Bennett 515-XP Supplement

Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456
USA 800-235-7618 ~ Outside USA 231-798-1310
[e-mail] ~ www.bennettpump.com
BENNETT 515-XP PUMP CONTROLLER
Installation & Service Manual
141938 Rev B 9/8/2021
Only Trained Personnel May Work on This Equipment
READ THIS MANUAL
This manual has important information for safe installation and operation of this equipment. Read and understand this manual before
applying power. Keep this manual and tell all service personnel to read this manual. If you do not follow the instructions, you can cause
bodily injury, death, or damage to the equipment.

Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456
USA 800-235-7618 ~ Outside USA 231-798-1310
[e-mail] ~ www.bennettpump.com
The material included in this installation manual is accurate at the date of publication. The intent of this manual is to assist.
If further assistance is required, please contact the Bennett Technical Service Department at 1-800-423-6638.
Bennett Marketing Services can be contacted by mail, facsimile, telephone or e-mail at the locations specified below:
Bennett Pump Company
Marketing Services
1218 East Pontaluna Road
Spring Lake, MI 49456
Telephone from USA 1-800-235-7618
Telephone from outside USA 231-798-1310, Extension 287 or 269
Customer Service USA 231-719-6050; Facsimile USA 231-799-6202
Email: [email protected] or [e-mail]
Website: www.bennettpump.com
For new manuals, visit our web page at www.bennettpump.com
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.
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 interference received, including interference that
may cause undesired operation.
Revision
Date
Description
A
3/23/2020
Original Document
B
Updates to support NA installations

Bennett 515-XP Pump Controller Instruction & Service Manual Table of Contents
i
TABLE OF CONTENTS
TABLE OF CONTENTS I
SECTION 1: SAFETY INFORMATION 1
General Information.......................................................................................................................................................................................................2
Hazardous locations.......................................................................................................................................................................................................2
Codes and Standards.....................................................................................................................................................................................................2
Unauthorized Alteration of Bennett Products ....................................................................................................................................................2
Abbreviations and Acronyms.....................................................................................................................................................................................2
SECTION 2: PRODUCT INTRODUCTION 3
Features...............................................................................................................................................................................................................................3
Specifications ....................................................................................................................................................................................................................3
Bennett Remote Fuel Control Protocol Parameters .........................................................................................................................................3
Hardware Connections .................................................................................................................................................................................................3
515-XP Pump Controller Assembly .........................................................................................................................................................................4
SECTION 3: INSTALLATION INSTRUCTIONS 9
515 Pump Controller - Recommended Equipment and Materials.............................................................................................................9
Point-of-Sale Requirements .......................................................................................................................................................................................9
How to Remove Knockouts from Enclosure ........................................................................................................................................................9
How to Remove Enclosure Cover..........................................................................................................................................................................10
How To Mount the 515 Pump Controller ..........................................................................................................................................................10
Grounding .......................................................................................................................................................................................................................10
AC Power Wiring ..........................................................................................................................................................................................................11
How to Connect Dispenser Fuel Communication Wires .............................................................................................................................11
Station Interconnectin diagram .............................................................................................................................................................................13
Connect Point of Sale Communication Wires..................................................................................................................................................14
Fleet System Configuration (Optional)................................................................................................................................................................ 14
How to Start-Up the 515 Pump Controller .......................................................................................................................................................14
SECTION 4: DIAGNOSTICS & TROUBLESHOOTING 17
Display Diagnostics .....................................................................................................................................................................................................17
Voltage Test Points......................................................................................................................................................................................................19
Troubleshooting ...........................................................................................................................................................................................................20
How To Place an Order for Parts ...........................................................................................................................................................................20
Spare Parts List..............................................................................................................................................................................................................21
APPENDIX A: MANAGER’S MODE 23
Programming the Dispenser ...................................................................................................................................................................................23
Mode 1 –Miscellaneous Diagnostic Data Message......................................................................................................................................23
Mode 2 –Fueling Point Communication Down Counters..........................................................................................................................24
Mode 5 –Fueling Point Communication Performance Counters............................................................................................................25
Mode 10 –Authorization Failure Counters .......................................................................................................................................................25
Mode 11 –De-Authorization Failure Counters ...............................................................................................................................................26
Mode 48 –Restarting the Software......................................................................................................................................................................27
Mode 49 –Clearing all Non-Volatile RAM ........................................................................................................................................................27
APPENDIX B: DISPENSER CONFIGURATION FOR 4-WIRE & 2-WIRE INSTALLATIONS 29
BENNETT LIMITED WARRANTY 31

Bennett 515-XP Pump Controller Instruction & Service Manual Table of Contents
ii
Page Intentionally Left Blank

