FUEL MASTER AIM 2 Installation Manual

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INSTALLATION

MANUAL

9 OCTOBER 2009

Syn-Tech Systems, Inc.

P.O. Box 5258

Tallahassee FL 32314

www.syntech-fuelmaster.com

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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 ................................................................ 9

FuelMaster® Warranty........................................................................................ 9

Initialization Requirement ..................................................................................10

Safety Related Inspections and Preventive Maintenance .....................................10

Consumables/Special Tools ...............................................................................10

Improvements ...................................................................................................11

SECTION 2 – SYSTEM DESCRIPTION ...................................................................13

FuelMaster® Passive Fueling..............................................................................13

Typical Fueling Transaction ..........................................................................13

Installation Requirements .............................................................................15

Components of a Passive Fueling System ..........................................................15

FMU-3500 and FMU Upgrades ......................................................................15

FMU-3535 Passive Mobile ............................................................................16

Automotive Information Module .....................................................................16

AIM2™ Module External Antenna ..................................................................17

Access Point ................................................................................................17

AIM2™ Programming Key .............................................................................17

Nozzle Tag ..................................................................................................17

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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 .......................................................................26

Selecting the Correct Filler Neck Ring and RFID Extension Cables......................27

Selecting the FMU Mounting Location ................................................................28

Identifying the Vehicle Application......................................................................29

SECTION 4 – AIM2™ INSTALLATION .................................................................... 31

Installation Options ...........................................................................................32

Using the OBD Port ......................................................................................33

Using a Vehicle Speed Sensor (Odometer) Input Only....................................34

Using an Analog Chronometer Input ..............................................................36

AIM2™ Post Installation Tests ...........................................................................39

SECTION 5 – AIM2™ PROGRAMMING...................................................................41

Develop an FMU-3500 Programmer....................................................................41

Configure an FMU-3500 as an FMU-3500 Programmer...................................41

Through a Laptop Connection ..................................................................41

Through the Central Controller.................................................................42

Develop a Portable FMU-3500 Programmer

from a Fully Configured FMU-3500................................................................42

Develop an FMU-3500 Programmer from an FMU-3500 Demonstration Unit.............. 43

Create an AIM2™ Programmer Prokee®/Smartcard

Programming the AIM2™ Module

...........................................................44

............................................................................ 46

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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™......................................................................................57

SECTION I

PRE-UPGRADE ................................................................................................58

UPGRADE SOFTWARE..................................................................................... 58

UPGRADE FMU(S)............................................................................................59

OPERATIONAL CHECKS .................................................................................. 59

SECTION II

AIM2™ SOFTWARE OPERATIONS ................................................................... 60

AIM2™ FMU CONFIGURATION......................................................................... 61

TRAINING ........................................................................................................ 61

TRAINING ATTENDEES.................................................................................... 62

VEHICLE DATA ................................................................................................62

SITE DATA .......................................................................................................63

NATIONAL ELECTRIC CODE (NEC) COMPLIANCE ........................................... 64

EXCEPTIONS ................................................................................................... 64

COMMENTS/SUGGESTIONS ............................................................................64

SIGNATURE AND FINAL SIGN-OFF

....................................................................... 65

Hold Harmless Agreement ............................................................................66

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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. Nozzle Tag Clamp and Kit Part Numbers................................................19

Figure 2-4. AIM2™ Vehicle Components ................................................................20

Figure 2-5. OBD II Pass-Thru Cable .......................................................................20

Table 2-4. Filler Neck Rings...................................................................................21

Table 2-5. Connecting Cables and Devices.............................................................22

Table 3-1. Version Compatibility ............................................................................26

Figure 3-1. CV Joint Boot Clamp Pliers ..................................................................27

Figure 3-2. Sample Nozzle Tag Installation.............................................................28

Figure 3-3. OBD Connectors ..................................................................................29

Figure 4-1. AIM2™ Connection – Flow Chart ..........................................................32

Figure 4-2. AIM2™ Module Layout .........................................................................33

Figure 5-1. 4x4 Keypad Shift Instructions ...............................................................46

APPENDICES

Access Point Installation and Setup Procedure ......................................................TBD

ATTACHMENTS

Acceptance Test Procedure (ATP) for Commercial Installations, Upgrades, Startup, and/or Training of FuelMaster

Hold Harmless Agreement (blank)

AIM2™ Installation Notice

AIM2™ (blank)

AIM2™ Vehicle Installation Worksheet (blank)

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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 software are copyrighted 2009, and are provided under a license agreement containing restrictions on its use. Except as stated in the license agreement, the firmware and software may not be copied or distributed in any form or medium or disclosed to third parties. Users are legally accountable for any violation of the License Agreement or of copyright law.

firmware and

Introduction

This manual provides installation and setup instructions for the Syn-Tech Systems, Inc., FuelMaster® AIM2™ Automotive Information Module (herein referred to as AIM2™) and associated equipment. These instructions have been prepared for the exclusive use of installation technicians who are qualified to complete electrical work on vehicular electrical systems. AIM2™ consists of equipment developed to initiate passive fueling through a FuelMaster FuelMaster

FMU-3535 Passive Mobile Fuel Management Unit.

FMU-3500 Fuel Management Unit, or a

Passive fueling, as used in this context, is the initiation of a fueling transaction by the AIM2™ equipment without the need for operator input. The fueling customer pulls his/her vehicle up to the fuel dispenser (or fuel truck), takes the fuel nozzle down from the dispenser, and inserts it into the vehicle fuel filler neck. This action prompts the AIM2™ equipment in the vehicle to transmit authorization via RF (radio frequency transmission) to the FuelMaster fueling hose. When complete, the fueling customer returns the nozzle to the dispenser, returns to his/her vehicle and drives away. The FMU-3500/3535 records the fuel transaction and stores the fueling information until downloaded by the FuelMaster

FMU-3500/3535 which, in turn, activates the

Fuel Management Software operator.

Purpose

FuelMaster® fuel accounting and control provides Syn-Tech’s customers with a means to control access to metered products at self-service service stations, and to account for and invoice for the dispensed products. FuelMaster maintaining complete accountability of each transaction as it occurs. FuelMaster provides for secure, accountable control of fuel dispensing without direct user access of the fuel management system. Transaction data is compiled after downloading data to a central accounting office hundreds, or thousands of miles remote from the servicing operations.

accomplishes this with security from unauthorized user access while

passive fueling

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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. The installer must be knowledgeable of these and any other applicable safety codes and standards. All FuelMaster complies with applicable federal, state, and local safety codes and standards.

This manual makes recommendations for commercially available equipment and materials that are required to complete an installation. Trade names and part numbers are also referenced to cite products that have been tested and known to be serviceable with passive fueling equipment. Modification of the equipment provided, substitution of any material requirements, or any deviation from these installation instructions must comply with all applicable safety codes and standards.

Use the following guidelines during installation and maintenance to help protect your passive fueling equipment from potential damage and ensure your own personal safety:

Protecting Against Electrostatic Discharge

passive fueling equipment

Static electricity can harm delicate AIM2™ components. To prevent static damage, discharge static electricity from your body by touching an unpainted metal surface before you touch any AIM2™ electronic components.

As you continue to work with AIM2™, periodically touch an unpainted metal surface to remove any accumulated static charge. Use of a wrist-grounding strap is highly recommended.

The following steps should also be taken to prevent damage from electrostatic discharge (ESD):

• Keep a static-sensitive component in its antistatic packing material until ready for use. Just before unwrapping the antistatic packaging, discharge accumulated static electricity by touching an unpainted metal surface.

• 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.

Correcting RF Interference

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;

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• 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. Nameplates displaying the ETL logo are affixed to the AIM2™ module, FMU-3500, and FMU-3535.

WARNINGS, CAUTIONS, and NOTES

This manual emphasizes special operations with WARNINGS, CAUTIONS, or

NOTES preceding the applicable procedure:

• A

WARNING indicates a safety precaution that, if not followed, could result in personal

injury;

CAUTION indicates a safety precaution that, if not followed, could result in damage to

• A equipment; and,

NOTE indicates a procedure requiring special emphasis for the proper installation and

• A operation of Passive Mobile equipment.

FuelMaster® Warranty

The basic warranty on all FuelMaster® equipment begins 12 months after the completion of initialization or 15 months after shipment from Syn-Tech Systems. Initialization must be completed by a Syn-Tech Systems FuelMaster® technician, or a technician who has completed Syn-Tech Systems installation certification training. Each Prokee® is warranted against defects in material and workmanship for a period of five years. A toll-free number for technical assistance is also included. This line affords the customer access to product support personnel who will answer questions regarding operation of FuelMaster® hardware or software, and provide diagnostic capabilities when necessary.

Under terms of this agreement, FuelMaster® technicians will telephonically diagnose problems, with the assistance of the customer, to determine warrantable conditions, and possible problem solutions. Syn-Tech Systems will replace all defective parts and provide assistance to the customer in installation of replacement parts to allow the unit to be repaired as expeditiously as possible. Please note that FuelMaster® was designed in a modular manner to provide easy and rapid exchange of parts, even by non-technical personnel. Other systems are not designed this way and consequently; do not offer warranties comparable to FuelMaster®. This warranty does not cover site visits by FuelMaster® technicians for repair.

Please note that damage resulting from acts of god, user abuse, accidents, faulty installation or operation is not covered under the warranty. This warranty specifically excludes any indirect, special, or consequential damages to include, but not limited to, loss of product, profit, or litigation fees. Additionally, associated equipment including printers, personal computers, and other items not

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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® Fuel Management Systems must be initialized by Syn-Tech trained personnel. Initialization is the startup inspection and tests performed to certify the installation. Initialization can be completed only by a Syn-Tech FuelMaster® technician, or a technician who has completed installation certification training for AIM2™. Final certification must be accomplished jointly by the Customer and Syn-Tech trained personnel.

Safety Related Inspections and Preventative Maintenance

AIM2™ requires no preventative maintenance to retain its user safety features. Whenever AIM2™ is updated or repaired, a post-installation safety inspection should be performed of all wire connections and hardware installations.

Consumables/Special Tools

Consumable/Special Tool Application

CV joint boot clamp pliers Crimp nozzle tag security clamps

Dielectric grease Prevent corrosion and protect electrical connections exposed to the environment

12 AWG THHN stranded wire (Green) AIM2™ module ground wire(s)

Wire loom Cable/wire protection

Rubber grommets Protect cables/wires routed through drilled holes

Silicon sealant (GE blacktop/roof, 100% silicon) Seal grommets

Cable ties (black UV protected) Secure cables/wires

3M Scotch® Rubber Mastic Tape 2228 Weatherproof RFID Interface Module

18 AWG THHN stranded wire (Red, Black, Speed sensor wires Green, White, Brown)

18 AWG THHN stranded wire (Orange, Analog chronometer wires Blue)

AC power cord w/18 AWG conductors Power cable for FMU-3500 Programmer and male plug

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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), [email protected] or by mailing to:

SYN-TECH SYSTEMS

Attn: Product Support

P.O. Box 5258

Tallahassee, FL 32314

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SECTION 2

SYSTEM DESCRIPTION

Syn-Tech Systems, Inc. offers a passive fueling version of their world renowned Fuel Management Unit (FMU). The FuelMaster the addition of components required to facilitate passive operation. AIM2™ is the trademarked name of Syn-Tech’s passive fueling system. The name AIM2™ is derived from the principle component of the system, the second generation Automotive Information Module.

The installation procedures contained herein will only cover the taskings unique to AIM2™ passive fueling, and any differences as they apply to FMU and software installations. Basic FMU installation must be referred to the FMU-2500 Installation Manual. Software setup and operation must be referred to the FMPlus User Guide.

Plus FMU-3500 is built on the widely accepted FMU-2500 platform with

FuelMaster® Passive Fueling

FuelMaster® passive fueling provides for secure, accountable control of fuel dispensing without the need for user access of the FMU.

Vehicles (or other equipment items) and fuel island dispensers are fitted with passive fueling equipment, and an FMU-3500 is installed to authorize and record fueling. The FMU-3500 links the vehicle to the dispenser. Options are available to upgrade other existing models of FMUs to the FMU3500 configuration. It may not be necessary to purchase new FMUs to acquire passive fueling.

