Gasboy Fuel Point Vehicle Module User Manual

Fuel Point® Fuel Management System

Vehicle Module Programming Manual

MDE-4524A

(formerly C35629)

Computer Programs and Documentation

Federal Communications Commission (FCC) Warning

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 control unit, Model GKE-B Series

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,

9800A, 9840A, 9850A, 9852A, 9853A, 9140

9800Q, 9840Q, 9852Q, 9853Q

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 # 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 © 2006 GASBOY · All Rights Reserved

Table of Contents

1 – Introduction 1-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Intended Users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Related Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 – Important Safety Information 2-1

In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

3 – Component Overview 3-1

Vehicle Module Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Charging the Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Battery Pack Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

4 – Preparation for Programming 4-1

Vehicle Module Field Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

System ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Vehicle Module Number (Enter VM Number). . . . . . . . . . . . . . . . . . . . . . . .4-1

ID Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

FleetKey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

CFN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Reader Entry Fields (RDR FLD 1,2, or 3) . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Expiration Date (Enter EXPIRE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Product Limit (Enter LIMIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Product Authorization (Enter AUTH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Price Level (Enter PRICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Odometer Or Hours Selection (SEL ODOMETER - 0, HOURS - 1) . . . . . . . . . . . . . . 4-7

MDE-4524A Vehicle Module Programming Manual· May 2006 Page i

Table of Contents

Odometer or Hours Entry (Enter ODOMETER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Odometer Ratio (Enter ODO RATIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Hours Ratio (Enter ODO Ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Dual Counters (DUAL COUNTERS, NO - 0, YES - 1) . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Vehicle Module Program Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

5 – Operation 5-1

Ground Loop Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General Programmer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Turning On Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Turning Off Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Accepting Old Data and Clearing the Display for New Data Entry . . . . . . . 5-2

Entering Numeric Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Entering Alphanumeric Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Entering Spaces and Special Characters . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Entering Odometer or Hours Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Editing Within a Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Programmer Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Testing the Odometer/Hours Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Calibrate Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Master Authorizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Limitations of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Page ii MDE-4524A Vehicle Module Programming Manual· May 2006

Purpose Introduction

1 – Introduction

Purpose

This manual describes the Vehicle Module (VM) Programmer and the steps needed to program

the vehicle module component of your Fuel Point module contains all system information including system and vehicle identification, authorized fuel type and transaction limit information. This manual also describes the Master Authorizer, a hand-held device that allows the site supervisor to authorize the pump for a single transaction on an equipment not equipped with a vehicle module.

The Vehicle Module (VM) itself should be installed according to the guidelines and restrictions outlined in C35699 Fuel Point Vehicle Module Installation Manual.

Gasboy provides a toll-free number for customers and installers having any questions pertaining to the installation: 1-800-444-5529.

System. When programmed, the vehicle

Intended Users

This manual is written for Authorized Service Contractors (ASCs) and Customer Specified Contractors (CSCs).

Abbreviations and Acronyms

The following table contains a list of abbreviations and acronyms used in this guide.

Acronym Definition

ASC Authorized Service Contractor

CSC Customer Specified Contractor

FMS Fuel Management System

ID Identification

MM Month

PCM Powertrain Control Module

VM Vehicle Module

YY Year

Warranty

For information on warranty, refer to MDE-4255 Gasboy’s Warranty Policy Statement. If you have any warranty-related questions, contact Gasboy’s Warranty Department at its Greensboro location.

Page 1-2 MDE-4524A Vehicle Module Programming Manual· May 2006

2 – Important Safety Information

Important Safety Information

This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death or serious injury if these safe service procedures are not followed.

Preliminary Precautions

You are working in a potentially dangerous environment of flammable fuels, vapors, and high voltage or pressures. Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment.

Emergency Total Electrical Shut-Off

The first and most important information you must know is how to stop all fuel flow to the pump and island. Locate the switch or circuit breakers that shut-off all power to all fueling equipment, dispensing devices, and submerged turbine pumps (STPs).

WARNING

The EMERGENCY STOP, ALL STOP, and PUMP STOP buttons at the cashier’s station WILL NOT shut off electrical power to the pump/dispenser.

Total Electrical Shut-Off Before Access

Any procedure requiring access to electrical components or the electronics of the dispenser requires total electrical shutoff of that unit. Know the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gasboy equipment.

Evacuation, Barricading and Shut-Off

Any procedures requiring accessing the pump/dispenser or STPs requires the following three actions:

This means that even if you activate these stops, fuel may continue to flow uncontrolled.

You must use the TOTAL ELECTRICAL SHUTOFF in the case of an emergency and not only these cashier station “stops.”

Read the Manual

Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand a procedure, call the Gasboy Customer Service at 1-800-444-5579, Tech Support 1-800-444-5529. It is imperative to your safety and the safety of others to understand the procedures before beginning work.

