Gasboy FMS KE200 User Manual

FleetKey Fuel Management System
KE200 Key Encoder/Maintenance Terminal Operation Manual
MDE-4465A
Computer Programs and Documentation
All Gasboy computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy. Such computer programs and documents may also contain trade secret information. The duplication, disclosure, modification, or unauthorized use of computer programs or documentation is strictly prohibited, unless otherwise licensed by Gasboy.
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate this equipment.
Approvals
Gasboy, Greensboro, is an ISO 9001:2000 registered facility. Underwriters Laboratories (UL):
UL File# Products listed with UL
MH4314
MH6418
MH7404 MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s
All dispensers and self-contained pumping units
Power operated Transfer Pump Models 25, 25C, 26, 27, 28, 72, 72S, 72SP , 72X, 73 and 1820
Hand operated Transfer Pump Models 1230 Series, 1243 Series, 1520 and 1720 Series
Card reader terminals, Models 1000, 1000P Site controller, Model 2000S CFN Series Data entry terminals, Model TPK-900 Series Fuel Point Reader System
New York City Fire Department (NYFD):
NYFD C of A # Product
4823 9100A, 9140A, 9152A, 9153A,
4997 9822A, 9823A 5046 9100Q, 9140Q, 9152Q, 9153Q,
5087 8753K, 8853K, 9153K, 9853K
9800A, 9840A, 9850A, 9852A, 9853A, 9140
9800Q, 9840Q, 9852Q, 9853Q
(restricted to diesel and non­retail gasoline sales)
National Conference of Weights and Measures (NCWM) - Certificate of Compliance (CoC):
Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:
CoC# Product Model # CoC# Product Model #
95-179A2 Dispenser
95-136A5 Dispenser 9800 Series 91-057A3 Controller
9100 Retail Series, 8700 Series, 9700 Series
91-019A2 Dispenser
9100 Commercial Series
1000 Series FMS, 2000S-CFN Series
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery G-70-150-AE VaporVac
Patents
Gasboy products are manufactured or sold under one or more of the following US patents:
Dispensers
5,257,720
Point of Sale/Back Office Equipment
D335,673
Trademarks
Non-registered trademarks
Atlas™ Consola™ Infinity™
Registered trademarks
ASTRA Fuel Point Gasboy Keytrol Slimline
Additional US and foreign patents pending.
®
®
®
®
®
Additional US and foreign trademarks pending.
Other brand or product names shown may be trademarks or registered trademarks of their respective holders.
This document is subject to change without notice. · For information regarding Gasboy Literature, call (336) 547-5661 E-mail: literature@gasboy.com · Internet: http://www.gasboy.com © 2007 GASBOY · All Rights Reserved

Table of Contents

1 – System Overview 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
KE200 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Communications Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
KE200 Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Communications Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Internal Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Using the KE200 Keypad and Key Receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Using the KE200 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Using Your Logger Printout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
System Access and Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Before Proceeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2 – KE200 Setup - Standalone 15
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Accessing KE200 Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Maintenance Mode (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . .15
Encode Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Setting Up the KE200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Load Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Load Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Load Station ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Load System ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Load Working Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Configure ID Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Number of ID Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Edit or View Field Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Configure Maintenance Transactions (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Reset Transaction Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Reset Transaction File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Load Transaction Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Configure Maintenance Table (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Build a Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Clear the Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Load Country Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3 – KE200 Setup - Terminal 35
Using the Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Entering Commands and Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Signing On to the Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page i
Signing Off of the Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lost or Forgotten Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Setting Up the KE200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Clear Maintenance (CL MA) (1000 FleetKey only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Encode Key (EN KE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Exit (EX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Help (HE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Load Country (LO CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Load Date (LO DA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Load Format (LO FO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load IDFIELDS (LO ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Load Maintenance (LO MA) (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Load PIN (LO PI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Load Signon (LO SI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Load Station (LO ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Load System (LO SY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Load Transactions (LO TR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Print Country (PR CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Print Date (PR DA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Print Format (PR FO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Print IDfields (PR ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Print Maintenance (PR MA) (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Print PIN (PR PI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Print Records (PR RE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Print Station (PR ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Print System (PR SY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Print Transactions (PR TR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Read Key (REA KE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Reset Pointer (RES PO) (1000 FleetKey only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Reset Records (RES RE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Reset Transactions (RES TR) (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Version (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 – Encoding Keys 63
Methods of Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Key Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Field Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Key Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Field Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
System ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Key Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ID Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Supervisor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Expiration Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Product Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Product Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Price Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Check Digit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Previous Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Last Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Reasonableness Check Digit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Odometer Retries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Page ii MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Minimum Miles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Maximum Miles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Vehicle Class (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Maintenance X Odometer (1000 FleetKey Systems only). . . . . . . . . . . .69
Maintenance X Date (1000 FleetKey Systems only) . . . . . . . . . . . . . . . .69
PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
CRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Preparing for Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Filling Out the Key Encoding Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Series 1000/CFN Key Encoding Form. . . . . . . . . . . . . . . . . . . . . . . . . . .71
Encoding from the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Reading Key from the Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
View Encode Records - Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Reset Encode Records - Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Encoding from the Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
5 – Performing Maintenance 77
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Perform Maintenance (1000 FleetKey only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
View Maintenance (1000 FleetKey only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Appendix A – Error Messages A-1
Appendix B – Parts List and Preventive Maintenance B-1
KE200 - Exterior View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
FleetKeys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
KE200 - Inside Top Cover View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Modem Option (Not Illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
KE200 - MPU View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Index Index-1
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page iii
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Page iv MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Introduction System Overview
1 – System Overview

