FuelMaster® Installation Manual Table of Contents (con’t) A/C Power ............................................................................................... 70 Telephone/Two-Way Ringdown Device ................................................... 70 Quick Stop Button as FMU Stop Switch ................................................... 70 Quick Stop Button as Auxiliary Emergency Stop Switch .......................... 72 On-Site/Transaction Printer ....................................................
FuelMaster® Installation Manual Table of Contents (con’t) VALIDATE FMU ACCESS WITH PROKEE®, SMARTCARD, CREDIT CARD, AND/OR KEYPAD ................................................................................... 113 ACTIVATE PRODUCT DISPENSERS ..................................................... 113 VERIFY SINGLE HOSE AUTHORIZATION ............................................. 113 SIMULTANEOUS TRANSACTIONS ........................................................
FuelMaster® Installation Manual Figures and Tables Figure 1-1. Boundaries of a Flammable Liquid Hazardous ...........................................................16 Figure 1-2. FMU Electrical Safety Spacing ....................................................................................17 Figure 1-3. FMU ID Plates ............................................................................................................18 Table 1-1. FMU Door Key Reference ...........................................
FuelMaster® Installation Manual Figures and Tables (con’t) Figure 4-21. Connecting to Open Collector Pulser (Gasboy 9800 Pump I/F shown) ....................93 Figure 4-22. I/O Silver Board ........................................................................................................95 Figure 4-23. Satellite I/O Control Board .......................................................................................96 Figure 4-24. Satellite Connections ................................................
FuelMaster® Installation Manual Introduction Proprietary Information Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means – electronic, mechanical, photocopying, recording, or otherwise – without the prior written permission of the publisher: Syn-Tech Systems, Inc. PO Box 5258 Tallahassee, Florida 32314 Phone: (850)878-2558 Fax: (850)877-9327 Support: (800)888-9136, Ext.
FuelMaster® Installation Manual Section 2 - System Description This section contains a description of all FuelMaster® standard and optional equipment available at the time of publication of this manual. Section 3 – Site Planning and Preparation This section provides guidelines for preparing your site for a FuelMaster® installation. Section 4 - Installation This section provides guidelines for performing a FuelMaster® FMU and EIU installation.
FuelMaster® Installation Manual Section 1 General Information Introduction FuelMaster® consists of equipment developed to control access to, account for, and compile reports for transactions from dispensing equipment. FuelMaster® accomplishes this with security from unauthorized user access while maintaining complete accountability of each transaction as it occurs.
FuelMaster® Installation Manual • NIST Handbook 44, Specifications, Tolerances, and Other Technical Requirements for Weighing and Measuring Devices, technical requirements for the purpose of eliminating from use weights and measures and weighing and measuring devices that give readings that are false, that are of such construction that they are faulty, or that facilitate the perpetration of fraud. Section 3 contains most of the guidelines for retail self service fuel site inspection criteria.
FuelMaster® Installation Manual • Wear a wrist grounding strap or touch an unpainted metal surface on the chassis, such as the back panel, before touching anything inside your FMU. • While you work, periodically touch an unpainted metal surface on the FMU chassis to dissipate any static electricity that might harm internal components.
FuelMaster® Installation Manual stored by FuelMaster® need not be secure, but your Central Controller and FMU may be connected to a network containing private information you want to be secure. Syn-Tech cannot emphasize enough the potential ramifications of breached network security.
FuelMaster® Installation Manual intrinsically safe or must be enclosed within an explosion-proof enclosure. Intrinsically safe devices are generally limited to very low voltage and low current devices, such as that portion of a pulser before the barrier. Examples of explosion-proof enclosures are rigid metal conduit, and junction boxes and conduit fittings approved for use in hazardous locations.
FuelMaster® Installation Manual Figure 1-3.
FuelMaster® Installation Manual ID Plates An ID plate (see Figure 1-3) is affixed to the side of the FMU pedestal closest to the pedestal door locks. The ID plate contains the serial number of the unit as well as certification information, and a code to cross reference the key number used in the door locks (see Table 1-1). If a pedestal is replaced due to an upgrade or damage, the new pedestal will not have an ID plate installed.
FuelMaster® Installation Manual first. Each Prokee® is warranted against defects in material and workmanship for a period of five years. A toll-free number for technical assistance is also included. This line affords the customer access to product support personnel who will answer questions regarding operation of FuelMaster® hardware or software, and provide diagnostic capabilities when necessary.
FuelMaster® Installation Manual Figure 1-4.
FuelMaster® Installation Manual FuelMaster® Equipment Specifications Rated Supply Voltage Limits Rated Supply Frequency Rated Supply Current Heaters (2 each) Other electronics Operating Altitude, Max Max Operating Relative Humidity Installation Category (surge arrestor) Installation Category (after surge arrestor) Pollution Degree 120VAC +/- 15% (upper limit) 75 +/- 10% (lower limit) 50 or 60 Hz 2.4 amps Max operating 1.0 amps (each) 0.
FuelMaster® Installation Manual Battery Reference There are batteries on the mainboard, card reader board, and data logger. All applications use the same battery. All batteries are lithium 3V with Syn-Tech part number 180181, and Rayovac part number BR2325-B 3V. The classic FMU-2500 mainboard and card reader board each use two batteries. The FMU-2500Plus mainboard uses one battery. The data logger uses one battery.
FuelMaster® Installation Manual Commercially Available Products This FuelMaster® Installation Manual makes reference to commercially available equipment and materials that are required to complete an installation. Trade names and part numbers are also referenced to cite products that have been tested and known to be serviceable with FuelMaster® equipment. These references should not be construed as restrictions only to those referenced products.
FuelMaster® Installation Manual Section 2 System Description Introduction Components. The FuelMaster® Fuel Management System consists of equipment designed to automate control and accountability of any metered liquid or gas. It is not limited only to fuels applications.
FuelMaster® Installation Manual Figure 2-1.
FuelMaster® Installation Manual All current versions of the standard FMU are delivered with an alpha-numeric keypad, a 33.6 baud modem, a Type II compact flash memory card (for current and future memory requirements), weatherproof Prokee®, Smartcard, and/or magnetic stripe card receptacles, and a backlit display for visibility at night. A 4x4 keypad with 10 digits, 4 letters, ENTER/YES, and CLEAR/NO keys is available, if desired. Automatic/Manual (Bypass) Operation.
FuelMaster® Installation Manual Relay Options. An FMU may be thought of as a switch installed in a control circuit of a dispensing device. It is installed where it can interrupt flow to each dispensing hose. When authorization is provided, the FMU “closes the switch” to complete the circuit. Relays are used to “close the switch”. FMUs may be ordered with 50 amp solid state relay assemblies or with dual control relay assemblies.
FuelMaster® Installation Manual • • • • • User Keys are encoded with a user identification number and are assigned to a user Supervisor Keys are authorized special access to reconfigure the FMU, run built-in tests of the FMU, issue fuel to operators without a Prokee®, and enter inventory-tracking information. Manual Issue Keys are used to issue fuel to individuals or vehicles that do not have a Prokee®.
FuelMaster® Installation Manual Prokee®/Smartcard Encoder The Encoder uses data entered in the Fuel Management Software to encode, re-encode, or read Prokee® and Smartcard data, and to update Preventive Maintenance or odometer mileage. The Encoder is available for either USB or parallel connection to the Central Controller. The parallel connected Encoder requires a 115 VAC connection for its power supply where the USB encoder draws its power through the USB connection.
