Scully Signal VDC001403 User Manual 8

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Document Description	8
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Permanent Confidential	No
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Document Type	User Manual
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Filesize	65.79kB (822400 bits)
Date Submitted	1999-07-06 00:00:00
Date Available	1999-11-22 00:00:00
Creation Date	2001-06-09 21:47:25
Producing Software	Acrobat Distiller 4.0 for Windows
Document Lastmod	2001-06-09 21:47:27
Document Title	8

scully
SAFsmAutomated Fueling System
Vehicle Data Computer
Installation and Programming Manual
Part No‘ 61464 Rev. A 8/98
............................................................................................... Table of Contents
Table of Contents
Section 1 Description .......... ......
Section 2 Installation ........ ....... ....... ....... ..
2.1 Defining the Installation layout ..
2.2 Tools and Parts Required ..
2.3 VDC Mounting Location
2.4 Odometer Transducer location ..
2.6 Engine Hours Connection ........
2.6 flansmitter Coil (T-Ring) Mounting
2.7 Optional Harness Assembly .
,_ ,_,,_,. . ..
an—oqmmb h
2.8 Final Inspection .................
Section 3 Configuration .. ....... ........ 14
3.1 Battery Replacement . .. 15
3.2 Keypad Operation ....... 4 15
.17
.19
3.3 HHP Operating Modes
3.4 Odometer Pulse Factor .
3‘5 CALC Pulse Factor ...... . 20
3.6 Testing the Programmed VDC . 20
3.7 Manual Authorizer .................. .21
Section 4 Maintenance......... ........ ....... ...... ....... 22
4.1 Troubleshooting ............................ 22
4.2 Battery Life Conservation Selfing.. 23
4.3 T-Ring Maintenance ....................... 23
4.4 Odometer Transducer Maintenance. 23
Section5 Appendix
5.1 VDC Dimension .
52 VDC Wiring; Mechanic ometer
5.3 VDC ering Electronic Odometer .
VDC Program Data Sheet ...........
Vehicle Calibration Factor Data Sheet .
scuIIy
........................... General Description
Section 1 Description
Please read this manual carefully before beginning installation and programming of
the Vehicle Data Computer (VDC). It is strongly recommended that an installation plan
be developed for each specific vehicle. The VDC must be installed as described in this
manual to ensure the reliability and proper operation of the system. Scully Signal
Company provides a toll-free number for customers and installers having any question
pertaining to fire installation. Please call SAFS'“ Technical Support at 1-800-272—8559.
This document is provided to assist in installation, programming, service and
maintenance of the Scully Automated Fueling System (SAFS'“), VDC and associated
equipment. SAPSm allows die secure unattended refueling of a fleet of vehicles from
a land based or mobile station and records vehicle transaction information for use
in managing the fleet. Vehicles in the fleet are authorized to pump by transnutting
authorizing information from a VDC. The authorizing information or Vehicle
Communications (VCOMM) contains the Vehicle ID, Fleet ID, Engine Hours, Odometer
Mileage, and CHECKSUM for error detection The Vehicle Communications packets
are sent electromagnetically from the VDC through a transmitter coil (T-Ring) on the
vehicle‘s fuel tank inlet, to a receiving coil on the refueling nozzle (N-Ring). The
VCOMM packets are then transmitted electronically to the System Controller, which
validates the packets, controls pumping, and keeps track of transaction information.
VDC installation must be done in accordance with federal, smte and local codes, and
the National Fire Protection Association code NFPA~30, “Flammable and Combustible
Liquids Code". The VDC complies with Part 15 of the FCC rules. Operation is subject
to the two following conditions:
1. The device may not cause harmful interference.
2. The device must accept any interference received, including interference that may
cause undesired operation,
Changes or modifications to this equipment not expressly
approved by the party responsible for FCC part 15 compliance
could void the users authority to operate the equipment.
Failure to receive authorization violates the warranty
conditions of the equipment.
Section 2 ......
Section 2 Installation
2.1
%4
Before performlng any of the following procedures be sure the
engine ls turned off. Insure that the engine cannot be started
while work Is in progress. When installing the VDC, do not
tamper with the brake or steering systems or attach wires
or cables to the steering column, brake system cable or any
moving mechanical parts.
Defining the Installation Layout
When considering the installation layout for the VDC, four basic areas must be
considered:
It The National Fire Protection Agency (NFPA) code.
2. Practical considerations within the jurisdiction of this code
Flammable and Combustible Liquids Code
Location NEC Class 1, Extent of
Group D Division Classified Area
Tank Vehicle and Tank Car“ 1 Within 3 feet of edge of dome,
Loading through open dome extending in all directions.
