FuelMaster_guide.pdf

Fuel Management

Unit

(FMU)

Installation Manual

FMU-2500, 3000, 3500,

Classic and Plus, Commercial and DoD

24 May 2013

SYN-TECH SYSTEMS, INC.

100 Four Points Way

Tallahassee FL 32305 800-888-9136 Toll Free

850-878-2558 850-877-9327 Fax www.myfuelmaster.com i

ADDENDUM

The following necessary changes/additions to the Fuel Management Unit (FMU) Installation Manual dated 24 May 2013 have been identified. Insert this Addendum inside the manual title page. Changed text is in italics.

Location of the change/addition is identified in the manual with a checkmark .

1. Procedures were not included for attaching the FMU Upper Cabinet to the

FMU Pedestal. Following are actions necessary to complete this procedure:

a. Text to be entered on page 67 between FMU Installation, and Mounting the FMU Pedestal:

As it is removed from the shipping container, the FMU Pedestal will have some cables connected on one end only, and stowed in the Pedestal near the Relay Assembly(ies).

These cables will be connected in the FMU Upper Cabinet after the Pedestal is mounted, and the necessary wire and cable connections are made.

b. NOTE to be inserted before step 3, page 72:

NOTE

If being performed as part of a new FMU installation, omit step 3 until after the FMU Upper Cabinet is installed.

c. NOTE to be inserted between steps 11) and 12) on page 87:

The following procedures cannot be performed until the FMU Upper Cabinet is installed, and power is applied to the FMU.

d. NOTE to be inserted on page 94 before “Perform the following to configure Monitor

Mode:”

The following procedures cannot be performed until the FMU Upper Cabinet is installed, and power is applied to the FMU.

e. Insert 2nd paragraph/bullet to NOTE on page 95 before step 6):

• The PULSE FILTERING dipswitch is located in the FMU Upper Cabinet. If it is necessary to turn on the PULSE FILTERING dipswitch, do so after installing the FMU Upper Cabinet.

f. NOTE to be inserted before step e on page 99:

The PULSE FILTERING dipswitch is located in the FMU Upper Cabinet. If it is necessary to turn on the PULSE FILTERING dipswitch, do so after installing the FMU Upper Cabinet.

g. Add to Section 4, page 100, after 8f, before 9. Tank Monitor Interface:

ii

Install FMU Upper Cabinet. See Figure 4‐26a. Installation of the FMU Upper Cabinet should be delayed until it is necessary to complete the installation. If desired, the FMU Upper Cabinet may be rotated 180 degrees before installation to accommodate situations where the FMU pedestal door needs to open from the reverse side of the FMU (such as in a kiosk mount). The interfacing cables are long enough to reach their connection points.

Perform the following:

1. Verify the FMU Upper Cabinet is removed from its shipping container.

2. Unlock and open the Upper Cabinet door.

3. On the underside of the Upper Cabinet are six ¼‐20 x ¾ stainless panhead screws threaded through gasket holes into the nutserts of the Cable Interface Plate.

Remove the screws. After the screws are removed, the Cable Interface Plate is free floating in the Upper Cabinet.

CAUTION

When the door is open, the Upper Cabinet is front heavy and must be supported to prevent dropping.

Figure 4-26a. Install FMU Upper Cabinet iii

4. Position the Upper Cabinet on the Pedestal. Support the Upper Cabinet and insert the ¼‐ 20 x ¾ attach screws through the attach holes in the underside of the top flange of the Pedestal, through the holes in the Upper Cabinet, and thread into the nutserts in the Cable Interface Plate. Do not tighten the screws until all six screws are installed.

5. Repeat until all six screws are installed. Tighten the screws.

6. Unlock and open the FMU Pedestal door.

7. Loosen (do not remove) the four attach screws and remove the Upper Electrical Access

Panel in the FMU Pedestal.

8. Locate the 198439 Power Cable, the 200085 Communications Cable (Master FMU only), the 194735 wide ribbon cable, and one or two 180556 ribbon cable(s). There will be one 180556 ribbon cable if one Relay Assembly is installed; two 180556 ribbon cables if two Relay Assemblies are installed.

9. Connect the 198439 Power Cable to the power cable connector on the underside of the Cable Interface Plate. If the connector keyways align, the pins will be properly aligned.

10. (Master FMU Only) Connect the 200085 Communications Cable to the communications cable connector on the underside of the Cable Interface Plate. If the connector keyways align, the pins will be properly aligned.

11. Route the 194735 wide ribbon cable up through the thru‐hole bushing into the Upper Cabinet, and connect into the keyed connector at J7 near the bottom center of the Satellite I/O Control Board.

The 180556 ribbon cables cross when installed correctly. The cable from the left Relay Assembly (for hoses 1‐4) connects into the right (PRB1) connector. The cable from the right Relay Assembly (for hoses 5‐8) connects into the left (PRB2) connector.

12. Route the 180556 ribbon cable(s) into the Upper Cabinet. Connect the ribbon cable from

JP2 on the left Relay Assembly (for hoses 1 through 4) to PRB1 in the lower right corner of the Satellite I/O Control Board.

13. If applicable, connect the ribbon cable from JP2 on the right Relay Assembly (for hoses 5 through 8) to PRB2 in the lower left corner of the Satellite I/O Control Board.