Introduction

The Gasboy® KE200 Key Encoder/Maintenance T e rminal allows you to encode Fleetkeys that are used in the 1000 FleetKey system and the CFN system with the key option. It also allows you to update the data key with maintenance information for the FleetKey system.
Figure 1-1: FleetKey
A Fleetkey is a small, plastic-encased integrated circuit which is capable of storing and retaining data. The Fleetkey is inserted, for encoding and maintenance purposes, into the receptacle labeled “FLEETKEY” that is located on the face of the KE200. Encoding involves electronically writing user-identification information for system access onto a Fleetkey.
The encoder itself can function as a standalone unit, or it can be attached to a data terminal or host computer that allows easier setup and encoding. For the standalone unit, the keypad allows you direct access to all setup, encoding, and maintenance procedures using a series of menus. When a data terminal is attached, you can perform all setup and all encoding (with the exception of inserting the key , which must be done at the KE200) using simple commands and stored encoding formats. Maintenance tables and transactions can be set up and updated from the data terminal. However, key updating must be performed at the KE200. When attached to a host computer, communication is via command and response packets. All data exchanged between the KE200 and the host computer is packaged as a data packet. C35365 KE200 Host Communications Command and Response Format manual contain s info rma tion on communications and commands.
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 1
System Overview Hardware Description

Hardware Description

The KE200 Key Encoder/Maintenance Terminal is a microprocessor controlled unit that encodes and updates Fleetkeys. It also serves as a maintenance terminal where technicians can update keys as part of the Fleetkey Maintenance Option.
It can be used in any of the following ways:
• Standalone
• With an ASCII terminal or a Cathode Ray Tube (CRT) monitor
• With a PC using appropriate interface software
The unit is compact and durable, and is equipped with a 20-position tactile feel membrane keypad and a key receptacle for insertion of Fleetkeys. A Manager's keyswitch is provided with two key types (Manager and Maintenance) to safeguard the system from unauthorized access. The system has 32K of battery-backed RAM, which safeguards system data in the event of a power failure. Two communication ports are provided: an RS-232 logger port, which is usually used for a printer, and an RS-232/RS-422 port used for communication with external devices (PC, CRT, and so on). A third port is also available for use with an optional 1200/2400 baud built-in modem.
Power 120 VAC, 60 Hz., 22W. Plugs into any standard 115 VAC
Operating Environment 0 to 40° C, 32 to 104° F, with a relative humidity of 20 - 80%,
Location The KE200 should be located in an office or garage type
wall outlet. The power line should be free from any surges or other electrical interference.
non-condensing.
environment in an area protected from direct contact with the weather. It should not be installed over a hazardous location.
Page 2 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Hardware Description System Overview
Figure 1-2: KE200 Hardware
8.5”
8.875”
5.1”
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 3
System Overview KE200 PCB

KE200 PCB

The KE200 PCB is the controller for the key encoder. Jumper settings on the PCB for each of the following must be made to ensure correct operation.
• Port 1 configuration for RS-232 or RS-422
• Baud Rates for Ports 1, 2, and 3
• Program address (map type)
Figure 1-3 illustrates the jumper position for each and shows where the jumper patch appears
on the PCB.
Figure 1-3: KE200 PCB
K2 Baud Rate Port 1
K3 Baud Rate Port 2
K4 Baud Rate Port 3 Modem
K5 Beeper Enable
Page 4 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Communications System Overview