2 Area between 3 feet and 15 feet
from edge of dome, extending in
all directions.
Loading through bottom 1 Within 3 feet of point of venting
connections with atmospheric to atmosphere extending in all
venting directions.
2 Area. between 3 feet and 15 feet
from point of venting to
atmosphere, extending in all
directions Also up to 18 inches
above grade Wifllin a horizontal
radius of 10 feet. from point of
loading connection.
Flammable and Combustible Liquids Code (continued)
Location NEC Class 1, Extent of
Group D Division Classified Area
Loading through closed dome 1 Within 3 feet of open end of vent,
with atmospheric venting extending in all directions.
2 Area between 3 feet and 15 feet
from open end of vent, extending
in all directions. Also within 3
feet of edge of dome, extending
in all directions
Loading through closed dome 2 Within 3 feet of point of connec
with vapor control tion of both fill and vapor lines,
extending in all directions.
Bottom loading with vapor control. 2 Within 3 feet of point of connec-
Any bottom unloading fions extending in all directions.
Also up to 18 inches above grade
within horizonml radius of
10 feet from point of connection.
tank vehicles may be spotted at varying points. Therefore, the extremities of the load-
ing or unloading positions shall be used.
3. Locate the VDC in a non-hazardous area at least 8 feet from the fuel tank,
protected from excessive electrical interference within the vehicle.
4. The odometer transducer types
- Vehicles with electromecham’cal odometer/speedometeis
- Vehiclee with an electronic odometer/speedometer
5. The Engne “ON" Hours connection
6. The transmitter coil (T—Ring) and it’s cable routing
\5%W%=
Section 2 .........
2.2
2.3
Tools & Parts Required
Installation of the VDC requires the following tools and parts:
Electric Drill Rubber grommet assortment“
Crimp tool Ring terminal assortment"
Screwdriver Butt connector assortment*
Pliers Heat Shrink Tube)“
Heat gun or mini-butane torch Self~drilling screws“
2 Conductor shielded Cable?“ Convoluted Tube*
* These parts are supplied with the VDC installation kit All terminals and connectors
contain corrosion protection gel. One tube (2 oz) of corrosion preventive compound
for electrical contacts is provided with the kit for all connections that do not have
protection gel
VDC Mounting Location
Select a suitable location for the VDC, preferably where wiring connections are
protected from excessive heat, water, oil, or other agents which could be harmful to
electronic componens. Sufficient room should be left around the installation area
to connect wires to the VDC. Prepare the surface by cleaning away all dirt and oil
where the unit is to be mounted, make sure it: is at least 3 feet from the fuel
tank inlet. Mount the VDC us" g self-drilling screws at two diagonal outer holes.
VDC installation kit is supplied with self-drilling screws, however, drilling pilot holes
might be required on some installation.
wire is needed to reach the battery post, use the 2 conductor shielded cable. The
VDC black wire must be grounded to the negative battery post The VDC case is
isolated from its electronic circuit, therefore the chasis does not provide a reference
ground. Cut the drain wire on battery connection end and ground the drain wire at the
V'DC end. The VDC red wire is connected to constant HOT (battery voltage) and must
be from a constant power source. For negative ground vehicles, you can use one of the
existing VDC mounting holes as the drain wire ground point, as long as it is mounted
on a metal surface with a good chassis ground.
SecdonZ
Installation
2.4 Odometer Transducer Location
2.4.1 Electronic Odometer/Speedometer
The optional odometer/speedometer transducer is a device that converts mechanical
rotation to electronic pulses so that the VDC can calculate mileage. Vehicles with an
electronic odometer/speedometer or an electronic dashboard already have electronic
sensor. This sensor is usually found Where the transmission or transaxle connects to
the drive shaft For such vehicles, connect the two wires from the VDC harness (white
and black/white) to the odometer/speedometer cable. The vehicle speed sensor should
be wired to the VDC with correct polarity to guarantee that the high to low transition
occurs on the “clean” side of the sine wave (see Figure 1). If the connection is made
with wrong polarity, reverse the connection.
Starting from the VDC, run the white and black/white harness wires to where the
electronic sensor is located. Crimp harness wires to sensor wires by using one of the
following recommended methods.
When routlng wires or cables, it is Important to keep away
from any moving parts, and any parts that generate excesslve
heat, or areas that may impede safety. Keep away from drive
shafts, fan
blades, belts, adjustable steering column, foot
pedals, radiator, and exhaust system.
