ball valve. WARNING: All covers must be returned to their designed locations or the pump will be unsafe to operate.

Dispenser Start-Up and Checklist

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Item Procedure Completed

1 Verify that all CNG fittings are tight and not leaking. 2 All hanging hardware must be checked for proper installation and no leaks. 3 The units must be properly bolted to the island. 4 Vent line must not contain vapor traps. 5 Electrical field conduits must be properly potted per local, state and national

codes.

6 Equipment must be installed in conjunction with an emergency power cutoff to remove all power from the equipment in the case of an emergency. Test this system for proper operation.

7 All grounds must be properly connected per the installation manual requirements as well as local, state and national codes.

8 Use of properly sized neutral breaking circuit breakers for the units involved.

9 All dispenser electrical power is wired to the same phase of electrical power.

10 Use 3 wire shielded cable or 3 wires together for the card reader RS485 communications circuit. (Bennett highly suggests that these should be twisted at least 3 times per foot.)

11 Use 3 wire shielded cable or 3 wires together for the Fuel RS485 communications circuit. (Bennett highly suggests that these should be twisted at least 3 times per foot.)

12 New site wiring must be megger tested. Pull new wires in conduits in existing installations.

13 Verify the correct brand panels, nozzles and hoses are installed for each grade.

14 Verify that all ball valves are opened.

15 Calibrate the meters per the procedure on page 20.

16 Close and lock all dispenser doors, covers and panels.

17 Verify that bolts have replaced the eyebolts used for transporting the dispenser.

Final Installation Checklist

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Field Wiring and Communication Diagram - Current Loop

Diagram 1 - Current Loop Field Wiring

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Field Wiring and Communication Diagram - Current Loop

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Diagram 2 - RS485 Field Wiring

Field Wiring and Communication Diagram - RS-485

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Field Wiring and Communication Diagram - RS-485

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How to Perform an Electronic Calibration in Menu Code 27 NOTE: If the E-Cal isnt performed properly then the dispenser could produce a Calibration Error.

To retrieve the calibration value follow this procedure: To calculate the percent error read the display and the scale. The units of the display need to be converted to the same units on the scale. For example if Gasoline Gallon Equivalent (GGE) is used on the dispenser multiply the value by 5.660 to convert it to pounds.

For example: Display = 60 GGE x 5.660 = 339.60 lbs (Test Can = 339 lbs)

E-Cal Value percent error = (-.18)

Prior to entering Mode 27 slide the switch to E-Cal Mode on the CPU Board. Figure 15 shows the switch in Normal Operating Mode. If this switch is not moved to E-Cal Mode then the dispenser will not enter into Mode 27. If the dispenser is attempted to run in normal mode while this switch is in E-Cal Mode then the dispenser will give an Error 74. If this happens place the nozzle back into the Nozzle Boot, close the switch and start the sale over. The Direct Percentage Entry Procedure This procedure provides a way to enter the electronic calibration. To perform the direct percentage entry, follow this procedure: 1. After the Managers Mode has been accessed, press the number 2 and 7, then the MODE button on

the keypad. The first display shows the current electronic calibration correction constant of the configured meter. At this time press ENTER.

2. The main display now shows the direct percentage entry menu. Enter the result of the calibration procedure. The example above would reflect a -.12 entry.

3. As the new electronic calibration correction constant is entered, it will show up in the main volume display. When the ENTER button is pressed, the entered electronic calibration correction constant is loaded into the meter and appears in the PPV display.

4. Press the CANCEL button to exit out of Mode 27. 5. Unplug the keypad. 6. Slide switch to Normal Operating Mode and use wire seal to protect from tampering.

