TABLE OF CONTENTS SECTION 1 - GENERAL INFORMATION ..............7 Proprietary Information ..................7 Introduction....................... 7 Purpose ......................7 Safety Precautions and Corrective Actions ............8 Protecting Against Electrostatic Discharge .............. 8 Correcting RF Interference ..................8 Certification/Approval ..................9 WARNINGS, CAUTIONS, and NOTES ..............
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TABLE OF CONTENTS (con’t) Programming Hose Tag (PHT) ..............17 Filler Neck Rings/RFID Interface Module ............19 Connecting Cables ..................19 SECTION 3 - SYSTEM PLANNING ................. 23 Fundamental Do’s/Don’ts ................... 23 Version Compatibility..................26 Developing a Database of Vehicle Records ............26 Selecting the Correct Nozzle Tag ...............
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TABLE OF CONTENTS (con’t) Program an AIM2™ ....................46 Calibrate AIM2™ ..................48 Change the AIM2™ Interface ................ 51 Clean the AIM2™ ....................53 SECTION 6 – ACCEPTANCE TEST PROCEDURE (ATP) ......... 57 Acceptance Test Procedure (ATP) for Commercial Installations, Upgrades, Startup, and/or Training Of FuelMaster AIM2™...
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FIGURES AND TABLES Table 2-1. AIM2™ OBD Data Collection Parameters ..........14 Figure 2-1. FMU Radio Board (FRB) ................ 15 Figure 2-2. AIM2™ Modules ................... 16 Figure 2-3. Sample Nozzle Tag ................18 Table 2-2. Nozzle Tag Applications ................ 18 Table 2-3.
SECTION 1 GENERAL INFORMATION Proprietary Information This FuelMaster AIM2™ Installation Manual is copyrighted 2009. Any unauthorized duplication, ® distribution, or disclosure to third parties without specific written authorization from Syn-Tech Systems, Inc., P.O. Box 5258, Tallahassee, FL 32314, is a violation of the law. FuelMaster firmware and ®...
Safety Precautions and Corrective Actions NFPA 70, the National Electrical Codes (NEC), define a fuel dispensing site as a hazardous location and contains guidelines for the installation and operation of any equipment in such a location. NFPA 30, Flammable and Combustible Liquids Code, contains guidelines for electrical equipment and installations in areas where Class I liquids are stored or handled, and where Class II or Class III liquids may be stored at or above their flash points.
• Connect the equipment into an outlet on a circuit different from that to which the radio/TV’s receiver is connected; and, • Consult the dealer or an experienced radio/TV technician for help. Certification/Approval The equipment supplied with AIM2™, FMU-3500, and FMU-3535 is tested and safety certified by Intertek’s ETL SEMKO Division.
manufactured by Syn-Tech Systems are warranted only to the extent covered by the original manufacturer. Additionally, warranty is limited to approved locations (generally the continental United States) and is not transferable except by written permission of Syn-Tech Systems. Initialization Requirement All FuelMaster®...
Consumables/Special Tools (con’t) Consumable/Special Tool Application Tyco Electronics 1-480305 connector housing Power connector for FMU-3500 Programmer Tyco Electronics 60618-4 contacts (3 each) Wire contacts in power connector for FMU-3500 Programmer Improvements Recommendations for improvement or corrections to this manual may be reported to Syn-Tech's Product Support at 800-888-9136 (phone), 850-877-9327 (FAX), support@syntech-fuelmaster.com or by mailing to:...
SECTION 2 SYSTEM DESCRIPTION Syn-Tech Systems, Inc. offers a passive fueling version of their world renowned Fuel Management Unit (FMU). The FuelMaster Plus FMU-3500 is built on the widely accepted FMU-2500 platform with ® the addition of components required to facilitate passive operation. AIM2™ is the trademarked name of Syn-Tech’s passive fueling system.
Installation Requirements : The normal sequence of events to complete the installation of an AIM2™ fueling system entails software installation, FMU installation, then AIM2™ module installation and programming. AIM2™ programming is required, but cannot be performed until the software is installed and databases are developed, the FMU is installed, and the AIM2™...
and B channel outputs/inputs, and five LEDs: a red, steady Power LED, and four green, flashing transmit/receive LEDs as shown in Figure 2-1. • Two 926 MHz antennas for receiving RF transmissions from the AIM2™ module. These antennas may be attached to the FMU, or external (remote) antennas may be installed to ensure best possible RF coverage.
