Alemite FCS 343000 Operating instructions

Alemite FCS Fluid Control System
Installation and Operation Guide
343000
343000-1
670996

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Alemite FCS Fluid Control System: Installation and Operation Guide
TABLE OF CONTENTS
DISCLAIMER .............................................................. 3
BEFOREYOUBEGIN....................................................... 4
1.0 DESCRIPTION ........................................................ 5
2.0 LOCATIONANDINSTALLATION ....................................... 6
3.0 ELECTRICALWIRING ................................................. 7
4.0 PLC KEYPAD ........................................................ 10
5.0 SYSTEMSETUPANDPROGRAMMING ................................. 11
5.1 Reel Relationship Setup.......................................................... 11
5.2 TankSetup.................................................................... 12
5.3 Setting Tank Level Alerts..................................................... 13
5.4 Tank Refill Parameters ........................................................... 14
5.5 WasteTankLevelAlerts..................................................... 15
6.0 FLOW METER CALIBRATION.......................................... 16
7.0 OPERATIONALSETTING ............................................. 17
7.1 Prompts ................................................................. 17
7.2 Preset Quantity ........................................................... 17
7.3 Maximum Dispense Settings ................................................. 18
7.4 PrintHeaders ............................................................ 19
7.5 DisplayAdjustment ........................................................ 19
8.0 USERSETTINGS..................................................... 20
8.1 Add User................................................................. 20
8.2 Delete User .............................................................. 21
8.3 View/Print Users ........................................................... 21
8.4 Make Manager............................................................. 22
9.0 OPERATION ......................................................... 23
9.1 Dispensing ............................................................... 23
9.2 DisplayTankLevels ........................................................ 24
9.3 Entering Tank Refill Information............................................... 24
9.4 EmptyingWasteTank....................................................... 25
10.0 ADDITIONALDEVICESETTINGS...................................... 26
10.1 Set Date and Time ........................................................ 26
10.2 SD Card Backup Settings ................................................... 26
11.0 ACCESSORIES....................................................... 28
CONTACTINFORMATION ................................................ 29

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Alemite FCS Fluid Control System: Installation and Operation Guide
DISCLAIMER
The user/purchaser is expected to read and understand the information provided in this
manual, follow any listed Safety Precautions and Instructions and keep this manual with the
equipment for future reference.
The information in this manual has been carefully checked and is believed to be entirely
reliable and consistent with the product described. However, no responsibility is assumed for
inaccuracies, nor does Alemite LLC assume any liability arising out of the application and use of
the equipment described.
Should the equipment be used in a manner not specified by Alemite LLC, the protection
provided by the equipment may be impaired.
Questions or Service Assistance
If you have questions regarding the product or this document contact:
Alemite LLC
1057 521 Corporate Center Dr.
Fort Mill, SC 29707
Tel: [phone] ext. 6232
Fax: [phone]
On the Web: www.alemite.com
Product Identification Information
Record the product identification numbers from the nameplate here.
Alemite FCS Unit without printer: Product number 343000
Alemite FCS Unit with inbuilt printer: Product number 343000-1
Model Number: ________________________________________
Serial Number: ________________________________________

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Alemite FCS Fluid Control System: Installation and Operation Guide
BEFORE YOU BEGIN
Product Unpacking and Inspection
NOTE: If damage to the shipping container is evident upon receipt, request the carrier to be
present when the products are unpacked.
Upon receipt of the products, perform the following unpacking and inspection procedures:
Follow any instructions that may be marked on the exterior. Carefully open the shipping•
package.
Remove all cushioning material surrounding the products and carefully lift the products from•
the package.
Retain the package and all packing material for possible use in reshipment or storage.•
Visually inspect the products and applicable accessories for any physical damage such as•
scratches, loose or broken parts, or any other sign of damage that may have occurred during
shipment.
NOTE: If damage is found, request an inspection by the carrier’s agent within 48 hours of
delivery and file a claim with the carrier.A claim for equipment damage in transit is the sole
responsibility of the purchaser.
NOTE: A pressure relief valve is required or warranty is invalid. Please refer to Section 7.0,
Typical Configuration Schematic. For further questions, call Alemite Customer Service at
1-800 Technical Service
For installation, service or technical questions, call:
800-628-9069 (US & Canada)

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Alemite FCS Fluid Control System: Installation and Operation Guide
1.0 DESCRIPTION
The Alemite FC Fluid Controller is designed to accommodate up to twelve
reels, 6 different fluids, and up to six air valves depending on the configuration.
The Alemite FC represents the state-of-the-art in automated fluid control
and dispensing technology, providing a simple and cost effective fluid use
management and reporting, using an intuitive PLC controller.Two controller
models are available, one using a remote printer and the other featuring an
inbuilt printer.
Alemite FC with inbuilt
printer option.

