Islander PLUS and ICR PLUS INSTALLATION MANUAL

Wiring

MDE - 4811F

Islander PLUS and ICR PLUS

INSTALLATION MANUAL

This document is based on Orpak’s Island controller (OrIC)

installation manual P/N 817438050

SAFETY CONSIDERATIONS

Read all warning notes and instructions carefully. They are included to help you installing the Product safely in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions could result in serious injury or property damage. It is the installer responsibility to install, operate and maintain the equipment according to the instructions given in this manual, and to conform to all applicable codes, regulations and safety measures. Failure to do so could void all warranties associated with this equipment.

Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure that actual installation is performed by experienced personnel, licensed to perform work in fuel station and at a flammable environment, according to the local regulations and relevant standards.

WARNING - EXPLOSION HAZARD

Use separate conduit for the intrinsically safe. Do not run any other wires or cables through this conduit, because this could create an explosion hazard. Use standard test equipment only in the non- hazardous area of the fuel station, and approved test equipment for the hazardous areas. In the installation and maintenance of the Product, comply with all applicable requirements of the National Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70 “National Electric Code”, federal, state and local codes and any other applicable safety codes and regulations. Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury, property loss and damage to you and other persons.

CAUTION - SHOCK HAZARD

Dangerous AC voltages that could cause death or serious personal injury are used to power the Product. Always disconnect power before starting any work. The Product has more than one power supply connection points. Disconnect all power before servicing.

CAUTION – EXTERNAL WIRING

For supply connections, use wires suitable for at least 90°C.

Signal wiring connected in this box must be rated at least 300 V.

WARNING – PASSING VEHICLES

When working in any open area of fuel station, beware of passing vehicles that could hit you. Block off the work area to protect yourself and other persons. Use safety cones or other signaling devices.

WARNING

Components substitutions could impair intrinsic safety. Attaching unauthorized components or equipment will void your warranties.

CAUTION

Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all warranties related to this equipment.

PROPRIETY NOTICE

This document contains propriety and confidential information. It is the property of ORPAK SYSTEMS Ltd. It may not be disclosed or reproduced in whole or in part without written consent of ORPAK SYSTEMS. The information in this document is current as of the date of its publication, but is subject to change without notice.

DISCLAIMER

This document is provided for reference only. Although every effort has been made to ensure correctness, ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.

FCC Compliance Statement

The FCC Wants You to Know: This equipment has been tested and found to comply with the limits for a Class B & C digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures : a) Reorient or relocate the receiving antenna. b) Increase the separation between the equipment and receiver. c) Connect the equipment to an outlet on a circuit different from that to which the receiver is connected. d) Consult the dealer or an experienced radio/TV technician.

FCC Warning

Modifications not expressly approved by the manufacturer could void the user authority to operate the equipment under FCC Rules.

This document is the property of:

ORPAK SYSTEMS Ltd.

ISRAEL

TABLE OF CONTENTS

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GENERAL DESCRIPTION SECTION 11-1. SCOPE ................................................................................................................................ 1 1-2. DESCRIPTION .................................................................................................................. 1 1-3. SYSTEM OVERVIEW ...................................................................................................... 3 1-3.1. Islander PLUS System ................................................................................................... 3 1-3.2. Vehicle Identification – FuelPoint PLUS ...................................................................... 3 1-3.3. Remote Web Access ...................................................................................................... 3 1-3.4. Head Office .................................................................................................................... 3 1-3.5. Restrictions and Limits .................................................................................................. 3 1-3.6. Islander PLUS Capabilities for Forecourt Management ................................................ 4 1-3.7. System Workflow Example ........................................................................................... 4 1-3.7.1. Refueling Scenario with FuelPoint PLUS ................................................................. 5 1-3.7.2. Refueling Scenario with Magnetic Cards .................................................................. 5 1-4. ISLANDER PLUS STRUCTURE ..................................................................................... 6 1-4.1. Main Components .......................................................................................................... 6 1-4.2. Islander PLUS Internal Configuration – Mechanical Pump .......................................... 9 1-4.3. Islander PLUS Main Components Location ................................................................... 11 1-5. AVAILABLE CONFIGURATIONS ................................................................................. 16 1-5.1. General ........................................................................................................................... 16 1-5.2. Islander PLUS / ICR PLUS ........................................................................................... 16 1-5.3. Printer Option ................................................................................................................. 16 1-5.4. Vehicle Identification System ........................................................................................ 16 1-5.5. Dispensers ...................................................................................................................... 16 1-5.6. Contactless Tags/Cards .................................................................................................. 17 1-5.6.1. Data Key Sockets – Fleet key ................................................................................... 17 1-5.6.2. HID Device ............................................................................................................... 17 1-5.6.3. Configurations ........................................................................................................... 17 1-6. SECURITY AND PROTECTION ..................................................................................... 20 1-6.1. General ........................................................................................................................... 20 1-6.2. Authorization Security ................................................................................................... 20 1-6.3. Network Security ........................................................................................................... 20 1-6.4. RF Network Security ..................................................................................................... 20 1-6.5. Maintenance Security ..................................................................................................... 20 1-7. HOUSING .......................................................................................................................... 20

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1-8. SPECIFICATIONS ............................................................................................................. 22 1-9. STANDARDS ..................................................................................................................... 23 1-9.1. Communication Standards ............................................................................................. 23 1-9.2. Security Standards .......................................................................................................... 23 1-10. MANUAL STRUCTURE ................................................................................................... 24 1-11. USING THIS MANUAL .................................................................................................... 25 1-12. REFERENCES ................................................................................................................... 26

PRELIMINARY INSTALLATION INSTRUCTIONS SECTION 22-1. GENERAL .......................................................................................................................... 28 2-2. PRELIMINARY INSTALLATION INSTRUCTIONS ..................................................... 28 2-2.1. General ........................................................................................................................... 28 2-2.2. Precautions and Safety Notes ......................................................................................... 28 2-3. CONDUITS LAYOUT/INSTALLATION SPECIFICATIONS ........................................ 29 2-4. CONDUITS ........................................................................................................................ 29 2-4.1. General ........................................................................................................................... 29 2-4.2. Conduit Requirements .................................................................................................... 30 2-4.3. Conduits at Islander PLUS ............................................................................................. 30 2-4.4. Required Conduits in Island ........................................................................................... 32 2-4.5. Required Conduits in Islander PLUS ............................................................................. 32 2-5. CONDUITS INSTALLATION .......................................................................................... 33 2-5.1. General ........................................................................................................................... 33 2-5.2. Installing Conduits in Island .......................................................................................... 33 2-5.3. Sealing Conduits ............................................................................................................ 33 2-6. CABLES INSERTION ....................................................................................................... 36 2-6.1. General ........................................................................................................................... 36 2-6.2. Types of Cables .............................................................................................................. 36 2-6.3. Cables Routing ............................................................................................................... 37 2-7. POWER SETUP ................................................................................................................. 37 2-7.1. General ........................................................................................................................... 37 2-7.2. Islander PLUS for 8 hoses - AC Power Supply Setup ................................................... 38 2-7.3. Connecting the Power Equipment .................................................................................. 40 2-7.4. Grounding....................................................................................................................... 40 2-8. WIRING THE PERIPHERALS ......................................................................................... 41 2-8.1. Pump Wiring .................................................................................................................. 41 2-8.2. TLG wiring ..................................................................................................................... 41

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ISLANDER PLUS INSTALLATION PROCEDURES SECTION 33-1. GENERAL .......................................................................................................................... 43 3-2. INSTALLATION SPECIFICATIONS .............................................................................. 43 3-2.1. General ........................................................................................................................... 43 3-2.2. Precautions and Safety Notes ......................................................................................... 43 3-2.3. Safety Distances ............................................................................................................. 44 3-3. HOME BASE STATION - OVERVIEW ........................................................................... 44 3-3.1. General ........................................................................................................................... 44 3-3.2. Home Base Station Architecture .................................................................................... 45 3-3.2.1. Main Power Cabinet .................................................................................................. 45 3-3.2.2. Home Base Forecourt ................................................................................................ 45 3-3.2.3. Head Office System (Optional) ................................................................................. 45 3-4. MAPPING THE SITE– EXAMPLE .................................................................................. 49 3-4.1. General ........................................................................................................................... 49 3-4.2. Locating all objects of the site ....................................................................................... 49 3-4.3. Assigning Logical IDs ................................................................................................... 49 3-4.3.1. To each fuel tank ....................................................................................................... 49 3-4.3.2. To each Dispenser Unit ............................................................................................. 49 3-4.3.3. In the Islander PLUS pole ......................................................................................... 49 3-4.4. Mapping ......................................................................................................................... 49 3-5. CONNECTIONS TO ISLANDER PLUS .......................................................................... 50 3-6. INSTALLING THE ISLANDER PLUS PEDESTAL POLE ............................................ 52 3-6.1. General ........................................................................................................................... 52 3-6.2. Installation Procedure Steps ........................................................................................... 52 3-6.3. Pedestal Site Preliminary Setup Procedures .................................................................. 52 3-6.4. Installation Assembly Parts ............................................................................................ 53 3-6.5. Base Plate Installation Procedures ................................................................................. 53 3-6.6. Pedestal Installation Instructions ................................................................................... 56 3-6.7. Base Plate Installation Procedures – Optional ............................................................... 56 3-6.8. Sealing Conduits ............................................................................................................ 57 3-7. WIRING ............................................................................................................................. 58 3-7.1. General ........................................................................................................................... 58 3-7.2. Types of Wiring ............................................................................................................. 58 3-7.3. Wiring Requirement ....................................................................................................... 58 3-7.4. Types of Cable ............................................................................................................... 58

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3-8. MECHANICAL PUMP – WIRING ................................................................................... 59 3-8.1. General ........................................................................................................................... 59 3-8.2. 4 – Mechanical Pump – Terminal Block - Pin-Out Connections ................................... 59 3-8.3. 8-Mechanical Pump – Terminal Block - Pin-Out Connections ..................................... 61 3-8.4. Mechanical Pump - Required Connections .................................................................... 65 3-8.5. Mechanical Pump - Pulser Connections......................................................................... 70 3-8.5.1. Electronic Pulser ........................................................................................................ 70 3-8.5.2. Mechanical Pulser ..................................................................................................... 70 3-9. ELECTRONIC PUMP – WIRING DESCRIPTION .......................................................... 72 3-9.1. General ........................................................................................................................... 72 3-9.2. Tokheim Electronic Pump .............................................................................................. 74 3-9.3. Current Loop Electronic Pump ...................................................................................... 75 3-9.4. RS-485 Electronic Pump ................................................................................................ 76 3-10. WIRING TO GENERAL COMPONENTS ........................................................................ 77 3-10.1. General ........................................................................................................................... 77 3-10.2. Connection to TLG Controller ....................................................................................... 77 3-10.3. Connection to Journal Printer ......................................................................................... 77 3-11. POST-INSTALLATION CHECKLIST ............................................................................. 80 3-12. ISLANDER PLUS SETUP ................................................................................................. 80

PRINTER SECTION 44-1. OVERVIEW ....................................................................................................................... 81 4-2. DESCRIPTION ................................................................................................................... 82 4-3. MAIN COMPONENTS ...................................................................................................... 83 4-4. PRINTER CONNECTOR PIN-OUT ................................................................................. 84 4-5. INDICATORS .................................................................................................................... 85 4-6. SPECIFICATIONS ............................................................................................................. 85 4-7. INSTALLATION PRINTING PARAMETERS ................................................................ 86 4-7.1. Jumpers Configuration ................................................................................................... 86 4-7.2. Parameters for Printing................................................................................................... 87 4-7.3. Cutter .............................................................................................................................. 87 4-7.4. Printing the Status Report .............................................................................................. 87 4-8. PAPER ROLL REPLACEMENT ....................................................................................... 88 4-8.1. General ........................................................................................................................... 88 4-8.2. Paper Roll Replacement ................................................................................................. 88 4-8.2.1. Automatic Insertion of Paper ..................................................................................... 90

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4-8.2.2. Manual Insertion of Paper ......................................................................................... 90 4-9. PRINTER CLEANING ...................................................................................................... 91 4-9.1. General ........................................................................................................................... 91 4-9.2. Thermal Printer Head –Cleaning Instructions ............................................................... 91 4-9.2.1. General ...................................................................................................................... 91 4-9.2.2. Cleaning Procedures .................................................................................................. 91 4-10. TROUBLESHOOTING ..................................................................................................... 93 4-10.1. General ........................................................................................................................... 93 4-10.2. Troubleshooting ............................................................................................................. 93 4-10.3. Releasing Jammed or Crumpled Paper .......................................................................... 93 4-11. THERMAL PAPER STORAGE ........................................................................................ 94

MAINTENANCE SECTION 55-1. GENERAL .......................................................................................................................... 95 5-2. TROUBLESHOOTING ..................................................................................................... 95 5-2.1. Islander PLUS Troubleshooting .................................................................................... 95 5-2.2. OrPT Troubleshooting ................................................................................................... 102 5-2.3. Printer Troubleshooting ................................................................................................. 106 5-2.4. Communication Troubleshooting .................................................................................. 108 5-3. CLEANING ........................................................................................................................ 111 5-3.1. General ........................................................................................................................... 111 5-3.2. Cleaning ......................................................................................................................... 111 5-3.3. Magnetic Card Reader – Cleaning Instructions ............................................................. 111 5-3.4. Printer – Cleaning Instructions ...................................................................................... 112

GLOSSARY SECTION 66-1. FUELOMAT GLOSSARY ................................................................................................ 113 6-2. COMMUNICATION GLOSSARY ................................................................................... 114

APPENDIX A SITE SURVEY

APPENDIX B WIRING DIAGRAM

APPENDIX C HID ASASEMBLY INSTALLATION

INTRODUCTION .......................................................................................................................... 125

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INSTALLATION INSTRUCTIONS ............................................................................................. 127

