FUEL MASTER AIM 2 User manual

INSTALLATION
MANUAL
9 OCTOBER 2009
Syn-Tech Systems, Inc.
P.O. Box 5258
Tallahassee FL 32314
www.syntech-fuelmaster.com

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TABLE OF CONTENTS
SECTION 1 - GENERAL INFORMATION ................................................................. 7
Proprietary Information ...................................................................................... 7
Introduction....................................................................................................... 7
Purpose ............................................................................................................ 7
Safety Precautions and Corrective Actions ......................................................... 8
Protecting Against Electrostatic Discharge .............................................................. 8
Correcting RF Interference ..................................................................................... 8
Certification/Approval ........................................................................................ 9
WARNINGS, CAUTIONS, and NOTES ................................................................ 9
FuelMaster
®
Warranty........................................................................................ 9
Initialization Requirement ..................................................................................10
Safety Related Inspections and Preventive Maintenance .....................................10
Consumables/Special Tools ...............................................................................10
Improvements ...................................................................................................11
SECTION 2 – SYSTEM DESCRIPTION ...................................................................13
FuelMaster
®
Passive Fueling..............................................................................13
Typical Fueling Transaction ..........................................................................13
Installation Requirements .............................................................................15
Components of a Passive Fueling System ..........................................................15
FMU-3500 and FMU Upgrades ......................................................................15
FMU-3535 Passive Mobile ............................................................................16
Automotive Information Module .....................................................................16
AIM2™ Module External Antenna ..................................................................17
Access Point ................................................................................................17
AIM2™ Programming Key .............................................................................17
Nozzle Tag ..................................................................................................17

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TABLE OF CONTENTS (con’t)
Programming Hose Tag (PHT) ......................................................................17
Filler Neck Rings/RFID Interface Module .......................................................19
Connecting Cables .......................................................................................19
SECTION 3 - SYSTEM PLANNING .........................................................................23
Fundamental Do’s/Don’ts...................................................................................23
Version Compatibility.........................................................................................26
Developing a Database of Vehicle Records ........................................................26
Selecting the Correct Nozzle Tag .......................................................................26
Selecting the Correct Filler Neck Ring and RFID Extension Cables......................27
Selecting the FMU Mounting Location ................................................................28
Identifying the Vehicle Application......................................................................29
SECTION 4 – AIM2™ INSTALLATION ....................................................................31
Installation Options ...........................................................................................32
Using the OBD Port ......................................................................................33
Using a Vehicle Speed Sensor (Odometer) Input Only....................................34
Using an Analog Chronometer Input ..............................................................36
AIM2™ Post Installation Tests ...........................................................................39
SECTION 5 – AIM2™ PROGRAMMING...................................................................41
Develop an FMU-3500 Programmer....................................................................41
Configure an FMU-3500 as an FMU-3500 Programmer...................................41
Through a Laptop Connection ..................................................................41
Through the Central Controller.................................................................42
Develop a Portable FMU-3500 Programmer
from a Fully Configured FMU-3500................................................................42
Develop an FMU-3500 Programmer from an FMU-3500 Demonstration Unit.............. 43
Create an AIM2™ Programmer Prokee
®
/Smartcard ...........................................................44
Programming the AIM2™ Module ............................................................................ 46

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TABLE OF CONTENTS (con’t)
Program an AIM2™ .............................................................................................. 46
Calibrate AIM2™ ..........................................................................................48
Change the AIM2™ Interface ........................................................................51
Clean the AIM2™ ................................................................................................. 53
SECTION 6 – ACCEPTANCE TEST PROCEDURE (ATP).........................................57
Acceptance Test Procedure (ATP) for Commercial
Installations, Upgrades, Startup, and/or Training
Of FuelMaster
®
AIM2™......................................................................................57
SECTION I
PRE-UPGRADE ................................................................................................ 58
UPGRADE SOFTWARE..................................................................................... 58
UPGRADE FMU(S)............................................................................................59
OPERATIONAL CHECKS .................................................................................. 59
SECTION II
AIM2™ SOFTWARE OPERATIONS ................................................................... 60
AIM2™ FMU CONFIGURATION......................................................................... 61
TRAINING ........................................................................................................ 61
TRAINING ATTENDEES.................................................................................... 62
VEHICLE DATA ................................................................................................ 62
SITE DATA ....................................................................................................... 63
NATIONAL ELECTRIC CODE (NEC) COMPLIANCE ........................................... 64
EXCEPTIONS ................................................................................................... 64
COMMENTS/SUGGESTIONS ............................................................................ 64
SIGNATURE AND FINAL SIGN-OFF ....................................................................... 65
Hold Harmless Agreement ............................................................................66

