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Syn-Tech Systems FuelMaster FMU-2500 Classic - User Manual

Syn-Tech Systems FuelMaster FMU-2500 Classic
207 pages
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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

Table of Contents

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Summary

Section 1 - General Information

Introduction

Overview of the FuelMaster system, its purpose, and manual structure.

Safety Precautions

General safety guidelines and compliance with codes for installation.

References

Lists applicable safety codes and standards for technicians.

Safety Guidelines

Guidelines to protect FMU from damage and ensure personal safety.

Certifications;Approvals

Details on ETL SEMKO certification and NEC Class 1, Division 2.

ID Plates

Information on FMU pedestal ID plates and their contents.

WARNINGS, CAUTIONS and NOTES

Defines the meaning and usage of safety warnings in the manual.

Basic FuelMaster FMU Warranty

Describes the warranty coverage for FMU and Prokee® components.

Initialization Requirement

Explains the necessity of initialization for warranty validation.

FuelMaster Equipment Specifications

Details on electrical specifications, temperature ranges, and ratings.

Cleaning Instructions

Guidance on cleaning the FMU chassis, keypad, and receptacles.

Fuse Reference

Lists fuse locations, descriptions, quantities, and part numbers.

Section 2 - System Description

Introduction

Overview of FuelMaster components and applications.

Components

Lists the base system components required for automated fueling.

Version Differences

Highlights differences between Classic and Plus FMU series.

Equipment Description and Location

Describes FMU function, appearance, and master/satellite roles.

Optional Equipment and Taskings

Details various optional equipment and their functions.

Section 3 - Site Planning and Preparation

Introduction

Considers planning for FuelMaster servicing and Central Accounting Office sites.

FMU Dimensions

Provides FMU dimensions for selecting mounting locations.

EIU Dimensions

Illustrates EIU dimensions applicable for all existing versions.

Conduit Requirements

Specifies rigid metal conduit requirements per NEC and NFPA 70.

Conduit Applications

Details conduit requirements for FMU, EIU, and other devices.

Servicing Site Requirements

Discusses site arrangements and power requirements for FMUs/EIUs.

Surge Protection

Covers standard and optional surge protection for FMUs and related equipment.

Backup Power Sources

Explains the need for backup generators and UPS for retail operations.

Communications with Central Controller

Details communication options between FMU and Central Controller.

Dispenser Compatibility

Lists compatible fuel dispensers and interface requirements.

Dispenser Control

Explains methods for controlling product output from dispensing hoses.

Control Methods

Discusses various methods for controlling FMU functions.

Pulsers

Information on pulse output devices for quantity measurement.

Quick Stop Button

Describes the optional button for resetting FMU power.

Data Logger;On-Site Printer

Details connections and functions of data loggers and printers.

Tank Monitor Interface

Explains interfacing FMUs with tank monitors for data extraction.

Satellite;EIU Communications

Covers communication methods between master and satellite FMUs/EIUs.

Section 4 - FMU Installation

Introduction

Overview of procedures for installing a complete FuelMaster system.

Unpacking and Inspection

Steps for unpacking FMU components and inspecting for damage.

Central Controller Installation

Guidance on installing the Central Controller hardware.

Connecting a Two-Way Ring-Down Device

Instructions for connecting a two-way ring-down device for communication.

Mounting the FMU Pedestal

Procedures for securely mounting the FMU pedestal.

Finishing Conduit Connections to FMU Pedestal

Details on sealing conduit entry points and routing within the pedestal.

Wire;Cable Connections at the Dispensers

Instructions for making connections at the dispenser end.

Pulling Wires;Cables

Guidance on pulling wires and cables according to recommendations.

Wire;Cable Recommendations

Specifies wire sizes and types for various connections.

Wire;Cable Connections at FMU

Details on making AC power, phone, and network cable connections.

On-Site;Transaction Printer

Instructions for connecting on-site or transaction printers.

Dispenser Control

Covers methods for controlling dispenser functions.

Controlling Reset

Method to interrupt power to the dispenser reset mechanism.

Controlling Motors

Procedures for controlling pump motors or solenoid valves.

Controlling Solenoid Valves

Instructions for controlling single or two-stage solenoid valves.

Using Dual Control Relay Assembly (DCRA) to Control Two Devices

Utilizing DCRA for controlling two devices per hose selection.

Two-Stage Valve Control

Method for controlling fast and slow stages of two-stage valves.

Controlling DC Devices (Hose Reels;Bulk Oil Dispensers)

Guidance for controlling DC devices like hose reels.

Controlling Carwashes, Gate Openers

Methods to control carwashes and gate openers.