How to Electronically Calibrate (E-Cal) the Dispenser

Electronic Calibration Switch

Figure 15 - E-Cal Switch

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Natural Gas Dispensers Pacific Series Warranty on parts, labor, and travel is 12 months from date of installation or 18 months from date of Bennetts original invoice, whichever comes first. Warranty excludes nozzles, hoses and fittings, hose retractor, filters, belt adjustments, paper jams, light bulbs, or any leaks after the installation start-up and audit. Minor adjustments such as meter calibration, pulser adjustments, and handle switch adjustments, customer specified items manufactured by others, and customer requested repro-gramming of equipment are not covered by warranty. Field Retrofitted Kits, Card Readers, Cash Acceptors and all Other Field Retrofit Accessories The field retrofit assembly is warranted for parts only for 12 months from date of installation or 18 months from date of original invoice, whichever comes first, except the receipt printer and driver board which is warranted for parts for ninety (90) days from the date of installation or 180 days from original invoice, whichever comes first. Consumable Items such as receipt paper are not warranted. The use of receipt paper not specified by Bennett will void the printer assembly warranty. Model 515 Pump Controller, 621 Module, Fan Out Boxes Warranty on parts, labor and travel is 12 months from the date of installation or 18 months from the date of original invoice, whichever comes first. Software Bennett Pump Company warrants Bennett products and software packages, whose operation is controlled by Bennett designed and developed software, shall be free of material defects and conform to current Bennett specifications for a period of ninety (90) days from the date of original invoice. Bennett shall use its best effort to correct such defects and to supply to purchaser at Bennetts expense, a corrected version within a reasonable time after purchaser notifies Bennett in writing of any defects and provides the programs and instructions required to reproduce the claimed defect. This would not cover any modification to the program, the Bennett product, and/or connection to unapproved equipment made by any person or any defect caused by such modifications/connections. Upgrade Kits Bennett offers kits which are installed at the purchasers option to enhance operating features of an existing Bennett product. These upgrade kits are warranted for parts only for ninety (90) days from date of installation or 12 months from date of original invoice, whichever comes first. This warranty applies to kit components only. The warranty status of the remainder of the product is unchanged. Spare Parts For equipment under warranty: The warranty period for all spare parts replaced is the remainder of the original warranty. Spare Parts are warranted for the value of the parts only (no labor, mileage, or other charges). For equipment not under warranty: The warranty period is 90 days from the date of invoice to the end user, or 12 months from the date of original invoice, whichever comes first. Spare Parts are warranted for the value of the parts only (no labor, mileage, or other charges). General Exclusions 1. Warranty does not apply to any product which has been altered, subjected to unusual physical or electrical stress, an Act of God, damaged by

accident, tampered with, or subjected to misuse or abuse including substituting parts or accessories from other manufacturers without the written consent of Bennett Pump Company. The above warranties shall not exist if the original identification marks have been removed or altered.

2. Bennett makes no warranty with respect to the Bennett equipment or Bennetts performance of services under this agreement, express or implied, and Bennett hereby disclaims the implied warranties of merchantability and fitness for a particular purpose.

3. In no event shall Bennett be liable for any loss of profits, loss of use, interruption of business or indirect, special, incidental or consequential damages of any kind in connection with or arising out of the furnishing, performance, use or failure of the Bennett equipment, software or services acquired from Bennett, the distributor or the user, whether alleged as a breach of contract or tortuous conduct, including negligence. Bennetts liability hereunder for damages shall not, in any event, exceed the amounts paid by the buyer to Bennett for equipment, software or services as to which the claim arose.

4. No action arising out of any claimed breach of the Warranty Agreement or transaction under this Warranty Agreement may be brought by either party more than two (2) years after the cause of action has accrued.

5. Use of non-Bennett replacement parts, unless specified by Bennett, will void the equipment warranty. 6. This warranty only applies to Bennett equipment installed in the United States of America and Canada. 7. Failure to pay the Bennett invoice within stated invoice terms, covering the respective Bennett equipment purchased under this limited warranty

may, at Bennetts discretion, void this limited product warranty. THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING, WITHOUT LIMITATION, THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

BENNETT PUMP COMPANY 1218 E. Pontaluna Road Spring Lake, MI 49456 Tel: 231-798-1310 Fax: 231-799-6202

Bennett Limited Warranty for Products Installed in the United States - Natural Gas Dispensers

Bennett Pump Company guarantees new Service Station Equipment manufactured by Bennett against defects in material or workmanship during the warranty period in accordance with the provisions stated below: The Site Audit Report issued with all equipment must be completed and returned at time of installation to Bennett Pump Company, Spring Lake,

MI to initiate warranty.

Warranty service must be performed by the nearest Bennett Authorized Service Representative qualified to perform service on the defective equipment. Only Authorized and Certified Service Representatives are allowed to perform warranty service. Use of service personnel other than qualified Bennett Service Representatives without prior approval by Bennett Pump Company will void payment of any warranty claims.

Labor and travel costs incurred while servicing Bennett equipment will be paid at previously contracted rates subject to published standard repair time allowances to qualified Bennett Service Representatives with travel cost limited to 200 miles. Travel cost shall be limited to 4 hours round trip.

Bennett equipment has been installed according to the manufacturers instructions and diagrams. During the warranty period, Bennett Pump Company will, at its option, repair or replace defective parts returned to its factory, transportation

charges prepaid.