14. As required, reinstall the Upper Electrical Access Panel and tighten the four attach screws.

15. As required, close and lock the FMU Pedestal Door.

16. As required, close and lock the FMU Upper Cabinet door.

17. Installation of the FMU Upper Cabinet on the FMU Pedestal is complete.

2. Reference page 89, paragraph 7g(1), change to read:

1) Configuration Settings for Non-Programmable Wiring Workaround. The duration of the momentary and pulse is regulated by the Pump Finish Timer No Pulse Timer. If the device being controlled requires a 15 second momentary, set the Pump Finish Timer No Pulse Timer to 15 seconds. Because only one pulse is being generated when one of these transactions is recorded, the divide rate must be set to 1:1. Pump handle detection should must be set to NO or NONE. Repeat these settings for each FMU hose position used.

FuelMaster® Installation Manual

Table of Contents Introduction

Proprietary Information Trademark Acknowledgements Purpose Section/Appendix Layout

Section 1 - General Information Introduction Safety Precautions

References Safety Guidelines Protecting Against Electrostatic Discharge Protecting Against Radio Interference

Wireless Network Security Certifications/Approvals ID Plates WARNINGS, CAUTIONS and NOTES Basic FuelMaster® FMU Warranty Initialization Requirement FuelMaster® Equipment Specifications Safety Related Inspections & Preventive Maintenance Cleaning Instructions Fuse Reference Battery Reference Switch Ratings Terminal Ratings (For External Component Connections) Parts Substitution and Modification Commercially Available Products Support Improvements

Section 2 - System Description Introduction

Components Version Differences

Equipment Description and Location Fuel Management Unit (FMU)

Description Automatic/Manual (Bypass) Operation Hose Control FMU Power Requirements Surge Protection Communications with Central Controller Integral Heater Pads Program Memory Counting Rapid Pulse Inputs Relay Options

Table of Contents (con’t)

Solid State Relay Assemblies Dual Control Relay Assemblies Automatic/Manual Mode Switch Differences

Prokee® Smartcards Fuel Management Software Central Controller Prokee®/Smartcard Encoder Optional Equipment and Taskings

Abierto Gateway Dial-to-IP Converters

AIM

Americans with Disabilities Act (ADA) Automatic Call Processor Credit Card Access Data Logger Digital Cell Modem Direct Connect Cable Direct Connect Through a Two-Way Ringdown Device/ Phone Line Simulator Drop Mode Electronic Dispenser Interface Equipment Interface Unit (EIU) Keyless FMU Access Landcell Large Remote Display Local Authorization FMU Access Monitor Mode Multi-Product Authorization (MPA) OTR (Over the Road) Proximity Card Reader Pulsers Pulse Delay Circuits Quick Stop Button Receipt Printer Retail Applications RS-232/RS-422 Mini Converter and Short-Haul Modem Satellite FMUs Security Cameras Semi-Manual Mode Special Applications Specialty Equipment Tank Monitor/Tank Gauge Interface Telephone Line Extender Transaction Printer Wired and Wireless Network Communications Wireless RS-232/422 Communications

Table of Contents (con’t)

Section 3 - Site Planning and Preparation Introduction FMU Dimensions EIU Dimensions Conduit Requirements

Conduit Size Conduit Fill Capacity Conduit Applications

Servicing Site Requirements AC Power

Errors on Power-Up Power Conditioners/Voltage Regulators

Surge Protection Standard Protection Optional Protection

Backup Power Sources Backup Generators Uninterruptible Power Supply (UPS)

Communications with Central Controller Phone/Modem Communications

Through analog phone lines Through a two-way ringdown device Through a phone line extender Through a cell modem

Network Communications Through a network cable Through a fiber optic cable Through a wireless network

Direct Connect Credit Card Authorization Dispenser Compatibility Dispenser Control

Pump Handle/Switch Detection What it does How to get it What if I have a constant hot or neutral on LN?

AIM2™ scenario What about the NO or NONE settings?

Controlling counts during reset

Control Methods Controlling Dispenser Reset Power Controlling Solenoid Valves and/or Pump Motors Controlling Two-Stage Valves Using the FMU to automatically remove pump power Controlling Lube Bay Hose Reels

RC Networks (Snubbers/Spark Quenchers)

Resistors Pulsers

Pulse Filtering Dual Output Pulsers Opto-Isolators

Quick Stop Button Data Logger/On-Site Printer Tank Monitor Interface Satellite/EIU Communications

Temporary Conversion of Satellite FMU to Master FMU EIU Control

Accessory (Gate/Door/Carwash) Control through an EIU Redundant FMUs

Central Accounting Office Requirements Central Controller Communications to FMU(s)

Network Communications Telephone Line Communications Two-Way Ringdown Device Wireless Phone Lines Direct Connect

Report Printer Prokee®/Smartcard Encoder Surge Protection File Backups

Section 4 - FMU Installation Introduction Unpacking and Inspection Central Controller Installation

Positioning the Central Controller Connecting the Communications Medium/Devices Loading the Software Connecting the Prokee®/Smartcard Encoder Connecting a Two-Way Ring-Down Device

FMU Installation Mounting the FMU Pedestal Finishing Conduit Connections to FMU Pedestal Wire/Cable Connections at the Dispensers Pulling Wires/Cables

Wire/Cable Recommendations AC Power to FMU(s) Communications Line to Master FMU

Telephone/Two-Way Ringdown Device Network cable Network fiber optic

Printer Cable to Master FMU (On-Site or Transaction Printer)

Dispenser Hose Control Dispenser Pulse Satellite/EIU Communications Tank Monitor Indoor Receipt Printer

