Bennett CNG Series Electronic Service Manual
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Bennett CNG Series Electronic Service Manual

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Bennett CNG Series
CNG Series Remote Dispensers
Electronic Service Manual
Only Trained Personnel May Work on This Equipment
READ THIS BOOK
This book has important
information for safely servicing of this equipment.
Read and understand this book before attempting
troubleshooting. 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 may occur.
For new books, FAX to:
BENNETT MARKETING SERVICES
(231)799-6202
Or visit our web page at:
http://www.BennettPump.com
Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456
USA 800-235-7618 ~ Outside USA 231-798-1310
sales@bennettpump.com ~ www.bennettpump.com
125870 Rev A 8-12-14

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Summary of Contents for Bennett CNG Series

  • Page 1 For new books, FAX to: BENNETT MARKETING SERVICES (231)799-6202 Or visit our web page at: http://www.BennettPump.com 125870 Rev A 8-12-14 Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456 USA 800-235-7618 ~ Outside USA 231-798-1310 sales@bennettpump.com ~ www.bennettpump.com...

  • Page 2: Table Of Contents

    Table of Contents Introduction............................. 4 Safety Instructions ..........................5 Overview of 708 Electronic Components .................... 6 Basic Electrical Theory of Operation ....................6 Basic Hydraulic Theory of Operation ....................9 Filter Changing Instructions………………………………………………………………………………… Power Distribution Board ........................15 Board Functions ..........................15 Theory of Operation ...........................
  • Page 3 Table of Contents Connectors ............................45 Intrinsically Safe Barrier Board ......................47 Theory of Operation ........................... 48 Connectors ............................48 Fuses..............................48 Handle Switch Board ..........................49 Theory of Operation ........................... 49 Test Point ............................50 Connector ............................50 LEDs..............................50 Communication Hub Board ........................

  • Page 4: Introduction

    Bennett Customer Response Department at Bennett Pump in Spring Lake, Michigan. UNAUTHORIZED ALTERATION OF BENNETT PRODUCTS Bennett Pump Company products are designed to meet or exceed the standards of UL, FCC and the National Institute of Standards and Technology.

  • Page 5: Safety Instructions

    Safety Instructions 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”...

  • Page 6: Overview Of 708 Electronic Components

    Overview of 708 Electronic Components Basic Electrical Theory of Operation: 110VAC 60 cycle power comes into the dispenser through the field wiring conduit, into the Junction Box and to the bottom of the Power Distribution Board terminal strip (TS1). Power then passes through a 3 amp fuse and then is filtered for noise.
  • Page 7 Overview of 708 Electronic Components The CPU Board - The CPU Board is the heart of the system. It runs the software, has the memory, communicates with Point of Sale, sends display signals to the display boards, communicates with the product select touch panel, interfaces with the handles, controls the control valves through a wiring harness.
  • Page 8 Overview of 708 Electronic Components Main Display Board - The Main Display Board is used for the customer to view the currency and mass amount of the sale. The display gets its information from the CPU Board through the Product Select Board.

  • Page 9: Basic Hydraulic Theory Of Operation

    Overview of Hydraulic Components Basic Hydraulic Theory of Operation: Refer to figure 1.1 (next page) and figure 1.2 (page 11) for flow direction and component placement. Prior to this procedure the customer will have already attached the nozzle onto the vehicle tank. Once that is completed and the customer starts the dispenser the following procedure occurs in the Hydraulics portion of the dispenser: CNG enters the dispenser inlet traveling up through the shut off valve and up to the solenoid valve.
  • Page 10 Overview of Hydraulic Components 3 Bank Figure 1.1 - Hydraulics Schematic 125870 Rev A 8-12-14...
  • Page 11 Overview of Hydraulic Components Single Bank Figure 1.1 - Hydraulics Schematic 125870 Rev A 8-12-14...
  • Page 12 Overview of Hydraulic Components Refer to figure 1.1 (Previous Page) and figure 1.2 for flow direction and component placement. Shut off Valve (A)- There is one shut off valve for each CNG bank located at the inlet of the dis- penser.
  • Page 13 Changing A CNG Filter CNG Filter Change: 1. Turn off all CNG inlet ball valves to shut off the flow of CNG into the dispenser. 2. Slowly open the needle valve to relieve pressure in the hydraulics. 3. Plug in the manager’s keypad and open the valves in mode 80. (4-Activates all valves side 1) (8-Activates all valves side 2).
  • Page 14 Notes 125870 Rev A 8-12-14...

