Service Bulletin SB 3028 Rev H 5/12 ® Spectrum 100 V2.6 Electronic Fluid Inventory System Model 3110-006P .....Queuing Console Model 3120-030....Smart Controller Model 3120-031......Ready Light Model 3120-032....Fluid Solenoid Valve Model 3120-033....Air Solenoid Valve Model 3120-036.......Power Adapter Thoroughly read and understand this manual before installing, operating or servicing described equipment.
Safety: General Notes, Warnings, and Precautions Thoroughly read and understand this manual before WARNING installing, operating or servicing described equip- DANGER: Not for use with fl uids that ment. have a fl ash point below 100 Deg F (38 CAUTION Deg C, examples: gasoline, alcohol).
Do not substitute valves, cable or other devices in place of Spectrum components. Substitution may cause malfunction, or loss of eligibility for Balcrank’s warranty. Dispensing Ease... This equipment is designed for indoor use only. Spectrum...
Specifi cations: Product Specifi cations Dispense Control and Tracking: System Capacity: The Spectrum system control program is protected The Spectrum 100 system has a control capacity from unauthorized dispensing operations. PIN for dispensing 4 fl uids at 1-16 stations or 3 fl uid at identifi...
fl uid thermal expansion. Select correct model 3120-026 Ticket Printer to Model 3110-007 Queuing Console, from the Balcrank Catalog based on the pump model used. Pres- allowing remote viewing of printer reports. Up to two extensions sure relief valves must be installed in all Spectrum...
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150, 200, 250, 500 and 1000 ft. lengths. Refer to layout planning as standard Access database. PC Interface cannot be used if sheet, Spectrum installation instructions and Balcrank price list. Model 3120-035 Ticket Printer is utilized. Dash number =cable length in feet. Page 7...
3120-035 Ticket Printer estimated current tank level (all in gallon units). At 3120-103 Impulse Meter factory set-up time, Balcrank will add meter PPG factors. At fi eld installation time, adjust exact tank current-level 3123-xxx Solenoid Cable amounts. 3121-xxx...
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Ports: Ports: SC 08 SC 09 Station: Station: Ports: Ports: for factory entry only: Balcrank Sales Order No.: User: Pre-programming Date: User City, State: Console Serial No.: Balcrank Distributor: Programmed By: Distributor PO No.: Figure 17 F5192 Rev A 7/04...
Station: Ports: Ports: SC 08 SC 09 Station: Station: Ports: Ports: for factory entry only: Balcrank Sales Order No.: 242355 Jerry's Auto Mart User: Los Angeles, CA 7/21/04 Pre-programming Date: User City, State: 10037 V3.2 City Oil Company Console Serial No.:...
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SC 09 Station: 15 15 16 16 Station: 17 17 18 18 Ports: Ports: for factory entry only: Balcrank Sales Order No.: 242355 Car City User: 7/21/04 Austin, TX Pre-programming Date: User City, State: Console Serial No.: 10037 V3.2 Texas Pump Service...
17, page 9] to “WIRING DETAIL, AIR VALVES”, [Figure 28, page Spectrum purchase order at Balcrank. Locate your 21] and “WIRING DETAIL, SMART CONTROLLERS”, copy of the worksheet, which was shipped with the [Figure 26, page 20] equipment order.
Installation: Step-by Step Procedure (outgoing side of terminal strip) using a fl at screw- NOTE driver blade to push the terminal opening buttons. Be sure to match meter fl uid-number color codes to the Use care when wiring components. wiring in the pump room. Refer to “WIRING DETAIL, Prepare wire ends per WIRE END CONSOLE”, [Figure 25, page 19]...
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Installation: Step-by Step Procedure For each dispense point, run one length of Place the console Power Adapter (model 3120- Solenoid Cable (model 3123-xxx) from the Fluid 036) beneath the counter and plug into the con- Solenoid Valve to its associated Smart Controller. sole.