Typical Fueling Transaction: Automation and control are totally transparent to the fueling

customer in a typical AIM2™ fueling transaction. The fueling customer drives an AIM2™ equipped vehicle up to the fuel dispenser, takes the fueling hose down, turns on the dispenser, inserts the fuel nozzle into the fuel tank filler neck, and pumps fuel. When fueling is complete, the customer removes the nozzle, turns off the dispenser, hangs the nozzle up, then returns to the vehicle and drives away. Through this procedure, the passive fueling system has authorized the transaction, then recorded the vehicle, quantity, product, hose, date, time, and odometer/chronometer reading at the time of the transaction, and accomplished all this without user access of the FMU. Table 2-1 reflects additional data which may be recovered by AIM2™ through an OBD II (onboard diagnostics) connection. Availability of this data will be dependent upon the vehicle and its ability to generate the data. Light/Heavy Duty is primarily to differentiate between the types of OBD connections available. As shown in the table, Heavy Duty vehicles may generate more data.

Insertion of the fuel nozzle into the vehicle’s filler neck triggers the AIM2™ module (vehicle transceiver) to send authorization information to the FMU. Upon receipt of an authorized input, the FMU turns on the selected dispenser hose and records the fuel quantity pumped into the vehicle. Removing the fuel nozzle from the vehicle’s filler neck ends the transaction. Fueling cannot be resumed without reinserting the nozzle into an AIM2™ equipped vehicle, or by the user accessing the FMU with an alternate access device (Prokee Automated transactions may only be initiated by vehicles or access devices with the same Site Signature (unique customer identifier) as the FMU controlling the fuel dispensers.

Passive fueling transactions may also record user identification through keypad entry at the FMU, or by passing a proximity card across the optional Proximity Card Reader.

, Smartcard, credit card) or keyless configured entry.

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Table 2-1. AIM2™ OBD Data Collection Parameters

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Installation Requirements

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™ modules are installed in the vehicles.

Although not absolutely required, Syn-Tech Systems recommends installation of the FMU-3500 and Central Controller initially for use with a direct access device such as a Prokee card, or Keyless entry. This permits the development of the required databases, and installation of the AIM2™ modules in preparation for passive fueling. As the AIM2™ modules are installed, the other interfaces will already be in place to bring passive fueling online.

: The normal sequence of events to complete the installation of an

, Smartcard, credit

Components of a Passive Fueling System

FMU-3500 and FMU Upgrades. The FMU-3500 is an FMU-2500 equipped for passive

fueling. FMUs of other configurations may be upgraded to FMU-3500 to gain passive fueling capabilities. The FMU-3500 will have a backup function for user access with a Prokee Smartcard, magstripe card, or through Keyless transaction entry. Features which make an FMU3500 compatible with passive fueling are:

Firmware Version

Power LED

Channel A Receive LED

Channel A Transmit LED

Channel B Receive LED

Channel B Transmit LED

Channel A

Channel B

Figure 2-1. FMU Radio Board (FRB)

• An FMU Radio Board (FRB) which functions as a transceiver to receive inputs from, and send programming information to AIM2™ equipped vehicles and equipment. The FRB includes A

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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. The antennas are connected internally to the FRB. External antennas may be necessary when an FMU is physically separated from line-of-sight with the fueling vehicles. The external antennas may be used to restore line-of-sight to the fueling vehicles. External antennas installed under a roof or higher than FMU height should be installed horizontally instead of vertically. The two antennas should be spaced 8 inches (or in multiples of 8 inches) apart.

• Quad UART board to control a second FRB when a secondary application requiring directional antennas (for Access Point) is needed.

• A Compact Flash Card for operating and programming memory. It is absolutely necessary for FMU-3500 functions. The compact flash card is now standard in all FMU-2500 series units. Some older FMU-2500 units being upgraded to FMU-3500 may require a newer revision mainboard to accept and correctly read compact flash cards.

FMU-3535 Passive Mobile. The FMU-3535 Passive Mobile is an FMU-3500 adapted for

mobile use on tanker trucks. The FMU-3535 provides a mobile capability for fueling AIM2™ equipped vehicles or equipment which may not be able to return to a service station for fueling. Passive Mobile installations are covered in a separate installation manual.

Automotive Information Module. The Automotive Information Module (see Figure 2-2) is

an intrinsically safe vehicle mounted transceiver/computer which stores vehicle information and communicates with the FMU to authorize fueling hoses and receive programming information. The standard module (part number 941B0420A) has an internal antenna and is suitable for most applications. When necessary, an external antenna may be installed and connected to part number 941B0420B AIM2™ modules. 941B0420A modules do not have external antenna connections. 941B0420B modules do not have internal antennas. External dimensions of both modules are approximately 5-5/8 inch long x 2-3/8 inch wide x 1 inch high. Acceptable input power is 12 VDC to 42 VDC. AIM2™ modules draw 0.4 amps when active, and 0.0134 amps in sleep mode. The AIM2™ module is designed for operation in temperatures ranging from -60 to +140 degrees F.

Indicator LEDs

External Antenna

Connector

941B0420A 941B0420B

Figure 2-2. AIM2™ Modules

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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. The chronometer cable does not make power connections.

Amber, Yellow, Green, and Red indicator lights (LEDs) are built into the center top surface of the AIM2™ module for feedback of operating and programming conditions. These LEDs must remain visible after installation for testing and troubleshooting.

AIM2™ modules go to “sleep” (become idle and operate on reduced input power) 2 minutes after the vehicle ignition is turned off or, if within communications range of an active FMU-3500, 15 minutes after the vehicle ignition is turned off. The module must be “wakened” before fueling may occur. Turning on the vehicle ignition or starting the engine will waken the module.

AIM2™ modules have three possible interface settings or states: NONE, OBD, or SPEED SENSOR. NONE is the default. When the module is set to NONE, it will not go to sleep. OBD and SPEED SENSOR indicate an OBD or analog connection. When connected to an OBD connector, an AIM2™ module will detect OBD and change state as soon as the vehicle is turned on. When connected to a SPEED SENSOR, the AIM2™ module will not change state until the vehicle starts moving. Reefers require the engine to be started after installation to change state.

AIM2™ Module External Antenna. The AIM2™ module has to communicate with the FMU

FRB. Some vehicle mounting applications may not readily support communications between the AIM2™ and FMU. In these instances an external antenna may be mounted on the vehicle and connected to the AIM2™ module to ensure RF coverage. Syn-Tech has external antenna kits available with 13 or 20 foot long cables, mount brackets, and the necessary fittings to connect to AIM2™ modules equipped to accept external antenna connections.

Access Point. An Access Point is a device developed solely to control gate/door/carwash

access or description and installation procedures for an Access Point may be found in Appendix A to this manual.

AIM2™ Programming Key. A Prokee

Programming Key will only permit programming of an AIM2™ module.

monitor vehicle movement via RF transmission from an AIM2™ equipped vehicle. A full

/Smartcard with special application; an AIM2™

Nozzle Tag (sometimes referred to as Hose Tag). The Nozzle Tag is an intrinsically safe device

installed on the fuel dispenser (or Passive Mobile) fueling nozzle to initiate a passive fueling transaction. The Nozzle Tag contains an antenna coil and RF/ID chip programmed with a number to identify the fueling nozzle it is attached to. Unique to FuelMaster require a cable routed down or through the fueling hose for power. Nozzle Tags are available in a variety of sizes and shapes to accommodate most known fuel nozzle types. Figure 2-3 is an example of a nozzle tag. Table 2-2 is a listing of nozzle tags in production at the time of this writing. Additional nozzle tags may be developed as the need arises. Table 2-3 is a listing of CV (constant velocity) boot clamps offered by Syn-Tech Systems to secure the nozzle tag to the fuel nozzle. Table 2-3 also lists a kit part number which contains the more popular nozzle tags with a CV boot clamp.

, the Nozzle Tag does not

Programming Hose Tag (PHT). A specially programmed nozzle/hose tag used to identify

vehicles when programming. These are identified with an attached label containing a letter (one letter,

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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. Sample Nozzle Tag

Table 2-2. Nozzle Tag Applications

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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). Filler neck rings are available in a variety of sizes for installation on a variety of vehicle fuel tank filler necks (see Table 2-4 for a breakdown of sizes, profiles, and pigtail lengths). Filler neck rings may be glued in place with a gasoline and oil-resistant adhesive such as Seal-All from Eclectic Products, Permatex or 3M Super Weatherstrip adhesive, or Gorilla Glue (for rough surfaces). If you cannot find one of these adhesives, try to find something with similar properties which is gas and oil-resistant, and will not damage the rubber surface of the filler neck ring. Lipped filler neck rings may also be tacked in place with screws if care is taken not to contact the internal coil of the filler neck ring.

The RFID Interface Module generates the signal for the filler neck ring to communicate to the nozzle tag. When the nozzle tag is brought close enough to the filler neck ring, information (hose number) in the nozzle tag is received by the filler neck ring and transmitted through the RFID Interface Module and RFID Extension Cable to the AIM2™ module. Early variations on the RFID Interface Module had connectors exiting straight out of the end of the module. Current versions of the module have connectors positioned at right angles to the module. There are also some newer variations with clear (instead of black) potting. Figure 2-4 illustrates a sampling of the vehicle components which complete the connections from the filler neck ring forward to the AIM2™ module.

Connecting Cables. The AIM2™ module receives connections from an assortment of cables

designed for the application. RFID Extension Cables connect between the RFID Interface Module and AIM2™ module, and are available in 15, 20, 30, 50, and 80 foot lengths. Connections through the OBD port provide information and power to the AIM2™ module. Figure 2-5 is of an OBD II light duty connection cable with a pass-thru connector which allows for connection of an OBD diagnostic tester without disconnecting AIM2™. Other cables are available for other types of OBD connections.

Cables for analog connections to a speed sensor or chronometer have pigtails for the necessary connections. Analog chronometer connections do not connect to vehicle power. AIM2™ module power must be derived from an OBD or speed sensor cable connection.

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AIM2™ Module

Filler Neck Ring

RFID Extension Cable

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. Engine runtime may be a power source which is only supplying power when the engine is running; PTO (power takeoff) engage time may be a power source which is only supplying power when the PTO is engaged. Chronometer inputs may be from as many as three different sources: through the OBD connection and up to two analog chronometer inputs, to record vehicle run and idle time, and PTO time.

Cables are available for combining two separate fuel tanks and their filler neck rings into one AIM2™ module. When this is done, fillups to either tank are recorded. When the transactions are downloaded into the software, the vehicle record has only one tank record so transactions from

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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™ module when a separate fuel tank is installed.

Table 2-4. Filler Neck Rings

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Table 2-5. Connecting Cables and Devices

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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. First, the nozzle tag must communicate with the filler neck ring to initiate a transaction and, secondly, the AIM2™ module must communicate with the FMU to activate the transaction.

NOTE

A vehicle/equipment listing is requested from new customers planning AIM2™ installations. Syn-Tech Systems will review the listing and select the nozzle tags, filler neck rings, and connecting cables required to outfit the vehicles and equipment items.

System planning involves the following considerations:

1. Review of the “Fundamental Do’s/Don’ts” which follow these considerations;

2. Developing a database of vehicle records for each vehicle/equipment item receiving AIM2™;

3. Selection of the correct nozzle tag;

4. Selection of a filler neck ring compatible with the vehicle and nozzle tag;

5. Selection of the proper length RFID Extension Cable to connect between the RFID Interface

Module and AIM2™;

6. Selection of the correct interfacing cables to connect the AIM2™ module to the vehicle OBD,

analog speed sensor, and/or analog chronometer;

7. Examination of the vehicles/equipment items receiving AIM2™ to determine if external

antennas will be required; and

8. Selection of a suitable mounting location for the FMU where it can communicate to all the

passive-equipped vehicles fueling through it. If such a location is not available, are there locations available for mounting external FMU antennas?

Insufficient consideration of any one of these functions will return poor performance from the passive fueling system.

Fundamental Do’s/Don’ts

There are fundamental key points which must be considered for installation success. Follow these crucial Do’s/Don’ts closely when planning your AIM2™ installation:

Don’ts

Don’t mount the FMU/FRB antenna in a kiosk. RF transmission will be blocked, or range will be

greatly reduced. If the FMU is already installed in a kiosk, install FMU external antennas so the vehicle/equipment can communicate to the FMU with direct line-of-sight.