AIM2™ modules may receive odometer and chronometer inputs through an OBD II connection, or through analog speed sensor and analog chronometer inputs. Power for the AIM2™ module may be supplied either directly through the OBD II connection, or through an analog speed sensor cable.
A through F). Each FMU may be configured to use a single PHT. A PHT is needed to complete the programming interface between an AIM2™ module and the FMU. PHTs are made from operational nozzle tags which closely match the application in which they are used. Figure 2-3.
Table 2-3. Nozzle Tag Clamp and Kit Part Numbers Filler Neck Rings/RFID Interface Module . Like the nozzle tags, filler neck rings contain an antenna coil and RF/ID chip for communications with the nozzle tag. The filler neck ring has a 48 inch pigtail for connection to the RFID Interface Module (also referred to as Lump Board).
AIM2™ Module RFID Extension Cable Filler Neck Ring RFID Interface Module Figure 2-4. AIM2™ Vehicle Components Figure 2-5. OBD II Pass-Thru Cable A chronometer need not be a physical device added to the vehicle/equipment to attain the desired information. A chronometer input may be as simple as a power source which is only powered under special circumstances.
both vehicle tanks are combined to look as if one tank was filled. Reefer applications may require special consideration before installations begin. Reefers may draw from the same fuel tank as the truck, or fuel consumption may be separately tracked through the use of its own AIM2™...
SECTION 3 SYSTEM PLANNING With a passive fueling system there is much more to consider than the basic FMU connections to power, dispenser pulse and control, and Central Controller communications. For an FMU-3500 to turn on a fueling hose when the nozzle is inserted into the vehicles filler neck, two additional communications functions must perform satisfactorily.
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Don’t mount the FMU/FRB antenna close to a metal overhead or wall. RF range will be reduced. Don’t mount the FMU/FRB antenna around the corner of a building or an aboveground storage tank. RF will be blocked, or range will be greatly reduced. The RF transmission is most effective when there is line-of-sight between the FMU and fueling vehicle.
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Don’t expect all downloaded transaction data to be perfect. Improper initial configuration of the FMUs or AIM2™ modules may result in incorrect data. This is verified by post-installation tests performed in accordance with the Acceptance Test Procedure (ATP) provided in the back of this manual.
Version Compatibility As AIM2™ has evolved, enhancements were introduced in a specific version of the hardware, firmware, or software. If problems are being experienced, or if a specific feature or option is not available, it may be because the current version of the hardware, firmware, or software being used is not compatible with another system component, or does not contain the desired feature or option.
means it can perform its function on or off the fueling nozzle. If the nozzle tag is not secured to the nozzle, the nozzle tag may be removed and placed next to a filler neck ring of any vehicle with an authorized AIM2™...
Nozzle Tag (example, without security clamp) Security Clamp Installation (example) Nozzle Hang-Up Extension (example) Figure 3-2. Sample Nozzle Tag Installation A list of vehicles is sent to Syn-Tech Systems when new passive fuel systems are purchased. Syn- Tech reviews the list and selects the appropriate filler neck rings and connecting cables best suited for the vehicles.
Identifying the Vehicle Application NOTE The vehicle/equipment manufacturers have no obligation to inform Syn-Tech Systems of changes they make to their products. Consequently, it is very possible new vehicles or equipment may incorporate changes unknown to Syn-Tech Systems which are not compatible with AIM2™. If you find changes incompatible with AIM2™, inform Syn-Tech’s Customer Satisfaction Center or your FuelMaster representative (regional sales manager or distributor) and every effort will be made to...
SECTION 4 AIM2™ INSTALLATION Installation requirements are coordinated with the purchasing customer when the sale is made. A complete passive fueling system requires the installation of the FMU, all AIM2™ vehicle equipment, and a Central Controller. Installation of the FMU and Central Controller may be accomplished by anyone qualified, and must be installed before installation of the AIM2™...
Installation Options Installations will vary according to the type of connection to the vehicle, and the type of information to be collected. The following installation options are available: 1. Using the OBD Port. See Figure 3-3 for the three types of OBD connections currently supported by AIM2™.
Figure 4-2. AIM2™ Module Layout Using The OBD Port CAUTION • Do not install any AIM2™ components in close proximity to hot or moving vehicle parts. • The AIM2™ module should be mounted out of harms way, but remain accessible for service and troubleshooting.