Communications

Communications Ports

The KE200 has two asynchronous ports to connect a logger printer and/or a data terminal. The connection can be made by a direct cable or via a telephone modem. Ports 1 and 2 can be set to a variety of baud rates (300, 600, 1200, 2400, 4800, and 9600) depending on the equipment being connected.
• Port 1 is an RS-232/RS-422 port used to connect to external devices such as a PC, CRT or external modem.
• Port 2 is an RS-232 port used to directly connect a printer (logger) to the KE200.
• A third port is also available for use with a built-in 1200/2400 baud modem (optional).
The cable length from the RS-232 port to the device is limited to 100 feet. If the distance exceeds 100 feet, a Gasboy Short Haul Modem (P/N C05618) is required.

Communication Protocol

Devices that communicate with the KE200 must be able to transmit and receive full duplex, ASCII, asynchronous data via an EIA RS-232 connection.
The KE200 uses a simple terminal protocol. No special characters are transmitted to designate the beginning or end of the data blocks. Data is transmitted in serial bit format per character , as follows:
One start bit, eight data bits, one stop bit.
Each character is echoed back to the transmitting device. This checks the integrity and enables CRT operators to display transmitted data.
When used with the computer (or host) mode interface, the host computer initiates all communications between itself and the KE200, with command packets. The KE200 responds to the host command packets with response packets. All data exchanged between the KE200 and the host computer is packaged as a data packet.

KE200 Switch Settings

An 8-position switch bank, located on the KE200 CPU board is used to set the poll address and the communications mode for the KE200. On switch bank SW1, for SW1-1 through SW1-4, set the poll address when the Computer Mode interface is active. SW1-5 indicates the communications mode for the KE200's Port 1. The last three switch positions (SW1-6 through SW1-8) are currently unused. All switch settings are read during program initialization, at power-up. If changes are made, the KE200 must be turned off then on, to recognize them.
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 5
System Overview Communications
The following table contains Poll Address Switch Settings for SW1-1 through SW1-4.
Address SW1-1 SW1-2 SW1-3 SW1-4
01 CLOSED CLOSED CLOSED CLOSED 02 OPEN CLOSED CLOSED CLOSED 03 CLOSED OPEN CLOSED CLOSED 04 OPEN OPEN CLOSED CLOSED 05 CLOSED CLOSED OPEN CLOSED 06 OPEN CLOSED OPEN CLOSED 07 CLOSED OPEN OPEN CLOSED 08 OPEN OPEN OPEN CLOSED 09 CLOSED CLOSED CLOSED OPEN 10 OPEN CLOSED CLOSED OPEN 11 CLOSED OPEN CLOSED OPEN 12 OPEN OPEN CLOSED OPEN 13 CLOSED CLOSED OPEN OPEN 14 OPEN CLOSED OPEN OPEN 15 CLOSED OPEN OPEN OPEN 16 OPEN OPEN OPEN OPEN
Note: The poll address is the same for both Port 1 and Port 3 (internal modem port).
Position 5 on switch bank SW1 is used to select the communications mode for Port 1. When position 5 is closed, the port operates in the Standard Terminal mode providing operator prompts and messages. Activity through Port 1 is also sent to the logger port while Port 1 is in the Terminal mode.
When position 5 is open, the Computer Mode interface is selected for Port 1. While in the Computer mode, the port only responds to Computer mode command packets. Gasboy PC software uses Computer mode to communicate with the KE200. Activity through Port 1 is not sent to the logger port while it is set for Computer mode.
SW1-5 Definition
CLOSED Terminal mode selected for Port 1 OPEN Computer mode selected for Port 1
Page 6 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Communications System Overview

Communications Terminations

The wiring terminations for various communication options are provided below:
RS-232 - Data Terminal Communications for Ports 1 and 2
Pin Function Input/Output
2 TxD - Transmit data Input 3 RxD - Receive data Output 7 Signal ground Ground 8 DCD - Data Carrier Detect Output
20 DTR - Data Terminal Ready Input
RS-422 - Device Communications for Port 1
Pin Function Input/Output
1 Tx+ - Transmit data Output 2 Tx- - Transmit data Output 3 Rx+ - Receive data Input 4 Rx- - Receive data Input 5 Signal ground Ground