Islander PLUS Manual vi

LIST OF ILLUSTRATIONS

Figure Page

Figure 1-1 - Islander PLUS / ICR PLUS - General View ................................................................... 2 Figure 1-2 - Islander PLUS in Home Base Station - General Configuration Diagram ....................... 4 Figure 1-3 - Internal Configuration Diagram – 4 Mechanical Pump .................................................. 9 Figure 1-4 - Internal Configuration Diagram – 8 Mechanical Pumps ............................................... 10 Figure 1-5 - Internal Components Location –4 Mechanical Pumps .................................................. 11 Figure 1-6 - Internal Components Location –8 Mechanical Pumps .................................................. 12 Figure 1-7 – Islander PLUS with Optional Internal Printer (Sectional View) .................................. 13 Figure 1-8 – Islander PLUS for 8 hoses with Optional Internal Printer (Sectional View)................ 14 Figure 1-9 – Islander PLUS with Data Key Reader (Optional) ........................................................ 17 Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions .................................................................. 21 Figure 2-1 Islander PLUS Lower Protective Plate ........................................................................... 31 Figure 2-2 Standard Bottom Metal Plate's Knockout –Close View ................................................. 31 Figure 2-3 Conduit Fitting ................................................................................................................ 33 Figure 2-4 Conduits Layout for Mechanical Pump .......................................................................... 34 Figure 2-5 Conduits Layout for Electronic Pump ............................................................................ 35 Figure 2-6 Power Equipment Connections ....................................................................................... 38 Figure 2-7 Power Supply Components and Grounding Studs ......................................................... 39 Figure 2-8 VAC Power Supply – Jumpers Setup ............................................................................. 39 Figure 2-9 Islander PLUS ground description .................................................................................. 40 Figure 2-10 Communications Cable Wiring .................................................................................... 41 Figure 3-1 Islander PLUS– Installation Control Drawing................................................................ 44 Figure 3-2 Home Base Station with 4 Mechanical Pumps – System Diagram ................................ 46 Figure 3-3. Home Base Station with 8 Mechanical Pumps – System Diagram ............................... 47 Figure 3-4 Home Base Station with Electronic Pumps – System Diagram ..................................... 48 Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections ..................................... 51 Figure 3-6 Islander PLUS Terminal Block, Power and LAN Connections (8 pumps) ................... 52 Figure 3-7 Pedestal Pole Installation ................................................................................................ 54 Figure 3-8 Base Plate Installation (Example) ................................................................................... 55 Figure 3-9 Rosette (Upside down view) ........................................................................................... 55 Figure 3-10 Rosette Dimensions ...................................................................................................... 55 Figure 3-11 Expansion Bolt .............................................................................................................. 56 Figure 3-12 Conduit Fitting .............................................................................................................. 57 Figure 3-13 Terminal Lug ................................................................................................................ 58 Figure 3-14 Islander PLUS Terminal Block..................................................................................... 63 Figure 3-15 Islander PLUS - Terminal Block (8 pumps) ................................................................. 64 Figure 3-16 Islander PLUS – Terminal Block –4 Mechanical Pump - Wiring List Label ............... 64 Figure 3-17 Islander PLUS – Terminal Block – 8 Mechanical Pump - Wiring List Label .............. 65 Figure 3-18 Mechanical Pump – Single Dispenser Connections ..................................................... 67

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Figure 3-19 Mechanical Pump – Twin Dispenser Connections ....................................................... 68 Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections .......... 69 Figure 3-21 Terminal Block and 3-Wire Pulser – Wiring Connections ........................................... 70 Figure 3-22 Terminal Block and 2-Wire Pulser – Wiring Connections ........................................... 71 Figure 3-23 Islander PLUS Terminal Block – Wiring List Label .................................................... 73 Figure 3-24 Tokheim Electronic Pump - Wiring Diagram ............................................................... 74 Figure 3-25 Current Loop Electronic Pump - Wiring Diagram........................................................ 75 Figure 3-26 RS-485 Electronic Pump - Wiring Diagram ................................................................. 76 Figure 3-27 Terminal Block – TLG Wiring Link ............................................................................. 77 Figure 3-28 Journal Printer – General View ..................................................................................... 78 Figure 3-29 Journal Printer – Rear Panel.......................................................................................... 79 Figure 4-1. Printer Module in Islander PLUS .................................................................................. 81 Figure 4-2. Printer Module within Islander PLUS ........................................................................... 82 Figure 4-3. Printer Module– Main Components ............................................................................... 83 Figure 4-4. Printer Connector ........................................................................................................... 84 Figure 4-5. Printer Connector – Pin-out Description ........................................................................ 84 Figure 4-6. Printer Module – Jumpers Default Configuration.......................................................... 86 Figure 4-7. Printer Module– Jumpers Configuration Examples ....................................................... 87 Figure 4-8. Door Handle and Paper Lock Lever .............................................................................. 88 Figure 4-9. Printer - Paper Replacement .......................................................................................... 89 Figure 4-10. Pressing Paper-Lock Lever .......................................................................................... 92 Figure B-1 Islander PLUS – Wiring Diagram (Mechanical Pump) ............................................... 122 Figure B-2 Islander PLUS – Wiring Diagram (Electronic Pump) .................................................. 123 Figure B-3 Islander PLUS for 8 hoses – Wiring Diagram ............................................................. 124 Figure 1. HID Unit and Connector ................................................................................................. 126 Figure 2. HID Holder and Nuts ...................................................................................................... 126 Figure 3. OrCU Location in Islander PLUS 8-Hoses ..................................................................... 127 Figure 4. Rectangular Plate Connecting Points Location ............................................................... 128 Figure 5. HID back cover Removal ................................................................................................ 128 Figure 6. Attaching Back Cover to HID Holder ............................................................................. 129 Figure 7. Assembled Back Cover and HID Holder ........................................................................ 129 Figure 8. HID Mounted on Pedestal Door ...................................................................................... 130 Figure 9. Upper Left Corner Spacer ............................................................................................... 130 Figure 10. HID Connector Inserted to OrPT Connector ................................................................. 131 Figure 11. Placing Hand Tag Label on Pedestal ............................................................................. 132

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LIST OF TABLES

Table Page

Table 1-1. Islander PLUS - Standard Models.................................................................................... 18 Table 1-2. Pump Card Definition ..................................................................................................... 19 Table 2-1. Conduits into Islander PLUS .......................................................................................... 32 Table 2-2. Islander PLUS, Cables Type ........................................................................................... 37 Table 2-3. Islander PLUS, Cables Routing ...................................................................................... 37 Table 3-1. Islander PLUS, Assembly Parts ...................................................................................... 53 Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition ........... 59 Table 3-3. Islander PLUS for 8 hoses Terminal Block -8 Mechanical Pump – Connections Definition ........................................................................................................................................... 61 Table 4-1. Printer Main Components ............................................................................................... 83 Table 4-2. Printer Module Connector – Pin-out Description ........................................................... 84 Table 4-3. Printer Troubleshooting .................................................................................................. 93 Table 5-1. Islander PLUS Troubleshooting ....................................................................................... 96 Table 5-2. OrPT Troubleshooting ................................................................................................... 102 Table 5-3. Printer Troubleshooting ................................................................................................. 106 Table 5-4. Communication Troubleshooting................................................................................... 108 Table 1. HID Installation Kit Items ................................................................................................. 125

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SECTION 1 GENERAL DESCRIPTION

1-1. SCOPE

This manual is provided to assist you in installing Islander PLUS / ICR PLUS. The system must be installed as described in this manual to ensure the system reliability and proper operation.

This manual includes a general and functional description of the products, their main components, installation requirements and procedures.

This manual is intended for qualified authorized installers of Islander PLUS / ICR PLUS and its components. It is also intended for the Island electrician.

This document refers to Islander PLUS (including the model with 8 mechanical hoses) and ICR PLUS. Whenever Islander PLUS is mentioned it also refers to ICR PLUS with the exceptions mentioned in section 1-5.2 below.

1-2. DESCRIPTION

The Islander PLUS is a fuel control and data acquisition system. Islander PLUS system is self-contained in a forecourt compatible and weather-resistant cabinet installed on top of a pedestal.

Islander PLUS (see Figure 1-1) is a core component in Gasboy’s solution for Home Base Refueling Station (Home Base Station). Islander PLUS provides the central function of Site Controller. It also fulfills other essential services on the Island such as Vehicle/Driver Identification System (FuelPoint PLUS), Transaction data storage, Forecourt devices control and more. Its ergonomic design, as well as its user-friendly operating program, enables fast and accurate service for the driver in the refueling site.

Islander PLUS can control up to 8 mechanical hoses or up to 64 electronic hoses. The hoses may be linked together or standalone.

Islander PLUS is equipped with the OrPT, a Payment Panel and communication receptacle. The Payment Panel is equipped with an alphanumeric LCD (graphic LCD, optional) and a keyboard to interface with the client. This enables the Islander PLUS to support all common refueling identification devices such as: Vehicle/Driver Identification Unit (FuelPoint PLUS), magnetic cards, contact-less RFID tags, keypad entry and others.

Islander PLUS Manual 1

Figure 1-1 - Islander PLUS / ICR PLUS - General View


1-3. SYSTEM OVERVIEW

1-3.1. Islander PLUS System Islander PLUS is an innovative product that enables refueling in Home Base stations for fleets authorized vehicles or drivers. Islander PLUS electronically locks all dispensers and pumps thereby ensuring that only appropriately authorized vehicles and plants receive the required fuel. The system also ensures accurate recording of each transaction (see Figure 1-2).

The heart of the Home Base Station solution is the SiteOmat automation software. SiteOmat runs on an embedded operating system on the OrCU (Orpak Controller Unit). OrCU is an embedded hardware platform designed to survive the harsh gas station environment. It uses a solid state Flash disk and RTC (Real Time Clock) with back-up, along with surge suppressors for transient and noise immunity. The system also includes power fail recovery mechanisms.

1-3.2. Vehicle Identification – FuelPoint PLUS Vehicle Identification is an important option for maximal control and savings on fuel expenditure. The dispenser is authorized to refuel after a positive identification of the vehicle and only while the nozzle is inside the fuel inlet of the identified vehicle. All transaction information is automatically recorded. A combined vehicle and driver identification is also possible for tight tracking.

1-3.3. Remote Web Access Remote Web-based capabilities for monitoring, management and maintenance are available. A standard PC with Internet Browser (Explorer) is used for management of the site either locally or remotely (secured). There is no need for special management software; thanks to the built-in Web server technology integrated into the station controller and a large variety of communication links is supported – both wired and wireless.

1-3.4. Head Office Centralized management is provided by the optional Fleet and Fuel Head Office server. The Fleet and fuel Head Office consolidates the data from multiple sites and generates reports, including exception reports. It also enables control of the limits and restrictions placed on the various fleet vehicles. Furthermore, authorized fleet personnel are able to log-in remotely and are always in control. Head office enables authorized users to control and manage wet stock inventory on all stations including orders, deliveries and reports.

1-3.5. Restrictions and Limits Control of a fleet’s fuel expenses can be maximized by defining limits (day, week, month), maximum number of refueling (day, week, month) and setting restrictions (days of the week, fuel type, stations, time intervals). In case of system configuration for multiple sites, the centralized Fleet Head Office needs to synchronize the data between all sites so that the limits can be applied to a whole system rather than to an individual site. In case of communication failure, the specific site will be able to refuel for a predefined grace period (parameter) using the most recent limits stored in its database.


1-3.6. Islander PLUS Capabilities for Forecourt Management Islander PLUS provides the following operational features for a comprehensive Forecourt management:

• Supports over 50 different types of dispensers in use in many countries. For UL listing; this

product has only been evaluated for use with UL Listed Dispensers.

• Advanced electronic support of mechanical dispensers, enabling pump with totalized, preset

and price update

• Tank Level Gauging System (TLG) available for several brands. For UL listing; this product

has only been evaluated for use with UL Listed TLG’s.

• Support of large variety of communication links: cellular, dial-in modem, VPN, satellite,

ADSL and more.

Figure 1-2 - Islander PLUS in Home Base Station - General Configuration Diagram

1-3.7. System Workflow Example Following are examples of an operational workflow for self-service at the Home Base Station.


1-3.7.1. Refueling Scenario with FuelPoint PLUS A motorist stops for fuel at the station. His authorization device for the fueling transaction is a FuelPoint PLUS mounted in his car. The client lifts the nozzle and inserts it in the car inlet.

The FuelPoint PLUS information is automatically read and sent to the Site Controller (OrCU) for authentication and approval. Upon approval, the fueling transaction starts, at the end of which the transaction data is kept internally and transfer to the Fuel Head Office (FHO) for future billing. Once the refueling is completed, the motorist replaces the nozzle to pump.

1-3.7.2. Refueling Scenario with Magnetic Cards A motorist stops for fuel at the station. His authorization device for the fueling transaction is a magnetic card. The client swipes the card through the magnetic card reader on the Payment Panel.

The magnetic card information is read and sent to the Site Controller (OrCU) for authentication and approval. The client lifts the nozzle and inserts it in the car inlet. Upon approval, the fueling transaction starts, at the end of which the transaction data is kept internally. The data is transferred to the Fuel Head Office (FHO) for future billing.

The client may add more data to the transaction, by manually entering the information using the Payment Panel keyboard, or by scanning a barcode in the Barcode Reader (optional) on the front panel. Once the refueling is completed, the motorist replaces the nozzle to pump.

In both options, the motorist may print a transaction ticket from the Islander PLUS printer (optional).


1-4. ISLANDER PLUS STRUCTURE

1-4.1. Main Components Following is a short description of the Islander PLUS main sub units (see Figure 1-3 and Figure 1-5):

Orpak Controller Unit (OrCU) Orpak Controller Unit (OrCU) is a complete forecourt controller with its own embedded operating system. The unit consists of an embedded hardware platform with a solid state Flash hard disk, Real Time Clock (RTC) with back up, along with surge suppressors for transient and noise immunity

OrCU features two separate and isolated networks (TCP/IP over Ethernet). One network links the Islander PLUS system components. The second network is intended for external remote communication (Head Office, 3rd party systems).

This network is protected by SSL security.

OrCU includes a built-in server for Web access trough an internet browser (Explorer).

Wireless Gateway Terminal (WGT) (Optional)

WGT (Wireless Gateway Terminal) receives both DataPass and FuelOpass vehicle data, decrypts the information and transmits it to the Station automation system in a secure manner over an RF signal.

To obtain maximal grid availability, several WGT units are installed at the station to create a robust 'mesh'

network. This setup enables the RF signal to travel through various routes and bypass possible interferences (such as a big truck/bus).

The units that provide data to the WGT are:

DataPass - DataPass is a miniature unit that connects to the vehicle bus and captures data from the vehicle CPU/BUS. It then transmits this data to the nearest Wireless Gateway Terminal (WGT) in the forecourt.

FuelOpass - FuelOpass is a passive vehicle identification tag for refueling. Its encrypted data includes the account to be charged and is read by the Nozzle Reader device using RFID contactless technology.

Nozzle Reader (NR) - Nozzle Reader is a self contained unit installed on the nozzle which reads the FuelOpass data using contactless technology.


OrPT Panel

The OrPT panel consists of Payment Panel and communication equipment. The Panel is equipped with an alphanumeric LCD (graphic LCD, optional) and a keyboard to interface with the client. The Payment Panel is equipped with several authorization options: Magnetic card reader, RFID tag reader and barcode reader (optional). These authorization tools enable the Islander PLUS to accept all common authorization methods such as: Credit cards, magnetic cards, contact-less RFID tags and Bar Codes.

OrPT supports keyboard entry for authorization, and other parameters’ input from the user such as odometer, engine hours, vehicle plate number and PIN code.