Bennett 515-XP Pump Controller Instruction & Service Manual Safety Information
1
SECTION 1: SAFETY INFORMATION
For safe installation of this equipment, read and understand all dangers, warnings, and cautionary information. Save this safety
information in a readily accessible location. Look for the following warnings throughout the manual:
Red and White “DANGER” means: If you do not follow the instructions, severe injury or death will occur.
Orange and Black “WARNING” means: If you do not follow the instructions, severe injury or death can occur.
Yellow and Black “CAUTION” means: If you do not follow the instructions, damage can occur to the dispenser.
Blue and White “IMPORTANT” means: Helpful tips and other recommendations on equipment installation, usage, and
maintenance should be observed.
DANGER PELIGRO DANGER
FIRE, EXPLOSION, INJURY, OR DEATH WILL OCCUR IF FUEL
FILTERS ARE CHANGED BY UNTRAINED PERSONNEL. MAKE SURE,
ONLY TRAINED PERSONNEL CHANGE FILTERS.
TO PREVENT INJURY TO YOU FROM VEHICLES AND ONLOOKERS,
ALWAYS PLACE A BARRIER AROUND THIS EQUIPMENT BEFORE
PERFORMING SERVICE OR MAINTENANCE.
GASOLINE AND FUEL ETHANOL IS FLAMMABLE. NO SMOKING
OR OPEN FLAME.
FUEL ETHANOL IS POISONOUS AND SHOULD NOT BE INGESTED.
DISCONNECT ALL POWER, RELIEVE PRESSURE TO THIS
EQUIPMENT, AND ASSOCIATED COMPRESSOR DURING
INSTALLATION, SERVICE, OR ANY MAINTENANCE I.E.,
CHANGING FILTERS.
THE 515 IS NOT DESIGNED TO BE MOUNTED ON THE FUEL
ISLAND. MOUNT IN EQUIPMENT ROOM NEAR POWER PANELS.
WARNING ADVERTENCIA MISE EN
GARDE
You must have training in the installation, service, or maintenance
of this equipment (dispenser, pump, console, control box, or
submerged pump) before working on it. Maintenance repairs
must be done by authorized personnel only. Warranty work may
only be performed by Bennett certified technicians.
To prevent electric shock, keep the electrical parts of the
dispenser dry.
Electronic components are static sensitive. Use only proper static
precautions (e.g. static straps) before working on the equipment.
The emergency shut-off valve (also called the fire valve, shear
valve, or impact valve) must be closed when service or
maintenance is performed on this equipment.
You must have training in the operation and programming of this
dispenser before using it. READ THE OPERATORS MANUAL.
Make sure this equipment is correctly grounded. Failure to do will
cause injury or damage equipment or improper operation.
Improper grounding voids the warranty.
When anchoring the dispenser, always level the dispenser with
shims before bolting to the island. DO NOT shim the middle of
base rails to bolt down the dispenser.
Make sure that all labels, decals, warning, cautions, and
instructions are fastened to the equipment. Order replacement
labels from Bennett.
CAUTION PRECAUCIÓN MISE EN GARDE
Do not drill holes in fuel dispensers. Holes can cause failure of the
electronic equipment. THE WARRANTY WILL BECOME VOID. Use
only adhesive backed sign mounting brackets.
IMPORTANT IMPORTANTE IMPORTANT
All trained technicians must work in accordance to all
requirements, standards, and guidelines specified by the suppliers
Environmental Standards® Health, Safety, Security & Environment
(HSSE) policies. Note: Bennett Pump highly recommends all
technicians observe HSSE policies defined by the supplier. Bennett
Pump does not impose any restrictions or additional
requirements contained in Environmental Standards® Health,
Safety, Security & Environment (HSSE) policies.
!! READ AND UNDERSTAND ALL WARNING LABELS ATTACHED TO THE DISPENSER !!