Internal Modem

The optional built-in modem on the KE200 is a Bell 103J/212A compatible answer modem. The KE200 supports a 2400 baud internal modem, which is part of the modem kit (P/N C06319).
The modem is designed for 0-300, 1200, or 2400 baud, full duplex, asynchronous communication. The modem is mounted inside the KE200 system at the factory . Power for the modem is supplied by the KE200 system.
The modem is designed to meet or exceed the direct connection registration requirements of the FCC rules. This means the modem will connect directly with a jack supplied by the phone company. The customer has to order this jack and have it installed. To order this equipment from the phone company, specify the following:
• Any one of the following jacks: RJ11C or RJ41S, or RJ45S.
• The registration number of 6BHUSA-24793-DT-E.
• The data transmission rate of 0-300 baud, 1200 baud, or 2400 baud.
• The Bell equivalent of 103J/212A.
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 7
System Overview Communication Wiring

Communication Wiring

The figures below show the various wiring schemes that are available for the installation of the KE200.
Figure 1-4: RS-232 Connection
KE200 Port 1 or 2
Peripheral Device (Terminal or Modem)
EIA 1:1 Cable P/N C04549
Figure 1-5: Short Haul Modem - ME800
KE200 Port 1 or 2
EIA 1:1 Cable (P/N C04549)
SHM -ME800 (P/N C02479)
AC Power AC Ground
Protector
(P/N C08159)
Maximum Distance
(see Note)
Shield GND (if used)
2 Twisted Pairs (see Note)
Protector
(P/N C08159)
AC Ground
SHM -ME800 (P/N C02479)
Peripheral Device
EIA 1:1 Cable (P/N C04549)
AC Power
Note: Maximum distances specified by the manufacturer are listed here. These distances are
valid when you use 22 AWG or 24 AWG two twisted-pair unshielded cable (a shielded cable will reduce the distance to one-third of the values shown).
Baud Rate Distance
300 and 1200 baud 10 miles 2400 baud 5 miles 4800 baud 4 miles 9600 baud 2 miles
Page 8 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Cables System Overview
Figure 1-6: RS-422 Gasboy Short Haul Modem
KE200 Port 1
P2

Cables

Field Wiring 1500 Feet Max.
Shield Ground
Port 1
AC Ground
Gasboy SHM (P/N C05618)
AC Power
Peripheral Device
EIA 1:1 Cable (P/N C04549)
The drawing below shows the pin-to-pin layout of the EIA 1:1 cable (Gasboy P/N C04549).
Figure 1-7: Pin-to-Pin Layout of EIA 1:1 Cable
Male Connector
100 Feet Max.
P/N C05758
Male Connector Male Connector
(Wire End View)
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 9
System Overview Using the KE200 Keypad and Key Receptacle

Using the KE200 Keypad and Key Receptacle

The keypad for the encoder is simple, consisting of numeric keys 0-9, and the following keys:
Figure 1-8: KE200 Keypad and Receptacle
ENTER transmits entered information to the encoder and allows you to move through the
prompts. It is also used to acknowledge and clear error or status messages.
CLEAR clears the entry. It is used as a “NO” response to a verification prompt. When
pressed twice in encoding mode, it enters special field separators and supervisor entry characters.
•F1 in Setup and Maintenance modes allows you to move to the next prompt. It is disabled
for Encoding mode.
F2 in Setup and Maintenance modes allows you to move to the previous prompt. It is
disabled for Encoding mode.
RESET in Encoding or Setup modes returns you to the first prompt in the group. It is
disabled in Edit mode.
PREV in Encode mode returns you to the previously displayed prompt. If you are at the
first prompt in a group, you will exit to the Encode menu. In Setup or Maintenance modes, it backs you out by group. Use the flow diagram in Section 2 to visualize the following: If you are at FIELD SIZE, under the group SELECT ID FIELD and you press PREV once, you return to SELECT ID FIELD. If you press PREV again, CONFIG ID MENU displays. If you press PREV again, SETUP MENU displays.
ENCODE in Encode mode skips any intermediate prompts, validates remaining unentered data, and takes you immediately to the ENCODE KEY verification menu from whatever prompt you were at. If errors exist in the unentered data, the system returns to the prompt in error and displays RANGE ERROR.
•“A”, “B”, “C” selects maintenance category in Setup and Maintenance modes.
• A key receptacle on the right-hand side of the encoder face allows you to insert Fleetkeys for encoding or maintenance updating.
Page 10 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Using the KE200 Display System Overview

