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FuelMaster® Installation Manual 7 Table of Contents (con’t) A/C Power ...

FuelMaster® Installation Manual 16 stored by FuelMaster® need not be secure, but your Central Controller and FMU may be connected to a network contai

FuelMaster® Installation Manual 106  282

FuelMaster® Installation Manual 107 Section 5 Initialization CAUTION STOP! Initialization may only be completed by a technician who has completed th

FuelMaster® Installation Manual 108 5. Defining customers, vehicles, and users who will be using the system (Chapter 6: Customers, Vehicles, and User

FuelMaster® Installation Manual 109 3. To change the satellite configuration to an EIU, depress the space bar until GATE MASTER is displayed, then d

FuelMaster® Installation Manual 110 PIN ENTRY REQUIRED! 9 CHAR VMN ID ENTRY RQD! RELAY DELAY = 5 sec. NOTE A 0 (zero) second relay setting will resu

FuelMaster® Installation Manual 111 Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units This ATP a

FuelMaster® Installation Manual 112 3. SOFTWARE UPGRADE (For Upgrades Only) a. Verify tasking is an upgrade. Customer must have an operational cop

FuelMaster® Installation Manual 113 2) All FMU’s displayed an asterisk (*) to the left of the hose number and prompted, “HOSE BUSY, SELECT ANOTHER…”

FuelMaster® Installation Manual 114 k. DISABLE DISPENSER AFTER TRANSACTION. Repeat for multiple FMUs. Note any deviations on page 5. 1) Each FMU di

FuelMaster® Installation Manual 115 3) Download transactions and make sure that card record reflects transaction. Mark NA if not used. Prepaid Proke

FuelMaster® Installation Manual 17 intrinsically safe or must be enclosed within an explosion-proof enclosure. Intrinsically safe devices are general

FuelMaster® Installation Manual 116 5) FMU board/backplate attach screws are secure. Screws holding mainboard and Satellite I/O Control Board to bac

FuelMaster® Installation Manual 117 g. Number of Satellite FMU’s: Self-explanatory h. FMU Firmware version: Can be found by watching FMU display

FuelMaster® Installation Manual 118 HOLD HARMLESS AGREEMENT (to be completed when installing wireless networking equipment) TO: Customer’s name an

FuelMaster® Installation Manual 119 Appendix A Glossary This Appendix provides definitions for the most common terms, acronyms, and abbreviations re

FuelMaster® Installation Manual 120 Initialization (aka Startup) – initialization and startup are the same. Initialization includes inspection and te

FuelMaster® Installation Manual 121 Software – in this context, the FuelMaster® operating program which is loaded on the Central Controller SSRA – S

FuelMaster® Installation Manual 122 298

FuelMaster® Installation Manual 123 Appendix B Dispenser Compatibility Following this description is a sample FuelMaster® Dispenser Compatibility li

FuelMaster® Installation Manual 124 The eight column, Note, contains a number corresponding to a note on the last page of the listing. These Notes s

FUELMASTER® DISPENSER COMPATIBILITY 03-Sep-10IMPORTANT DISCLAIMER!This list is compiled from the best information available from the various dispenser

FuelMaster® Installation Manual 18 Figure 1-3. FMU ID Plates 194

CompatibleElectronic Require with Mechanical/ Commercial/ Direct Dispenser Pulse Require DoDManufacturer/Model Electronic Retail Interface Interface*

CompatibleElectronic Require with Mechanical/ Commercial/ Direct Dispenser Pulse Require DoDManufacturer/Model Electronic Retail Interface Interface*

128304

FuelMaster® Installation Manual 129 Appendix C FMU/EIU Configurations Following is a listing of FMU and EIU configurations, by model number, availab

FuelMaster® Installation Manual 130 FMU-3550PLUS Master - Passive AIM2™ unit with Prokee® and Credit Card readers FMU-3560PLUS Master - Passive

FuelMaster® Installation Manual 131 Appendix D Laptop Direct Connect to FMU The information herein may also be found in Product Bulletin 111, dated

FuelMaster® Installation Manual 132 6. Save the file you created so the settings you entered will be available the next time you use Hyperterminal.

