Syn-Tech Systems FuelMaster FMU-2500 Classic User manual

Fuel
Management
Unit
(FMU)
Installation
Manual
FMU-2500, 3000, 3500,
Classic and Plus,
Commercial and DoD
24 May 2013
SYN-TECH SYSTEMS, INC.
100 Four Points Way
Tallahassee FL 32305
800-888-9136 Toll Free
850-878-2558
850-877-9327 Fax
www.myfuelmaster.com

i
ADDENDUM
The following necessary changes/additions to the Fuel Management Unit
(FMU) Installation Manual dated 24 May 2013 have been identified. Insert
this Addendum inside the manual title page. Changed text is in italics.
Location of the change/addition is identified in the manual with a
checkmark .
1. Procedures were not included for attaching the FMU Upper Cabinet to the
FMU Pedestal. Following are actions necessary to complete this procedure:
a. Text to be entered on page 67 between
FMU Installation
, and
Mounting the FMU
Pedestal
:
As it is removed from the shipping container, the FMU Pedestal will have some cables
connected on one end only, and stowed in the Pedestal near the Relay Assembly(ies).
These
cables will be connected in the FMU Upper Cabinet after the Pedestal is
mounted, and the
necessary wire and cable connections are made.
b.
NOTE
to be inserted before step 3, page 72:
NOTE
If being performed as part of a new FMU installation, omit step 3 until after the FMU
Upper Cabinet is installed.
c.
NOTE
to be inserted between steps 11) and 12) on page 87:
NOTE
The following procedures cannot be performed until the FMU Upper Cabinet is installed,
and power is applied to the FMU.
d. NOTE to be inserted on page 94 before “Perform the following to configure Monitor
Mode:”
NOTE
The following procedures cannot be performed until the FMU Upper Cabinet is installed,
and power is applied to the FMU.
e. Insert 2nd paragraph/bullet to NOTE on page 95 before step 6):
•The PULSE FILTERING dipswitch is located in the FMU Upper Cabinet. If it is necessary
to turn on the PULSE FILTERING dipswitch, do so after installing the FMU Upper
Cabinet.
f. NOTE to be inserted before step e on page 99:
NOTE
The PULSE FILTERING dipswitch is located in the FMU Upper Cabinet. If it is necessary to
turn on the PULSE FILTERING dipswitch, do so after installing the FMU Upper Cabinet.
g. Add to Section 4, page 100, after 8f, before 9. Tank Monitor Interface:

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Install FMU Upper Cabinet
. See Figure 4 ‐ 26a. Installation of the FMU Upper Cabinet
should be delayed until it is necessary to complete the installation. If desired, the FMU
Upper Cabinet may be rotated 180 degrees before installation to accommodate
situations where the FMU pedestal door needs to open from the reverse side of the FMU
(such as in a kiosk mount). The interfacing cables are long enough to reach their
connection points.
Perform the following:
1. Verify the FMU Upper Cabinet is removed from its shipping container.
2. Unlock and open the Upper Cabinet door.
3. On the underside of the Upper Cabinet are six ¼
‐ 20 x ¾ stainless panhead screws
threaded through gasket holes into the nutserts of the Cable Interface Plate.
Remove the screws. After the screws are removed, the Cable Interface Plate is
free floating in the Upper Cabinet.
CAUTION
When the door is open, the Upper Cabinet is front heavy and must be supported to
prevent dropping.
Figure 4-26a. Install FMU Upper Cabinet