  • Page 15: Power Distribution Board

    Power Distribution Board Figure 2.1 Power Distribution Board Assembly - 116449 Board Functions:  Incoming A.C. Voltage (TS1)  Incoming A.C. Voltage filter (FIL1).  Fuse protection for the system (F1, F2, F3, F4 -7)  D.C. voltage distribution (J1) ...

  • Page 16: Theory Of Operation

    Power Distribution Board Power Distribution Board Theory of Operation - The Power Distribution Board is located in the center of the dispenser in the electronics cabinet. This board is covered by a metal cover to protect anyone working inside the equipment from receiving an electrical shock.

  • Page 17: Battery Backup

    Power Distribution Board Battery Backup - A separate rechargeable 12 volt battery (see figure 2.6) is connected to the Power Distribution Board. When the dispenser is in normal operation the battery is not used. It is charged by the 14 VDC battery charging circuit located on the Power Distribution Board.

  • Page 18: Pad Jumpers

    Power Distribution Board PAD Jumpers - There are a series of PAD jumpers located below the solid state relays (see figure 2.9). These PAD jumpers should not change in the CNG dispenser. Fuses - A series of fuses are located on the Power Distribution Board.

  • Page 19: Connectors

    Power Distribution Board Terminal Strips, Connectors and Pin-outs - The following is a description of the connections to the terminal strips, and pin-outs of all the connections on the Power Distribution Board. Note: Voltage readings can be taken right on the terminal strip connector pins. Terminal Strip 1 (TS1) - Dispenser Input Power ...
  • Page 20 Power Distribution Board J3 - Grey ribbon cable that connects the CPU Board to the Power Distribution Board. This cable handles the card reader communication and dispenser communication (Current Loop) from the CPU Board to the Power Distribution Board. It also turns off the battery back-up after 30 seconds, is responsible for P-Fail and Recall.
  • Page 21 Notes 125870 Rev A 8-12-14...

  • Page 22: Power Supply

    Power Supply Figure 3.1 Power Supply Assembly Part Number—111209 Board Functions -  Creates Direct Current (DC) voltages from Alternating Current (AC) voltages Power Supply Assembly Theory of Operation - AC power 110VAC 60 cycle comes from the Power Distribution Board on Power Supply Assembly connector J1. The purpose of the Power Supply is to take incoming AC and convert it to various DC voltages for use throughout the system.
  • Page 23 Power Supply NOTE: Most of the voltages and wires are color coded, but not always. Here are the color codes: Orange - 24VDC Red - 12 VDC Violet - 5 VDC Black - DC Common If any of these voltages are out of range then the performance may be erratic and it may be necessary to replace the Power Supply.
  • Page 24 Notes 125870 Rev A 8-12-14...

  • Page 25: Cpu Board

    CPU Board Figure 4.1 CPU Board Assembly - 110185 (Standard) & 115651 (Includes RS485 Daughter Board) Board Functions:  Runs Software  Contains Memory (RAM)  Communicates with the Point of Sale  Sends display signals to the Display Board ...

  • Page 26: Theory Of Operation

    Communication with the Point of Sale Current Loop - Communication is routed from the Point of Sale through the Bennett model 515 box. From the model 515 box the dispenser communication channel is connected by two field wires for each side of the dispenser. So, a dual sided...
  • Page 27 Bennett RS485 Fuel Protocol. From the POS or NexGen, communication interfaces to the Bennett Dual Fan Out Box (see figure 4.6). From the Fan Out Box the wires are routed via 3 twisted RS-485 wires to a white terminal block in the dispenser.

  • Page 28: Communication With Spm

    The chips have markings on them that describe the software revision level (which can also be seen in diagnostics), the Bennett part numbers and the date code of the chips. These are replaceable chips, but should not be replaced by untrained personnel.

  • Page 29: Ni-Cad Battery

    CPU Board On Board Battery - There is a 3.6 VDC Ni-cad battery that is used by the RAM chip to store all of the programming information if the dispenser is programmed and loses power. This battery is soldered right onto the CPU Board (see figure 4.13). It should maintain programming for extended and prolonged periods of power outage.

  • Page 30: Test Points

    CPU Board Communication LEDs - These LEDs are located on the right side middle of the CPU Board (see figure 4.16). D28 - Side 1 RXD for POS D29 - Side 1 TXD for POS D30 - Not Used D31 - Not Used NOTE: If it is communicating with the console these LEDs are constantly blinking.