The OrPT panel is connected to the Site Controller (OrCU) via a LAN (Ethernet) link.

Outdoor Printer (Optional) The Islander PLUS includes an optional printer for purchase receipts printout, as well as data output. The printer is linked to the central payment terminal that sends to it the transaction data for printout (see Figure 1-7).

The thermal printer is installed at the center of the Islander PLUS pedestal door. It includes an integrated paper cutter, paper feeder, paper spool and an "End of paper" warning sensor.


8-Port CommVerter The 8-Port CommVerter consists of a communication board for all Islander PLUS electronic units and for the peripheral equipment interface.

The CommVerter includes two MPI-C cards for interface to the mechanical pumps, an Ethernet Switch, RS/485 ports and one RS/232 port. For electronic pump, a different interface card is installed. See Chapter 3 for more details.

The CommVerter communicates with the Site Controller (OrCU) via a LAN (Ethernet) link.


1-4.2. Islander PLUS Internal Configuration – Mechanical Pump Figure 1-3 shows a general configuration diagram of the Islander PLUS up to four mechanical pumps.

Figure 1-3 - Internal Configuration Diagram – 4 Mechanical Pump


Figure 1-4 shows a general configuration diagram of the Islander PLUS for eight mechanical pumps.

Figure 1-4 - Internal Configuration Diagram – 8 Mechanical Pumps


1-4.3. Islander PLUS Main Components Location The following Figure 1-5 shows the location of the main components of the Islander PLUS, without the Printer. Figure 1-6 shows the location of the main components of the Islander PLUS for 8 hoses. Figure 1-7 and Figure 1-8 show the location of the Printer within the two configurations, when it is installed.

Figure 1-5 - Internal Components Location –4 Mechanical Pumps


Figure 1-6 - Internal Components Location –8 Mechanical Pumps


Figure 1-7 – Islander PLUS with Optional Internal Printer (Sectional View)


Figure 1-8 – Islander PLUS for 8 hoses with Optional Internal Printer (Sectional View)


1-5. AVAILABLE CONFIGURATIONS

1-5.1. General Islander PLUS is available in several configurations, in accordance with its intended use and with the components installed. All configurations are manufactured in accordance with specific customer request and receive a Part Number.

The following paragraphs describe the several configurations, and their devices composition.

1-5.2. Islander PLUS / ICR PLUS Islander PLUS is supplied with the OrCU (Orpak Controller Unit) embedded in the unit. In this configuration, Islander PLUS performs as full station controller, providing functions such as authorization unit, central forecourt devices controller, linked to the Head Office, etc.

In ICR PLUS configuration, the OrCU is removed from the pedestal. The ICR PLUS operates as an authorization terminal in order to ease the use of the system in large home base stations. ICR PLUS is linked to another Islander PLUS or CFN PLUS in order to connect to the Head Office. In this configuration, the OrCU in the Islander PLUS pedestal is shared by both units.

1-5.3. Printer Option The printer in the Islander PLUS /ICR PLUS is provided as an option. The printer issues a printout of the transaction to the driver.

1-5.4. Vehicle Identification System Some options are available for vehicle identification in the Islander PLUS /ICR PLUS:

• FuelPoint PLUS - WGT (Wireless Gateway Terminal) is Vehicle identification process performed in a wireless mode. WGT can be installed on top of the Islander PLUS pedestal or in an external outdoor unit (P/N PA04000001). WGT receives DataPass or FuelOpass signals, decrypts their information and transmits it to the Station automation system (OrCU) in a secure manner over an RF signal. This setup enables the RF signal to travel through various routes and bypass possible interferences (such as a big truck/bus). The transmission signal range is 10 meters. The WGT is designed to be installed in a designated external box on the station wall or in a pedestal. The WGT should be connected to the OrCU box using CAT5E cable. More than one WGT outdoor unit can be mounted in one station to ensure improved RF area coverage. In this case one WGT box is Master and the other(s) are routers. For further details, refer to WGT outdoor unit Installation Guide, document no. MDE-4815.

• No vehicle identification unit: The vehicle identification process will be done manually by the driver with any accepted authorization devices such as cards, tags or manual entry.

1-5.5. Dispensers Islander PLUS can support either mechanical or electronic dispensers, in accordance with its configuration.


Mechanical dispensers require the installation of MPIC cards on the 8-port Convertor. Electronic dispensers (Tokheim, Current Loop, RS-485) require installation of interface relevant cards on the 8-port Convertor.

1-5.6. Contactless Tags/Cards

1-5.6.1. Data Key Sockets – Fleet key The pedestal can be supplied with an optional key reader for payment with Data Key Sockets (see Figure 1-9). The key reader is installed behind the printer door cover on the front panel.

Figure 1-9 – Islander PLUS with Data Key Reader (Optional)

1-5.6.2. HID Device The pedestal can be supplied with an optional HID card reader for payment with specific cards. The HID reader supports Track 2 and 26/37/32 bit card formats. For further information on HID reader format setup, please refer to the OrPT Installation, Setup and Operation Manual, P/N MDE-4819.

The HID reader is installed behind the decorative black cover of the front panel (Refer to Appendix C).

1-5.6.3. Configurations Table 1-1 define all the available product numbers for the different configurations of Islander PLUS:


Table 1-1. Islander PLUS - Standard Models

Name Gilbarco P/N Orpak P/N Islander PLUS for Electric Pumps PA039400000 800938103

Islander PLUS for Mechanical Pumps - 2 hose PA039400200 800938105



Islander PLUS w/Fleetkey for Electric Pumps PA039401000 800938167

Islander PLUS w/Fleetkey for Mechanical Pumps - 2 hose PA039401200 800938169



Islander PLUS w/HID for Electric Pumps PA039402000 800938231

Islander PLUS w/HID for Mechanical Pumps - 2 hose PA039402200 800938233



Islander PLUS w/Printer for Electric Pumps PA039400010 800938135

Islander PLUS w/Printer for Mechanical Pumps - 2 hose PA039400210 800938137

Islander PLUS w/Printer for Mechanical Pumps - 4 hose PA039400410 800938139

Islander PLUS w/Fleetkey & Printer for Electric Pumps PA039401010 800938199

Islander PLUS w/Fleetkey & Printer for Mechanical Pumps - 2 hose PA039401210 800938201

Islander PLUS w/Fleetkey & Printer for Mechanical Pumps - 4 hose PA039401410 800938203

ICR PLUS PA039500000 800938102

ICR PLUS w/Mechanical Pumps - 4 hose PA039500400 800938106

ICR PLUS w/Fleetkey PA039501000 800938166


ICR PLUS w/Fleetkey & Mechanical Pumps - 4 hose PA039501400 800938170

ICR PLUS w/HID PA039502000 800938230

ICR PLUS w/HID & Mechanical Pumps - 4 hose PA039502400 800938234

ICR PLUS w/Printer PA039500010 800938134

ICR PLUS w/Printer & Mechanical Pumps - 4 hose PA039500410 800938138

ICR PLUS w/Fleetkey & Printer PA039501010 800938198

ICR PLUS w/Fleetkey, Printer & Mechanical Pumps - 4 hose PA039501410 800938202

NOTE

Islander PLUS with 8 mechanical dispensers does not support TLG or additional electronic dispensers from the pedestal. Those devices require an external box.

In the order form, you are required to define also the P/N for the specific pump card in use (MPI-C, Tokheim, Current Loop or RS-485 – see Table 1-2).

Table 1-2. Pump Card Definition

No. Pump Card Description Gilbarco P/N Orpak P/N

1 Tokheim interface (8P) P.B. M09680B028 819223420

2 Current Loop interface (8P) P.B. M09680B029 819223431

3 RS232 Interface (8P) P.B. M09680B016 819223451

4 RS485 Interface (8P) P.B. M09680B017 819223460

5 MPI-C + Sub Interface (8P) P.B. M09680B019 819223490


1-6. SECURITY AND PROTECTION

1-6.1. General The transaction activities of the Islander PLUS are secured and protected for transmission and authorization activities.

1-6.2. Authorization Security The contact-less tags include Triple DES encrypted data for user identification and billing. Consequently, Islander PLUS includes a special Security Application Module (SAM) for decryption and matching identification. Upon tag reading, Islander PLUS attempts to decrypt the string from the tag. Islander PLUS disregards Tags whose security scheme does not match the Islander PLUS internal SAM.

1-6.3. Network Security The Ethernet LAN is isolated from the external WAN by the Site Controller (OrCU). In case of remote maintenance, a firewall should be applied either at the router level or preferably at the Home Base Station level.

1-6.4. RF Network Security Islander PLUS EIA 802.15.4 RF network is encrypted, using the AES 128 security standard.

1-6.5. Maintenance Security Islander PLUS maintenance and setup procedures require inserting a user name and password for access. For further information, please refer to the SiteOmat Setup Manual. P/N MDE-4817

1-7. HOUSING

Islander PLUS system enclosure is made of a metal cabinet, with plastic panels, in the form of a pedestal. The enclosure is weather-proof in order to sustain the harsh environment of a Home Base Station. The Payment Panel of the Islander PLUS is made of rugged plastic. The devices in its front panel are sealed to prevent humidity and dust penetration.

Islander PLUS pedestal is locked by key for safety and security. The key should be kept in a well-kept, secure and safe place.

Figure 1-10 shows Islander PLUS/ICR PLUS dimensions in inches.


Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions


1-8. SPECIFICATIONS

The following physical, electrical and environmental specifications are applicable to the Islander PLUS:

Islander PLUS - Pedestal with up to 4 mechanical pumps

Islander PLUS - Pedestal with up to 8 mechanical pumps

Name Islander PLUS Islander PLUS

Supply voltage: 100 – 240 VAC 120 / 240 VAC

Power consumption: 2A max. 2A - 1A max. (Accordingly)

Operating temperature: -22 °F to +113 °F (-30°C to +45 °C)

-4 °F to +113 °F F (-20°C to +45 °C) (Option with printer)

-40 °F to +104 °F (-40°C to +40 °C)

-4 °F to +104 °F (-20°C to +40 °C) (Option with printer)

Storage temperature: -40 °F to +158 °F (-40°C to +70 °C) -40 °F to +158 °F (-40°C to +70 °C)

Humidity: 80% Non-condensing 80% Non-condensing

Dimensions: W x H x D: 9.45 x 61.02 x 9.45 " (24 x 155 x24 cm)

W x H x D: 9.45 x 61.02 x 9.45 " (24 x 155 x24 cm)

Communication interface:

RS-485 – 9600 bps, Half-Duplex RS-232 Ethernet RJ-45 - 10 Mbps EIA 802.15.4

RS-485 – 9600 bps, Half-Duplex RS-232 Ethernet RJ-45 - 10 Mbps EIA 802.15.4

Pump Control Maximum Current (4 Solid State Relay Channels):

Motor maximum: 1 HP at 115 VAC or 2 HP at 230 VAC. Additional external relay must be used if pump motor exceeds these limitations.

Motor maximum: 3/4 HP at 115 VAC or 1.5 HP at 230 VAC. Additional external relay must be used if pump motor exceeds these limitations.

Power supply output voltage to Pulsar unit Power supply maximum output current

12 VDC +/- 20% 80 mA max

12 VDC +/- 20% 30 mA max

Pulsar Input High level voltage Pulsar Input High level sink current (@15V)

9 to 15 VDC 3 mA

9 to 15 VDC 3 mA

In use "On" level (Input) 100 – 240 VAC, 50/60 Hz, 2 W (20 mA)

100 – 240 VAC, 50/60 Hz, 2 W (20 mA)

In use "Off" level (Input) 0 to 20 VAC 0 to 20 VAC


1-9. STANDARDS

1-9.1. Communication Standards Islander PLUS communicates, in its different models, over the following standards: • RS-232 link • RS-485 link • TCP/IP over Ethernet • EIA 802.15.4

1-9.2. Security Standards • Triple DES encryption for Payment Devices (Contact-less tags, magnetic stripe cards, etc.) • AES 128 for RF Network Communication


1-10. MANUAL STRUCTURE

This manual comprises of the following sections: Section 1: General Description

This section provides a general description of the Islander PLUS system.

Section 2: Preliminary Installation Procedures

This section provides the preliminary installation requirements and procedures to be performed before installing Islander PLUS.

Section 3: Islander PLUS Installation Procedures

This section provides a detailed description of Islander PLUS installation requirements and procedures.

Section 4: Printer

This section provides a detailed description of the Islander PLUS printer, as well as basic troubleshooting instructions.

Section 5: Maintenance

This section provides general maintenance instructions for the Islander PLUS as well as a comprehensive troubleshooting guide.

Section 6: Glossary

This section includes a glossary of terms employed for the Islander PLUS description.

Appendix A: Station Survey

This section includes instructions for conducting gas station survey.

Appendix B: Wiring Diagram

This section includes the Wiring Diagram of the Islander PLUS.

Appendix C: HID Assembly Installation

This section includes the description of HID device installation.


1-11. USING THIS MANUAL

This manual includes alerting comments inserted along the document, in order to draw the reader’s attention to important issues. The comments are accompanied by symbols for ease of reference. The following comment types are used:

WARNING

An operating procedure, practice, etc', that if not correctly followed, could result in injury or loss of life.

CAUTION

An operating procedure, practice, etc', that if not strictly observed, could result in damage to, or destruction of equipment.

TIP

This note is aimed for using the system in better efficiently way.

NOTE

This comment is of importance for emphasizing.

INSIGHT

More detailed technical/ functional information in regard relevant issue.


1-12. REFERENCES

For additional and complementary information regarding the Islander PLUS system, please refer to the following manuals:

OrPT - Installation, Setup and Operation Manual For Home-Base Stations, Document No. MDE-4819

8-Port CommVerter User’s Manual, Document No. MDE-4812

SiteOmat Station Controller User’s Manual, Document No. MDE-4817

SiteOmat Station Controller Setup Manual, Document No. MDE-4818


0

SECTION 2 PRELIMINARY INSTALLATION INSTRUCTIONS

2-1. GENERAL

This section provides the preliminary installation procedures for the Islander PLUS.

These procedures include:

• Preliminary instructions

• Wiring and Wire Conduits requirements

2-2. PRELIMINARY INSTALLATION INSTRUCTIONS

2-2.1. General

NOTE

Perform a site survey of the station prior to installation (see Appendix A)

Installation procedures and requirements depend, to some extent, on the specific fuel dispenser models and the site layout. Therefore, use the information in this section to develop installation plans for each specific installation. Since installation requirements vary widely from case to case, no installation hardware is supplied by the equipment manufacturer, and installation planners must develop their own requirements.

The customer should provide an installation plan, designed by an authorized engineer, and applicable to all authorities. This plan design should reflect the existing electric infrastructure of the site.

2-2.2. Precautions and Safety Notes Prior to actual installation activities, carefully observe the precautions and safety notes below.