CAUTION Protective wire loom should be used to enclose and protect cabling routed outside the vehicle passenger compartment. 3. The RFID Extension Cable must be routed from the AIM2™ module outside the passenger compartment to the RFID Interface Module near the fuel tank filler neck. If possible use an existing wire chase opening to route the RFID Extension Cable outside the passenger compartment.
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1. Select a mounting location for the AIM2™ module. Recommended locations are under the dash or under the seat on the same side of the vehicle as the fuel tank’s filler neck. The Analog Speed Sensor Cable has five conductors: 1) RED (8 feet long) to +12 to +42 VDC fused and unswitched, 2) BLACK (2 feet long) to chassis ground, 3) GREEN (8 feet long) to positive odometer, 4) WHITE (8 feet long) to negative odometer, and 5) BROWN (8 feet long) for wakeup/switched +4 to +42 VDC.
compartment. As required, drill a hole large enough for the connector on the RFID Extension Cable to fit through. 8. Either end of the RFID Extension Cable may be connected to the AIM2™ module. Plug one end of the cable into one of the module’s two Tank Ring Ports (Figure 4-2). 9.
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Analog Chronometer Cable has two conductors eight feet long for connections to a maximum of two analog chronometers. b. (Analog Only) The Analog Speed Sensor Cable and Analog Chronometer Cable both must be connected to the AIM2™ module. The Analog Speed Sensor Cable uses eight foot conductors to connect to switched and unswitched power, and a two foot conductor to connect to vehicle/battery ground.
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6. Determine the desired application(s). For engine run time a connection must be made to a source providing power only when the engine is running. For power takeoff (PTO) engage time, a connection must be made to a source providing power only when the PTO is engaged. Connect the Analog Chronometer Cable channel 1 ORANGE wire to the first choice.
AIM2™ Post Installation Tests Following successful installation of the AIM2™ vehicle equipment, the module must be programmed with information sent from the Central Controller. The information is sent to an FMU-3500, then from the FMU to the AIM2™ module. The AIM2™ module cannot be programmed if it 1) does not have a heartbeat, 2) does not recognize the OBD/power connection, 3) does not recognize a nozzle tag insertion into a filler neck ring, and 4) does not recognize an FMU-3500.
SECTION 5 AIM2™ PROGRAMMING Develop an FMU-3500 Programmer An FMU-3500 Programmer is needed to program the AIM2™ module before it is placed in use, and may also be used to perform AIM2™ post installation tests. For small quantity installations, the AIM2™...
e. As desired, input 73,1 to confirm. The following will be displayed: SITE>73,1 SITE> YES confirms the FMU is configured as a Programmer. g. Disconnect in accordance with Product Bulletin 111. 2. Through the Central Controller: a. Verify the FMU is a master FMU configured as an FMU-3500 with AIM2™ antennas, an FMU Radio Board, and a compact flash card, and communications with a laptop or Central Controller has been established.
4. Fabricate a power connection to the upper cabinet. A power cable may be fabricated from components available through Tyco Electronics, and an AC power cord with 18AWG conductors and a male connector. Select an AC power cord with sufficient length to reach from a wall outlet to the Programmer.
CURRENT SIGNATURE = 1234 NEW SIGNATURE (XXXX hex –or- #99999 dec) = 4321 SITE SIGNATURE SET TO: 4321 SAVING SYSTEM CONFIGURATION… CONFIGURATION RECORDED. 2. Use command 59 to change the system type, as required: a. When the 59 command is sent to the FMU, the following display appears: CURRENT SYSTEM OPTIONS (MENU 1) CONFIGURATION --------------------------------------------- A.
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1. Access the FuelMaster software main window. ® NOTE If AIM2 Programmer in the following step is not available, or grayed out, there is no Central Controller operator authorized to make an AIM2™ Programmer Prokee /Smartcard. ® 2. Click on Tables from the menu bar. If AIM2 Programmer is not available or grayed out, proceed to step 3.
Programming the AIM2™ Module Programming AIM2™ modules may only be performed through an FMU-3500 configured as an AIM2™ Programmer. The AIM2™ Programmer may be a fuel island FMU configured as a programmer, or a portable programmer configured from an FMU upper cabinet or an FMU demonstration unit.
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NOTE AIM2™ programming may be initiated with a Supervisor Prokee /Smartcard or an AIM2™ ® Programmer Prokee /Smartcard. following instructions begin using Supervisor ® Prokee /Smartcard. Procedures when using an AIM2™ Programmer Prokee /Smartcard begin with ® ® the display shown in step 6. 4.