Bennett 515-XP Pump Controller Instruction & Service Manual Safety Information
2
GENERAL INFORMATION
Read this manual carefully and read all tags/labels attached to the 515-XP Pump Controller before starting any maintenance and/or
service. A controller that is not properly maintained will not perform properly and will void the Bennett Limited Warranty.
Before installation, operation, maintenance and/or service ensure that protection against lighting strikes are in accordance with the
American Petroleum Institute Recommended Practice RP 2003, Protection Against Ignitions Arising out of Static, Lightening, and Stray
Currents.
Service of the Bennett products and all accessories must be performed by a technician who is trained in accordance to all codes,
standards, and regulations.
HAZARDOUS LOCATIONS
For safe operation, ensure that the dispenser is in a classified area as detailed below per NFPA 30, Flammable and Combustible Liquids
Code and NFPA 70, National Electric Code. For further information on the classification of locations for Fuel Dispensers, see NFPA 30,
Flammable and Combustible Liquids Code.
CODES AND STANDARDS
Follow all local, state, and federal requirements for installation of all equipment.
•API 2003 –Protection Against Ignitions Arising Out of Stray, Lightning, and Stray Currents
•NFPA 30 –Flammable and Combustible Liquids Standard
•NFPA 30A –Motor Fuel Dispensing Facilities Standard
•NFPA 70 –National Electric Code
•International Fire Code –2000 Edition
UNAUTHORIZED ALTERATION OF BENNETT PRODUCTS
DANGER: BEFORE PERFORMING ANY TYPE OF SERVICE TO THE DISPENSERS, BE SURE TO SHUT OFF ALL ELECTRICAL
SUPPLIES AND SECURE THEM IN THE OFF POSITION. CLOSE ALL VALVES IN INCOMING PIPING. MAINTENANCE
MUST BE PERFORMED BY TRAINED PERSONAL ONLY.
Bennett Pump Company products are designed to meet or exceed the standards of Underwriters Laboratories, Inc., Federal
Communication Commission, and National Institute of Standards and Technology. Compliance with these standards protects the operator
and the consumer from personal injury and ensure an accurate delivery of product. Any deviation from the use of authorized
replacement parts or alteration of a designed product configuration may cause personal injury, death or the revocation of one or all of
the above approvals.
Bennett Pump Company will not assume responsibility or liability for any consequential injury or damage caused by the unauthorized
alteration of its products.
ABBREVIATIONS AND ACRONYMS
Term
Description
AC
Alternating Current
API
America Petroleum Institute
ASR
Automatic Statistical Reconciliation
BRFCP
Bennett Remote Fuel Control Protocol
DC
Direct Current
DIP
Dual In-Line Package
EPA
Environmental Protection Agency
Hz
Hertz
NEC
National Electrical Code
NFPA
National Fire Protection Agency
NPT
National Pipe Taper or National Pipe Thread
NREL
National Renewable Energy Laboratory
OEM
Original Equipment Manufacturer
POS
Point-of-Sale
PEI
Petroleum Equipment Institute
PVC
Polyvinyl Chloride
RAM
Random Access Memory
SCS
Serial Command Set
THHN
Thermoplastic High Heat-resistant Nylon-coated
UL
Underwriters Laboratories, Inc.
VAC
Voltage Alternating Current
VDC
Voltage Direct Current
VOM
Volt-Ohm Meter

Bennett 515-XP Pump Controller Instruction & Service Manual Product Introduction
3
SECTION 2: PRODUCT INTRODUCTION
The Bennett Model 515-XP Pump Controller is an interface device for third party point-of-sale systems. It allows the customer to use
Bennett fuel dispensing equipment with any third party point-of-sale consoles that supports Bennett Remote Fuel Control Protocol and
any third party POS systems that utilizes the Tokheim SCS or Veeder-Root ASR Protocols.
FEATURES
•The 515-XP Pump Controller communicates with 1 to 32 fueling points.
•Four FUEL ONLY (female DB9) communication ports used to communicate to various third party point-of-sale providers including the
VeriFone interface.
•A 4 x 20 LCD screen is used to display diagnostic, programming, and start-up messages. The numeric and function keys on the
manager’s keypad are used to access various manager modes.
•LED indicators are provided to aid the Bennett technician to troubleshoot site occurrences.
•The 515-XP Pump Controller uses a 24V 1A power adapter.
SPECIFICATIONS
Dimensions (length x width x height)........................................................................................12in x 12in x 4in (30.5cm x 30.5cm x 10.2 cm)
Operang Temperature......................................................................................................................................0C to +40C / +32F to +104F
Storage Temperature......................................................................................................................................... -20C to +65C / -4F to +149F
Operang Humidity ..................................................................................................................................................0 to 95% Non-Condensing
Storage Humidity .................................................................................................................................................30% to 70% Non-Condensing
Power Supply ............................................................................................................................................................. 120/240 VAC 60HZ Input
24V / 1A Output
Protocols (Fuel Only).....................................................................................Bennett Remote Fuel Control / Tokheim SCS / Veeder-Root ASR
BENNETT REMOTE FUEL CONTROL PROTOCOL PARAMETERS
Baud Rate 2400 & 9600 (Programmable DIP Switch)
Data Bits 7 Bits
Parity Odd
Stop Bit 1
HARDWARE CONNECTIONS
IMPORTANT: The RS-232 STANDARD DB9 (DE-9) FUEL COMMUNICATION SERIAL CABLE SHOULD BE NO MORE THAN 100 FEET.
Third Party Point-of-Sale
BENNETT 515-XP PUMP CONTROLLER
Dispenser
Current Loop
Male DB9 Connector
Fuel Communication
(Manufacturer Supplied Cable)
AC Power Supply Cable
(p/n 140783)
AC Receptacle
Earth Ground