WARNING

Before installing or servicing equipment, carefully observe the warnings and precautions provided at the beginning of this manual.


Remember that the Home Base Gas Station environment is highly flammable and combustible. Therefore, make sure that actual installation is performed by experienced personnel, licensed to perform work in Home Base Station and capable of implementing all applicable requirements of the National Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70A “National Electric Code”, federal, state and local codes and any other applicable safety codes and regulations.

System power may come from more than one source. Disconnect all power sources, including pumps, before attempting to work on the system.

Install the Islander PLUS in an area in accordance with the safety restrictions as shown in Figure 3-1.

Islander PLUS site preparation is in the customer’s responsibility.

Do not connect power to the Islander PLUS and other peripherals in the whole system, including pumps, until complete installation is inspected and certified.

Do not perform any metal work in the hazardous area. Sparks generated by drilling, tapping and metal work operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury, property loss and damage to you and other persons.

When working in any open area of Home Base Station, beware of passing vehicles that could hit you. Block off the work area to protect yourself and other persons. Use safety cones or other signaling devices.

2-3. CONDUITS LAYOUT/INSTALLATION SPECIFICATIONS

The installation of the Islander PLUS requires preparing beforehand the cables layout in the Home Base Station. This procedure consists of installing conduits within the Island, inserting the proper cables and setting the proper power equipment and sensors.

This chapter provides the procedures for infrastructure groundwork. These procedures consist of, in a descending order of performance:

• Wire conduits installation • Cables routing within the conduits • Power equipment setup • Forecourt equipment wiring

2-4. CONDUITS

2-4.1. General The installation of the Islander PLUS in the Island requires digging and setting several conduits in the Station ground. The conduits are required for the routing and protection of the different types of cables in use in a Home Base Station with Islander PLUS. In sites where the infrastructure is already setup, you can use the existing conduits only if they meet the requirements defined below.


2-4.2. Conduit Requirements Conduits must comply with:

• All conduits must be made and installed according to local regulations. • High-voltage AC and low-voltage DC must NOT be combined in a common conduit,

junction box or wire through. • RS-485 or LAN communication must not exceed 330 feet (100 m). Cables must be

inserted in a separate low voltage conduit, away from AC wires. Communication range can be extended with 3rd party devices.

• RS-232 communication must not exceed 50 feet (15 m). RS-232 communication shielded cable must be inserted in a separate low voltage conduit, away from AC wires. Communication range can be extended with 3rd party devices.

• Antenna wire must not exceed 330 feet (100 m) in case the VIU is in use, and 50 feet (15m) in case the FuelOpass is used. Antenna wire must be inserted in a separate low voltage conduit, away from AC wires.

• All conduits must be inserted in the Islander PLUS pedestal through the holes and knockouts provided in the lower protective plate (see Figure 2-1). Do not make any other hole in this unit. If you must make holes at locations other than those provided, contact Gasboy for approval.

• After completing the installation, all open holes should be sealed.

2-4.3. Conduits at Islander PLUS Islander PLUS includes a protective plate below the Terminal Block in the installation pole. The plate is perforated with circles that enable to insert four conduits (see Figure 2-1, Figure 2-2):

• Four conduits of 1" diameter • Four conduit of 1/2" diameter

The conduits are in use for:

• Two conduits of 1" diameter are intended for high voltage cables • One conduit of 1" is intended for low voltage conduit

The cables and wires to/from the other units in the forecourt are connected to the Terminal Block. The cables and wires are inserted through the conduits in accordance with their types and routed to their sources.


Figure 2-1 Islander PLUS Lower Protective Plate

Figure 2-2 Standard Bottom Metal Plate's Knockout –Close View


2-4.4. Required Conduits in Island The types of conduits in the Island are a function of the different equipment, and their location in the Island. Basically, there are two functional conduits:

• High voltage conduits • Low voltage conduits

The following conduits are required in the Island:

• High voltage conduits o AC power for Islander PLUS o Pump control from pumps to Islander PLUS o Pump In-use signal from pumps to Islander PLUS

• Low voltage conduits

o Internet line from LAN at Office to Islander PLUS o RS-232 communication line from TLG at office to Islander PLUS o RS-485/422/C.L. or Tokheim o Pulser from pumps to Islander PLUS

• Grounding

o At least 10 mm (OOO AWG) Grounding cable to pump chassis o At least 10 mm (OOO AWG) Grounding cable to Islander PLUS pole

(Connected to the external chassis grounding post) o Grounding cable to TLG – in accordance with TLG manufacturer

instructions.

• Tank conduit o TLG probe

2-4.5. Required Conduits in Islander PLUS Four conduits can be inserted in the Islander PLUS, each carrying specific wires, as listed in Table 2-1 and shown in Figure 2-4.

Table 2-1. Conduits into Islander PLUS

No. Conduit Type Type

1 Low voltage Pulser, TLG, LAN

2 High voltage AC power, GND , In-use

3 High voltage Control


2-5. CONDUITS INSTALLATION

2-5.1. General This paragraph describes the infrastructure groundwork necessary to install the conduits in the Island (see Figure 2-1).

2-5.2. Installing Conduits in Island Proceed as follows:

1. Determine the location of the Islander PLUS in the Island. 2. Dig and prepare passageways for the necessary conduits 3. Take care to route the following conduits to the inspection boxes: • Low voltage cables inspection box:

o One conduit to Office (control room) o One conduit to each pump o Two conduits to Islander PLUS

• High voltage cables inspection box: o One conduit to Office (control room) o One conduit to each pump o Two conduits to Islander PLUS

2-5.3. Sealing Conduits The conduits shall be sealed in accordance with NFPA requirements and local regulations, to prevent the passage of gases through conduits, cables and conductors. The fittings are requested wherever volatile liquids or gases are present in the surroundings (see Figure 2-3).

Figure 2-3 Conduit Fitting


Figure 2-4 Conduits Layout for Mechanical Pump


Figure 2-5 Conduits Layout for Electronic Pump


2-6. CABLES INSERTION

2-6.1. General This paragraph describes the requirements and procedures for the insertion of cables in the conduits.

NOTE

All devices in the system must be connected to the same electric power phase.

NOTE

The type of cable needed vary in accordance with the device it connects. The wire used must be stranded and not a solid core. Select a cable specification in accordance with local environment conditions.

CAUTION

For supply connections, use wires suitable for at least 90°C.

Signal wiring connected in this box must be rated at least 300 V

2-6.2. Types of Cables Table 2-2 lists the types of cable in use for the wiring of the Islander PLUS system.


Table 2-2. Islander PLUS, Cables Type

No. Function Type

1 AC Power from Office Power cable, 3x1.5 mm2 NYY (14 AWG), in accordance with local standards

Control to pumps (valves or engine)

In-use signal

2 Pulser Data communication cable, 300 V RMS, 90ºC, shielded twisted pair, oil resistant, 24 AWG, low capacitance below 60 PF/meter similar to Belden 9729 cable

TLG (RS-232)

3 LAN CAT5E, Shielded, 300 V RMS, 90ºC similar to Belden 121700A

4 GND Ground cable 0.4" (10.8 mm2)

2-6.3. Cables Routing Route the cables from the peripherals and the Office to Islander PLUS as listed in Table 2-3 and shown in Figure 2-4. Proceed as follows:

Table 2-3. Islander PLUS, Cables Routing No. Functional Description From Through Insert Cable Type (*)

1 Power AC Office High voltage conduit 1

2 GND Office High voltage conduit 4

3 TLG Office Low voltage conduit 2

4 LAN Office Low voltage conduit 3

5 Control, Pump A Pump A High voltage conduit 1

6 In-use, Pump A Pump A High voltage conduit 1

7 Pulser, Pump A Pump A Low voltage conduit 2

(*) Refer to Table 2-2.

2-7. POWER SETUP

2-7.1. General The power equipment shall be installed in the Main Power Cabinet of the station office. It should include the following:


• Mains Circuit Control Box (MCC)

• Uninterruptible Power Supply (UPS) – Online ("True") UPS Figure 2-6 shows the requested connections of the power equipment.

Figure 2-6 Power Equipment Connections

Beside the power equipment, other components shall be connected to the power supply such as the TLG and the dispensers.

2-7.2. Islander PLUS for 8 hoses - AC Power Supply Setup

In Islander PLUS for 8 hoses the power supply can be fed either 110 VAC or 220 VAC. The Mains cable is first connected to the terminal block. Between the terminal block and transformer the system uses a Line Filter in order to attenuate conducted radio frequencies - RFI, electromagnetic interference (EMI) - between the line and the equipment (see Figure 2-7). AC power is then supplied to an AC/AC High to Low Transformer – 110/220 VAC to 25 VAC. The transformer requires jumpers' setup for either 110 VAC or 220 VAC Mains input, as shown in Figure 2-8. A settings label is also found on top of the transformer.


Figure 2-7 Power Supply Components and Grounding Studs

WARNING

Islander PLUS is shipped configured for 110 VAC Mains power supply. Take care to set it accordingly to your local Mains power supply specifications. Failure to do so may result in damages.

1 32 4 5 6

220VAC JUMPER

1 32 4 5 6

110VAC JUMPERS

~ Neutral ~ Neutral

Figure 2-8 VAC Power Supply – Jumpers Setup


2-7.3. Connecting the Power Equipment Proceed as follows:

• External Mains o Connect Mains power to the Mains Circuit Control Box (MCC) o Wire one 0.4" (10mm) ground cable from the Mains ground

connection to the MCC. • Uninterruptible Power Supply (UPS)

o Connect the MCC to the UPS. • If any doubt concerning grounding arises, ask for a ground test performed by a

qualified electrician.

2-7.4. Grounding Proper system grounding is an extremely important part of the system installation. As with the AC power, the grounds for all system components should return to the same circuit breaker panel. This helps you to assure a common ground throughout the system, which is necessary for protection of the RS-485 data loop circuitry. Ground for all system devices should be wired to the breaker panel ground bus bar, which in turn should be grounded to a ground rod. A conduit ground does not provide sufficient ground. It is recommended that the neutral and ground bus bars be bonded together when it is not prohibited by local codes.

Figure 2-9 Islander PLUS ground description


2-8. WIRING THE PERIPHERALS

2-8.1. Pump Wiring Islander PLUS is capable of directly driving pump motors up to 3/4 HP at 115 VAC or 1-1/2 HP at 230 VAC. Additional external relay must be used if pump motor exceed this limitations. A separate circuit breaker should be supplied for each dispenser. Wire the pump as follows:

• Wire one Mains AC cable from the UPS-MCC to the pump enclosure, intended for the pump motor.

• For an electronic pump, wire RS485 / Current Loop / Tokheim communication cable from the Islander PLUS to the pump head.

• Wire one 0.4" (10 mm) ground cable from the Mains ground connection to the pump chassis.

• The communication cable shield must be connected to ground at one end-side only, preferably at the controller installation side (see Figure 2-10).

Figure 2-10 Communications Cable Wiring

2-8.2. TLG wiring RS-232/LAN is used for communication between the TLG and Islander PLUS. Follow these installation requirements when installing the RS-232/LAN communications lines:

NOTE

These requirements shall be compatible with the recommendations of the TLG manufacturer.

• Distance: the following distances must be adhered to when installing the communication lines:

o RS-232: 1 – 50 feet (1 – 15 m) for direct connection to a TLG device.


o LAN: 1- 330 feet (100m) for direct connection to a TLG device • Conduit: All direct connect RS-232/LAN cable must be in a low voltage conduit

away from any AC wires. • Cable: The type of cable required should be according to the device it is connected

to. The wire used must be stranded and not a solid core. Select a cable specification in accordance with local environment conditions.


0

SECTION 3 ISLANDER PLUS INSTALLATION PROCEDURES

3-1. GENERAL

This section provides the installation procedures for the Islander PLUS.

These procedures include:

• Islander PLUS Pedestal installation

• Wiring

• Post installation check.

3-2. INSTALLATION SPECIFICATIONS

3-2.1. General

NOTE

Perform a site survey of the station prior to installation

Installation procedures and requirements depend, to some extent, on the specific fuel dispenser models and the site layout. Therefore, use the information in this section to develop installation plans for each specific installation. Since installation requirements vary widely from case to case, no installation hardware is supplied by the equipment manufacturer, and installation planners must develop their own requirements.

The customer should provide an installation plan, designed by an authorized engineer. This plan design should reflect the existing electric infrastructure of the site.

3-2.2. Precautions and Safety Notes Prior to actual installation activities, carefully observe the precautions and safety notes detailed in paragraphs 2-2.2 and 2-4.2, and at the opening pages.


3-2.3. Safety Distances Figure 3-1 shows the safety distances required for the installation of the Islander PLUS adjacent to the dispensers. When mounting the Islander PLUS, a minimum clearance of 18 inches (0.5m) between the unit and any of the pumps or the dispensers must be maintained. This clearance allows room for the wiring and maintenance of the system.

Islander PLUS is designed and approved for installation and use at a convenient location at or near fuel Island in the appropriate hazardous (classified) location:

• Where hazardous location is classified as Class 1, Division 2 and it does not extend higher than 18 inches (0.5m) from surface and

• A minimum safety separation of 18 inches (0.5m) from any nearest pump/dispenser.

Figure 3-1 Islander PLUS– Installation Control Drawing

3-3. HOME BASE STATION - OVERVIEW

3-3.1. General Prior to installation, you are required to obtain an overview of the Home Base Station functional architecture. This overview is required in order to draw an architecture diagram with all components and their communication links.

Figure 3-2 shows a functional diagram of the links within the Home Base Station with 4 mechanical pumps.

Figure 3-3 shows a functional diagram of the links within the Home Base Station with 8 mechanical pumps.


Figure 3-4 shows a functional diagram of the links within the Home Base Station with electronic pumps.

3-3.2. Home Base Station Architecture The Home Base Station functional architecture consists of the following levels:

• Main Power Cabinet and Home Base Station forecourt

• Head Office Center

3-3.2.1. Main Power Cabinet The Main Power Cabinet includes the following components:

• Mains Circuit Control Box (MCC)

• Uninterruptible Power Supply (UPS)

• TLG Controller

3-3.2.2. Home Base Forecourt The Home Base Forecourt includes the following components:

• Islander PLUS/ICR PLUS

• Dispenser(s) – up to four nozzles for each Islander PLUS/ ICR PLUS. For UL listing; this product has only been evaluated for use with UL Listed Dispensers.

• One or more Underground gas tanks

• TLG probe for each gas tank. For UL listing; this product has only been evaluated for use with UL Listed TLG’s.

3-3.2.3. Head Office System (Optional) The Head Office system consists of fully integrated management hardware and software tool that supports Home Base Station and small gas stations with their sale management of products including inventory management and reporting.

The Head Office system is a remote control center that stores, processes and analyzes all the transactions at the Home Base Station. The Head Office Station provides an integrated retail solution.