MAGNETIC FIELD
SPEEDOMETER
SENS\Oi
SENSOR OUTPUT VOLTAGE /
TRANSMISSION SPEEDOMET ER
GEAR
Figme 1 — Speed Sensor
E7%”y\\=
Section 2 ......
Method A: Using MOISTURE-RESISTANT Tap Connector.
1. Open hinged side wall. Place unsuipped
sensor wire inside run channel and close QUICK TAP wNN. VEH. SENSOR me
hinge sidewall 00 90“ position to keep the
sensor wire in place. The connector is
gel-filled for corrosion protection.
2. Insert unstripped VDC white wire
completely into tap pom
3. Hold pliers perpendicular to the wire and \
make the connection by crimping the u-con—
tact down flush with the top of the insulator.
4. Close cover until securely latched.
[Lg Important
It is strongly recommended to
cover all connections with moisture vuc Wm
resistant tape.
Using the above procedure crimp the VDC 2
black/white wires to the other sensor wire
(Stagger the connection point).
Cover connections with 6 inches of
convoluted tubing.
Recommended Connector. 3Mo Scotchlok“ 804
MOISTURE-RESISTANT Tap Connector.
Figure 2 — Method A
flws
Section 2 ...................
Method B: Using MOISTURE-RESISTANT Butt Connector:
1. Cut the sensor wire and strip off about 1/4" of insulation from each end.
2. Cut and place 1.5" of self sealing heat shrink tube over one end of sensor wire.
3. Strip off 1/ " of insulation from the VDC white wire. Mt the stripped VDC wire
together with one of the sensor wire.
4. Crimp a butt splice connector onto the twisted wires. Crimp the other side of the
connector onto the other stripped sensor wire.
5. Place the heat shrink tube over the butt connector.
6. Use a heat gun, or mini—butane torch to shrink and seal the tubing. Shrink the tubing
to form a moismre-tight seal around the wire when heated.
7. Use the above procedure to crimp the VDC black/white wires to the other sensor
wire (stagger the connection).
WARNING
When heating the shrink connector, make sure it is positioned at least
3 feet from fuel lines or batteries, in order to avoid an explosion.
Cover harness wires with 6 inches of convoluted tubing. Using cable ties, secure the
harness wires to the chassis supports. Be sure to leave some slack and provide suffi-
cient clearance from any moving parts, brake or steering components. Leave at least 4
inches of clearance from any ignition system wiring or hot surfaces. Do not attach the
wires to any moving parts, pneumatic or hydraulic lines or to clutch to brake cables. If
the wirs must be run along the chassis, it must be routed away from exhaust pipes,
and it must be protected from any object which could strike it.
Recommended Connector. 3M Scotchlok MNGISCMX MOISTURE-RESISTANT
Butt Connector.
ELECTRONIC
SPEEDOMETEH
CABLE BUTT SPLICE
T0 VDC CONN,
Figure 3 —Method B
2.4.2 Electra-Mechanical Odometer/Speedometer
The optional odometer transducer is connected to the VDC via a three-wire cable
which is supplied in 12 foot length The transducer is installed on the vehicle odometer
shaft or directly to a gear box odometer output.
9 scuIIyA
Section 2 ..........
To install the odometer transducer remove the existing odometer/speedometer drive
cable. Select the proper odometer key or keys for the vehicle being insmlled. Attach
the appropriate end of the odometer/speedometer cable back onto the odometer trans-
ducer per the manufacturer instructions Insure the flexible cable does not have exces—
sive slack or kinks. Periodically grease any fittings per manufacturer’s instructions. The
transducer cable nms from the transmission gearbox to the VDC. Connect Transducer
red to VDC red/white, white to white and black to black/white wires using Method B.
Secure the cable to the chassis supports. Cover any exposed cables with convoluted
tubing provided in the installation kit Be sure to leave some slack and provide suffi-
cient clearance from any ignition system wiring or hot surfaces. Do not attach the
cable to any moving parts, pneumatic or hydraulic lines or to clutch or brake cables.
If the cable must be run along the chassis, it must be routed away from exhaust pipes,
and it must be protected from any object which could strike it. Use rubber grommets
to secure and protect the cable.
T0 VDC
REAl'I'ACH
SPEEDOMETEFI ATTACH T0
CABLE TRANSMISSION
, ,
‘ l KEV /
m - ll. . m ~— =b=
KEY SUPPLIED EV
SENSOR MFR.