Using a Smart Relay Assembly

Details on programming and using Smart Relay Assemblies.

Monitor Mode

Procedure to configure FMU for continuous monitoring of fuel flow.

Pulse Inputs

Information on connecting pulsers for quantity registration.

Tank Monitor Interface

Steps for connecting FMUs to Tank Monitor Units.

Satellite Connections

Instructions for making hardwire master-satellite connections.

Indoor Receipt Printer

Details on connecting the indoor receipt printer.

Equipment Interface Unit (EIU) Installation

Procedures for installing the EIU.

Wire Connections at Master FMU

Describes EIU connections to the Master FMU.

Configure Master FMU for EIU Operation

Steps to configure the Master FMU for EIU control.

Section 5 - Initialization

Software Installation and Setup

Procedures for installing software and setting up the system.

Post Installation Inspection and Test

Comprehensive inspection and testing of the installed equipment.

Acceptance Test Procedure (ATP) for Upgrades and Installations At Retail Sites

1. SITE EXAMINATION

Verifies site equipment is operational and installed per NEC.

2. FMU UPGRADE (For FMU Upgrades Only)

Steps to verify and perform FMU upgrades.

3. SOFTWARE UPGRADE (For Software Upgrades Only)

Steps to verify and perform software upgrades.

4. FMU NEW INSTALLS

Checks for new FMU installations including product, teleprompting, access, and data.

SIGNATURE AND FINAL SIGN-OFF

HOLD HARMLESS AGREEMENT

Appendix A - Glossary

Access Point

Passive system component for controlling or monitoring vehicles with AIM.

AIM

Abbreviated name for Syn-Tech’s passive fueling system.

Central Controller

PC with FuelMaster software loaded on it.

Fuel Management Unit (FMU)

Fuel Management Unit.

Installation

The physical act of mounting the FMU and providing interfaces.

Appendix B - Dispenser Compatibility

Description

Explains the compatibility listing for FuelMaster FMUs and dispensers.

When Is It Required?

Details when an Electronic Dispenser Interface Kit is necessary.

Appendix C - FMU;EIU Configurations

Plus Series (current production)

Lists FMU and EIU configurations for the Plus Series.

Classic Series

Lists FMU and EIU configurations for the Classic Series.

Appendix D - Laptop Direct Connect to FMU

Setup Hyperterminal

Instructions for setting up Hyperterminal for FMU connection.

Setup Procomm Plus

Steps to set up Procomm Plus for FMU connection.

Using PuTTY

Guide to setting up PuTTY for FMU connection.

Appendix E - Retail Applications

Setup Considerations for Weights and Measures Compliance

Compliance requirements for self-serve retail fueling.

Presets

Allows customers to preset dollar or gallon limits for transactions.

Setup Considerations for System Reliability

Ensures system reliability and prevents pump motor burnout.

Appendix F - Wiring Differences for Canadian and European Certified FMUs

Canadian Certification

Differences in FMUs certified for Canadian use.

European Certification

Differences in FMUs certified for European use.

Appendix G - FMU Wire and Cable Connection Points

Component 1

Locates connection points for wires and cables.

Component 2

Identifies the other connection point for wires and cables.

Appendix H - Electronic Dispenser Interface

Components;Part Numbers

Lists components and part numbers for the interface kit.

FuelMaster Supplied Equipment

Details the parts supplied by FuelMaster for the interface kit.

Installation

Recommends equipment testing prior to installation and power-up.

FMU Configuration

Explains FMU configuration for electronic dispenser interface.

Software Configuration

2. Add;Configure Products

Procedure to add and configure products in the software.

3. Add Miscellaneous Fields (as desired)

Option to create additional miscellaneous fields for configuration.

4. Add;Configure Site

Procedure to add or open the desired site in the software.

5. Add;Configure Tanks

Steps to add or configure tanks for products.

6. Add;Configure Electronic Fueling;Grade Positions

Configuring electronic hoses and grade positions in the FMU.

Troubleshooting

Operational Note

Note on FMU Auto/Manual switches affecting dispenser operation.

PIE Diagnostic Programs

Information on PIE diagnostic programs for troubleshooting.

Laptop Connections

Performing diagnostic functions via laptop connection to FMU.

LEDs

Explains the meaning of LEDs on the Controller and Configurator.

Syn-Tech Systems FuelMaster FMU-2500 Classic Specifications

General IconGeneral
CategoryIndustrial Equipment
ManufacturerSyn-Tech Systems
ModelFuelMaster FMU-2500 Classic
Power Supply120/240 VAC, 50/60 Hz
Communication InterfaceRS-232, Ethernet
DisplayAlphanumeric LCD

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