Figure 3-2 Home Base Station with 4 Mechanical Pumps – System Diagram


Figure 3-3. Home Base Station with 8 Mechanical Pumps – System Diagram


Figure 3-4 Home Base Station with Electronic Pumps – System Diagram


3-4. MAPPING THE SITE– EXAMPLE

3-4.1. General This paragraph shows an example of the mapping of a site. This procedure consists of the following steps:

• Locating and mapping all objects of the site • Assigning logical identifications (Id.) to the devices • Assigning the Ethernet and Serial addresses of devices linked to the network • Obtaining a functional and physical map of the devices in the site.

3-4.2. Locating all objects of the site • Locate the roads around the site • Locate the islands and their dispensers • Locate the fuel tanks • Locate the intended position of the Islander PLUS pole • Locate the intended position of each ICR PLUS • Draw a basic map of the site with all the objects

3-4.3. Assigning Logical IDs

3-4.3.1. To each fuel tank • Assign the tank sequential number (coordinated with the station manager) • Assign its fuel code and name • Assign its TLG Probe (AP) Id.

3-4.3.2. To each Dispenser Unit • Assign an id. to every dispenser name and Pump Server • Assign an id. to every dispenser pump (P) • Assign an id. to every pump CPU addresses if any • Assign an id. to its nozzles (N) • Assign to each nozzle the tank (T) Id. to whom it is linked.

3-4.3.3. In the Islander PLUS pole • Assign the Islander PLUS its id. • Assign the panel printer (PP) its Id. • Assign their ids in an ascending order with the dispenser unit ids

3-4.4. Mapping • Draw a map of the site. • Use the map methodology and Ids. for later setup configuration.


3-5. CONNECTIONS TO ISLANDER PLUS

All connections to the Islander PLUS must be performed to the Terminal Block located at the bottom of the Islander PLUS pedestal (see Figure 3-5, Figure 3-6). The required connections are:

1. Dispenser wiring connections:

• Pulser (Low Voltage)

• In Use signal (High voltage)

• Valve (High voltage) 2. Communications

• RS-232/LAN to TLG Controller to Gas Tank

• RS-485 for Orpak peripheral device

• Pump communication line (e.g. Current Loop, RS485, Tokheim, RS422) 3. Mains AC Power and Ground

4. LAN connection


Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections


Figure 3-6 Islander PLUS Terminal Block, Power and LAN Connections (8 pumps)

3-6. INSTALLING THE ISLANDER PLUS PEDESTAL POLE

3-6.1. General The Islander PLUS pedestal is mounted in the Home Base Station (see Figure 3-7) on a base plate that is fastened to the Home Base Station concrete floor. The base plate upper side includes 4 holding screws immersed in the Home Base Station concrete floor.

3-6.2. Installation Procedure Steps Installation of the Islander PLUS pedestal consists of the following general steps:

• Running conduits to the pedestal site

• Installing the Base Plate

• Installing the Pedestal Base

• Installing the Pedestal

• Running the cable conduits to the installation hole and filling all open holes

• Installing the Rosettes to firmly lock the Islander PLUS pedestal.

3-6.3. Pedestal Site Preliminary Setup Procedures Proceed as follows:

1. Determine the spot for the Islander PLUS pedestal installation


2. Run cable conduits for each type of cables to the spot:

• One High Voltage conduit from the dispenser

• One Low Voltage conduit from the dispenser

• One Low Voltage conduit from the Office

• One High Voltage conduit from the Mains Distribution Box 3. In the installation spot, dig a hole on the ground of the following dimensions:

• Width: 11.8" (300 mm)

• Length: 11.8" (300 mm)

• Depth: 15.75" (400 mm) 4. Run the cable conduits to the hole.

5. All holes in this panel must be filled when the unit is installed.

3-6.4. Installation Assembly Parts Table 3-1 lists the assembly parts for the installation of the Islander PLUS.

Table 3-1. Islander PLUS, Assembly Parts

Item No. Orpak Part Number Description Qty

1 Islander PLUS 1

2 814906200 Bolt, ICU 4

3 815103000 Nut, M10 8

4 815300200 Washer, Flat, M10 8

5 814908400 Bottom Plate 1

6 814982200 Rosette, Islander PLUS 1

3-6.5. Base Plate Installation Procedures Proceed as follows (see Figure 3-7):

1. Prepare the Bottom Plate (5 in Table 3-1) with four ICU bolts (2 in Table 3-1) attached to it with M10 nuts (3 in Table 3-1). Check that the bolts protrude from the plate by 1.4" (35 mm).

2. Insert the Bottom Plate in the hole

3. Take care that all power and communication conduits pass through the central hole in the Bottom Plate


4. Pour concrete type B200 in the hole as a support base for the pole

Figure 3-7 Pedestal Pole Installation

5. Take care that, as the concrete fills the hole, the Bottom Plate is on a same level as the ground (asphalt, pedestal) on which it is installed. Check repeatedly that the Bottom Plate is leveled. Otherwise make the necessary adjustments so the plate is perfectly leveled

6. Wait the necessary time for the concrete to harden and dry (as per local practice), Check anew that the Bottom Plate is leveled.


Figure 3-8 Base Plate Installation (Example)

Figure 3-9 Rosette (Upside down view)

Figure 3-10 Rosette Dimensions


3-6.6. Pedestal Installation Instructions Proceed as follows:

1. Remove the four M10 nuts (1 in Figure 3-8) from the four bolts attached to the Bottom Plate.

2. Insert the Pedestal Base (3 in Figure 3-7) (1 in Table 3-1) on top of the Bottom Plate.

3. Insert the Pedestal Pole (4 in Figure 3-7) (1 in Table 3-1) on top of the Pedestal Plate.

4. Anchor the Pedestal Pole onto the Pedestal Plate with the four bolts (1 in Figure 3-7) protruding from the inner ground.

5. Secure the Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in Figure 3-8) (3 in Table 3-1)

6. Insert the Rosette (see Figure 3-9) (6 in Table 3-1) on the Pedestal Base, and secure it to Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in Figure 3-8) (3 in Table 3-1).

3-6.7. Base Plate Installation Procedures – Optional The Base Plate can be attached to the spot ground by four expansion bolts as an option. Proceed as follows:

1. Set the Bottom Plate (1 in Figure 3-7) (5 in Table 3-1) in the spot and mark the four holes location for drilling

2. Drill four holes in the installation spot

3. Insert four expansion bolts (see Figure 3-11) in the holes. Check that the bolts protrude from the Bottom Plate by 1.4" (35 mm).

4. Insert the Bottom Plate on the spot so that its installation holes fit with the protruding bolts.

5. Take care that all power and communication conduits pass through the central hole in the Bottom Plate

Figure 3-11 Expansion Bolt

7. Insert the Pedestal Base (3 in Figure 3-7) (1 in Table 3-1) on top of the Bottom Plate.

8. Insert the Pedestal Pole (4 in Figure 3-7) (1 in Table 3-1) on top of the Pedestal Plate.


9. Anchor the Pedestal Pole onto the Pedestal Plate with the four expansion bolts protruding from the inner ground.

10. Secure the Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in Figure 3-8) (3 in Table 3-1)

11. Insert the Rosette (see Figure 3-9) (6 in Table 3-1) on the Pedestal Base, and secure it to Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in Figure 3-8) (3 in Table 3-1).

3-6.8. Sealing Conduits The conduits shall be sealed in accordance with NFPA requirements and local regulations, to prevent the passage of gases through conduits, cables and conductors. The fittings are requested wherever volatile liquids or gases are present in the surroundings (see Figure 3-12).

Figure 3-12 Conduit Fitting


3-7. WIRING

3-7.1. General After completing the installation procedure, perform the following wiring procedures. The wiring is performed in the Islander PLUS Terminal Block only.

The wires should be pulled from the conduits that protrude from the Installation Base, or in the opposite direction, from the Terminal Block to the device in the Home Base Station.

3-7.2. Types of Wiring The wiring in the Terminal Block differs in accordance with the type of pump installed in the Home Base Station. There are several types of pumps:

• Mechanical Pump

• Electronic Pumps The following paragraphs provide the wiring requirements for each type of pump.

3-7.3. Wiring Requirement For any type of wire, prior to inserting it to the terminal block, proceed as follows:

1. Insert any wire with a terminal lug only.

2. Use the proper Terminal Crimper to attach the lug to the wire.

3. For UL Listing; The Terminal Lug must be a UL recognized component.

Figure 3-13 Terminal Lug

TIP

Mark each cable at its both ends with a number or sign that will identify its functionality in the future.

3-7.4. Types of Cable The following cables are in required for the Islander PLUS installation:

• Power cable – In accordance with local regulations


• LAN cable – CAT5e

• RS232/485/422/Tokheim/Pulser – Communication cable, twisted pair, separately shielded, low capacitance, e.g. Belden 8723 or equivalent.

NOTE

The shield should be connected to Ground in one side of the cable only, preferably on the Islander PLUS side.

• Antenna cable - Communication cable, Twisted pair, separately shielded, low capacitance (example – Belden 9729/30)

3-8. MECHANICAL PUMP – WIRING

3-8.1. General The wiring for mechanical pumps is provided in two modes:

• Table 3-2 and Table 3-3 list the wiring in the sequential order of the terminals. This table provides the signal name and a functional description of the signal.

• Figure 3-16 and Figure 3-17 show the wiring list for connection to the Terminal, as published in the Wiring Label added to the inner door. The Wiring Label follows the physical location of the wires in the Terminal Block, as shown in Figure 3-14 and Figure 3-15.

3-8.2. 4 – Mechanical Pump – Terminal Block - Pin-Out Connections The Islander PLUS Terminal Block connections for a 4-Mechanical Pump are listed in Table 3-2.

Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition

Terminal No. Signal Name Functional Description 1 TX-RS232 Data link to TLG Controller 2 GND-RS232 Transmit / Transmit/Receive Data Return /



Terminal No. Signal Name Functional Description 3 RX-RS232 Receive Data interface 4 RS-485 GND Data link to Density Probes Console Box / 5 RS-485_+ Density Display 6 RS-485_- Chassis / Positive / Negative connections 7 PULSER_1 Pulser Input – Nozzle 1 8 PULSER_2 Pulser Input – Nozzle 2 9 PULSER_3 Pulser Input – Nozzle 3 10 PULSER_4 Pulser Input – Nozzle 4 11 GND_1_P Nozzle Grounding – Nozzle 1 12 GND_2_P Nozzle Grounding – Nozzle 2 13 GND_3_P Nozzle Grounding – Nozzle 3 14 GND_4_P Nozzle Grounding – Nozzle 4 15 +12V_1_P +12 VDC Output to Pulser – Nozzle 1 16 +12V_2_P +12 VDC Output to Pulser – Nozzle 2 17 +12V_3_P +12 VDC Output to Pulser – Nozzle 3 18 +12V_4_P +12 VDC Output to Pulser – Nozzle 4 19 IN USE 1 A Handle Up - In Use signal input - Nozzle 1 20 IN USE 2 A Handle Up - In Use signal input - Nozzle 2 21 IN USE 3 A Handle Up - In Use signal input - Nozzle 3 22 IN USE 4 A Handle Up - In Use signal input - Nozzle 4 23 IN USE 1 B(-) Handle Up – AC In Use signal return - Nozzle 1 24 IN USE 2 B(-) Handle Up – AC In Use signal return - Nozzle 2 25 IN USE 3 B(-) Handle Up – AC In Use signal return - Nozzle 3 26 IN USE 4 B(-) Handle Up – AC In Use signal return - Nozzle 4 27 LINE 1 Pump control 220/110 VAC Input - Nozzle 1 28 LINE 2 Pump control 220/110 VAC Input - Nozzle 2 29 LINE 3 Pump control 220/110 VAC Input - Nozzle 3 30 LINE 4 Pump control 220/110 VAC Input - Nozzle 4 31 LOAD 1 Pump control output - Nozzle 1 32 LOAD 2 Pump control output - Nozzle 2 33 LOAD 3 Pump control output - Nozzle 3 34 LOAD 4 Pump control output - Nozzle 4 35 LINE IN (115/230v) Line Connection, Islander PLUS power input 36 NEUTRAL IN (115/230v) Neutral Connection, Islander PLUS power input



Terminal No. Signal Name Functional Description

37 GROUND IN Ground Connection, Islander PLUS power input 38 BARRIER 1 Connection to Safety Barrier for Nozzle 1 (1st wire) 39 BARRIER 2 Connection to Safety Barrier for Nozzle 2 (1st wire) 40 BARRIER 3 Connection to Safety Barrier for Nozzle 3 (1st wire) 41 BARRIER 4 Connection to Safety Barrier for Nozzle 4 (1st wire) 42 BARRIER 1 Connection to Safety Barrier for Nozzle 1 (2nd wire) 43 BARRIER 2 Connection to Safety Barrier for Nozzle 2 (2nd wire) 44 BARRIER 3 Connection to Safety Barrier for Nozzle 3 (2nd wire) 45 BARRIER 4 Connection to Safety Barrier for Nozzle 4 (2nd wire) 46 LAN 2 CONNECTOR RJ45, separate LAN connector for connection to external

network

3-8.3. 8-Mechanical Pump – Terminal Block - Pin-Out Connections The Islander PLUS Terminal Block connections for an 8-Mechanical Pump are listed in Table 3-3.

Table 3-3. Islander PLUS for 8 hoses Terminal Block -8 Mechanical Pump – Connections Definition

Terminal No. Signal Name Functional Description 1 GND_1_P Nozzle Grounding – Nozzle 1

2 GND_2_P Nozzle Grounding – Nozzle 2







17 +12V_1_P +12 VDC Output to Pulser – Nozzle 1






Terminal No. Signal Name Functional Description 22 +12V_6_P +12 VDC Output to Pulser – Nozzle 6



25 IN USE 1 A Handle Up – AC In Use signal input - Nozzle 1








33 IN USE 1 B(-) Handle Up – AC In Use signal Return - Nozzle 1








41 LINE 1 Pump control 220/110 VAC Input - Nozzle 1








57 NEUTRAL IN (115/230v) Neutral Connection, OrIC power input

58 LINE IN (115/230v) Line Connection, OrIC power input

59 GROUND IN Ground Connection, OrIC power input

9 PULSER_1 Pulser Input – Nozzle 1


Terminal No. Signal Name Functional Description 10 PULSER_2 Pulser Input – Nozzle 2







49 LOAD 1 Pump control output - Nozzle 1








Figure 3-14 Islander PLUS Terminal Block


Figure 3-15 Islander PLUS - Terminal Block (8 pumps)

Figure 3-16 Islander PLUS – Terminal Block –4 Mechanical Pump - Wiring List Label


Figure 3-17 Islander PLUS – Terminal Block – 8 Mechanical Pump - Wiring List Label

3-8.4. Mechanical Pump - Required Connections This paragraph describes the required wiring connections between the mechanical pump and the Islander PLUS. Figure 3-18 and Figure 3-19 show a schematic diagram of the connections between the Islander PLUS and the mechanical pump components. Figure 3-20 to Figure 3-22 show a detailed wiring diagram between the Islander PLUS terminal block and the pump components.