ATTACH T0
REATTACH TRANSMISSNDN
SPEEDOMETEH
CABLE
KEY
W7 _' -— q:
KEY SUPPLIED BY
SENSOR MFR.
Figure ll — Afier Market Transducer
2.5 Engine Hours Connection
For the VDC to record engine hours, VDC's yellow wire must be connected to a point
in the vehicle that provides HOT (battery voltage) signal while the engine is ON or
running, and OFF (zero voltage) when the engine is off. Check the vehicle’s Wiring
diagram to detemu'ne the best connection point. Suggested connection points are an
existing hour meter, the positive side of the oil pressure switch, or the switched side
of ignition key Verify that the connection point is one where me battery voltage is
present when the ignition switch is on, and is open or grounded when the switch is off.
Follow one of the recommended Methods A or B, to make your connections.
fljl’Y/Lm
Section 2 ................................
2.6 Transmitter Coil (T-Ring) Mounting
WARNING
When performing any work around the fuel tank inlet be sure to
comply with all applicable federal, state, local and other applicable
codes and regulations as well as the requirements of NFPA-30
“Flammable and Combustible Liquids Code". Do not smoke or
perform any metal work with the fuel tank cover removed, or
when fuel vapor is present. Do not perform any operation which
may impair the fuel tank or fuel pipe safety Use only pneumatic
tools for metal work.
The VCOMM packets are sent electromagnefically from the VDC through a transmitter
coil (T-Ring) on the fuel tank inlet, to a receiving coil on the refueling nozzle (N—Ring).
One T-Ring should be installed around each fuel tank inlet with the mounting eats
down (two T—Rings pet VDC maximum). The T-Ring should be positioned as close to
the fuel tank opening as possible, preferably within four inches due to Nozzle Ring
(N-Ring) sensitivity. Two sizes of T-Rings are available; 2.7" ID and 4.7" ID. The 2.7" ID
T—Ring fits most passenger cars, light trucks, and buses with 2—1/2" fill pipe. The 4.7' ID
T-Ring fits truck saddle tanks with 4-1/2" fill pipe. T—Rings have a thin flexible flange
inside a rigid outer ring that keeps them in place on the fuel tank. They are supplied
with approximately 12 inches of wire and must be extended using the coil harness
and/or two conductor shield cable Scully part number 000766. Use Method B - Using
MOISTURE-RESISTANT Butt Connectors to make your connections.
When routing the T-Rlng wires, be sure to keep it at least
2 inches from any other wires in order to preserve the intrinsic
wiring requirements.
2.7" LD.
4.7" 1D.
Figure 5 — fillings
Section 2
2.7
flgyigm
Before beginning the installation, have the fuel pipe repaired or replaced if it shows
any signs of leakage or excessive wear. Check to make sure that the fuel inlet cover
fits tightly Position the T-Ring around the fuel tank inlet and check to make sure that
there is sufficient room to remove and replace the fuel inlet cover. The T-Rings are
designed to be held in place by fitting the diaphragm over the fuel tank inlet neck. In
cases where the coil mounting ears are unused, and interfere with proper fit the ears
may be removed. Be careful not to cut into any wires within the coil.
The mounting ears provide an alternate method of attachment External threaded
adhesive studs (Click Bond CS series) should be positioned to accept the mounting
ears. Since power tools can not be used in a Class I, Division I location, use of studs
is strongly recommended. Please consult Click Bond (702) 885-8000 for your specific
application. If drilling in hole is absolutely needed, you must remove the shroud and
take it to a safe place to drill hole, then re-attach the shroud.
Cover the T—ring wires and connections with a 12 inch piece of convoluted tubing.
Add a cable tie at the neck of the T—Ring to keep tubing in place.
Optional Harness Assembly
The optional harness assembly is provided to reduce the installation time. The harness
contains weatherproof connectors with suitable length of Wires for a typical vehicle
installation. VDC T—Ring wiring is provided via a short harness and must be extended
using the coil harness and two conductor shield cable Scully part number 000766.
T~Ring wiring should run along the vehicle side on which the fuel tank inlet is located.
T-Ring harness should have a minimum clearance of 2" from all other wires and the
harnesses.
IEIE]
Figure 5 — VDC hamess assembly
Section 2
2.8 Final Inspection
Verify that all work has been completed according to you: mmllation plan, and is in
agreement with me National Fire Protection Association NFPA30 “Flammable and
Combustible Liquids Code", federal, state and local and any other applicable codes
and regulations. Conduct a visual inspecfion to make sure all wires are secure and
well protected. Do not attach any VDC cable to any moving parts, pneumatic or
hydraulic lines or to clutch or brake cables.
Figure 6 — VDC with weatherman] connectors
fimfivg
Section 3 "We. ...... Programming and System Checkout
Section 3 Configuration
A Hand Held Programmer (HHP) is used to interface tn the Scully Automated Fueling
System (SAFS"')t The HHP has three operating modes:
Programmer - At the time of VDC histallation, the HHP program; file VDC with the
desired information to identify the vehicle and keep track of impomm: vehicle
parameters.
Calculate Pulse Factor - This is used initially to automatically calculate the
odometer ratio also referred to as Pulse Factor. This may also be used periodically
to adjust for slight variation between the dashde odometer and the VDC
odometer readings
Manual Authorize:- - Manually Authorize; the pump for a single transaction on
equipment which may not. be registered as part of the fleet, and does not have a
VDC installed.
fig Imponant
It is strongly recommended that users of the HHP be limited to the
administrative service attendants and installation technicians,
Fimn‘e 7 — Handheld Programmer
jfl’it 1“
Section 3 ........................... ngmnum‘ng and System Checkout
3.1 Battery Replacement
The HHP uses a 9 volt alkaline battery. Replace the battery as needed.
3.2 Keypad Operation
This section describes the keypad operating style of the HHP common to all operating
modes.
ON
To turn the Hl-lP on, press the ONIOFF key once. The display first goes through a
powemn self-test and then displays the main menu
OFF
Press ONIOFF key once while HHP is ON to turn it OFF. To conserve battery power,
the HHP will also shut itself off when there is no key activity within 3 minutes.
VERIFY
Controller. This will not only verify that the VDC has been correctly programmed,
but also that the VDC’s transmitter coils work properly.
BS (back space)
Press BS key to set the cursor back one space. Eaeh subsequent press of the BS key
sets the cursor back another space. ‘
ENTER
BACK
Press BACK to go back to the previous field. Each subsequent press of the BACK key
sets back one field.
ke%’yt=
Section}. ngzauuningandfiystemfiheckom
Entering Numeric Data
On the keypad, press the number that you want entered into the field. The cursor will
automatically advance to the next position. After all digits have been entered, press
ENTER key to advance to the next field.
Entering Alphanumeric Dam
On the keypad the keys 1 flrrough 9 have letters above the numbers. Pressing and
holding the number key will scroll tluough all characters every 1.5 seconds. When
entering data into an alphanumeric field, if you press and hold a number, it shows that
character, but the cursor doesn‘t advance to the next position. Continuing to hold the
number for 1.5 seconds shows the first letter marked above the number, continuing to
hold the number shows the second letter marked above the number followed by third
letter. For example, to enter the string PBF96:
Press and hold key 7 until P is displayed. Release the key, letter P is registered and
cursor automatically advances to the next position.
Press and hold key 2 until B is displayed. Release the key, letter B is registered and
cursor automatically advances to the next position.
Press and hold key 3 until F is displayed. Release the key, letter F is registered and
cursor automatically advances to the next position
Press and release key 9. Number 9 is registered and cursor automatically advances
to the next position
Press and release key 6. Number 6 is registered and cursor automatically advances to
the next position.
Entering Spaces and Special Characters
If you need to enter space, press and hold key 1 until space is placed. Release the key,
space is registered and cursor automatically advances to the next position.
Special characters available are: +, -, and '. Scroll through (Decimal Point) key to
select one of the special characters.
Editing Mthin a. Field
To edit data within a. field, press the BS key to set the cursor back one space. It has
now erased the data previously entered in that position. Each subsequent press of the
BS key sets the cursor back another space. Once you get to the position you want,
start entering the correct data.
illlyw—1G
...... Programming and System Checkout
3.3 HHP Operating Modes
Programmer
Once the VDC installation is completed, the HHP is used to program the VDC with
the desired data in order m authorize it for refueling and enable it to keep track of
important vehicle information. The VDC can be reprogrammed with new data at any
time. Tum the HHP on and from the main menu select mode 1-PROGRAMMER.
You need to hold HHP Ring near the VDC T-Ring to establish communication for
programming. If the vehicle is equipped with two ’l‘-Rings, perform the programming
at one Ring, and then use the second Ring during die Testing the Programmed VDC.
When conunurucation with the VDC is established, the factory default parameters are
read Press ENTER and program new data specific for the vehicle as prompted on the
HHP display. Remember, you do not need to maintain communication with the VDC
T-Ring while entering new data. It“ at any time you make a mistake typing the data,
you can press the BS key to back up one space at a time to the beginning of me
current field, then type the correct data Once all data is entered, hold the HHP Ring
near the VDC T—Ring to transfer new parameters to the VDC.
11? Important
Do not program 6! VDC when the vehicle’s engine is running,
Make sure the vehicle is shutoff during programming.
VDC Program Data Sheet
As you will see, there are many fields that may be programmed into a VDC. It is helpful
to write all of the data into a chart as you program a VDC. At the end of this manual,
there is a sample chart that you can use to tailor your system.
Following is file information recorded in the VDC:
Vehicle ID
Twelve characters alphanumeric string identifymg the specific vehicle.
I@ Important
Every VDC must have a unique Vehicle ID because SAFS" uses
Vehicle ID as well as Fleet ID to monitor on-going transactions to
tell if the nozzle is still inserted into the same vehicle/equrpment
Fleet 1D
A maximum Five digit numeric string (1 to 66534) will identify the fleet or departrnent
the vehicle is assigned to.
’
[lg Important
Every VDC must have a Fleet ID because SAFS’" uses Vehicle ID as
well as Fleet ID to monitor on-going transactions to tell if the nozzle
is still inserted into the same vehicle/equipment.
17£I\%
....... Programming and System Checkout
Engine Hours
This field is 7 whole digits and 2 decimal places indicating the amount of time the
vehicle's engine has been running. For vehicle's equipped with an hour meter, use the
meter reading for Engine Hours, otherwise select a default value. The VDC counts time
in increments of approximately 4 seconds once this signal is at +12 or +24 volts.
Odometer
This field is 7 whole digits and 2 decimal places indicating the current vehicle mileage.
Use the reading from the vehicles dashboard odometer with any rollover factored in.
The VDC receives odometer data as a series of pulses and counts in 1/100 of a mile.
Pulse Factor
The Conversion factor to interpret the number of pulses from the odometer to the
number of miles traveled. The maximum value of the Pulse Factor is 131070. If the
vehicle specification is not known, use CALC PUISE FACTOR feature to narrow
down to the correct Pulse Factor.
Install Odometer
her with any rollover factored in.
TX Interval
VCOMM broadcast cutoff time after the engine is turned off is TX Interml. This feature
reduces VDC's vehicle battery consumption fiom 40 milli amp during nomial operation
to 20 milli amp during NO VCOMM (also referred as sleep mode). The default time
for this post engine shutdown sleep time is 256 minutes (approximately 4 hours);
maximum interval time is 45 days. TX interval is reset every time Engine Hour signal
is set to +12 volt or +24 volt OR when Odometer pulses are received.
I]? Important
If there is no Engine Hour signal or no Odometer pulses, the VDC
will remain in NO VCOMM (sleep) and usling is not permitted
TX With Engine On (YIN)
Allows VDC VCOMM broadcast with engine ON. Default is N (no), fueling permitted
only when engine is off. [fit is desired to fuel while the engine is running, this field
should be set to Y (yes)
After completion of programming you will be prompted with the following three
screens before going back to the main menu Verify the dam shown is correct;
otherwise go back to me PROGRAMMING mode and change the data fiom main menu
Section 3 ................ Freya-main; and System Checkout
‘ 3.4 Odometer Pulse Factor
The VDC receives odometer data as a series of pulses. These pulses may come from
sensors mounted to the transmission, iransaxle, transaxle, or drive shaft The number
of pulses of the odometer transducer required to register one mile is called Pulse
Factor. The Pulse Factor is affected by several factors such as, the size, axle ratio,
and transmission specifications.
3.4.1 Mechanical Odometer Cable
Older vehicles use a. mechanical cable to deliver odometer pulses to the dashboard
To allow the VDC to record these pulses, a transducer should have been purchased
and installed according to the VDC Installation section. The formula for mechanical
odometer Pulse Factor is:
Cable revaluations per mile multiplied by sensor puLs'es per revolution
Cable revolutions per mile is the number of revolutions the mechanical cable turns
for each mile. This can be found in the llansmission specification. For domestic
vehicles the typical value is 1000 revs/mile and for foreign vehicles is 900 revs/mile.
Sensor pulses per revolution is the number of electronic pulses generated for each
revolution of the sensor input This is determined by the sensor manufacturer and may
be smmped on the sensor. A typical value is 8 pulses per revolution. Therefore, the
typical Pulse Factor for a domestic vehicle is 8000 and for a foreign vehicle it is 7200.
3.4.2 Electronic Odometer
On newer vehicles, the odometer signal to the VDC is tapped off an existing sensor.
