PRODUCT MANUAL FUEL CAP ISOLATION SYSTEM. Part No

Transcription

1 PRODUCT MANUAL FUEL CAP ISOLATION SYSTEM Part No

2 DISCLAIMER Copyright Remote Control Technologies Pty Ltd (RCT) All rights reserved. No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written permission of Remote Control Technologies Pty Ltd. (RCT). Information provided in this manual is intended to be accurate and reliable. However, Remote Control Technologies Pty Ltd (RCT) assumes no responsibility for its use or infringements upon the rights of third parties that may result from its use. All examples and diagrams shown in this manual are intended only as an aid to understanding the text, not to guarantee operation. Remote Control Technologies Pty Ltd (RCT) will accept no responsibility for actual use of the product based on these illustrative examples. Please contact your nearest Remote Control Technologies Pty Ltd (RCT) branch for more information concerning applications in life critical situations or high reliability. Remote Control Technologies Pty Ltd (RCT) reserves the right to make changes to any product herein to improve reliability, function or design. All specifications are subject to change without notice. 6 M08.docx Rev. Modified on //05 Copyright RCT

3 Contents PRODUCT OVERVIEW FEATURES AND FUNCTIONS OPERATION AND USE 5 OPERATION OF THE STANDARD INSTALL 5 OPERATION OF THE PARK RAKE INTERLOCK INSTALL 5 INSTALLATION GUIDE 6 WIRING CONNECTIONS 6 STAY UP REGULATOR (OPTIONAL) 6 DIAGRAMS 7 External Wiring Diagram Standard (78) (57k) 7 External Wiring Diagram Ignition to Park rake Interlock (78) (9s) 8 External Wiring Diagram Dual Fuel Cap (06) (08p) 9 CALIRATION 0 SERVICE INFORMATION 0 SERVICE SCHEDULE 0 SERVICE PROCEDURE 0 PARTS LIST 0 78 KIT 0 06 KIT 0 TECHNICAL SPECIFICATIONS STATEMENT OF CONFORMITY COMPLIANCE AND STANDARDS TROULESHOOTING GLOSSARY WARRANTY M08.docx Rev. Modified on //05 Copyright RCT 6

4 PRODUCT OVERVIEW The Muirhead Fuel Cap Isolation systems, part numbers 7808, 78 and 06, have been designed to prevent the machine operator from starting the machine and driving away with the fuel filler still attached. This will eliminate damage to machines, refuelling stations, hoses and prevent hazardous spills. The systems inhibit the operator from starting the machine, without firstly ensuring the fuel cap has been placed securely back onto the quick fill adaptor on the fuel tank. The Muirhead Fuel Cap Isolation systems have an intrinsically safe circuit design with supporting safety certification for the fuel cap component to be fitted in zone 0 hazardous area and the control unit to be fitted in zone hazardous area. Refer to drawing 57k for further information. FEATURES AND FUNCTIONS Intrinsically safe circuit design High quality connectors and wiring components Water and vibration resistant Safety Certification for fuel cap component (inductive sensor) to be fitted in hazardous area zone 0 Prevents damage to the refuelling station Prevents refuelling accidents Reduces contaminants entering tank Maintenance free operation Easy to install 6 M08.docx Rev. Modified on //05 Copyright RCT