Follow the Regulations

There is applicable information in NFPA 30A; Automotive and Marine Service Code, NFPA 70; National Electrical Code (NEC),

OSHA regulations and federal, state, and local codes which must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gasboy replacement parts and retrofit kits on your pump/dispenser. Using parts other than genuine Gasboy replacement parts could create a safety hazard and violate local regulations.

Safety Symbols and Warning Words

This section provides important information about warning symbols and boxes. Alert Symbol

This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death.

Signal Words

These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions that follow must be followed to prevent death, injury or damage to the equipment

DANGER - This signal word is used to alert you to a hazard to unsafe practice which will result in death or

serious injury WARNING - This alerts you to a hazard or unsafe practice that could result in death or serious injury.

CAUTION with Alert symbol - This signal word designates a hazard or unsafe practice which may

result in minor injury. CAUTION without Alert symbol - When used by itself, CAUTION designates a hazard or unsafe practice which may result in property or equipment damage.

- An evacuation of all unauthorized persons and vehicles using safety tape, cones or barricades to the effected units

- A total electrical shut-off of that unit

MDE-4524A Vehicle Module Programming Manual· May 2006 Page 2-1

Working With Fuels and Electrical Energy

Prevent Explosions and Fires

Fuels and their vapors will become explosive if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause explosive vapors in the vicinity of dispenser or island.

t c f

w a a s c t

t d

e e a c

c e

Important Safety Information

No Open Flames

Open flames from matches, lighters, welding

orches or other sources can ignite fuels and their vapors.

No Sparks - No Smoking

parks from starting vehicles, starting or using power tools,

burning cigarettes, cigars or pipes can also ignite fuels and

heir vapors. Static electricity, including an electrostatic

harge on your body, can cause a spark sufficient to ignite

uels and their vapors. After getting out of a vehicle, touch the metal of your vehicle to discharge any electrostatic charge before you approach the dispenser island.

orking Alone

It is highly recommended that someone who is capable of rendering first aid be present during servicing. Be familiar

ith Cardiopulmonary Resuscitation (CPR) methods if you re working with or around high voltages. This information is vailable from the American Red Cross. Always advise the tation personnel about where you will be working, and aution them not to activate power while you are working on

he equipment. Use the OSHA tag out and lock out

procedures. If you are not familiar with this requirement, refer

o information in the service manual and OSHA

ocumentation.

orking With Electricity Safely

Be sure to use safe and established practices in working with

lectrical devices. Poorly wired devices may cause a fire, xplosion or electrical shock. Be sure grounding connections re properly made. Make sure that sealing devices and ompounds are in place. Be sure not to pinch wires when

replacing covers Follow OSHA Lock-Out and Tag-Out requirements. Station employees and service contractors need to understand and comply with this program completely

o ensure safety while the equipment is down.

Emergency First Aid

Informing Emergency Personnel

Compile the following information for emergency personnel:

• Location of accident (for example, address, front/back of building, and so on.)

• Nature of accident (for example, possible heart attack, run over by car, burns, and so on.)

• Age of victim (for example, baby, teenager, middle-age, elderly)

• Whether or not victim has received first aid (for example, stopped bleeding by pressure, and so on.)

• Whether or not a victim has vomited (for example, if swallowed or inhaled something, and so on.)

WARNING

Gasoline ingested may cause unconsciousness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately.

WARNING

Gasoline inhaled may cause unconsciousness and burns to lips, mouth and lungs. Keep airway open. Seek medical advice immediately.

WARNING

Gasoline spilled in eyes may cause burns to eye tissue. Irrigate eyes with water for approximately 15 minutes. Seek medical advice immediately

Hazardous Materials

ome materials present inside electronic enclosures may

present a health hazard if not handled correctly. Be sure to

lean hands after handling equipment. Do not place any quipment in mouth.

WARNING

Gasoline spilled on skin may cause burns. Wash area thoroughly with clear/water. Seek medical advice immediately.

WARNING

This area contains a chemical known to the State of California to cause cancer.

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/Tagout

WARNING

This area contains a chemical known to the State of California to cause birth defects or other reproductive harm.

Lockout/Tagout covers servicing and maintenance of Machines and equipment in which the unexpected energization or start up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. Lockout/Tagout applies to all mechanical, hydraulic, chemical or other energy, but does not cover electrical hazards. Reference Subpart S of 29 CFR Part 1910

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice

- Electrical Hazards, 29 CFR Part 1910.333 contains specific Lockout/Tagout provision for electrical hazards.

immediately.

Page 2-2 MDE-4524A Vehicle Module Programming Manual· May 2006

In an Emergency

The following actions are recommended regarding these hazards:

Important Safety Information

WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow creates a serious hazard.

Fire or explosion may result causing serious injury or death.

Follow established emergency procedures.

Collision of Vehicle with Unit Fire at Island Fuel Spill

• Do not go near fuel spill or allow anyone else in the area.

• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).

• Do not use console E-STOP, ALL STOP keys to shut off power. These keys do not remove AC power and do not always stop product flow.

• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. No open flames, smoking or power tools in the area.

• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.

• Call emergency numbers.

MDE-4524A Vehicle Module Programming Manual· May 2006 Page 2-3

Important Safety Information

This page is intentionally left blank.

Page 2-4 MDE-4524A Vehicle Module Programming Manual· May 2006

Vehicle Module Programmer Component Overview

3 – Component Overview

Vehicle Module Programmer

The Vehicle Module (VM) Programmer is a hand-held, cordless device used to interact with the Fuel Point System components. It contains an antenna for communicating to the VM through the vehicle T-Ring antenna. The two-line, alphanumeric display prompts the user through each step, making it easy to use in the shop, in the fleet yard, at the job site, or at the fueling island.

Figure 3-1

C06736 VM Programmer with Charger

3 9/16 (90.50)

1/4

(57.15)

(158.75)

6 1/4

2 3/4

(69.85)

CHARGER

CONNECTOR

CHARGER

32 CHARCTER ALPHANUMERIC DISPLAY

ALPHANUMERIC KEYPAD

FACTORY PROGRAMMING CONNECTOR

Note: C06736 VM Programmer will be shipped only till end of February 2006. Starting

March 2006, M06728A001 VM Programmer will be shipped.

The Programmer has five operating modes which are explained in detail in “Programmer

Operating Modes” on page 5-7.

• Program. When initially installing the VM, it allows you to load the vehicle's identification and fuel control data, similar to encoding data for a card- or key-based Fuel Management System (FMS). The VM can be re-programmed with new data at any time.

• Edit. This mode allows you to read back data to verify that a VM was programmed correctly. It can also be used to change partial data in a programmed VM without reentering the entire VM data (as in Program mode).

MDE-4524A Vehicle Module Programming Manual· May 2006 Page 3-1

Component Overview Vehicle Module Programmer

• Calibrate. The calibration feature is used initially to automatically calculate the odometer ratio if it is not known. It is also used periodically to adjust for slight variations between the odometer or hour meter and the VM.

• Diagnostic. Reads the entire VM and displays the results as a string of data.

• Ver si on . Reads and displays a VM's software revision date.

Figure 3-2 M06728A001 VM Programmer with Charger

View from top

Note: New programmer does not use old batteries (C09492).

View from below

Page 3-2 MDE-4524A Vehicle Module Programming Manual· May 2006

Vehicle Module Programmer Component Overview

Charging the Programmer

Before using your Programmer for the first time, you must charge it overnight. After which the Programmer and charger should always be plugged into a 115 VAC outlet when not in use to keep the batteries charged.

Battery Pack Replacement

C06736 Replacement Batteries

In the event that the original batteries fail to hold a charge, Gasboy offers a replacement battery pack (C09492).

Figure 3-3 C09492 Replacement Battery Pack

M06728A001 Replacement Batteries

The M06728A001 VM Programmer uses 5 commercially available AA Nickel Metal Hydride (NiMH) batteries. Nickel Cadmium batteries (NiCd) may not be used in this programmer.

Note: The battery pack used in the Fuel Point Programmer may be damaging to the

environment if it is not disposed properly. Gasboy urges you to support your community's recycling effort.

MDE-4524A Vehicle Module Programming Manual· May 2006 Page 3-3

Component Overview Vehicle Module Programmer

This page is intentionally left blank.

Page 3-4 MDE-4524A Vehicle Module Programming Manual· May 2006

Vehicle Module Field Descriptions Preparation for Programming

4 – Preparation for Programming

Vehicle Module Field Descriptions

The VM contains various data fields such as vehicle identification, allowable fuel type and quantity, and miles or hours driven. It is important to understand these fields and their interaction with the rest of the system. The Programmer is ordered from the factory to match the base FMS, therefore, some of the fields described below might not be available with every Programmer. Also, the VM does not use all of the fields that are encoded on a card or key, such as the restriction digit, which serves no purpose with Fuel Point. Additionally, some of these fields may be programmed into every VM at a site, but not prompted for during the programming sequence, either for security reasons, or because the data is always the same. Default prompts for commonly used fields are shown in parentheses after the field description.

System ID

The System ID is a unique number that identifies your system and safeguards against access by users of other systems. Your unique System ID is assigned to the Programmer at the factory; you will not be prompted for it during programming.

Vehicle Module Number (Enter VM Number)

The VM Number is used to identify the VM and is the lockout field used in the fuel management system. The VM number length is fixed at 5 digits for FleetKey systems and makes up the entire lockout field. For CFN systems, the VM Number can be up to 8 digits, and can make up the entire lockout field for bit-mapped lockout, or can be combined with other fields on the VM for limited lockout.

IMPORTANT INFORMATION

Every VM used at a site must have a unique VM Number because the Fuel Point Reader uses the VM Number and System ID to monitor on-going transactions to tell if the nozzle is still inserted into the same vehicle.

MDE-4524A Vehicle Module Programming Manual· May 2006 Page 4-1

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