Alemite 343530 Instruction Manual

User and maintenance instructions
Model 
AFCS Enterprise controller
Date of issue September 
Form number 
Version 

Contents
Explanation of safety signals . . . . . . . . . 
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Introduction . . . . . . . . . . . . . . . . . . . . . . 
Controller overview. . . . . . . . . . . . . . . . . 
Mounting dimensions. . . . . . . . . . . . . . . 
Cat  ethernet network wiring . . . . . . . . 
Wiring diagram . . . . . . . . . . . . . . . . . . . . 
Configure controller . . . . . . . . . . . . . . . . 
Tank monitor functions. . . . . . . . . . . . . . 
AFCS Enterprise controller parts/kits. . . 
Troubleshooting . . . . . . . . . . . . . . . . . . . 
EC Declaration of Conformity . . . . . . . . . 
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 
Explanation of safety
signals
CAUTION
Indicates a hazardous situation that may
result in minor or moderate injury
and/or damage to equipment if not
avoided.
WARNING
Indicates a hazardous situation that may
result in death or serious injury if not
avoided.
DANGER
Indicates a hazardous situation that will
result in death or serious injury if not
avoided.
NOTE
Failure to comply with any danger,
warning or caution, and any unintended
use or misuse, will result in loss of claim
for warranty or liability for equipment.
DANGER
Disconnect all power supplied to system
before performing any installation or
maintenance.
Failure to comply will result in death
or serious injury.
DANGER
All electrical wiring must be performed
by a fully certified electrician.
Failure to comply will result in death
or serious injury.
NOTE
Emphasizes useful hints and
recommendations as well as
information for efficient and trouble-
free operation.


Safety
Read and carefully observe installation
instructions before installing, operating or
troubleshooting referenced equipment.
Equipment must be installed, maintained
and repaired exclusively by persons familiar
with instructions.
While unpacking, verify unit is complete
and free from any damage. Install unit with
power supply cords and wiring secured away
from vehicle and other types of contact.
Do not place unit near or over radiator or
heat register. Verify unit is properly grounded
AFCS Enterprise controller must be
equipped with plug having third (grounding)
pin fitting only into grounding type outlet.
Remove power from controller unit before
attempting to clean or decontaminate.
External cleaning can be done with moist
towel. Use compressed air to remove dust
or other contaminants from inside
enclosure.
NOTE
Do not use AFCS Enterprise controller
without properly grounded outlet.
Failure to properly ground controller
may cause damage to unit or data
stored.
NOTE
Place locking device on eyelet of enclo-
sure to prevent unauthorized users from
accessing controller.
Introduction
AFCS Enterprise controller model 
controller integrates with otherAFCS
Enterprise components over system
network, allowing precise control and
tracking of oil dispense points.
Network configuration is performed
directly through LCD touchscreen interface.
This guide provides mounting, wiring and
configuring instructions and other helpful
information forAFCS Enterprise controller
model  installation and maintenance.
Product specification
Temperature range  to  °F (0 to 50 °C)
Net weight . lbs. (2,38 kg)
Input voltage - V AC, - Hz
Minimum current . A
Maximum current . A
Pulse switch voltage  V
Pulse switch current  mA
Analog input voltage range - V
Analog input current range - mA
Valve output voltage  V
Maximum valve output current . A
Fuse V A medium-acting
glass/ceramic  x mm)
Altitude Up to  m
Humidity Maximum RH % for temperatures
up to  °C decreasing to % RH at  °C
Transient over-voltage Category II
Mains supply voltage +/-% of nominal voltage
Table 
WARNING
Only use product under conditions
specified in document.
Failure to comply may result in death
or serious personal injury.
NOTE
Install socket-outlet near equipment in
a place that is easily accessible. Mains
plug is disconnect device.
WARNING
For indoor use only.
Failure to comply may result in
serious personal injury and/or damage
to equipment.
) Reference: Littelfuse MXP.
NOTE
Unplug controller from ACVoltage
source before servicing fuse. Verify fuse
holder is fully inserted before plugging
controller back into AC voltage source.