FuelMaster® Installation Manual Digital Cell Modem: a digital cell modem may be installed in an FMU to facilitate communications to the FMU through a digital cell phone. Syn-Tech builds a kit designed to accept cell modems from several different vendors. The cell modem is not supplied with the kit. Direct Connect Cable: some customers may choose to use a laptop for a Central Controller.
FuelMaster® Installation Manual Keyless FMU Access: FMUs may be selected for keyless access. Users do not need Prokee®s, Smartcards, or credit cards to access keyless FMUs. Users depress the FMU keypad Enter key to bring up the first question to start a transaction. Large Remote Display: the Large Remote Display is available to display the quantity or price of fuel pumped in four inch numbers on a large display mounted anywhere outside a hazardous area.
FuelMaster® Installation Manual Receipt Printer: two Receipt Printer options are available: FMU pedestal mount or indoor. Both Receipt Printer options print a receipt for automated transactions. The receipts print system owner name, date, time, User ID, Vehicle ID, hose, product, and quantity. Additional custom information may be programmed for receipt printing. The pedestal receipt printer cuts off receipts after printing and deposits them in a chute with a clear plastic access door.
FuelMaster® Installation Manual Specialty Equipment: Syn-Tech may be tasked to supply an assortment of specialty equipment with your order. We have supplied such things as solenoid valves, pulse output boards for dispensers, computers, monitors, tank monitor RS-232 boards, etc. If you are having difficulty locating what you need, call us. We may have the part on our shelf, or a convenient source of supply.
FuelMaster® Installation Manual as a replacement part. The fiber optic transceiver accepts only MT-RJ fiber optic connectors. Options exist for wireless network communications, an option that could eliminate the need for a communications conduit to the FMU, and minimize the surge potential otherwise present with a cable or phone line communications connection. When network communications are established to a master FMU, communications to satellite FMUs continue to be through RS-422 communications cable.
FuelMaster® Installation Manual 36 212
FuelMaster® Installation Manual Section 3 Site Planning and Preparation Introduction This section includes considerations which must be given to planning and preparation for FuelMaster® servicing and Central Accounting Office sites. Each servicing site identified in the Fuel Management Software will contain, as a minimum, one master FMU, one product dispenser, and one product tank.
FuelMaster® Installation Manual Figure 3-1.
FuelMaster® Installation Manual Figure 3-2. EIU Dimensions (in inches) Figure 3-2 does not illustrate the interface between the EIU pedestal and EIU cabinet. From the rear of the EIU pedestal to the rear of the EIU cabinet is 4-1/4 inches. Overall front to rear distance including the extension of the visor over the Prokee receptacle is 11-5/8 inches. The EIU base plate is 3/16 inch thick and 10 inches square.
FuelMaster® Installation Manual Conduit Requirements CAUTION Although PVC conduit is allowed by the NEC, only metal conduit will be used for FuelMaster® applications. Syn-Tech insists upon this because of non-metal conduit’s higher susceptibility to surge (lightning) damage. Failure to use metal conduit and the recommended shielded cables voids all warranties. ATTENTION Bien que le conduit de PVC soit permis par NEC, seulement le conduit en métal sera utilisé pour l'équipement de FuelMaster®.
FuelMaster® Installation Manual Conduit Size 1/2 3/4 1 1-1/4 1-1/2 2 Total Inside Area 0.314 0.549 0.887 1.526 2.071 3.408 40% Area 0.1256 0.2196 0.3548 0.6104 0.8284 1.3632 25% Area 0.0785 0.1373 0.2218 0.3815 0.5178 0.8520 Table 3-1. Rigid Metal Conduit Fill Capacity Wire/Cable 18 AWG TFFN 16 AWG TFFN 14 AWG THHN 12 AWG THHN 10 AWG THHN Belden 8723 Belden 9552 Diameter 0.0841 0.096 0.111 0.130 0.164 0.160 0.368 Area 0.0055 0.0072 0.0097 0.0133 0.0211 0.0201 0.1064 Table 3-2.
FuelMaster® Installation Manual Figure 3-3.
FuelMaster® Installation Manual Conduit entering an FMU typically enter the FMU through the opening in the base of the pedestal. If conduit enter the FMU through holes punched/drilled through its exterior, the holes must be sealed to prevent water intrusion into the FMU. Keep in mind, conduit entering the FMU through holes punched/drilled through its exterior will make it more difficult to move the FMU should it need to be moved or relocated.
FuelMaster® Installation Manual approximately 400 milliamps. The total current draw will be less than 3 amps. Errors on Power-Up: an FMU newly installed in a cool, damp environment may display errors after power-up until the electronics dry out and warm up. Let the FMU run for a couple hours before assuming there are non-recoverable errors. NOTE While voltage regulators and power conditioners both offer protection, they do not perform the same functions.
FuelMaster® Installation Manual Uninterruptible Power Supply (UPS): Weights & Measures requirements call for a backup power source for retail fueling operations. The customer who starts a transaction with a credit card must be provided a receipt should there be a power failure while a retail transaction is in progress. A UPS may be installed between the FMU and its power source (i.e., breaker panel) as a backup power source.
FuelMaster® Installation Manual • Through analog phone lines: download through phone lines will require access to an analog, data-grade, USA telephone line. A telephone line in use by a fax machine may be shared for this purpose. Previous versions of this install manual specified a voice-grade analog telephone line. When it became necessary to troubleshoot telephone line problems, the line was tested for its ability to transmit voice signals.
FuelMaster® Installation Manual If a device is mounted in the FMU which requires connection to an electrical outlet, an outlet box must be installed. Installation of an outlet box is covered in Section 4, Installation. • Through a network cable: download through a network cable will require a Cat 5 (or equivalent) network cable routed from the nearest network connection to the master FMU. For maximum reliability, it is not recommended that any single run of network cable be greater than 200 feet.
FuelMaster® Installation Manual Electronic dispensers have an internal CPU (central processing unit) which controls dispenser functions. The CPU typically requires two-wire communications inputs from a proprietary device (OEM control box) to initiate dispensing functions and extract quantity information. FuelMaster® uses an Electronic Dispenser Interface Kit to make the required connection and communicate with the dispenser CPU.
FuelMaster® Installation Manual What it does: if pump handle detection is not turned on and used to end a transaction, timers (No Pulse Timeout and Pump Finish Timer) must be set to end the transaction. When timers are used to end a transaction, they must be set to accommodate the longest fueling scenario to ensure the transaction is completed before authorization is removed. The transaction remains authorized until the timeout occurs.
FuelMaster® Installation Manual the beginning of the transaction but detects the turn off at the end of the transaction. AIM2™ scenario: an AIM2™ passive transaction does not require someone to start their transaction at the FMU. Instead, they park their vehicle next to the dispenser, take the fuel nozzle down, turn on the pump handle, insert the fuel nozzle into the fuel tank filler neck, and pump fuel. AIM2™ fueling scenarios ignore pump handle detection.
FuelMaster® Installation Manual NOTE It is recommended dispenser reset power be obtained from a separate power source, and not the same power source as the FMU. If constant AC pump reset power is derived from the FMU power source, current spikes or low FMU voltage may occur when the solenoid valve/pump motor is activated which may generate power resets in the FMU.
FuelMaster® Installation Manual constant. It should be power applied when a pump handle or pump switch is turned on. When this power source is found, find a convenient place to break the connection. There will usually be a wirenut connection that may be separated. Use the FMU LN and LD positions as switch contacts to control power to the valve or motor. Attach the incoming power for the valve or motor to a wire routed to an FMU LN position (LN1 for hose 1, LN2 for hose 2, LN3 for hose 3, etc.).
FuelMaster® Installation Manual Controlling Lube Bay Hose Reels: control of lube bay hose reels is very similar to the control of other types of dispensing equipment with the exception of the power source. Equipment designed for controlling lube bay hose reels is typically 12 or 24 VDC, and an added power supply may be necessary to power the equipment. A DC power supply may be installed in the FMU to minimize the number of wires needed to control each hose reel.
FuelMaster® Installation Manual Pulsers NOTE In accordance with the NEC, “Class 1 circuits shall be permitted to occupy the same cable, enclosure, or raceway without regard to whether the individual circuits are alternating current or direct current, provided all conductors are insulated for the maximum voltage of any conductor in the cable, enclosure, or raceway.” Ref: NFPA 70, para 725.26(A). The FMU obtains quantity information from pulse output devices in the dispensing equipment.
FuelMaster® Installation Manual per minute. This would equate to using a 1000:1 divide rate pulse output with a hose pumping 120 gallons per minute. Dual Output Pulsers: dispensers may be tasked to provide pulse outputs to both a fuel management system such as FuelMaster®, and a tank monitor/tank gauge system such as the VeederRoot TLS-350R. Dispensers may be equipped with pulsers with dual outputs, when necessary.
FuelMaster® Installation Manual Some customers have asked to use the Quick Stop Button as an emergency stop switch. In most locations it cannot be legally used as an emergency stop switch because it is too close to the fueling equipment. If it is used as an emergency stop switch, it is supposed to remove power from all fuel island equipment. If used for this purpose, it should only control a remote emergency stop switch.
FuelMaster® Installation Manual FuelMaster® software program, the TMU reported quantity can be used to reconcile FuelMaster® reported quantity. An optional Tank Monitor Interface Kit must be added to the Master FMU to provide for the TMU interface. Most TMUs receive communication inputs via RS-232. If a TMU will accept an RS-232 input, an interface to FuelMaster® is possible. An RS-232 connection will be standard in some TMUs, and an extra cost option in others.
FuelMaster® Installation Manual in each jumper position of the Satellite I/O Control Board which corresponds with a receptacle position on the I/O Silver Board. Example: if satellite connectors are plugged into positions 1, 2, 3, and 4 of the I/O Silver Board, jumpers must be installed in jumper positions 1, 2, 3, and 4 of the SATELLITES INSTALLED JUMPERS. This applies to both master and satellite FMUs. Master FMUs may have multiple connections for multiple satellites.
FuelMaster® Installation Manual EIU Control EIUs may be programmed for Prokee® and/or keypad input through a laptop or Customer Satisfaction Center connection to the controlling master FMU. Activation options are: 1) through use of a Prokee® only, 2) through use of an ID number only, or 3) through use of both a Prokee® and an ID number. Since it can be programmed for ID number only input, a vehicle operator can activate the EIU without a Prokee® (that may be on a key ring with his ignition keys).
FuelMaster® Installation Manual communications medium for communications with the FMUs. Refer to the FuelMaster® Plus User Manual for minimum PC requirements, and installation and operation of the Fuel Management Software. Central Controller The Central Controller must be capable of interfacing with the Master FMU(s) to send and receive data, and the Prokee®/Smartcard Encoder to encode and read Prokee®s/Smartcards.
FuelMaster® Installation Manual Wireless Phone Lines: wireless phone line connections should only be considered when other mediums are not an option. Digital cell modem communications between analog devices is not reliable. Phone line extenders are considerably more expensive than wireless networking equipment, but may be considerably cheaper than trenching to install conduit.
FuelMaster® Installation Manual Surge Protection The Central Controller is susceptible to surge damage through its AC power source and/or communication lines. The use of surge protection is highly recommended. File Backups The Central Controller contains transaction and database information peculiar to each customer that cannot be duplicated by Syn-Tech Systems.
FuelMaster® Installation Manual Section 4 FMU Installation Introduction Following are procedures for installing a complete FuelMaster® Fuel Management System including optional equipment. Detailed planning and preparation for these procedures was covered in Section 3, Site Planning and Preparation. All the following procedures may not have to be performed, nor may they have to be performed in the order shown.
FuelMaster® Installation Manual Central Controller Installation For the purposes of this manual, Central Controller installation includes only hardware installation. The FuelMaster® Plus User Manual must be referred to for software setup and operation. Positioning the Central Controller NOTE The Central Controller need not be a desktop PC. A Central Controller may be developed from a laptop computer.
FuelMaster® Installation Manual Connecting a Two-Way Ring-Down Device If a Two-Way Ring-Down Device is to be used, see Figure 4-1 and position the Two-Way Ringdown Device where the necessary connections may be made. A two conductor communications cable from the FMU must be routed to the Two-Way Ringdown Device, then an RJ-11 jack must be installed on the end of the communications cable for connection into the Device.
FuelMaster® Installation Manual The FMU pedestal will not always be mounted directly over conduit. Figure 4-3 illustrates some alternate mounting methods. Installations have been performed where conduit entered the pedestal through holes punched/drilled through the pedestal. Such holes must be sealed watertight. In some instances, other automated systems have been removed and their pedestal has been retained for use as a junction box.
FuelMaster® Installation Manual Figure 4-2. FMU Footprint (in inches) Figure 4-3.
FuelMaster® Installation Manual NOTE Screw anchor nuts may be left loose in step 4 to assist with the installation of conduit or liquid-tight flex up to the FMU pedestal electrical access panel. If additional conduit or liquid-tight flex are not being installed, the screw anchor nuts should be tightened when initially installed. 4. Mount the pedestal on the screw anchors, and install the screw anchor nuts and washers.
FuelMaster® Installation Manual Wire/Cable Recommendations. Where wire/cable sizes are listed, larger conductors may be used to gain additional range: 1. AC Power to FMU(s). Three conductors; 12 AWG THHN (increase to 10 AWG if length exceeds 400 feet) stranded; black for hot, white for neutral, green for ground; should be derived from separate 15 amp circuit breaker. Minimum power requirements may not be met at all times if derived from another source (dispenser).
FuelMaster® Installation Manual Wire/Cable Connections at FMU Make the following wire/cable connections at the FMU: NOTE Many wire/cable connections are made to Phoenix-style pluggable printed circuit board connectors with terminals closed by turning a screw. Continuity will not exist if insulation is not stripped from the wires before insertion into the terminal. 1.
FuelMaster® Installation Manual Figure 4-4. AC Power and Phone Connections Figure 4-5.
FuelMaster® Installation Manual 4. Quick Stop Button as Auxiliary Emergency Stop Switch. The Quick Stop Button has two terminals to receive wire connections. It removes power by depressing the red mushroom-shaped button. Power is restored by turning the button clockwise a partial turn until it pops back out to the reset position. Check local requirements for an Emergency Stop Switch. Most regulations require an Emergency Stop Switch to be remotely located at least 20 feet from the fuel island.
FuelMaster® Installation Manual Table 4-1. Transaction Printer Cable Connection Points J3 EXTERNAL Pin YEL (TX) BLU (RX) ORG (GND) Printer DB25 Pin 3 2 7 201669 Cable Color RED BLACK CLEAR 6. Dispenser Control (see Figure 4-6 for connection points on the Pedestal I/O Board). These procedures only cover dispenser control. Additional connections from the FMU to the dispenser will be required for pulser connections.
FuelMaster® Installation Manual Figure 4-6.
FuelMaster® Installation Manual NOTE Whenever pump handle detection is wired into the PHS positions of the Pedestal I/O Board, one leg of the resistor at positions R92 for hose 1, R93 for hose 2, etc., must be cut to transfer pump handle detection from LN to PHS. a. Controlling Reset. See Figure 4-7. This control method interrupts power from the circuit breaker to each dispenser reset mechanism.
FuelMaster® Installation Manual Figure 4-7. Wiring Diagram - Controlling Reset 4) Connect one end of one wire to LD1 at the FMU, and the other end to hose 1 RESET FEED in the dispenser. 5) (Using pump handle detection) Connect one end of the second wire to PHS1 at the FMU, and the other end to hose 1 RESET COMPLETE in the dispenser. 6) (Using pump handle detection) Refer to Figure 4-6. Clip one leg of the resistor at R92 so power cannot travel through the resistor.
FuelMaster® Installation Manual Figure 4-8. Wiring Diagram - Controlling Reset in Dual Hose Single Product Dispenser without Backfeed (One Solution) b. Controlling Motors. See Figure 4-9. When controlling a classic or DoD FMU, and pump handle detection is needed, the control method most likely used will be controlling motors or solenoid valves. If solenoid valves are not present, motors must be controlled. There must be one motor feed per hose.
FuelMaster® Installation Manual Figure 4-9. Wiring Diagram - Controlling Motors If the dispenser is being fed from the top of an aboveground tank, there must be an anti-siphon valve on the tank, or inline between the dispenser and tank. Without an anti-siphon valve, the siphon effect created when a previous transaction was performed will permit fuel to siphon through the dispenser and pump motor to the dispenser nozzle after the pump motor is turned off. Product may then be obtained without authorization.
FuelMaster® Installation Manual most likely a red or orange wire from the dispenser reset mechanism wire-nutted to one of the motor leads (or contact starter). There should be power present when the dispenser pump handle is turned on, and power should be removed when the pump handle is turned off. If the motor is powered by 220 VAC, the second motor feed will be from another power source, and power may be present on the RESET COMPLETE line when the pump handle is turned off.
FuelMaster® Installation Manual Figure 4-10. Wiring Diagram – Controlling Solenoid Valves Perform the following to control solenoid valves: 1) Inside the dispenser junction box, locate the RESET COMPLETE wire feeding the solenoid valve for hose 1. It is most likely an orange wire from the dispenser reset mechanism wirenutted to an AC input to the solenoid valve. There should be power present when the dispenser pump handle is turned on, and power should be removed when the pump handle is turned off.
FuelMaster® Installation Manual 8) Repeat steps 1 through 7, as required, for all additional hoses. Figure 4-11. Wiring Diagram - Using Dual Control Relay Assembly (DCRA) to Control Two Devices f. Using Dual Control Relay Assembly (DCRA) to Control Two Devices. See Figure 4-11. Classic and DoD FMUs do not provide for control of dispenser reset while also providing pump handle detection.
FuelMaster® Installation Manual valves and one SUBMERSIBLE STARTER. If the dispenser had two SUBMERSIBLE STARTERs, there would be individual wires from the DCRA to each starter. A wire would be run from 1B to hose 1 SUBMERSIBLE STARTER, and another wire from 2B to hose 2 SUBMERSIBLE STARTER.
FuelMaster® Installation Manual Figure 4-12. Wiring Diagram – Two-Stage Valve Control Two relay assemblies are used to accomplish two-stage valve control. This limits the maximum number of possible hose controls to four. An option in the firmware must be turned on to enable two-stage valve control. The point at which the fast valve turns off before the slow valve is called the setpoint. The setpoint may be set to any value between 0.1 and 10.0 units (dollars or gallons).
FuelMaster® Installation Manual Preset quantities or costs may only be set with credit card transactions. The transaction is started with both the fast and slow valves turned on. When the setpoint is reached, the fast valve shuts off and the transaction is finished on the slow valve. With Prokee®s and smartcards, the transaction is also started with both the fast and slow valves turned on, but the transaction ends with the transaction limit encoded into the Prokee® or smartcard.
FuelMaster® Installation Manual 7D command. Default is 3 minutes. h. Controlling DC Devices (Hose Reels in Lube Bays/Bulk Oil Dispensers). NOTE Whenever a part is field modified, mark/label it to inform others of the modification so a replacement part may be modified in the same manner. Make Syn-Tech aware of the modification when ordering a replacement part. Some minor modifications are necessary when controlling DC devices such as solenoid valves for hose reels in lube bays, or bulk oil dispensers.
FuelMaster® Installation Manual Figure 4-13. Location of 75K ohm Pump Handle Detect Resistors i. Controlling Carwashes, Gate Openers. There are some devices which may be controlled by simple contact closure switching, but do not have pulse emitters.
FuelMaster® Installation Manual application. A Smart Relay Assembly originally purchased to control one device may not control three devices without reprogramming the PIC. The PIC will have a label imprinted with SIMPLE1, SIMPLE2, or SIMPLE3 to indicate whether it is programmed to control 1, 2, or 3 devices. Smart Relay Assemblies do not utilize the Pedestal I/O Board and FMU Auto/Manual Switches when controlling devices. Control wires are wired direct into the Smart Relay Assembly.
FuelMaster® Installation Manual Smart Relay Assemblies produce a momentary contact closure adjustable for 1 to 16 seconds through dip switches located on the board. The dip switches are numbered 1-4 and provide the following momentary settings: All Off = 1 second 1 On = 4 seconds 1 and 2 On = 8 seconds 1, 2, and 3 On = 12 seconds All On = 16 seconds The J3 receptacle is fitted with a 7-pin terminal plug for control wiring inputs.
FuelMaster® Installation Manual In the Monitor Mode, no authorization signal is required so nothing needs to be connected to the Pedestal I/O Board LN and LD positions. FMU firmware activates the relay for the hose put in Monitor Mode. An LED on the Relay Assembly corresponding to the activated relay will illuminate steady while in Monitor Mode. Pulses from a pulser or flowmeter are needed, so connections are made to the Pedestal I/O Board pulser connectors on J4, J5, J6, and/or J7, as needed.
FuelMaster® Installation Manual pulsers are with two or three conductors. All mechanical pulsers will require a 12 VDC input to return a 12 VDC pulse for the FMU. Many will also require a third conductor connection to 0V ground, or common. CAUTION Some open collector pulse generators such as the Gasboy Pump I/F Board cannot accept a direct 12 VDC input. Applying 12 VDC directly to the Pump I/F Board will damage it.
FuelMaster® Installation Manual Figure 4-15. Connecting to Veeder-Root 1871 Pulser Figure 4-16. Connecting to Veeder-Root 7671 Pulser Figure 4-17.
FuelMaster® Installation Manual Figure 4-18. Connecting to ICS 110 VAC Pulsers Figure 4-19. Connecting to OPW 12 VDC Pulsers Figure 4-20.
FuelMaster® Installation Manual Figure 4-21. Connecting to Open Collector Pulser (Gasboy 9800 Pump I/F shown) a. Dual Output Pulsers. Pulsers are available with dual outputs; pulsers which provide outputs to two different devices such as an FMU and a tank monitor. An application which may require a dual output pulser is a system having both an FMU and a TLS-350R Veeder-Root tank monitor. Pulses from the fuel dispenser are needed by both the FMU and the TLS-350R.
FuelMaster® Installation Manual count cannot exceed 9000 pulses per minute. The pulse count is determined by multiplying the flow rate (i.e., 9 gallons per minute) times the divide rate (i.e., 100 pulses per gallon). This example would be 900 pulses per minute. Separating the AC control wires and DC pulser cables in separate conduit will also eliminate any bleedover. e. One Pulser, Two FMUs.
FuelMaster® Installation Manual Index A B C D E F G H I J K Description Satellite Position Number Electronic Dispenser Interface or Indoor Receipt Printer Ribbon Cable Connector, JP12 (see Note) Electronic Dispenser Interface or Indoor Receipt Printer RS-232 Connector, JP11 (see Note) Attach Screws Over Standoffs (6 places) Satellite Ribbon Cable Connector for Satellites 5-8, JP10 Board Part Number and Revision Level Marking Cut E1-E2 Trace for RS-232 (Do Not Cut for RS-422) Tank Monitor RS-232/RS-422 Cab
FuelMaster® Installation Manual Figure 4-23.
FuelMaster® Installation Manual 8. Tank Monitor Interface (see Figures 4-22 and 4-23). Tank monitor interfaces are only possible to a Master FMU equipped with a Tank Monitor Interface Kit, part number 202002A. Interface cable connections at the FMU will be dependent upon the use of RS-232 (3-conductor) or RS-422 (2-pair with drain) cable. In either case, connections will be made to a 5-pin connector in JP13 on the I/O Silver Board. RS-422 may be necessitated by the length of the cable run.
FuelMaster® Installation Manual baud rate. The same parameters must be set in the FMU for an effective communications interface. The parameters may be set with a laptop connection and command 5a, or by a dial-in from the Syn-Tech Customer Satisfaction Center. 9. Satellite Connections (see Figure 4-24). Both master and satellite FMUs must be equipped with a Satellite Option (STS part number 200034A) to accept the wire terminations and provide the necessary internal interface cables.
FuelMaster® Installation Manual Master-satellite connections are hardwired with RS-422, or wireless connected. The use of B&B Electronics Zlinx Radio Modems for a wireless connection is described in Product Bulletin 133. A kit including a pair of Zlinx Radio Modems is available from Syn-Tech under part number 249912. Perform the following to make a hardwire master-satellite connection: a.
FuelMaster® Installation Manual Equipment Interface Unit (EIU) Installation EIUs provide secure access to accessory devices such as gate openers, car washes, or door openers. They do not directly control these devices, but activate them by providing a 1, 5, 8, 11, 14, 17, or 20 second momentary power signal to the accessory controller. The accessory controller must be capable of activation through a momentary input signal. EIUs cannot operate independently.
FuelMaster® Installation Manual c. Pedestal I/O Board. Master FMU/EIU communications cables cannot be “daisy-chained” between EIUs. Individual communications cables are necessary from the Master FMU to each EIU. Control of Accessory Controller. Pull two 14 AWG THHN wires from the EIU to the accessory controller. The wiring diagram in Figure 4-27 calls out blue and orange, but any color may be used which are easily identifiable when making the wire connections.
FuelMaster® Installation Manual Figure 4-27.
FuelMaster® Installation Manual CAUTION If the Pedestal is mounted on an uneven surface and the screw anchors are tightened, the welds at the base of the Pedestal may be cracked. Washers, as spacers, should be installed on the screw anchors under the corners of the Pedestal to account for minor irregularities in the mounting surface, or to level the Pedestal.
FuelMaster® Installation Manual described in Product Bulletin 133. A kit including a pair of Zlinx Radio Modems is available from Syn-Tech under part number 249912. Perform the following to make the wire connections at the Master FMU: WARNING Removing power from the Master FMU at the FMU power switch does not remove incoming AC power. To prevent personal injury, ensure power is removed by turning off the circuit breaker for the Master FMU and each connected dispenser.
FuelMaster® Installation Manual 9. Refer to the wiring diagram in Figure 4-27, and the wire connections noted in step 9 under Mounting the Pedestal. Connect the Master FMU/EIU communications cable routed from the EIU Pedestal Cover and Wiring Assembly to a 5-pin connector of the I/O Silver Board receptacle selected in step 6: a. Connect the wire from J2, pin 1 (Brn), to IN+. b. Connect the wire from J2, pin 2 (Red), to IN-. NOTE The GND pin is for connection of a cable drain.
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FuelMaster® Installation Manual Section 5 Initialization CAUTION STOP! Initialization may only be completed by a technician who has completed the Syn-Tech FuelMaster® installation training course. If power is applied by unqualified personnel damage to the system will be the liability of the installer. ATTENTION STOP! Initialisation ne peut être remplie par un technicien qui a terminé le cours de Syn-Tech ® FuelMaster formation sur l'installation.
FuelMaster® Installation Manual 5. Defining customers, vehicles, and users who will be using the system (Chapter 6: Customers, Vehicles, and Users). 6. Setup prepaid Prokee®s or Smartcards, and discounted pricing for specific credit cards. Not required for all customers (Chapter 7: Prepaid and Discount Cards) 7. Develop and encode Supervisor, Manual Issue, and Tanker Truck utility keys or Smartcards (Chapter 8: Utility Keys). 8.
FuelMaster® Installation Manual 3. To change the satellite configuration to an EIU, depress the space bar until GATE MASTER is displayed, then depress ENTER: USAGE - =CHANGE VALUE, =NEXT FIELD, =EXIT ---------------------------------------------------------------------------------------------------------EIU SETUP FOR SAT#1: GATE MASTER USING PROKEES! 4.
FuelMaster® Installation Manual PIN ENTRY REQUIRED! 9 CHAR VMN ID ENTRY RQD! RELAY DELAY = 5 sec. NOTE A 0 (zero) second relay setting will result in no delay and no momentary activation of the relay. Select any other setting to attain a momentary relay activation. 8. The relay setting may be set to 0, 1, 5, 8, 11, 14, 17, or 20 seconds.
FuelMaster® Installation Manual Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units This ATP applies to upgrades and installations of all FMU-2500, 3000, and 3500 series Classic and Plus Fuel Management Units (FMUs), except aviation sites (a separate Aviation ATP is available). Complete an ATP for each site. Place a check mark (√) in the space provided for each step performed. Some procedures will not be applicable to all installations.
FuelMaster® Installation Manual 3. SOFTWARE UPGRADE (For Upgrades Only) a. Verify tasking is an upgrade. Customer must have an operational copy of FuelMaster® software with an existing FuelMaster® database. If an existing database does not exist, software must be a new install. b. Disable any auto download settings and stop all services. Some services may prevent proper setup and operation of the FuelMaster® software.
FuelMaster® Installation Manual 2) All FMU’s displayed an asterisk (*) to the left of the hose number and prompted, “HOSE BUSY, SELECT ANOTHER…” when dispenser in use was selected from the FMU keypad. Indicator to users starting a transaction that a hose cannot be selected because it is in use. c. VALIDATE FMU ACCESS WITH PROKEE®, SMARTCARD, CREDIT CARD, AND/OR KEYPAD 1) FMU’s validated authorized access by stepping to next menu prompt.
FuelMaster® Installation Manual k. DISABLE DISPENSER AFTER TRANSACTION. Repeat for multiple FMUs. Note any deviations on page 5. 1) Each FMU disabled the applicable dispensers connected to it within the specified time limits after dispensing was complete. Verification that PUMP FINISH TIMER is functioning according to its setting to terminate the transaction. Only necessary to perform this check on one hose.
FuelMaster® Installation Manual 3) Download transactions and make sure that card record reflects transaction. Mark NA if not used. Prepaid Prokee record should reflect balance after transaction is deducted. p. RECORD TRANSACTION DATA. Perform automated test transactions on each hose. Record the quantity displayed on the dispenser as DISPENSER QTY. Go to the Central Controller and download the test transactions and record them under POLLED QTY. Perform a test transaction and anotate under DISPENSER QTY.
FuelMaster® Installation Manual 5) FMU board/backplate attach screws are secure. Screws holding mainboard and Satellite I/O Control Board to backplate are secure, and four screws holding backplate assembly into FMU are secure. Screws (from outside FMU) holding relay assemblies and Pedestal I/O Board in pedestal are secure. 6) Wire/cable connections are correct and secure. Self-explanatory. 7) Board retainer for mainboard expansion cards is installed and secure.
FuelMaster® Installation Manual g. Number of Satellite FMU’s: Self-explanatory h. FMU Firmware version: Can be found by watching FMU display after power is turned on. i. Dispenser control method: Reset, solenoid valves, or suction pump motors. j. Pulser type/divide ratio: Examples are: 1:1, 10:1, 100:1, 1000:1 k. Computer operating system: Examples are Vista Business 32 bit, Windows 7 64 Bit l. FuelMaster® software version: Can be found by clicking on Help/? in software. m.
FuelMaster® Installation Manual HOLD HARMLESS AGREEMENT (to be completed when installing wireless networking equipment) TO: Customer’s name and organization SUBJECT: Potential Security Breaches Through Wireless Network Connections to FuelMaster® FuelMaster® Fuel Management Units (FMUs) and software do not contain personal information subject to the Privacy Act of 1974. However, when added to a network the FMU may provide a link to other resources which do contain personal or privileged information.
FuelMaster® Installation Manual Appendix A Glossary This Appendix provides definitions for the most common terms, acronyms, and abbreviations referred to in this FuelMaster® Installation Manual. AIM2™ - trademarked name for Syn-Tech’s second generation passive fueling system. AIM is an abbreviation for Automotive Information Module. AIM2™ Installation Training – instruction to the customer in the installation of AIM2™ modules in vehicles.
FuelMaster® Installation Manual Initialization (aka Startup) – initialization and startup are the same. Initialization includes inspection and testing of an installed FMU and loading the software. Initialization does not include the installation or pricing of any installation materials, but may include the termination of wires/cables. Training the customer is normally included in Initialization, but may be performed as a separate function and at a different time.
FuelMaster® Installation Manual Software – in this context, the FuelMaster® operating program which is loaded on the Central Controller SSRA – Solid State Relay Assembly Startup – see Initialization Station House – location at a fueling site where the office equipment (Central Controller, phones, printer, fax machine) may be located Training – instruction to the customer in the proper operation of the FMU and software.
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FuelMaster® Installation Manual Appendix B Dispenser Compatibility Following this description is a sample FuelMaster® Dispenser Compatibility listing. This listing was compiled, and is periodically updated, to keep our customer’s (users and technicians) informed of the interface capabilities of FuelMaster® FMUs. The listing is an Adobe Acrobat file with an integrated date: Dispenser_Compatibility_090310.pdf.
FuelMaster® Installation Manual The eight column, Note, contains a number corresponding to a note on the last page of the listing. These Notes should be followed to correctly interface an FMU to the dispenser make and model shown on that line of the listing. The last column, Compatible with DoD, was added to make it easier for our DoD customers to quickly determine if a direct interface is possible between a DoD FMU, and a specific make and model of a fuel dispenser.
FUELMASTER® DISPENSER COMPATIBILITY 03-Sep-10 IMPORTANT DISCLAIMER! This list is compiled from the best information available from the various dispenser manufacturers, their websites, or field experience developing the interfaces. Although this list is the most current as of the date shown above, you should call Syn-Tech Systems' Customer Satisfaction Center at 800-888-9136, ext. 1500, to confirm the most current compatible dispenser listing.
Electronic Mechanical/ Commercial/ Direct Dispenser Electronic Retail Interface Interface* Require Pulse Option Require OINK* Manufacturer/Model Gasboy (con't) 1820 Consumer Pump 72S Consumer Pump Split 70 Series Transfer Pump 25/26 Consumer Pump 67/68 Consumer Pump 3460/4460/4860 Meter Registers Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Commercial Commercial Commercial Commercial Commercial Commercial √ √ √ √ √ √ Gilbarco Legacy (JC/JCA Series) Legacy (JM/JMA Series) Legacy (
Electronic Mechanical/ Commercial/ Direct Dispenser Electronic Retail Interface Interface* Require Pulse Option Compatible with DoD (see Notes) Require Manufacturer/Model OINK* Note Veeder-Root EMR 3 Electronic Register Series Electronic Commercial √ 8,20 √ Notes: * Do not use OINKs in retail applications. Use the Electronic Dispenser Interface. 1.
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FuelMaster® Installation Manual Appendix C FMU/EIU Configurations Following is a listing of FMU and EIU configurations, by model number, available at the time of printing of this manual. Check with your FuelMaster® sales person for availability of other/newer configurations. • • NOTE Classic and Plus series equipment are compatible with Plus series software, but Plus series equipment is not compatible with Classic software.
FuelMaster® Installation Manual FMU-3550PLUS Master - Passive AIM2™ unit with Prokee® and Credit Card readers FMU-3560PLUS Master - Passive AIM2™ unit with Smartcard and Credit Card readers EIU-2530PLUS Plus EIU Classic Series Units are available only with tan finish with black and gold markings FMU-2500 Prokee® (only) Master FMU-2501 Satellite - Units are configured for use with Prokee®s, only FMU-2520 OTR (Over The Road) Master FMU-2501 OTR (Over The Road) Satellite - Units are configured for use with Pr
FuelMaster® Installation Manual Appendix D Laptop Direct Connect to FMU The information herein may also be found in Product Bulletin 111, dated 7/25/2007. If any information changes, a revision to the product bulletin will reflect the change. Several programming and troubleshooting options are possible by direct connecting to the FMU mainboard with a laptop and direct connect cable (Syn-Tech part number 941C0105, or local manufactured).
FuelMaster® Installation Manual 6. Save the file you created so the settings you entered will be available the next time you use Hyperterminal. When Hyperterminal is opened, and the saved file is opened, a blank window should be showing with a flashing cursor in the upper left corner of the window. Press Ctrl D to log on to the FMU. An abbreviation of the FMU’s site name should appear. From this point, commands may be entered to view or program information into the FMU.
FuelMaster® Installation Manual 1C 1D,ARG1,ARG2 1E,ARG1,ARG2 1F,ARG1,ARG2 20,ARG1 21,ARG1 22 23 26 27,ARG1 28 29 2A 2B 2C,ARG1 2D 2F,ARG1 reset. 30 31 33,ARG1 34,ARG1,ARG2,ARG3 ARG2. 35 36,ARG1 37 38 39 3A 3B 3C 3D 3E 3F 40 41,ARG1 42 43 44 45 46 47 48 49 4A,ARG1 4B 4C 4D 4E 50,ARG1 51,ARG1 52,ARG1 pumps. 53,ARG1 54 56 57 Send message to LCD, wait for user response, or 45 sec.. Same as 1F, also include out of range but don't rollover. List ARG2 transactions (in HEX) starting from tx. #ARG1.
FuelMaster® Installation Manual 58 59 5A 5B 5C 5D 5E 5F 60 61,ARG1,ARG2,ARG3 63 64 66 67,ARG1 Sat}. 68,ARG1,ARG2 69,ARG1 Sat}. 6A 6B,ARG1 6C,ARG1 6F 70,ARG1 71,ARG1,ARG2 72,ARG1,ARG2 Logger). 73,ARG1,ARG2 74 75,ARG1 76 77 78,ARG1 79,ARG1 7A,ARG1,ARG2 7B,ARG1 7C,ARG1,ARG2 7D,ARG1,ARG2 7E 7F 80 87 88,ARG1 89,ARG1 8B,ARG1,ARG2 8F 93 94,ARG1 95 96 97 98 99 9C,ARG1 9D,ARG1 9E,ARG1 9F,ARG1 A0 Set System Configuration parameters. Set System Option (Menu 1) parameters. Set Tank Monitor Option parameters.
FuelMaster® Installation Manual A1,ARG1,ARG2 ARG1. A2,ARG1,ARG2 A3,ARG1 A4,ARG1 A5,ARG1 AA AB AF B4,ARG1,ARG2 B5,ARG1,ARG2 B9 BA BB BC C0 C1 C2 C3 C5 C6 C7 CA CC,ARG1,ARG2,ARG3 CD,ARG1 DB,ARG1,ARG2,ARG3 DC DE,ARG1 DF,ARG1 E5,ARG1 E6,ARG1,ARG2 1=ONLINE. E7 E8 E9 EA it. EB code. EC ED EE EF F1,ARG1 F2 F3 F4 F5,ARG1 F6 F7 F8 FB FC FD FE FF List 284 saved LCD prompts/list ARG2 prompt(s) start at List saved LCD prompts from ARG1 through ARG2. Second Verified List Operations. Vehicle Key/ID List Operations.
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FuelMaster® Installation Manual Appendix E Retail Applications This appendix has been prepared to describe the setup of systems developed for retail applications. At this point, our primary retail customers are small airports. Considerable development work has been accomplished to meet the needs of small airport owners. Many of the references are to small airports, but may be related to other retail applications.
FuelMaster® Installation Manual Setup Considerations for Weights and Measures Compliance Self-serve retail fueling applications are obligated to meet the compliance requirements of their local Department of Agriculture, Weights and Measures (W&M) department to sell fuel to the public. Even though one document (NIST Handbook 44) is usually referenced for requirements, local regulations may be tailored by location. The considerations mentioned herein may not apply to every application.
FuelMaster® Installation Manual Presets: when the FMU is accessed with a credit card (presets do not apply to Prokee® or Smartcard transactions) to start a transaction, the customer is afforded the opportunity to preset a dollar or gallon limit (the preset question may be turned off in newer firmware, if desired, or if equipment to support presets is not installed). If a preset dollar or gallon limit is set, the transaction must end exactly at that preset amount.
FuelMaster® Installation Manual Firmware Setup: • • NOTE When an FMU is purchased for the TWO RELAYS PER PUMP option, there is no additional charge for the additional hardware. If the option is added at a later date, the additional hardware must be purchased at the current selling price. Preset transaction limits may only be initiated in credit card transactions. Presets cannot be initiated with a Prokee® or smartcard transaction.
FuelMaster® Installation Manual Setting the Setpoint: 1. Type a 57 command and press Enter. A display similar to the following should appear: CURRENT HIGH FLOW SETPOINTS: PUMP A: 0.0 PUMP B: 0.0 PUMP C: 0.0 PUMP D: 0.0 ENTER PUMP POSITION TO MODIFY [A-D, to EXIT]: 2. At the prompt ENTER PUMP POSITION TO MODIFY [A-H, to EXIT]:, enter A to modify the setpoint for pump position A. A display similar to the following should appear: CURRENT HIGH FLOW SETPOINTS: PUMP A: 0.0 PUMP B: 0.0 PUMP C: 0.
FuelMaster® Installation Manual 5. Press Y to save the configuration changes. The configuration changes will be recorded and a display similar to the following should appear: SAVING SYSTEM CONFIGURATION… CONFIGURATION RECORDED. Enter Pump Pricing: for pump pricing for a credit card transaction to be effective, it must be sent to the FMU. Very Important! Refer to the FMPlus User Manual to enter pump pricing. It is highly recommended pump pricing be sent from the FuelMaster® software.
FuelMaster® Installation Manual 4. To verify the desired configuration change was recorded, enter 7D. A display similar to the following should appear: Weights & Measures: Display Last TX Configuration ---------------------------------------------------------------------Command Interface: 7D, ARG1, #ARG2 ARG1 – Display Last TX: 0 Disable, 1 Enable ARG2 – Timeout in Seconds (Optional: Default=300, 0=Indefinitely) Current Configuration Display Last Transaction: Enabled Duration: 300 secs 5.
FuelMaster® Installation Manual J. K. L. M. N. PRINT MASTER PRODUCT DESCRIPTION: DISABLED PRINT RECEIPTS FOR AIM : DISABLED PROMPT FOR AIM RECEIPTS : DISABLED ALLOW $0.00 FOR PROKEE PRICING : ENABLED RESTORE DEFAULT VALUES USAGE - =CHANGE VALUE, =EXIT 2. Press G. PRINT DOLLAR FOR PROKEE RECEIPTS: DISABLED should change to PRINT DOLLAR FOR PROKEE RECEIPTS: ENABLED. 3. Press Esc to exit.
FuelMaster® Installation Manual 3. Press Esc to exit. A display similar to the following should appear: CONFIGURATION HAS CHANGED! WOULD YOU LIKE TO SAVE IT ? (Y/N) 4. Press Y to save the configuration change. The following prompt will appear: SAVING SYSTEM CONFIGURATION… CONFIGURATION RECORDED. Receipts Print on Power UP: if the FMU resets during a power failure, and it reverts to UPS power, a firmware option must be turned on to ensure the FMU prints a receipt for the customer.
FuelMaster® Installation Manual Large Remote Display: An optional Large Remote Display provides a quantity display with four inch LED digits visible up to 150 feet. The Large Remote Display is wired into the pulser circuit which provides quantity information to the FMU. The display is preprogrammed at the factory to match the pulser divide rate. As such, the quantity shown on the display is identical to the quantity recorded by the FMU.
Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units At Retail Sites This ATP applies to upgrades and installations of Classic and Plus Fuel Management Units (FMUs) installed at retail sites. Complete an ATP for each site. Place a check mark (√) in the space provided for each step performed. Some procedures will not be applicable to all installations. Mark NA for those procedures which are not applicable. Some procedures may be repeated for multiple FMUs.
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3. SOFTWARE UPGRADE (For Software Upgrades Only) a. Verify tasking is an upgrade. Customer must have an operational copy of FuelMaster® software with an existing FuelMaster® database. b. Disable any auto download settings and stop all services. c. Retrieve transactions from all FMUs. d. Retrieve and record unit configuration and options. e. Make a copy of the customer’s existing software database and save to the desktop. f.
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d. ACTIVATE PRODUCT DISPENSERS. All FMU’s successfully activate appropriate dispensing hoses after authorized access. e. VERIFY SINGLE HOSE AUTHORIZATION. Activate each hose (one hose at a time) in automatic mode and verify no other hoses will dispense. f. SIMULTANEOUS TRANSACTIONS. Each FMU allowed simultaneous operation of each connected dispensing hose. g. VERIFY NO COUNTS DURING DISPENSER RESET. Select COUNT TEST from the Configuration Menu. Move Automatic/Manual Mode switches to Manual.
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m. PRICING. Repeat for multiple FMUs. Note any deviations on page 6. 1) Check all price levels stored at the FMU 2) If receipts for ProKee is turned on verify that the price on the receipt is correct 3) If credit card, run a few transactions verify pricing and functionality n. DISCOUNT CREDIT CARDS. Repeat for multiple FMUs. Note any deviations on page 6. 1) Set up discount credit card in software and send to FMU 2) Run a test transaction and verify that proper price level appear o. PREPAID CARDS/KEYS.
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3) If the dispensing equipment counter may be reset to 0 (zero) after the hose is pressurized, has a pulse delay been installed? YES / NO (circle one). A pulse delay must be installed that starts counting after the hose is fully pressurized. Delay Type and Length: r. Use cc command to set applicable credit card configuration. s. Using cc command, enable Auto End of Day to ensure transaction batches are settled each night at midnight. Ensure auto download is not set for same time (midnight). t.
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i. How to use Price Levels, j. How to send pricing changes to FMU, k. How to use Discount Credit cards and a prepaid Prokee®/Smartcard, l. How to settle transaction batches with a Supervisor Key, m. Who to call for troubleshooting/training assistance. 6. DATA a. Site Signature: b. FMU telephone number: c. FMU IP Address: d. Network is Cable, Fiber, Wireless, No Network (circle one) e. Zlinx Baud Rate/Data Bits/Stop Bits/Parity/Channel: f. Number of Master FMU’s: g. Number of Satellite FMU’s: h.
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SIGNATURE AND FINAL SIGN-OFF Customer Representative (print): Customer Representative (signature): Date: Certified Startup Technician (print): Certified Startup Technician (signature): ASR Number: Organization: Date: 7 of 7 335
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HOLD HARMLESS AGREEMENT (to be completed when installing wireless networking equipment) TO: _________________________________________________ SUBJECT: Potential Security Breaches Through Wireless Network Connections to FuelMaster® FuelMaster® Fuel Management Units (FMUs) and software do not contain personal information subject to the Privacy Act of 1974. However, when added to a network the FMU may provide a link to other resources which do contain personal or privileged information.
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FuelMaster® Installation Manual Appendix F Wiring Differences for Canadian and European Certified FMUs Fuel Management Units (FMUs) manufactured for use in Canada and Europe are configured differently than FMUs designed for U.S. operation. Syn-Tech researched the requirements for Canadian and European certification, designed and manufactured the required equipment, then subjected FuelMaster® to tests necessary to achieve certification.
FuelMaster® Installation Manual European Certification There are significant differences between a U.S. certified FMU and a European (CE) certified FMU. The CE unit has a transformer mounted in a “backpack” housing on the back of the FMU pedestal which converts 230 VAC, 50 Hz power to 110 VAC, 60 Hz. In addition, other components are configured differently to comply with European standards. A European certified FMU can be identified by an ID plate with a CE stamp, as shown in Figure 2. Figure 2.
FuelMaster® Installation Manual Appendix G FMU Wire and Cable Connection Points Use the following to locate connection points for an unknown wire or cable. Part Number is the wire or cable. Component 1 is one connection point. Component 2 is the other connection point.: Component 1 Part Number Component 2 Solid State Relay Assy Auto/Manual Switch 1-8 ............. 198455 ............................Pedestal I/O Board J11-J18 Dual Control Relay Assy Auto/Manual Switch 1-8 ............. 234397 ...........
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Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units This ATP applies to upgrades and installations of all FMU-2500, 3000, and 3500 series Classic and Plus Fuel Management Units (FMUs), except aviation sites (a separate Aviation ATP is available). Complete an ATP for each site. Place a check mark (√) in the space provided for each step performed. Some procedures will not be applicable to all installations. Mark NA for those procedures which are not applicable.
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4. FMU NEW INSTALLS. Repeat for each FMU. Note any deviations on page 5. a. EXAMINATION OF PRODUCT 1) All equipment on packing list is accounted for. 2) Equipment matches customer requirement. 3) FMU is configured with correct number of hose positions and correct communications boards are installed. Master FMU has internal communications cable. 4) FMU upper cabinet is correctly matched to pedestal. 5) Doors and locks operate freely. 6) No visible shipping damage. b.
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2) If a solenoid valve is not installed, verify fuel stops flowing when the transaction is ended by squeezing the nozzle trigger after the pump handle switch is turned off. Fuel should not flow. l. PROTECT DATA DURING POWER FAILURE. Repeat for multiple FMUs. Note any deviations on page 5. 1) In automatic mode, when power was removed from each FMU the applicable dispensers connected to that FMU were disabled. 2) Transactions in progress during power failure were recorded. No transaction data was lost.
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q. SAFETY. Repeat for multiple FMUs. Note any deviations on page 5. 1) FMUs are installed in accordance with the NEC. If mounted in a Class I, Div 2, location, all electronic components, switches, and relays are located over 18 inches above grade level, and FMU is not installed within 18 inches of a gasoline or E85 dispenser (or 5 feet of a CNG dispenser). Explain any deviations on page 5.
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f. Number of Master FMU’s: g. Number of Satellite FMU’s: h. FMU Firmware version: i. Dispenser control method: j. Pulser type/divide ratio: k. Computer operating system: l. FuelMaster® software version: m. Site Contact: n.
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HOLD HARMLESS AGREEMENT (to be completed when installing wireless networking equipment) TO: _________________________________________________ SUBJECT: Potential Security Breaches Through Wireless Network Connections to FuelMaster® FuelMaster® Fuel Management Units (FMUs) and software do not contain personal information subject to the Privacy Act of 1974. However, when added to a network the FMU may provide a link to other resources which do contain personal or privileged information.
Syn-Tech Systems, Inc. Home of the FuelMaster® FuelMaster® Plus User Manual Version 5.
Table of Contents Copyright© Syn-Tech Systems, Inc. 1998-2010 Publish Date: 4/29/2010 All Rights Reserved. This Document was printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means – electronic, mechanical, photocopying, recording or otherwise – without the prior written permission of the publisher: Syn-Tech Systems, Inc.
Table of Contents FuelMaster® Plus System Overview......................................... 13 System Components.................................................................... 13 Central Controller .................................................................. 13 FMU ......................................................................................... 13 TMU ......................................................................................... 13 Access Devices ..............................
Table of Contents Wait for Tone Option ......................................................... 36 Dial Method Options .......................................................... 36 Encoder Options ..................................................................... 37 AIM Options............................................................................ 37 Odometer ............................................................................. 37 Receipt.....................................................
Table of Contents FMU Name .............................................................................. 47 Modem Hours.......................................................................... 47 Totalizer Digits ........................................................................ 47 Valid Key Timeout.................................................................. 47 Message Duration ................................................................... 47 Decimal Digits for Onsite ....................
Table of Contents Price Level ........................................................................... 69 Match Customer Price Level ............................................. 69 Vehicle PROKEE®/Smart Card Tab ................................... 70 Odometer ............................................................................. 70 PIN........................................................................................ 70 User ID ................................................................
Table of Contents Creation Date .......................................................................... 82 Balances Tab ............................................................................... 83 PROKEE® Balance in Database........................................... 83 Unclaimed outstanding credit................................................ 83 Credit Card Configuration Walkthrough ................................ 84 Chapter 8: Utility Keys.......................................................
Table of Contents Supervisor Misc Tab............................................................. 100 Agency................................................................................ 100 Organization...................................................................... 100 Usage .................................................................................. 100 Date Service Began ........................................................... 100 Miscellaneous Fields ..................................
Table of Contents Polling Report ........................................................................... 119 Pump Prices Report.............................................................. 120 Message Reports ................................................................... 120 Misc Tab .................................................................................... 120 Chapter 11: FuelMaster® Reports......................................... 121 Report Configuration ..............................
Table of Contents Transactions Tab .............................................................. 138 Supervisor and Manual Issue Tab .................................. 138 Vehicle and User Tabs...................................................... 139 Tanker Truck Tab ............................................................ 139 AIM2™ Tab ...................................................................... 140 Card Owners Tab .............................................................
Table of Contents COMM ADC Field Names Selector ........................................ 165 COMM ADC PDA Diagnostics ............................................... 166 Current ADC Transactions......................................................