Wire/Cable Connections at FMU 1.A/C Power 2.Telephone/Two-Way Ringdown Device 3.Network Cable 4.Quick Stop Button as FMU Stop Switch 5.Quick Stop Button as Auxiliary Emergency Stop Switch 6.On-Site/Transaction Printer 7.Dispenser Control a.Controlling Reset b.Controlling Motors c.Controlling Solenoid Valves d.Using Dual Control Relay Assembly (DCRA) to Control Two Devices e.Two-Stage Valve Control f.Controlling DC Devices (Hose Reels in Lube Bays/

Bulk Oil Dispensers) g.Controlling Carwashes, Gate Openers

1).Configuration Settings for Non-Programmable Wiring Workaround a).Using Dual Control Relay Assembly (DCRA) to Generate Pulses b).Using Solid State Relay Assembly (SSRA) to Generate Pulses 2).Using a Smart Relay Assembly h.Monitor Mode 8.Pulse Inputs a.Standard Accessory Pulsers/Pulse Generators b.Dual Output Pulsers c.Opto-Isolators c.Counts During Reset d.AC Bleedover to Pulse Inputs e.Redundancy: Two FMUs, One Dispenser/Pulser

9.Tank Monitor Interface 10.Satellite Connections 11.Indoor Receipt Printer

Equipment Interface Unit (EIU) Installation Pulling Wires and Finishing Conduit

1.AC Power 2.Master FMU/EIU Communications 3.Control of Accessory Controller

Mounting the Pedestal Wire Connections at Master FMU

Table of Contents (con’t)

Wire Connections at Accessory Controller Configure Master FMU for EIU

Section 5 – Initialization Software Installation and Setup Configure Master FMU for EIU Operation Post Installation Inspection and Test Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units

1.SITE EXAMINATION

2.FMU UPGRADE (For Upgrades Only) 3.SOFTWARE UPGRADE (For Upgrades Only)

4.FMU NEW INSTALLS

a.EXAMINATION OF PRODUCT b.PROVIDE TELEPROMPTING c.VALIDATE FMU ACCESS WITH PROKEE®, SMARTCARD, CREDIT CARD, AND/OR KEYPAD d.ACTIVATE PRODUCT DISPENSERS e.VERIFY SINGLE HOSE AUTHORIZATION f.SIMULTANEOUS TRANSACTIONS g.VERIFY NO COUNTS DURING DISPENSER RESET h.ENCODE, VERIFY, AND REVISE PROKEE®S OR SMARTCARDS i.PROVIDE FOR MANUAL OPERATION j.TRANSACTION HANDLING k.DISABLE DISPENSER AFTER TRANSACTION l.PROTECT DATA DURING POWER FAILURE m.PRICING n.DISCOUNT CREDIT CARDS o.PREPAID CARDS/KEYS p.RECORD TRANSACTION DATA q.SAFETY r.POST INSTALLATION INSPECTION

5.TRAINING

6.DATA

6.Comments

SIGNATURE AND FINAL SIGN-OFF

HOLD HARMLESS AGREEMENT

Appendices Appendix A – Glossary Appendix B – Dispenser Compatibility Listing Appendix C – FMU & EIU Configurations Appendix D – Laptop Direct Connect to FMU

Appendices (con’t) Appendix E – Retail Applications Appendix F – Wiring Differences for Canadian and

European Certified FMUs Appendix G – FMU Wire and Cable Connection Points Appendix H – Electronic Dispenser Interface

Figures and Tables

Figure 1-1. Boundaries of a Flammable Liquid Hazardous Figure 1-2. FMU Electrical Safety Spacing Figure 1-3. FMU ID Plates Table 1-1. FMU Door Key Reference Figure 1-4. Sample FMU Initialization Form

Figure 2-1. Fuel Management Unit (FMU) Figure 2-2. Prokee® Figure 2-3. Prokee® Encoder Figure 2-4. Two-Way Ringdown Device/Phone Line Simulator Figure 2-5. Equipment Interface Unit (EIU)

Figure 3-1. FMU Dimensions (in inches) Figure 3-2. FMU Dimensions (in inches) Americans with Disabilities Act (ADC) FMU Figure 3-3. EIU Dimensions (in inches) Table 3-1. Rigid Metal Conduit Fill Capacity Table 3-2. Typical Wire/Cable Cross Sectional Area Figure 3-4. Sample Site Layout Figure 3-5. Satellite Option Installation

Figure 4-1. Two-Way Ringdown Device Connection Figure 4-2. FMU Footprint (in inches) Figure 4-3. Alternate Mounting Methods Figure 4-4. AC Power and Phone Connections Figure 4-5. AC Power and Phone Connections (from reverse side of Surge Panel) Figure 4-6. Network Cable Connection Table 4-1. Transaction Printer Cable Connection Points Figure 4-7. Pedestal I/O Board Figure 4-8. Wiring Diagram - Controlling Reset Figure 4-9. Wiring Diagram - Controlling Reset in Dual Hose Single

Product Dispenser without Backfeed (One Solution) Figure 4-10. Wiring Diagram - Controlling Motors Figure 4-11. Wiring Diagram – Controlling Solenoid Valves Figure 4-12. Wiring Diagram - Using Dual Control Relay Assembly (DCRA) to Control Two Devices

Figures and Tables (con’t)

Figure 4-13. Wiring Diagram – Two-Stage Valve Control Table 4-2. Pedestal I/O Board Inputs/Outputs for AC and DC