Bennett 515-XP Pump Controller Instruction & Service Manual Product Introduction
4
515-XP PUMP CONTROLLER ASSEMBLY
The 515-XP Pump Controller uses optical isolation to isolate the pump data communication lines from the 515 electronics.
HARDWARE CONNECTIONS
The 515-XP Pump Controller has four FUEL ONLY communication ports that are used to communicate to various third party point-of-sale
providers. The communication (ports 1 through 4) are D connector panel mount, 9-pin female type. A male DB9 serial cable must be used
to connect directly to the port using a straight through cable.
•Port 1 - Tokheim SCS Protocol
•Port 2 - Veeder-Root ASR Protocol
•Port 3 - Bennett Remote Fuel Control Protocol
•Port 4 - Bennett Remote Fuel Control Protocol
DISPLAY AND KEYPAD ASSEMBLY LAYOUT
A 4 x 20 LCD screen is used to display diagnostic, programming, and start-up messages. The numeric and function keys on the keypad are
used to access various managers’ modes.
ITEM
DESCRIPTION
1
Display Assembly
2
Display Cable
3
Enclosure
4
Circuit Board Assembly
5
Power Supply Port (2 Position Plug)
6
Manager’s Keypad Port (Ribbon Cable)
7
Communication Ports (Female DB9)
N/A
Front Cover (not shown)
N/A
Manager’s Keypad (not shown)
N/A
VeriFone Adapter (not shown)
FRONT VIEW
Port 1
Port 2
Port 3
Port 4
SIDE VIEW
7
5
6
Display
Manager’s Keypad
1
3
4
2
P/N 140003

Bennett 515-XP Pump Controller Instruction & Service Manual Product Introduction
5
515 PUMP CONTROLLER CIRCUIT BOARD ASSEMBLY
CONNECTOR DESCRIPTIONS
The following is a description of the connections and LED’s located on the 515 circuit board.
J1 Point of Sale Communication (PORT 2 and PORT 4)
J1 is a dual D-Sub 9-pin connector serial communication interface port that is dedicated for point of sale communication. A customer
supplied DB-9 (DE-9) cable is used to connect the point of sale device to the fuel controller.
➢Port 2 (Top)- Veeder-Root ASR Protocol
➢Port 4 (Bottom) - Bennett Remote Fuel Control Protocol
J2 Point of Sale Communication (PORT 1 and PORT 3)
J2 is a dual D-Sub 9-pin connector serial communication interface port that is dedicated for point of sale communication. A customer
supplied DB-9 (DE-9) cable is used to connect the point of sale device to the fuel controller.
➢Port 1 (Top) - Tokheim SCS Protocol
➢Port 3 (Bottom) - Bennett Remote Fuel Control Protocol
TS1
DISPENSER COMMUNICATION
LOOPS 1 –4
SW1
DIP SWITCH
J1
POS COMMUNICATION PORTS
Port 2 (Top) - Veeder-Root ASR
Port 4 (Bottom) - Bennett
J2
POS COMMUNICATION PORTS
Port 1 (Top) –Tokheim-SCS
Port 3 (Bottom) - Bennett
TS4
DISPENSER COMMUNICATION
LOOPS 13-16
J7
DISPLAY
J8
MANAGERS KEYPAD
J12
POWER
TS2
DISPENSER COMMUNICATION
LOOPS 5 –8
TS3
DISPENSER COMMUNICATION
LOOPS 9 –12
PORT 2
PORT 4
PORT 1
PORT 3