******AIM PROGRAMMING COMPLETE******* changing to: NOTE Some older versions of FMU firmware may show RESET instead of CLEAN in the following display. VID: 1001555 [-MAIN MENU-] (PHT A) 1=CALIBRATE 2=INTERFACE 3=CLEAN D=EXIT NOTE The message No Record Found indicates no AIM2™ vehicle record has been found for the VID entered.
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3. Depress 2=PROGRAM. The FMU will search for an AIM2™ to program, but will not find the AIM2™ until a PHT is placed on the vehicle filler neck ring: NOTE If an AIM2™ Programmer Prokee /Smartcard is being used, the following is the first display to be ®...
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must be driven at least 5 miles (a greater distance is recommended for accuracy) and a second odometer reading is entered. AIM2™ will then use this information to calibrate analog speed sensor odometer readings. • Two odometer entries are required to calibrate the odometer. If no odometer entry is shown in step 7, the steps performed to input an odometer entry must be repeated after driving the vehicle to obtain a second odometer entry.
• If a specific chronometer value is not known when calibrating, enter 0 (zero) for the chronometer value and continue. VID: 1001555 [-CALIBRATE-] (PHT A) 1=ODOMETER 2=RUN TIME 3=IDLETIME D=EXIT 12. Depress 2=RUN TIME to calibrate engine run time. A prompt will be displayed to confirm recalibration of engine run time: VID: 1001555 RUN TIME: 000000 (PHT A)
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* SUPV: 1=SYSTEM, 2=PM, 3=ODOM, 4=AIM * * A=CONFIG, B=ISSUES, C=TANKS, D=EXIT * 2. Depress 4=AIM. The following will be displayed: NOTE Some older versions of FMU firmware may show RESET instead of CLEAN in the following display. AIM SUPERVISOR MENU 1=SET PHT, 2=PROGRAM, 3=CLEAN, D=EXIT 3.
NOTE Some older versions of FMU firmware may show RESET instead of CLEAN in the following display. VID: 1001555 [-MAIN MENU-] (PHT A) 1=CALIBRATE 2=INTERFACE 3=CLEAN D=EXIT 6. To change the interface (OBD or SPEED SENSOR), depress 2=INTERFACE. The following will be displayed (example shows OBD, could show SPEED SENSOR instead): VID: 1001555 [-INTERFACE-]...
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NOTE Some older versions of FMU firmware may show RESET instead of CLEAN in the following display. AIM SUPERVISOR MENU 1=SET PHT, 2=PROGRAM, 3=CLEAN, D=EXIT 3. Depress 2=PROGRAM. The FMU will search for an AIM2™ to program, but will not find the AIM2™...
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6. To select clean (reset) the AIM2™, depress 3=CLEAN: VID: 1001555 [-CLEAN-] (PHT A) CLEAN ALL PROGRAM AND CALIB DATA (Y/N)? 7. Depress the Yes key to clean the AIM2™: VID: 1001555 [-CLEAN-] (PHT A) CLEANING... changing to: VID: 1001555 [-CLEAN-] (PHT A) '********** AIM CLEAN COMPLETE **********'...
SECTION 6 ACCEPTANCE TEST PROCEDURE (ATP) When the installation and programming is complete, an Acceptance Test Procedure is performed to document the correct installation of AIM2™, and to verify the system is prepared for day-to-day operation by the purchasing customer. A Commercial AIM2™...
SECTION I Complete when performing upgrades to existing FMUs and/or software. PRE-UPGRADE CAUTION Do not proceed if any site equipment is not installed in accordance with NEC. (Consider the liability to you and Syn-Tech Systems if you proceed without NEC compliance!) 1.
UPGRADE FMU(S) 10. Verify all fixed and mobile transactions (if applicable) were successfully downloaded. Some older mobile systems would download to a master FMU. All transactions being stored in the FMU should be downloaded into the customer’s database before the upgrade is performed.
20. All FMU’s prompted, “PUMP CURRENTLY IN USE, SELECT ANOTHER…” when a dispenser in use was selected from the FMU keypad. Should also display an asterisk (*) to the left of the hose number when selecting the hose. Asterisk indicates hose is in use. 21.
3. FMU hose configuration in the software was updated with correct AIM2™ nozzle IDs (ANIDs), and ANIDs are configured in ascending order. “Grade Positions – XXX” window should contain column for “ANID”, and ANIDs must be numbered in ascending order. 4.