Solid State Relays (SSRs) Figure 4-14. Location of 75K ohm Pump Handle Detect Resistors Figure 4-15. Generating Pulse with Dual Control Relay Assembly Figure 4-16. Generating Pulse with Solid State Relay Assembly Figure 4-17. Smart Relay Assembly Table 4-3. Wiring Smart Relay Assembly (SRA) to Pedestal I/O Board Figure 4-18. Connecting to Veeder-Root 1871 Pulser Figure 4-19. Connecting to Veeder-Root 7671 Pulser Figure 4-20. Connecting to ICS 12VDC Pulsers Figure 4-21. Connecting to ICS 110 VAC Pulsers Figure 4-22. Connecting to OPW 12 VDC Pulsers Figure 4-23. Connecting to OPW 110 VAC Pulsers Figure 4-24. Connecting to Open Collector Pulser (Gasboy 9800 Pump I/F shown) Figure 4-25. Removing Counts During Reset Figure 4-26. Redundant FMUs, One Dispenser, One Pulser Figure 4-27. I/O Silver Board Figure 4-28. Satellite I/O Control Board Figure 4-29. Install Tank Monitor Interface Kit Figure 4-30. I/O Silver Board Connections for Tank Monitor Interface Figure 4-31. Satellite Connections Table 4-4. Indoor Receipt Printer Cable Connections Figure 4-32. EIU Components Figure 4-33. EIU Footprint Figure 4-34. EIU Wiring Figure 4-35. Connecting Wire Harnesses

Attachments Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster® Fuel Management Units (back of manual; tear out, complete and return to Syn-Tech Systems, Inc., in provided self-addressed, postage-paid envelope)

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. 1500; support@myfuelmaster.com

Copyright©Syn-Tech Systems, Inc. 1998-2010

All Rights Reserved. This Document was printed in the United States of America.

Trademark Acknowledgements Trademarks of other products mentioned in this manual are held by the companies producing them. Use of a term in this manual should not be regarded as affecting the validity of any trademark. All other trademarks are acknowledged.

Purpose This manual provides installation instructions for the Syn-Tech Systems, Inc., FuelMaster® Fuel Management Unit (FMU) for fixed fueling sites. These instructions have been prepared for use by technicians who are qualified to complete electrical work in hazardous locations.

Though different systems have been developed for commercial (civilian) and DoD (Department of Defense) applications, only one installation manual has been prepared to cover both applications.

Likewise, commercial systems are available as both Classic and Plus systems, and passive and non-passive systems. Where distinctions must be made between the different applications, notations (i.e., commercial, classic, Plus, or DoD) will be added to identify the differences.

Reference is made herein to Product Bulletins. Product Bulletins have been prepared to cover individual maintenance tasks, and are forwarded with each replacement part. There is no maintenance manual encompassing all maintenance tasks.

Section/Appendix Layout This manual is divided into six sections, and eight appendices. Appendices have been created to provide special instructions for specific topics. Included are:

Section 1 - General Information

This section contains safety precautions, specifics about equipment safety certification, an explanation of the system warranty, and a detailed definition of Initialization.

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.

Section 5 - Initialization

This section contains procedures for performing the post-installation inspections and tests, and completing the final certification jointly with the customer to validate the system warranty.

Appendix A – Glossary

An explanation of terms, abbreviations, and acronyms used in this manual.

Appendix B – Dispenser Compatibility Listing

A listing of known dispenser makes and models and how they interface with FuelMaster®.

Appendix C – FMU & EIU Configurations

A description of the various model numbers and configurations of Fuel Management Units (FMUs) and Equipment Interface Units (EIUs).

Appendix D – Laptop Direct Connect To FMU

Instructions for direct connecting to an FMU with a laptop to view or change FMU programming information.

Appendix E – Retail Applications

Instructions for applying FuelMaster® to the special needs of retail applications such as small airports and marinas. Includes listing of compatible credit card networks and procedures to assist with the setup of credit card accounts in FMUs used for retail applications. Also includes Acceptance Test Procedure (ATP) for retail installations and startups.

Appendix F – Wiring Differences for Canadian and European Certified FMUs

Explanation of differences between U.S. and Canadian and European certified FMUs

Appendix G – FMU Wire and Cable Connection Points

Listing of connection points for an unknown FMU wire or cable.

Appendix H - Electronic Dispenser Interface

Instructions for using FuelMaster® with electronic dispensers.

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. The FuelMaster® equipment for each installation is assembled to fulfill specific site requirements and must be installed accordingly.

FuelMaster® permits true self-service, automated, fuel dispensing for any application ranging from small service stations to large-scale fleet operations, including retail sales. The FMUs (Fuel Management Units) and Fuel Management Software are encoded by Syn-Tech Systems with matching system designators (site signatures) to assure security and allow access only by the customer to which the system designator is assigned. DoD systems may be utilized universally by all DoD personnel; unauthorized users are “locked out”.

The FuelMaster® equipment can be integrated to extract accumulated transaction data from one service station, or several far removed and isolated service stations that report to one central accounting office. Transaction data is compiled after data communication to a central accounting office which may be hundreds, or thousands of miles remote from the servicing operations.

The FuelMaster® equipment may be adapted to control dispensing equipment for any product (not just fuel) that can be metered. Optional equipment are available to utilize the same system and system access devices to activate electronic gate openers, door openers, and automated car washes.

