Balcrank Director Jr. 3110-031 Instruction Manual

!CAUTION
It is strongly recommended that shielded
wiring be used for ALL impulse meter
connections. The use of unshielded
wiring could results in erroneous dispense
volumes. The Director batch register
and the totaling register will read the
correct amounts requested, but the
actual dispense volume will be less. This
condition is a result of the unshielded
wiring picking up stray signals from
adjoining electrical wires and/or electrical
equipment. If unshielded wiring is used,
the condition described above will not
be covered under Balcrank’s Product
Warranty.
Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
SERVICE BULLETIN SB3101
Rev. B 6/16
®
Director Jr.
Model #3110-031
24V DC Output

GENERAL SAFETY REQUIREMENTS
NOTE: THOROUGHLY READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLING,
OPERATING, OR SERVICING THIS EQUIPMENT.
WARNING
!
 DANGER:Notforusewithuids
 thathaveaashpointbelow100°F
 (38°C).Examples:gasoline,alcohol.
Sparkingcouldresultinanexplosionwhich
could result in death.
Check equipment regularly and
repair or replace worn and
damaged parts.
Never alter or modify any part of this unit,
doing so may cause damage to the unit and/or
personal injury.
Alwaysreadandfollowtheuidmanufacturer’s
recommendations regarding the use of proper
use, handling, and disposal.
Release pressures built up in the system
before any service or repair is begun on a
pressurized component on the system (e.g.
lters).Seethepressurereliefprocedure
below.
IMPORTANT
!
Pressure Relief Procedure:
Follow this procedure whenever you shut off
the pump, when checking or servicing any part
of the system and when installing, cleaning or
changing any part of the system.
1) Disconnecttheairtothepump.
2) Pointdispensingvalveawayfrom
yourself and others.
3) Opendispensingvalveuntil
pressure is relieved.
WARNING
!
WARNING
!
High Voltage may be present
when servicing this equipment.
This equipment should only be serviced by
authorized persons. Remove power from the
console before attempting to replace the
fuse.
Apressurereliefvalveattheuidsupplypoint
is mandatory for protection of the system and
personnel, and to maintain the warranty in
effect.ReliefKit3120-085(1/2”NPT)or3120-
086 (3/4” NPT) will protect the system from
possible overpressure damage. Excess uid
pressure above 850 psi (56 bar) is relieved.
Reliefoverowisdirectedbackintothesupply
container to reduce the risk of equipment
damage or serious bodily injury.
WARNING
!
1

2
TABLE OF CONTENTS
General Safety Information..............................................................................................................................1
Introduction.......................................................................................................................................................3
General Description............................................................................................................................................3
SystemSpecications ........................................................................................................................................3
ConsoleFeatures ...............................................................................................................................................3
Product Specications.....................................................................................................................................4
OperationalSchematic .......................................................................................................................................4
InterconnectionBox............................................................................................................................................5
Impulse Meter.....................................................................................................................................................5
Installation.........................................................................................................................................................5
General...............................................................................................................................................................5
Plumbing.............................................................................................................................................................5
Electrical.............................................................................................................................................................6
Wiring Diagram...................................................................................................................................................7
Console Setup ..................................................................................................................................................8
PulseCalibrationFactor .....................................................................................................................................9
Post Installation Check..................................................................................................................................10
OperationalCheck............................................................................................................................................10
Operation Instructions...................................................................................................................................10
NormalOperation .............................................................................................................................................10
TotalizerOperation ...........................................................................................................................................11
KeylockOperation ...........................................................................................................................................11
ReadyLightOperation......................................................................................................................................11
StationRotarySwitchOperation ......................................................................................................................11
Example............................................................................................................................................................11
Emergency Stop...............................................................................................................................................11
Reset ................................................................................................................................................................12
Service and Maintenance...............................................................................................................................12
General Policy ..................................................................................................................................................12
Periodic Inspection ...........................................................................................................................................12
Troubleshooting................................................................................................................................................12
Troubleshooting Chart ......................................................................................................................................13
Factory Service...............................................................................................................................................15
Repair...............................................................................................................................................................15
Parts List...........................................................................................................................................................15
Associated Components...................................................................................................................................15
Warranty Statement........................................................................................................................................17

