Balcrank Fusion 3110-027 Reference manual

3110-027
3110-029
SERVICE BULLETIN SB3092
Rev C 9/17
Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
INSTALLATION AND CONFIGURATION GUIDE
fusion 2.4 - DCS
®
Model 3110-027������������������������������������������������������������������������������ Master Keypad
Model 3110-028��������������������������������������������������������������������������Dispense Keypad
Model 3110-029��������������������������������������������Dispense Keypad w/internal printer
3110-028
8

CONTENTS
INTRODUCTION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
System Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
 SystemCompositionandDataow..........................................5
 Specications........................................................6
 Certication . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation/Mounting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Keypad Description � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
Operation Modes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
MASTER KEYPAD � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
System Version Screen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10
Settings Overview / Supervisor Menus � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
Initialization (INI) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
 Conguration(CNF)Menu... . . . ...... . . . ...... . . . . ...... . . . ...... . . . . ...11
Test Communication (DK) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �13
Reports (REP) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
Radio (RAD) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
DISPENSE KEYPAD � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17
System Version Screen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �17
Settings Overview / Supervisor Menus � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17
 Conguration(CNF)Menu. . . . ..... . . ..... . . . ..... . . ...... . . ..... . . ...... 18
Delete Prepared WOs (MET) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
Reports (REP) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
190 (Internal Ticket Printer) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �22
 RFCommunicationTest(LNK)Menu.........................................22
Radio (RAD) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23
Network Connect (CON) Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24
 SystemOverride (SYS)Menu... ................................. ..... .....25
 DispenseKeypadMenuOverview . .... . ..... . .... . .... . ..... . .... . ..... . ...26
DISPENSE PROCESS � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �27
Starting a Work Order � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
FUSIONRF METER . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .29
Key Description � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29
 RFMode(StandardPre-SelectionMode)......................................30
Changing the Battery � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31
 Programmingthe FusionRFMeter...... ......... ........... ........... .....31
INSTALLINGANDLAUNCHINGTHE FMS SOFTWARE................ . . . . . . . . . . . . . . . . 32
System Requirements � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
 FMSSoftwareDescription... . . . . . ........ . . . . . ....... . . . . . ........ . . . . . .32
 InstallingtheFMS Server.. .... ... .... ... ....... ... .... ... .... ... .... ... .33
 InstallingtheFMS Client .... . .... .... . .... . .... .... . .... . .... ..... .... . ..36
 LaunchingtheFMS Software... .... .... .... .... .... .... ... . ... . ... .... ....38
 FMSSystemConguration .... . ... . .... .... .... .... .... . ... . .... .... .... .38
USING THE FMS SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Setting Up New Users � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39
 SettingUpTanksandFluids. ... .... .... .... ... .... .... .... ... . ... .... .... 40
Setting Up Keypads and Hoses � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 43
System Settings � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 47
2

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 . . ........ . . . . . ....... . . . . . ........ . . . . . ....... . . . . 53
 TanksandFluids.. . ..... . . ..... . ..... . ..... . . .... . . ..... . ..... . ..... . .55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
 DispenseKeypadErrorMessages...........................................56
 MeterErrorCodes . ..... . .... . .... . ..... . .... . ..... . .... . .... . ..... . ...56
WORKSHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INTRODUCTION
TheFusion2.4FluidManagementSystemhasbeendesignedtocontrolandmonitortheconsumptionand
inventorybalancesofautomotiveuidproductswithminimalinstallationandprogrammingcosts.
TheDistributedControlSystem(DCS)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manages
serialcommunicationtothePCandRFcommunicationtotheDispenseKeypadsinthesystem.Thesystem
veriestheoperator’spinnumberandvalidatestheworkordernumber,uidquantitiesandthevalidhose/
meter�
TheMasterKeypadcancommunicatewithupto36DispenseKeypadsthatcanbepositionedtosupportthe
workowofthefacilitythebestway.EachDispenseKeypadcancontrolupto24meters,withamaximumof
250meterspersystem.Thesystemsupportsupto16tanksand16uidsasapartofthesystemcongura-
tion.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300feetwithunob-
structedline-of-sight.Aremoteantennaisavailableforsituationswheremultiplebuildingsareinvolvedinthe
installationorobstructionshinderRFtransmission/reception.
ThePCisusedtocongurethesystem,maintainsystemdataandenterworkorders.Theservicedeskwould
usethePCtoenteraworkorderselectingtheuid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exibility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.Option-
ally,thesystemcanbeconguredtoallowservicepersonneltofreelyenterworkorders,withoutthemrst
beingenteredatthePC.
Thereareanumberofsystemutilizationreportsbyuser,uidtype,tankormetersavailableforthesystem’s
management�
Aunique,patentedfeatureofthesystemisthattheRFmeter’sdispensetriggerislockeduntilanauthoriza-
tionfromthekeypadisreceived.Afterthedispensebatchiscompleted,theusercantopo󰀨ifmoreuid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o󰀨eringcontrolandmonitoringofhigh-cost
lubricationproducts.
3