Some electronic fuel dispensers may only be controlled through a two-wire connection to the dispenser CPU. For these dispensers, an Electronic Dispenser Interface Kit must be installed between the FMU and dispenser distribution box. Appendix B contains a Dispenser Compatibility Listing which will identify when an Electronic Dispenser Interface Kit is needed. Appendix H provides details on the use of the Electronic Dispenser Interface.

Safety Precautions In addition to the safety precautions contained within this installation manual, the FuelMaster® installer must be familiar with the guidelines contained within all other safety codes and standards applicable to the installation and operation of electrical equipment, particularly within hazardous locations. All FuelMaster® and non-FuelMaster® equipment supplied by Syn-Tech Systems, Inc., complies with all applicable federal, state, and local safety codes and standards.

References: The following references, as a minimum, and as they apply to the installation, must be familiar to the technician performing a FuelMaster® installation:

• NFPA Handbook 30, Flammable and Combustible Liquids Code, provides requirements for the safe storage and handling of flammable and combustible liquids.

• NFPA Handbook 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages, provides safeguards for dispensing liquid and gaseous motor fuels into the fuel tanks of automotive vehicles and marine craft.

• NFPA Handbook 70, National Electrical Code (NEC), contains guidelines for the installation and operation of electrical equipment. Chapter 5 specifically addresses the installation of electrical equipment in hazardous locations.

• NFPA Handbook 407, Standard for Aircraft Fuel Servicing, provides minimum fire safety requirements for procedures, equipment, and installations during ground fuel servicing of aircraft using liquid petroleum fuels. Knowledge of this reference is necessary when performing an installation in support of aircraft fuel servicing.

• 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.

Knowledge of this reference is necessary when performing an installation in support of retail fuel sales.

Safety Guidelines: Use the following guidelines to help protect your FMU from potential damage and ensure your own personal safety.

WARNING

Do not operate your FMU with any cover removed or door open.

AVERTISSEMENT

N'actionnez pas votre FMU quand aucune couverture est déplacée ou aucune porte est ouverte.

CAUTION

Do not open your FMU’s doors during wet weather.

ATTENTION

N'ouvrez pas les portes de Votre FMU par le temps de pluie.

As you use your FMU, observe the following safety guidelines:

• To help avoid damaging your FMU, be sure the AC power available at your location is 110 volts, 50 or 60 hertz (Hz).

• To help prevent electrical shock, connect the FMU into properly grounded sources.

• To help avoid possible damage to the FMU and or other interfacing equipment, wait 5 seconds after turning off all interfacing equipment before disconnecting any interconnecting cables.

• To help protect your FMU from sudden, transient electrical increases, your FMU is equipped with Surge Protection. All equipment interfacing your FMU needs to use a surge suppressor, line conditioner, or uninterruptible power supply (UPS).

• Be sure nothing rests on your FMU’s cables and that the cables are not located where they can be stepped on or tripped over.

• Do not spill food or liquids on your FMU or interfacing equipment.

• Do not push any objects into the openings of your FMU. Doing so can cause fire or electrical shock by shorting-out internal components.

• Keep your FMU away from radiators and heat sources.

WARNING

Do not attempt to service the FMU yourself, except as explained in this manual. Always follow installation and service instructions closely.

AVERTISSEMENT

N'essayez pas d'entretenir le FMU vous-même, excepté comme expliqué en ce manuel. Suivez toujours les instructions d'installation et de maintenance précisément.

Before you open the door or remove any FMU covers, perform the following steps in the sequence indicated:

• Turn off/unplug your FMU and any devices. Certain system board components continue to receive power anytime the FMU is connected to AC power.

• Disconnect your FMU and devices from their sources. Also disconnect any telephone or telecommunication lines from the FMU to reduce the potential for personal injury or shock.

• 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.

In addition, take note of these safety guidelines when appropriate:

• When you disconnect a cable, pull on its connector or on its strain-relief loop, not on the cable itself. Some cables have a connector with locking tabs. To disconnect this type cable, press in the locking tabs before disconnecting the cable. As you pull connectors apart, keep them evenly aligned to avoid bending any connector pins. Also, before you connect a cable, make sure both connectors are correctly oriented and aligned.

• Handle components and Prokee®s with care. Don’t touch the contacts on a Prokee®

• Hold components by their edges or by their metal mounting bracket.

Protecting Against Electrostatic Discharge: static electricity can harm delicate components inside your FuelMaster® FMU. To prevent static damage, discharge static electricity from your body before you touch any of your FuelMaster® FMU’s electronic components. You can do so by touching an unpainted metal surface on the FuelMaster® FMU chassis.

As you continue to work inside your FuelMaster® FMU, periodically touch an unpainted metal surface to remove any static charge your body may have accumulated. Use of a wrist-grounding strap is highly recommended.

You can also take the following steps to prevent damage from electrostatic discharge (ESD):

• Keep a static-sensitive component in its antistatic packing material until you are ready to install the component in your FuelMaster® FMU. Just before unwrapping the antistatic packaging, discharge electricity from your body.

• Transport sensitive components in antistatic containers or packaging.

• Handle all sensitive components in a static-safe area. If possible, use antistatic floor pads and workbench pads.

Protecting Against Radio Interference: this equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning off and on the equipment, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the radio/TV’s receiving antenna;

• Increase the separation between the equipment and the radio/TV’s receiver;

• Connect the equipment into an outlet on a circuit different from that to which the radio/TV’s receiver is connected; and,

• Consult the dealer or an experienced radio/TV technician for help.