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4. Position the Upper Cabinet on the Pedestal. Support the Upper Cabinet and insert the ¼
‐
20 x ¾ attach screws through the attach holes in the underside of the top flange of the
Pedestal, through the holes in the Upper Cabinet, and thread into the nutserts in the Cable
Interface Plate. Do not tighten the screws until all six screws are installed.
5. Repeat until all six screws are installed. Tighten the screws.
6. Unlock and open the FMU Pedestal door.
7. Loosen (do not remove) the four attach screws and remove the Upper Electrical Access
Panel in the FMU Pedestal.
8. Locate the 198439 Power Cable, the 200085 Communications Cable (Master FMU only),
the 194735 wide ribbon cable, and one or two 180556 ribbon cable(s). There will be one
180556 ribbon cable if one Relay Assembly is installed; two 180556 ribbon cables if two
Relay Assemblies are installed.
9. Connect the 198439 Power Cable to the power cable connector on the underside of the
Cable Interface Plate. If the connector keyways align, the pins will be properly aligned.
10. (Master FMU Only) Connect the 200085 Communications Cable to the communications
cable connector on the underside of the Cable Interface Plate. If the connector keyways
align, the pins will be properly aligned.
11. Route the 194735 wide ribbon cable up through the thru
‐ hole bushing into the Upper
Cabinet, and connect into the keyed connector at J7 near the bottom center of the
Satellite I/O Control Board.
NOTE
The 180556 ribbon cables cross when installed correctly. The cable from the left Relay
Assembly (for hoses 1
‐ 4) connects into the right (PRB1) connector. The cable from the
right Relay Assembly (for hoses 5
‐ 8) connects into the left (PRB2) connector.
12. Route the 180556 ribbon cable(s) into the Upper Cabinet. Connect the ribbon cable from
JP2 on the
left Relay Assembly (for hoses 1 through 4) to PRB1 in the lower right corner of the
Satellite I/O
Control Board.
13. If applicable, connect the ribbon cable from JP2 on the right Relay Assembly (for hoses 5
through 8)
to PRB2 in the lower left corner of the Satellite I/O Control Board.
14. As required, reinstall the Upper Electrical Access Panel and tighten the four attach screws.
15. As required, close and lock the FMU Pedestal Door.
16. As required, close and lock the FMU Upper Cabinet door.
17. Installation of the FMU Upper Cabinet on the FMU Pedestal is complete.
2. Reference page 89, paragraph 7g(1), change to read:
1)
Configuration Settings for Non-Programmable Wiring Workaround
. The duration of
the momentary and pulse is regulated by the Pump Finish Timer No Pulse Timer. If the
device being controlled requires a 15 second momentary, set the Pump Finish Timer
No Pulse Timer to 15 seconds. Because only one pulse is being generated when one of
these transactions is recorded, the divide rate must be set to 1:1. Pump handle
detection should must be set to NO or NONE. Repeat these settings for each FMU
hose position used.

FuelMaster®Installation Manual
3
Table of Contents
Introduction.............................................................................................................. 11
Proprietary Information ....................................................................................................11
Trademark Acknowledgements........................................................................................11
Purpose...........................................................................................................................11
Section/Appendix Layout.................................................................................................11
Section 1 - General Information............................................................................. 13
Introduction......................................................................................................................13
Safety Precautions...........................................................................................................13
References................................................................................................... 13
Safety Guidelines......................................................................................... 14
Protecting Against Electrostatic Discharge................................................... 15
Protecting Against Radio Interference.......................................................... 15
Wireless Network Security...............................................................................................15
Certifications/Approvals...................................................................................................16
ID Plates..........................................................................................................................19
WARNINGS, CAUTIONS and NOTES.............................................................................19
Basic FuelMaster
®
FMU Warranty ...................................................................................20
Initialization Requirement ................................................................................................20
FuelMaster
®
Equipment Specifications............................................................................22
Safety Related Inspections & Preventive Maintenance....................................................22
Cleaning Instructions.......................................................................................................22
Fuse Reference...............................................................................................................22
Battery Reference............................................................................................................23
Switch Ratings.................................................................................................................23
Terminal Ratings (For External Component Connections) ...............................................23
Parts Substitution and Modification..................................................................................24
Commercially Available Products.....................................................................................24
Support............................................................................................................................24
Improvements..................................................................................................................24
Section 2 - System Description............................................................................. 25
Introduction......................................................................................................................25
Components................................................................................................. 25
Version Differences...................................................................................... 25
Equipment Description and Location................................................................................25
Fuel Management Unit (FMU) ...................................................................... 25
Description.............................................................................................. 25
Automatic/Manual (Bypass) Operation .................................................... 27
Hose Control........................................................................................... 27
FMU Power Requirements ...................................................................... 27
Surge Protection ..................................................................................... 27
Communications with Central Controller.................................................. 27
Integral Heater Pads ............................................................................... 27
Program Memory..................................................................................... 27
Counting Rapid Pulse Inputs................................................................... 27
Relay Options.......................................................................................... 28