FuelMaster® Installation Manual 133 1C Send message to LCD, wait for user response, or 45 sec.. 1D,ARG1,ARG2 Same as 1F, also inc

FuelMaster® Installation Manual 134 58 Set System Configuration parameters. 59 Set System Option (Menu 1) parameters. 5

FuelMaster® Installation Manual 135 A1,ARG1,ARG2 List 284 saved LCD prompts/list ARG2 prompt(s) start at ARG1. A2,ARG1,ARG2 List saved LCD

FuelMaster® Installation Manual 19 ID Plates An ID plate (see Figure 1-3) is affixed to the side of the FMU pedestal closest to the pedestal door loc

FuelMaster® Installation Manual 136 312

FuelMaster® Installation Manual 137 Appendix E Retail Applications This appendix has been prepared to describe the setup of systems developed for re

FuelMaster® Installation Manual 138 Setup Considerations for Weights and Measures Compliance Self-serve retail fueling applications are obligated to

FuelMaster® Installation Manual 139 Presets: when the FMU is accessed with a credit card (presets do not apply to Prokee® or Smartcard transactions)

FuelMaster® Installation Manual 140 Firmware Setup: NOTE • When an FMU is purchased for the TWO RELAYS PER PUMP option, there is no additional cha

FuelMaster® Installation Manual 141 Setting the Setpoint: 1. Type a 57 command and press Enter. A display similar to the following should appear: CU

FuelMaster® Installation Manual 142 5. Press Y to save the configuration changes. The configuration changes will be recorded and a display similar to

FuelMaster® Installation Manual 143 4. To verify the desired configuration change was recorded, enter 7D. A display similar to the following should

FuelMaster® Installation Manual 144 J. PRINT MASTER PRODUCT DESCRIPTION: DISABLED K. PRINT RECEIPTS FOR AIM : DISABLED L. PROMPT FOR AIM RECEI

FuelMaster® Installation Manual 145 3. Press Esc to exit. A display similar to the following should appear: CONFIGURATION HAS CHANGED! WOULD YOU LIK

FuelMaster® Installation Manual 20 first. Each Prokee® is warranted against defects in material and workmanship for a period of five years. A toll-fr

FuelMaster® Installation Manual 146 Large Remote Display: An optional Large Remote Display provides a quantity display with four inch LED digits vis

FuelMaster® Installation Manual 21 Figure 1-4. Sample FMU Initialization Form 197

FuelMaster® Installation Manual 163 Appendix F Wiring Differences for Canadian and European Certified FMUs Fuel Management Units (FMUs) manufactu

FuelMaster® Installation Manual 164 European Certification There are significant differences between a U.S. certified FMU and a European (CE) certi

FuelMaster® Installation Manual 165 Appendix G FMU Wire and Cable Connection Points Use the following to locate connection points for an unknown w

FuelMaster® Installation Manual 22 FuelMaster® Equipment Specifications Rated Supply Voltage Limits 120VAC +/- 15% (upper limit) 75 +/- 10% (lo

FuelMaster® Installation Manual 166 342

10/22/10 Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units This ATP applies to upgrades and

FuelMaster® Installation Manual 23 Battery Reference There are batteries on the mainboard, card reader board, and data logger. All applications use

Syn-Tech Systems, Inc. Home of the FuelMaster® FuelMaster® Plus User Manual Version 5.1 354

Table of Contents2Copyright© Syn-Tech Systems, Inc. 1998-2010Publish Date: 4/29/2010All Rights Reserved. This Document was printed in the United Stat

Table of Contents3FuelMaster® Plus System Overview... 13System Components...

Table of Contents4Wait for Tone Option ... 36Dial Method Options ...

Table of Contents5FMU Name ... 47Modem Hours...

Table of Contents6Price Level ... 69Match Customer Price Level ...

Table of Contents7Creation Date ... 82Balances Tab ...

Table of Contents8Supervisor Misc Tab... 100Agency...

FuelMaster® Installation Manual 24 Commercially Available Products This FuelMaster® Installation Manual makes reference to commercially available equ

Table of Contents9Polling Report ... 119Pump Prices Report...

Table of Contents10Transactions Tab ... 138Supervisor and Manual Issue Tab ...

Table of Contents11COMM ADC Field Names Selector ... 165COMM ADC PDA Diagnostics ...

FuelMaster® Installation Manual 25 Section 2 System Description Introduction Components. The FuelMaster® Fuel Management System consists of equipment

FuelMaster® Installation Manual 8 Table of Contents (con’t) VALIDATE FMU ACCESS WITH PROKEE®, SMARTCARD, CREDIT CARD, AND/OR KEYPAD ...

FuelMaster® Installation Manual 26 Figure 2-1. Fuel Management Unit (FMU) 202

FuelMaster® Installation Manual 27 All current versions of the standard FMU are delivered with an alpha-numeric keypad, a 33.6 baud modem, a Type II

FuelMaster® Installation Manual 28 Relay Options. An FMU may be thought of as a switch installed in a control circuit of a dispensing device. It is

FuelMaster® Installation Manual 29 • User Keys are encoded with a user identification number and are assigned to a user • Supervisor Keys are autho

FuelMaster® Installation Manual 30 Prokee®/Smartcard Encoder The Encoder uses data entered in the Fuel Management Software to encode, re-encode, or

FuelMaster® Installation Manual 31 Digital Cell Modem: a digital cell modem may be installed in an FMU to facilitate communications to the FMU throu

FuelMaster® Installation Manual 32 Keyless FMU Access: FMUs may be selected for keyless access. Users do not need Prokee®s, Smartcards, or credit car

FuelMaster® Installation Manual 33 Receipt Printer: two Receipt Printer options are available: FMU pedestal mount or indoor. Both Receipt Printer opt

FuelMaster® Installation Manual 34 Specialty Equipment: Syn-Tech may be tasked to supply an assortment of specialty equipment with your order. We hav

FuelMaster® Installation Manual 35 as a replacement part. The fiber optic transceiver accepts only MT-RJ fiber optic connectors. Options exist for wi

FuelMaster® Installation Manual 9 Figures and Tables Figure 1-1. Boundaries of a Flammable Liquid Hazardous ...

FuelMaster® Installation Manual 36 212

FuelMaster® Installation Manual 37 Section 3 Site Planning and Preparation Introduction This section includes considerations which must be given to p

FuelMaster® Installation Manual 38 Figure 3-1. FMU Dimensions (in inches) 214

FuelMaster® Installation Manual 39 Figure 3-2 does not illustrate the interface between the EIU pedestal and EIU cabinet. From the rear of the EIU

FuelMaster® Installation Manual 40 Conduit Requirements CAUTION Although PVC conduit is allowed by the NEC, only metal conduit will be used for FuelM

FuelMaster® Installation Manual 41 Conduit Applications. See Figure 3-3 for a sample site layout containing a Master FMU on one island, a Satelli

FuelMaster® Installation Manual 42 Figure 3-3. Sample Site Layout 218

FuelMaster® Installation Manual 43 Conduit entering an FMU typically enter the FMU through the opening in the base of the pedestal. If conduit enter

FuelMaster® Installation Manual 44 approximately 400 milliamps. The total current draw will be less than 3 amps. Errors on Power-Up: an FMU newly ins

FuelMaster® Installation Manual 45 Uninterruptible Power Supply (UPS): Weights & Measures requirements call for a backup power source for retail

FuelMaster® Installation Manual 10 Figures and Tables (con’t) Figure 4-21. Connecting to Open Collector Pulser (Gasboy 9800 Pump I/F shown) ...

FuelMaster® Installation Manual 46 • Through analog phone lines: download through phone lines will require access to an analog, data-grade, USA tele

FuelMaster® Installation Manual 47 If a device is mounted in the FMU which requires connection to an electrical outlet, an outlet box must be install

FuelMaster® Installation Manual 48 Electronic dispensers have an internal CPU (central processing unit) which controls dispenser functions. The CPU t

FuelMaster® Installation Manual 49 What it does: if pump handle detection is not turned on and used to end a transaction, timers (No Pulse Timeout an

FuelMaster® Installation Manual 50 the beginning of the transaction but detects the turn off at the end of the transaction. AIM2™ scenario: an AIM2™

FuelMaster® Installation Manual 51 NOTE It is recommended dispenser reset power be obtained from a separate power source, and not the same power sour

FuelMaster® Installation Manual 52 constant. It should be power applied when a pump handle or pump switch is turned on. When this power source is fou

FuelMaster® Installation Manual 53 Controlling Lube Bay Hose Reels: control of lube bay hose reels is very similar to the control of other types of d

FuelMaster® Installation Manual 54 Pulsers NOTE In accordance with the NEC, “Class 1 circuits shall be permitted to occupy the same cable, enclosure,

FuelMaster® Installation Manual 55 per minute. This would equate to using a 1000:1 divide rate pulse output with a hose pumping 120 gallons per minut

FuelMaster® Installation Manual 11 Introduction Proprietary Information Except as permitted under the United States Copyright Act of 1976, no part o

FuelMaster® Installation Manual 56 Some customers have asked to use the Quick Stop Button as an emergency stop switch. In most locations it cannot be

FuelMaster® Installation Manual 57 FuelMaster® software program, the TMU reported quantity can be used to reconcile FuelMaster® reported quantity. An

FuelMaster® Installation Manual 58 in each jumper position of the Satellite I/O Control Board which corresponds with a receptacle position on the I/O

FuelMaster® Installation Manual 59 EIU Control EIUs may be programmed for Prokee® and/or keypad input through a laptop or Customer Satisfaction Cente

FuelMaster® Installation Manual 60 communications medium for communications with the FMUs. Refer to the FuelMaster® Plus User Manual for minimum PC r

FuelMaster® Installation Manual 61 Wireless Phone Lines: wireless phone line connections should only be considered when other mediums are not an opti

FuelMaster® Installation Manual 62 Surge Protection The Central Controller is susceptible to surge damage through its AC power source and/or communi

FuelMaster® Installation Manual 63 Section 4 FMU Installation Introduction Following are procedures for installing a complete FuelMaster® Fuel Manage

FuelMaster® Installation Manual 64 Central Controller Installation For the purposes of this manual, Central Controller installation includes only har

FuelMaster® Installation Manual 65 Connecting a Two-Way Ring-Down Device If a Two-Way Ring-Down Device is to be used, see Figure 4-1 and position th

FuelMaster® Installation Manual 12 Section 2 - System Description This section contains a description of all FuelMaster® standard and optional equipm

FuelMaster® Installation Manual 66 The FMU pedestal will not always be mounted directly over conduit. Figure 4-3 illustrates some alternate mounting

FuelMaster® Installation Manual 67  Figure 4-2. FMU Footprint (in inches) Figure 4-3. Alternate Mounting Methods 243

FuelMaster® Installation Manual 68  NOTE Screw anchor nuts may be left loose in step 4 to assist with the installation of conduit or liquid-tight fle

FuelMaster® Installation Manual 69 Wire/Cable Recommendations. Where wire/cable sizes are listed, larger conductors may be used to gain additional ra

FuelMaster® Installation Manual 70 Wire/Cable Connections at FMU Make the following wire/cable connections at the FMU: NOTE Many wire/cable connectio

FuelMaster® Installation Manual 71  Figure 4-5. AC Power and Phone Connections (from reverse side of Surge Panel) Figure 4-4. AC Power and Phone C

FuelMaster® Installation Manual 72 4. Quick Stop Button as Auxiliary Emergency Stop Switch. The Quick Stop Button has two terminals to receive wire

FuelMaster® Installation Manual 73 Table 4-1. Transaction Printer Cable Connection Points J3 Printer 201669 EXTERNAL DB25 Ca

FuelMaster® Installation Manual 74  Figure 4-6. Pedestal I/O Board 250

FuelMaster® Installation Manual 75 NOTE Whenever pump handle detection is wired into the PHS positions of the Pedestal I/O Board, one leg of the resi

FuelMaster® Installation Manual 13 Section 1 General Information Introduction FuelMaster® consists of equipment developed to control access to, accou

FuelMaster® Installation Manual 76  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)

FuelMaster® Installation Manual 77  b. Controlling Motors. See Figure 4-9. When controlling a classic or DoD FMU, and pump handle detection is need

FuelMaster® Installation Manual 78  If the dispenser is being fed from the top of an aboveground tank, there must be an anti-siphon valve on the ta

FuelMaster® Installation Manual 79 most likely a red or orange wire from the dispenser reset mechanism wire-nutted to one of the motor leads (or cont

FuelMaster® Installation Manual 80  Perform the following to control solenoid valves: 1) Inside the dispenser junction box, locate the RESET COMP

FuelMaster® Installation Manual 81 8) Repeat steps 1 through 7, as required, for all additional hoses. f. Using Dual Control Relay Assembly (DC

FuelMaster® Installation Manual 82 valves and one SUBMERSIBLE STARTER. If the dispenser had two SUBMERSIBLE STARTERs, there would be individual wires

FuelMaster® Installation Manual 83  Two relay assemblies are used to accomplish two-stage valve control. This limits the maximum number of possible h

FuelMaster® Installation Manual 84 Preset quantities or costs may only be set with credit card transactions. The transaction is started with both the

FuelMaster® Installation Manual 85 7D command. Default is 3 minutes. h. Controlling DC Devices (Hose Reels in Lube Bays/Bulk Oil Dispensers). NOT

FuelMaster® Installation Manual 14 • NIST Handbook 44, Specifications, Tolerances, and Other Technical Requirements for Weighing and Measuring Devic

FuelMaster® Installation Manual 86  i. Controlling Carwashes, Gate Openers. There are some devices which may be controlled by simple contact closur

FuelMaster® Installation Manual 87 application. A Smart Relay Assembly originally purchased to control one device may not control three devices witho

FuelMaster® Installation Manual 88 Smart Relay Assemblies produce a momentary contact closure adjustable for 1 to 16 seconds through dip switches loc

FuelMaster® Installation Manual 89 In the Monitor Mode, no authorization signal is required so nothing needs to be connected to the Pedestal I/O Boar

FuelMaster® Installation Manual 90 pulsers are with two or three conductors. All mechanical pulsers will require a 12 VDC input to return a 12 VDC pu

FuelMaster® Installation Manual 91  Figure 4-15. Connecting to Veeder-Root 1871 Pulser Figure 4-16. Connecting to Veeder-Root 7671 Pulser Fig

FuelMaster® Installation Manual 92  Figure 4-18. Connecting to ICS 110 VAC Pulsers Figure 4-20. Connecting to OPW 110 VAC Pulsers Figure 4-19. Co

FuelMaster® Installation Manual 93  a. Dual Output Pulsers. Pulsers are available with dual outputs; pulsers which provide outputs to two differe

FuelMaster® Installation Manual 94 count cannot exceed 9000 pulses per minute. The pulse count is determined by multiplying the flow rate (i.e., 9 ga

FuelMaster® Installation Manual 95  Figure 4-22. I/O Silver Board Index Description A Satellite Position Number B Electronic Dispenser

FuelMaster® Installation Manual 15 • Wear a wrist grounding strap or touch an unpainted metal surface on the chassis, such as the back panel, before

FuelMaster® Installation Manual 96  Index Description Index Description A Mainboard Connector (J1) H TANK MONITOR (J4) B Attach Screws (

FuelMaster® Installation Manual 97 8. Tank Monitor Interface (see Figures 4-22 and 4-23). Tank monitor interfaces are only possible to a Master FMU

FuelMaster® Installation Manual 98 baud rate. The same parameters must be set in the FMU for an effective communications interface. The parameters ma

FuelMaster® Installation Manual 99 Master-satellite connections are hardwired with RS-422, or wireless connected. The use of B&B Electronics Zlin

FuelMaster® Installation Manual 100 Equipment Interface Unit (EIU) Installation EIUs provide secure access to accessory devices such as gate openers

FuelMaster® Installation Manual 101 Pedestal I/O Board. Master FMU/EIU communications cables cannot be “daisy-chained” between EIUs. Individual commu

FuelMaster® Installation Manual 102  Figure 4-27. EIU Wiring 278

FuelMaster® Installation Manual 103 CAUTION If the Pedestal is mounted on an uneven surface and the screw anchors are tightened, the welds at the bas

FuelMaster® Installation Manual 104 described in Product Bulletin 133. A kit including a pair of Zlinx Radio Modems is available from Syn-Tech under

FuelMaster® Installation Manual 105 9. Refer to the wiring diagram in Figure 4-27, and the wire connections noted in step 9 under Mounting the Pedes