The manufacturer reserves the right to make changes in the design or to make additions

120950 Rev B 08-2-13 23

Natural Gas Dispensers Pacific Series Warranty on parts is 12 months, labor and travel is 90 days. Warranty begins at date of installation or 180 days after shipment, whichever comes first This warranty excludes nozzles, hoses and fittings, hose retractor, filters, belt adjustments, paper jams, light bulbs, or any leaks after the installation start-up and audit. Minor adjustments such as meter calibration, pulser adjustments, and handle switch adjustments, customer specified items manufactured by others, and customer requested repro-gramming of equipment are not covered by warranty. Field Retrofitted Kits, Card Readers, Cash Acceptors and all Other Field Retrofit Accessories The field retrofit assembly is warranted for parts only for 90 days from date of installation or 180 days from date of original invoice, whichever comes first. The receipt printer and driver board which is warranted for parts for ninety (90) days from the date of installation or 180 days from original invoice, whichever comes first. Consumable Items such as receipt paper are not warranted. The use of receipt paper not specified by Bennett will void the printer assembly warranty. Model 515 Pump Controller, 621 Module, Fan Out Boxes Warranty on parts, labor and travel is 90 days from the date of installation or 180 days from the date of original invoice, whichever comes first. Software Bennett Pump Company warrants Bennett products and software packages, whose operation is controlled by Bennett designed and developed software, shall be free of material defects and conform to current Bennett specifications for a period of ninety (90) days from the date of original invoice. Bennett shall use its best effort to correct such defects and to supply to purchaser at Bennetts expense, a corrected version within a reasonable time after purchaser notifies Bennett in writing of any defects and provides the programs and instructions required to reproduce the claimed defect. This would not cover any modification to the program, the Bennett product, and/or connection to unapproved equipment made by any person or any defect caused by such modifications/connections. Upgrade Kits Bennett offers kits which are installed at the purchasers option to enhance operating features of an existing Bennett product. These upgrade kits are warranted for parts only for ninety (90) days from date of installation or 180 days from date of original invoice, whichever comes first. This warranty applies to kit components only. The warranty status of the remainder of the product is unchanged. Spare Parts For equipment under warranty: The warranty period for all spare parts replaced is the remainder of the original warranty. Spare Parts are warranted for the value of the parts only (no labor, mileage, or other charges). For equipment not under warranty: The warranty period is 90 days from the date of invoice to the end user, or 180 days from the date of original invoice, whichever comes first. Spare Parts are warranted for the value of the parts only (no labor, mileage, or other charges). General Exclusions 1. Warranty does not apply to any product which has been altered, subjected to unusual physical or electrical stress, an Act of God, damaged by





5. Use of non-Bennett replacement parts, unless specified by Bennett, will void the equipment warranty. 6. This warranty only applies to Bennett equipment installed in the United States of America and Canada. 7. Failure to pay the Bennett invoice within stated invoice terms, covering the respective Bennett equipment purchased under this limited warranty



Bennett Limited Warranty for Products Installed in Canada - Natural Gas Dispensers






charges prepaid.


120950 Rev B 08-2-13 24

Natural Gas Dispensers Pacific Series Warranty on parts & Labor is 24 months and travel is 12 Months. Warranty begins at date of installation or 180 days after shipment, whichever comes first This warranty excludes nozzles, hoses and fittings, hose retractor, filters, belt adjustments, paper jams, light bulbs, or any leaks after the installation start-up and audit. Minor adjustments such as meter calibration, pulser adjustments, and handle switch adjustments, customer specified items manufactured by others, and customer requested repro-gramming of equipment are not covered by warranty. Field Retrofitted Kits, Card Readers, Cash Acceptors and all Other Field Retrofit Accessories The field retrofit assembly is warranted for parts only for 90 days from date of installation or 180 days from date of original invoice, whichever comes first. The receipt printer and driver board which is warranted for parts for ninety (90) days from the date of installation or 180 days from original invoice, whichever comes first. Consumable Items such as receipt paper are not warranted. The use of receipt paper not specified by Bennett will void the printer assembly warranty. Model 515 Pump Controller, 621 Module, Fan Out Boxes Warranty on parts, labor and travel is 90 days from the date of installation or 180 days from the date of original invoice, whichever comes first. Software Bennett Pump Company warrants Bennett products and software packages, whose operation is controlled by Bennett designed and developed software, shall be free of material defects and conform to current Bennett specifications for a period of ninety (90) days from the date of original invoice. Bennett shall use its best effort to correct such defects and to supply to purchaser at Bennetts expense, a corrected version within a reasonable time after purchaser notifies Bennett in writing of any defects and provides the programs and instructions required to reproduce the claimed defect. This would not cover any modification to the program, the Bennett product, and/or connection to unapproved equipment made by any person or any defect caused by such modifications/connections. Upgrade Kits Bennett offers kits which are installed at the purchasers option to enhance operating features of an existing Bennett product. These upgrade kits are warranted for parts only for ninety (90) days from date of installation or 180 days from date of original invoice, whichever comes first. This warranty applies to kit components only. The warranty status of the remainder of the product is unchanged. Spare Parts For equipment under warranty: The warranty period for all spare parts replaced is the remainder of the original warranty. Spare Parts are warranted for the value of the parts only (no labor, mileage, or other charges). For equipment not under warranty: The warranty period is 90 days from the date of invoice to the end user, or 180 days from the date of original invoice, whichever comes first. Spare Parts are warranted for the value of the parts only (no labor, mileage, or other charges). General Exclusions 1. Warranty does not apply to any product which has been altered, subjected to unusual physical or electrical stress, an Act of God, damaged by