FuelMaster®Installation Manual
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Table of Contents (con’t)
Solid State Relay Assemblies ..............................................................28
Dual Control Relay Assemblies ............................................................28
Automatic/Manual Mode Switch Differences.........................................28
Prokee®...........................................................................................................................................................
28
Smartcards................................................................................................... 29
Fuel Management Software.......................................................................... 29
Central Controller ........................................................................................ 29
Prokee®/Smartcard Encoder ........................................................................ 30
Optional Equipment and Taskings................................................................ 30
Abierto Gateway Dial-to-IP Converters.................................................... 30
AIM ......................................................................................................... 30
Americans with Disabilities Act (ADA) ..................................................... 30
Automatic Call Processor........................................................................ 30
Credit Card Access ................................................................................. 30
Data Logger ............................................................................................ 31
Digital Cell Modem.................................................................................. 31
Direct Connect Cable.............................................................................. 31
Direct Connect Through a Two-Way Ringdown Device/
Phone Line Simulator......................................................................... 31
Drop Mode .............................................................................................. 31
Electronic Dispenser Interface................................................................. 31
Equipment Interface Unit (EIU)................................................................ 32
Keyless FMU Access............................................................................... 32
Landcell .................................................................................................. 32
Large Remote Display............................................................................. 32
Local Authorization FMU Access............................................................. 32
Monitor Mode.......................................................................................... 32
Multi-Product Authorization (MPA) .......................................................... 32
OTR (Over the Road).............................................................................. 33
Proximity Card Reader............................................................................ 33
Pulsers.................................................................................................... 33
Pulse Delay Circuits................................................................................ 33
Quick Stop Button ................................................................................... 33
Receipt Printer ........................................................................................ 33
Retail Applications................................................................................... 33
RS-232/RS-422 Mini Converter and Short-Haul Modem.......................... 33
Satellite FMUs......................................................................................... 34
Security Cameras.................................................................................... 34
Semi-Manual Mode ................................................................................. 34
Special Applications................................................................................ 34
Specialty Equipment................................................................................ 34
Tank Monitor/Tank Gauge Interface........................................................ 34
Telephone Line Extender ........................................................................ 35
Transaction Printer.................................................................................. 35
Wired and Wireless Network Communications ........................................ 35
Wireless RS-232/422 Communications ................................................... 35

FuelMaster®Installation Manual
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Table of Contents (con’t)
Section 3 - Site Planning and Preparation ........................................................... 37
Introduction......................................................................................................................37
FMU Dimensions .............................................................................................................37
EIU Dimensions...............................................................................................................37
Conduit Requirements.....................................................................................................41
Conduit Size................................................................................................. 41
Conduit Fill Capacity .................................................................................... 41
Conduit Applications..................................................................................... 42
Servicing Site Requirements............................................................................................44
AC Power..................................................................................................... 44
Errors on Power-Up................................................................................. 44
Power Conditioners/Voltage Regulators.................................................. 44
Surge Protection .......................................................................................... 45
Standard Protection................................................................................. 45
Optional Protection.................................................................................. 45
Backup Power Sources ............................................................................... 45
Backup Generators ................................................................................. 45
Uninterruptible Power Supply (UPS)........................................................ 45
Communications with Central Controller....................................................... 45
Phone/Modem Communications.............................................................. 46
Through analog phone lines............................................................... 46
Through a two-way ringdown device .................................................. 46
Through a phone line extender........................................................... 47
Through a cell modem........................................................................ 47
Network Communications........................................................................ 47
Through a network cable.................................................................... 47
Through a fiber optic cable................................................................. 47
Through a wireless network................................................................ 47
Direct Connect ........................................................................................ 48
Credit Card Authorization............................................................................. 48
Dispenser Compatibility................................................................................ 48
Dispenser Control......................................................................................... 48
Pump Handle/Switch Detection ............................................................... 49
What it does....................................................................................... 49
How to get it....................................................................................... 49
What if I have a constant hot or neutral on LN?.................................. 50
AIM2™ scenario................................................................................. 50
What about the NO or NONE settings? .............................................. 50
Controlling counts during reset........................................................... 50
Control Methods...................................................................................... 51
Controlling Dispenser Reset Power.................................................... 51
Controlling Solenoid Valves and/or Pump Motors............................... 52
Controlling Two-Stage Valves ............................................................ 53
Using the FMU to automatically remove pump power......................... 53
Controlling Lube Bay Hose Reels....................................................... 53
RC Networks (Snubbers/Spark Quenchers) ........................................... 54

FuelMaster®Installation Manual
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Table of Contents (con’t)
Resistors................................................................................................. 54
Pulsers......................................................................................................... 54
Pulse Filtering ......................................................................................... 55
Dual Output Pulsers................................................................................ 55
Opto-Isolators ......................................................................................... 56
Quick Stop Button ........................................................................................ 56
Data Logger/On-Site Printer......................................................................... 57
Tank Monitor Interface ................................................................................. 57
Satellite/EIU Communications ...................................................................... 58
Temporary Conversion of Satellite FMU to Master FMU.......................... 59
EIU Control .................................................................................................. 59
Accessory (Gate/Door/Carwash) Control through an EIU ........................ 60
Redundant FMUs ......................................................................................... 60
Central Accounting Office Requirements .........................................................................60
Central Controller......................................................................................... 61
Communications to FMU(s).......................................................................... 61
Network Communications........................................................................ 61
Telephone Line Communications ............................................................ 61
Two-Way Ringdown Device..................................................................... 61
Wireless Phone Lines.............................................................................. 62
Direct Connect ........................................................................................ 62
Report Printer............................................................................................... 62
Prokee®/Smartcard Encoder......................................................................... 62
Surge Protection .......................................................................................... 63
File Backups................................................................................................. 63
Section 4 - FMU Installation................................................................................... 65
Introduction......................................................................................................................65
Unpacking and Inspection................................................................................................65
Central Controller Installation ..........................................................................................66
Positioning the Central Controller................................................................. 66
Connecting the Communications Medium/Devices....................................... 66
Loading the Software ................................................................................... 66
Connecting the Prokee®/Smartcard Encoder ............................................... 66
Connecting a Two-Way Ring-Down Device .................................................. 67
FMU Installation...............................................................................................................67
Mounting the FMU Pedestal ......................................................................... 67
Finishing Conduit Connections to FMU Pedestal.......................................... 70
Wire/Cable Connections at the Dispensers................................................... 70
Pulling Wires/Cables .................................................................................... 70
Wire/Cable Recommendations................................................................ 71
AC Power to FMU(s).......................................................................... 71
Communications Line to Master FMU................................................. 71
Telephone/Two-Way Ringdown Device......................................... 71
Network cable............................................................................... 71
Network fiber optic ........................................................................ 71
Printer Cable to Master FMU (On-Site or Transaction Printer)............ 71

FuelMaster®Installation Manual
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Table of Contents (con’t)
Dispenser Hose Control ..................................................................... 71
Dispenser Pulse................................................................................. 71
Satellite/EIU Communications............................................................ 71
Tank Monitor...................................................................................... 71
Indoor Receipt Printer ........................................................................ 71
Wire/Cable Connections at FMU .................................................................. 72
1.A/C Power............................................................................................ 72
2.Telephone/Two-Way Ringdown Device................................................ 72
3.Network Cable...................................................................................... 72
4.Quick Stop Button as FMU Stop Switch................................................ 72
5.Quick Stop Button as Auxiliary Emergency Stop Switch....................... 74
6.On-Site/Transaction Printer.................................................................. 75
7.Dispenser Control................................................................................. 75
a.Controlling Reset............................................................................. 76
b.Controlling Motors........................................................................... 80
c.Controlling Solenoid Valves............................................................. 82
d.Using Dual Control Relay Assembly (DCRA)
to Control Two Devices................................................................. 84
e.Two-Stage Valve Control................................................................. 85
f.Controlling DC Devices (Hose Reels in Lube Bays/
Bulk Oil Dispensers)...................................................................... 88
g.Controlling Carwashes, Gate Openers ............................................ 89
1).Configuration Settings for Non-Programmable
Wiring Workaround .................................................................. 89
a).Using Dual Control Relay Assembly (DCRA)
to Generate Pulses............................................................. 90
b).Using Solid State Relay Assembly (SSRA)
to Generate Pulses............................................................. 90
2).Using a Smart Relay Assembly................................................. 92
h.Monitor Mode.................................................................................. 94
8.Pulse Inputs ......................................................................................... 94
a.Standard Accessory Pulsers/Pulse Generators............................... 94
b.Dual Output Pulsers........................................................................ 98
c.Opto-Isolators.................................................................................. 98
c.Counts During Reset....................................................................... 99
d.AC Bleedover to Pulse Inputs.......................................................... 99
e.Redundancy: Two FMUs, One Dispenser/Pulser............................. 99
9.Tank Monitor Interface ......................................................................... 100
10.Satellite Connections.......................................................................... 105
11.Indoor Receipt Printer ........................................................................ 107
Equipment Interface Unit (EIU) Installation......................................................................107
Pulling Wires and Finishing Conduit ............................................................ 108
1.AC Power............................................................................................. 108
2.Master FMU/EIU Communications........................................................ 108
3.Control of Accessory Controller............................................................ 108
Mounting the Pedestal.................................................................................. 108
Wire Connections at Master FMU................................................................. 111

FuelMaster®Installation Manual
8
Table of Contents (con’t)
Wire Connections at Accessory Controller.................................................... 113
Configure Master FMU for EIU ..................................................................... 113
Section 5 – Initialization ......................................................................................... 115
Software Installation and Setup .......................................................................................115
Configure Master FMU for EIU Operation........................................................................116
Post Installation Inspection and Test ...............................................................................118
Acceptance Test Procedure (ATP) for Upgrades and
Installations of FuelMaster® Fuel Management Units......................................................119
1.SITE EXAMINATION................................................................................. 119
2.FMU UPGRADE (For Upgrades Only)....................................................... 119
3.SOFTWARE UPGRADE (For Upgrades Only)........................................... 120
4.FMU NEW INSTALLS................................................................................ 120
a.EXAMINATION OF PRODUCT............................................................. 120
b.PROVIDE TELEPROMPTING.............................................................. 120
c.VALIDATE FMU ACCESS WITH PROKEE®, SMARTCARD,
CREDIT CARD, AND/OR KEYPAD...................................................... 121
d.ACTIVATE PRODUCT DISPENSERS.................................................. 121
e.VERIFY SINGLE HOSE AUTHORIZATION.......................................... 121
f.SIMULTANEOUS TRANSACTIONS...................................................... 121
g.VERIFY NO COUNTS DURING DISPENSER RESET.......................... 121
h.ENCODE, VERIFY, AND REVISE PROKEE®S OR SMARTCARDS .... 121
i.PROVIDE FOR MANUAL OPERATION................................................. 121
j.TRANSACTION HANDLING.................................................................. 121
k.DISABLE DISPENSER AFTER TRANSACTION................................... 122
l.PROTECT DATA DURING POWER FAILURE ...................................... 122
m.PRICING............................................................................................. 122
n.DISCOUNT CREDIT CARDS ............................................................... 122
o.PREPAID CARDS/KEYS...................................................................... 122
p.RECORD TRANSACTION DATA ......................................................... 123
q.SAFETY............................................................................................... 123
r.POST INSTALLATION INSPECTION.................................................... 123
5.TRAINING................................................................................................. 124
6.DATA ........................................................................................................ 124
6.Comments................................................................................................. 125
SIGNATURE AND FINAL SIGN-OFF............................................................ 125
HOLD HARMLESS AGREEMENT................................................................ 126
Appendices
Appendix A – Glossary.............................................................................................127
Appendix B – Dispenser Compatibility Listing..........................................................131
Appendix C – FMU & EIU Configurations................................................................137
Appendix D – Laptop Direct Connect to FMU..........................................................141