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Service Guide339000-A339003 339004-1339006 338315
Fluid Management System (FMS)
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Overview of the FMS
The fluid management system is an electro-mechanicmonitoring and security system for fluids.
Compact Controller
The heart of the system is the Compact Controller.
The Compact Controller can manage up to 6 fluid outlets.
Data within the controller includes:• fluid tank description• quantity (preset if desired) and fluid unit of measur• fluid costs (values for both purchases and sales)• usage by fluid grades, fluid outlets, and operator • fluid tank low warning indicator• prompts (w/ data on date and time fluid brand, grad
quantity, and value)
Alemite167 Roweland Drive, Johns
www.alem
Copyright © 2005
This document contains confidential info670833 and is not to be copied, used, or disclose
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FMS Description
System Components
The components used to assemble a complete systeare:
• Compact Controller Model 339000-A• Power Supply Model 339003• Printer Model 339004-1• Pulse Meter(s) Model 339005• Pulse Meter(s) Model 340080• Air Solenoid Valve(s) Model 339006• Fluid Solenoid Valve(s) Model 338315
NOTE: A typical system is shown on pages2 and 3.
FMS Operation
Floor Technician
The floor technician enters all the necessary data (within the proper time limit, if set) into the Compact Controller to allow fluid delivery. Prompts set within the controller include:
• PIN code• reel number• tank grade• quantity dispensed
Up to four (4) additional prompts can be set that areuser-defined.
Printed Ticket
The Compact Controller transaction can be printed to42-column Ticket Printer.
SER 339000-A
, LLCon City, Tennessee 37601ite.com
by Alemite, LLC
rmation that is the property of Alemite, LLCd to others without express written permission. Revision (3-05)
SER 339000-A Fluid Management System
Revision (3-05) 2 Alemite, LLC
Fluid Management System SER 339000-A
Alemite, LLC 3 Revision (3-05)
SER 339000-A Fluid Management System
Revision (3-05) 4 Alemite, LLC
Figure 1 Typical Pumping Station
Legend: Items in Bold are part of the Fluid Management System
Fluid Management System SER 339000-A
Alemite, LLC 5 Revision (3-05)
Figure 2 Typical Dispensing Stations
Legend: Items in Bold are part of the Fluid Management System
SER 339000-A Fluid Management System
Electrical AccessoriesThe FMS also includes electrical accessories.
These items include cable grips, junction boxes, and terminal strips.
Cable Grips
Two types of strain-relief liquid-tight cable grips are recommended for connection from the Power Supply to the Compact Controller. See Figure 3.
Figure 4 Compact Controller Model 339000-A
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Figure 3 Single- and Quad Strain-Relief Liquid-Tight Cable Grips
Cable Grip Usage
The number of stations and how many fluids dispensed at each station determines cable grip usage.
IMPORTANT: Create a layout of theentire system to determine the numberand types of cable grips required.
Compact ControllerNOTE : For operation procedures,refer to the Compact ControllerOperation manual for details.
Controller Fabrication
Cable Grip Location
Once the type and number of cable grips has been established for the Compact Controller, thelocation must be determined.
Revision (3-05)
CAUTIONMake sure to locate the holes for the Cable Grips in theareas designated in Figure 6. Damage to internal Con-troller components can occur.
As many cable grips as possible should enter the Controllethe bottom. This is the highest priority surface. See Figure 5. The least desirable surface is the top.
IMPORTANT: Make sure to leave sufficient spacebetween the cable grips to tighten the Locknut.
1. Remove the four screws that secure the cover of the Controller to its base.• Remove the cover from the base.
2. Remove the four screws that secure the circuit board to tbase of the Controller.• Remove the circuit board from the base.
3. With the proper size drill or hole saw (See Table 1), cut the hole(s) in the base of the Controller.
4. From the outside surface of the Controller, install the shothreaded end of the Cable Grip into the hole.
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6 Alemite, LLC
Fluid Management System SER 339000-A
Figure 5 Designated Areas (by Priority) on Compact Controller for Single- and Quad-Cable Grips
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5. Install the Locknut from inside the Controller.• Do not tighten at this time.
6. Install the cable through the Grip and into the Controller.
Wiring and Mounting
7. Install the wire to its proper connection in the Controller.• Refer to SER 339000-A-IN for details on wiring
the Compact Controller.
8. Tighten the cap on the Cable Grip.• This secures the Grip to the Cable.
9. Tighten the Locknut securely.
10. Mount the Controller as required.• Refer to SER 339000-A-IN for details on
mounting the Compact Controller.
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Cable GripMounting Hole Size
Inch mm
Single-Cable 0.61 15.5
Quad-Cable 0.91 23
Table 1 Cable Grip Mounting Hole Size
Junction Boxes
The layout of the system should include the use of junctiboxes whenever possible. Junction boxes aid in power cablconsolidation.
7 Revision (3-05)
Figure 6 Junction Box Model 339007
SER 339000-A Fluid Management System
Revision (3-05) 8 Alemite, LLC
Power SupplyThe Power Supply transforms 120 V
ac into 24 V dc. Its output is 4.2 Amperes.
It is fitted with a 1-Amp circuit breaker. Security is provided with a lock and key.