Fig. 
AFCS Enterprise network
Fig. 
AFCS Enterprise Hardware
2
3
4
1
5
6
7
8
9
1
23
56 7 89
5
4
4
3
2
C
B
A
Item Description
AFCS Enterprise web server
 AFCS Enterprise database
 Oil tank
Pump
 Tank level sensor
 AFCS controller
 Combo unit
 Hose reel
 PC/web browser
Item Description
A System line with wall-
mounted pump
B System line with tank-
mounted pump
C Line to hose reels
 Check valve
 Pump (wall or pump
mounted)
 Air supply
 Tank return line located
below check valve
 Pressure relief valve
 Shut off valve
 Filter
 Fluid solendoid
 Pulse meter


Fig. 
Controller overview
1
2
3
4
8
6
5
7
9
Item Description Quantity
/in universal bushing 
 Electrical enclosure 
 PCB mounting bracket and power supply 
 AC power entry module with fuse 
 Controller PCB 
 Ethernet port 
 PCB wire terminal 
 Touchscreen LCD display 
 Solenoid test button 


1.22 in
(31 mm)
Ø.185 in
(4,7 mm)
Ø.287 in
(7,3 mm)
1.22 in
(31 mm)
7.24 in
(183,8 mm)
6.06 in
(154 mm)
11.23 in
(285,3 mm)
0.61 in
(15,4 mm)
Mounting dimensions
Fig.  shows unit dimensions and wall
mounting hardware.
Fig. 


Combo unit
Model  all in one combo unit includes
solenoid, pulse meter and  micron filter.
Refer to form  for further
specifications.
Ready light – 
Optional ready light illuminates when fluid
solenoid is open and station is ready to
dispense. Ready light is hard wired into
combo unit. Refer to  wiring diagram
and instructions. Mount ready light near
combo unit, reel or work bench to be easily
seen by mechanic. Includes  ft. (0,6 m) wire
that connects from ready light to combo unit.
Fig. 
Fig. 
Combo unit
Ready light


Tank monitor probe Fig. 
Fig. 
5.9 in
150 mm
2 in
51 mm
2.8 in
71 mm
1)
2)
NOTE
 in dimension must remain  in or less.
Moving sensor tip further from threaded
end of adapter can cause sensor to work
improperly.
) /in NPT thread
)  in NPT thread
Use  in NPT mounting assembly to
mount sensor to standard  in bung for
optimal results. Sensor assembly comes
configured for mounting solution and can
be mounted to standard  in NPT tank
bung directly out of box. Default settings
in controller are setup and sensor settings
require no adjustment.
In cases where  in NPT bung is not
available and /in bung is available, there
is an option to disassemble  in NPT
mounting solution and use /in NPT
portion of fitting. Adjust sensor so that tip
is above bottom of /in NPT fitting and
adjust sensor configuration settings on
controller.
 Use wrench to disconnect /in NPT
fitting from larger assembly.
 Loosen lock nut from sensor and thread
back sensor so that tip of sensor is
recessed a maximum of /in above
bottom of /in NPT fitting (Fig. ).
 Tighten lock nut.
 Adjust tank standoff value in tank
settings on controller.
34/
/
/ in NPT
12
12
34
/ in
NPT
Fig. 


Fig. 
A
A
A
A
B B B
B
C
D
D D D
E
E
E
Fig.  shows if fluid level is at or above
blind zone, tank monitor system will read it
as % full.
A - Fluid level in tank
B - Blind zone for ultrasonic sensor -
All non-contact ultrasonic sensors have
an area close to the sensor that is
unable to be measured, known as the
blind zone.
C - Tank standoff value
D - Maximum fluid level sensor can read
E - Tank monitor reading
NOTE
Sensor range:  in (2 200 mm) to
 in (200 mm) from tip of sensor.


Configuration of tank monitor
To fully configure AFCS Enterprise controller
tank monitor features connect to computer
that is on same network as controller and
type IP address into browser URL.
Fig. 
NOTE
If AFCS Enterprise controller is using
static IP addressing, computer must
have same base IP address (first three
numbers in IP address) as controller,
and last number must be unique to
network. No other controllers or
computer can have it.
NOTE
Password is pin number used to log into
menu system accessible from LCD
screen on controller (Default: ).