There are several ways to determine the electronic odometer Pulse Factor.
Match Working Vehicle. If a previously equipped vehicle is keeping accurate
odometer data in the VDC, use that same Pulse Factor for all other similar vehicles
in the fleet
Use Engine Computer Ratio. Over—theread trucks have smart engines allowing you
to view many parameters through the diagnostic port If the VDC odometer input is
tapped ofi‘ of the same signal source as the dashboard speedometer, you can use the
speedometer ratio stored in the engine computer for the VDC Pulse Factor.
Calculate From Vehicle Specs. Ifthe VDC odometer input is directly from the
speedometer sensor mounted in the transmission, you may be able to calculate the
correct ratio using specs from the vehicle manufacturer. Although there are variations
among manufacturers and vehicle types, a typical speedometer system on a rear-drive-
axle vehicle is described here. There is a gear, usually called the speedometer signal
gear, mounted to the output shaft of the transmission. The speedometer sensor is
mounted to the transmission so that its tip is in close proximity to the signal gear’s
teeth. A permanent magnet located in the speedometer sensor establishes a magnetic
field at the tip. The magnetic field is repeatedly cut by the teeth on the signal gear,
%m%’%=
Section 3
Propmnming and System Checkout
creating alternating current voltage impulses that are transmitted to the speedometer.
The frequency and amplitude of the signal is directly proportional to die speed of the
signal gear. The speed of the signal gear is determined by the rotation of the drive
shaft, which is determined by the drive axle ratio and tire size. Therefore, the number
of pulses—per—mile from the speedometer sensor is calculated from the following
formula:
Number of teeth on signal year multiplied by lire revolution per mile multiplied by
d'nlw axle ratio
Number of teeth on signal gear is found in the transmission specifications. A typical
number of teeth is 16.
Tire revolution per mile can be found in the tire manufacturer’s spec sheet These
figures are standard throughout the tire industry. For example, a new Michelin”
275/80R22.5 tire turns 514 revolutions per mile.
Drive axle ratio can be found in the manufacturer’s line setting tickets, and also on a
tag attached to the differential assembly on rear wheel drive vehicles.
If you do not know the vehicle specification, CAIC PUISE FACTOR will help you to
determine the Pulse Factor. This feature is also used when you are required to narrow
down or recalibrate to the correct Pulse Factor after a vehicle has traveled for a few
weeks.
3.5 CALC Pulse Factor
At the lime of initial VDC programming, enter 4000 as default Pulse Factor and drive
the vehicle for a minimum of 10 miles Make a note of the vehicle odometer reading
turn the vehicle HHP on and:
- Select CALC PUISE FACTOR mode and hold HHP coil near the vehicle transmitter
coil to establish and maintain conununicau'on during calculation process.
- Press ENTER key and enter the data as prompted on the HHP display.
- HHP automatically calculates the new Pulse Factor and updates both VDC
Odometer and Install Odometer based on the data entered.
3.6 Testing the Programmed VDC
The HHP VERIFY function reads and displays data from a programmed VDC. It is the
easiest way to confirm that the VDC is transmitting information. To test, tum on the
HHP and hold its ring over a VDC T-Ring. Press the VERIFY key and immediately the
display fills with data. Check that parameters are correct. If there is no display, replace
programmer battery and check programmer operation on another VDC:
0 Compare displayed vehicle identity to its nameplate.
0 Check displayed fleet identification against presaibed parameters.
scuIIy/t 2°
Section 3 ,....
3.7
Progxarnrning and System Checkout
- When the odometer monitoring option is used, check displayed value againfl
vehicle mileage.
- When the odometer monitoring option is used, compare displayed Pulse Factor
value with prescribed paramete .
0 When the engine ON monitoring option is used, compare displayed value against
vehicle’s hour meter. If the vehicle is not equipped with hour meter, compare with
prescribed parameters.
0 For vehicles with two T—Rings, repeat the above. Parameters should be identical to
those of the first T-Ring.
Manual Authorizer
The Manual Authorizer mode is used to authorize (turn on) a pump for one
transaction. This allows vehicles or other non-VDC equipped vessels to receive fuel
and transmits important fleet management information to the System Controller,
which keeps track of refueling transactions.
To operate the Manual Authorizer:
0 Place the pump nozzle into the fuel inlet of the vehicle.
Turn ON the HEP.
Select mode 3. MANUAL AUTHORIZER.
0 Enter the data as prompted on the HHP display.
Hold HHP Coil within a few inches of the purnp’s Nozzle Ring (N-Ring) for
10 seconds.
