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:

ii
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

iii
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
4
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
5
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
6
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
7
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

FuelMaster®Installation Manual
9
Appendices (con’t)
Appendix E – Retail Applications.............................................................................149
Appendix F – Wiring Differences for Canadian and
European Certified FMUs..................................................................177
Appendix G – FMU Wire and Cable Connection Points ..........................................179
Appendix H – Electronic Dispenser Interface...........................................................181
Figures and Tables
Figure 1-1. Boundaries of a Flammable Liquid Hazardous ...........................................................16
Figure 1-2. FMU Electrical Safety Spacing....................................................................................17
Figure 1-3. FMU ID Plates............................................................................................................18
Table 1-1. FMU Door Key Reference...........................................................................................19
Figure 1-4. Sample FMU Initialization Form.................................................................................21
Figure 2-1. Fuel Management Unit (FMU).....................................................................................26
Figure 2-2. Prokee
®....................................................................................................................................................................................
28
Figure 2-3. Prokee
®
Encoder.........................................................................................................30
Figure 2-4. Two-Way Ringdown Device/Phone Line Simulator.....................................................31
Figure 2-5. Equipment Interface Unit (EIU) ...................................................................................32
Figure 3-1. FMU Dimensions (in inches)......................................................................................38
Figure 3-2. FMU Dimensions (in inches) Americans with Disabilities Act (ADC) FMU.................39
Figure 3-3. EIU Dimensions (in inches)........................................................................................40
Table 3-1. Rigid Metal Conduit Fill Capacity .................................................................................41
Table 3-2. Typical Wire/Cable Cross Sectional Area.....................................................................41
Figure 3-4. Sample Site Layout....................................................................................................43
Figure 3-5. Satellite Option Installation.........................................................................................59
Figure 4-1. Two-Way Ringdown Device Connection.....................................................................67
Figure 4-2. FMU Footprint (in inches)...........................................................................................69
Figure 4-3. Alternate Mounting Methods ......................................................................................69
Figure 4-4. AC Power and Phone Connections.............................................................................73
Figure 4-5. AC Power and Phone Connections (from reverse
side of Surge Panel)................................................................................................................73
Figure 4-6. Network Cable Connection .........................................................................................74
Table 4-1. Transaction Printer Cable Connection Points ..............................................................75
Figure 4-7. Pedestal I/O Board......................................................................................................77
Figure 4-8. Wiring Diagram - Controlling Reset.............................................................................79
Figure 4-9. Wiring Diagram - Controlling Reset in Dual Hose Single
Product Dispenser without Backfeed (One Solution) ..............................................................80
Figure 4-10. Wiring Diagram - Controlling Motors.........................................................................81
Figure 4-11. Wiring Diagram – Controlling Solenoid Valves ........................................................83
Figure 4-12. Wiring Diagram - Using Dual Control Relay Assembly (DCRA)
to Control Two Devices ...........................................................................................................84

FuelMaster®Installation Manual
10
Figures and Tables (con’t)
Figure 4-13. Wiring Diagram – Two-Stage Valve Control ............................................................86
Table 4-2. Pedestal I/O Board Inputs/Outputs for AC and DC
Solid State Relays (SSRs).......................................................................................................88
Figure 4-14. Location of 75K ohm Pump Handle Detect Resistors...............................................89
Figure 4-15. Generating Pulse with Dual Control Relay Assembly ...............................................91
Figure 4-16. Generating Pulse with Solid State Relay Assembly..................................................91
Figure 4-17. Smart Relay Assembly..............................................................................................93
Table 4-3. Wiring Smart Relay Assembly (SRA) to Pedestal I/O Board........................................93
Figure 4-18. Connecting to Veeder-Root 1871 Pulser ..................................................................96
Figure 4-19. Connecting to Veeder-Root 7671 Pulser ..................................................................96
Figure 4-20. Connecting to ICS 12VDC Pulsers ...........................................................................96
Figure 4-21. Connecting to ICS 110 VAC Pulsers.........................................................................97
Figure 4-22. Connecting to OPW 12 VDC Pulsers........................................................................97
Figure 4-23. Connecting to OPW 110 VAC Pulsers......................................................................97
Figure 4-24. Connecting to Open Collector Pulser (Gasboy 9800 Pump I/F shown)....................98
Figure 4-25. Removing Counts During Reset................................................................................98
Figure 4-26. Redundant FMUs, One Dispenser, One Pulser........................................................100
Figure 4-27. I/O Silver Board........................................................................................................101
Figure 4-28. Satellite I/O Control Board .......................................................................................102
Figure 4-29. Install Tank Monitor Interface Kit...............................................................................103
Figure 4-30. I/O Silver Board Connections for Tank Monitor Interface..........................................104
Figure 4-31. Satellite Connections ...............................................................................................106
Table 4-4. Indoor Receipt Printer Cable Connections...................................................................107
Figure 4-32. EIU Components.......................................................................................................107
Figure 4-33. EIU Footprint.............................................................................................................109
Figure 4-34. EIU Wiring.................................................................................................................110
Figure 4-35. Connecting Wire Harnesses .....................................................................................111
Attachments
Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster
®
Fuel
Management Units (back of manual; tear out, complete and return to Syn-Tech Systems, Inc., in
provided self-addressed, postage-paid envelope)

FuelMaster®Installation Manual
11
Introduction
Proprietary Information
Except as permitted under the United States Copyright Act of 1976, no part of this publication
may be reproduced, stored in a retrieval system, or transmitted in any form or by any means –
electronic, mechanical, photocopying, recording, or otherwise – without the prior written
permission of the publisher:
Syn-Tech Systems, Inc.
PO Box 5258
Tallahassee, Florida 32314
Phone: [phone]
Fax: [phone]
Support: [phone], Ext. 1500; [e-mail]
Copyright©Syn-Tech Systems, Inc. 1998-2010
All Rights Reserved. This Document was printed in the United States of America.
Trademark Acknowledgements
Trademarks of other products mentioned in this manual are held by the companies producing
them. Use of a term in this manual should not be regarded as affecting the validity of any
trademark. All other trademarks are acknowledged.
Purpose
This manual provides installation instructions for the Syn-Tech Systems, Inc., FuelMaster®Fuel
Management Unit (FMU) for fixed fueling sites. These instructions have been prepared for use by
technicians who are qualified to complete electrical work in hazardous locations.
Though different systems have been developed for commercial (civilian) and DoD (Department of
Defense) applications, only one installation manual has been prepared to cover both applications.
Likewise, commercial systems are available as both Classic and Plus systems, and passive and non-
passive systems. Where distinctions must be made between the different applications, notations (i.e.,
commercial, classic, Plus, or DoD) will be added to identify the differences.
Reference is made herein to Product Bulletins. Product Bulletins have been prepared to cover
individual maintenance tasks, and are forwarded with each replacement part. There is no
maintenance manual encompassing all maintenance tasks.
Section/Appendix Layout
This manual is divided into six sections, and eight appendices. Appendices have been created to
provide special instructions for specific topics. Included are:
Section 1 - General Information
This section contains safety precautions, specifics about equipment safety certification, an
explanation of the system warranty, and a detailed definition of Initialization.

FuelMaster®Installation Manual
12
Section 2 - System Description
This section contains a description of all FuelMaster®standard and optional equipment
available at the time of publication of this manual.
Section 3 – Site Planning and Preparation
This section provides guidelines for preparing your site for a FuelMaster®installation.
Section 4 - Installation
This section provides guidelines for performing a FuelMaster®FMU and EIU installation.
Section 5 - Initialization
This section contains procedures for performing the post-installation inspections and tests,
and completing the final certification jointly with the customer to validate the system
warranty.
Appendix A – Glossary
An explanation of terms, abbreviations, and acronyms used in this manual.
Appendix B – Dispenser Compatibility Listing
A listing of known dispenser makes and models and how they interface with FuelMaster®.
Appendix C – FMU & EIU Configurations
A description of the various model numbers and configurations of Fuel Management Units
(FMUs) and Equipment Interface Units (EIUs).
Appendix D – Laptop Direct Connect To FMU
Instructions for direct connecting to an FMU with a laptop to view or change FMU
programming information.
Appendix E – Retail Applications
Instructions for applying FuelMaster®to the special needs of retail applications such as small
airports and marinas. Includes listing of compatible credit card networks and procedures to
assist with the setup of credit card accounts in FMUs used for retail applications. Also
includes Acceptance Test Procedure (ATP) for retail installations and startups.
Appendix F – Wiring Differences for Canadian and European Certified FMUs
Explanation of differences between U.S. and Canadian and European certified FMUs
Appendix G – FMU Wire and Cable Connection Points
Listing of connection points for an unknown FMU wire or cable.
Appendix H - Electronic Dispenser Interface
Instructions for using FuelMaster®with electronic dispensers.

FuelMaster
®
Installation Manual
13
Section 1
General Information
Introduction
FuelMaster®consists of equipment developed to control access to, account for, and compile reports
for transactions from dispensing equipment. FuelMaster®accomplishes this with security from
unauthorized user access while maintaining complete accountability of each transaction as it
occurs. The FuelMaster®equipment for each installation is assembled to fulfill specific site
requirements and must be installed accordingly.
FuelMaster®permits true self-service, automated, fuel dispensing for any application ranging from
small service stations to large-scale fleet operations, including retail sales. The FMUs (Fuel
Management Units) and Fuel Management Software are encoded by Syn-Tech Systems with
matching system designators (site signatures) to assure security and allow access only by the
customer to which the system designator is assigned. DoD systems may be utilized universally by
all DoD personnel; unauthorized users are “locked out”.
The FuelMaster®equipment can be integrated to extract accumulated transaction data from one
service station, or several far removed and isolated service stations that report to one central
accounting office. Transaction data is compiled after data communication to a central accounting
office which may be hundreds, or thousands of miles remote from the servicing operations.
The FuelMaster®equipment may be adapted to control dispensing equipment for any product (not
just fuel) that can be metered. Optional equipment are available to utilize the same system and
system access devices to activate electronic gate openers, door openers, and automated car
washes.
Some electronic fuel dispensers may only be controlled through a two-wire connection to the
dispenser CPU. For these dispensers, an Electronic Dispenser Interface Kit must be installed between
the FMU and dispenser distribution box. Appendix B contains a Dispenser Compatibility Listing which
will identify when an Electronic Dispenser Interface Kit is needed. Appendix H provides details on the
use of the Electronic Dispenser Interface.
Safety Precautions
In addition to the safety precautions contained within this installation manual, the FuelMaster®
installer must be familiar with the guidelines contained within all other safety codes and standards
applicable to the installation and operation of electrical equipment, particularly within hazardous
locations. All FuelMaster®and non-FuelMaster®equipment supplied by Syn-Tech Systems, Inc.,
complies with all applicable federal, state, and local safety codes and standards.
References: The following references, as a minimum, and as they apply to the installation, must
be familiar to the technician performing a FuelMaster® installation:
•NFPA Handbook 30, Flammable and Combustible Liquids Code, provides requirements for
the safe storage and handling of flammable and combustible liquids.
•NFPA Handbook 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages,
provides safeguards for dispensing liquid and gaseous motor fuels into the fuel tanks of
automotive vehicles and marine craft.
•NFPA Handbook 70, National Electrical Code (NEC), contains guidelines for the installation
and operation of electrical equipment. Chapter 5 specifically addresses the installation of
electrical equipment in hazardous locations.

FuelMaster
®
Installation Manual
14
•NFPA Handbook 407, Standard for Aircraft Fuel Servicing, provides minimum fire safety
requirements for procedures, equipment, and installations during ground fuel servicing of
aircraft using liquid petroleum fuels. Knowledge of this reference is necessary when performing
an installation in support of aircraft fuel servicing.
•NIST Handbook 44, Specifications, Tolerances, and Other Technical Requirements for
Weighing and Measuring Devices, technical requirements for the purpose of eliminating from
use weights and measures and weighing and measuring devices that give readings that are
false, that are of such construction that they are faulty, or that facilitate the perpetration of fraud.
Section 3 contains most of the guidelines for retail self service fuel site inspection criteria.
Knowledge of this reference is necessary when performing an installation in support of retail
fuel sales.
Safety Guidelines: Use the following guidelines to help protect your FMU from potential
damage and ensure your own personal safety.
WARNING
Do not operate your FMU with any cover removed or door open.
AVERTISSEMENT
N'actionnez pas votre FMU quand aucune couverture est déplacée ou aucune porte est ouverte.
CAUTION
Do not open your FMU’s doors during wet weather.
ATTENTION
N'ouvrez pas les portes de Votre FMU par le temps de pluie.
As you use your FMU, observe the following safety guidelines:
•To help avoid damaging your FMU, be sure the AC power available at your location is 110 volts,
50 or 60 hertz (Hz).
•To help prevent electrical shock, connect the FMU into properly grounded sources.
•To help avoid possible damage to the FMU and or other interfacing equipment, wait 5 seconds
after turning off all interfacing equipment before disconnecting any interconnecting cables.
•To help protect your FMU from sudden, transient electrical increases, your FMU is equipped
with Surge Protection. All equipment interfacing your FMU needs to use a surge suppressor,
line conditioner, or uninterruptible power supply (UPS).
•Be sure nothing rests on your FMU’s cables and that the cables are not located where they can
be stepped on or tripped over.
•Do not spill food or liquids on your FMU or interfacing equipment.
•Do not push any objects into the openings of your FMU. Doing so can cause fire or electrical
shock by shorting-out internal components.
•Keep your FMU away from radiators and heat sources.
WARNING
Do not attempt to service the FMU yourself, except as explained in this manual. Always follow
installation and service instructions closely.
AVERTISSEMENT
N'essayez pas d'entretenir le FMU vous-même, excepté comme expliqué en ce manuel. Suivez
toujours les instructions d'installation et de maintenance précisément.
Before you open the door or remove any FMU covers, perform the following steps in the sequence
indicated:
•Turn off/unplug your FMU and any devices. Certain system board components continue to
receive power anytime the FMU is connected to AC power.

FuelMaster
®
Installation Manual
15
•Disconnect your FMU and devices from their sources. Also disconnect any telephone or
telecommunication lines from the FMU to reduce the potential for personal injury or shock.
•Wear a wrist grounding strap or touch an unpainted metal surface on the chassis, such as the
back panel, before touching anything inside your FMU.
•While you work, periodically touch an unpainted metal surface on the FMU chassis to dissipate
any static electricity that might harm internal components.
In addition, take note of these safety guidelines when appropriate:
•When you disconnect a cable, pull on its connector or on its strain-relief loop, not on the cable
itself. Some cables have a connector with locking tabs. To disconnect this type cable, press in
the locking tabs before disconnecting the cable. As you pull connectors apart, keep them evenly
aligned to avoid bending any connector pins. Also, before you connect a cable, make sure both
connectors are correctly oriented and aligned.
•Handle components and Prokee®s with care. Don’t touch the contacts on a Prokee®
•Hold components by their edges or by their metal mounting bracket.
Protecting Against Electrostatic Discharge: static electricity can harm delicate
components inside your FuelMaster®FMU. To prevent static damage, discharge static electricity
from your body before you touch any of your FuelMaster® FMU’s electronic components. You can
do so by touching an unpainted metal surface on the FuelMaster® FMU chassis.
As you continue to work inside your FuelMaster®FMU, periodically touch an unpainted metal
surface to remove any static charge your body may have accumulated. Use of a wrist-grounding
strap is highly recommended.
You can also take the following steps to prevent damage from electrostatic discharge (ESD):
•Keep a static-sensitive component in its antistatic packing material until you are ready to install
the component in your FuelMaster®FMU. Just before unwrapping the antistatic packaging,
discharge electricity from your body.
•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.
Protecting Against Radio Interference: this equipment has been tested and found to
comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful interference in a commercial
installation. 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;
•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.
Wireless Network Security
The means exists for wireless network communications between your Central Controller and FMU.
As the technology and equipment becomes more available and affordable, the options make it
easier for wireless connectivity. In addition to the ease afforded you, easy connectivity is also
available to those you may not wish to share your information with. The information gathered and
stored by FuelMaster®need not be secure, but your Central Controller and FMU may be connected
to a network containing private information you want to be secure.

FuelMaster
®
Installation Manual
16
Syn-Tech cannot emphasize enough the potential ramifications of breached network security.
Without proper wireless network security, outside users can access your network to attain
information such as social security numbers, credit card numbers, bank account numbers, and
countless other very valuable and private information sources stored on your network. In planning
your wireless network, ensure you purchase the right equipment and plan for a secure network that
won’t allow outsiders access to your information.
A Hold Harmless Agreement is attached to this manual, and requested to be signed by the using
customer. This agreement references the potential hazards associated with wireless network
security, and serves to remove liability from the seller (Syn-Tech Systems or its distributors) when
wireless networking equipment is installed for communications to the FMU.
Certifications/Approvals
FuelMaster®FMUs have been tested and safety certified by the ETL SEMKO division of Intertek to
ANSI/UL Specification 1238 for connection to UL-certified dispensers in NEC Class 1, Division 2,
Group D locations. Equipment versions certified by ETL are identified by the ETL logo imprinted on
the ID plate riveted to the FMU pedestal.
Figure 1-1 illustrates the boundaries of a hazardous location which dispenses flammable liquids
such as gasoline and E85. Propane (liquefied petroleum gas) has the same basic boundaries.
The boundary area around a compressed natural gas (CNG) dispenser is different. It extends 5 feet
from, and above, the dispenser. Any electrical device installed within these boundaries must be
Figure 1-1. Boundaries of a Flammable Liquid Hazardous Location

FuelMaster
®
Installation Manual
17
intrinsically safe or must be enclosed within an explosion-proof enclosure. Intrinsically safe devices
are generally limited to very low voltage and low current devices, such as that portion of a pulser
before the barrier. Examples of explosion-proof enclosures are rigid metal conduit, and junction
boxes and conduit fittings approved for use in hazardous locations. If the electrical device is not
intrinsically safe, or is not explosion-proof, then it must be installed outside the hazardous area.
Figure 1-2 illustrates an FMU and the distance from its mounting surface to where electrical
components are installed. All internal electrical components are 28 inches above the mounting
surface. This places all electrical components in the FMU a full 10 inches outside the hazardous
location. This 10 inch separation provides additional spacing for the installation of outlet boxes or
other devices which are not explosion-proof, and which cannot be installed in hazardous locations.
FuelMaster®has been certified for use in electrical installations in Canada and Europe as well as
the United States. FMUs certified for use in Canada and Europe may be identified through the ID
plate riveted to the FMU pedestal. See Figure 1-3 for examples of FMU ID plates for U.S., Canadian
and European certification.
Figure 1-2. FMU Electrical Safety Spacing

FuelMaster
®
Installation Manual
18
Figure 1-3. FMU ID Plates