For configuration options, go to Configure
tab on navigation banner at top of page.
Select tank to configure. Configure tanks
individually or all the same. Refer to Fig. ,
page .
•Save changes
•Tank Dimensions - Only required tank
dimensions for given tank shape will be
displayed for entry. Please reference tank
shape diagram to find the fields
corresponding to values.
•Sensor Maximum Range - Sensor
maximum range and inversion options are
for people not using Alemite tank monitor
sensor. In this case, maximum range and
inversion option for sensor being used
must be entered here.
NOTE
Do not forget to save changes before
leaving configuration screen. If you leave
screen without saving, configuration
parameters will be lost.
•Enable Monitoring - Enables or disables
tank monitor for chosen port. Only
enabled ports will have results displayed
in Monitor tab and Enterprise software.
•Fluid Type - New Fluids and Used Fluids
have different warning levels because new
fluid tanks are being emptied by pumps
and used fluid tanks are being
filled by pumps.
•Tank Volume Units - Tank volume units
can be measured in Gallons and Liters.
•Tank Dimension Units - Units used when
configuring tank dimensions. Available
options are Inches, Feet, Millimeters and
Meters.
•Tank Shape - Shape of tank is important
to calculate volume of tank. Choose tank
shape closest to tank. If tank that is desired
to be monitored has an irregular shape,
irregular shape tank option can be
selected. This presents option to fill in a
“look-up table” that corresponds a fluid
height to a percentage and volume.
NOTE
Do not use Calibration Settings or
Advanced Features unless you have
been through AFCS Enterprise training.
NOTE
Do not attempt to calibrate sensors
arbitrarily. Calibrating sensors to be
more accurate than default values
require extreme precision.
NOTE
Measurements should be taken from
inside of tank if tank has double wall.
•Warning Level - Volume of initial warning
level that alerts user that tank level
needs attention.
•Stop Level - Volume of stop level that will
prevent Enterprise software from allowing
further fluid dispensing from tank.
•Sensor Standoff - Distance between tip
of fluid sensor and top of tank.
•Maximum Fluid Height - Maximum
height of fluid in tank. By default this is
assumed to be maximum height of tank as
entered in Tank Dimensions section.
•Calibration Settings - Controller comes
with factory default calibration settings for
Tank Monitor probe kit. Default settings
are accurate within /in. If maximum
accuracy is needed, further calibration can
be accomplished on system by taking two
point measurement and entering precise
distances and raw analog value measured
by sensor. Two point measurement
calibration procedure is available from
touchscreen menu and described in
further detail there.
•Advanced Features


Fig. 


Fig. 
Monitor
If you are an Enterprise software customer,
all configuration options will be automatically
sent to Enterprise software.


Cat  or  ethernet network wiring for networking controllers
 Pull cable off reel to desired length and
cut. It is easier to attach RJ- plugs after
cable is pulled if pulling cable through
holes. Total length of wire segments
between two points cannot exceed  ft.
(100 m).
 Start on one end and strip cable
jacket off (about  in (25 mm)) using
stripper or knife.
 Spread, untwist pairs, and arrange wires
in order of chart above.
 Flatten end between thumb and
forefinger. Trim ends of wires evenly,
leaving only /in (13 mm) in wire length.
If longer than /in (13 mm) it will be out
of specification and susceptible to
crosstalk.
 Flatten and ensure there are no spaces
between wires.
 Hold RJ plug with clip facing down,
away from body.
Blue and blue/white
Brown and brown/white
Green and green/white
Orange and orange/white
 Push wires firmly into plug.
•Inspect each wire is flat at
front of plug.
•Confirm order of wires.
Double check again.
•Verify jacket is fitted flush against
stop of plug.
 Carefully hold wire and firmly crimp RJ
with crimper.
 Analyze color orientation, verifying
crimped connection will not come apart,
and make sure wires are flat against
front of plug. Must start over if one
requirement is incorrect.
 Test ethernet cable.
Ethernet cable tips
•Odd numbered pins are always striped;
even numbered pins are always solid
colored.
•Looking at RJ with clip facing away,
brown is always right, and pin  is left.
•No more than /in (13 mm) of
ethernet cable should be untwisted
otherwise it will be susceptible to
crosstalk.
RJ PIN # Wire color (TB) Wire diagram (TB)  base–T signal  base TX signal  base–T signal
 White/orange Transmit+ BI_DA+
 Orange Transmit –BI_DA–
 White/green Receive + BI_DB+
 Blue Unused BI_DC+
 White/blue Unused BI_DC –
 Green Receive- BI_DB–
 White/brown Unused BI_DD+
 Brown Unused BI_DD–
Pin position
Fig. 
Pin positions
Fig. 
Wire identification colors






