Alemite RFC-Plus User manual

Service Guide RFC-PLUS
671051
RFC-Plus
Fluid Management System
FMS-3 2.4 GHz RF High-End Software
Alemite LLC
167 Rowand Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright©2013 by Alemite LLC

and is not to be copied, used, or disclosed to others without express written permission SER RFC-PLUS
Revision (09-13)

Fluid Management System
Page ii Alemite LLCRevision (09-13)
SER RFC-PLUS

CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
System Composition and Dataow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Certication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Keypad Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MASTER KEYPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Version Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Settings Overview / Supervisor Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Initialization (INI) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conguration (CNF) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Test Communication (DK) Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Reports (REP) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Radio (RAD) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DISPENSE KEYPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Version Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Settings Overview / Supervisor Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Conguration (CNF) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Delete Prepared WOs (MET) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reports (REP) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
190 (Internal Ticket Printer) Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
RF Communication Test (LNK) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Radio (RAD) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Network Connect (CON) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System Override (SYS) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Dispense Keypad Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DISPENSE PROCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Starting a Work Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SER RFC-PLUS Fluid Management System
Page iiiRevision (09-13) Alemite LLC

MODEL 3580 RF METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Key Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
RF Mode (Standard Pre-Selection Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AUTO Mode (Autonomous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Changing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Programming the Model 3580 RF Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLING AND LAUNCHING THE FMS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FMS Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing the FMS Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the FMS Client. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Launching the FMS Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
FMS System Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
USING THE FMS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Setting Up New Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Setting Up Tanks and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Setting Up Keypads and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INITIALIZE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Test Comm Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Initialize All Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Initialize Changes Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
PARTS DEPARTMENT USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Creating a New Work Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Work Order Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Tanks and Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Dispense Keypad Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Meter Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
WORKSHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fluid Management System
Page iv Alemite LLCRevision (09-13)
SER RFC-PLUS

INTRODUCTION
The Alemite LLC, Fluid Management System has been designed as a modular system using RF communications to control and
monitor the consumption and inventory balances of automotive fluid products with minimal installation and programming
costs using RF communications.
The high end system hardware consists of one Master Keypad and at least one Dispense Keypad as well as at least one radio
frequency (RF) electronic preset meter. The Master Keypad handles serial communication between the PC or a host server
(ERP system) and RF communication to the Dispense Keypads in the system. The system verifies the operator’s pin number
and validates the work order number, fluid quantities and the valid hose/meter.
The Master Keypad can communicate with up to 36 Dispense Keypads that can be positioned to support the workflow of the
facility the best way. Each Dispense Keypad can control up to 24 meters, for a total of 250 meters. The system supports up to
16 tanks and 16 fluids as a part of the system configuration. The system supports 250 unique operator IDs and pin numbers.
The system uses direct sequence spread spectrum RF technology to prevent communication problems with other equipment
in the facility. The RF system will look for a clear channel for transmission to insure that there is reliable communications at all
times. Communication distances are typically up to 100 meters, but can go up to 300 meters with unobstructed line-of-sight.
A remote antenna is available for situations where multiple buildings are involved in the installation.
The PC is used to configure the system, maintain system data and enter work orders. The service desk would use the PC to
enter a work order selecting the fluid and quantity required. The PC can stack as many work orders as required, limited only by
the disk storage space of the PC. There is no need to predetermine where the work is going to occur. This allows the flexibility
to service a vehicle at any open bay and select a meter when the work is going to be performed. When the work order is
going to be performed, the service personnel simply enters their pin number, work order and hose that is going to be used at
the Dispense Keypad.
There are a number of system utilization reports by user; fluid type, tank or meters available for the system’s management.
Optionally, the system can be connected with an ERP or DMS system via its RS232 interface. The real-time communication is
based on an open interface protocol (ASCII-code) and can be easily adapted to local conditions.
A unique, patented feature of the system is that the RF meter’s dispense trigger is locked until an authorization from the
keypad is received. After the dispense batch is completed, the user can top off if more fluid is required, the actual dispensed
amount is sent back to the keypad and the meter returns to the locked status. Additionally, the meter can be installed on
portable dolly systems offering control and monitoring of high-cost lubrication products.
SER RFC-PLUS Fluid Management System
Page 5Revision (09-13) Alemite LLC