The power supply is manually-operated by a key. Turn the key to the ON position and the light on the cover illuminates.
Turn the key OFF and remove to prevent unauthorized entry into the system.
WiringRefer to SER 339000-A-IN for
details on wiring the Power Supply.
Figure 7 Power Supply Model 339003
Fluid Management System SER 339000-A
Ticket Printer
The Ticket Printer provides a hard copy of the data(a transaction receipt) relayed from the Compact Controller.
This POS (Point of Sale) 42-column Ticket Printer includes a printer cable and a 120 V ac transformer. It cgenerate two- or three-part copies.
Alemite, LLC 9
Figure 8 Ticket Printer Model 339004
an
Pulse Meter
Each Meter measures the amount of fluid being dispensed. The signal is sent to the:
• Keypad Controller to record the count • Master Controller (computer via the PC Interface
Box) to identify the unit of measure
Refer to SER 339005 for details on Pulse Meter models 339005 and 340080.
Refer to the Installation manual SER 339000-A-IN for details on wiring the Pulse Meter and entering the required scale factor.
IMPORTAN T: On ce th e Pu l s e Me te r i sinstalled, confirm Meter operation at the Key-pad Controller.
1. Disconnect the cable from the Keypad.
2. Connect a ohmmeter to each of the cable wires.
3. Operate the system. • The ohmmeter should cycle.
Revision (3-05)
-1 (Includes Transformer and Printer Cable)
SER 339000-A Fluid Management System
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Figure 9 Air Solenoid Valve Model 339006
Air Solenoid Valve
Manufacturer
The air solenoid valve is manufactured by
ASCO Joucomatic
Charlotte, North CarolinaSingapore
Replacement parts should be procured froeither address.
Installation
CAUTIONA filter/separator must be used with thisvalve.
Cleanliness is essential during installa-tion. Make sure all of the air lines arefree of foreign material prior to valveoperation. Valve may become cloggedand not function properly.
Description
The Air Solenoid Valve is normally closedand pilot-operated. The valve is equipped witan LED indicator light and a manual overrideWhen energized, the valve allows regulated apressure to operate the pump.
Operation
This 3-way normally closed pilot-operatedvalve consists of a spring-loaded poppet. Whethe solenoid is energized, inlet air pressure overcomes the spring pressure and causes tpoppet valve to move downward.
Revision (3-05)
Specifications
Inlet and OutletConnections
Min. Operating Pressure
Max. OpPres
psi Bars psi
1/2 '' NPTF (f) 30 2.1 150
Table 3 Air Sole
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The upper portion of the poppet seats and isolates the pilot airfrom the line air.
Removing power from the solenoid allows air to vent from the valve and the solenoid’s stem. The spring returns the poppet to itoriginal position.
Wiring
Refer to the Installation manual SER 339000-A-IN for details on wiring the Air Solenoid Valve to the Compact Controller.
10 Alemite, LLC
erating sure
Power Requirement Current Draw Termination Seal Type
Bars
10.3 24 V dc 0.12 Amps DIN 43650 Buna N
noid Valve Model 339006 - Specifications
Fluid Management System SER 339000-A
alve.
Figure 10 Fluid Solenoid Valve Model 338315
Fluid Solenoid Valve
Manufacturer
The fluid solenoid valve is manufactured by:
HydraForce, Inc.
Lincolnshire, IllinoisTokyo, Japan
Replacement parts should be procured fromeither address.
Installation
CAUTIONA 40-micron filter must be used with thisvalve. The filter is normally installed nearthe outlet of the pump.
Cleanliness is essential during installa-tion. Make sure all of the fluid tubing isfree of foreign material prior to valveoperation. Valve may become cloggedand not function properly.
Description
The Fluid Solenoid Valve is normally closedand pilot-operated. The valve is equipped withan LED indicator light and a manual override.When energized, the valve opens and allows fluid to be dispensed from the control valve.
Operation
The valve assembly consists of two separainternal valves; the primary needle valve and the secondary valve. The primary valve actuates first, which in turn, causes the secondary valve to operate.
When the coil is energized, the primary
Alemite, LLC
Specifications
Inlet and OutletConnections
Min. Operating Pressure
Flow Rate
psi Bars
1/2 '' NPTF (f) 30 - 3000 2.1 - 207 See Figure 11
Table 4 Fluid Sole
te
needle valve lifts and allows fluid into the delivery port. Fluid pressure equalizes and assists the movement of the secondary v
Manual Override
To place the valve in the manual override mode-of-operation:• Push down on the knob and turn counterclockwise 180 °.
Wiring
Refer to the Installation manual SER 339000-A-IN for details on wiring the Fluid Solenoid Valve to the Compact Controller.
11 Revision (3-05)
Power Requirement
Current Draw Termination
OperatingTemperature Required
Filtration° F ° C
24 V dc 0.60 Amps DIN 43650 -40 to 248 -40 to 120 40-Micron
noid Valve Model 338315 - Specifications
SER 339000-A Fluid Management System
Revision (3-05) 12 Alemite, LLC
Figure 11 Fluid Solenoid Valve Pressure Drop versus Flow Rate
Changes Since Last Printing
Added Ticket Printer 339004-1