NOTE
Do not damage wire during stripping
process or wire will be need to be
replaced.
NOTE
When handling ethernet cables:
•Do not deform.
•Do not bend.
•Do not stretch.
•Do not staple.
•Do not run parallel with power
cables.
•Do not run near noise inducing
components.
Table 


Fig. 
A
(+)
(-)
(+)
(-)
(+)
(-)
J
K
L
B
D
C
EFG
H
21
34
1
2
4
3
(+)C
E
B(-)F
Wiring diagram
Fig.  shows wiring connections from
hardware to controller wiring terminals.
Four conductor AWG shielded cable (A)
is recommended.
Configure controller
Once controller wiring connections are
complete, assign each controller unique unit
number for each site and site number, then
configure each controller to network.
•Assign unit number and site number.
•Obtain MAC address.This is based on unit
number and site number.
•Assign IP mode (static or DHCP).
•Configure network settings (static
mode only).
DANGER
Disconnect all power supplied to
controller before performing installation
or wiring.
Failure to comply will result in death
or serious injury.
Item Description Item Description
AConductor  AWG shield cable () E Analog signal
- ft. (30,48 m) FBlue wire
- ft. (76,2 m) GTank sensor
- ft. (152,4 m)
BBlack wire (not used) H Combo unit (refer to service page )
CBrown wire J Solenoid valve cable connection (+ and -)
D White wire K Pulse switch cable connection (+ and -)
L Cable shield ground connection
NOTE
Do not exceed  ft. (60,96 m) with
 AWG cable when connecting solenoid
and pulse meters. Individual cable
lengths should be  ft. (30,48 m) or
less.
NOTE
Apply power and configure controller
before connecting to network via
ethernet networking cable.
NOTE
Assign each controller unique unit
number for each site.
Unit and site numbers are used to
generate a unique MAC address for each
controller.


1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
your
password
Unit Number 1 is online at 10.10.10.1
Full operating mode & communicating
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
your
password
X
Currently in
Normal Operating
Mode
(not override)
Switch to
Override
(allows manual
dispenses with no
computer access)
Switch to Automatic
(goes to override
when the network
seems to be down)
X
PasswordTank Monitor
DHCP: OffIP Address
Site: 1Controller: 1
MAC Address
00:50:C2:77:D1:01
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
this
dispense
unit’s
number
(1-30)
This is
currently
unit #1
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
this
dispense
unit’s
site
number
(1-30)
This is
currently
site #1
X
Switch to DHCP mode
Currently in Static IP mode
X
IP Address: 10.10.10.2
Subnet Mask: 255.255.255.0
Default Gateway: 10.10.10.200
MAC Address
00:50:C2:77:D1:01
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
the
new
password
The current
password
Is:
1234
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
the
default
gateway
address
The current
default
gateway
address
Is:
10.10.10.200
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
the
subnet
mask
address
The current
subnet
mask
address
is:
255.255.255.0
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
the
IP
address
The current
IP address
Is:
10.10.10.1
Fig. 