INTRODUCTION
General Description
Controlleddispensingofmotoroil,ATF,gearoil,andantifreezeisavailablewiththeelectricalDIRECTORJR.
Theunitallowstheselectionofoneofuptoten(10)stations.OneDirectorJr.isrequiredforeachuidtype
dispensed. The console size is very small allowing for easy placement of as many units as may be required
forthenumberofuidstobedispensed.Eachunitiscompletelyself-contained.Theunitsofmeasurecanbe
set to quarts, pints, liters, or gallons. The voltage controlling the solenoid valves and the impulse meter is 24
VDC.
System Specications
Power Required.......................................................................................................................... 110 VAC, 60 Hz
Control Capacity............................................................................................................... 1 Product, 10 Stations
OperatingTemperature................................................................................................. 0°-140°F(-17°-60°C)
MaximumAmountDispensed......................................................................................99,999.9 Units of Volume
Impulse Meter Rating ............................................................................................................................... 30VDC
Resolution............................................................................................................................... 0.1 Unit of Volume
ControlOutputRating.............................................................................................................................. 24 VDC
Dimensions.....................................................................................................................5.7”Hx6.7”Wx5.7”D
MaximumFlowRate(ImpulseMeter)........................................................................................................8 GPM
Cable Length ...............................................................................................................................................6 feet
3

PRODUCT SPECIFICATION
Figure 1 showsasimplied,pictorialschematicofoneproductcontrolledto5stationsandreferencedexten-
sionofasixthstationaddition.
Typically, the following items are necessary:
1. Director Jr. (3110-031)-TheDirectorJr.allowscentralizedcontrolandmonitoringofindividualdeliveries
as well as a running total.
2. Isolation Air Valve (3230-004) - This valve will isolate the pump, air regulator, and air solenoid valve for
any servicing requirements, etc.
3. Air Regulator-Toregulateairpressuretothepump,sonottoexceed80psiand/orlimitpumpoutput
pressureto850psi(59bar)ifnormalairsupplywouldmakeithigherthanrecommended.
4. Air Solenoid Valve (3120-033) - This valve opens and closes air line to start the pump when activated by
theDirectorJr.(Balcrankrecommendsthisfeaturetohelppreventaccidentalspills.)
5. Pumps-1.3:1,3:1,5:1,and10:1ratioscanprovideandmaintainsufcientlinepressuresanduid
volumesformostsystems(systemplumbinglengthwilldictatepumpratiorequired).
6. Impulse Meter (3120-114) -Electricimpulsemetermeasurestheamountofuidthatisbeingdispensed.
System can be set to measure in quarts, liters, pints, or gallons.
7. Relief Kit (MANDATORY IN EACH SYSTEM) - 3120-085 for 1/2” NPT or 3120-086 for 3/4” NPT systems.
TheReliefKitlimitsuidpressurebuildupinlinesduetothermalexpansion,byrelievinguidpressure
over850psi(59bar).
8. Gate Valve-Isolatesthepumpanduidmeterfromuidow-backwhenservicing,etc.
9. Fluid Shut-off Valve (3230-002) - Isolates solenoid valve and dispensing station for servicing, etc.
10. Fluid Line Y-Strainer (3120-010 for 3/4” or 3120-040 for 1”)- Protects system against foreign
contaminants.
11. Fluid Solenoid Valve (3120-032) -
Thisvalveopensuidlinetodispens-
ing station when activated by the
DirectorJr.
12. Ready Light (3120-031) - Alerts the
operatorwhentheuidathisstation
has been enabled for dispensing.
Figure 1
Pictorial of a typical
DirectorJr.installation
4