4
System Overview

The main data streams:
1.TheFMSsoftwarestoresthecongurationdatainitsdatabase.
2.ByusingtheInitializeSystemmenuoftheFMSsoftwarethecongurationdatais
senttotheMasterKeypadviatheserialinterfaceandnallyviaradiotoallDispense
Keypads�
3.TheFMSrecordsalldispensesinthedatabase.
5
System Composition and Dataow

6
Certication
•ContainsFCCID:S4GEM35XB
•ContainsIC:8735A-EM35XB
•FCCCERTIFIED,PART15,SUB-PARTC
•CE0681EC-R&TTECertied
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opera-
tion�
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)
Specications
WARNING
!
TosatisfyFCCRFexposurerequirementsformobiletransmitting
devices,aseparationdistanceof20cmormoreshouldbemain-
tainedbetweentheantennaofthisdeviceandpersonsduring
operation.Toensurecompliance,operationsatcloserdistances
than this are not recommended�
NOTE
It is highly recommended to use surge
suppressors for AC power connections
on all keypads� Warranty does not cover
damage due to power surge
!
CAUTION
Ifthereareanyotherwirelessdevices/networksinthefaciltiy,
ensure that they are powered up and active before powering up
thefusionkeypad(s).Thisissofusioncandetectandavoidany
otherwirelessdevices/networksinthefacility/area.
!

7
7-5/8”
3-13/16”
7-3/8”
Figure1:KeypadInstallation
(HolesonKeypadareThreadedforM6x1Screw)
MountingDimensionsforKeypad
Keypad Installation
•Mountthekeypaduprightwiththeantennapointingupward,neara120VACelectricaloutlet.
•Mountthekeypadtoastructurallysoundwallthroughthetwoholesonthetopofthekeypadcaseandone
holeonthebottomofthekeypad.
•Heightonthewallshouldbe5feetto6feet.
•Avoiddirect,signicant,heatsources.
•Donotmountthekeypadonorbehindanysteelobjects(toolstoragecabinets,metalwalls,metalbeams
ormetalchainlinkfences)thatmayinterferewithorblocktheRFcommunicationsignals.

8
Keypad Keys
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.
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�
Keypad Description
Function Signal Name PIN
Received Data CarriesdatafromDCEtoDTE RxD 2
Transmitted Data CarriesdatafromDTEtoDCE TxD 3
Common Ground ---- GND 5
9
5
1
6
-PCfunctionsasDTE(DataTerminalEquipment)
-KeypadfunctionsasDCE(DataCommunicationsEquipment)
-PCtoKeypadconnectionismadeusingstandard9-pinmaleto9-pinfemaleserialportcable

9
Operation Modes
Theconguration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congure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uidandamounttobedispensed.
TheresultsofthedispensewillthenbestoredonthePC.
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.ThismodestillrequiresaPCwiththeFMSsoftwareinstalledforinitialsetup.
NOTE
Each meter can only be associated with
one Dispense Keypad�All system users can
access each of the Dispense Keypads
!
NOTE
Maximumof24metersperdispensekeypad
!
IMPORTANT
The PC must be equipped with a physi-
cal9-PinSerialInterface,aUSBtoSerial
Convertor will not work
!

10
Enter time
--:--
Time and Date Screens
To change or set the system time:
1� Select the INI menu and press Enter�
2.Usethenumerickeystoseta24-hourmilitarytimeofday.
3� Press Enter to save the setting and advance�
To change or set the system date:
1� Use the numeric keys to enter the two-digit day
The cursor automatically moves to the month�
2� Press the Scroll key to select a month�
3.Usethenumerickeystoenterthefour-digityear.
4� Press Enter to save the setting�
Enter date
19/aug/2012
TheMasterKeypadactsasthecommunicationsdirectorfortheRFcommunications.Ithandlesallcommuni-
cationsbetweentheDispenseKeypadsandthePC.TherearenooperatormenusassociatedwiththeMaster
Keypad—onlysupervisormenusforsettingupthesystemorcreatingreports.
Theremainderofthisdocumentshowsonlytheactualdisplay,nottheentirekeypad.
Togainaccesstothesupervisormenus,thesupervisorPINhastobeentered.ThedefaultPINis0001at
initial power-up�
System Version
16aug2012 08:35
V3.00
Thestandardscreenshowsthesystemdateandsoftware
versionnumber.Thedisplaywillalternatebetweenthestan-
dard screen and the Enter Pin Number screen� The Enter
Pin Number screen is used to access the supervisor menus�
Enter Pin No.
- - - -
NOTE: An “N” displayed in the lower left-hand corner of
the system version screen indicates a Radio Network error�
See“Radio Status”onpage23tocheckthesourceofthe
error�
Settings Overview / Supervisor Menus
ThefollowingchangescanonlybemadeattheMasterKeypadinthesetupmode.Allothersettingscanbe
changedbyusingtheFMSsoftware.
The INImenuisusedtosetthesystem’sdateandtime.
16aug2012 08:35
V3.00
N
Enter PIN Number
Toaccessthesetupmode:
EnterthesupervisorPINnumberandpressEnter�
ThedefaultPINis0001atinitialpower-up.
Select
INI CNF MET REP
INITIALIZATION (INI) MENU
Enter date
--/jan/----
Master Keypad