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FIGURES AND TABLES
Table 2-1. AIM2™ OBD Data Collection Parameters ................................................14
Figure 2-1. FMU Radio Board (FRB)........................................................................15
Figure 2-2. AIM2™ Modules ...................................................................................16
Figure 2-3. Sample Nozzle Tag ..............................................................................18
Table 2-2. Nozzle Tag Applications ........................................................................18
Table 2-3. Nozzle Tag Clamp and Kit Part Numbers ................................................19
Figure 2-4. AIM2™ Vehicle Components ................................................................20
Figure 2-5. OBD II Pass-Thru Cable .......................................................................20
Table 2-4. Filler Neck Rings...................................................................................21
Table 2-5. Connecting Cables and Devices.............................................................22
Table 3-1. Version Compatibility ............................................................................26
Figure 3-1. CV Joint Boot Clamp Pliers ..................................................................27
Figure 3-2. Sample Nozzle Tag Installation.............................................................28
Figure 3-3. OBD Connectors ..................................................................................29
Figure 4-1. AIM2™ Connection – Flow Chart ..........................................................32
Figure 4-2. AIM2™ Module Layout .........................................................................33
Figure 5-1. 4x4 Keypad Shift Instructions ...............................................................46
APPENDICES
Access Point Installation and Setup Procedure ......................................................TBD
ATTACHMENTS
Acceptance Test Procedure (ATP) for Commercial Installations, Upgrades, Startup,
and/or Training of FuelMaster
®
AIM2™ (blank)
Hold Harmless Agreement (blank)
AIM2™ Installation Notice
AIM2™ Vehicle Installation Worksheet (blank)

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SECTION 1
GENERAL INFORMATION
Proprietary Information
This FuelMaster®AIM2™ Installation Manual is copyrighted 2009. Any unauthorized duplication,
distribution, or disclosure to third parties without specific written authorization from Syn-Tech Systems,
Inc., P.O. Box 5258, Tallahassee, FL 32314, is a violation of the law. FuelMaster®firmware and
software are copyrighted 2009, and are provided under a license agreement containing restrictions on
its use. Except as stated in the license agreement, the firmware and software may not be copied or
distributed in any form or medium or disclosed to third parties. Users are legally accountable for any
violation of the License Agreement or of copyright law.
Introduction
This manual provides installation and setup instructions for the Syn-Tech Systems, Inc., FuelMaster®
AIM2™ Automotive Information Module (herein referred to as AIM2™) and associated equipment.
These instructions have been prepared for the exclusive use of installation technicians who are
qualified to complete electrical work on vehicular electrical systems. AIM2™ consists of equipment
developed to initiate passive fueling through a FuelMaster®FMU-3500 Fuel Management Unit, or a
FuelMaster®FMU-3535 Passive Mobile Fuel Management Unit.
Passive fueling, as used in this context, is the initiation of a fueling transaction by the AIM2™
equipment without the need for operator input. The fueling customer pulls his/her vehicle up to the fuel
dispenser (or fuel truck), takes the fuel nozzle down from the dispenser, and inserts it into the vehicle
fuel filler neck. This action prompts the AIM2™ equipment in the vehicle to transmit authorization via
RF (radio frequency transmission) to the FuelMaster®FMU-3500/3535 which, in turn, activates the
fueling hose. When complete, the fueling customer returns the nozzle to the dispenser, returns to
his/her vehicle and drives away. The FMU-3500/3535 records the fuel transaction and stores the
fueling information until downloaded by the FuelMaster®Fuel Management Software operator.
Purpose
FuelMaster®fuel accounting and control provides Syn-Tech’s customers with a means to control
access to metered products at self-service service stations, and to account for and invoice for the
dispensed products. FuelMaster®accomplishes this with security from unauthorized user access while
maintaining complete accountability of each transaction as it occurs. FuelMaster®passive fueling
provides for secure, accountable control of fuel dispensing without direct user access of the fuel
management system. Transaction data is compiled after downloading data to a central accounting
office hundreds, or thousands of miles remote from the servicing operations.