Pulse Input Wires: The dispenser outputs pulses to the system by means of the Pulser unit, installed in accordance with the manufacturer instructions. The Pulse rate


per volume (liter/gallon) is determined by the Pulser unit. It is programmed as a "factor" by the Head Office controller.

Handle Status Input Wires:

The handle signal is used to signal the system that the pump is "In Use" mode. When the dispenser handle is lifted this contact will close. This should signal the system that the pump is "In Use" or that the transaction ended.

Authorization Output Wires:

The dispenser requires an authorization signal from the Islander PLUS to start a sale transaction. Without this authorization signal, the electric valve (or pump) will not open and the sale transaction will not begin. The Islander PLUS switches the AC power signal to the valve. When the dispenser receives the authorization signal, fuel is flowing.

NOTE

All terminal block references and numbers in the following drawings (up to figure 3.27) refer to Islander PLUS with 4 pumps only.


Figure 3-18 Mechanical Pump – Single Dispenser Connections


Figure 3-19 Mechanical Pump – Twin Dispenser Connections


Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections


3-8.5. Mechanical Pump - Pulser Connections This paragraph describes the required wiring connections between the pulser in the mechanical pump and the Islander PLUS. The system can accept many types of pulsers, please contact Gasboy for more information. Two types of pulser can be found in trucks:

- Electronic pulser - Mechanical pulser Connect the Islander PLUS to the Pulser in accordance to its characteristics.

NOTE

Pulser should be installed in accordance with the pulser manufacturer's instructions. Some pulsers do not have a barrier, in that case you must add a pulser barrier! Barriers are not provided with Islander PLUS.

3-8.5.1. Electronic Pulser • 3-Wire Pulser - requires an external power source (12V) in order to operate

Figure 3-21 shows a schematic diagram of the connections between the Terminal Block and a 3-wire Pulser.

Figure 3-21 Terminal Block and 3-Wire Pulser – Wiring Connections

3-8.5.2. Mechanical Pulser • 2-Wire Pulser - powered by the Islander PLUS.


Figure 3-22 shows a schematic diagram of the connections between the Terminal Block and a 2-wire Pulser.

Figure 3-22 Terminal Block and 2-Wire Pulser – Wiring Connections


3-9. ELECTRONIC PUMP – WIRING DESCRIPTION

3-9.1. General The wiring in the Terminal Block differs in accordance with the type of electronic pump installed in the Home Base Station. There are several types of electronic pumps. The wiring of some of the major one are described below. The major pumps are:

• Tokheim

• Current Loop

• RS-485

• RS - 422 See Figure 3-23 for the wiring list label applied within the inner wall of the unit. This label consists of a wiring list table for the Terminal block. You are requested to connect the Forecourt equipment to OrIC in accordance with this table:

• The rows are the connection ports in the Terminal Block, in an ascending order.

• Each column is dedicated for a specific pump.

• Each cell defines the signal attached to the Terminal Block port.

The wiring of some of the major pumps is described below.


Figure 3-23 Islander PLUS Terminal Block – Wiring List Label


3-9.2. Tokheim Electronic Pump The wiring for the Tokheim electronic pump is provided as follows:

• Figure 3-24 shows the specific wiring connections between OrIC and the Tokheim pump nozzle, and the terminals that differ from the Mechanical Pump.

• Figure 3-23 shows the wiring list for connection to the Terminal, as published in the Wiring Label added to the inner door. The Wiring Label follows the physical location of the wires in the Terminal Block, as shown in Figure 3-14.

Figure 3-24 Tokheim Electronic Pump - Wiring Diagram


3-9.3. Current Loop Electronic Pump The wiring for the Current Loop electronic pump is provided as follows:

• Figure 3-25 shows the specific wiring connections between OrIC and the Current Loop pump nozzle, and the terminals that differ from the Mechanical Pump. The figure shows the serial connection between two Current Loop pumps and the Terminal Block.


Figure 3-25 Current Loop Electronic Pump - Wiring Diagram

NOTE

Recommended maximum distance is 2600'.


3-9.4. RS-485 Electronic Pump The wiring for the RS-485 electronic pump is provided as follows:

• Figure 3-26 shows the specific wiring connections between OrIC and the RS-485 pump nozzle, and the terminals that differ from the Mechanical Pump. The figure shows the prallel connection between two RS-485 pumps and the Terminal Block.


Figure 3-26 RS-485 Electronic Pump - Wiring Diagram


3-10. WIRING TO GENERAL COMPONENTS

3-10.1. General The following paragraphs show the specific wiring between the Islander PLUS Terminal Block and components common in both types of Home Base Stations, either with mechanical or electronic pump.

3-10.2. Connection to TLG Controller Figure 3-27 shows the required connection between the TLG controller in the site and the Islander PLUS Terminal Block.

Figure 3-27 Terminal Block – TLG Wiring Link

3-10.3. Connection to Journal Printer A journal printer (P/N M09680B090, see Figure 3-28) is available for journaling important operations such as all transactions on hard copy.


Figure 3-28 Journal Printer – General View

The Journal Printer is connected to the 8-Port Commverter through one of the channels of the RS-485 Module (P/N M09680B017) with a shielded twisted- pair cable (maximum length 100m). The Printer is provided with the SPRN interface board which includes an RS-485 connector (see Figure 3-29).


Figure 3-29 Journal Printer – Rear Panel


3-11. POST-INSTALLATION CHECKLIST

After completing the installation procedure, inspect carefully the connection between the Islander PLUS and the external power mains and the data sources.

In particular, pay attention to the following issues:

• Correct wiring

o Is all the wiring inserted in metal conduits?

o Is the AC and the DC wiring inserted in separate conduits, throughs and so on?

o Is the system/peripheral equipment powered on a separate dedicated breaker?

o Is the system grounded properly?

o Are the cables correctly routed in the Island?

o Are the communication lines under the maximum allowable distance?

RS-232: 50 feet (15m)

RS-485: 330 feet (100m)

Antenna wire:

• 330 feet (100m) for VIU

• 50 feet (15m) for FuelOpass

• Clean dirt and wire remnants

In case problems are detected after installation or during operation, repeat the post-installation checks listed above.

CAUTION

The OrPT display should not be exposed to direct sunlight. It is highly recommended to add an awning.

3-12. ISLANDER PLUS SETUP

Please refer to the SiteOmat Setup Manual P/N MDE-4817


0

SECTION 4 PRINTER

4-1. OVERVIEW

This section describes the (optional) Printer, its technical characteristics and its operation. The Printer (, P/N M09680B034) provides the customer a receipt once a refueling action is completed.

This section provides as well as instructions. It includes instructions on replacing the printer paper roll. In addition, this section includes several recommended steps for checking the printer operability.

Figure 4-1. Printer Module in Islander PLUS


The Printer provides visual and audio indications of its activities by means of two green LEDs and a buzzer. The visual and audio indications are used to indicate whether the printer runs out of paper or when there is approximately 25% of the paper roll left or when the receipt is ready.

Figure 4-2. Printer Module within Islander PLUS

4-2. DESCRIPTION

The Printer is a compact, ruggedized thermal printer suitable for the harsh environment of the gas station. It uses thermal printer paper only (55 gr., 57 mm width, 101 mm diameter).

The Printer is connected to the OrPT via an RS-485 link. The Printer requires a 24 – 26 VDC power supply input.

The Printer enclosure is designed to survive the harsh forecourt environment. It uses Spark Gaps protection for the links and 1.5 KV isolation.

The printer includes two sensors for paper usage alerts:

• Low paper sensor - activated when there is approximately 25% of the paper roll left

• End paper sensor - activated when printer paper runs out completely The paper usage and receipt indications include a buzzer sound and LED indicators or the combination of both.


4-3. MAIN COMPONENTS

The Printer consists of the following main items (see Table 4-1 and Figure 4-3).

Table 4-1. Printer Main Components

Item Functionality Printer Cutter Lock Shifts away from the printer and unlocks the cutter lock Printer Cutter Cuts the paper Thermal Printer Prints the text on the thermal paper by means of the thermal head Paper Lock Lever Push down to unlock the paper lock Electronic Board Printer controller

Figure 4-3. Printer Module– Main Components


4-4. PRINTER CONNECTOR PIN-OUT

The printer connector is located on the printer rear panel (see Figure 4-4). It provides the printer both the communication link and the power supply input (24 – 26 VDC). The power is supplied via an external power supply.Figure 4-5 and Table 4-2 show the Printer connector pin-out description.

Figure 4-4. Printer Connector

Figure 4-5. Printer Connector – Pin-out Description

Table 4-2. Printer Module Connector – Pin-out Description

Pin Number Functionality Description 1 VIN - DC Power Supply GND 2 VIN + DC Plus Voltage 3 SLN Not Applicable 4 GND RS-485 GND 5 485 - RS-485 Communication Line 6 485 + RS-485 Communication Line


4-5. INDICATORS

The printer module includes a buzzer to provide audio display on the following events:

• Printing is in progress

• Paper alerts – paper run out or approximately 25% left (see paragraph 4-8.1)

• Receipt ready The printer also includes LEDs (see Figure 4-3) in its front panel for communication monitoring.

At turn on, the LEDs and the buzzer are activated for a short period of time.

4-6. SPECIFICATIONS

This section lists the physical, electrical and environmental specifications of the printer, as follows:

Supply Voltage: 24 - 26 VDC

Power Consumption: Standby 15 W Typical 60 W

Communication Interface: RS-485 – 9600 bps Half-Duplex

Paper Type: Thermal, 57 mm (W), 55 gr., 101 mm diameter

Paper Maximum Printing Area Width:

54 mm

Maximum Printing Speed: 120 mm/sec.

Autocutter: Integrated


4-7. INSTALLATION PRINTING PARAMETERS

4-7.1. Jumpers Configuration The Printer includes jumpers that enable setting the RS-485 address and selecting the number of copies automatically produced during each printout.

The jumpers are set in a matrix of 8 jumpers, where the five first jumpers determine the RS485 address. The last three jumpers determine the number of copies. Figure 4-6 shows the jumpers default configuration, where the RS485 Address = 70 Hex. Figure 4-7 provides examples of jumpers configuration and the corresponding RS485 address.

CAUTION

On a single RS485 bus, each device must be assigned a different address.

Figure 4-6. Printer Module – Jumpers Default Configuration


Figure 4-7. Printer Module– Jumpers Configuration Examples

4-7.2. Parameters for Printing The Printer features two printing modes, as determined by the controller in the Head Office:

• Print only when the door is lifted – Paper save mode

• Print always

4-7.3. Cutter The paper cutter may be set to one of three modes, as determined by the controller in the Head Office:

• No Cut

• Full Cut

• Partial Cut

4-7.4. Printing the Status Report The G2 Printer enables producing a printer status report. Proceed as follows:

1. Turn off the printer

2. Open the printer’s service door

3. Turn on power to the printer

4. The G2 Printer prints a status report.


4-8. PAPER ROLL REPLACEMENT

4-8.1. General The Printer Module is a thermal printer and uses thermal printer paper only. The Printer is equipped with two sensors for paper usage alerts as follows:

• Low paper sensor - warns when there is approximately 25% of the paper roll left

• End paper sensor - warns when printer paper runs out completely

4-8.2. Paper Roll Replacement This procedure applies when the printer is on-line and connected to a power source. In that state the printer pulls the paper automatically and cuts it when paper feeding is completed.

Perform the following procedures to replace the printer paper roll:

1. Open the Islander PLUS front panel with the key

2. Lift the printer door and hold

3. Release the green paper-lock lever

4. Release the attached paper.

Figure 4-8. Door Handle and Paper Lock Lever


Figure 4-9. Printer - Paper Replacement

5. Press the paper roll pivot (see Figure 4-9) and release pivot

6. Lift the paper roll pivot and remove the paper roll

7. Prepare a new paper roll facing down

8. Press the paper roll pivot pawl and slide back the new paper roll when it is facing down

NOTE

Insert the paper as shown in Figure 4-9, with the thermal (shining) side facing out.


NOTE

Verify that the green paper-lock lever is closed

9. The paper can be inserted into the printer automatically or manually.

4-8.2.1. Automatic Insertion of Paper Proceed as follows:

NOTE

Verify that the green locking handle is closed

10. Slide the paper gently along the grooves until the printer motor starts pulling the paper. At the end of the process the paper will exit from the cutter.

NOTE

Do not pull the paper. The printer pulls the paper automatically and cuts it.

11. Slide the paper from the printer door slice.

4-8.2.2. Manual Insertion of Paper Proceed as follows:

1. Release green paper-lock lever (see Figure 4-9).

2. Slide the paper gently along the grooves until the paper exits from the cutter.

3. Lock back the green locking handle and let the printer fall back in its place. 4. Slide the paper from the printer door slice and close the door.


4-9. PRINTER CLEANING

4-9.1. General The Printer should be cleaned periodically at short intervals, due to the harsh environment of the Home Base Station where it operates.

Proceed as follows:

• Clean the Printer front panel and other devices with a damp cloth only.

CAUTION

Clean the printer front panel with a damp cloth only. DO NOT use any solvents such as thinner or benzene to clean the printer front panel.

4-9.2. Thermal Printer Head –Cleaning Instructions

4-9.2.1. General This paragraph provides the cleaning procedures for the thermal printer head in the printer. The cleaning is performed with the Printer Cleaning Card. The Printer Cleaning Card is provided in a protective package to prevent dryness.

The cleaning procedure shall be performed whenever the "Print Fade Away" is observed all over any receipt, and even when observed in some areas of the receipt.

NOTE The cleaning procedure must be done quickly as the substance in the cleaning card may fade away in a short time.

4-9.2.2. Cleaning Procedures Proceed as follows:

1. Turn on the printer

2. Insert the normally used paper in the printer slot, and make sure that the printer guillotine cuts the

paper protruding from the printer

NOTE This procedure ensures that the guillotine will not cut the cleaning card after a cold start up.

3. Press the green paper-lock lever and pull out the paper from the printer


Figure 4-10. Pressing Paper-Lock Lever

4. Remove the cleaning card from its packaging

5. Insert the cleaning card manually into the printer paper slot (roller)

6. Press the green paper-lock lever back to its initial state

7. Push and pull the cleaning card so that the printer head is cleaned

8. Verify that the cleaning card gets out of the printer guillotine without being affected

NOTE Since the width of the Cleaning Card is narrower than the printer thermal paper, the cleaning procedure should be repeated twice - First, the cleaning card should be tilted to the far right of the printer paper slot. Next, the cleaning card should be tilted to the left.