Wireless Network Security The means exists for wireless network communications between your Central Controller and FMU.

As the technology and equipment becomes more available and affordable, the options make it easier for wireless connectivity. In addition to the ease afforded you, easy connectivity is also available to those you may not wish to share your information with. The information gathered and 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.

Without proper wireless network security, outside users can access your network to attain information such as social security numbers, credit card numbers, bank account numbers, and countless other very valuable and private information sources stored on your network. In planning your wireless network, ensure you purchase the right equipment and plan for a secure network that won’t allow outsiders access to your information.

A Hold Harmless Agreement is attached to this manual, and requested to be signed by the using customer. This agreement references the potential hazards associated with wireless network security, and serves to remove liability from the seller (Syn-Tech Systems or its distributors) when wireless networking equipment is installed for communications to the FMU.

Certifications/Approvals FuelMaster® FMUs have been tested and safety certified by the ETL SEMKO division of Intertek to ANSI/UL Specification 1238 for connection to UL-certified dispensers in NEC Class 1, Division 2, Group D locations. Equipment versions certified by ETL are identified by the ETL logo imprinted on the ID plate riveted to the FMU pedestal.

Figure 1-1 illustrates the boundaries of a hazardous location which dispenses flammable liquids such as gasoline and E85. Propane (liquefied petroleum gas) has the same basic boundaries.

The boundary area around a compressed natural gas (CNG) dispenser is different. It extends 5 feet from, and above, the dispenser. Any electrical device installed within these boundaries must be

Figure 1-1. Boundaries of a Flammable Liquid Hazardous Location 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. If the electrical device is not intrinsically safe, or is not explosion-proof, then it must be installed outside the hazardous area.

Figure 1-2 illustrates an FMU and the distance from its mounting surface to where electrical components are installed. All internal electrical components are 28 inches above the mounting surface. This places all electrical components in the FMU a full 10 inches outside the hazardous location. This 10 inch separation provides additional spacing for the installation of outlet boxes or other devices which are not explosion-proof, and which cannot be installed in hazardous locations.

FuelMaster® has been certified for use in electrical installations in Canada and Europe as well as the United States. FMUs certified for use in Canada and Europe may be identified through the ID plate riveted to the FMU pedestal. See Figure 1-3 for examples of FMU ID plates for U.S., Canadian and European certification.

Figure 1-2. FMU Electrical Safety Spacing

Figure 1-3. FMU ID Plates

Syn-Tech received notification of PCI compliance in May 2009. If it is desired to validate compliance through the PCI Security Standards Council website, go to Validated Payment Applications and search on Syntech-Fuelmaster.

FuelMaster® has also been certified by the National Conference on Weights and Measures, and has NTEP (National Type Evaluation Program) Certificate 02-115. The NTEP certificate applies to the FMU-2500 and FMU-3000 series, and is referenced on the FMU ID plate. The series covers FMU- 2500 classic and Plus FMUs, and FMU-3000 and FMU-3500 passive FMUs.

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. Remove the ID plate from the older unit and install it on the newer unit using pop-rivets. Pop-rivets 1/8 inch wide x 1/4 inch long should be used to secure the ID plates to the pedestal.

The FMU is shipped in two pieces, in two separate shipping containers. The upper cabinet has a bar code label inside the cabinet on the side wall closest to the door hinges. The bar code label has the FMU serial number printed to match the serial number on the pedestal ID plate. The shipping containers are also marked with the FMU serial number.

WARNINGS, CAUTIONS and NOTES

This manual emphasizes special operations with Warnings, Cautions, or Notes preceding the applicable procedure:

• A WARNING indicates a safety precaution that, if not followed, could result in personal injury;

• A CAUTION indicates a safety precaution that, if not followed, could result in damage to equipment; and,

• A NOTE indicates a procedure requiring special emphasis for the proper installation and operation of FuelMaster® equipment.

Warnings and Cautions in this manual are provided in both English and French to meet the needs of our French speaking customers in Canada.

Key Number ID Plate Code 300 0 325 1 350 2 375 3 400 4 425 5 450 6 475 7 500 8 523 9 333 10

Table 1-1. FMU Door Key Reference

Basic FuelMaster® FMU Warranty The basic warranty for each FuelMaster® FMU provides coverage for parts and telephonic labor for a period of one year from date of start-up or fifteen months from date of shipment, whichever occurs 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.

Under terms of this agreement, FuelMaster® technicians will telephonically diagnose problems, with the assistance of the customer, to determine warrantable conditions, and possible problem solutions. Syn-Tech Systems, Inc. will replace all defective parts and provide assistance to the customer in installation of replacement parts to allow the unit to be repaired as expeditiously as possible. Please note that the FuelMaster® was designed in a modular manner to provide easy and rapid exchange of parts, even by non-technical personnel. Other systems are not designed this way and consequently; do not offer warranties comparable to FuelMaster®. This warranty does not cover site visits by FuelMaster® technicians for repair.

Please note that damage resulting from acts of God, user abuse, accidents, faulty installation or operation is not covered under the warranty. This warranty specifically excludes any indirect, special, or consequential damages to include, but not limited to, loss of product, profit, or litigation fees. Additionally, associated equipment including printers, personal computers, and other items not manufactured by Syn-Tech Systems, Inc. are warranted only to the extent covered by the original manufacturer. Additionally, this warranty is limited to approved locations (generally the continental United States) and is not transferable except by written permission of Syn-Tech Systems, Inc.

