Hamilton HTK User manual

Document #101-0204 1 10/21/2011
HTK
Installation Manual

Document #101-0204 2 10/21/2011
TABLE OF CONTENTS
I. INTRODUCTION ................................................................................................... 4
II. INSTALLATION ................................................................................................... 5
MECHANICAL INSTALLATION ..............................................................................................5
Unpacking............................................................................................................................5
Positioning ...........................................................................................................................6
Mounting..............................................................................................................................6
Running Conduit..................................................................................................................6
HTK Dimensions (For brick-in installation) ............................................................ 7
HTK Dimensions (Free Standing installation) ......................................................... 8
Brick-In Installation.................................................................................................. 9
Free-Standing Installation....................................................................................... 10
Brick-In Installation.................................................................................................11
Free-Standing Installation....................................................................................... 12
Gate Orientation...................................................................................................... 13
Access Control Lane Layout................................................................................... 14
III. ELECTRICAL INSTALLATION...................................................................... 15
Pulling Wires......................................................................................................................15
Wire Terminations .............................................................................................................15
Power Supply Wiring Connection .......................................................................... 17
BRING MAIN POWER INTO OUTLET TO POWER MACHINE ..................... 17
Wash Interface ........................................................................................................ 18
HTK “Automatic” Wiring ...................................................................................... 19
HTK “Gated Tunnel” Wiring.................................................................................. 20
HTK “Ether Vend” Wiring...................................................................................... 21
Additional Wire Terminations For Use With The Credit Card or Customer Value Card
System. ..............................................................................................................................22
Additional Wire Terminations For Use With A Hamilton Code System or POS 4000 .....22
Additional Wire Terminations For Camera In HTK. ........................................................23
Additional Wire Terminations for Help Button in HTK....................................................23
Setting Car Wash Cycle Synchronization .........................................................................24
IV. COMPONENT CONNECTIONS ...................................................................... 25
Power Supply.......................................................................................................... 26
Controller................................................................................................................ 27
Distribution............................................................................................................. 28
Smart Bus Hub........................................................................................................ 29
Bill Dispenser ......................................................................................................... 30
Stacker Interface..................................................................................................... 31
Gate and Loop References...................................................................................... 32

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PLEASE READ THIS MANUAL CAREFULLY
PRIOR TO INSTALLING THIS UNIT. A complete
understanding of the operation of this unit is
essential for a successful installation.
Refer to the Table of Contents for easy
navigation through this manual.
This manual was designed to introduce the Hamilton Transaction Kiosk and to provide general infor-
mation about installation. This manual will enable the installer to properly install the HTK and make
the proper wire connections to the HTK. To obtain assistance from the manufacturer, please call (800)
837-5561 or [phone]. Or contact Hamilton Mfg. online @ http:\\www.hamiltonmfg.com.
When calling for assistance, it is important to have serial numbers readily available. Please record these
numbers in the spaces provided.
HTK MODEL & SERIAL #
CONTROLLER MODEL & SERIAL #
HOPPER MODEL & SERIAL #
HOPPER MODEL & SERIAL #
STACKER MODEL & SERIAL #
VALIDATOR SERIAL #
BILL DISPENSER SERIAL #
LOCK/KEY #
Please complete the warranty card, which was included with your machine, and return it to the manu-
facturer.
ABOUT THIS MANUAL

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I. Introduction
This manual will describe the installation of the Hamilton Transaction Kisok from a mechanical and
electrical perspective.
Automatic / Rollover
•Brick in Mounting
• Schematic drawing of mounting configuration of HTK
• Schematic drawing of cabinet dimensions
• Schematic drawing of conduit mounting holes
• Schematic of HTK wiring connections
Tunnel / Gated
•Schematic drawing of mounting configuration of HTK
• Schematic drawing of positioning of HTK and Gate
• Schematic drawing of cabinet dimensions
• Schematic drawing of conduit mounting holes
• Schematic drawing of wiring connections for HTK, Gates and Gated
PLC
NOTE: Website links to Gate and Loop information is provided on
page 24.
*IMPORTANT NOTICE: HAMILTON MFG. RECOMMENDS
THAT THE HTK OPERATE ON A DEDICATED POWER
SOURCE. UNDER NO CIRCUMSTANCE SHOULD ADDI-
TIONAL EQUIPMENT BE OPERATING OFF THE DEDICAT-
ED POWER SOURCE FOR THE HTK.