  • Page 31: Ram Clear

    NOTE: This procedure will zero out electronic pump totals. NOTE: Do not show the customer how to do this procedure. This procedure should only be performed by the Bennett Certified Technician. NOTE: RAM clear procedure is not a warranted procedure unless Technical Support is contacted and recommends it.
  • Page 32 CPU Board To Perform a Manual RAM Clear: Solder Points Step 1 - Turn off the dispenser power and over ride the battery. Step 2 - Open the electronic head door on SIDE 2 of the dispenser. Step 3 - On the CPU Board locate RAM chip U31 (see figure 4.19). Step 4 - Take a piece of scrap wire and short Pins 16 (bottom left) and 32 (top right) of the chip for 10 seconds (see figure 4.20).

  • Page 33: Connectors

    CPU Board Figure 4.22 - CPU Board J2 - Internal LAN side 1 Electronic Calibration Switch J4 - Comm Hub Board (Dispenser Interface) J3 - Comm Hub Board (Back Office PLC-LNG J7 - DC voltages Only) from Power Board J8 - Communication signals to Power Board J10 - Intrinsically...

  • Page 34: Jumpers

    CPU Board J7 - DC Voltages from the Power Distribution Board Pin 1 - 24 VDC Pin 5 - 12 VDC Pin 9 - Ground Pin 2 - 24 VDC Pin 6 - 12 VDC Pin 10 - Ground Pin 3 - 12 VDC (standby) Pin 7 - Ground Pin 11 - 5 VDC Pin 4 - 12 VDC (standby)

  • Page 35: Valves

    Valve Control Valves : The valves are operated by a 24 VDC signal coming from the CPU Board. When the CPU Board sends a signal to the valve it opens up and allows for the flow of CNG to begin throughout the dispenser. Solenoid Valves Figure 4.25 - 125870 Rev A 8-12-14...

  • Page 36: Calibration

    Calibration Electronic Calibration Switch Board Part Number - 111663 Board Functions:  Enables / Disables Electronic Calibration functions of the dispenser. The Electronic Calibration Board is soldered onto the CPU Board on the J11 connection (see figure 4.27). There is a stud provided to prevent anyone from moving the switch into the Calibration Mode.
  • Page 37 Notes 125870 Rev A 8-12-14...

  • Page 38: Product Select / Auxiliary Display Board

    Product Select / Auxiliary Display Board Figure 5.1 - Product Select / Auxiliary Display Backlight Board Product Select / Auxiliary Display Backlight Board - 107336  The Manager Keypad plugs into this board to program the dispenser.  The Electromechanical Totalizers are plugged into this board. ...
  • Page 39 Product Select / Auxiliary Display Board Figure 5.2 - Product Select / Auxiliary Display Backlight Board Diagram 125870 Rev A 8-12-14...

  • Page 40: Preparation For Programming

    Product Select / Auxiliary Display Board How to Prepare the dispenser for Programming - The Manager’s Keypad is plugged into the Product Select / Auxiliary Display Board using the J4 Connector. As soon as the Manager’s Keypad is plugged into the board the dispenser automatically goes into Manager’s Mode.
  • Page 41 Notes 125870 Rev A 8-12-14...

  • Page 42: Main Display Board

    Display Board Figure 6.1 - Main Display Board Main Display Board - Part Number - 107330  Displays Mass, Currency and Price information  Displays information for diagnostics and sales totals  Recalls the last Sale if there is a power outage ...

  • Page 43: Leds

    Display Board LEDs - Other than the Liquid Crystal Display (LCD) there are no LEDs. The LCD is not field replaceable. Terminal Strips, Connectors and Pin-outs - The following is a description of the connections to the terminal strips of all the connections on the Main Display Board. JP-1 Communication Ribbon Cable from Product Select / Auxiliary Backlight Board JP-2 Power for the Main Display Backlight Board The Display Board for each model CNG is the same.
  • Page 44 Notes 125870 Rev A 8-12-14...

  • Page 45: Backlight Board

    Backlight Board Figure 7.1 - Main Display Backlight Board Main Display Backlight Board Part Number - 107334  Used to illuminate the Money / Mass Display. Theory of Operation - The backlight board is simply a board with numerous LEDs mounted to it. This board has no “smart functions”.
  • Page 46 Notes 125870 Rev A 8-12-14...