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Safety Precautions and Corrective Actions
NFPA 70, the National Electrical Codes (NEC), define a fuel dispensing site as a hazardous location
and contains guidelines for the installation and operation of any equipment in such a location. NFPA
30, Flammable and Combustible Liquids Code, contains guidelines for electrical equipment and
installations in areas where Class I liquids are stored or handled, and where Class II or Class III
liquids may be stored at or above their flash points. The installer must be knowledgeable of these
and any other applicable safety codes and standards. All FuelMaster®passive fueling equipment
complies with applicable federal, state, and local safety codes and standards.
This manual makes recommendations for 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 passive fueling equipment.
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.
Use the following guidelines during installation and maintenance to help protect your passive fueling
equipment from potential damage and ensure your own personal safety:
Protecting Against Electrostatic Discharge
Static electricity can harm delicate AIM2™ components. To prevent static damage, discharge static
electricity from your body by touching an unpainted metal surface before you touch any AIM2™
electronic components.
As you continue to work with AIM2™, periodically touch an unpainted metal surface to remove any
accumulated static charge. Use of a wrist-grounding strap is highly recommended.
The following steps should also be taken to prevent damage from electrostatic discharge (ESD):
•Keep a static-sensitive component in its antistatic packing material until ready for use. Just before
unwrapping the antistatic packaging, discharge accumulated static electricity by touching an
unpainted metal surface.
•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.
Correcting RF Interference
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;

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•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.
Certification/Approval
The equipment supplied with AIM2™, FMU-3500, and FMU-3535 is tested and safety certified
by Intertek’s ETL SEMKO Division. Nameplates displaying the ETL logo are affixed to the AIM2™
module, FMU-3500, and FMU-3535.
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 Passive Mobile equipment.
FuelMaster®Warranty
The basic warranty on all FuelMaster® equipment begins 12 months after the completion of
initialization or 15 months after shipment from Syn-Tech Systems. Initialization must be completed
by a Syn-Tech Systems FuelMaster® technician, or a technician who has completed Syn-Tech
Systems installation certification training. 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 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 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

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manufactured by Syn-Tech Systems are warranted only to the extent covered by the original
manufacturer. Additionally, warranty is limited to approved locations (generally the continental
United States) and is not transferable except by written permission of Syn-Tech Systems.
Initialization Requirement
All FuelMaster® Fuel Management Systems must be initialized by Syn-Tech trained personnel.
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
installation certification training for AIM2™. Final certification must be accomplished jointly by the
Customer and Syn-Tech trained personnel.
Safety Related Inspections and Preventative
Maintenance
AIM2™ requires no preventative maintenance to retain its user safety features. Whenever AIM2™ is
updated or repaired, a post-installation safety inspection should be performed of all wire connections
and hardware installations.
Consumables/Special Tools
Consumable/Special Tool Application
CV joint boot clamp pliers Crimp nozzle tag security clamps
Dielectric grease Prevent corrosion and protect electrical
connections exposed to the environment
12 AWG THHN stranded wire (Green) AIM2™ module ground wire(s)
Wire loom Cable/wire protection
Rubber grommets Protect cables/wires routed through drilled holes
Silicon sealant (GE blacktop/roof, 100% silicon) Seal grommets
Cable ties (black UV protected) Secure cables/wires
3M Scotch® Rubber Mastic Tape 2228 Weatherproof RFID Interface Module
18 AWG THHN stranded wire (Red, Black, Speed sensor wires
Green, White, Brown)
18 AWG THHN stranded wire (Orange, Analog chronometer wires
Blue)
AC power cord w/18 AWG conductors Power cable for FMU-3500 Programmer
and male plug