Using the KE200 Display

The display has some distinguishing characteristics that will help you determine what entry is required. A flashing cursor at the end of a prompt indicates that the KE200 is waiting for input from the keypad (0-9) or “A”, “B”, “C” keys. If there is no flashing cursor on an input prompt, use the “F1” or “F2” keys to toggle between possible choices for that prompt. When you encounter an error or status message, press ENTER to clear the message. In an error condition, the KE200 displays the field in error for correction. In Encoding mode, you may see the following special characters on the display: “~” for field separator and “*” for supervisor entry . These are discussed later in Field Descriptions, ID Fields (see
page 23).
“Configure ID Fields” on

Using Your Logger Printout

When you have a logger (printer) attached to Port 2 of your KE200 system, all significant events are recorded on this printout. The following events are logged: power-ups, sign-ons, sign-offs, mode changes, setup and load commands, encode key commands, reset commands, encode records (if you answered yes to LOG KEY DATA?) and maintenance transactions.
Each logger printout entry is set up the same. It contains where the command originated (system, keypad, Port 1 or Port 3), the command or event, and a date/time stamp. A sample logger printout is shown below.
Figure 1-9: Logger Printout
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 11
System Overview System Access and Operating Modes

System Access and Operating Modes

To guard against unauthorized use, the KE200 system has two types of access keys:
• A manager key, which allows access to both the Encoding and Maintenance modes
• A maintenance key, which allows access to Maintenance modes only.
The key is inserted into the front of the encoder cabinet. It has three possible positions which correspond to the system modes:
•Idle
• Maintenance
• Encode/Setup
The key position for each mode is shown in Figure 1-10. You can access the modes only when the proper key is inserted and in the correct position.
Figure 1-10: Key Positions for Each Mode
When a data terminal is in use, the KE200 must be in Idle mode to enable operation of all the commands. When the KE200 is a standalone, Idle mode has no function other than to display the current date and time.
Maintenance mode allows you to view and update maintenance information on a key. All maintenance is performed from the KE200; you cannot perform maintenance from the data terminal.
Encode/Setup mode allows access to all system setup parameters and encoding fields . The key must be in this position for you to set up your system from the KE200 or to encode keys from the KE200.
Page 12 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Before Proceeding System Overview

Before Proceeding

You can begin to set up the KE200 for operation, if you have a general understanding of how the system works.
When you first use the system, you will have to perform setup functions to define your system attributes, configure the maintenance table, set your units and date format, and run any diagnostics that are required. The procedure for setting up the KE200 differs depending on whether you are using the keypad or a data terminal.
With the keypad, you must progress through a series of displayed menus and fill in the data for each. With the terminal, you can run a “SETUP” routine that automatically prompts you for the data necessary to run your system, or you can execute commands individually.
The section “KE200 Setup - Standalone” on page 15 describes setting up the system using the Standalone KE200. The section “KE200 Setup - Terminal” on page 35 describes setting up the system using the data terminal.
Once your system is set up, you must encode your keys, based on your system layout and use some of the values you entered in Setup mode. Once your keys are initially encoded, you will have to access Encode mode infrequently, when you need to add additional keys, or change data on a key. The section encoding and encoding procedures for both the standalone KE200 and the data terminal.
“Encoding Keys” on page 63 contains general information on key
Finally, you will have to record Performed Maintenance as scheduled. The section
“Performing Maintenance” on page 77 describes viewing maintenance information on the key
and performing maintenance.
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 13
System Overview Before Proceeding
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Page 14 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Overview KE200 Setup - Standalone
2 – KE200 Setup - Standalone

Overview

The standalone KE200 allows you direct access to all setup, encoding (numeric fields only), and maintenance procedures. You must enter commands via the keypad and a series of menus are displayed, which guide you through setup, encoding, and maintenance.

Accessing KE200 Modes

The different modes of the KE200 are determined by the position of the Manager’s key. When the KE200 is standalone, Idle mode has no function, other than to display the current date and time. Maintenance mode allows you to view and update maintenance information on a key. Encode/Setup mode allows access to all system setup parameters and encoding fields. The key must be in this position for you to set up your system from the KE200 or to encode keys from the KE200.

Maintenance Mode (1000 FleetKey only)

Note: You can use either the Manager key or the Maintenance key to access Maintenance
mode.
To access Maintenance mode, proceed as follows:
1 Turn th e Manager key to MAINT. The system displays the following:
MAINTENANCE MODE: PERFORM MAINTENANCE
2 Press ENTER to display the first Perform Maintenance prompt.
PERFORM MAINTENANCE: INSERT KEY
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 15
KE200 Setup - Standalone System Flow Diagram

Encode Mode

To access Encode mode, proceed as follows:
1 Turn th e Manager key to ENCODE. The system displays the following:
SELECT OPTION: ENCODE
2 If you wish to encode keys, press ENTER. The system displays the following:
ENCODE MENU: ENCODE KEY

Setup Mode

To access Setup mode, proceed as follows:
1 Turn th e Manager key to ENCODE. The system displays the following:
SELECT OPTION: ENCODE
2 If you wish to enter Setup mode, press F1. The system displays the following:
SELECT OPTION: SETUP
3 Press ENTER to display the first Setup prompt.
SETUP MENU: LOAD DATE

System Flow Diagram

The KE200 Key Encoder/Maintenance Terminal software is designed to facilitate easy navigation.
Page 16 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Figure 2-1 on page 17 shows the system layout by manager key position.
System Flow Diagram KE200 Setup - Standalone
Figure 2-1: System Flow Diagram
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 17
KE200 Setup - Standalone Setting Up the KE200

Setting Up the KE200

The first time you use your Key Encoder/Maintenance Terminal, perform the following steps in order to load your system with the necessary data for processing.
1 With the Manager key inserted and in the idle position, turn the power switch, located on the
left side of the face to “ON”. The KE200 displays the current date and time (these were set at the factory to Eastern time).
2 Perform the Reset Records command. See “Encoding Keys” on page 63 and “Reset Encode
Records - Keypad” on page 75.
3 Enter Setup mode and perform the following:
• Load Date (if not correct)
• Load Time (if not correct)
• Load Station ID for your key encoder/maintenance terminal.
• Load System ID: This must match the system ID of your FleetKey system. Refer to the key layout provided with your FleetKey system.
• Load Working Key: This must match the working key of your FleetKey system. Refer to the key layout provided with your FleetKey system.
• Load Country options.
• Configure ID fields: The fields you configure must match the fields as you ordered them. Only numeric fields can be encoded using the KE200 keypad. If your ID fields are alphanumeric (FleetKey only), you must use a data terminal for encoding input. Refer to your key layout.
• Configure Maintenance Transactions (FleetKey only): This includes resetting the transaction pointer, resetting the transaction file and loading the transaction number.
• Configure Maintenance table (FleetKey only): This includes clearing the Maintenance Table to eliminate any data that may have been present from testing and loading a Maintenance Table that matches the one defined in your FleetKey system.
• Run diagnostics, if necessary.
Once the above steps are performed, your system is ready to encode keys and record Performed Maintenance.
The commands listed above are discussed on the pages that follow, in the order in which they appear on the Setup menu.
Page 18 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Load Date KE200 Setup - Standalone

Load Date

Use “LOAD DATE” to load the current date. The KE200 should be factory set with the correct date, but occasionally you may need to change it.
To load date, proceed as follows:
1 Enter the Setup mode as described previously. The system displays the following:
SETUP MENU: LOAD DATE
2 Press ENTER. The system displays the following:
3 Type the correct date and press ENTER. The display returns to the following:

Load Time

SETUP MENU:
The currently loaded date appears on the second line of the display.
MMDDYY 1 2 1 6 9 1
SETUP MENU: LOAD DATE
To display another primary prompt, press F1 or F2 until the desired prompt appears.
To exit back to “SELECT OPTION: SETUP”, press PREV.
Use “LOAD TIME” to load the current time in 24-hour format (00:00 to 23:59). The KE200 is factory set to Eastern time with the correct time, but occasionally you may need to change it.
To load time, proceed as follows:
1 Enter Setup Mode as described previously. The system displays the following:
SETUP MENU: LOAD DATE
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 19
KE200 Setup - Standalone Load Station ID
2 Press F1 or F2 until the following is displayed:
SETUP MENU: LOAD TIME
3 Press ENTER. The prompt now reads:
LOAD TIME: HHMMSS 095521
The currently loaded time appears on the second line of the display.
4 Type the correct time and press ENTER. The display returns to the following:
SETUP MENU: LOAD TIME
5 To display another primary prompt, press F1 or F2 until the desired prompt appears.
6 To exit back to “SELECT OPTION”, press SETUP > PREV.

Load Station ID

Use “LOAD STATION ID” to load a number of up to three digits to identify the key encoder/ maintenance terminal. This identifier is similar to the site ID used in the FleetKey system. It is used mainly to identify the station for communication with PCs or other communications equipment.
To load station ID, proceed as follows:
1 Enter Setup Mode as described previously. The system displays the following:
SETUP MENU: LOAD DATE
2 Press F1 or F2 until the following appears:
SETUP MENU: LOAD STATION ID
Page 20 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Load System ID KE200 Setup - Standalone
3 Press ENTER. The currently loaded value appears on the second line of the display.
LOAD STATION ID:
000
4 Type a one to three digit identifier and press ENTER. The display returns to the following:
SETUP MENU: LOAD STATION ID
5 To display another primary prompt, press F1 or F2 until the desired prompt appears.
6 To exit back to “SELECT OPTION”, press SETUP > PREV.

Load System ID

Use “LOAD SYSTEM ID” to load the 4-digit system ID of your FleetKey system. This number is verified with the key when you perform maintenance.
To load system ID, proceed as follows:
1 Enter Setup Mode as described previously. The system displays the following:
SETUP MENU: LOAD DATE
2 Press F1 or F2 until the following appears:
SETUP MENU: LOAD SYSTEM ID
3 Press ENTER. The currently loaded value appears on the second line of the display.
SYSTEM ID: 5630
4 Type the system ID of your FleetKey system. This number appears on your key layout.
5 Press ENTER. The display returns to the following:
SETUP MENU: LOAD SYSTEM ID
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 21
KE200 Setup - Standalone Load Working Key
6 To display another primary prompt, press F1 or F2 until the desired prompt appears.
7 To exit back to “SELECT OPTION”, press SETUP > PREV.

Load Working Key

Use “LOAD WORKING KEY” to load the 4-digit working key used with your FleetKey system. This number is used to encrypt and decrypt Personal Identification Numbers (PINs) when you encode your keys.
To load working key, proceed as follows:
1 Enter Setup Mode as described previously. The system displays:
SETUP MENU: LOAD DATE
2 Press F1 or F2 until the following appears:
SETUP MENU: LOAD WORKING KEY
3 Press ENTER. The currently loaded value appears on the second line of the display.
LOAD WORKING KEY: 1234
4 Type the working key for your FleetKey system. This number appears on your key layout.
5 Press ENTER. The display returns to the following:
SETUP MENU: LOAD WORKING KEY
6 To display another primary prompt, press F1 or F2 until the desired prompt appears.
7 To exit back to “SELECT OPTION”, press SETUP > PREV.
Page 22 MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007
Configure ID Fields KE200 Setup - Standalone

Configure ID Fields

Use “CONFIG ID FIELDS” to identify the number of ID fields and the name, size, and format of each. The system has a set number of predefined field names (VEHICLE, EMPLOYEE, TRAILER, EQUIPMENT, PATRON, S.S. NO., MISC, DRIVER, ACCOUNT, or DEPARTMENT). You must choose one of these names. If you have a field that does not exactly match one of these names, select one that is close or select “MISC”. ID fields used on CFN systems with the key option must be numeric.
To configure ID fields , proceed as follows:

Number of ID Fields

1 Enter Setup Mode as described previously. The system displays:
SETUP MENU: LOAD DATE
2 Press F1 or F2 until the following appears:
SETUP MENU: CONFIG ID FIELDS
3 Press ENTER. The display prompts:
CONFIG ID MENU: NO. OF ID FIELDS
4 To identify the number of ID fields, proceed to step 5. To edit/view ID fields, proceed to step
7.
5 Press ENTER. The currently loaded value appears on the second line of the display.
NO. OF ID FIELDS
2
6 Type the number of ID fields configured in your FleetKey system and press ENTER. The
display returns to the following:
CONFIG ID MENU: NO. OF ID FIELDS
MDE-4465A KE200 Key Encoder/Maintenance Terminal Operation Manual · October 2007 Page 23
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