5. Use of non-Bennett replacement parts, unless specified by Bennett, will void the equipment warranty. 6. This warranty only applies to Bennett equipment installed in Australia. 7. Failure to pay the Bennett invoice within stated invoice terms, covering the respective Bennett equipment purchased under this limited warranty



Bennett Limited Warranty for Products Installed in Australia - Natural Gas Dispensers






charges prepaid.


120950 Rev B 08-2-13 25

Page Intentionally Left Blank

120950 Rev B 08-2-13 26

CNG Site Audit Report

Model and Serial Number of Dispensers and Serial Number of Credit Card Readers (if applicable): ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________

Site Information: Phone: ________________________________ Name: _________________________________ Address: _______________________________ ______________________________________ City: _______________ State: _____ Zip: _____ Owned by: ______________________________ Equipment Purchased Date: ________________

Bennett Pump Company 1218 E. Pontaluna Road Spring Lake, MI. 49456 Fax: 231-799-6202

CNG Site Audit Report This form must be filled out and sent in to Bennett to establish

the equipment warranty.

Date of Audit

Date of Installation

What type of Interface Box in use for the Fuel Communication? ______________________________ What type of Point of Sale (P.O.S.) in use? ____________________ Software Version? ___________

Enter Y = Yes, N = No or N/A = not applicable:

______ Is the dispenser mechanically mounted to the island using securing bolts and metal shims? ______ Are the card readers field wiring twisted at least 3 times per foot? ______ Is the distance between the dispenser(s) and the Interface Box less than 500 feet (150m)? ______ For the field wiring does each dispenser have a dedicated rigid metal conduit? ______ Is the field wiring Oil and Gas resistant, THHN, the right gauge and copper stranded? ______ Is the field wiring continuous with no splices? ______ Are the field wire conduits sealed for vapors in the head of the dispenser? ______ Is the resistance between Neutral and Earth Ground less than 1 ohm?

Reading: Ohms. ______ Is the voltage between Neutral and Earth Ground less than 1volt AC or DC?

Readings: VAC VDC ______ Are there no more than 2 dispensers on one dedicated 15 Amp breaker? ______ Are the wires between the P.O.S. within 100 feet (30m)? ______ Has the dispenser been tested for leaks at all fittings and are all leaks repaired (if any)? ______ Is all piping and valves secured per manufactures specifications and State regulations? ______ Is the Pump Controller on the same phase of power as the dispensers? ______ Are all of the dispensers on the same phase of power? ______ Is the approved emergency stop relay installed and working properly on the dispenser(s)? ______ Was the Bennett Warranty statement reviewed with the station Manager / Owner and do they understand

the policy? ______ Has the start-up and checklist been completed? ______ Were all Bennett installation instructions followed per our Installation Manual? If not, please explain, in

detail, anything out of the ordinary on next page.

120949 Audit Report Form CNG Rev. A

120950 Rev B 08-2-13 27

Exceptions to Bennett Installation Instructions: Please list anything out of the ordinary or worth mentioning that may affect the safety or dispensing of the installed equipment. If there were any confusing instructions in the Instal-lation Manual or start-up procedure please add comments here.

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Audited by: Technician: Company: Name: ___________________________________ Name: __________________________________ Email: ___________________________________ Address: ________________________________ Phone: __________________________________ Phone: _________________________________ Certification #: _____________________________ Technician Signature: Owner/Manager Signature: ________________________________________ _______________________________________

120949 Audit Report Form CNG Rev. A

120950 Rev B 08-2-13 28

Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456 USA 800-235-7618 ~ Outside USA 231-798-1310

[email protected] ~ www.bennettpump.com

bennett cng dispenser installation

Documents

safe installation

pipeline installation

power requirements

equipment bennett

environmental requirements

general wiring instructions

safety instructions

cng dispenser din