Bennett 515-XP Pump Controller Instruction & Service Manual Product Introduction
6
J7 Display
J7 is a 16-position header used to connect the 4 x 20 LCD display.
J8 Managers Keypad
J8 is a 10-position header used for the manager’s keypad.
J12 Power Supply (DC Power Input)
J12 is a 2-position header used to connect the 24V Power Supply to the 515-XP Pump Controller. Each 515-XP Pump Controller
uses one 120/240VAC, 60Hz circuit for power. Make sure the power source has the correct frequency and voltage.
TS1, TS2, TS3, TS4 Dedicated Loop Dispenser Communication (16 or less Fueling Points)
Terminal strips TS1, TS2, TS3, and TS4 are used for dispenser communication on a dedicated loop. Each fueling point has a (+) positive
and (–) negative connection. Note: A fueling point is one side of a dispenser and a two-sided dispenser would have two fueling points.
Terminal Strip
Fueling Point
Pin
TS1
1
(+) positive
(-) negative
2
(+) positive
(-) negative
3
(+) positive
(-) negative
4
(+) positive
(-) negative
TS2
5
(+) positive
(-) negative
6
(+) positive
(-) negative
7
(+) positive
(-) negative
8
(+) positive
(-) negative
TS3
9
(+) positive
(-) negative
10
(+) positive
(-) negative
11
(+) positive
(-) negative
12
(+) positive
(-) negative
TS4
13
(+) positive
(-) negative
14
(+) positive
(-) negative
15
(+) positive
(-) negative
16
(+) positive
(-) negative
1
+
-
2
+
-
3
+
-
4
+
-
5
+
-
6
+
-
7
+
-
8
+
-
9
+
-
10
+
-
11
+
-
12
+
-
13
+
-
14
+
-
15
+
-
16
+
-
TS1
TS2
TS3
TS4
fueling position shown

Bennett 515-XP Pump Controller Instruction & Service Manual Product Introduction
7
TS1, TS2, TS3, TS4 Shared Loop Dispenser Communication (1 to 32 Fueling Points)
Terminal strips TS1, TS2, TS3, and TS4 are used for dispenser communications on a shared loop. This configuration allows the use of one
pair of wires for fuel communication, with two fueling points daisy chained together. Note: One to two fueling points per loop. Two
fueling points are wired in series on one current loop.
SW1 DIP SWITCH
A DIP Switch located at (SW1) on the circuit board is used to enable access for price changes (fleet management systems) and for baud
rate control. All switches are turned OFF by default. Note: Not used on Pacific dispensers.
•To turn a switch ON move the switch to the right.
•To turn a switch OFF move the switch to the left.
Terminal Strip
Fueling point
PIN
TS1
1
1 (+) positive
2
2 (-) negative
3
3 (+) positive
4
4 (-) negative
5
5 (+) positive
6
6 (-) negative
7
7 (+) positive
8
8 (-) negative
TS2
9
9 (+) positive
10
10 (-) negative
11
11 (+) positive
12
12 (-) negative
13
13 (+) positive
14
14 (-) negative
15
15 (+) positive
16
16 (-) negative
TS3
17
17 (+) positive
18
18 (-) negative
19
19 (+) positive
20
20 (-) negative
21
21 (+) positive
22
22 (-) negative
23
23 (+) positive
24
24 (-) negative
TS4
25
25 (+) positive
26
26 (-) negative
27
27 (+) positive
28
28 (-) negative
29
29 (+) positive
30
30 (-) negative
31
31 (+) positive
32
32 (-) negative
SWITCH
DESCRIPTION
SETTING
1
Port 3 - Price Change –Fleet Management Systems
OFF = Access Permitted / ON = Access Prohibited
2
Port 4 - Price Change –Fleet Management Systems
OFF = Access Permitted / ON = Access Prohibited
3
Port 3 - Baud Rate Control
OFF = 2400 / ON = 9600
4
Port 4 - Baud Rate Control
OFF = 2400 / ON = 9600
5
Verifone Zero Sale Support
OFF / ON
6
Forced Dispenser Next State Transition
OFF = Normal Operation / ON = Forced Transition State
7
Shared Communication Switch
OFF / ON
8
Price Selection
OFF = 4-digit price / ON = 5-digit price
1
+
-
3
+
-
5
+
-
7
+
-
2
4
6
8
9
+
-
11
+
-
13
+
-
15
+
-
10
12
14
16
17
+
-
19
+
-
21
+
-
23
+
-
18
20
22
24
25
+
-
27
+
-
29
+
-
31
+
-
26
28
30
32
fueling position shown
TS1
TS4
TS3
TS2