Page 24

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.

Don’t mount AIM2™ modules in a metal or fiberglass box. AIM2™ modules have built-in antennas and are designed to communicate directly with passive FMUs. RF transmission will be blocked or greatly reduced if installed in a metal or fiberglass box. If it is absolutely necessary to mount the AIM2™ module inside a metal or fiberglass enclosure, plan on using an external AIM2™ antenna.

Don’t expect fueling to occur if there is any obstruction (semi, bus, ready-mix truck, etc) between the FMU and vehicle. There will be no link between the FMU and vehicle. RF will be

blocked, or range will be greatly reduced. The RF transmission is most effective when there is lineof-sight between the FMU and fueling vehicle.

Don’t expect more than about 50 feet communication range between the FMU and vehicle in most fuel island scenarios. AIM2™ was designed to transmit between a vehicle at a fueling point,

and the FMU controlling that fueling point. Typically this distance is limited by the size of the fueling island. Some minor range extensions may be expected when using external AIM2™ and/or FMU antennas. Installation costs may be minimized by planning for a 50 foot communications range, and deferring the installation of external antennas.

Don’t expect satisfactory operation from all in-vehicle under-dash installations. Some will require the AIM2™ module to be mounted in a less obstructed area. Some will require connection to an external antenna. Some under-dash installations may not allow RF

communication with an FMU. Should this occur, move the AIM2™ module to another location with less obstruction, or install an external antenna.

Don’t expose the AIM2™ module to road debris, gasoline, ozone, freezing rain, road salt, UV radiation, and human abuse. The AIM2™ module can survive the same temperatures as the

vehicle, but service life will be greatly shortened by exposure to the environment.

Don’t expect consistent filler neck ring antenna to RF/ID nozzle tag communication if the range is more than a couple of inches. The nozzle tag and filler neck ring are tuned to

communicate with each other at a distance of two inches or less, and to terminate the transaction when the nozzle is removed from the filler neck.

Don’t install nozzle tag behind/above splash guard. A splash guard will block nozzle tag RF connection to filler neck ring.

Don’t expect all vehicles to be OBD II compatible even if they have an OBD II connector.

Some vehicles may have multiple OBD connectors, some of which will not power the AIM2™ module. Some vehicles will have an OBD connector and use an analog speedometer or chronometer.

Don’t expect all nozzles to be RF/ID Tag compatible. Interfaces have been made to a wide variety of nozzles, but new nozzle types still appear. If the nozzle is not common and listed in Table 2-2, call your FuelMaster

regional sales manager or distributor. Custom applications have been

made for unique fueling nozzles.

Don’t complete all your vehicle and FMU installations before testing the system for satisfactory operation. If some error has been made in the installation of any of the equipment,

don’t wait until all the installations are complete to find out. Test some newly installed vehicles to verify satisfactory performance. Whenever a new installation is performed on a new type vehicle or with a new cable, test the installation before proceeding with similar installations.

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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.

Don’t let vehicles sit for extended periods of time without charging the battery. An AIM2™ is another vehicle accessory drawing approximately 30 milliamps. Extended periods of inactivity without charging the battery may draw the battery down.

Don’t expect nozzle tags to last forever. Continued exposure to fuel, ozone, the sun’s radiation and human contact will, over time, cause the material to break down.

Do’s

Do mount an FMU on each fuel island. AIM2™s were designed to transmit 50 feet between a

vehicle at a fueling point, and the FMU controlling that fueling point. Fueling vehicles on islands where there are no passive FMUs results in extended RF range, and continual vehicle movement between the islands, both of which will degrade RF performance.

Do consider remote, external antenna configurations for both the vehicle and FMU where existing conditions may limit RF performance. These antenna options may be used to increase

range.

Do request assistance with scenarios requiring more than 50 feet of FMU to vehicle range. Our experience could save a lot of time and expense with scenarios which may not match the requirements listed herein. Discuss with your FuelMaster

regional sales manager or distributor.

Do protect environmentally exposed AIM2™ modules. If the only available enclosure on the vehicle or equipment is metal or fiberglass, purchase an inexpensive weatherproof plastic box to house the AIM2™ module, or mount the module in the existing metal or fiberglass enclosure and use an external antenna for RF communications.

Do insure the filler neck ring is mounted as close as possible to the top of the filler neck, and is secured in place. The filler neck ring is an antenna which must remain within two inches of the

nozzle tag when a fuel nozzle is inserted into the filler neck.

Do install, configure and test vehicle installations individually. The basic principles of troubleshooting prevail. If a problem appears you want the problem limited to the fewest probable causes.

Do check the transaction data downloaded from the FMU. Downloaded transaction data may be used for invoicing, tax purposes, and verifying credit card transactions. Proof the downloaded transaction data to verify it remains accurate. Retail transactions should especially be monitored to keep pricing current with fuel costs, and to ensure download quantities match pumped quantities.

Do read FMU-2500/3500 and Passive Mobile Installation and User Manuals. FMU, Passive Mobile, and software installation and operation instructions are incorporated in other, separate manuals.

Do insure FMUs are configured correctly. FMUs may be configured from either the FMU or the Central Controller. They may also be reconfigured with incorrect data from either the FMU or Central Controller. It’s a good practice to make a backup paper copy of a known good configuration

report.

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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. See Table 3-1 for a list of version compatibilities.

Table 3-1. Version Compatibillity

Developing a Database of Vehicle Records

The Central Controller must be set up and the Fuel Management Software installed in accordance with the FMPlus User Guide. Particular attention should be given to selecting AIM2™ as the passive system type so the software will prompt for the correct information as the database is developed. The chapter covering AIM2™ Software Operations must be followed and all procedures performed to properly set up the vehicle records needed to program the AIM2™ modules.

If an upgrade is being performed and the software was previously set up for a non-passive system, the software may be reconfigured to develop vehicle records for an AIM2™ passive system. In the FMPlus User Guide, refer to System Configuration, Passive System Type. This paragraph will describe what is necessary to change the program to an AIM2™ passive system program which will allow for the development of vehicle records for programming AIM2™ modules.

Once developed, the vehicle records for the AIM2™ equipped vehicles are uploaded to the FMU selected to be the programming FMU. See AIM2™ Programming after Installation.

Selecting the Correct Nozzle Tag

The nozzle tag must fit on the dispenser fueling nozzle. When the nozzle is inserted into the vehicles fuel tank filler neck, the nozzle tag must be within two inches of the filler neck ring, preferably closer, or touching, and the two devices should be parallel to each other. Being within 2 inches on one side and 3 inches on another side will not initiate communications. This alignment has initiate a fueling transaction. The nozzle tag is programmed with a hose number corresponding to a specific product. The nozzle tag will mark the transaction with the hose number and corresponding product pumped during a transaction.

to be correct to

The nozzle tag has no wire connections to the fuel dispenser or vehicle. It is totally independent. This

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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™ module. This will actuate the hose the nozzle tag was removed from permitting it to fuel anything the nozzle is inserted into. Installation must Nozzle tags should be secured to fueling nozzles by placing a clamp around the nozzle tag as shown in Figure 3-2. CV joint boot clamps which require a special tool for installation provide the best security because of their difficult removal. Kits are available through Syn-Tech Systems which contain some of the more common nozzle tags and a CV joint boot clamp (see Table 3-1). CV joint boot clamp pliers (Figure 3-1) are required to install these clamps, and are available through any automotive parts outlet.

provide for security of the nozzle tag.

Figure 3-1. CV Joint Boot Clamp Pliers

Nozzle tags have been developed for a wide variety of fueling nozzles to include Stage 1, Stage 2, vacuum assist, and balanced vapor recovery, Emco Wheaton Posi/Lock, Healy EVR, and others. Nozzle tags may be cross-referenced to the fueling nozzle being used. Use Table 2-2 to select a nozzle tag for the fueling nozzle in use.

Nozzle tags may prevent the normal hang-up of the fueling nozzle after the transaction is complete. Figure 3-2 also shows an example of a Nozzle Hang-up Extension installed to permit the nozzle to be hung up on the dispenser after a nozzle tag is installed. The extension shown was manufactured by the customer. We are not aware of any nozzle hang-up extensions commercially available for this application.

Selecting the Correct Filler Neck Ring and RFID Extension Cables

Filler neck rings must 1) fit around the filler neck of the fuel tank, 2) allow the filler cap to be installed,

3) permit the nozzle tag on the fuel nozzle to be brought up against (or parallel within 2 inches) of the

filler neck ring, and 4) connect to the RFID Interface Module (Lump Board) installed in a protected mounting location. All this must be considered when selecting the correct filler neck ring.

The appropriate RFID Extension Cables in the correct length must be selected to connect between the RFID Interface Module and the AIM2™ module. It may be prudent to opt for a longer cable if the needed length is close to one of the cable lengths. All the AIM2™ vehicular equipment may one day be transferred to another vehicle, and the additional length may be needed. RFID Extension Cables should not be extended or spliced.

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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. SynTech reviews the list and selects the appropriate filler neck rings and connecting cables best suited for the vehicles. For other requirements, refer to Table 2-4 to select the correct filler neck ring, and Table 2-5 to select suitable connecting cables/devices.

Selecting the FMU Mounting Location

In addition to the need for dispenser control, a passive FMU-3500 also needs to be positioned where it can communicate to all the vehicles being fueled through it. Communications to the vehicle is to the AIM2™ module which is not usually mounted within direct sight of the FMU. The AIM2™ module is often installed under the vehicle dash or in some kind of weatherproof compartment to protect it from the elements.

When using the standard antennas provided with the FMU, the FMU-3500 should be mounted within 40-60 feet of the vehicle fueling positions. If traffic is continually moving between the fueling vehicles, or if the FMU is inside a building or behind a wall, external antennas may be installed to restore the line-of-sight.

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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 make AIM2™ operable with the changes.

Light duty general purpose vehicles (sedans, vans, pickups) manufactured since 1996 have an OBD

generation on-board diagnostic) port. Heavy duty vehicles with on-board diagnostics have a

II (2 different protocol resulting in a different type connector. The connector style will determine the cable necessary to connect the AIM2™ module to the vehicle. The cable provided must plug into one of the connectors illustrated in Figure 3-3. These vehicles power the AIM2™ module through this diagnostic connection.

Some heavy duty vehicles may have multiple data ports. To determine which port to use, connect a compatible cable between the data port and the AIM2™ module. A yellow OBD Connect light will illuminate when an active port is connected, and the vehicle ignition is switched on.

representative (regional sales manager or distributor) and every effort will be made to

Light Duty

Pass-Thru;

243256A

With

Use

Cable

Heavy Duty

J1708 6-Pin;

Use

244058

Cable

Heavy Duty

J1939 9-Pin;

Use

244066

Cable

Figure 3-3. OBD Connectors

Most vehicles manufactured prior to 1996, and other vehicles which do not have computers, may require AIM2™ connection to an analog speed sensor or chronometer to recover vehicle mileage or operating hours. Some vehicles with computers may also have cable driven speedometers. If a speed sensor or chronometer is not installed, it may be provided with the purchase of the other AIM2™ equipment. Connection through a speed sensor or chronometer requires a connection to an external power source. AIM2™ may be powered by any power source from 12 to 42 VDC. Two connections are required: one to an unswitched power source, and another to a switched power source powered through the ignition switch.

The AIM2™ module need not be heated for protection from the cold, but it must be installed where it will not be exposed directly to the weather. It is not weatherproof. If the vehicle requires the AIM2™ module to be installed inside a metal box for protection from the weather, an external antenna should be considered. AIM2™ modules are available with an external antenna connector, and external antennas are available through Syn-Tech Systems to function with the AIM2™ module in closed mounting applications.

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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™ vehicle equipment. FMU installation is performed in accordance with the FMU Installation Manual. Basic software (Central Controller) installation is performed in accordance with the FMPlus User Guide.

The AIM2™ vehicle equipment installation may be accomplished by the customer (or their representative) or Syn-Tech Systems. Most customers have their own mechanics, and the mechanics are trained to perform their own AIM2™ vehicle installations. This can be of great advantage to the customer. Their passive systems may be removed and reinstalled as vehicles are replaced without seeking outside assistance. When the customer chooses to install their own vehicle equipment, Syn-Tech Systems or one of their qualified distributors provides installation training to the customer’s mechanics.

Some additional things to consider in your AIM2™ installations:

• The FMU FRB will not find the correct radio channel to communicate with the AIM2™ module until the hoses are configured.

• The AIM2™ module uses RF technology to communicate with the FMU. If the AIM2™ module is fully enclosed in metal or fiberglass enclosures it may not communicate with the FMU unless an external antenna is connected to the AIM2™ module. Most vehicle installations will not require an external antenna.

• If more than one OBD connection is available in the vehicle being installed, the serviceability of the connection may be tested by making a connection to the vehicle OBD connector and turning the vehicle ignition switch on. If the connection is serviceable, a yellow OBD connect light will illuminate on the AIM2™ module.

• If an installation is being made in a vehicle with a cable driven speedometer (no OBD connection), a transducer may be required to send vehicle speed data to the AIM2™ module. Syn-Tech Systems does not stock transducers for these installations. Consult a parts distributor for the make of vehicle under consideration.

• Installations will vary from vehicle-to-vehicle by year, make, and model. Do not assume an installation will work without testing if similar installations were performed on similar vehicles. Changes have been seen between two vehicles of the same make, model, and year.

• Do not install any AIM2™ components within close proximity of hot or moving vehicle parts.

• AIM2™ nozzle tags must be installed in numerical order of their ID number (ANIDs), lowest to

highest. For example, if a nozzle tag with ID 2 is installed on hose 1, a nozzle tag with ID 3 or higher must be installed on hose 2.

• The use of dielectric grease to prevent corrosion is recommended to seal cable connections exposed to the environment.

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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™. One of these connectors must be available for an operable OBD connection. In addition to transaction information, OBD connections may provide all the information shown in Table 2-1 if the vehicle is capable of sending this information to the OBD port, and the correct software and FMU firmware are in use (see Table 3-1, Version Compatibility).

2. Using a Vehicle Speed Sensor (Odometer) Input. When an OBD connection is not possible,

connection to a vehicle speed sensor (VSS) will provide a vehicle odometer input to record the vehicle’s mileage at the time of the transaction. The VSS cable also provides vehicle power to the AIM2™ module.

3. Using an Analog Chronometer Input. A chronometer input need not be a physical device

connection. It may be a connection to a circuit which provides the desired input, such as a power source which is only powered when the engine is running to capture engine run time. Chronometer inputs may be either OBD or analog, and include engine idle time, engine run time, and PTO (power takeoff) time. Analog inputs can only track engine run time and PTO time. Analog inputs cannot track engine idle time. Engine idle time must be an OBD input. OBD chronometer inputs are gathered through the OBD connection.

Up to two analog chronometer connections may be made to an AIM2™ module, and they may be made in conjunction with an OBD connection for a total of three chronometer inputs. When used in conjunction with an OBD connection, the AIM2™ module is powered through the OBD connector. When an OBD connection is not available, AIM2™ power must be obtained through a speed sensor cable connection.

*Analog Installations To Speed Sensor: substitute OBD II connection for connection to Speed Sensor, 12 VDC unswitched, and 12 VDC switched with Speed Sensor cable. To Chronometer: requires Chronometer and unswitched and 12 VDC switched with Speed Sensor cable, and to chronometer input

Figure 4-1. AIM2™ Connection – Flow Chart

Speed Sensor cable. Connect to 12 VDC

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Figure 4-2. AIM2™ Module Layout

Using The OBD Port

• 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.

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. Consider the distance from the OBD Port to the mounting location. The OBD Diagnostic Pass-Thru cable must connect between the AIM2™ module and the OBD connector. The cable is 48 inches long and cannot be extended. Mount the AIM2™ module in the selected location.

Installations in Canada require the use of two 12 gauge wires to ground the AIM2™ module to a chassis ground.

2. Using 12 AWG THHN wire, make a ground connection between the AIM2™ ground connector and the vehicle/equipment chassis.

CAUTION

NOTE

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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. As required, drill a hole large enough for the connector on the RFID Extension Cable to fit through.

4. 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).

5. Route the other end of the RFID Extension Cable from the AIM2™ module to the fuel tank filler neck. Use protective wire loom for any cable routed outside the passenger compartment, and install grommets to seal any drilled holes. Leave room to adjust slack, and loosely attach the loom and cable to the vehicle with cable ties.

6. Place the Filler Neck Ring around the filler neck under the fuel tank cap.

CAUTION

Use caution when working around the fuel tank filler neck with power tools. Some fuels are easily ignitable, and some tools may generate sparks.

7. Route the Filler Neck Ring cable down the filler neck. As required, drill an access hole for the Filler Neck Ring connector to pass through the housing at the top of the filler neck where the fuel tank cap is located. If an access hole was drilled, protect the cable with a grommet.

8. Attach the RFID Interface Module to the Filler Neck Ring cable and the RFID Extension Cable and secure in place with cable ties. If these connections are not in a protected space, use a product similar to 3M Scotch Rubber Mastic Tape (product number 2228) or equivalent to cover and protect all exposed connections.

9. From the AIM2™ module mounting location pull the slack from the RFID Extension Cable. Coil any slack, and secure out of the way of the vehicle operator and/or moving parts.

10. As required, repeat steps 3 through 9 for the second tank of a dual tank installation.

11. Pull all cable ties tight and clip off the tag ends of the ties.

12. Seal any drilled holes/grommets with silicon sealant.

13. Connect the OBD interface cable to the vehicle OBD connector and AIM2™ module OBD port (Fig. 4-2). Secure the cable out of the way of the vehicle operator and/or any moving parts.

14. Proceed to AIM2™ Post Installation Tests.

Using A Vehicle Speed Sensor (Odometer) Input Only

• 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.

• The brown Analog Speed Sensor Cable wire must be connected to a source providing a 4 to 42VDC source wakeup signal to the AIM2™ module. This source must drop off to 2 VDC or less to permit the module to go to sleep.

CAUTION

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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. Consider the distance from the AIM2™ Power/Speed Sensor Port to the required connections when selecting a mounting location. Mount the AIM2™ module in the selected location.

CAUTION

Some vehicles use more than one battery to increase system voltage, or How the batteries are connected together will determine if the increase is in voltage or current. If the same vehicle chassis ground to which the batteries are grounded is not used when wiring the ground to the AIM2™ module, AIM2™ power will not match vehicle power and damage to the AIM2™ module and/or vehicle electrical system may occur. Always ground the AIM2™ module to the

same ground used by the batteries for the vehicle chassis ground.

NOTE

Installations in Canada require the use of two 12 gauge wires to ground the AIM2™ module to a chassis ground.

2. Using 12 AWG THHN wire, make a ground connection between the AIM2™ ground connector and the vehicle/equipment chassis.

CAUTION

To avoid possible damage to the AIM2™ module, do not connect the Analog Speed Sensor Cable to the AIM2™ module until all other cable connections are complete.

NOTE

Important! Some applications may not function correctly unless the WHITE negative odometer wire

is connected directly to the negative side of the speed sensor.

3. Connect the Analog Speed Sensor Cable BLACK ground wire and WHITE negative odometer wire to a chassis/battery ground.

CAUTION

If multiple batteries are in use in the vehicle being installed, take a voltage reading of the switched and unswitched inputs of another existing vehicle accessory. Select power sources for AIM2™ which have the same voltage inputs. Doing so may prevent damage to the AIM2™ module and/or the vehicle electrical system.

4. Connect the Analog Speed Sensor RED wire to an unswitched (constant with ignition OFF) +12 to +42 VDC power supply.

5. Connect the Analog Speed Sensor BROWN wire to a switched (constant with ignition ON only) +4 to +42 VDC power supply. This connection will “wakeup” the AIM2™ module when the ignition switch is turned ON.

NOTE

On vehicles with Allison transmissions, DO NOT connect the Analog Speed Sensor Cable GREEN wire to the transmission speed sensor. Connect the GREEN wire to the ECM speed sensing output.

available starting current.

6. Connect the Analog Speed Sensor Cable GREEN wire to the VSS (Vehicle Speed Sensor) output. This signal may also be found at the vehicle’s computer module (ECM). Many speed sensors have a two-wire connection. The output will be the wire with the higher resistance reading.

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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. Route the other end of the RFID Extension Cable from the AIM2™ module to the fuel tank filler neck. Use protective wire loom for any cable routed outside the passenger compartment, and install grommets to seal any drilled holes. Leave room to adjust slack, and loosely attach the loom and cable to the vehicle with cable ties.

10. Place the Filler Neck Ring around the filler neck under the fuel tank cap.

CAUTION

Use caution when working around the fuel tank filler neck with power tools. Some fuels are easily ignitable, and some tools may generate sparks.

11. Route the Filler Neck Ring cable down the filler neck. As required, drill an access hole for the Filler Neck Ring connector to pass through the housing at the top of the filler neck where the fuel tank cap is located. If an access hole was drilled, protect the cable with a grommet.

12. Attach the RFID Interface Module between the Filler Neck Ring cable and the RFID Extension Cable and secure in place with cable ties. If these connections are not in a protected space, use a product similar to 3M Scotch Rubber Mastic Tape (product number 2228) or equivalent to cover and protect all exposed connections.

13. From the AIM2™ module mounting location, pull the slack from the RFID Extension Cable. Coil any slack, and secure out of the way of the vehicle operator and/or moving parts.

14. As required, repeat steps 7 through 13 for the second tank of a dual tank installation.

15. Pull all cable ties tight and clip off the tag ends of the ties.

16. Seal any drilled holes/grommets with silicon sealant.

17. Connect the Analog Speed Sensor Cable to the AIM2™ module Power/Speed Sensor Port (Fig. 4-2).

18. Proceed to AIM2™ Post Installation Tests.

Using An Analog Chronometer Input

Installations for analog chronometer input may be made with or without an OBD connection. When made with an OBD connection, AIM2™ module power is derived through an OBD cable. When made without an OBD connection an Analog Speed Sensor cable must be installed to connect to vehicle power.

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.

NOTE

• 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 only is powered under special circumstances. Engine runtime may be a power source which only supplies power when the engine is running. PTO engage time may be a power source which only supplies power when the PTO is engaged.

• The Analog Speed Sensor Cable and Analog Chronometer wires may be lengthened, as needed.

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. Consider the distance to the required connections when selecting a mounting location. Mount the AIM2™ module in the selected location. a. (With OBD) The OBD Diagnostic Pass-Thru Cable is 48 inches long and cannot be

extended. It must be connected between the AIM2™ module and the OBD connector. The

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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. The Analog Chronometer Cable has two conductors eight feet long for connections to a maximum of two analog chronometers.

CAUTION

same ground used by the batteries for the vehicle chassis ground.

NOTE

Installations in Canada require the use of two 12 gauge wires to ground the AIM2™ module to a chassis ground.

2. Using 12 AWG THHN wire, make a ground connection between the AIM2™ ground connector and the vehicle/equipment chassis.

CAUTION

To avoid possible damage to the AIM2™ module, do not connect the Analog Speed Sensor Cable to the AIM2™ module until all other cable connections are complete.

NOTE

Some applications may not function correctly unless the WHITE negative odometer wire is connected directly to the negative side of the speed sensor.

3. (Analog Only) Connect the Analog Speed Sensor Cable BLACK ground wire and WHITE negative odometer wire to a chassis/battery ground.

CAUTION

4. (Analog Only) Connect the Analog Speed Sensor RED wire to an unswitched (constant with ignition OFF) +12 to +42 VDC power supply.

5. (Analog Only) Connect the Analog Speed Sensor BROWN wire to a switched (constant with ignition ON only) +4 to +42 VDC power source. This connection will “wakeup” the AIM2™ module when the ignition switch is turned ON. This power source must drop to 2 VDC or less when switched off for the module to go to sleep.

NOTE

• Step 6 calls out connections to obtain engine run time and power takeoff (PTO) engage time. These connections may be used to obtain any combination of either operation such as engine run time from both the parent truck engine and a reefer engine.

• Either channel (1=orange or 2=blue) may be used for any analog chronometer connection. Ensure the application is tracked so the software may be configured to match. In the vehicle record in the software, the channel number and application must be selected for each configured chronometer. Be sure to check Analog in the vehicle record when using the Analog Chronometer Cable.

available starting current.

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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 connection must be made to a source providing power only the Analog Chronometer Cable channel 1 ORANGE wire to the first choice. If needed, connect the channel 2 BLUE wire to the second choice. Note the channel and connection type for software configuration.

7. 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. 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 (Fig. 4-2).

10. Place the Filler Neck Ring around the filler neck under the fuel tank cap.

Use caution when working around the fuel tank filler neck with power tools. Some fuels are easily ignitable, and some tools may generate sparks.

13. From the AIM2™ module mounting location pull the slack from the RFID Extension Cable. Coil any slack, and secure out of the way of the vehicle operator and/or moving parts.

14. As required, repeat steps 7 through 13 for the second tank of a dual tank installation.

15. Pull all cable ties tight and clip off the tag ends of the ties.

16. Seal any drilled holes/grommets with silicon sealant.

17. (Analog) Connect the Analog Speed Sensor Cable to the AIM2™ module Power/Speed Sensor Port (Fig. 4-2).

18. (With OBD) Connect the OBD interface cable to the vehicle OBD connector and AIM2™ module OBD Port (Fig. 4-2). Secure the cable out of the way of the vehicle operator and/or any moving parts.

19. Proceed to AIM2™ Post Installation Tests.

when the engine is running. For power takeoff (PTO) engage time, a

when the PTO is engaged. Connect

CAUTION

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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. All these conditions must be met before the AIM2™ module may be programmed.

A Programming Hose Tag (PHT) is shipped with each new AIM2™ system. The PHT may be used to test a nozzle tag insertion into a filler neck ring.

An FMU-3500 is required to complete the AIM2™ post installation tests. An FMU-3500 Programmer is necessary to program installed AIM2™ modules. A portable FMU-3500 Programmer may be developed to test and program at a location remote from the fuel island FMU-3500 (at the AIM2™ installation location). See Develop an FMU-3500 Programmer (Section 5) for instructions to prepare a Programmer. The instructions include development of a portable FMU-3500 Programmer.

Perform the following:

1. (OBD) Turn the vehicle ignition switch on. The amber Heartbeat LED should start pulsing, and the yellow OBD/Speed Sensor LED should illuminate.

2. (Analog) Drive the vehicle. The yellow OBD/Speed Sensor LED should illuminate.

3. Position a PHT over the filler neck ring. Check the red Hose Inserted LED illuminates.

4. Remove the PHT. Check the red Hose Inserted LED goes out.

NOTE

The green FMU Connect LED will illuminate solid green when the AIM2™ module connects to an FMU-3500. The green FMU Connect LED may blink when the AIM2™ module detects an FMU3500 but has not connected to it. In AIM2™ firmware revisions 1.18 through 1.21, a nozzle tag must be inserted into the filler neck ring for the AIM2™ module to connect to the FMU-3500. AIM2™ firmware revisions 1.22 and above do not require a nozzle tag to be inserted into the filler neck ring to connect to an FMU-3500. The AIM2 connects as soon as the vehicle stops. Connection will also occur if a nozzle tag is inserted into the filler neck ring.

5. Move the vehicle within RF range of an FMU-3500 or FMU-3500 Programmer. If using AIM2™ firmware revision 1.18 through 1.21, position a nozzle tag over the filler neck ring. The green FMU Connect LED should illuminate. If the green LED is blinking, the AIM2™ sees the FMU but cannot connect.

6. When all LEDs can illuminate, the AIM2™ module is ready to be programmed. Proceed to AIM2™ Programming (Section 5).

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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™ equipment may be tested and programmed using the FMU-3500 installed at the fuel island. For larger numbers of installations in a garage or someplace remote from the fuel island, a portable programmer may be developed and carried to the installation site for testing and programming. A portable Programmer may be developed by removing the upper cabinet from a fuel island FMU-3500, or it may be developed from a demonstration unit provided by a FuelMaster® distributor. After testing and programming is complete, the Programmer may be restored to its original configuration as a fully configured FMU-3500 or demonstration unit.

A portable Programmer must be configured with the same upper cabinet components as the fuel island FMU-3500. It must have a compact flash card, an FMU radio board (FRB), antennas, matching site signature and system type, and a means to receive uploads from the Central Controller.

Configure an FMU-3500 as an FMU-3500 Programmer:

1. Through a laptop connection:

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.

NOTE

The FuelMaster to configure an FMU-3500 as an FMU-3500 Programmer in accordance with 3. Through the Central Controller, below.

b. Establish a laptop connection in accordance with the guidance provided in Product Bulletin

111.

c. At the SITE> prompt, input command 73. The following will be displayed:

AIM2 Configure Programming Unit Status

--------------------------------------

73, ARG1, ARG2 ARG1 – Operation = 0, Is command supported? = 1, Is this an AIM programming unit? = 2, Disable FMU as AIM programming unit. = 3, Enable FMU as AIM programming unit. = 4, Set programming hose tag. = 5, Display current programming hose tag. ARG2 – Hose Tag Number (use with ARG1 = 4)

d. Input 73,3 and press Enter. The following will be displayed:

FMU programming status set to YES or FMU programming status was already YES

software may also be loaded on a laptop, and a direct connect cable may be used

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e. As desired, input 73,1 to confirm. The following will be displayed:

SITE>73,1 YES SITE>

f. 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.

NOTE

The FuelMaster

software may reflect the selected FMU-3500 is an AIM2™ Programmer, but it

cannot be verified until the configuration change has been uploaded to the FMU. To ensure the FMU is configured as an AIM2™ Programmer, the configuration should be changed as shown below and uploaded to the FMU.

b. Access the FuelMaster

software main window.

c. Click on the Config icon. A Configuration window will open. d. Click on the System tab. The System window will be displayed. e. In the lower right corner of the window, verify the Passive Sys Type is AIM2 (AIM2 may be

grayed out, but still visible as AIM2). Click OK to save and exit this window.

f. Click on the Site icon. A dropdown Site List menu will open. g. In the site listing shown, click on to highlight the site to be configured as a Programmer. h. Once highlighted, click on Open to open the desired site window. A Site ID XXXX window

will open.

i. In the lower right corner of the window, change the FMU: description to FMU 2500 Plus AIM

II Prog. Click on Apply to save the change.

j. In the lower left under the FMU(s) tab, click the Online button. The Configuration

Upload/Do… window will open.

k. Under Selected FMUs, click in the box to the left of the FMU selected to be a Programmer.

A checkmark (√) will appear in the box, and the U

l. Click on the U

pload button. A Status Output Window will open and display the upload

pload and Download buttons will open.

progress.

m. When a connection to the selected FMU is established, the new configuration will be

uploaded and the FMU will be converted to a Programmer. When the upload is complete, the Central Controller will disconnect from the FMU.

n. Close all open windows and exit the FuelMaster

software program. The selected FMU-

3500 is an AIM2™ Programmer.

Develop a portable FMU-3500 Programmer from a fully configured FMU-3500:

1. Perform “Convert an FMU-3500 into an FMU-3500 Programmer” to ensure the FMU has been converted to a Programmer.

2. Remove the FMU-3500 upper cabinet from the FMU-3500 pedestal: a. Unlock and open the FMU pedestal access door, and turn off the FMU power switch. b. Unlock and open the FMU upper cabinet door. c. Disconnect all cables, as required, which extend from the pedestal and connect to the upper

cabinet. Check for the power cable and communications cable connections to the cable interface plate in the bottom of the upper cabinet, a possible network cable connection to the NIC card, and any cables routed through the bulkhead thru-hole to the Satellite I/O Control Board.

d. Support the upper cabinet and remove the six screws securing the upper cabinet to the

pedestal.

e. Remove the upper cabinet.

3. Separate the AC power connection (black, green, white wires) at the base of the upper cabinet.

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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. Ensure one end of the power cable has exposed black, white, and green wires. a. Strip approximately ¼ inch of insulation from the exposed ends of the black, white, and

green wires.

b. Obtain one Tyco Electronics 1-480305-0 connector housing, and three Tyco Electronics

60618-4 contacts. c. Crimp the three contacts onto the exposed ends of the black, white, and green wires. d. The connector housing has pin receptacles numbered 1, 2, and 3. The contacts crimped

onto the ends of the black, white, and green wires have keepers that hold the pins in the

connector housing. Push the contact on the white wire into the receptacle numbered “1” until

it bottoms in the housing. The keeper should retain the pin in the housing. Repeat with the

contact on the green wire into the “2” receptacle, and the contact on the black wire into the

“3” receptacle. When finished you should have a power cable with a male plug at one end,

and the connector housing at the other end.

5. Position the Programmer out of the way but within line of sight of the vehicles being fitted with AIM2™.

6. Plug the connector housing end of the power cable into the female power receptacle of the FMU upper cabinet. The connectors should be keyed so they will only connect one way. After connection, verify the wires at both sides of the connectors match white to white, green to green, and black to black.

7. Plug the power cable into a 115 VAC power outlet. After a brief power-up delay and initialization, the FMU Programmer should display:

**FuelMaster FUELS ACCOUNTING SYSTEM** ** INSERT KEY OR CARD TO BEGIN **

8. Recommend the circuit breaker for the FMU pedestal be turned off, and a lockout/tagout tag installed to let people know it should not be turned on.

9. Cover the opening at the top of the FMU pedestal to prevent rain/snow/debris from entering the exposed pedestal.

Develop an FMU-3500 Programmer from an FMU-3500 demonstration unit: an

FMU-3500 demonstration unit may have all the hardware components to meet the task, but it may not have the correct site signature and system type, nor may it be set to be a Programmer.

1. Set the correct site signature, system type, and Programmer option: a. Determine the site signature and system type necessary to change the demonstration unit. b. Plug the demonstrator unit into a 115 VAC power outlet. After a brief power-up delay and

initialization, the unit should display:

**FuelMaster FUELS ACCOUNTING SYSTEM** ** INSERT KEY OR CARD TO BEGIN **

c. A laptop connection to the demonstrator unit will be necessary to change the site signature

and system type, as required. Make the laptop connection in accordance with Product Bulletin 111.

d. Use command 38 to change the site signature:

1) When the 38 command is sent to the FMU, the following display appears:

Entering Configuration Mode!

CURRENT SIGNATURE = 1234

NEW SIGNATURE (XXXX hex –or- #99999 dec) = ___

2) 1234 is an example. Enter the new site signature at the flashing cursor:

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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. SYSTEM INPUT TYPE : VMN - VEH. KEY B. CUSTOM SYSTEM OPTION : DISABLED C. ENTERED VEHICLE IDs ARE : NUMERIC D. SEMI MANUAL MODE : DISABLED E. REAL GATE TXN : DISABLED F. POWER FAIL CHECK : NOT AVLAILABLE G. ENTERED USER IDs ARE : NUMERIC H. FURNACE LOGGING : DISABLED I. USING OLD PROKEES : DISABLED J. SHOW PROKEE/SMARTCARD ID : DISABLED K. CONFIRM PROKEE/SMARTCARD ID : DISABLED L. DISPLAY PUMP PRICING : DISABLED M. EIU PROKEE/SMARTCARD WHICH KEYS : VEH & USER KEY N. TWO RELAYS PER PUMP : DISABLED O. AUTO ACTIVATE SINGLE PUMP : DISABLED P. MODEM CONNECT UPPER SPEED LIMIT : MAXIMUM

USAGE - <LETTER>=CHANGE VALUE, <ESC>=EXIT

b. Option A shows the system type. If the system type is not correct, depress A until the correct

system type appears.

c. When the correct system type is displayed, press Esc. The new system type will be

recorded and the following will be displayed:

CONFIGURATION HAS CHANGED! WOULD YOU LIKE TO SAVE IT ? (Y/N)

d. If the new system type is correct, depress Y to save it. The following will be displayed:

SAVING SYSTEM CONFIGURATION… CONFIGURATION RECORDED.

3. Perform “Convert an FMU-3500 into an FMU-3500 Programmer” to configure the FMU

demonstrator unit as a Programmer.

Create an AIM2™ Programmer Prokee®/Smartcard

AIM2™ programming through an FMU-3500 is initiated using either a Supervisor Prokee Prokee used to authorize fuel transactions, or to reconfigure an FMU, or most other taskings a Supervisor Prokee assigned to individuals identified in the AIM2 Programmer List.

Create an AIM2™ Programmer Prokee®/Smartcard:

/Smartcard, or an AIM2™ Programmer Prokee®/Smartcard. An AIM2™ Programmer

/Smartcard may not be used for functions other than programming AIM2™. It cannot be

/Smartcard can accomplish. AIM2™ Programmer Prokee/Smartcards are

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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. If AIM2 Programmer is available, proceed to step 10.

3. Click on the Config icon. A Configuration window will open.

4. Click on the System tab. The System window will appear.

5. In the lower right corner of the System window, change the Passive Sys Type to AIM2.

6. In the right margin, click on O

K. The System window will close.

7. Click on the Exit icon to exit the software program.

8. Re-enter the FuelMaster

software main window.

9. Click on Tables from the menu bar. AIM2 Programmer… should now be listed in the

dropdown menu, but may be grayed out.

10. From the menu bar, click on System. A dropdown menu will appear.

11. From the dropdown menu, click on O

perator Options and select List Maintenance…. An

Operator List window will open.

12. Highlight the operator who will be making the AIM2™ Programmer Prokee

/Smartcard, then

click on the Open button at the bottom of the window. An Operator Name: XXX window will open

13. Select the options this operator should have by clicking on the box to the left of each option.

All options may be selected or deselected by clicking on the appropriate Select All or Deselect All button in the bottom left corner of the window.

14. Click OK at the bottom of the window to save and close the window. There is now a Central

Controller operator authorized to make AIM2™ Programmer Prokee

/Smartcards.

15. Click on Tables from the menu bar. AIM2 Programmer… should now be listed in the

dropdown menu and should not be grayed out.

16. Click on AIM2 Programmer… An AIM2 Programmer List window will open. This window

identifies individuals who have been selected to receive an AIM2™ Programmer Prokee

/Smartcard. The Encoded column indicates if the Programmer Prokee® has already

been encoded.

17. Click on A

dd in the right margin to add a programmer. An AIM2 Programmer ID [NEW]

window opens.

18. Enter an AIM2 Prog. ID in the space provided. Up to 8 characters may be used. If fewer than

8 characters are entered zeros will be entered to the left to complete 8 characters. After the AIM2 Prog. ID is entered, the window title will change to reflect the new ID.

19. Complete as much additional information in this window as desired. A name should be

entered as a minimum.

20. Click on the PROKEE tab if it is desired for this programmer to use a PIN, then in the

PROKEE window click on the box next to PIN.

21. Ensure the Encoder is connected and a Prokee

22. Click on E

ncode in the right margin. A Prokee window will open and prompt Insert Prokee

/Smartcard is available.

into Encoder for Writing.

23. Push a Prokee

(or insert a Smartcard) into the Encoder for encoding. When encoding is

complete, the Prokee window will prompt Prokee Encoded Successfully!

24. The AIM2™ Programmer Prokee/Smartcard is encoded. Click on the OK button to close the

Prokee window.

25. Click on O

K in the right margin to close the AIM2 Programmer ID window. The new programmer ID and name should be listed in the AIM2 Programmer List with Encoded marked YES.

26. Close any open windows and exit the software program.

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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. Additionally, only vehicle records marked a may be used to program an AIM2™.

ome prompts may ask to depress a key not found on a 4x4

S keypad (keypad with 16 keys). If that is the case, follow the instructions shown in Figure 11 to shift to attain the desired key.

Program an AIM2™:

1. At the Central Controller, ensure vehicle records in the FuelMaster AIM2™ with AIM Program Pending.

2. From the Central Controller, Send Au to the AIM2™ Programmer.

3. As required, set PHT in FMU: a. Insert a Supervisor Pro

following will be displayed:

software program are marked for

thorization List

kee /Smartcard. The

* SUPV: 1=SYSTEM, 2=PM, 3=ODOM, 4=AIM * * A=CONFIG, B=ISSUES, C=TANKS, D=EXIT *

b. Depress 4=AIM. The following will be displayed:

AIM SUPERVISOR MENU

T, D=EXIT

1=SET PHT, 2=PROGRAM, 3=RESE

c. Depress 1=PHT. The following will be displayed:

AIM SUPERVISOR MENU

Curr :__

ent PHT A: New PHT (A-F)

NOTE

Very Important! The PHT letter entered must m

and, if multiple Programmers are within RF range of each other, they must all

atch the letter assigned to the Programming Hose Tag

d. Depress the key to set the desired PHT letter (i.e., B) at the cursor, then depress the

Enter key. The following will be displayed:

AIM SUPERVISOR MENU

Curr ): B

ent PHT A: New PHT (A-F

changing to:

AIM SU MENU

PERVISOR

Programming Hose Tag Changed to B

e. Exit the FMU Supervisor menu.

s AIM2™ with AIM Program Pending

Figure 5-1. 4x4

Keypad Shift

Instructions

be using different PHT’s.

Page 47

NOTE

AIM2™ programming may be initiated with a Supervisor Prokee Programmer Prokee Prokee the display shown in step 6.

/Smartcard. Procedures when using an AIM2™ Programmer Prokee®/Smartcard begin with

/Smartcard. The following instructions begin using a Supervisor

/Smartcard or an AIM2™

4. Insert a Supervisor Prokee®/Smartcard. The following will be displayed:

* SUPV: 1=SYSTEM, 2=PM, 3=ODOM, 4=AIM * * A=CONFIG, B=ISSUES, C=TANKS, D=EXIT *

5. 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

6. 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 observed.

/Smartcard is being used, the following is the first display to be

***** SEARCHING FOR AIM TO PROGRAM *****

* Insert Programming Hose Tag *

NOTE

If an AIM2™ is not found, it may be because the module was previously cleaned and the interface is set to NONE. If this occurs, remove the PHT, turn the vehicle ignition switch on for 20 seconds then turn the ignition switch off and repeat step 4. The interface should be set and the module should be detected when the PHT is placed on the filler neck ring.

7. Position the PHT on the tank ring of the vehicle being programmed. The FMU briefly displays the AIM2™ has been found, then prompts to insert the vehicle ID (VID):

***** Found AIM To Program *****

COMMUNICATING WITH AIM…

changing to:

VID: UNKNOWN (PHT A)

ENTER VEHICLE ID -> ________

8. Enter the VID and press Enter. The FMU briefly displays it is programming the AIM2™. Notification is given when programming is complete, then the display changes to the Main

Menu (see following NOTE if display prompts No Record Found):

VID: 1001555 (PHT A)

PROGRAMMING AIM…

changing to:

VID: 1001555 (PHT A)

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******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. Ensure the correct vehicle ID was entered, and the AIM2™ vehicle record has been sent to the FMU. In the Central Controller, the vehicle record should display AIM Program Pending. If an error was found, respond to the following question by depressing the Yes key, and try again.

VID: 1001555 (PHT A)

NO RECORD FOUND. TRY AGAIN (Y/N)?

9. Depress D=EXIT until the FMU returns to the default display. Insert an AIM2™ Installation Notice in the vehicle to inform users of the AIM2™ installation. If calibration, change

interface, or clean is desired, continue to one of the following actions.

Calibrate AIM2™: calibration may be used to recalibrate odometer or chronometer settings, a

useful option when transferring AIM2™ modules to a new vehicle. Odometer will appear under the CALIBRATE choices, regardless of OBD or analog interface, or regardless of any chronometer selection. If no chronometers were selected when building the vehicle record, odometer recalibration will be the only option. If chronometers were selected when building the vehicle record, the recalibrate options will include odometer plus the selected chronometers. Access to the [-MAIN MENU-] is only possible by first reprogramming the AIM2™ module.

NOTE

AIM2™ programming may be initiated with a Supervisor Prokee®/Smartcard or an AIM2™ Programmer Prokee®/Smartcard. The following instructions begin using a Supervisor Prokee®/Smartcard. Procedures when using an AIM2™ Programmer Prokee®/Smartcard begin with the display shown in step 3.

1. Insert a Supervisor Prokee®/Smartcard. The following will be displayed:

* 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

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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 observed.

/Smartcard is being used, the following is the first display to be

***** SEARCHING FOR AIM TO PROGRAM *****

* Insert Programming Hose Tag *

NOTE

4. Position the PHT on the tank ring of the vehicle being programmed. The FMU briefly displays the AIM2™ has been found, then prompts to confirm the found vehicle ID (VID):

***** Found AIM To Program *****

COMMUNICATING WITH AIM…

changing to:

VID: 1001555 (PHT A)

IS THIS CORRECT (Y/N)?

NOTE

If the VID is not correct, press the No key and be prompted to enter the correct VID.

5. Depress the Yes key. The FMU briefly displays it is programming the AIM2™. Notification is given when programming is complete, then the display changes to the Main Menu:

VID: 1001555 (PHT A)

PROGRAMMING AIM…

changing to:

VID: 1001555 (PHT A)

******AIM PROGRAMMING COMPLETE*******

changing to:

VID: 1001555 [-MAIN MENU-] (PHT A)

1=CALIBRATE 2=INTERFACE 3=RESET D=EXIT

6. To calibrate the AIM2™ module, depress 1=CALIBRATE. The CALIBRATE menu is displayed:

NOTE

If PTO was one of the chronometer choices made when building the vehicle record, it will be shown in the following display as one of the calibrate options.

VID: 1001555 [-CALIBRATE-] (PHT A) 1=ODOMETER 2=RUN TIME 3=IDLETIME D=EXIT

NOTE

• Steps 7 thru 9 are for recalibrating odometer with an OBD connection. For analog speed sensor connections a prompt will appear to input an initial odometer reading, then the vehicle

Page 50

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. See step 8.

7. Depress 1=ODOMETER to calibrate the odometer. A prompt will be displayed to confirm recalibration of the odometer:

VID: 1001555 ODOM: 0000129 (PHT A)

RECALIBRATE ODOMETER (Y/N)?

NOTE

If the following message appears, the FMU cannot detect the odometer reading. Exit the FMU, run the vehicle engine for one or two minutes, and try again.

* VEHICLE NOT READY. TURN VEHICLE KEY * * ON. WAIT 20 SECONDS, AND TRY AGAIN. *

8. Depress the Yes key to recalibrate the odometer. A prompt will appear for the input of the CURRENT ODOMETER (MILES):

VID: 1001555 ODOM: 0000129 (PHT A)

CURRENT ODOMETER (MILES) -> _______.__

9. Enter the current odometer reading and press Enter. If a previous odometer entry had been entered, AIM2™ will recalibrate based on the new odometer entry:

VID: 1001555 ODOM: 0000129 (PHT A)

CURRENT ODOMETER (MILES) -> 1111_.__

changing to:

VID: 1001555 ODOM: 0001111 (PHT A)

*** ODOMETER RECALIBRATION 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

10. If a previous odometer entry was not displayed in step 7, drive the vehicle at least 5 miles and repeat steps 6 through 9 to accurately calibrate odometer.

11. To recalibrate a chronometer, depress 1=CALIBRATE. The CALIBRATE menu is displayed:

NOTE

• In the following display, the chronometers listed will be those selected for the AIM2™ when the vehicle record was developed with the software. The choices may be run time, idle time, and/or PTO time. The recalibration procedure is the same for all chronometer options. Version 5 software may offer the selection of up to 3 chronometers. The following display may reflect as many as 3 chronometers in addition to odometer. Select the chronometer to recalibrate.

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• 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)

RECALIBRATE RUN TIME (Y/N)?

13. Depress the Yes key to recalibrate engine run time. A prompt will appear for the input of the current vehicle hour meter:

VID: 1001555 RUN TIME: 000000 (PHT A)

CURRENT RUN TIME -> ________

NOTE

In step 13, if the current engine run time is not available, enter zero.

14. Enter the current engine run time and press Enter. AIM2™ will recalibrate based on the new engine run time entry:

VID: 1001555 RUN TIME: 000000 (PHT A)

CURRENT RUN TIME -> 222___

changing to:

VID: 1001555 RUN TIME: 000222 (PHT A) *** RUN TIME RECALIBRATION COMPLETE ***

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

15. As required, depress D=EXIT to exit the FMU.

Change the AIM2™ Interface: interface options are NONE, OBD, and SPEED SENSOR.

When an AIM2™ is “cleaned”, the interface is set to NONE. The module cannot be programmed when the interface is NONE. Modules should detect the correct interface when installed in a vehicle and powered through the ignition switch. If it is necessary to change the interface through the FMU, perform the following (access to the MAIN MENU is only possible by first reprogramming the AIM2™ module):

NOTE

AIM2™ programming may be initiated with a Supervisor Prokee Programmer Prokee Prokee the display shown in step 3.

/Smartcard. Procedures when using an AIM2™ Programmer Prokee®/Smartcard begin with

/Smartcard. The following instructions begin using a Supervisor

1. Insert a Supervisor Prokee®/Smartcard. The following will be displayed:

/Smartcard or an AIM2™

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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. 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 observed.

/Smartcard is being used, the following is the first display to be

***** SEARCHING FOR AIM TO PROGRAM *****

* Insert Programming Hose Tag *

NOTE

4. Position the PHT on the tank ring of the vehicle being programmed. The FMU briefly displays the AIM2™ has been found, then prompts to enter the vehicle ID (VID):

***** Found AIM To Program *****

COMMUNICATING WITH AIM…

changing to:

VID: UNKNOWN (PHT A)

VEHICLE FOUND, SEARCHING FOR RECORD…

changing to:

VID: UNKNOWN (PHT A) ENTER VEHICLE ID -> ____________

5. Type in the VID and press Enter. The FMU briefly displays it is programming the AIM2™. Notification is given when programming is complete, then the display changes to the Main

Menu:

VID: 1001555 (PHT A)

PROGRAMMING AIM…

changing to:

VID: 1001555 (PHT A)

******AIM PROGRAMMING COMPLETE*******

changing to:

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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-] (PHT A)

COMMUNICATING WITH AIM…

changing to:

VID: 1001555 [-INTERFACE-] (PHT A)

OBD: CHANGE INTERFACE (Y/N)?

7. Depress the Yes key. A prompt requests the selection of the desired interface:

VID: 1001555 [-INTERFACE-] (PHT A)

SELECT INTERFACE: 1=SPEED SENSOR, 2=OBD

8. Depress 1 or 2 to select the desired interface (1=SPEED SENSOR shown):

VID: 1001555 [-INTERFACE-] (PHT A)

SET AIM TO USE SPEED SENSOR (Y/N)?

9. Depress the Yes key to set AIM2™ to use SPEED SENSOR. The interface is changed:

VID: 1001555 [-INTERFACE-] (PHT A)

SETTING AIM VEHICLE INTERFACE…

10. The interface is changed. As required, depress D=EXIT to exit the FMU.

Clean the AIM2™: if an AIM2™ is removed from one vehicle for installation in another, the

module should be “cleaned” to ensure proper programming and operation in the new vehicle. This is the only procedure through conventional means which will remove one protocol and recognize another. “Cleaning” an AIM2™ will change the interface to NONE. When reinstalled in a different vehicle, the interface must be detected before it can be programmed. Step 8 provides instruction for resetting the interface to match the new vehicle. As with other FMU AIM2™ options, access to the MAIN MENU is only possible by first reprogramming the AIM2™ module.

NOTE

AIM2™ programming may be initiated with a Supervisor Prokee Programmer Prokee Prokee the display shown in step 3.

/Smartcard. Procedures when using an AIM2™ Programmer Prokee®/Smartcard begin with

/Smartcard. The following instructions begin using a Supervisor

/Smartcard or an AIM2™

1. Insert a Supervisor Prokee®/Smartcard. The following will be displayed:

* 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:

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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™ until a PHT is placed on the vehicle filler neck ring:

NOTE

If an AIM2™ Programmer Prokee observed.

/Smartcard is being used, the following is the first display to be

***** SEARCHING FOR AIM TO PROGRAM *****

* Insert Programming Hose Tag *

NOTE

4. Position the PHT on the filler neck ring of the vehicle being programmed. The FMU briefly displays the AIM2™ has been found, then prompts to enter the vehicle ID (VID):

***** Found AIM To Program *****

COMMUNICATING WITH AIM…

changing to:

VID: UNKNOWN (PHT A)

VEHICLE FOUND, SEARCHING FOR RECORD…

changing to:

VID: UNKNOWN (PHT A) ENTER VEHICLE ID -> ____________

5. Type in the VID and press Enter. The FMU briefly displays it is programming the AIM2™. Notification is given when programming is complete, then the display changes to the Main

Menu:

VID: 1001555 (PHT A)

PROGRAMMING AIM…

changing to:

VID: 1001555 (PHT A)

******AIM PROGRAMMING COMPLETE*******

changing to:

VID: 1001555 [-MAIN MENU-] (PHT A)

1=CALIBRATE 2=INTERFACE 3=CLEAN D=EXIT

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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 **********'

changing to:

'** WAIT FOR AIM TO POWER CYCLE. TURN **'

'** VEHICLE ON FOR AIM TO RECONNECT **'

8. The module has been cleaned and has lost its interface memory. If it will be reprogrammed in this vehicle, it must first detect the interface. Observe the LEDs on the module as it completes the power cycle. When the amber Heartbeat LED starts pulsing, turn the vehicle ignition switch on, wait 20 seconds then turn the ignition switch off. The module should have detected the current interface and may now be reprogrammed, as necessary, in this vehicle.

9. As required, depress D=EXIT to exit the FMU.

Page 56

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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™ Startup and Training Acceptance Test Procedure (ATP) form is attached to the end of this installation manual. The form is to be completed by the technician completing the startup and training, and signed by the customer’s representative. A copy of the completed ATP should be left with the customer. Another copy must be forwarded in the included prepaid envelope to Syn-Tech Systems, Inc.

Immediately following the ATP is a sample Hold Harmless Agreement. The Hold Harmless Agreement is provided to inform the customer of the dangers of unsecured wireless networks, and to remove liability from Syn-Tech Systems, Inc., and the individual completing the FuelMaster installation. Complete the form only when needed.

Following is an expanded version of the Acceptance Test Procedure to be used as a guide for completing the abbreviated ATP. An ATP should be completed for each AIM2™ customer. In the following breakdown of the Acceptance Test Procedure, the original ATP form is standard print. The explanation is bold and italicized:

Acceptance Test Procedure (ATP) for Commercial

Installations, Upgrades, Startup, and/or Training of

FuelMaster® AIM2™

Customer: (enter the customer’s name)

Location: (enter the location of the site covered by this ATP)

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

This ATP is divided into sections to permit the completion of portions applicable to the task(s) being performed. Read the section header to determine if the section must be completed. Mark non-applicable sections N/A.

Complete an ATP for each customer location. Invite a customer representative to observe these tests as he/she must sign the final document. Comments may be added on page 6.

A space is provided to the left of each applicable procedure to show completion. Place a check mark (√) in the space for each completed procedure. Leave incomplete procedures unmarked, and explain on page 6. Mark non-applicable procedures N/A. Attach additional pages for additional comments.

Fuel Management Unit (FMU).

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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. Verify the FMU(s), all connected hoses, and all other site equipment are operational and

installed in accordance with the NEC (note any exceptions on page 6). Pre-inspect the work

area and previously installed FMUs for operation and compliance with NEC. This will preclude liability for any non-operational equipment or non-NEC compliance after the work is accomplished.

2. Download transactions from all FMUs to be upgraded. This prevents the loss of transaction data stored in FMU memory.

3. Retrieve and record unit configuration and option bytes of installed FMUs to be upgraded. Allows restoring same configuration and options after upgrade is completed.

UPGRADE SOFTWARE

4. Verify tasking is an upgrade (not a new install). New installs will not have an existing database.

5. Verify an operational copy of the FuelMaster disk with the same software version is available. Upgrade will update existing software

and convert existing database to new function with updated software. Customer needs software disk should it become necessary to reload software.

6. Disable any auto download settings and stop all services. Services may be restored after the software upgrade, but verify services do not prevent proper Central Controller operation.

Auto download settings and some services may preclude successful upgrade. Settings and services may be restored after upgrade.

7. Make a copy of the customer’s existing software database and save to the desktop. This is the safest way to ensure the database is not lost or corrupted.

8. Upgrade the customer’s existing software through a local computer administrator log on. Full administrative rights are necessary for successful software upgrade.

In step 9, if not prompted “Database Conversion Finished” or if other errors occurred, discontinue upgrade and call Syn-Tech’s Customer Satisfaction Center (CSC) at 800-888-9136, ext. 1500, for assistance. (Any additional work performed after these errors occur may be lost during software

repair.)

9. When the upgrade is complete, restart the customer’s computer and verify the database converted to the new software version. Changes may not be saved and take effect until

the computer is restarted. Restart computer and verify upgrade was successful by accessing software, then clicking on HELP>About FuelMaster® Plus, and checking version number.

software is currently installed, and an install

NOTE

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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.

11. Turn off FMU power at the circuit breaker panel. Removing power at the circuit breaker is the only way to remove power from all components of the FMU.

12. Upgrade the FMU(s). Install upgrade components in accordance with the Product Bulletins forwarded with the parts.

13. Restore FMU power and use a laptop connection to (perform laptop connection in accordance with Product Bulletin 111):

a. Initialize FMU (commands 02, FF). This will clear old configuration and site

signature.

b. Set/verify site signature (command 38), This will set mainboard to function with

customer’s software, Prokee

c. Set system type and, if necessary, lock baud rate down (command 59). This will set

firmware system type to match software system type. Lower baud rates may sometimes provide more reliable communications.

s, Smartcards, and AIM2™ modules.

14. Using the customer’s computer, upload the site configuration, authorization list, and send pricing. Verify the site configuration recorded in step 3 matches the customer’s software site configuration. This will restore the same setup used by the customer with the previous

FMU configuration.

15. Use a laptop connection to reconnect to FMU(s) and verify the configuration, system options, authorization list, and pricing were sent successfully. This will verify what was sent was

loaded into the FMU.

OPERATIONAL CHECKS

16. All FMU’s prompt the user to INSERT KEY OR CARD TO BEGIN. This is the default prompt; indicates FMU is ready to begin a transaction. Second line of prompt may instead display “INSERT KEY, WAIT 1 SECOND TO BEGIN” if no Smartcards or credit cards are being used.

17. All FMU’s validated an authorized Prokee appear on LCD screen. Verifies FMU will correctly read authorized Prokee

and initiate a transaction.

18. All FMU’s rejected an unauthorized Prokee SIGNATURE…” prompt appeared on LCD screens. Verifies FMU will reject unauthorized

Prokee

/Smartcard, and prompt user with reason for rejection.

19. All FMU’s identify the pumps available for selection. The FMU will offer hoses with products matching those encoded into the Prokee transactions will offer all hoses.

/Smartcard, and user prompts to start a transaction

/Smartcard

/Smartcard; “UNAUTHORIZED KEY

or onto the Smartcard. Credit card

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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. All FMU’s successfully activate appropriate dispenser hoses after reading an authorized Prokee

FMU display, selected hose was activated for fueling. Run a test transaction on each hose. Record the hose number and quantity.

22. Accurate transaction data was received by Central Controller after polling master FMU.

Compare the transaction data accumulated in step 21, above, with transaction data downloaded to the Central Controller. Hose numbers and quantities must match.

23. Each FMU allowed simultaneous operation of all connected dispenser hoses, and all FMU’s operated simultaneously. It should be possible to activate every hose connected to each

FMU, and it should be possible to activate all the FMUs at the same time.

24. Activate each hose (one hose at a time) in automatic mode and verify no other hoses will dispense at the same time without being activated. This is a test to ensure each hose is

individually controlled, with no jumpers tying two hoses together.

25. Perform the Switch Test for manual mode. Verify hoses switched to auto display a “0” under the hose number, and hoses switched to manual display a “1” under the hose number. Verify hoses switched to manual do not appear on the FMU display as being available for an automated transaction. Verification that the system is correctly recognizing position of

auto/manual switches, and hoses are wired into the correct positions of the Pedestal I/O Board.

Smartcard, or credit card. When appropriate responses are given to prompts on

®,

26. If a receipt printer is in use, verify that the receipt prints and is correct. Verification that the receipt is accurate and provided for the fueling customer.

27. If FMU is using credit cards, run a transaction on each hose to verify pricing and functionality. Verification of correct setup of credit card functions, and accuracy of pricing.

28. If customer is using a Keyless system type, verify the FMU Keyless configuration has been set to match customer’s desired options, and the default screen prompts have been changed accordingly. When the Keyless option is enabled, FMU display prompts should remove

any requests to insert key or card.

29. If customer uses proximity cards and/or AIM2™ user IDs, ensure proper operation of both functions, and screen prompts reflect the selected options. FMU should display prompt for

entry of User ID/swipe proximity card if user ID option is turned on. Transaction should cancel if an authorized User ID or proximity card is not detected.

SECTION II. Complete when performing startups for new AIM2™ sites. This includes sites

upgraded for AIM2™ operation. The following checks are unique to AIM2™, and in addition to the checks required to be performed following the completion of an FMU installation.

AIM2™ SOFTWARE OPERATIONS

1. AIM2™ was enabled in the software system configuration. “Configuration” window should reflect AIM2 “Passive Sys Type”.

2. FMU type in the site configuration was configured for AIM2™ or AIM2™ programmer. “Site ID XXXX” window should reflect “FMU:” as “FMU 2500 Plus AIM II” or “FMU 2500 Plus AIM II Prog”.

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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. Vehicle records could be modified for proper AIM2™ configuration. Vehicle record “Fuelmaster Plus” window contains “Passive Status” box, “Authorized” status for “AIM”, and tab for “AIM II”.

5. User logon privileges allow the encoding of AIM2™ programming keys. “Operator Name: XXXX” window has AIM2 tab. Under AIM2 tab, options for “AIM2 Programmer” and “Prokee” are enabled.

6. Authorization list with new AIM2™ records was successfully sent. Go to “Go Online with FMUs” window, and “Send Auth

7. AIM2™ transactions were successfully downloaded with correct quantity, odometer and, if applicable, chronometer data. View information in “Polling Report”.

. Lists”.

AIM2™ FMU

CONFIGURATION

8. AIM2™ nozzle tags were installed on the desired hoses with the correct AIM2™ nozzle ID (ANID) configured to match the FMU hose configuration in the software. Self-explanatory.

9. The FMU Supervisor Prokee

/Smartcard, and AIM2™ Programming Prokee®/Smartcard

function correctly. Test both keys to ensure the access the appropriate menus.

10. AIM2™ installed vehicles can be successfully programmed from a FMU configured for AIM2™ programming. As needed, modify an AIM2 vehicle record, send to the FMU, then

program the AIM2 module from the FMU with a Programmer Key.

11. Each hose configured for AIM2™ operation can successfully start, record and terminate an AIM2™ transaction with an authorized and programmed AIM2™ vehicle. Perform a test

transaction on each hose with a nozzle tag in an AIM2™ equipped vehicle using the same product.

TRAINING The customer or his/her representative(s) were trained on the following:

12. New features or changes in FuelMaster differences between the old and new systems.

13. AIM2™ vehicle configuration operations. Vehicle setup in software.

14. Site configuration changes for AIM2™ sites. Site setup in software.

software. (for upgrade sites) Explain the

15. Online operations for AIM2™ data. Sending AIM2™ vehicle records to FMU.

16. Reports providing AIM2™ transaction and vehicle data. Show software report options for

AIM2™ transaction and vehicle data.

17. Overview of all AIM2™ hardware, hardware connections and hardware operations. Provide description of AIM2™ hardware and relationships.

18. Installation process using the AIM2™ Installation Manual. Provide overview of installation as described in AIM2™ Installation Manual.

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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.

21. AIM2™ transaction operations at the fuel island. Explain fuel transaction in AIM2™ equipped vehicle.

22. Fuel Island operations and basic FuelMaster

occurring during fuel transaction with AIM2™, and basic troubleshooting should errors occur.

23. Customer was provided a copy of the completed AIM2™ ATP. Leave a copy of this document after completed and signed.

24. Explanation of basic warranty and Customer Satisfaction Center 1-800-888-9136 ext. 1500 number. Explain warranty coverage and contact info for warranty service/assistance.

troubleshooting procedures. Explain what is

TRAINING ATTENDEES Site representative(s) who received training. (Provide printed name and

signature of trained customer representatives.)

PRINTED NAME SIGNATURE

VEHICLE DATA

AIM2™ during training session)

Vehicles installed with AIM2™ during AIM2™ training: (list vehicles installed with

YEAR MAKE MODEL

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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®)

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

location if different than site location)

(address of Central Controller

Street Address:

State & Zip code:

NATIONAL ELECTRIC CODE (NEC) COMPLIANCE. Note 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. If it

is a safety issue, do not proceed without correcting the deficiency.)

EXCEPTIONS. Note any other exceptions to this ATP below. All exceptions must be approved by Syn-

Tech Systems, Inc.

COMMENTS/SUGGESTIONS. Note below any comments or suggestions the customer may have

for product improvement, or changes to this upgrade/installation process.

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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:

Page 66

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®

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. If accessibility is achieved, outside users can access anything stored in your network, not just FuelMaster® related information.

The FuelMaster® Fuel Management Unit (FMU) is not, nor does it contain, a wireless device of any kind. To establish a wireless network connection to the FMU, wireless components must be installed as additional equipment in an existing and operational network.

Though the physical installation of the equipment may be accomplished by anybody with the knowledge and experience, the responsibility for the network, IP addresses, wireless components and devices, access points and network configuration rests entirely on the Information Technology (IT) person(s) or Network Administrator(s) of that site.

Syn-Tech Systems, Inc. cannot emphasize enough the potential damage that may result from a breach in network security. When a wireless network connection to FuelMaster® is established, Syn-Tech Systems, Inc. cannot prevent accessibility by outside users. As such, this HOLD HARMLESS AGREEMENT is prepared to remove liability from Syn-Tech Systems, Inc., for any breach of security resulting from the development of a wireless network connection to FuelMaster®. Please acknowledge receipt and concurrence with the terms of this agreement by signing below:

Customer Representative (Printed Name):

Customer Representative (Signature):

Date:

Page 67

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

Complete an ATP for each customer location. Invite a customer representative to observe these tests as he/she must sign the final document. Comments may be added on page 6.

A space is provided to the left of each applicable procedure to show completion. Place a check mark (√) in the space for each completed procedure. Leave incomplete procedures unmarked, and explain on page 6. Mark nonapplicable procedures N/A. Attach additional pages for additional comments.

Fuel Management Unit (FMU).

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.

1. Verify the FMU(s), all connected hoses, and all other site equipment are operational and installed in accordance with the NEC (note any exceptions on page 6).

2. Download transactions from all FMUs to be upgraded.

3. Retrieve and record unit configuration and option bytes of installed FMUs to be upgraded.

UPGRADE SOFTWARE

4. Verify tasking is an upgrade (not a new install).

5. Verify an operational copy of the FuelMaster the same software version is available.

6. Disable any auto download settings and stop all services. Services may be restored after the software upgrade, but verify services do not prevent proper Central Controller operation.

7. Make a copy of the customer’s existing software database and save to the desktop.

8. Upgrade the customer’s existing software through a local PC administrator log on.

software is currently installed, and an install disk with

Page 68

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.

9. When the upgrade is complete, restart the customer’s computer and verify the database converted to

the new software version.

UPGRADE FMU(S)

10. Verify all fixed and mobile transactions (if applicable) were successfully downloaded.

11. Turn off FMU power at the circuit breaker panel.

12. Upgrade the FMU(s).

13. Restore FMU power and use a laptop connection to:

a. Initialize FMU (commands 02, FF)

b. Set/verify site signature (command 38),

c. Set system type and, if necessary, lock baud rate down (command 59).

15. Use a laptop connection to reconnect to FMU(s) and verify the configuration, system options, authorization list, and pricing were sent successfully.

OPERATIONAL CHECKS

16. FMU’s validated an authorized Prokee®/Smartcard; user prompts to start a transaction appear on LCD screen.

17. All FMU’s rejected an unauthorized Prokee prompt appeared on LCD screens.

18. All FMU’s successfully prompted the user to insert Prokee for selection.

19. All FMU’s prompted, “PUMP CURRENTLY IN USE, SELECT ANOTHER…” when a dispenser in use was selected from the FMU keypad.

20. All FMU’s successfully activate appropriate dispenser hoses after reading an authorized Prokee

21. Each FMU allowed simultaneous operation of respective dispensers and all FMU’s operated simultaneously. Accurate transaction data was received by Central Controller after polling master FMU.

/Smartcard.

/Smartcard; “UNAUTHORIZED KEY SIGNATURE…”

/Smartcard and identified pumps available

22. Activate each hose (one hose at a time) in automatic mode and verify no other hoses will dispense at the same time without being activated.

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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

25. If FMU is using credit cards, run a transaction on each hose to verify pricing and functionality.

26. If customer is using a Keyless system type, verify the FMU Keyless configuration has been set to match customer’s desired options, and the default screen prompts have been changed accordingly.

27. If customer uses proximity cards and/or AIM2™ user IDs, ensure proper operation of both functions, and change screen prompts to reflect the selected options.

is turned on, verify that the price on the receipt is correct.

SECTION II. Complete when performing startups for new AIM2™ sites. This includes sites upgraded for

AIM2™ operation. The following checks are unique to AIM2™, and in addition to the checks required to be performed following the completion of an FMU installation.

AIM2™ SOFTWARE OPERATIONS

1. AIM2™ was enabled in the software system configuration.

2. FMU type in the site configuration was configured for AIM2™ or AIM2™ programmer.

3. FMU hose configuration in the software was updated with correct AIM2™ nozzle IDs (ANIDs), and ANIDs are configured in ascending order.

4. Vehicle records could be modified for proper AIM2™ configuration.

5. User logon privileges allow the encoding of AIM2™ programming keys.

6. Authorization list with new AIM2™ records was successfully sent.

7. AIM2™ transactions were successfully downloaded with correct quantity, odometer and chronometer data (if applicable).

AIM2™ FMU

CONFIGURATION

8. AIM2™ nozzle tags were installed on the desired hoses with the correct AIM2™ nozzle ID (ANID) configured to match the FMU hose configuration in the software.

9. The FMU Supervisor Prokee correctly.

10. AIM2™ installed vehicles can be successfully programmed from a FMU configured for AIM2™ programming.

11. Each hose configured for AIM2™ operation can successfully start, record and terminate an AIM2™ transaction with an authorized and programmed AIM2™ vehicle.

/Smartcard, and AIM2™ Programming Prokee®/Smartcard function

TRAINING The customer or his/her representative(s) were trained on the following:

12. New features or changes in FuelMaster

software. (for upgrade sites)

13. AIM2™ vehicle configuration operations.

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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. Training for the customer to install up to 10 customer provided vehicles to include OBD and analog (if applicable) type vehicles.

20. AIM2™ programming procedures OBD and analog (if applicable) vehicles.

21. AIM2™ transaction operations at the fuel island.

22. Fuel Island operations and basic FuelMaster

23. AIM2™ basic troubleshooting procedures.

24. Customer was provided a copy of the AIM2™ installation training document.

25. Explanation of basic warranty and 1-800-888-9136 ext. 1500 number.

troubleshooting procedures.

TRAINING ATTENDEES Site representative(s) who received training.

PRINTED NAME SIGNATURE

VEHICLE DATA Vehicles installed with AIM2™ during AIM2™ training:

YEAR MAKE MODEL

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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

compliance. All exceptions must be explained to, and accepted by, the customer before the ATP is signed

ote below any occurrences of NEC non-

EXCEPTIONS. Note any other exceptions to this ATP below. All exceptions must be approved by Syn-Tech

Systems, Inc.

COMMENTS/SUGGESTIONS. Note below any comments or suggestions the customer may have for

product improvement, or changes to this upgrade/installation process.

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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®

Customer Representative (Printed Name):

Customer Representative (Signature):

Date:

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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.

Step 4 ~ Turn dispenser handle on.

Step 5 ~ Squeeze handle. Fuel should begin to

flow in 10 seconds or less.

** Please notify your supervisor if your system does not fuel **

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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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