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Alemite FCS Fluid Control System: Installation and Operation Guide
2.0 LOCATION AND INSTALLATION
The Alemite FC Fluid Control System should be mounted in a central location,
near a 120VAC electrical outlet. Mounting feet are provided on the back of the
unit, which can be turned to a suitable angle for the mounting position.
Unit
mounting
feet

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Alemite FCS Fluid Control System: Installation and Operation Guide
3.0 ELECTRICAL WIRING
Cables to be wired as follows:
White: Connect to Pulse Counter (Either Wire)
Green: Connect to Pulse Counter (Either Wire)
Red: Connect to Valve 24v (+)
Black: Connect to Valve 0V (–)
NOTE: Ensure that wire gage is appropriate to the length of run.
1.5 Amp, 250 V fuse

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Alemite FCS Fluid Control System: Installation and Operation Guide
Plug valve/meter combo wire into plug 1-6.
For additional fluid solenoid utilizing an already wired flow meter, plug into 7-12.
For air solenoid, plug into 7-12.
Refer to following page for example.
#7 #12
#1 #6

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Alemite FCS Fluid Control System: Installation and Operation Guide
Air Supply
PULSE VALVE 2VALVE 1
REEL 1
BAY 1
10W/30
MOTOR OIL
PLUG 1
PLUG 2
PLUG 7
FLUID FLUID
VALVE 7
AIR
BAY 2
REEL 2
METER 1
Piping
REEL #
1
EXAMPLE:
2
VALVE #
1 2
TANK #
1 1
METER #
1 1
CONTENTS AIR VALVE #
10W30 10W30
7 7
TANK 1
TWO REELS USING ONE TANK.
NOTE:
AIR VALVE CAN SHARE MULTIPLE TANKS .

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Alemite FCS Fluid Control System: Installation and Operation Guide
4.0 PLC KEYPAD
The controller keypad is your interface to all unit programming and operating
functions. Using intuitive commands accessed via the control, numeric, and toggle
keys, all functions can be accessed, programmed, and controlled.
ESCAPE
+/–Symbols
.
Function One
Display
Function Two ENTER
0 and Space
Toggle Controls,
 also
Switches Capital
and Lowercase
Alpha-numeric
Keys

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Alemite FCS Fluid Control System: Installation and Operation Guide
5.0 SYSTEM SETUP AND PROGRAMMING
The relationships between reels, flow meters, and tanks must be programmed
as part of system setup, per the configuration of your specific installation. Note
that installations vary, and the following setup instructions are an example of a
typical system.
5.1 Reel Relationship Setup
Step 1: Log in as manager (Default Admin code is 1111. This manager code
can be deleted later.)
Step 2: In main menu, scroll to (3) System Setup.
Step 3: Scroll to submenu item (1) Reel/Tank/FM.

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Alemite FCS Fluid Control System: Installation and Operation Guide
Step 4: Enter reel relationships as follows:
A. Enter Reel number.
B. Enter related Flow Meter number.
C. Enter related Tank number.
D. Press F1 to change units associated with reel.
E. Press F2 to save.
F. Repeat with remaining reels.
NOTE: If two or more reels share the same flow meter, the software is designed
to recognize this and will not allow those reels to operate at the same time.
After all Reels are entered, press ESC to exit to previous menu.
5.2 Tank Setup
Step 1: From main menu, choose (3) System Setup, (2) Tanks.
Step 2: Scroll to submenu item (4) Tank Fluid Setup.

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Alemite FCS Fluid Control System: Installation and Operation Guide
Step 3: Enter tank fluid parameters as follows:
A. Enter Tank Number.
B. Enter Content Label.
C. Enter Air Valve controlling the pump on that tank (if connected).
D. Press F1 to choose the units (Liters, Gal, etc.) associated with this tank.
E. Press F2 to save.
F. Repeat with remaining tanks.
After all tanks are entered, press ESC to exit to previous menu.
5.3 Setting Tank Level Alerts
Step 1: From main menu, choose (3) System Setup, (2) Tanks
and scroll to (5) Set Tank Level Alerts.
Step 2: Enter level alert parameters as follows:
A. Enter Tank Number
B. Enter the MAX capacity of the tank (in units selected in tank setup).
C. Enter the Low Warning Level (in % of tank maximum).
D. Enter the Stop Level (in % of tank maximum).
E. Press F2 to save.
F. Repeat with remaining tanks
After all tanks are entered, press ESC to exit to previous menu

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Alemite FCS Fluid Control System: Installation and Operation Guide
5.4 Tank Refill Parameters
Step 1: From main menu, choose (3) System Setup, (2) Tanks and scroll
to (2) Tank Refill Input.
Step 2: Enter refill parameters as follows:
A. Enter Tank Number
B. Enter the level to reset the tank. (defaults to Max, but can be set
to any value less than max).
C. Press F2 to save.
D. Repeat with remaining tanks
After all tanks are entered, press ESC to exit to previous menu
The System should now be able to dispense. The remaining setup selections can
be used to customize the system.