Fig. 
Unit Number 1 is online at 10.10.10.1
1: Hose 1
10W40
Idle
2: Hose 2
10W30
Idle
5: Hose 2
10W30
Idle
3: Hose 3
5W30
Idle
6: Hose 3
5W30
Idle
4: Hose 4
10W40
Idle
Full operating mode & communicating
13
14
11
15
16
12
17
To configure controller:
 Power on controller and wait for start up
screen to display (Fig. ).
 Select top screen button ().
 Enter password. Default password is 
or .
 Select Unit or Site to assign controller unit
number and site number
(Fig. , page ).
 Select IP mode (static or DHCP) for
network. Controller default is static.
 Select Unit Network Settings.
MAC Address is displayed at top.
MAC address
IT network administrator may require MAC
address of each controller. MAC addresses
are used for network identification and for
issuing IP addresses on DHCP-enabled
networks.
Item Description Item Description
 Unit configuration access  Tank fluid
 IP address  Hose status
 Terminal block  Operating mode
 Hose


Unit network settings (static
mode)
If network is running in static mode, enter
network settings for each controller.
•Fixed IP address
•Subnet mask
•Default gateway
To enter unit network settings:
 Power on controller and wait for start up
screen to display (Fig. , page ).
 Select top screen button ().
 Enter password. Default password is 
or .
 Select Unit Network Settings (Fig. ).
Enter IP address.
 Enter Subnet Mask address.
 Enter Default Gateway address.
DHCP mode
For networks in DHCP (Dynamic Host
Configuration Protocol) mode, IP addresses,
subnet masks and default gateways are
automatically assigned to controllers.
Operating modes
There are three operating mode options for
controllers:
•Normal operating mode - Controller is
operating normally. Fluid dispensing is
controlled by requests made through
AFCS Enterprise software.
•Switch to override - Manually initiates
override mode in event of network outage.
•Automatic mode - In event of network
outage exceeding  minutes, controller
switches automatically into override mode.
Fig. 
Fig. 
X
Currently in
Normal Operating
Mode
(dispenses done
via computer)
Switch to Automatic
(goes to override
when the network
seems to be down)
Switch to Override
(allows manual
dispenses with no
computer access)
XUnit : 1 Site: 1
IP Mode : Static
Unit Network Settings
Change Password
NOTE
Controller override mode is an operating
mode where all outputs are turned on
and all hoses can be used.
AFCS Enterprise system captures
total dispensed fluid volumes and sends
report to AFCS Enterprise software
when controller returns to normal oper-
ating mode while mode is active.
NOTE
Controllers function by default in static
mode.


Fig. 
Tank monitor
functions
Unit Number 1 is online at 10.10.10.1
Full operating mode & communicating
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1: Hose 1
10W40
Idle
1
4
7
DELETE
2
5
8
0
3
6
9
OKX
Enter
your
password
X
PasswordTank Monitor
DHCP: OffIP Address
Site: 1Controller: 1
MAC Address
00:50:C2:77:D1:01
X
Sensor Characteristics
Sensor StandoffCalibrate
Tank Monitor
X
Factory Default
Tank Sensor Testing &
Calibration
Perform a Sensor Calibration
Display Live Sensor Readings
X
Tank Sensor Calibration
OK
If you change a sensor, a standoff tube ,
the controller or controller port it’s wired
to, you must recalibrate . The sensor must
be mounted in its standoff tube, standing
upright on a hard flat surface beneath the
tube, simulating a fluid level reaching the
bottom of the tube. The green and yellow
sensor lights should be lit .
(1)
Tank: #1
Fluid: Name
(2)
Tank: #2
Fluid: Name
(3)
Tank: #3
Fluid: Name
(4)
Tank: #4
Fluid: Name
(5)
Tank: #5
Fluid: Name
(6)
Tank: #6
Fluid: Name
X
Select the sensor to calibrate
(1)
Tank: # 1
Fluid: Name
(2)
Tank: #2
Fluid: Name
(3)
Tank: #3
Fluid: Name
(4)
Tank: #4
Fluid: Name
(5)
Tank: #5
Fluid: Name
(6)
Tank: #6
Fluid: Name
X
Select a tank sensor to reset to
factory default calibration
X
Live Sensor Readings
Compute
Average
Port # 1
ADC 7
7.25"
Port # 4
ADC 9
7.25"
Port # 2
ADC 11
7.25"
Port # 5
ADC 14
7.25"
Port # 3
ADC 8
7.25"
Port # 6
ADC 16
7.25"
X
Tank Sensor Calibration
OK
To get accurate tank levels, you must
measure the Sensor Standoff distance.
This is the distance from the bottom tip of
the sensor to the highest point inside the
tank that the fluid is allowed to reach.
That point is the Maximum Fluid Height.
The sum of Maximum Fluid Height & the
Sensor Standoff must be the distance from
the tank bottom to the sensor tip.
(1)
Tank: #1
Fluid: Name
(2)
Tank: #2
Fluid: Name
(3)
Tank: #3
Fluid: Name
(4)
Tank: #4
Fluid: Name
(5)
Tank: #5
Fluid: Name
(6)
Tank: #6
Fluid: Name
X
Select a Tank Sensor
AFCS Enterprise controller parts/kits
Part number Description
 AFCS Enterprise ethernet switch kit
- AFCS Enterprise combo unit cable  ft. (30,48 m)
- AFCS Enterprise combo unit cable ft. (76,2 m)
- AFCS Enterprise combo unit cable  ft. (152,4 m)
 AFCS tank monitor probe with cable  ft. (14,3 m)
Table 