Initialization Requirement All FuelMaster® Fuel Management Systems must be initialized to validate the warranty of the equipment. Initialization is the startup, inspection, and tests performed to certify the installation.

Initialization can be completed only by a Syn-Tech FuelMaster® technician, or a technician who has completed the Syn-Tech FuelMaster® Installation School. Final certification must be accomplished jointly by the Customer and Syn-Tech factory trained personnel.

NOTE

The prompt for the activation code may not appear if a credit card is inserted. If a newly installed FMU is being setup, insert a Prokee® or smartcard to bring up the prompt for the activation code. An activation code must be entered to begin normal FMU operation.

When a Prokee® or smartcard is inserted after initial power-up, FMUs will prompt the initializing technician to call 1-800-888-9136, ext. 1500, for an activation code. This number connects to Syn- Tech’s Customer Satisfaction Center (Help Desk). The caller will be forwarded to a Customer Satisfaction Center (CSC) technician who has a 1-page form (see Figure 1-4) to complete before he/she can provide the activation code. The caller will be asked pertinent questions about the site and FMU. The CSC technician will need the FMU serial number to generate an activation code. It is very important the FMU is assembled with the correct upper cabinet which matches the pedestal with the serialized ID plate. If not, the activation code will not activate the FMU.

Figure 1-4. Sample FMU Initialization Form

FuelMaster® Equipment Specifications

Rated Supply Voltage Limits 120VAC +/- 15% (upper limit) 75 +/- 10% (lower limit) Rated Supply Frequency 50 or 60 Hz Rated Supply Current 2.4 amps Max operating Heaters (2 each) 1.0 amps (each) Other electronics 0.4 amps Operating Altitude, Max 2000 meters Max Operating Relative Humidity 100% Installation Category (surge arrestor) III Installation Category (after surge arrestor) II Pollution Degree 2 Electronics Operating Temperature Range Turn on at 37º F, turn off at 158ºF Heater Operational Range Turn on at any temp below 66º F Turn off when temp is above 73º F

Safety Related Inspections & Preventive Maintenance FMUs require no preventive maintenance to retain its user safety features. Whenever an FMU is updated or repaired, a safety inspection should be performed including wiring integrity (power and grounds), board retention, and safety covers.

Cleaning Instructions The FuelMaster® chassis, keypad & LCD glass should be washed with a mild detergent diluted with water. A soft sponge or cloth is recommended. Rinse and dry with a soft dry cloth. The FuelMaster® FMU works well and presents no safety problems when dirty. Frequency of cleaning is left to the user’s discretion. The FMU Prokee® and card receptacles will require cleaning when Prokee®s, smartcards, or credit cards are not being read correctly. Some products used by Syn-Tech in these applications are (follow the manufacturer’s instructions):

• Prokee®: RadioShack 64-4345 Precision Electronics Cleaner

• Smartcard: KIC Products K2-HSCB50 Smartcard cleaner

• Mag-stripe card: KIC Products KW3-H19B40

Fuse Reference Every fuse application in the FMU has a fuse description silk-screened next to the fuse holder. All fuses are rated for 250 VAC. Listed below are the fuses used in an FMU:

Location Description Quantity Manufacturer Part # AC Surge Panel 4 amp fast blo, 3AG 2 Littelfuse 312004

Phone Surge Panel ½ amp fast blo, 5x20mm 2 Littelfuse 216.500

FMU-2500 Modem ¼ amp fast blo, 5x20mm 2 Littelfuse 216.250

FMU-2000 Modem ¼ amp fast blo, 2AG 2 Radio Shack 270-1046

Power Mgmt Board ½ amp fast blo, 2AG 1 Littelfuse 225.500

Pedestal I/O Board ¼ amp slo blo, 2AG 1 Littelfuse 229.250

Power Fuse 4 amp slo blo, 3AB 1 Littelfuse 325004

Battery Reference There are batteries on the mainboard, card reader board, and data logger. The Plus mainboard and data logger use a battery with Syn-Tech part number 243736. The classic mainboard and card reader board use a battery with Syn-Tech part number 180181. 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.

The 243736 battery is a 5.4mm (approximately ¼ inch) thick battery. The 180181 battery is a 2.5mm (approximately 1/8 inch) thick battery. Though the voltages are the same, they cannot be used interchangeably because of the thickness of the battery and depth of the battery socket.

All batteries are lithium 3V. Syn-Tech part number 180181 is commercially available as Rayovac part number BR2325-B 3V. Syn-Tech part number 243736 is commercially available as Panasonic part number CR2354.

To avoid losing information stored in memory, FMU mainboard batteries should be replaced with FMU power

on. It is highly recommended all transactions be downloaded and a copy of the FMU configuration be made before removing the battery.

Switch Ratings The main power toggle switch and manual/automatic pump toggle switches are general purpose switches, rated for 15A @ 125VAC, 10A @ 250VAC, 3/4 hp @ 125VAC - 250VAC.

The optional FMU quick stop switch is a heavy duty, oil and watertight switch, rated for 1.0A/300VAC CSA, 0.5A/220VDC, and 1.0A/24VDC.

Terminal Ratings (For External Component Connections)

CAUTION

The following terminal ratings are as suggested by the component manufacturer as the maximum continuous voltage and current the component is designed to accept. These ratings do not necessarily correspond to the voltages normally applied to the component when integrated into FuelMaster® as part of a complete system.