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Alemite FCS Fluid Control System: Installation and Operation Guide
5.5 Waste Tank Level Alerts
This menu displays item displays the level of the waste tank.The system will
warn you when the waste tank is full. The level is calculated based on the
amount of fluid dispensed by all of the meters. By default the use of the waste
tank is turned off. If use of the waste tank is desired, proceed as follows:
Step 1: From main menu, choose (3) System Setup, (2) Tanks and scroll
to (5) Set Tank Level Alerts.
Step 2: Enter Tank Number 7 (waste tank) and proceed as follows:
A. Enter the MAX capacity of the waste tank in the units previously
selected).
B. Press F1 to change units associated with waste tank.
NOTE: Entering a MAX capacity of 0 will deactivate the waste
tank feature.
C. Enter the Warning Level (% of tank maximum).
D. Enter the Stop Level (% of tank maximum).
E. Press F2 to save.

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Alemite FCS Fluid Control System: Installation and Operation Guide
6.0 FLOW METER CALIBRATION
The Flow meter Calibration function allows the user to correct discrepancies
in the amount dispensed as calculated by the system vs. the actual amount
dispensed. Each Meter should be calibrated prior to using the system.To
calibrate a meter, proceed as below:
Step 1: Go to (1) Dispense in main menu.
Step 2: Set a reel that uses the flowmeter to dispense X units of fluid and
proceed as follows:
A. Measure the actual amount dispensed using an electronic
flowmeter or a container of known volume.
B. From Main Menu, return to (3) System Setup.
C. Scroll to menu item (3) Flow Meter Cal.
D. Enter the Amount that was requested.
E. Enter the actual amount dispensed as measured by the electronic
meter or container.
F. Press F2 to save.
Press ESC to exit
The system has calculated a new calibration factor which is now active.
Repeat these steps to check the new calibration and further refine the accuracy.
NOTE: If multiple reels use one flow meter, the Flow Meter Calibration
needs to be done only once.

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Alemite FCS Fluid Control System: Installation and Operation Guide
7.0 OPERATIONAL SETTING
7.1 Prompts
The software allows up to five custom prompts which can be displayed when
entering information for a dispense. These can be used to request specific
information such asVehicle ID, License Plate #, or work order #.
To enter prompts, proceed as follows:
A. Go to (3) System Setup on main menu.
B. Scroll to (4) Prompts
C. Enter prompt text as desired
D. Press F2 to save entry
E. Scroll with DOWN arrow to move to next Prompt entry
F. After all prompts have been entered and saved, hit ESC to exit this function.
7.2 Preset Quantity
The software allows each reel to be setup to dispense a user preset amount of fluid,
or a freeflow amount up to the defined maximum dispense. By default the system
is set up to use a preset amount.The preset amount may be set as follows:
A. Go to (3) System Setup in main menu.
B. Scroll to (5) Preset Quantity.

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Alemite FCS Fluid Control System: Installation and Operation Guide
C. Enter Reel Number
D. F1 switches between Preset option and Freeflow option.
E. Press F2 to save
F. Repeat with remaining reels, pressing F2 to save each change.
G. After all prompts have been entered, hit ESC to exit to previous menu.
7.3 Maximum Dispense Settings
Each reel can have a specified Maximum delivery amount and a timeout feature
to determine when a job is completed. If the maximum delivery amount
is reached the valve will be shut off and the job will be closed out. Also, if
“Timeout” minutes of inactivity occur on the active reel, the valves will be shut
off and the job will be closed out.These may be set as below:
A. Go to (3) System Setup in main menu.
B. Scroll to (6) Maximum Dispense.
C. Enter Reel Number
D. Enter Max Quantity (In units defined for each reel).
E. Enter Timeout (in minutes).
F. Press F2 to save
G. Repeat with remaining reels.
H. After all prompts are entered, press ESC to exit to previous menu.

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Alemite FCS Fluid Control System: Installation and Operation Guide
7.4 Print Headers
The software allows up to two lines of text to be printed at the top of the
printed ticket.
A. Go to (3) System Setup in main menu.
B. Scroll to (7) Print Headers.
C. Enter up to two lines of text (business name, etc).
D. Press F2 to save.
E. Press ESC to exit to previous menu.
7.5 Display Adjustment
The software allows users to set the screen contrast and backlight to suit the
operating conditions.
A. Go to (3) System Setup in main menu.
B. Scroll to (8) Screen Adjust
C. Set the Contrast and Backlight options as desired.
D. Press F2 to save.
E. Press ESC to exit to previous menu

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Alemite FCS Fluid Control System: Installation and Operation Guide
8.0 USER SETTINGS
8.1 Add User
All users must be entered into the system. Users may be added as follows:
A. Go to (4) User Setup in main menu.
B. Scroll to (1) Add User
C. Enter User Name
D. Enter PIN for User
E. Press F2 to save
F. Repeat with remaining users, pressing F2 to save each entry.
G. After all users have been entered, press ESC to exit to previous menu.