9. Verify that the cleaning card rolls out from the paper slot

10. Pull the cleaning card gently, and repeat procedures 5 to 9 with the same cleaning card now tilted to

the left

11. Repeat procedures several times – right and left – in order to obtain the best cleaning results

12. Stop when the cleaning card is dry

13. Press the green paper-lock lever and insert thermal paper in the printer from the paper roll

14. Press the green paper-lock lever back

15. Print a receipt with at least ten (10) rows of text. Check readability and verify the text font is proper

visually.


16. If readability is still poor all over the receipt, or even part of it, repeat cleaning procedures with a

new Cleaning Card.

4-10. TROUBLESHOOTING

4-10.1. General In case problems are detected after installation or during operation, repeat the installation procedures.

CAUTION

If the problem persists, contact Gasboy. Under no circumstances, attempt to dismantle the printer. The Printer Unit repair should be performed at Gasboy laboratories only.

4-10.2. Troubleshooting The Printer indicates a faulty operation by means of its Leds on the front panel. Perform the recommended corrective actions to troubleshooting the failure and to repair the unit

Table 4-3. Printer Troubleshooting

No. Failure Indication Probable Cause of Failure Recommended Corrective Action

1 Left-hand green Led flickers constantly

The Printer Unit is stuck 1. Check paper roll

2. Replace unit

2 Right-hand green Led flickers constantly

The Printer Unit is stuck 1. Check paper roll

2. Replace unit

NOTE

See paragraph 5-2.3 for detailed troubleshooting procedures.

4-10.3. Releasing Jammed or Crumpled Paper This procedure applies when a paper is crumpled or jammed inside the printer. In this case the printer is disabled and all actions should be performed manually. Use the following procedure to release the paper.


NOTE

Do not attempt to release the paper using sharp objects such as a knife or a screwdriver. Doing so will damage the printer paper cutter and void your warranty. Do not attempt to pull the paper from the printer. Doing so will damage the printer.

Perform the following procedures to release the paper when a paper jam occurs.

1. Open the printer front panel with its key.

2. Pull up the printer cover and release the green locking handle.

3. Pull out any crumpled paper

4. Clean the printer area from any paper remnants

5. Push the green paper-lock lever to its original state.

6. Slide the new paper roll into the Pivot Handle. Make sure the paper roll you insert is not crumpled.

7. Insert the paper into the printer either automatically or manually.

4-11. THERMAL PAPER STORAGE

The thermal paper is sensitive to the environmental conditions where it is stored.Just as well, the Printer Module operation is sensitive to the type of paper inserted. Proceed as follows:

• Use the right paper as specified.

• Insert the paper edge to the printer.

• Insert the paper in the correct side.

• Store the paper in a dry, shaded area, at 64 to 68 ºF (18 to 20 ºC).

• During paper replacement, avoid dust, moisture and rain.

NOTE

Dispose of wet or moisten paper. It may cause jamming in the printer


0

SECTION 5 MAINTENANCE

5-1. GENERAL

This section provides general maintenance instructions for the Islander PLUS as well as a comprehensive troubleshooting guide.

5-2. TROUBLESHOOTING

The next paragraphs provide a list of common pump/system problems which may be encountered when using the Islander PLUS system, as well as corrective action instructions, covering the following problems related to the system and its peripherals:

• Islander PLUS (see paragraph 5-2.1)

• OrPT (see paragraph 5-2.2)

• Printer (see paragraph 5-2.3)

• Communication to peripherals (see paragraph 5-2.4)

5-2.1. Islander PLUS Troubleshooting The Islander PLUS troubleshooting procedure and consequent corrective actions are described in Table 5-1.


Table 5-1. Islander PLUS Troubleshooting

Fault Probable Cause Checks Corrective Action

System is down

LCD display is blank

Doesn't accept Key/Card/Keypad input

No communication

OrCU LEDs are not lit

Islander PLUS main switch is off

Turn main switch on

No 115 VAC feed to the unit

1. Check power at Distribution Box

2. Check cabling from Distribution Box to the unit

3. Verify that power cable is properly connected to unit terminal block

4. Is 115V measured at the power input terminal block?

Correct wiring problems if 115VAC is not measured

Power failure Does the unit shut down immediately after being turned on?

1. Check for shorts in the power line cable

2. Check grounding

Circuit breaker is off

Is breaker off or tripped? Turn breaker on, if off

Is 115V being switched through breaker?

Replace breaker if 115V is not being switched

Is 115V measured at the power input terminal block?

Correct wiring problems if 115V is not measured

Does the breaker turn off immediately after being turned on?

Check for loads or shorts in the power line

Internal fuse blown Check the two pico fuses (red wires) at the bottom of the power supply using an ohmmeter

Replace the fuse if it is blown

Power supply failure

Verify that green LED on power supply is lit

1. Replace mini fuse

2. Replace power supply


Table 5-1. Islander PLUS Troubleshooting (Cont'd)


System is down (Continued)

Doesn't accept Key/Card/Keypad input No communication

OrPT setup is incorrect

Login into OrPT and check communication parameters

1. Set communication parameters

2. Submit and check again

OrCU setup is incorrect

Check OrCU setup:

• OrPT bus

• OrPT parameters

• OrCU Administrator parameters

1. Set communication parameters

2. Save and reload

3. Check again

No Magnetic Card response

Dirty or faulty Magnetic Card reader

Faulty Magnetic Cards

1. Visually check Magnetic Card reader

2. Present several Magnetic Cards

1. Clean Magnetic Card reader

2. Replace Magnetic Card reader

3. Replace OrPT

No Key response Loose cable

Faulty key receptacle

1. Visually check Key receptacle

2. Insert several keys

1. Replace Key receptacle

2. Replace OrPT

Customer display is blank

Faulty Customer display

Faulty OrPT

Verify that customer display board is properly connected to OrPT interface board

1. Replace customer display

2. Replace OrPT

Mechanic pump does not refuel

Pump does not supply fuel

Device is not allowed to refuel

1. Open the pump from SiteOmat Status screen

2. Verify that the vehicle/device has no limitation in FHO setup

Enable the device to refuel




Mechanic pump does not refuel (Continued)

Pump does not supply fuel

Pump setup is incorrect

Check pump setup:

• Pump server

• Buses

• Prices

• Pulse rate

1. Set pump parameters

2. Save and reload

3. Check again

Faulty connection to pump

Check Control cables from Islander PLUS to pump

Make good electrical connection

8-port failure Verify that Power LED is lit

If it is off, use a voltmeter to check power supply to the unit: If power supply is OK, then replace the 8-port board. If power supply is faulty, replace the power supply

Verify that Control red LED on MPI-C board is lit

1. Replace MPI-C board

2. Replace 8-port

Pump malfunction Turn the Islander PLUS bypass switch on, lift the nozzle and check that the pump supplies fuel

If the problem persist:

1. Check Handle-On Switch

2. Repair pump

Handle-on switch problem

Is the In Use red LED in MPI-C board lit when nozzle is lifted?

1. Check In Use cable and repair, if necessary

2. Check Terminal wires and repair, if necessary

3. Check The In Use Switch in the pump and repair, if necessary





Pump is authorized but Call state is not detected (nozzle icon in SiteOmat Status screen does not display Call state)

Faulty in-use switch in pump

Power off the pump, using a ohmmeter measure the switch in on and off states

Replace pump switch in cases where no short was detected

Faulty connections Check In Use cable

Check In Use terminal block connections

Make good electrical connection if faulty one exists

Faulty In Use terminal block

Replace In-use terminal block

Faulty MPI-C board Verify that the Call red LED is lit when nozzle is lifted

If the red LED is not lit, replace MPI-C board. If the led is lit, the problem is external to the controller

Faulty 8-Port Replace 8-Port

Pump is authorized, pump motor is running, but no fuel is supplied

Faulty solenoid valve

Faulty pump

Does the pump solenoid valve produce a clicking sound?

1. Replace valve

2. Repair pump

Payment device (card, key, tag, Fuel Ring) is not accepted

Communication fault between OrPT and SO

1. Check LAN cable

2. Check OrPT setup

3. Check SO setup

1. Replace LAN cable, if necessary

2. Set OrPT parameters properly

3. Set SO parameters properly

Communication fault between FHO and SO

1. Check connection path with FHO

2. Verify that the station is available and synchronized with FHO in FHO Stations Status screen

Repair communication between FHO and SO, providing a reliable communication line





Payment device (card, key, tag, Fuel Ring) is not accepted

Device was not defined/incorrectly defined in FHO

1. Login into FHO as Fleet manager

2. Check that the device is defined

3. Check device parameters

4. Check that device rules does not limit refueling

Define the device parameters in FHO properly

Device limit was passed

Verify that the device is within the limits of its rule

For testing only, remove any rule associated to this device

Device was set as Driver

1. Login into FHO and go Devices Management

2. Select the specific device and check if it was configured as Driver

Change the device setting to Vehicle

Device is blocked 1. Login into FHO and go to Devices Management

2. Check the status of the device in the Status column in the Devices grid (blocked/unblocked)

Change device status to Unblocked




Pump is Authorized and refueling but volume remains zero

Pump is refueling but volume remains zero

Pulse factor is zero Check SO pump setup Change Pump Settings to correct the factor for the relevant pump

Faulty MPI-C board

Faulty pulser

Disconnect the pulser and short the pulse-in wires to simulate pulses

If pulses are received during refueling, replace pump pulser

If not, replace MPI-C board

No control on refueling

Pump is refueling without any control

Pump is in bypass Verify that Islander PLUS bypass switch is off

Turn bypass switch off, if on

Faulty SSR Replace the relevant SSR unit inside the Islander PLUS

If an external relay is used to control the pump/valve, it may be stuck due to a small current leak

Add a snubber (capacitor + resistor) in parallel to relay input


5-2.2. OrPT Troubleshooting The OrPT troubleshooting procedure and consequent corrective actions are described in Table 5-2.

Table 5-2. OrPT Troubleshooting


OrPT display is not lit

OrPT display is blank

Internal fuse blown Check the mini fuse at the bottom of the power supply using an ohmmeter

Replace the fuse if it is blown


Verify that green LED on power supply is lit

Replace power supply

Faulty OrPT Replace OrPT

OrPT does not accept card

OrPT display does not respond correctly to cards

Bad card Present several cards to see if problem is consistent

Replace card and test again

Dirty card reader Verify that the card reader is clean

Clean the card reader using a cleaner card and try again

OrPT is busy performing another task

Verify that the display presents the idle message

1. Press Cancel

2. Present the card while the idle message is displayed

Faulty card reader Replace OrPT

OrPT does not accept RFID tag

OrPT display does not respond correctly to tags

Bad tag Replace tag and test again

Tag is not close to the OrPT antenna

Bring the key close to the antenna located on the red circle


Table 5-2. OrPT Troubleshooting (Cont'd)


OrPT does not accept RFID tag (Continued)

OrPT display does not respond correctly to tags



1. Press Cancel

2. Present the tag while the idle message is displayed


OrPT does not accept Gasboy key

OrPT display does not respond correctly to keys

Bad key Replace key and test again

Faulty connection

Open the Islander PLUS door and check the flat wire which connects key reader to the OrPT terminal




1. Press Cancel



OrPT does not respond to keypad entries

Pressing the keypad buttons does not generate any sound and does not affect the display

Dirty keyboard Clean the keyboard

Damaged keypad Visually check the keypad surface for any damage

Replace keypad if any damage is found



1. Press Cancel






OrPT does not accept HID card/key

OrPT display does not respond correctly to HID cards/keys

Bad card/key Replace key and test again

Faulty connection Open the Islander PLUS door and check the cable which connects HID reader to the OrPT terminal


OrPT is busy in another task

check that dsplay present the idle message

1. Press Cancel

2. Present the card/key while the idle message is displayed


OrPT displays "No communication" message

Communication disconnected

Open Islander PLUS door and check LAN cable from OrPT to 5-LAN switch

Make correct and good connection if it was incorrect

5-LAN switch is dead

No power to 8-Port Are 8-Port LEDs lit/blinking?

1. Check power connector to 8-Port

2. Replace 8-Port

Is 5-LAN switch LEDs are lit/blinking?

1. Check connection of LAN switch on 8-Port. It should be inserted in a socket on the 8-port main board

2. Replace 5-LAN switch board

OrCU problem Faulty connection Check power to OrCU Verify that the white power connector is plugged into the OrCU POWER socket


Is power supply on? 1. Replace fuse

2. Replace power supply

Faulty OrCU Replace OrCU




OrPT displays "No communication" message (Continued)

OrCU problem Incorrect SiteOmat setup

Verify that OrPT parameters defined in SiteOmat match the values presented in OrPT display at power-on

Set the OrPT bus and parameters according to OrPT values presented in OrPT display at power-on

Incorrect OrCU setup

Login into OrPT and verify that all parameters match OrCU setup

Login into OrPT and change setup so it suits OrCU setup


5-2.3. Printer Troubleshooting The Printer troubleshooting procedure and consequent corrective actions are described in Table 5-3.

Table 5-3. Printer Troubleshooting


Printer does not print

No printing at the end of transaction

Printer is out of paper

Check paper roll Replace paper roll

Paper Lock(green) switch is open

Check Paper Lock switch position

Close Paper Lock switch

Jammed paper Release paper

Incorrect SiteOmat setting

Check SiteOmat printer settings

Set printer parameters properly

Faulty Printer Replace Printer

No power to Printer

No printing, printer doesn't produce a beep sound at power-on

Power cable is disconnected

Check power cable connections between the printer and OrPT


Faulty power supply Check power supply outputs using a digital Voltemeter. the output voltage should be 24 VDC

Replace power supply


No communication to Printer

RS485 cable is disconnected

Check the RS485 cable connections between the printer and OrPT


LAN Cable is disconnected

Check the OrPT LAN cable



Table 5-3. Printer Troubleshooting (Cont'd)


No communication to Printer (Continued)

Incorrect Address settings

Check printer address jumpers (no Jumper means address is 70HEX)

Set the correct Hex address in SiteOmat


Paper is not automatically cut

Paper is not being cut at the end of the printing

Incorrect SiteOmat setting

Check SiteOmat printing settings

Set SiteOmat printing settings accordingly

Faulty Printer cutter Replace Printer cutter



5-2.4. Communication Troubleshooting The troubleshooting procedure for problems related to communication to peripherals and consequent corrective actions are described in Table 5-4.