Bennett 515-XP Pump Controller Instruction & Service Manual Product Introduction
8
LEDs DISPENSER & POS COMMUNICATION
The 515-XP Circuit Board has several surface mount LEDs that are used for troubleshooting. Flashing LED’s indicate that the signals are
present. For the communication ports, the controlling device must initiate communication before the 515 will respond. Note: If it is
communicating with the console or dispenser, these LEDs are constantly blinking. If not communicating with the console or dispenser the
LEDs will be off. Refer to the figure below for LED locations.
➢The “Red” LED indicates data transmitted from the 515-XP to the Point of Sale
➢The “Green” LED indicates data received by the 515-XP from the Point-of-Sale
LED D60 = HAPPY LED (SOFTWARE COMMUNICATION)
DISPENSER COMMUNICATION
LED
COLOR
FUNCTION
DESCRIPTION
D12
Red
Transmit
Loop 1 –TS1
D13
Green
Receive
Loop 1 –TS1
D14
Red
Transmit
Loop 2 –TS1
D15
Green
Receive
Loop 2 –TS1
D16
Red
Transmit
Loop 3 –TS1
D17
Green
Receive
Loop 3 –TS1
D18
Red
Transmit
Loop 4 –TS1
D19
Green
Receive
Loop 4 –TS1
D20
Red
Transmit
Loop 5 –TS2
D21
Green
Receive
Loop 5 –TS2
D22
Red
Transmit
Loop 6 –TS2
D23
Green
Receive
Loop 6 –TS2
D24
Red
Transmit
Loop 7 –TS2
D25
Green
Receive
Loop 7 –TS2
D26
Red
Transmit
Loop 8 –TS2
D27
Green
Receive
Loop 8 –TS2
D28
Red
Transmit
Loop 9 –TS3
D29
Green
Receive
Loop 9 –TS3
D30
Red
Transmit
Loop 10 –TS3
D31
Green
Receive
Loop 10 –TS3
D32
Red
Transmit
Loop 11 –TS3
D33
Green
Receive
Loop 11 –TS3
D34
Red
Transmit
Loop 12 –TS3
D35
Green
Receive
Loop 12 –TS3
D36
Red
Transmit
Loop 13 –TS4
D37
Green
Receive
Loop 13 –TS4
D38
Red
Transmit
Loop 14 –TS4
D39
Green
Receive
Loop 14 –TS4
D40
Red
Transmit
Loop 15 - TS4
D41
Green
Receive
Loop 15 - TS4
D42
Red
Transmit
Loop 16 - TS4
D43
Green
Receive
Loop 16 - TS4
FUEL COMMUNICATION
LED
COLOR
FUNCTION
DESCRIPTION
D44
Red
Transmit
Port 2 - Veeder-Root ASR Protocol
D45
Green
Receive
Port 2 - Veeder-Root ASR Protocol
D46
Red
Transmit
Port 4 - Bennett Remote Fuel Control Protocol
D47
Green
Receive
Port 4 - Bennett Remote Fuel Control
D48
Red
Transmit
Port 1 - Tokheim SCS Protocol
D49
Green
Receive
Port 1 - Tokheim SCS Protocol
D50
Red
Transmit
Port 3 - Bennett Remote Fuel Control Protocol
D51
Green
Receive
Port 3 - Bennett Remote Fuel Control Protocol
D13
D12
D15
D14
D17
D16
D19
D18
D21
D20
D23
D22
D25
D24
D27
D26
D29
D28
D31
D30
D33
D32
D35
D34
D37
D36
D39
D38
D41
D40
D43
D42
D60
D48
D49
D50
D51
D45
D46
D47
D44

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
9
SECTION 3: INSTALLATION INSTRUCTIONS
Bennett Pump Dispensers are to be installed by trained technicians. All technicians must be aware of ALL safety instructions. If you are
not a Bennett trained technician, please contact Bennett Technical Support at 1-800-423-6638 for training information.
Identifying the features of the unit prior to installation will provide an understanding of how to perform an accurate installation. Follow
the steps below to install a 515 Pump Controller.
515 PUMP CONTROLLER - RECOMMENDED EQUIPMENT AND MATERIALS
The items listed below are recommended for proper installation of the Bennett 515 Pump Controller. Note: Consult the control console
and/or point-of-sale manufacturer for component requirements.
•P/N 140766 –515-XP Pump Controller (1-32 Fuel Points)
•VeriFone Adapter - P/N 105471 (included) Note: For use with a VeriFone interface
•Male DB9/RJ45 serial cable (not included) Note: The length of the cable should be no more than 100 feet
•(4) –#10 x ½” Pan Head Phillips Thread-Forming Screws for Mounting (not included)
•Dispenser Communication Wires - 18 AWG or larger gas and oil resistant (customer supplied)
•Tool to remove knockouts
•Jumpers
•Voltmeter
•Personal Protection Equipment
POINT-OF-SALE REQUIREMENTS
Contact the console / third party point-of-sale manufacture prior to installation to determine if any additional cables and/or connectors
are required.
The 515 Pump Controller fuel only communication ports uses a Female DB9 pin connection serial port. A Male DB9 serial cable must be
used to connect directly to the communication port using a straight through cable. Note: VeriFone requires VeriFone Adapter - P/N
105471 (included with the 515 Pump Controller).
IMPORTANT: ALL POS MANUFACTURERS MUST SUPPLY AN RS-232 STANDARD DB9 (DE-9) SERIAL CABLE. THE LENGTH OF
THE CABLE SHOULD BE NO MORE THAN 100 FEET.
HOW TO REMOVE KNOCKOUTS FROM ENCLOSURE
CAUTION: SHARP EDGES MAY BE PRESENT AFTER REMOVING KNOCKOUTS. USE CUT RESISTANT GLOVES TO PREVENT
INJURY.
Several knockouts are located around the enclosure for accessibility. Select a knockout sized to fit the desired connector, wire, cable, etc.
and carefully remove. Try not to damage the enclosure when removing knockouts. Next, insert the connector from the outside of the
enclosure. BE CAREFUL of sharp edges.
MALE DB9 CONNECTOR
Manufacturer Supplied Cable