5 OPERATION AND USE OPERATION OF THE STANDARD INSTALL Once the fuel cap isolation system has been installed, there is no additional calibration required. When the fuel cap has been placed onto the fuel fill point, the start circuit will become active and the operator will be able to start the machine. The machine will be inhibited from starting when the fuel cap is removed or not secured properly. If there is an attempt to start the machine whilst the fuel cap is removed, the fuel cap removed LED will illuminate indicating that the fuel cap is removed and the machine will not start until the cap has been refitted. The 75 Stay Up Regulator incorporated with this product allows the machine/equipment to be started at lower voltages. As a battery ages on a machine, this component is highly recommended as the battery voltage may drop too low upon cranking of the engine. OPERATION OF THE PARK RAKE INTERLOCK INSTALL WARNING! DO NOT FIT THE FUEL CAP ISOLATION SYSTEM IN THIS CONFIGURATION WITHOUT THE PARK RAKE INTERLOCK. This alternate installation of the fuel cap isolation system adds control of the ignition circuit through an interlock park brake pressure switch. It will also illuminate the LED indicating the removal of the fuel cap whenever the fuel cap is not in place. Once the 7808 Fuel Cap Isolation system has been installed and the fuel cap has been installed onto the fuel fill point, the start circuit will become active and the operator will be able to start the machine. During operation of the machine, if the fuel cap is removed or dislodged, the fuel cap removed LED will illuminate and remain illuminated until the fuel cap has been refitted. If the fuel cap is dislodged during the operation of the machine, the machine will continue to operate until the park brake is applied. Machine shutdown will then occur. Machine shutdown only occurs when the park brake is applied because the operator may need to move the machine to a safe location in order to refit the fuel cap back onto the machine fill point. Once the fuel cap has been refitted, the fuel cap removed LED will then turn off, the start circuit will become active, and the operator will be able to start the machine. The 75 Stay Up Regulator incorporated with this product operates by allowing the machine/equipment to be started at lower voltages as a battery ages on a machine. This component is highly recommended as the battery voltage may drop to low upon cranking of the engine. M08.docx Rev. Modified on //05 Copyright RCT 5 6

6 INSTALLATION GUIDE. Mount the control unit in a suitable location.. Run the wiring in the most suitable way to keep the wiring harness protected and out of the way of moving parts.. Connect the wiring as specified, referring to the wiring tables below and the external wiring diagrams on the following pages. WIRING CONNECTIONS 6-Pin Plug Connections NO. DESCRIPTION Ignition switch battery +ve terminal Earth From start terminal on ignition switch To start relay 5 To LED indicator 6 Not connected Fuel Cap Wiring NO. N U DESCRIPTION Connect to terminal of the blue connector in the controller. Connect to terminal of the blue connector in the controller. Note: If the fuel cap is wired incorrectly, the red CHK LED on the controller will flash to indicate a fault. STAY UP REGULATOR (OPTIONAL). Connect the stay up regulator to the 6-pin Deutsch plug.. Run the wiring from the stay up regulator identical to the 6-pin wiring connections previously mentioned. 6 6 M08.docx Rev. Modified on //05 Copyright RCT

7 DIAGRAMS External Wiring Diagram Standard (78) (57k) A C D E F G H REV ZONE DESCRIPTION Y DATE added zones SD /0/ D7 added 75 to wiring updated titleblock fuse added to 75 AD /0/ GT 8/07/5 J //5 ZONE ONLY PROTECTION SYSTEMS Manufactured in Australia Perth Kalgoorlie N U WIRE TO LUE TERMINAL WIRE TO LUE TERMINAL ZONE 0, OR STATEMENT OF CONFORMITY FOR FITMENT ZONE 0//. CERTIFICATE No. AUS EX 0.8X PART No Mt Isa NON INTRINSICALLY SAFE CIRCUIT SERIAL No VOLTS Website: sales@rct.net.au (75) A FOR UNITS REQUIRING STAY UP REGULATOR STATEMENT OF CONFORMITY FOR FITMENT IN ZONE. STATEMENT OF CONFORMITY FOR USE IN CONJUNCTION WITH THE FUEL CAP FITTED IN ZONE 0//. CERTIFICATE No. AUS EX X NOTES ZONE 0 ZONE ZONE FLAMMALE ATMOSPHERE HIGHLY LIKELY TO E PRESENT - MAY E PRESENT FOR LONG PERIODS OR EVEN CONTINUOUSLY FLAMMALE ATMOSPHERE POSSILE UT UNLIKELY TO E PRESENT FOR LONG PERIODS. FLAMMALE ATMOSPHERE UNLIKELY TO E PRESENT EXCEPT FOR SHORT PERIODS OF TIME - TYPICALLY AS A RESULT OF A PROCESS FAULT CONDITION. NON INTRINSICALLY SAFE CIRCUIT R OFF C ON S ST KEY SWITCH FROM KEY REAKER CUT WIRE START RELAY MAIN EARTH FUEL CAP IGNITION REMOVED LED RELAY FUEL CAP ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT SCALE NTS A rd ANGLE PROJECTION COPYRIGHT - ALL RIGHTS RESERVED This drawing is the property of REMOTE CONTROL TECHNOLOGIES PTY LTD (RCT), and is not to be copied or used in whole or in part for any purpose without the express authority of RCT. The drawing is to be returned to RCT, on demand. FUEL CAP ISOLATION SYSTEM EXTERNAL WIRING WIRE LEGEND K - LACK PK - PINK U - LUE PU - PURPLE N - ROWN RD - RED GN - GREEN WH - WHITE GY - GREY YL - YELLOW OR - ORANGE TQ - TURQUOISE PART NO 78 STOCK CODE MH--RSI-K Y JR DRN W DATE 5/0/09 APPD JR DATE ---- SHEET of STATUS DWG No Released 57k REV A C D E F G H M08.docx Rev. Modified on //05 Copyright RCT 7 6