Table 5-4. Communication Troubleshooting


No communication between FHO and SO controller

No connection to the station from FHO Stations screen

Cabling issue Visually inspect the network cable to LAN2

1. Verify that LAN2 Port LED is blinking

2. Unplug the cable and plug it back in

3. Replace LAN cable, if necessary

4. If the cable is in good condition, contact the IT department to confirm that the switch/router connected to the LAN cable is properly set

5. Check the Controller network settings (IP addresses, mask, gateway, etc.)

No communication to the pumps (8-port CommVerter)

"Warning" signs displayed for all pumps on the SiteOmat Status screen

Incorrect 8-port CommVerter setup

Check the physical connection of the 8-port CommVerter to the local network (5-port switch activity)

1. If no activity on the LAN port connected to the 8-port CommVerter, replace the short Ethernet cable or/and change the LAN port to confirm normal operation


Table 5-4. Communication Troubleshooting


No communication to the pumps (8-port CommVerter) (Continued)

All pumps are showing "warning" signs on the SiteOmat Status screen

Incorrect 8-port CommVerter setup

Check network connectivity by performing a "ping" command locally or remotely, through PuTTY application

2. Check the status of the LEDs on the 8-port (upper right corner of the board): the first and the third LED should be lit to confirm power and network connection, while second LED should blink to confirm network activity. The last two LEDs (from left to right) should be blinking constantly, to confirm communication with controller

3. In cases where all LEDs are lit periodically (every 30 seconds) the unit is resetting due to connection loss to the controller

4. Reset the IP and reconfigure the Pump Server (PS) in controller setup

No communication to nozzles (Wireless Gateway)

Can’t read the vehicles and/or no authorization at the pumps

1. No communication to Wireless Gateway

2. Incorrect nozzle readers setup

Check the physical connection of the Wireless Gateway to the local network (5-port switch)

Check the Wireless Gateway network settings

1. If no activity on the LAN port, check the cable and/or change the port on the 5-port switch

2. Remove the top cover to access the Wireless Gateway and check the status of the LEDs


Table 5-4. Communication Troubleshooting (Cont'd)


No communication to nozzles (Wireless Gateway) (Continued)

Can’t read the vehicles and/or no authorization at the pumps

Check the programming of the WNRs

3. Connect to the Wireless Gateway through the 9-pin serial port and open Hyperterminal (115200, 8, None, 1, None), reset the Wireless Gateway and follow the startup messages to find the IP address.

No communication to OrPT

OrPT displays “No Host Communication” message

Incorrect OrPT communication and/or physical network setup

Check the network cable for activity on 5-port switch

Ping the OrPT to confirm proper settings in the controller

1. If no activity on the LAN port, check the cable and/or change the port on the 5-port switch

2. Reset the OrPT and follow the main screen messages for the IP address

3. Change the configuration of the OrPT according to the site setup (controller)

No communication to the TLS

"Warning" signs displayed for all tanks on the SiteOmat Tank Status screen

Incorrect TLS communication and/or physical network setup

Ping the TLS from controller (PuTTY)

Check network/RS-232 port on the TLS

1. If no response to the ping command from controller, check the IP address of the TLS. Contact the IT department in cases where there is no communication to the unit (if connected over the WAN)

2. Check the physical layer (Ethernet cable) and port activity to the TLS (if connected over the LAN)


Table 5-4. Communication Troubleshooting (Cont'd)


No communication to the TLS (Continued)

"Warning" signs displayed for all tanks on the SiteOmat Tank Status screen

3. Connect to the TLS network interface through telnet (“telnet XXX.XXX.XXX.XXX 9999”) and check the configuration. Confirm proper network settings and serial port settings (should be 9600, 8, None, 1, None and D6 as connection type). By default the port is set to 10001 – confirm similar setting of the TLS bus in the controller setup

5-3. CLEANING

5-3.1. General The Islander PLUS itself as a standalone unit should be cleaned periodically at short intervals, due to the harsh environment of the Home Base Station where they operate.

5-3.2. Cleaning The following instructions are valid for the OrPT front panel and the Islander PLUS pedestal.

• Clean the OrPT front plastic panel with a cloth lightly moistened with WD-40 or any other similar lubricant.

• Clean the pedestal metallic enclosure using a damp cloth and cleaning spray.

CAUTION DO NOT use any solvents such as thinner or benzene.

5-3.3. Magnetic Card Reader – Cleaning Instructions The Card Reader shall be cleaned periodically, preferably once every two (2) weeks, in order to ensure proper operation. The cleaning purpose is to remove any dust or foreign body that may harm the reader and consequently prevent the completion of a sale.

Proceed as follows:


• Remove the cleaning card from its packing

• Insert the cleaning card all the way in the Reader, and then pull it out slowly.

• Perform the previous procedures several times, until the card gets dry

• Insert any magnetic card, and verify that its stored data is read by the Magnetic Card Reader.

5-3.4. Printer – Cleaning Instructions Refer to paragraph 4-9.


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SECTION 6 GLOSSARY

6-1. FUELOMAT GLOSSARY

ComVerter LAN/232/485/422/C.L./Tokheim Communication Converter

DataPass Vehicle Data Transceiver

FHO Fleet and Fuel Head Office

MPI Mechanical Pump Interface

MPI-C Mechanical pumps Interface Card

NIS Non-Intrinsically Safe

NR Nozzle Reader (Wireless Nozzle Reader unit)

OrCU Orpak embedded Controller Unit

OrCU 3000 Orpak site Controller Unit

OrIC Orpak Island Controller

OrIT Orpak Island Terminal

OrPT Orpak/Outdoor Payment Terminal (display, Keyboard, key reader, magnetic card reader, LED’s, buzzer; install in fueling area)

OrTC Orpak Tanker Controller

OrTR Orpak Tag Reader

POS Point Of Sale

SAM Security Application Module (security card in the VIT/UPI)

TLS Tank Level System (measuring fuel tank level in station)

VBIS Vehicle Bus Information System

VIS Vehicle Information System


VIT Vehicle Information Transceiver

VIU Vehicle Identification Unit (VIU3/35/45)

WGT Wireless Gateway Terminal

μVIT ( = micro VIT) Mini VIT with RF/LAN/485 communication

6-2. COMMUNICATION GLOSSARY

Access Point An internetworking device that seamlessly connects wired and wireless networks together.

Ad Hoc A peer- to-peer wireless network without Access Point. A group of wireless clients consistent an independent wireless LAN.

Backbone The core infrastructure of a network, the portion of the network that transports information from one central location to another central location. The information is then off-loaded onto a local system.

BSS Basic Service Set. An Access Point associated with several wireless stations.

DES LANs with high level of security. A method of data encryption.

DHCP Dynamic Host Configuration Protocol.

ESS Extended Service Set. More than one BSS can be configured as an Extended Service Set. An ESS is basically a roaming domain.

ESSID Extended Service Set Identifier. The length of the ESSID information is between 0 and 32 octets. A zero-length identifier indicates the broadcast SSID.

Ethernet A popular local area data communications network, originally developed by Xerox Corp., which accepts transmission from computers and terminals. Ethernet operates on 10/100 Mbps transmission rate over shielded coaxial cable or over shielded twisted pair telephone wire.

Infrastructure An integrated wireless and wired LAN is called an infrastructure configuration.

LAN Local Area Network

Roaming A function that allows one to travel with a mobile end system (wireless LAN mobile station, for example) through the territory of a domain (an ESS, for example) while continuously connecting to the infrastructure.

SSID Service Set Identifier (SSID) is the network name used by the Wireless LAN. The length of the SSID information is between 0 and 32 octets.

TCP/IP Communication protocol used in Ethernet/Internet.

Triple DES A method of data encryption.


WAN Wide Area Network

WEP Wired Equivalent Privacy. The optional cryptographic confidentiality algorithm specified by IEEE 802.11 used to provide data confidentiality that is subjectively equivalent to the confidentiality of a wired local area network (LAN) medium that does not employ cryptographic techniques to enhance privacy.

WG Wireless Gateway


APPENDIX A SITE SURVEY

STATION INFORMATION FORMS (To be filled during site survey)

Home Base Station

Date:_______

Prepared by:

Name:______ e-mail:__________ Phone:_______

Gas station info: Company name __________________ Tel: ____________ Contact person: __________________ Mobile Phone:_____

Fax: ____________

A. STATION INFORMATION

• Power line � 110VAC � 220VAC �Other____

• Power stabilizer/UPS available? ______________ Spec _________________

• Station name __________________________

• Location _________________________

• FCC Tel. No._____________ / Direct connect _____________

• Internet connectivity method (Modem, GPRS, cable, frame relay,

SAT,ADSL etc) ______________

• Number of dispensers (to be connected to FCC): ______

• Number of nozzles (to be connected to FCC): ______

• Number of Authorizers required _____


• TLS type_________________________

B. STATION MODE OF OPERATION

How do the pumps being authorized?

o Console

o Preset Money, Preset Volume

o From office

o Auto-authorized (free mode)

Do they provide receipts? Y/N (attach samples)

D. DISPENSER INFORMATION (CONNECTED TO FCC)

• Dispenser No._________________

• Manufacturer_________________

• MODEL___________________________

• TYPE:

� Mechanical: have electronic pulse out ?_____ Pulses/liter factor_________

� Electronic (protocol communication)____________

• Pump link – Current Loop, RS-485, Other ___________________

• Type of wire used for pump link; is it shielded ?______________

• Number of CPU Heads per dispenser ______________________

• Number of Nozzles __________________

• Decimal Point: Price________ Volume _______ Total _______

• How many different dispenser TYPES in the station?_______________

E. NOZZLE EQUIPMENT-1

• HOSE SIZE : � 3/4” � 1” � other________

• Hose Length ___________________


• Break Away : Yes No Location on the hose:________

• Vapor Recovery: Yes No

• NOZZLE/HOSE THREAD: � INCH (NPT) � MILLIMETER (DSP)

• HOSE THREAD : � Male � Female

• MANUFACTURER: ___________________

• MODEL: ___________________________

• DIAMETER OF NOZZLE SPOUT: ________

•

F. NOZZLE EQUIPMENT-2

• HOSE SIZE : � 3/4” � 1” � other________

• Hose Length ___________________

• Break Away : Yes No Location on the hose:________

• Vapor Recovery: Yes No

• NOZZLE/HOSE THREAD: � INCH (NPT) � MILLIMETER (DSP)

• HOSE THREAD : � Male � Female

• MANUFACTURER: ___________________

• MODEL: ___________________________

• DIAMETER OF NOZZLE SPOUT: ________

G. CONDUIT

Exists _________ Can be used ____________ Sealed ______________

Need new conduit _____________ Type of surface ________________

Tanks

Is tank gage reading required � Yes � No

How many tanks and what type ?_______________________________________


Do they use a TLS, what type ?_________________________________________

How do they read tanks today ?_________________________________________

H . Site inspection (draw the station and attach photos):

Pay attention to the following:

• Photos of : Nozzle, Hose, Pump, Isle, Station

• Distances

• Location of office (to install FCC), Pumps, Tanks, Isles etc.

• Broadcast antennas, Power line cables/tower, Generators etc.

Color scheme and Graphics that may affect the appearance of our equipment at the

station (like the color of OrPT Box)


0

APPENDIX B WIRING DIAGRAM

This appendix provides the wiring diagram of the Islander PLUS, as follows:

• Figure B-1 Islander PLUS – Wiring Diagram (Mechanical Pump)

• Figure B-2 Islander PLUS – Wiring Diagram (Electronic Pump)

• Figure B-3 Islander PLUS 8 – Wiring Diagram (Mechanical Pump)


Figure B-1 Islander PLUS – Wiring Diagram (Mechanical Pump)


Figure B-2 Islander PLUS – Wiring Diagram (Electronic Pump)


Figure B-3 Islander PLUS for 8 hoses – Wiring Diagram


APPENDIX C HID ASASEMBLY INSTALLATION

INTRODUCTION

This appendix describes how to install the HID unit in the home base pedestal.

Make sure you have the complete HID installation kit P/N M09680B040. The installation kit includes the following items:

Table 1. HID Installation Kit Items

P/N Name Quantity

813118001 HID Assy 1

814982600 HID Holder 1

815102500 NUT, M3 4

815201300 SCREW, M3x8,FLAT HD.CROSS RECE 4

815302200 WASHER, SPRING M3 4

817310940 LABEL, HAND TAG 1

817418000 INSTL.INSTR.-HID KIT SET 1


Figure 1. HID Unit and Connector

Figure 2. HID Holder and Nuts


INSTALLATION INSTRUCTIONS

CAUTION

Only a technician authorized to work on Orpak's pedestals can perform HID installation. The technician must work in accordance with the instruction provided in the Islander PLUS installation manual MDE-4811.

1. In cases where installing the HID unit in Islander PLUS 8-hoses pedestals, remove the OrCU module from the internal side of the pedestal door (see Figure 3) as follows:

a. Unscrew four 4X10 screws and washers securing the OrCU module to the holder b. Remove the OrCU holder by unscrewing three M3 flat screws and spacers

Figure 3. OrCU Location in Islander PLUS 8-Hoses


2. Cut and remove the rectangular metal plate from the internal side of the pedestal door. Use a

cutter to cut the six connecting points holding the plate to the door. See arrows (Figure 4) for location of the connecting points that need to be broken. Make sure no sharp edges remained after cutting and the surface is smooth. Discard the metal plate.

Figure 4. Rectangular Plate Connecting Points Location

3. Remove the HID back cover by opening the side screw (see Figure 5).

Figure 5. HID back cover Removal


4. Attach the back cover to the HID holder using four screws (P/N 815201300) as shown in Figure 6. Tighten the screws using Phillips type screwdriver.

Figure 6. Attaching Back Cover to HID Holder

5. Run the connector cable through the hole in the holder from inside out as shown in Figure 8. Install the back cover, with the holder, in the HID unit using the side screw.

Figure 7. Assembled Back Cover and HID Holder


6. Place the unit in the hole while the HID logo faces the front of the pedestal and the cable facing the back. Place the four holder holes on the four studs soldered to the door and tighten the nuts and washers (P/N 815102500 and 815302200, respectively). In cases where installing the unit in Islander PLUS 8-hoses pedestals, proceed as follows:

a. Secure only three nuts and washers, excluding the nut in the upper left corner b. Place a spacer on the upper left corner stud (see Figure 9) c. Place the two remaining spacers and install the OrCU holder d. Secure the OrCU holder, utilizing three M3 flat screws e. Install and secure the OrCU module to the holder, utilizing four 4X10 screws and

washers

Figure 8. HID Mounted on Pedestal Door

Figure 9. Upper Left Corner Spacer

7. Connect the HID connector to the designated connector in the OrPT (for OrPT versions 5.24.03 and up only) and tighten the connector screws.


Figure 10. HID Connector Inserted to OrPT Connector

8. Adjust the cable ties to make sure the cable is fixed in its position. 9. Stick the ellipse hand tag label (P/N 817310940) on the front black decorative panel (see Figure

11). The hand tag label should be placed horizontally in the middle of the pedestal, 115 mm (4.528 inches) away from the side end, 53 mm (2.087 inches) away from the bottom line of the OrPT line).


Figure 11. Placing Hand Tag Label on Pedestal


Islander PLUS and ICR PLUS INSTALLATION MANUAL

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