ATTENTION

Les cotes de terminaux suivants sont comme suggéré par le fabricant de composants comme la tension maximale et le courant le composant est conçu pour accepter. Ces notes ne correspondent pas nécessairement aux tensions normalement appliqué à l'élément lorsqu'ils sont intégrés dans Fuelmaster ® dans le cadre d'un système complet.

P_ (J4-J7 on PEDESTAL I/O BOARD): 12 VDC

LN_ (TB 1, TB2 on PEDESTAL I/O BOARD): 300 V, 25 A

PHS_ (TB3 on PEDESTAL I/O BOARD): 300 V, 25 A

ON-SITE PRINTER (J2 on PEDESTAL I/O BOARD): 300 V, 10 A

TANK MONITOR UNIT (JP13 on I/O SILVER BOARD): 300 V, 10 A

INDOOR RECEIPT PRINTER (JP11 on I/O SILVER BOARD): 300 V, 10 A

PHONE (931C0110): 125 VAC, 500 mA

Parts Substitution and Modification Modification of the equipment provided, substitution of any material requirements, or any deviation from these installation instructions must comply with all applicable safety codes and standards.

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. There may be other products which have not yet been tested, but may be equally suitable.

Syn-Tech Systems inventories commercially available products necessary to complete a FuelMaster® installation. When these products are purchased from Syn-Tech Systems, the manufacturer’s warranty is honored and administered by Syn-Tech Systems.

Support

Syn-Tech Systems strives to provide the best customer and distributor support possible. Free on-site distributor and customer training is provided quarterly (or more often as needed) at the FuelMaster® factory in Tallahassee, Florida. Training at the distributor’s location is available where it may be more cost effective to send a trainer(s) from Syn-Tech rather than send several technicians to Tallahassee for factory training.

Webinars are available through the internet for training sessions between a Syn-Tech trainer in Florida, and customer representative(s) anywhere there is internet access. See the FuelMaster® website at http://www.myfuelmaster.com/ for assistance scheduling training.

Syn-Tech offers a well staffed Customer Satisfaction Center (CSC) to take questions and calls from FuelMaster® customers. In addition, a Distributor Support Center (DSC) provides answers from experienced field technicians for distributors needing installation, startup, training, or troubleshooting assistance.

Questions for the CSC should be called in to 800-888-9136, ext. 1500, or e-mailed to support@myfuelmaster.com.

Syn-Tech maintains an e-mail database of all FuelMaster® distributors. Whenever a new publication or other pertinent information is published, it is forwarded to all distributors on the mailing list. If your e-mail address changes, or other e-mail addresses are added, forward the new address to distributor_replies@myfuelmaster.com.

Improvements Recommendations for improvement or corrections to this manual may be reported to Syn-Tech's Customer Satisfaction Center at support@myfuelmaster.com or by mailing to:

SYN-TECH SYSTEMS, INC.

Attn: Customer Satisfaction Center

P.O. Box 5258 Tallahassee, FL 32314

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. The base system contains all equipment necessary to accomplish these tasks and consists of:

• Fuel Management Unit with controls for two hoses, upgradeable to eight hoses

• Prokee®s or Smartcards

• Fuel Management Software

• Prokee® or Smartcard Encoder

• Installation and Operation Manuals

Version Differences. FuelMaster® Fuel Management Systems may be Classic or Plus. The major differences between the two are: 1) the older Classic systems have an EPROM on the mainboard, two batteries, and four expansion slots, 2) the newer Plus series contains the latest configurations and options, has a flash loader and compact flash card on the mainboard, a single battery, and six expansion slots. Classic and Plus series FMUs may be intermixed only if the Plus series software is being used to communicate with the Fuel Management Units (FMUs).

Interconnected Master and Satellite FMUs must be from the same (Classic or Plus) series, using the same firmware. See Appendix C for a complete listing of the entire Classic and Plus lines of systems and options. Unless otherwise specified, where instructions reference the FMU-2500, the same instructions apply to the FMU-2500 Classic and Plus, the FMU-3000 (classic AIM), and the FMU-3500 (Plus AIM2™/AIM2.4™).

Equipment Description and Location Fuel Management Unit (FMU)

Description. (See Figure 2-1) The primary function of FMUs is to control access to connected product dispensers, and accumulate data for each automated transaction. FMUs may also be used to control and report access to carwashes, gate openers, or other restricted access devices, and to interface with tank monitors/tank gauges to receive a variety of reports. FMUs may be Fixed or Mobile (Mobile FMUs are covered in the Mobile Installation Manual). Fixed FMUs are permanently mounted on or near the service island, and may be a Master or Satellite. A Master FMU communicates with the Central Controller, and controls all connected Satellite FMUs and EIUs (Equipment Interface Units). Master FMUs and Satellite FMUs are identical in external physical appearance. A Satellite FMU or EIU must be connected to a Master FMU for proper operation.

Each fixed FMU can control up to eight dispenser hoses. A Master FMU can also control up to eight Satellite FMUs and/or EIUs. Control of Satellite FMUs/EIUs is through an RS-422 or wireless connection to the Master FMU. The base FMU (fixed Master or Satellite) is provided with hose controls for two hoses. Additional hose controllers, up to a total of eight, may be purchased in the equipment order. An EIU will control only one device.

Figure 2-1. Fuel Management Unit (FMU)

All current versions of the standard FMU are delivered…