8 5 External Wiring Diagram Ignition to Park rake Interlock (78) (9s) A C D E F G H NOTES. CUT THE EXISTING CONNECTION FROM THE KEY TO THE START RELAY AND UTILISE EITHER OPTION A OR AS SHOWN.. OPTION A: IF A NEUTRAL START RELAY EXISTS ON THE MACHINE, REMOVE THE ORIGINAL IGNITION SUPPLY WIRE AND CONNECT THE WIRE FROM PIN OF THE 78 OPTION : INTRODUCE A RELAY INTO THE EXISTING START CIRCUIT AND DRIVE THE RELAY'S 86 TERMINAL FROM PIN OF THE 78. Manufactured in Australia Perth N WIRE TO LUE TERMINAL U WIRE TO LUE TERMINAL Kalgoorlie Mt Isa PART No SERIAL No VOLTS Website: sales@rct.net.au NOTE IGNITION SUPPLY FROM KEY TO ECM. CUT WIRE RUN THROUGH CONTACTS 0 AND 87A AS SHOWN. 0 87A RL 85 IGNITION OUTPUT TO ECM R OFF C ON S ST KEY SWITCH FROM KEY REAKER START RELAY NOTE MAIN IGNITION RELAY PARK RAKE SWITCH N/C (SHOWN WITH PARK RAKE APPLIED) EARTH FUEL CAP REMOVED LED FUEL CAP P REV ZONE DESCRIPTION Y DATE 6 D6 REVISED TO SHOW OPTIONS A & nd option relay and park bake moved into position added operation ADDED 75 TO WIRING updated titleblock fuse added to 75 SD 6/0/0 SD 8/0/0 SD /0/ AD /0/ GT 8/07/5 J // (75) A OPERATION This alternate installation adds control of the ignition circuit through a park brake pressure switch interlock and will also illuminate the 'fuel cap removed' LED whenever the fuel cap is not fitted. FOR UNITS REQUIRING STAY UP REGULATOR OPTION 0 87A RL 85 ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT SCALE NTS A rd ANGLE PROJECTION Note: Do not fit fuel cap isolation system in this configuration without park brake interlock. Doing so could cause the engine to shut down when the machine is in motion if fuel cap is not fitted correctly. When the fuel cap is installed onto the nozzle the operator is able to start the machine. If the fuel cap is removed or becomes dislodged during operation, the 'fuel cap removed' LED will illuminate and remain this way until the cap is refitted. The machine will continue to operate until the park brake is applied. At this time the engine will shutdown. The machine may not be restarted until the fuel cap has been refitted. When the fuel cap has been refitted the 'fuel cap removed' LED will be off, the machine will start and run. COPYRIGHT - ALL RIGHTS RESERVED This drawing is the property of REMOTE CONTROL TECHNOLOGIES PTY LTD (RCT), and is not to be copied or used in whole or in part for any purpose without the express authority of RCT. The drawing is to be returned to RCT, on demand. FUEL CAP ISOLATION SYSTEM WITH IGNITION TO PARK RAKE INTERLOCK EXTERNAL WIRING WIRE LEGEND K - LACK PK - PINK U - LUE PU - PURPLE N - ROWN RD - RED GN - GREEN WH - WHITE GY - GREY YL - YELLOW OR - ORANGE TQ - TURQUOISE 6 PIN PLUG CONNECTIONS PIN IGNITION SW ATTERY +VE PIN EARTH PIN RELAY TERMINAL OF IGNITION SWITCH PIN TO START INHIIT RELAY TERM 86 PIN 5 TO LED INDICATOR PIN 6 NOT CONNECTED PART NO 78 STOCK CODE MH--RSI-K Y JG DRN JL DATE 5/0/0 APPD JG DATE ---- SHEET of STATUS DWG No Released 9s REV 6 A C D E F G H 8 6 M08.docx Rev. Modified on //05 Copyright RCT