  • Page 47: Intrinsically Safe Barrier Board

    Intrinsically Safe Barrier Board Figure 8.1 - Intrinsically Safe Barrier Board Intrinsically Safe Barrier (ISB) Board Assembly Part Number - 105660  Provides an intrinsically safe barrier between the CPU Board and the Pump Handle Switch.  Contains fuses and zener diodes that “Short” any high voltages and electrical current “away” from the handles in the hydraulic area of the dispenser.

  • Page 48: Theory Of Operation

    Intrinsically Safe Barrier Board Theory of Operation - The Intrinsically Safe Barrier Board (ISB) provides intrinsic safety protection to the handle circuit located in the lower half of the dispenser in the hydraulic area. These circuits are designed with fuses and zener diodes to prevent any potential energy from entering the hydraulic area so that under no condition will there be enough energy to create an electrical spark hot enough to ignite.

  • Page 49: Handle Switch Board

    Handle Switch Board Magnetic Handle Switch Board uses wire and barrel connectors. Magnetic Switch Figure 8.2 - Handle Switch Board Magnetic Pump Handle Assembly Part Number - 111171  Signals the CPU Board that a customer is requesting product at a fueling point when the nozzle is removed from the boot.

  • Page 50: Test Point

    Handle Switch Board Test Point TP1 - This is the voltage for the handle circuit side 1 (see figure 8.6). The expected voltages for the handle is as follows:  Handles Off (side 1) - 3.00 volts dc  Handle A - 2.790 volts dc Test Point TP3 - 3.000 volts dc NOTE: The blue potentiometers located on the lower left of the CPU Board will be sealed from the factory.
  • Page 51 Notes 125870 Rev A 8-12-14...

  • Page 52: Communication Hub Board

    Communication Hub Board Figure 9.1 - Communication Hub Board Communication Hub Board - 119462 Board Functions:  SPM Interface (RS-232)  Dispenser Interface (RS-485)  Back Room PLC Interface (Modbus)  Thermistor Temperature Transducer  Pt100 RTD Temperature Transducer  Pressure Transducer (Current Loop) ...

  • Page 53: Dispenser Peripherals Interface

    Communication Hub Board Dispenser Peripherals Interface - The Communication Hub Board on the wall of the dispenser and the Communication Hub Board on the Card cage of the Sled (Closest to the power distribution board) both communicate to the dispenser’s pe- ripherals.
  • Page 54 J3 - is used for upgrading the software on the Communication Hub Board. This is not used in the field unless the technician is instructed by Bennett Pump Company. J4 - is used to communicate data to and from the SPM (Card Reader). This allows the dispenser to tell the SPM when to display different instruction screens on the SPM’s Display Board.

  • Page 55: Leds

    Communication Hub Board Light Emitting Diodes - D1 - J1, TS1, TS2 and TS6 (TXD) Red D2 - J1, TS1, TS2 and TS6 (RXD) Green D3 - J2 (TXD) Red D4 - J2 (RXD) Green D5 - J4 (RXD) Green D6 - J4 (TXD) Red Jumper - There is one jumper on the Communication...
  • Page 56 Notes 125870 Rev A 8-12-14...

  • Page 57: Purging System

    Purging System Theory of Operation - Pressure Switch: The electrical cabinet must maintain a minimum pressure differential of 0.15 inches of water column at all times. This is achieved by at- taching a blower fan to the electrical enclosure (see figure 10.1). If at any time the pressure differential drops less than 0.15 inches of water column a switch (see figure 10.2) will turn off, causing a timer and relay (see figure 10.3) to remove power from the dispenser until...
  • Page 58 Timer Board Timer Board Bypass Button: At start up the timer board will not allow the dispenser to power up until 3 minutes after a purge pressure of .15 inches of water column is reached. This is required for a complete air change in the dispenser enclosure to eliminate any explosive gasses.

  • Page 59: Dispenser Error Codes

    RAM Error - The RAM initialization string does not match that in ROM Reverse Pulse Error - The pulser interface generated negative pulses on an active hose, or positive pulses on an inactive hose. Contact Bennett Technical Support. Communication lost with meter.

  • Page 60: Clearing Error Messages

    2. Make sure to repair the problem that may have caused the error condition first and then clear the message. For persistent error codes and their remedies contact Bennett Technical Support at 1-800-423-6638. 125870 Rev A 8-12-14...
  • Page 61 Notes 125870 Rev A 8-12-14...