Troubleshooting
Condition Cause Solution
Fluid will not come out of meter. Master air solenoid is not opening. Check if air solenoid opens after dispense is
initiated. Red light will be visible on controller board for port
assigned to air solenoid. Air solenoid will make easily
detectable air release sound when solenoid shifts from
open to close.
No air supplied to pump. Check that ball valves to pump are open for air and any
ball valves for fluid are open in tank room and by reel.
Fluid solenoid will not open. Check if ready light and red solenoid light on controller
board are activated. Wiring is presumably wrong if red
LED is activated on DU but not on ready light. Solenoid
is possibly bad if both lights are on and action items
 and  are good.
Pump does not run or needs repair. Check to see if pump cycles if air is supplied.
Pump needs to be repaired if it does not.
Ready light is always on/fluid can
always dispense.
Timeout setting for system is
set very high.
Change timeout setting to more reasonable time.
Controller unit in Override Mode.
This can be done if settings have been
configured for automatic override or
via touchscreen. Occurs if computer
network is not functioning for longer
than  minutes.
If override has been activated manually return controller
to normal operating mode via touchscreen. If automatic
override has been activated inform network administrator
of network outage.
Dispense unit is not working
properly.
Replace unit.
Pulse meter will not work but fluid
is flowing.
Pulse meter is not hooked up to DU. While dispensing, yellow indicator light should flash very
fast, appearing almost as if it is on. Replace
wiring and/or pulse meter if unit is not flashing.Pulse meter needs replaced.
Device not communicating. Multiple devices with same unit
number/site number combination
or same static IP address assigned.
Verify device has unique unit number/site number
combination and/or unique static IP address assigned.
Network cable is not correct. Check network cable to make sure all device are plugged in
and network wire checks out with network analyzer tool.
Note: Network analyzer can be purchased from any
hardware store. Device will connect to both end of wires to
alert if terminals are correct.
Device is not plugged in. Plug in network cable to device.
Power is not turned on. Plug in device to power.
Unit is dispensing more or less than
expected.
PPU settings not correct for
specific unit.
Measure unit several times with calibrated measuring device
like Seraphin tank to find exact PPU for fluid and pulse meter.
Refer to PC software manual for further instructions.
PC can not find any devices. PC software is not setup correctly. Analyze PC software to ensure device is checked under
hardware tab. Refer to PC software manual for further
instructions.
Tank level sensor reads full tank
despite tank level not being full
Sensor detects something in blind
zone.
Check to make sure sensor tip is mounted no more than  in
from top of open tank, and there are no obstructions in sensor
path. Tank fluid level must also be out of sensor blind zone to
begin registering levels below full. Sensor blind zone is  in
closest to tip of sensor.