Interconnection Box
ThereisnointerconnectionboxorjunctionboxprovidedwiththeDirectorJr.becausealloftheelectronicsare
containedintheconsole.Amultiwirecableisprovidedtoconnectinanyconvenientwiringbox.
Impulse Meter
Animpulsemeterisusedinthesystemtomeasuretheamountofuiddispensed.Thismeterisactuallya
simpleowmeterthatisinstalledintheuidline.Insidetheimpulsemeterisarotatingcamthatactuatesa
small microswitch that sends electrical impulses to the console. This meter can measure in quarts, pints, liters
or gallons.
INSTALLATION
General
TodeterminetheinstallationrequirementsforaDirectorJr.system(s),certainfactorsneedtobeestablished.
Ingeneral,thesefactorswilldeterminehowmuchmaterialsuchascablewire,uidlines,pumps,andetc.will
be needed. Answers to these questions below will help determine your material requirements.
1.Determinehowmanyuidtypesaretobedispensed.ThiswilldeterminehowmanyDirectorJr.systems
will be needed.
2. The number of reels or oil bars and solenoid valves needed will be determined by the number of stations
to be serviced.
3. Decidewheretolocatetheconsole(s),thereels,andoilbars,andtheuidsupplytanks.Oncethese
locationsareestablished,thelengthsofwire,cable,anduidlinescanbedetermined.
A pressure relief valve at the uid supply point is mandatory for protectionofthesystemand
personnel,andtomaintainthewarrantyineffect.ReliefKit3120-085(1/2”NPT)or3120-086(3/4”
NPT)willprotectthesystemfrompossibleoverpressuredamage.Excessuidpressureabove
850psi(56bar)isrelieved.Reliefoverowisdirectedbackintothesupplycontainertoreduce
the risk of equipment damage or serious bodily injury.
WARNING
!
Plumbing
TheDirectorJr.systemisacustomassemblytailoredtospecicneedsdependingontherelativepositionof
equipment, the number of products controlled and the number of stations for each product. To control a prod-
uct which will be monitored, an electric impulse meter will be installed in the main hydraulic line coming from
thepumporsourceofuidsupply,(Figure1,Item6).Themeterhas1/2”femalepipethreadsatbothinlet
and outlet. It is recommended that the meter be installed on a rigid line which will give it support. It is recom-
mendedthataexiblehosebeattachedbetweenthepumpandthemeter.Thiswillallowforslightmovement
orexingoftheinletline.
To make sure the system is as tamper proof and inconspicuous as possible, the impulse meter can be
installedatanypointinthehydrauliclinebetweentheuidsourceandtherstbranchofthesystem.Inthis
caseashortlengthofhoseatoneendissuggestedtosimplifythepipinghook-up.Acarefulstudyoftheoor
plan of the building where the system is to be installed should be made to determine the best location for this
meter, considering ease of installation and length of wiring to the console.
5