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47-56, before except current tank amount. Edit current tank proceeding further. Call Balcrank for factory assis- amount for each fl uid to show correct quanties now tance if required.
Illustrations: Pump & Smart Controller Model 3120-033 Air Solenoid Valve Model 3120-103 Electronic Impulse Model 3260-048 Lubricator Meter Air Line Filter and Pressure Regulator Pressure Relief Kit See page 6 for selection Fluid Line Hand Shut- off Valve and outlet check valve Model 3120-003 Air Line...
Illustrations: Fluid Valve & Ready Light Premium Reels: Ready light presses into 0.500” dia hole, located as shown. Enclosed Deluxe Reels: Ready light presses into Note Ready light and 0.500” dia. hole on outlet cast- solenoid valve wiring, ing, located as shown. Secure secured to the reel with cable with ties internally.
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Illustrations: Queuing Console Wiring Power/Signal Cable Model 3121-xxx Power/Signal Cable to Smart Controller SC 01 Model 3121-xxx (Service Area) to Smart Controller SC 00 Air (Pump Room) Impulse Meter Cable Model 3122-xxx to Meters Queuing Console Model 3110-006P C- C+ P- P+ C- C+ P- P+...
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Illustrations: Smart Controller Wiring Solenoid Cables Model 3123-xxx to Fluid Solenoid Valves or Air Solenoid Valves Smart Controller Model 3120-030 Output Port LED's (4) Installed Smart Controller Smart Controller Model 3120-030 With Cables Attached Power/ Signal Cable Model 3121-xxx to next Smart Controller Detection Zone for Magnetic...
Illustrations: Component Wiring Details Trim insulation on individual wires to this distance Red Wires 1/4” Air Solenoid Valve Model 3120-033 Wire Nut or Crimp Connector Trim cable cover to here. If 2” to 3” shielded, remove excess metal cloth from the cable shield, but leave bare shield wire intact.
Installation: System Set-up Wiring Note Four Tail End Resistors (120K Ohm) temporarily installed at fl uid ports “Port (+)” to “Port (-)” On each output port. Air Smart Controller: Remains in position through- out the ground level set-up process. Note Tail End Resistor (120K Ohm) installed at output “Signal Out (+)”...
Installation: Impulse Meter Wiring Note: Wiring a system for two meters is shown here. Wires for the other two meters are cut back Wire Nut to the end of the cable wrap, as shown or Crimp Connector Impulse Meter Cable Model 3122-xxx One to Two Connection at...
Operation: Understanding PIN Codes in memory and up to 5 additional “Management” PIN NOTE codes. These 4 levels of protection are applied in the following way: It is highly recommended that PIN code identifi cation be set up and utilized in all Confi...
Operation: Guide to Basic Procedures (BP) Nine console procedures are used to control dispense operations and manage jobs in queue, to review and maintain tank level information, and to inspect job history: General Access Procedures Management Access Procedures (All PIN numbers may use these procedures.) (Under some system set-up conditions, only management PIN numbers may use these procedures.
Operation: Special Methods and Suggestions During Spectrum operation, certain situations Turn OFF console power at night... Turning require special technique. For improved job handling off the console at the end of a workday assures and fl uid management, read and use the following that air solenoid valves in the pump room remain recommendations: closed overnight.
SP6 or b) save the current console setup to the Air SC using procedure SP6 (if you have just completed program changes, for example). Call Balcrank for assistance if you are not sure of approproate action. Press “ENTER” to resume the start-up rou-...
Basic Procedure BP2: New Dispense Job BP2: New Dispense During these steps, if you make an entry mistake, press “NEW” to erase the job entry and re-initiate the new job request. With the display showing “SPECTRUM SPECTRUM 100 100 IDLE”, Press “NEW” to begin key IDLE entries for a new dispense job.