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
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HOW TO REMOVE ENCLOSURE COVER
Remove the enclosure cover and set aside. Retain screws for reuse. Note: After installation is complete, replace cover using the screws
provided.
HOW TO MOUNT THE 515 PUMP CONTROLLER
The 515-XP Pump Controller measures 12” x 12” x 4”. Each enclosure requires four mounting screws. These four screws are on 10 ½” by
10 ½” centers.
1. Layout screws on wall 10 ½” x 10 ½” centers.
2. Slide enclosure’s four keyhole-mounting slots over screws and tighten.
3. After the enclosure is mounted and installation is complete, replace cover using the screws previously removed.
GROUNDING
A 12 AWG green earth ground wire must be connected to the ground screw inside the enclosure. The green ground screw MUST BE
within 1 Ohm of earth ground. This is located near the Display.
WARNING: MAKE SURE THE 515 PUMP CONTROLLER IS PROPERLY GROUNDED WITH 12AWG GREEN EARTH GROUND
WIRE IS CONNECTED TO THE GREEN GROUND SCREW INSIDE THE ENCLOSURE. FAILURE TO PROPERLY
GROUND THE EQUIPMENT CAN CAUSE INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID THE
BENNETT LIMITED WARRANTY.
IMPORTANT: Follow proper grounding procedures to reduce radio frequency interference (RFI). All Bennett equipment must
be properly grounded. Follow National Electrical Code, Article 514-7 for grounding requirements as well as
Bennett’s grounding procedures. It is UNACCEPTABLE to rely on the conduit for these grounding requirements.
1. A 12 AWG green earth ground wire must be connected to the ground screw inside the enclosure. The ground screw MUST BE within
1 Ohm of earth ground. This is located near the AC power terminal.
2. Connect the other end to the Breaker Panel. Refer to the Station Interconnection Diagram for more information.
MOUNTING HOLES
MOUNTING HOLES
GROUND SCREW

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
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AC POWER WIRING
The 515-XP Pump Controller is equipped with one 24V, 1.5A Power Supply Cable. Make sure the power source has the correct frequency
and voltage (120V/240, 60 Hz) required for power. Note: The 515-XP Fuel Pump Controller must be connected to a dedicated receptacle.
1. Connect the AC Power Module (141188) to [J2]on the 515-XP Pump Controller Circuit Board. Make sure locking connectors are
secure.
2. Connect the other end into a dedicated AC receptacle.
HOW TO CONNECT DISPENSER FUEL COMMUNICATION WIRES
CAUTION: All communication wires must be 18 AWG or larger gas and oil resistant.
CAUTION: DO NOT use wire nuts. Splicing with wire nuts can cause communication failure, system failure, and may void
warranty.
DEDICATED LOOP Dispenser fuel communication wires for fueling points 1 through 16 terminate directly to the 515 Circuit Board at TS1,
TS2, TS3, or TS4. Each fueling points has a (+) positive and (–) negative connection. Refer to your dispenser wiring
diagram for more information. Note: Sites with more than 16 fueling points please contact Technical Support for
assistance at 1-800-423-6638.
SHARED LOOP Dispenser fuel communication wires for fueling points 1 through 32 terminate directly to the 515 Circuit Board at TS1,
TS2, TS3, or TS4. Each fueling point has a (+) positive and (-) negative connection. This configuration allows the use of
one pair of wires for fuel communication, with two fueling points daisy chained together inside the dispenser. Refer to
your dispenser wiring diagram for more information. Note: One to two fueling points per loop. Two fueling points are
wired in series on one current loop.
1. Verify Manager’s Mode 22 - Dispenser Address. Refer to your dispenser’s operators manual for programming instructions.
2. Connect data wires to terminal strips TS1, TS2, TS3, or TS4. Make sure to connect the (+ positive) in the dispenser to the (+ positive)
on the 515 and the (- negative) in the dispenser to the (- negative) on the 515. Refer to the Dispenser Configuration for 2-wire
Installations or Dispenser Configurations for 4-wire Installations later in this section.
3. For dispensers on a shared loop, turn SW1 DIP Switch 7 ON. Note: All switches are turned OFF by default.
AC Power Module
(P/N 141188)
AC Receptacle
J2
Inside Dispenser Data Communication Wiring
DIP Switch 7
TS1
TS2
TS3
TS4
DIP Switch
TS1
TS2
TS2
TS1
1
1
1
1
1
1
2
2
2