Theelectricuidsolenoidvalve(3120-032)isinstalledinthehydrauliclineasneartothepointofdispensing
aspossible(Figure1,Item11).Onevalvemustbeinstalledinthelineofeachoutlettobecontrolled.Itissug-
gestedthatamanualby-passvalvebeinstalledaroundthesolenoidvalveasshowninthediagram(Figure
1,Item9).Thisallowsthesolenoidvalvetobeby-passedincaseofelectricpowerlinefailure.Theby-pass
valve should allow for locking in either the open or closed position by means of a padlock or sealing wire to
avoid tampering.
ELECTRICAL
RefertoFigures2and3forelectricalinstallation.
InstallationshouldbemadeinaccordancewiththeNationalElectricalCode(NFPA70)andtheFlammable
andCombustibleLiquidsCode(NFPA30).
PowerinputtotheDirectorJr.is110VAC.Allcontrolcircuitsare24VDCwhicharenotnormallyrestrictedby
electrical codes, however, local codes should be checked for applicability, and all electrical installations should
comply with codes.
Placetheconsole(s)whereitwillnormallybeused.Allelectricalconnectionsaremadethroughthemulti-wire
cablesuppliedwiththeunit.Somekindofpullboxshouldbemountedwithin5feetoftheconsole.Asuitable
placemightbebehindadeskorintheceilingwheretheexistingelectricalsystemislikelylocated.Connect
thesuppliedcabletoascrewtypeterminalstripwith14terminalsthatismountedinsidetheboxasindicated
inFigure2.
No.18AWGwireisrecommendedforallrunslessthan400feet.Forrunsfrom400to625feet,usewireno.
16 AWG or larger. Normally the 24 VDC wiring can be run around the overhead structure of the building with-
out using conduit. This wire should be clamped or secured to the structure in such a way that it is not subject
toanymechanicalstress.Useastrainrelievingclampanytimeacableentersajunctionbox.Thecables
fromalltheconsolesinthesystemcanberuntoonejunctionboxwithconduitrunningtothe110VACcircuit
breakers and then using multi-wire cable for the control circuit runs.
Anotherjunctionboxshouldbeinstalledwithinafewfeetoftheimpulsemeter(lessthan10feet).Acontrol
cablecanthenbeusedtorunbetweenthisboxandtheconsolejunctionbox.Solderlessconnections(wire
nuts)canbeusedfortheconnectionsinthisbox.
Anotherjunctionboxorgroupofboxesshouldbemountednearthesolenoidvalves.Inthecaseofareel
bank,onejunctionboxmaysufceforseveralvalves.Intheeventthatanumberofreelbanksoroilbarsor
otherdispensingpointsareused,itmaybenecessarytolocateseparatejunctionsboxesateachdispensing
location. The two wires from each electrical solenoid valve should be run inside of plastic or metal sheathing
formechanicalprotection.Intheeventthatthejunctionboxislocatedatadistancefromthevalvegreater
than the length of the valve wires, it may be necessary to splice two ends of the wires together, soldering
them and then covering the connection with heat shrinking tubing.
Anoptionalextratothesystemisa“Ready”light(3120-031).Thislightisinstalledwithinsightofthedispens-
ing mechanic. It may be attached to the side of the reel bank, oil bar, or an adjacent wall. The wires of the
“Ready”lightareruntothesolenoidvalvejunctionboxandarewiredinparallelwiththevalve.
6

Before attempting to operate the system a careful check should be made of all wiring to assure
that all connections are secure and that no frayed leads cause an unwanted connection between
terminals or leads.
CAUTION
!
7

8
SETUP INFORMATION
General
DirectorJR.3110-031,VDCcomespreprogrammedwithpulsesettingsfromthefactory(seeTable1below).
Units shipped from the factory come pre-set for quarts.
When the system is powered on, the display will indicate:
-thecurrentsystemsettingswithadelayof2seconds(seeimage2below)
- the total ammount dispensed with a delay of 2 seconds
-normaloperationdisplay(seeimage1below)
FirstDigit Unit of Measure Pulses Per Unit
(after6/2016)
Pulses Per Unit
(before6/2016)
0. Quarts 310 155
G Gallons 1242 621
P Pints 156 78
L Liters 328 164
Image 2 - Current System Settings; Units and Pulses Per Unit
Image 1 - Normal operation display
TherstDigitindicatesthecurrentunitsetting(seetablebelow),andthelast4digitsindicatethe
pulsesperunit.Fortheimageabovetheunitissettoquartsand310pulses.
Table 1: Units and Factory pre-set pulses

9
CONSOLE SETUP INFORMATION (CONTINUED)
Entering the Setup Menu:
- StartwiththeunitpoweredOFF
- Whilepressingthe“Zero”and“Uparrow”buttons,poweronunitbyturningkeyto“ON”position.
SETUP DISPLAY
Pulse Calibration Factor:
- Can be set to 1 through 5, or negative 1 through 5, allowing you to adjust pulses per unit up or down 5
pulses.
•Use the “Up arrow” key to scroll between Quarts, Gallons, Pints, and Liters.
•Press the “SET” button to enter edit mode (The Pulse Calibration Factor will begin flashing)
•Use the “Up arrow” key to change the numerical values from 0 to 5, -1 to -5
•Press the “SET” button to exit edit mode
•When finished press the “TOTAL” button to save changes.
•Wait till the display looks like -->
•Power unit off with key
Units Pulse
Calibration
Factor
# Pulses
per unit
•Example
•Setting the Pulse Calibration Factor to “-2” would look like:
•When powering the unit on the display will show:
•Unit set for Quarts and 153 pulses per unit