Basic Procedure BP3: Job Status Review BP3: Job Status Review During these steps, if you make an entry mistake, press “NEW” to return to “SPEC- TRUM 100, IDLE” . Begin with the program at home posi- SPECTRUM 100 tion: “SPECTRUM 100, BUSY (or IDLE)”. BUSY (or IDLE) Press the “STATUS”...
Basic Procedure BP4: Queue Jumping BP4: Queue Jumping During these steps, if you make an entry mistake, press “NEW” to return to “SPEC- TRUM 100, IDLE” . Begin with the program at home posi- SPECTRUM 100 tion: “SPECTRUM 100, BUSY (or IDLE)”. BUSY (or IDLE) Press the “STATUS”...
Basic Procedure BP5: Job Deletion BP5: Job Deletion During these steps, if you make an entry mis- take, press “NEW” to return to “SPECTRUM 100, IDLE” . Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, BUSY (or IDLE)”. Press BUSY (or IDLE) the “STATUS”...
Basic Procedure BP6: Tank Refi lling BP6: Tank Refi lling During these steps, if you make an entry mis- take, press “NEW” to return to “SPECTRUM 100, IDLE” . Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”)
Basic Procedure BP7: Inventory Status BP7: Inventory Status During these steps, if you make an entry mis- take, press “NEW” to return to “SPECTRUM 100, IDLE” . Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”)
Basic Procedure BP8: Dispense Log BP8: Dispense During these steps, if you make an entry mis- take, press “NEW” to return to “SPECTRUM 100, IDLE” . Begin with the program at home position: “SPECTRUM 100, IDLE”. Press the three- SPECTRUM 100 key simultaneous entry for management rou- IDLE tines (“NEW”+”ENTER”+”STATUS”)
Basic Procedure BP9: PIN Entry/Revision BP9: PIN During these steps, if you make an entry Entry/ mistake, press “NEW” repeatedly to return to “SPECTRUM 100, IDLE”. Revision Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”)
Special Procedure SP1: Console Initialization SP1: CAUTION Console Use this procedure with care. Initialization Follow instruction steps exactly. An incorrect key sequence can disrupt Spectrum programming, or require a lengthy re-setup. You SPECTRUM 100 IDLE may press NEW to escape the routine at any time.
Special Procedure SP2: Fluid Identifi cation SP2: Fluid Identifi cation Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”) 3 KEYS The next prompt will ask you to choose REQUIRED ACTIVITY: ? SCROLL ...
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Special Procedure SP2: Fluid Identifi cation, cont’d NOTE: Failure to load fl uid meter calibration factor (pulses per gallon) for each meter into FROM PREVIOUS Spectrum operating software will result in PAGE substantial dispense quantity errors. Next, enter the meter calibration factor for FLOWMETER SETUP PER GA:? the impulse meter measuring the selected 0533...
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Special Procedure SP3: SC Identifi cation SP3: Smart Controller Identifi cation Begin with the program at home position: “SPECTRUM 100, IDLE”. Press the three- SPECTRUM 100 IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”) 3 KEYS The next prompt will ask you to choose REQUIRED ACTIVITY: ? required management...
Special Procedure SP3: SC Identifi cation, cont’d FROM PREVIOUS PAGE When all stations have been through the STA: 00 port review scroll, the display will return SC 00 PORTS USED: 1234 EDIT VALUE: to a view of Station 00. Make one more scroll- pass through the displays to be sure that all ENTER ports are correctly set.
Special Procedure SP4: Comm Port Selection SP4: Comm Port Select Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”) 3 KEYS The next prompt will ask you to choose required management activity:...
Special Procedure SP5: Set Time/Date SP5: Set Time/Date Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”) 3 KEYS The next prompt will ask you to choose required management activity:...
Special Procedure SP6: System Confi guration SP6: System Confi guration SPECTRUM 100 IDLE Begin with the program at home position: “SPECTRUM 100, IDLE”. Press the three- 3 KEYS key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”) REQUIRED ACTIVITY: ? SCROLL The next prompt will ask you to choose SET-UP TANK REFILL...