WARNING
Ensure nozzle handle is not engaged.
- The pump is now authorized for one transaction.
@ Important
VEHICLE ID and FLEET ID data mus! be entered to authorize the
pump. It is strongly recommended to enter MILEAGE and ENGINE
HOURS data, however they are not required to authorize the pump.
21 scuIIy
Section 4
igyLzz
........ Service and Maintenance
Section 4 Maintenance
The VDC requires no maintenance other than a recalibration of me mileage for tire
wear, tire change, or any change to the power train. Before attempting to perform
recalibration, consider the tolerance of mileage discrepancy due m tire wear and
odometer accuracy. During vehicle preventive maintenance inspection, check
and verify.
° That the VDC is securely installed to the mounting surface.
- Inspect all connections for corrosion.
- Make sure all connectors are well mated.
0 Harness routing and fastening.
0 The '1'-Rir1g Wiring has a minimum of 2 inches clearance from any other wiring.
0 Wiring connections for correct wiring (according to wiring diagram).
- Make sure the VDC wiring and harness is not attached to the steering column, brake
cables, hydraulic or pneumatic conduits.
' When a transducer is included in the installation, make sure there is a. tight
connection between the harness and transducer.
Troubleshooting
If the VDC fails to program, using a voltmeter, check the red and black power lines .
for 12 or 24 volts. The switched 12V or 24V input (yellow wire) for monitoring engine
hours must also be off (zero volts). Check these points with a voltmeter. If the voltage
is out of range, troubleshoot the vehicle’s electrical installation. Check harness wires
for exposed conductors that could cause a short circuit. Inspect the connector pin
of the harness for damage and possible short Check wiring for loose connections.
Measure the resistance for 2 to 4 ohms of the T-Ring and check the polarity of the
T—Ring wiring. Connect another good T-Ring or else replace the unit if the unit won’t
program. Once the VDC is programmed, it is ready to receive fuel. If the vehicle cannot
be refueled, check the following:
- Incorrect programming of the vehicle identity (ID)
- Incorrect programming of the fleet identity (ID)
- Vehicle ID is not in the system’s computer authorized vehicle list
' Fleet 1D is not in the system’s computer authorized fleet list
Section 4
4.2
4.4
.............. Service and Maintenance
Battery Life Conservation Setting (Sleep Mode)
The VDC unit typically draws 40 mA with one T-Ring operating and 60 111A with two
T-Rings operating. A sleep mode feature has been incorporated into the VDC, which
when activated, reduces power draw on the vehicle's battery when the vehicle is not in
operation. While in sleep mode the draw on the battery is reduced to 20 mA. When
sleep mode is in effect the vehicle cannot comm "cate as an authorized vehicle to
receive fuel,
Vehicles such as police cars with conswnt power drawing accessories and vehicles not
used over a long period of time (example 2 weeks) should be programmed with a short
activating sleep mode to conserve battery draw.
The self—discharge rate for a typical automotive battery is 1096 per month. This is
equivalent to 8.3 mA constant draw. For a brand new battery with 425 CCA (cold
cranking amps) it would take approximately 10 weeks to self-discharge to 350 CCA,
a worstcase smrter requirement
T-Ring Maintenance
The T—Rings require no specific maintenance; however, for safety reasons no fuel
should be allowed to accumulate on the T—Rings Any T-Ring whose outer case has
been damaged by impact or excessive wear should be replaced The cause of such
wear should be addressed by repositioning the T-Ring for protection of its wires.
Odometer Transducer Maintenance .
Some odometer transducers require periodic greasing. Follow the manufacturer’s
instructions to avoid accelerated wear. The pulse factor to be programmed for each
vehicle is a function of the gearing, the tire size and the number of poles per shaft
rotation.
23 scuIIyA
.~.. Installation Drawings
Section 5 ..~
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25
Installation Drawings
Section 5
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26
Installation Drawings
Section 5 M
VDC PROGRAM DATA SHEET
DATE:
PULSE INSTALL
FACTOR LOCATION
INSTALL
MILES
INSTALL
HOURS
FUEL
TYPE
TANK
CAP
MODEL
8. YEAR
FLEET
ID No
VEHICLE
ID No
scuIIy
27
Section 5 .........................................................................................................................................................................
VEHICLE CALIBRATION FACTOR DATA SHEET
DATE:
VEHICLE
MANUFACTURER
VEHICLE YEAR TRANSDUCER TYPE
MODEL
Installation Drawings
PULSE FACTOR

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