System Overview
Figure 1: System Overview
Fluid Management System
Page 6 Alemite LLCRevision (09-13)
SER RFC-PLUS

System Composition and Dataow
Figure 2: System Data Flow
The main data streams:
1. The FMS software stores the conguration data into the SQL database.
2. By using the Initialize System menu of the FMS software the conguration data is processed to the Master Keypad and
nally via radio to all Dispense Keypads.
3. The FMS records all dispenses in the SQL database.
SER RFC-PLUS Fluid Management System
Page 7Revision (09-13) Alemite LLC

Specications
Power Requirements 120V AC 50/60 Hz
RF Communications 2-way, 2.4…2.5 GHz Direct Sequence Spread Spectrum
RF Network Self-healing Mesh Network
Operating Temperature 14…140° F (–10…60° C)
Internal Printer Thermal printer Type FT190 (optional)
External Printer Epson LX300 or similar (optional)
Certication
•Contains FCC ID: S4GEM35XB
•Contains IC: 8735A-EM35XB
•FCC CERTIFIED, PART 15, SUB-PART C
•CE0681 EC-R&TTE Certified
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may
not cause harmful interference, and (2) this device must accept any interference received, including interference that may
cause undesired operation.
WARNING
To satisfy FCC RF exposure requirements for mobile transmitting devices, a separation distance of 20 cm or
more should be maintained between the antenna of this device and persons during operation. To ensure compliance,
operations at closer distances than this are not recommended.
Wall-Mounting the Keypad
The keypad should be mounted upright with the antenna pointing upward, near a 120V AC electrical socket, to a structurally
sound wall through the two holes on the top of the keypad casing. Height on the wall should be at eye level. Care should be
taken to avoid mounting behind any steel objects (tool storage cabinets and metal chain linked fences) that may block the RF
communication signal. Care should also be taken to avoid direct, significant heat sources.
7 / in.
3 / in.
(193 mm)
58
316
(81 mm)
38
(81 mm)
7 / in.
Fluid Management System
Page 8 Alemite LLCRevision (09-13)
SER RFC-PLUS

Figure 2: Mounting Dimensions for Keypad
Keypad Description
The Scroll key selects options on the active display.
The Home key returns the display to the default screen.
The Backspace key deletes one character to the left of the cursor each time it is pressed.
The Enter key completes the current action then displays the next screen.
The Space key adds a blank space to the right of the data just entered.
to
The Alphanumeric keys enter numbers and alpha characters (letters).
•To enter a number, press and release a key.
•To enter a letter, press and hold the key until the letter you want displays, then release the key.
SER RFC-PLUS Fluid Management System
Page 9Revision (09-13) Alemite LLC

Operation Modes
The configuration of the system is generally done by using the PC-based FMS Software. Only some special functions like the
operation modes are set at the Master Keypad.
RF System with PC Operation Mode
In this mode the PC is used to configure the system entities and install the network. The PC will be used to enter work orders
for processing and provide the queuing for future processing. When an operator processes a work order the PC will validate
the work order number and provide the fluid and amount to be dispensed. The results of the dispense will then be stored on
the PC.
RF System with Host Operation Mode
In this mode the PC is used to configure the system entities and install the network.
The host will be used to enter work orders for processing and provide the queuing for future processing. It will also store
the dispense results that have been completed. Dispense results can be additionally stored on the PC. When an operator
processes a work order the host will validate the work order number and provide the fluid and amount to be dispensed.
Standalone Mode
Work orders will not be validated; each entered work order will be accepted by the system. Data will be stored in the Master
Keypad’s memory.
OTE:N Each meter can only be associated to one Dispense Keypad. All system users can access each of the
Dispense Keypads.
Fluid Management System
Page 10 Alemite LLCRevision (09-13)
SER RFC-PLUS