Special Procedure SP7: System Log SP7: Begin with the program at home position: System “SPECTRUM 100, IDLE”. Press the three- key simultaneous entry for management routines (“NEW”+”ENTER”+”STATUS”) The next prompt will ask you to choose the SPECTRUM 100 required management activity: “SCROLL” IDLE to highlight “SET-UP”, then press “ENTER”.
Special Procedure SP8: Test All SC’s SP8: Test All Smart Controllers Begin with the program at home position: SPECTRUM 100 “SPECTRUM 100, IDLE”. Press the three- IDLE key simultaneous entry for management rou- tines (“NEW”+”ENTER”+”STATUS”) ENTER The next prompt will ask you to choose the required management activity: “SCROLL”...
Special Procedure SP9: SC Comm Test SP9: Comm Test, Smart Controller Begin with the program at home position: “SPECTRUM 100, IDLE”. Press the three- key simultaneous entry for management routines (“NEW”+”ENTER”+”STATUS”) SPECTRUM 100 IDLE The next prompt will ask you to choose the required management activity: “SCROLL”...
“causal” status code, step by step. Observe system operation after each step and follow instructions in the tables. If causes of the operational problem cannot be determined using status codes, or repairs are not effective, contact Balcrank Customer Service for assistance. Page 47...
Diagnostic: Non-Fault Codes and Messsages Dispense Log Message Code: Dispense Log Message Code: Dispense Log Message Code: “Code 04” “Code 05” “Code 06” Successful Dispense Job Job Killed Job Time Out Interpretation: Interpretation: Interpretation: The job was successfully completd A dispense job in queue was discon- The dispense job has been deleted and logged in job history storage.
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Diagnostic: Non-Fault Codes and Messsages Error Message and Code: Error Message and Code: Error Message and Code: “Code 14” “Code 30” “Code 31” Printer Comm Error SC Message Time Out Framing/Parity Error Interpretation: Interpretation: Interpretation: The console cannot transfer data to A dispense job instruction from the The console received a garbled data an attached ticket printer.
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Diagnostic: Error Codes and Messsages Error Message and Code: Error Message and Code: Error Message and Code: “Code 32” “Code 33” “Code 34” Framing/Parity Error “Console Byte Mismatch” “Electrical Short in Valve” Interpretation: Interpretation: Interpretation: The console received a garbled data The Smart Controller reports a wiring C o n s o l e r e c e i v e d a m e s s a g e message from the specifi...
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Diagnostic: Error Codes and Messsages Error Message and Code: Error Message and Code: Error Message and Code: “Code 35” “Code 36” “Code 37” “Electrical Open Circuit to Valve” “Remote SC Framing Error” “Remote SC Illegal Command ” Interpretation: Interpretation: Interpretation: The Smart Controller reports a wiring or coil open circuit associated with The console received a garbled data...
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Diagnostic: Error Codes and Messsages Error Message and Code: Error Message and Code: Error Message and Code: “Code 38” “Code 39” “Code 40” “No Response to Valve Command” “No Response to Valve Command” “Serial EEPROM Error at SC” Interpretation: Interpretation: Interpretation: Console did not get confirmation The designated Smart Controller...
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Diagnostic: Error Codes and Messsages Error Message and Code: Error Message and Code: “Code 41” “Code 43” “Valve-ON Error at Status Check” “Valve Did Not Activate” Interpretation: Interpretation: Console detects that a valve did not activate on command. Smart Control- Console reports a valve-ON error ler replacement is appropriate.
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Diagnostic: No-Code Errors and Other Symptoms Error Message and Code: Error Message and Code: Error Message and Code: “No Code” “No Code” “No Code” “System Problem...” “SCxx No Response” “System Checksum Error” Interpretation: Interpretation: Interpretation: This leading text in a message means Console reports a checksum error The console cannot communicate that an error was detected during the...
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Diagnostic: No-Code Errors and Other Symptoms Error Message and Code: Observed Symptom: Error Message and Code: “No Code” Printer does not print job reports Cannot magnetically poll SC’s “Station not Available” Interpretation: Interpretation: Interpretation: Console cannot communicate with Attached ticket printer does not print Inappropriate magnetic fi...
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Diagnostic: No-Code Errors and Other Symptoms Observed Symptom: Observed Symptom: Observed Symptom: Incorrect Amount of Fluid is Dis- No Fluid is Dispensed No Console Display pensed Interpretation: Interpretation: Interpretation: An incorrect amount of fl uid is dis- Fluid will not fl ow from from a dis- Console display is blank at power-up pensed when a job is authorized.
Repair Procedures (RP): System Repair or Expansion Replace Model 3110-006P “PROCEDURES: PIN Entry/Revision” [Procedure BP9, Page 35]. Queuing Console: This repair will temporarily interrupt Spectrum dis- Confi rm the system is correctly dispensing by pense capability for approximately 1 hour. Set up authorizing a 1-quart sample job to EACH dis- an alternate dispensing method for temporary use: pense point.
Repair Procedures (RP): System Repair or Expansion through entries without changing values until you “SPECTRUM 100, IDLE”. reach the pulses per gallon entry for the meter being To purge air from the system, dispense two 1-gallon replaced. At that step, edit the PPG value to the default jobs at the repaired dispense point, into a hand value of 0390 PPG.
Repair Procedures (RP): System Repair or Expansion Replace Model 3120-030 Remove the alternate dispensing method for tem- porary use prepared in step 1. Smart Controller: This repair will temporarily interrupt Spectrum dis- Replace Model 3120-035 pense capability for approximately 1 hour. Set up Ticket Printer: an alternate dispensing method for temporary use: This repair will temporarily interrupt Spectrum...
Repair Procedures (RP): System Repair or Expansion TROLLER”, [Figure 17, Page 9] The remainder of this repair will temporarily inter- Adding another rupt Spectrum dispense capability for approxi- Fluid to an installed System: mately 2-4 hours. Set up an alternate dispensing Fill out a system PLANNING WORKSHEET, method for temporary use: portable drums with hand .
Valve & Port Wiring sample to EACH dispense point. Observe ready light, then cancel each job. Failure to use authentic Balcrank Solenoid Cable (model 3123-xxx) can result in Spectrum system Remove the alternate dispensing method for malfunction and error messages. If a cable material temporary use prepared in step 8.
Repair Procedures (RP): System Repair or Expansion in Smart Controller terminal port plugs and secured At the queuing console, turn the power switch on by the clamping screws. If any wire end condition is the back of the console OFF and then ON. The uncertain, remove wire ends, then carefully re-strip display will show SPECTRUM 100 IDLE after complet- and re-install.
Repair Procedures (RP): System Repair or Expansion It may be useful to magnetically “identify” Smart the wired cable plugs in place of the originally installed Controllers prior to their installation into the oper- plugs from SC02. Install resistors as before. ating wiring network in the bays.
Troubleshooting by completing the appropriate procedures [SP1 Dispense Quantity Errors through SP6, pages 36-43]. Consult with Balcrank When evaluating dispensed amounts, use a customer service before taking this action. calibrated measuring container only, per “Required Tools and Materials List”...
Estimate the amount of error by observing the calibration marks on the container. Balcrank recommends the installation of an Uninter- If the amount dispensed was less than one measured ruptable Power Supply (UPS) device, such as those...
In some situations, it may be necessary to use cable other than Balcrank’s. It is the installer’s responsibilty to assure that any cable substitutions conform with or exceed the requirements of our original equipment cables. Use the detail descriptions below to be sure that all substitutions meet our requirements.
Reference: PIN Code Record Pin Code Reference Sheet...cut out and save! Use this reference sheet to 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.