19. AIM2™ installation training for the customer on 10 customer provided vehicles to include OBD and analog (if applicable) type vehicles. Provide AIM2™ installation training on 10 vehicles of different OBD and analog configurations. 20. AIM2™ programming procedures for OBD and analog (if applicable) vehicles. Explain programming process to customer.
VEHICLE DATA (continued) YEAR MAKE MODEL SITE DATA (self explanatory) Master FMU phone number/IP address: (some may have a phone number and an IP address) FuelMaster software version: FMU Firmware Version: Mobile Truck Number and Firmware Version: (if equipped with FuelMaster ®...
If this site is downloaded from a different location, list below (address of Central Controller location if different than site location) Street Address: State & Zip code: NATIONAL ELECTRIC CODE (NEC) COMPLIANCE. N ote below any occurrences of NEC non-compliance. All exceptions must be explained to, and accepted by, the customer before the ATP is signed If the issue is an operational issue, and not a safety issue, document the operational problem.
Hold Harmless Agreement If the Central Controller is linked to the customer’s network, and a wireless network connection to the FMU has been installed, complete the following (not necessary for a point-to-point wireless network between the Central Controller and FMU when not linked to the customer’s network): Customer: SUBJECT: Potential Security Breaches Through Wireless Network Connections to FuelMaster...
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Acceptance Test Procedure (ATP) for Commercial Installations, Upgrades, Startup, and/or Training of FuelMaster AIM2™ ® Customer: Location: This ATP is for AIM2™ installations, upgrades, startup, and/or training. It does not replace the acceptance test required for the installation and startup of a FuelMaster Fuel Management Unit (FMU).
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NOTE In step 9, if not prompted “Database Conversion Finished” or if other errors occurred, call Syn-Tech’s Customer Satisfaction Center (CSC) at 800-888-9136, ext. 1500, for assistance. When the upgrade is complete, restart the customer’s computer and verify the database converted to the new software version.
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23. Each FMU functioned normally when selected dispensers were switched to manual operation. Dispensers switched to manual operation did not appear on the display as being available for a Prokee /Smartcard automated transaction. ® 24. If receipts for Prokee is turned on, verify that the price on the receipt is correct. ®...
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14. Site configuration changes for AIM2™ sites. 15. Online operations for AIM2™ data. 16. Reports providing AIM2™ transaction and vehicle data. 17. Overview of all AIM2™ hardware, hardware connections and hardware operations. 18. Installation process using the AIM2™ installation training document. 19.
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VEHICLE DATA (continued) YEAR MAKE MODEL SITE DATA Master FMU phone number/IP address: FuelMaster software version: FMU Firmware Version: Mobile Truck Number and Firmware Version: Site/Location: Street Address: State & Zip code: Point of Contact: Phone Number: Fax Number: Email Address:...
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If this site is downloaded from a different location, list below: Street Address: State & Zip code: NATIONAL ELECTRIC CODE (NEC) COMPLIANCE. N ote below any occurrences of NEC non- compliance. All exceptions must be explained to, and accepted by, the customer before the ATP is signed .
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SIGNATURE AND FINAL SIGN OFF Certified Installer/Startup Technician (Printed Name): Certified Installler/Startup Technician (Signature): Authorized Service Representative (ASR) Number: Date: Customer Representative (Printed Name): Customer Representative (Signature): Date:...
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Hold Harmless Agreement Customer: SUBJECT: Potential Security Breaches Through Wireless Network Connections to FuelMaster ® Wireless networks operate on radio waves that can be intercepted by anyone with the right equipment and within range of the transmitter. Without proper wireless network security, outside users can access your network to attain such valuable information as social security numbers, credit card numbers, bank account numbers, and countless other private information sources.
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Your vehicle has been installed with an AUTOMATED FUELING DEVICE (AIM2™) It is no longer necessary to use your fuel key at the Fuel Site. To fuel: Step 1 ~ Shut vehicle off. Step 2 ~ Remove nozzle from pump. Step 3 ~ Completely insert nozzle into tank.
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AIM2™ Vehicle Installation Worksheet VEHICLE ID: DATE INSTALLED: ODOMETER: CHRONOMETER: AIM MOUNTING LOCATION: CABLE TYPE: OBDII 6 PIN 9 PIN ANALOG RF / ID CABLE: 15 ft 20 ft 30 ft 50 ft AIM2 VER: FILLER RING: SINGLE TANK DUAL TANK INSTALLATION NOTES: Make: __________________ Model: ________________ Year:_______ INSTALLER(S):...
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