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
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Fueling Point 1+2
Fueling Point 3+4
Fueling Point 31+32
Fueling Point 29+30
Fueling Point 27+28
Fueling Point 5+6
Fueling Point 7+8
Fueling Point 9+10
Fueling Point 13+14
Fueling Point 17+18
Fueling Point 21+22
Fueling Point 25+26
Fueling Point 11+12
Fueling Point 15+16
Fueling Point 19+20
Fueling Point 23+24

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
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STATION INTERCONNECTIN DIAGRAM

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
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CONNECT POINT OF SALE COMMUNICATION WIRES
The following description is for connection to the VeriFone console connected to Port 1 of the 515 box. For any other POS that
communicates using Bennett protocol use Port 3 or Port 4 and any special cables/connectors for that console to the 515.
1. VeriFone Adapter P/N 105471 is supplied with the 515 Pump Controller. This is not a common connector sent with the VeriFone
console.
2. VeriFone must supply an RS-232 cable. The part number for this cable is 13836-xx (specify length needed). Port 1 is for the fuel
communication from the VeriFone console. Connect adapter supplied and tighten the screws.
•Port 1 –Tokheim SCS Protocol
•Port 2 –Veeder-Root ASR Protocol
•Port 3 - Bennett Remote Fuel Control Protocol
•Port 4 –Bennett Remote Fuel Control Protocol
FLEET SYSTEM CONFIGURATION (OPTIONAL)
Fleet systems using the Bennett Remote Fuel Control Protocol through port 3 or 4 may need change prices set by the fleet system. A DIP
Switch is used to control price changes from the fleet system. If the switch is on, the fleet system is not allowed to change any prices in
the 515. Note: All switches are turned OFF by default. Follow the steps below to allow or deny price change access.
1. Remove 515 Box cover.
2. Locate the SW1 DIP switch located on the 515 circuit board.
3. Turn Switch 1 ON to Prohibit Access or Turn Switch 1 OFF to permit access
•To turn a switch ON, move the switch to the right.
•To turn a switch OFF, move the switch to the left.
HOW TO START-UP THE 515 PUMP CONTROLLER
Refer to the Diagnostics & Troubleshooting section for a detailed description and/or if an error occurs. If a problem occurs, refer to the
service and troubleshooting section for more information or call Bennett Technical Support at 1-800-423-6638.
1. Apply power to the dispensers and program them for operation.
Refer to your dispenser operator’s manual or X19 technical and dispenser programming manual for programming instructions.
2. Apply power to 515 Pump Controller.
When the 515 Pump Controller is powered up, the display runs through a power up message sequence and stops at the idle display.
Note: The power up messages are only valid upon power and are ONLY displayed during the power up process.
3. View the Idle Display Messages and verify all configured fueling points are online.
There are three different idle displays for the fueling point status information. The fueling point status information display is
selected by pressing the +/- button on the manager keypad.
POS Fueling Point Communication Status (default):
The fueling point order is based on the POS point of view.
POS Communication Status:
This fueling point order is based on the Bennett Remote Fuel Control Protocol
VeriFone Adaptor
FP01 –FP08 12341234
FP09 –FP16 12341234
FP17 –FP24 12341234
FP25 –FP32 12341234

Bennett 515-XP Pump Controller Instruction & Service Manual Installation Instructions
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Dispenser Communication Status:
This Idle Display shows the Loops, Dispenser Address 0, Dispenser Address 1, Executive Loop Counter, Power Failure Counter, Suicide
Counter, and Software Restart Counter. Note: Each idle dispenser that is on-line will have a status of 1. Refer to the Diagnostics &
Troubleshooting section for fueling point state codes.
4. Apply power to Control Console and initialize dispensers for operation.
LOOPS
FUELING POINT STATE CODE
ADDRESS 0
COUNTERS
FUELING POINT STATE CODE
LP 123456789ABCDEFG
AD0 1234123412341234
AD1 0000000000000000
391 000 000 001
LOOP NUMBER
EXAMPLE SETTINGS
ADDRESS 1
POS Status View RFCP
FP 12341234123412341
FP 00000000000000000
391 000 000 001
COUNTERS

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