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

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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

Fuel Management Unit (FMU) Installation Manual

Introduction

Section 1 - General Information

Safety Precautions

Guidelines for safe installation and operation, adhering to electrical and hazardous location standards.

Protecting Against Electrostatic Discharge

Procedures to prevent static damage to electronic components during installation.

Wireless Network Security

Guidelines for securing wireless networks connected to the FMU and Central Controller.

Initialization Requirement

Mandatory procedures for validating warranty and certifying the FMU installation.

Section 2 - System Description

Equipment Description and Location

Description of the Fuel Management Unit (FMU) and its primary functions.

Electronic Dispenser Interface

Interface kit required for controlling electronic fuel dispensers via RS-232.

Section 3 - Site Planning and Preparation

Conduit Requirements

Guidelines for routing wires and cables through rigid metal conduit as per NEC and NFPA standards.

AC Power

Minimum power requirements for FMUs/EIUs and recommendations for power source selection.

Surge Protection

Details on standard and optional surge protection for power and communication lines.

Communications with Central Controller

Requirements for establishing communication links between Master FMU and Central Controller.

Direct Connect

Procedure for establishing a direct RS-232 connection between a PC and the FMU.

Dispenser Compatibility

Information on interfacing mechanical and electronic dispensers with FuelMaster systems.

Dispenser Control

Methods for controlling product output from dispensing hoses, including solenoid valves and pump motors.

Pump Handle;Switch Detection

Configuration and wiring for pump handle detection to end transactions and improve receipt printing.

Control Methods

Explanation of various control methods for dispensers, including solenoid valves and pump motors.

Controlling Solenoid Valves and;or Pump Motors

Procedures for controlling solenoid valves and pump motors using FMU outputs.

Central Controller

Requirements for the Central Controller's PC, software, and communication interfaces.

Section 4 - FMU Installation

Unpacking and Inspection

Guidance on unpacking FMU components, checking for damage, and verifying against packing lists.

Central Controller Installation

Hardware installation procedures for the Central Controller, referencing software setup.

Loading the Software

Instructions for loading FuelMaster software and performing system configuration.

FMU Installation

Procedures for installing the FMU, including mounting the pedestal and cabinet.

Mounting the FMU Pedestal

Critical steps for selecting a mounting location and securely mounting the FMU pedestal.

Finishing Conduit Connections to FMU Pedestal

Guidance on completing conduit connections to the FMU pedestal, including sealing exposed wires.

Wire;Cable Connections at the Dispensers

Instructions for making wire/cable connections at the dispenser, ensuring explosion-proof enclosures.

Wire;Cable Recommendations

Specifications for various wire and cable types used for FMU connections.

Wire;Cable Connections at FMU

Step-by-step instructions for making AC Power, telephone, network, and quick stop button connections.

Dispenser Control

Procedures for controlling dispenser operations, including reset, motors, and solenoid valves.

Controlling Reset

Method for interrupting power to the dispenser reset mechanism for control.

Controlling Motors

Methods for controlling suction pump motors or submersible pump motors.

Controlling Solenoid Valves

Procedures for controlling single or two-stage solenoid valves for dispenser operation.

Equipment Interface Unit (EIU) Installation

Description of EIU components and installation requirements.

Section 5 - Initialization

Software Installation and Setup

Procedures for installing software, creating databases, and configuring the FMU and Central Controller.

Configure Master FMU for EIU Operation

Configuring the Master FMU to control an EIU, including setting satellite numbers and relay delays.

Post Installation Inspection and Test

Comprehensive inspection and testing of installed equipment using the Acceptance Test Procedure (ATP).

Acceptance Test Procedure (ATP) for Upgrades and Installations of FuelMaster Fuel Management Units At Retail Sites

SITE EXAMINATION

Verifying all site equipment is operational and installed according to NEC standards.

FMU UPGRADE (For FMU Upgrades Only)

Procedures for verifying FMU operational status, retrieving data, and performing the upgrade.

SOFTWARE UPGRADE (For Software Upgrades Only)

Steps for verifying tasking, disabling auto downloads, retrieving data, and performing software upgrades.

FMU NEW INSTALLS

Checklist for new FMU installations, including product examination and teleprompting.

VALIDATE FMU ACCESS WITH PROKEE, SMARTCARD, CREDIT CARD, AND;OR KEYPAD

Validating authorized access and ensuring unauthorized access is rejected.

ACTIVATE PRODUCT DISPENSERS

Verifying FMUs successfully activate dispensing hoses after authorized access.

VERIFY SINGLE HOSE AUTHORIZATION

Confirming that only the selected hose dispenses product during single hose authorization.

SIMULTANEOUS TRANSACTIONS

Ensuring each connected dispensing hose operates independently.

VERIFY NO COUNTS DURING DISPENSER RESET

Verifying counts do not register after dispenser reset handle is activated.

ENCODE, VERIFY, AND REVISE PROKEES OR SMARTCARDS

Testing encoding and reading of Prokee®s or Smartcards for product availability.

PROVIDE FOR MANUAL OPERATION

Verifying FMU functions normally when dispensers are switched to manual operation.

TRANSACTION HANDLING

Ensuring transactions for each hose are assigned a sequential four-digit number.

DISABLE DISPENSER AFTER TRANSACTION

Verifying FMUs disable applicable dispensers within specified time limits after dispensing.

PROTECT DATA DURING POWER FAILURE

Checking if transactions are recorded and data is retained during power failures.

PRICING

Verifying price levels stored at the FMU and on receipts match customer requests.

RECORD TRANSACTION DATA

Performing automated test transactions and comparing dispenser and polled quantities.

DELAY COUNTS

Ensuring quantity counts are delayed until dispensing hoses are fully pressurized.

SAFETY

Verifying FMU installation compliance with NEC and safety standards.

POST INSTALLATION INSPECTION

Final checks on FMU mounting, seals, connections, and overall security.

TRAINING

Confirmation that user training was provided for various FMU and software operations.

Appendix D - Laptop Direct Connect to FMU

Establish Communications

Procedures to establish communication with the FMU using selected software.

Appendix E - Retail Applications

Setup Considerations for Weights and Measures Compliance

Meeting local Weights and Measures compliance requirements for self-serve retail fueling.

Firmware Setup

Enabling options like TWO RELAYS PER PUMP and SETPOINT via laptop connection.

Appendix H - Electronic Dispenser Interface

FMU Configuration

Instructions for configuring the FMU, referencing FMPlus User Manual and firmware versions.

Troubleshooting

Guidance on troubleshooting PIE diagnostic programs and observing LEDs for status.

Syn-Tech Systems FuelMaster FMU-2500 Plus Specifications

General IconGeneral
ManufacturerSyn-Tech Systems
Enclosure RatingNEMA 4X
ModelFMU-2500 Plus
DisplayLCD
CommunicationRS-232, Ethernet

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