9 External Wiring Diagram Dual Fuel Cap (06) (08p) A C D E F G H REV ZONE DESCRIPTION Y DATE OPERATION NOTE A /0/0 ADDED added 75 to wiring AD 5/0/ D6 updated titleblock fuse added to 75 GT 8/07/5 J //5 N U WIRE TO LUE TERMINAL WIRE TO LUE TERMINAL Manufactured in Australia Perth Kalgoorlie PART No SERIAL No Mt Isa N U WIRE TO LUE TERMINAL WIRE TO LUE TERMINAL VOLTS Website: sales@rct.net.au (75) A FOR UNITS REQUIRING STAY UP REGULATOR CUT WIRE ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT SCALE NTS A rd ANGLE PROJECTION R OFF C ON S ST COPYRIGHT - ALL RIGHTS RESERVED This drawing is the property of REMOTE CONTROL TECHNOLOGIES PTY LTD (RCT), and is not to be copied or used in whole or in part for any purpose without the express authority of RCT. The drawing is to be returned to RCT, on demand. OPERATION: OTH FUEL CAPS MUST E FITTED TO FUEL FILLERS TO ENALE A START OUTPUT. IF THE FUEL CAPS ARE NOT FITTED AND A MACHINE START IS ATTEMPTED, THE "FUEL CAP REMOVED" WARNING LED WILL FLASH AND THE START OUTPUT WILL E DISALED. WIRE LEGEND K - LACK PK - PINK U - LUE PU - PURPLE N - ROWN RD - RED GN - GREEN WH - WHITE GY - GREY YL - YELLOW OR - ORANGE TQ - TURQUOISE KEY SWITCH FROM KEY REAKER START RELAY MAIN IGNITION RELAY EARTH FUEL CAP REMOVED LED FUEL CAP FUEL CAP DUAL FUEL CAP ISOLATION KIT EXTERNAL WIRING PART NO 06 STOCK CODE MH--RSI-K-0 Y A DRN W DATE 0/09/0 APPD A DATE ---- SHEET of STATUS DWG No Released 08p REV A C D E F G H M08.docx Rev. Modified on //05 Copyright RCT 9 6

10 CALIRATION Not applicable. SERVICE INFORMATION SERVICE SCHEDULE The manufacturer recommends that the following service procedure should be performed at each machine s scheduled service interval. SERVICE PROCEDURE. Perform a visual inspection; include the following: a) Control unit. b) Wiring connections and looms.. Perform a system test as per the following: a) Remove the fuel cap from the nozzle. Attempt to crank the engine, the engine should not crank and the warning LED fuel cap removed should illuminate. b) Replace the fuel cap. The engine should crank as per normal. The LED should not illuminate. PARTS LIST 78 KIT PART NO. DESCRIPTION QTY 7808 Control unit 7809 Fuel cap 6 LED, red flashing 75 Regulator, stay up to suit fuel cap isolation system 06 KIT PART NO. DESCRIPTION QTY 0 Control unit 7809 Fuel cap 99 LED, red flashing 75 Regulator, stay up to suit fuel cap isolation system 0 6 M08.docx Rev. Modified on //05 Copyright RCT