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II. Installation
NOTE: It is very important to read and understand all of these in-
structions before attempting installation. Hamilton will not be
responsible for injury due to improper installation.
The installation process contains two distinct operations, Mechanical Installation, and Electrical
Installation
MECHANICAL INSTALLATION
 Unpacking
There are a number of points to keep in mind while unpacking your HTK. These items will make the
installation and continued operation of your machine run smoother. These tips are listed below.
Be sure to save your keys
The keys and lock inserts are placed inside a cushioned envelope bag, then placed inside the machine
located next to the power supply. When removing the shrink-wrap, be sure to locate the “T” handle
crank and set it aside so it does not get thrown away. MAKE A PERMANENT RECORD OF THE
NUMBERS ON YOUR KEYS IN CASE A KEY IS LOST AND MUST BE REORDERED.
Remove the packing strap from the hoppers
The hoppers comes shipped with a packing strap secured around it to minimize the vibrations caused
by shipping. If this strap is not removed, the hopper will not tip out for easy filling. The strap may be
cut off with a pair of wire cutters or sturdy scissors. Cardboard is placed around the edges of the hop-
per to protect it during shipping. After removing the strap, be sure to remove the cardboard as well.
In addition to the removal of the card board and strapping, one of the hoppers will be holding the
paper for the receipt printer.
Remove all packing debris from the hopper
During unpacking, ensure that debris does not fall into the hopper bowl. If this material is not removed,
the hopper could jam. With the power completely disconnected, remove all loose material inside the
hopper bowl.
Remove HTK from shipping pallet
The HTK is securely mounted to the pallet with 4 mounting bolts and nuts. To remove the HTK from
the pallet, open the main door and locate the cushioned envelope to retrieve the key for the vault. Once
you have the vault door open loosen and remove the two nuts from the bolts. Repeat this process on the
two bolts on the side of the power supply. Once this process is complete, you will be able to remove
the HTK from the pallet.
Removal of additional packing materials
Inside the HTK are additional components that have packing material holding the component in place
for secure shipping. The following will need to be removed for proper operation. The first is the strap-
ping around the Validator. Another is the removal of the tape around the coin mechanism. In addition
the tape and paper on the front of the bill dispenser, this also incudes the tape that holds the bill rejection
tray. Finally the removal of the tape from the coin box, which need to be placed underneath the coin
mechanism inside the cabinet.

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Brick Mounted
 The first method is to construct a brick or concrete enclosure that will house the HTK. Figure
on page 7 (HTK Bolt Pattern Brick-In) gives the HTK mounting hole locations.The HTK
provides for six 5/8” mounting holes. Have your engineer or contractor recommend con-
struction suitable for strength and stability.
Base Mounted (Free Standing)
 The other method involves mounting the HTK on an optional HTK Base . In this situation,
the base is secured to the pavement and the HTK is secured to the base. Fasteners to be used
should be recommended by your engineer as to strength and suitability.
NOTE: The HTK that mounts to the HTK Base is specifically
designed to be mounted together. Trying to mount a brick mount
style HTK to the base, is not compatiable.
 Running Conduit
Typical electrical code requires low and high voltage wiring to be run in separate conduits. Because of
this, the HTK has three 1 1/8 “ conduit mounting holes in the back of the cabinet, as well as six 1 1/8”
conduit holes in the bottom of the cabinet.
NOTE: When running your conduit refer to “HTK Bolt Pattern
Brick-In” located on page 7.
 Conduit carrying high voltage 120VAC power lines, should be connected to either one of
the bottom 2 right or 1 back right conduit holes, as viewed from the front of the machine.
These conduits are designated only for 110v for the power supply.
 Conduit carrying lines with 24VAC, 24VDC, 12VAC or 12VDC signals should be connected
to either one of the four bottom left or back 2 left conduit holes, as viewed from the front of
the machine.
 If any external communication lines (Cat 5 or Cat 5E, Video, POS etc.) are used, they should
be run through separate conduit and connected to any of the open conduits on the left bottom
or left back of the machine.
NOTE: In the Free Standing cabinet there will be no conduit holes
in the back.
 Positioning
There are no set guidelines for the placement of the HTK. However, it is recommended that the ma-
chine is positioned far enough away from the wash entrance to minimize the amount of overspray that
may get into the HTK. Also, there is a typical height, from the pavement to the bottom of the cabinet,
of approximately 24”.
 Mounting
It is recommended that the HTK be mounted in a permanent enclosure. Safety is a primary concern, so
the equipment must be securely mounted. Hamilton recommends using one of the following methods:

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HTK Dimensions (For brick-in installation)

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HTK Dimensions (Free Standing installation)

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Brick-In Installation

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Free-Standing Installation
1 7/8
2 3/4
6
CURB
Ø1 1/8 CONDUIT HOLES FOR SIGNAL WIRES AND ETHERNET Ø1 1/8 CONDUIT HOLES FOR SIGNAL WIRES AND ETHERNET
1 1/2
7 3/8
Ø1 1/8 CONDUIT HOLE FOR 110V ONLY
Ø5/8 MOUNTING HOLES ( 6 PLCS )
15 7/8
4 1/8
16
28 3/8
12
6
6 1/8
20 1/8 5 1/2
HTK FREE STANDING CABINET BOLT PATTERN ( CUTAWAY VIEW OF BOTTOM OF CABINET)

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53
24
18
6" CURB
47 GATE
KIOSK
DISPLAY
TRAFFIC FLOW
Brick-In HTK & Gate Conguration
10'- 0"
Brick-In Installation

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Free-Standing Installation

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CAUTION: WHEN MOUNTING THE GATE, THE SERVICE
DOOR SHOULD BE FACING INTO THE LANE IF NOT
MOUNTED CORRECTLY THE ARM WILL CLOSE IN THE
WRONG DIRECTION. WHEN CORRECTED THE LOOP
WILL NOT BE IN THE PROPER POSITION
Gate Orientation
SERVICE DOOR
FACING LANE
TRAFFIC
FLOW

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Access Control Lane Layout

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III. Electrical Installation
CAUTION! TOAVOID SEVER INJURY OR DEATH, ALWAYS
DISCONNECT POWER TO THE MACHINE WHEN SERVIC-
ING!
This HTK operates on 120 VAC, 60 Hz. This unit uses a 5AMP Circuit Breaker. This unit needs to be
hard-wired with conduit.
*IMPORTANT NOTICE: HAMILTON MFG. RECOMMENDS
THAT THE HTK OPERATE ON A DEDICATED POWER
SOURCE. UNDER NO CIRCUMSTANCE SHOULD ADDI-
TIONAL EQUIPMENT BE OPERATING OFF THE DEDICAT-
ED POWER SOURCE FOR THE HTK.
Pulling Wires
The number of wires needed to be pulled for the HTK system is shown below:
Three Wires Electrical Power (Hot, Neutral and Ground)
Five Wires 4 for Washes, 1 common
Two Wires Cycle Inhibit
Spare Wires For Future Options
2 Conductor Twisted Shielded Cable Hamilton Code System/POS 4000
Cat 5 Credit Card & CVC Acceptance
Shielded Video Cable Video
For proper operation of the HTK, all wires listed above must be pulled and terminated as explained in
the following section.
 Wire Terminations
The wire terminations should proceed as follows:
 One side of the three power supply wires (120VAC HOT, 120VAC NEU, and 120VAC GND)
should be attached directly to the electrical service panel supplying power to the installation.
They should be connected to a 15 AMP circuit breaker and the HTK should be the only de-
vice on this circuit. The other end of these three wires should be routed into the HTK through
the installed conduit. The wires should be terminated as follows: Refer to “Power Supply”
diagram on page 17.
NOTE: The removal of the Power Supply and duplex outlet is rec-
ommended for ease of connection to backside of duplex outlet
NOTE: The signal presented to the car wash controller is a nor-
mally open, dry contact relay closure.

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• The Vend 3 wire is used to signal the car wash controller that a customer has completed a
transaction and has selected the Vend 3 sequence. The connection for Vend 3 is position 3 on
the phoenix connnector.
• The Vend 4 wire is used to signal the car wash controller that a customer has completed a
transaction and has selected the Vend 4 sequence. The connection for Vend 4 is position 4 on
the phoenix connector.
• The Common wire pulled to the HTK from the car wash controller is connected in Position
11 (C) of the phoenix connector on the Wash Interface.
• The CYCLE/INHIBIT wires are used for the car wash controller to signal the HTK when a
car has completed its wash and left the bay. The signal coming from the car wash control-
ler must be able to energize the coil of a relay on the wash interface. This means that the car
wash controller must be supplying both voltage and current when it energizes the coil. Inside
the HTK, the wiring connection depend on the signal provided by the car wash controller.
The CYCLE/INIBIT wires should be connected directly to the 4 position phoenix connector.
Position 1 and 2 on the wash interface. Note: Refer to the “Wash Interface” for proper wiring
connection.
• The OUT-OF SERVICE relay is included in the HTK. The connection is made at a 3 position
phoenix connector on the controller. Position 1 (common), Position 2 (Normally closed) and
Position 3 (normally open) Refer to “Controller” diagram on page 28.
• The ALARM relay is included in the HTK. The connection is made at a 3 position phoenix
connector on the controller. Position 1 (common), Position 2 (normally closed) and Position
3 (normally open). Refer to “Controller” Diagram on page 28.
NOTE: When setting up an HTK with the Hamilton Gated PLC
and Gates please refer to diagram “HTK Gated Tunnel Diagram”
for additional terminations needed at the Gated PLC and Gates.
Refer to page 20 and 21.
NOTE: For proper Vend connection refer to “Wash Interface”
diagram page 18
• The Vend 1 wire is used to signal the car wash controller that a customer has completed a
transaction and has selected the Vend 1 sequence. The connection for Vend 1 is position 1 on
the phoenix connector.
• The Vend 2 wire is used to signal the car wash controller that a customer has completed a
transaction and has selected the Vend 2 sequence. The connection for Vend is position 2 on
the phoenix connector.

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Power Supply Wiring Connection
DC 24 12 5
120V
120V
120V
BILL DISPENCER AUX
EXT. DISPLAY
SMART BUS
SMART BUS
CONTROLLER
HIGH VOLTAGE
MODEL
RISK
5 AMP
120 VAC BROUGHT INTO MACHINE FROM BREAKER
120 VAC FEED THROUGH RECEPTICLE TO POWER MACHINE
BRING MAIN POWER INTO OUTLET TO POWER MACHINE

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Wash Interface
BUS
VEND OUTPUTS CYCLE/W.I.S.
AUX IN
PB
VEND 1
VEND 2
VEND 3
VEND 4
VEND 5
VEND 6
VEND 7
VEND 8
ISOLATED VEND
CYCLE
W.I.S.
INPUT
TXD
RXD
DIAG.
RELAY POWER
POWER
12345678910c 1234
12
1 = VEND 1
2 = VEND 2
3 = VEND 3
4 = VEND 4
5 = VEND 5
6 = VEND 6
7 = VEND 7
8 = VEND 8
9 = ISOLATED VEND
10 = ISOLATED VEND
C =VEND COMMON
VEND OUTPUTS
1 & 2 = CYCLE SIGNAL
3 & 4 = WASH IN SERVICE SIGNAL
CYCLE/W.I.S.
AUX IN
1 & 2 NOT CURRENTLY USED

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HTK “Automatic” Wiring

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HTK “Gated Tunnel” Wiring