  • Page 62: Diagnostics

    Diagnostics How to Use Diagnostics Menu Code 0 To enter Diagnostics the manager’s keypad must be connected to the dispenser to place the dispenser into manager’s mode and gain access to Diagnostics. See Operator’s Manual for instructions on how to attach the manager’s keypad. Make sure the A.C. Reset switch is in the ON position, and the pump handles are all in the OFF position.
  • Page 63 Diagnostics Diagnostic Code 0 dESIGn This test is used to display the design type, software revision level, and the software identification or checksum of this software. To enter this test, enter diagnostics and press the 0 button dIAG on the keypad and the ENTER button. Press ENTER to see the first level of Test 0.

  • Page 64: Menu Code 1

    Diagnostics Diagnostic Code 1 - Display Segment Test PrESS This test is used to identify failed segments in the main sales displays or the individual price per mass (IPPM) displays. To enter this test, enter diagnostics and press the 1 button ---- ---- ----...

  • Page 65: Menu Code 3

    Diagnostics Diagnostic Code 3 - CPU Test Error This test deliberately introduces a fault into the arithmetic unit of the CPU. The display must then read ERROR 99 indicating the system has detected the fault. If the message is not displayed, the test has failed. dIAg To enter this test, enter diagnostics and press the 3 button on the keypad and the ENTER button.

  • Page 66: Menu Code 5

    Diagnostics Diagnostic Code 5 - Pump Handle Test HAndLE To enter this test, enter diagnostics and press the 5 button on the keypad and the ENTER button. This test checks the status of the pump handle on the dispenser. The CPU reads the pump handle switch and dIAg writes the status of the handle to the display.

  • Page 67: Menu Code 6

    Diagnostics Diagnostic Code 6 - PFAILS Power Failure Counter This code is used to investigate intermittent problems with power. The counters keep track of the number of times a power failure occurs. dIAg To enter this test, enter diagnostics and press the 6 button on the keypad and the ENTER button.
  • Page 68 Diagnostics Continued … Press ENTER to advance to the next counter. Cold Start Counter This code is used to tell the technician how many times a Cold Start has been performed on the dispenser. 6.3 - Cold Start The display shown in figure D-10c appears. The Price display shows the dispenser is in Diagnostics Level 6.2.

  • Page 69: Menu Code 7

    Diagnostics Continued ... Diagnostic Code 7 - Keyboard, Switch and Beeper Test PrESS To enter this test, enter diagnostics and press the 7 button on the keypad and the ENTER button. The display shown in figure D-11 appears. dIAg This code is used to test the switches for the product buttons.

  • Page 70: Menu Code 9

    Diagnostics Diagnostic Code 8 - StArt State Transition History This test is used to view the state transition log main- tained by the CPU Board. It stores a history of all state transitions which occur during the operation of the dis- penser.
  • Page 71 Diagnostics Continued... Table 1—State Descriptions nnnnnn State State Code Name Description Event Code Event Name Idle Handle Active IdLE Handle Idle Auth Handle Set Arm HANdLE Ready Clear Arm rEAdy Flow Flow Active Suspend Set Paid Collect Attendant Key On SUSPNd Pending Attendant Key Off...
  • Page 72 Diagnostics Diagnostic Code 9- Comm Hub Test In order to perform a Comm Hub Test an RS232 to RS485 converter will have to be connected between Me- ter Communication and SPM ports. Once the diagnostic mode is entered the Comm Hub will be placed in a self test mode, where all functions of the board will be tested and results will be sent back to the 0000...

  • Page 73: Maintenance

    Maintenance WARNING: Do not use a high pressure washer to clean the dispenser. Liquid under pressure can enter the dispenser cabinet and damage electronic components. Keep the dispenser clean and protected. It will keep a new pump appearance longer. To clean painted surfaces, follow this procedure: 1.

  • Page 74: Literature

    CNG Series Part Manual 116029 Bennett SPM (Debit / Credit) Manual 105022 515 Pump Controller Installation and Service 116186 621 Fuel Interconnection Box Manual 117866 NexGen Controller Installation Guide for Bennett Pumps 118602 Color SPM Manual 125870 Rev A 8-12-14...
  • Page 75 Page Intentionally Left Blank 125870 Rev A 8-12-14...
  • Page 76 125870 Rev A 8-12-14 Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456 USA 800-235-7618 ~ Outside USA 231-798-1310 sales@bennettpump.com ~ www.bennettpump.com...

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