11 TECHNICAL SPECIFICATIONS Dimensions, control unit only Dimensions, boxed for freight Weight, control unit only Weight, including harness and packaging for freight Input voltage Standby current draw Output current draw Length: 6 mm Width: 6 mm Height/Depth: 9 mm Length: 00 mm Width: 00 mm Height/Depth: 65 mm.5 kg.5 kg 0 to 0 V DC < 50 ma A Operating temperature range 0 to +60 C Connection types Inputs Min & max input voltage Circuit protection Enclosure type Environmental protection IP rating 6-pin Deutsch receptacle Ignition, fuel caps, earth 0 to 0 V DC A fuse Intrinsically safe, refer to the statement of conformity IP66 STATEMENT OF CONFORMITY Group, category type 7809 Fuel Cap εx II G EEx ia IIC T6 For fitment into hazardous area zone 0// 7808 Control Unit εx II () GD EEx ia IIC For application in conjunction with 7809 fuel cap in hazardous area zone 0// 7808 Control Unit εx II () G (EEx nl) IIC X For fitment in hazardous area zone M08.docx Rev. Modified on //05 Copyright RCT 6

12 COMPLIANCE AND STANDARDS TA TROULESHOOTING FAULT Device not working. Intermittent fault. POSSILE CAUSE Check wiring and connections. Check wiring and connections. 6 M08.docx Rev. Modified on //05 Copyright RCT

13 GLOSSARY A Amp (Ampere) N/A Not Applicable AC Alternating Current N/C Normally Closed AMS Advanced Management System N/O Normally Open CAN Controller Area Network OEM Original Equipment Manufacturer CMIO Control Master Input Output PC O/P Outputs CMR Control Master Receiver Out Output CMT Control Master Transmitter P Push utton CM00 Control Master 00 Remote Set PC Personal Computer COMMS Communications PC Printed Circuit oard CPU Central Processor Unit PIN Personal Identification Number DC Direct Current PLC Programmable Logic Controller E.G. For example POT Potentiometer FET Field Effect Transistor PPM Pulses Per Metre GND Ground PWM Pulse Width Modulation H Hours PWR Power HEX Hexidecimal Numbering System RCT Remote Control Technologies Pty Ltd ID Identity Rev Revision i.e That is RF Radio Frequency In Input RH Relative Humidity IP Ingress Protection RPM Revolutions per minute kg Kilogram RX Receiver Recommended Standard (number ) Km/h Kilometres Per Hour RS for serial data transfer LCD Liquid Crystal Display SYS System LED Light Emitting Diode TOV Text On Video LK Link TX Transmitter M Minutes V Volts ma Milli Amps VSC Variable Spray Controller MAX Maximum WSC Water Spray Controller MCU Multi Control Unit C Degrees Centigrade MFU Multi Function Unit # Number Mega Hertz (million(s) cycles per MHz second) < Less Than MIN Minimum > Greater Than mm millimetres % Percentage mw Milli Watts WARRANTY Please see the RCT standard warranty, available on our website - M08.docx Rev. Modified on //05 Copyright RCT 6

14 NOTES 6 M08.docx Rev. Modified on //05 Copyright RCT

15 NOTES M08.docx Rev. Modified on //05 Copyright RCT 5 6

16 PERTH Unit -5/5 Abernethy Road Kewdale WA 605 Ph: +6 (0) Fax: +6 (0) RISANE Unit 6/6 Flinders Parade North Lakes QLD 509 Ph: +6 (0) Fax: +6 (0) KALGOORLIE Percy Road Kalgoorlie WA 60 Ph: +6 (0) Fax: +6 (0) MT ISA A Ryan Road Mt Isa QLD 85 Ph: +6 (0) Fax: +6 (0) MELOURNE Unit Hallmarc Office Park 5 Ricketts Road Mt Waverley VIC 9 Ph: +6 (0) Fax: +6 (0) AFRICA: +7 (0) NORTH AMERICA: RUSSIA/CIS: +7 (90) -7 SOUTH AMERICA: