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
Paragraph
Page
SECTION 1
GENERAL DESCRIPTION
1-1. 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
Islander PLUS Manual
i
TABLE OF CONTENTS
Paragraph
1-8.
1-9.
1-9.1.
1-9.2.
1-10.
1-11.
1-12.
SPECIFICATIONS ............................................................................................................. 22
STANDARDS..................................................................................................................... 23
Communication Standards ............................................................................................. 23
Security Standards .......................................................................................................... 23
MANUAL STRUCTURE ................................................................................................... 24
USING THIS MANUAL .................................................................................................... 25
REFERENCES ................................................................................................................... 26
SECTION 2
2-1.
2-2.
2-2.1.
2-2.2.
2-3.
2-4.
2-4.1.
2-4.2.
2-4.3.
2-4.4.
2-4.5.
2-5.
2-5.1.
2-5.2.
2-5.3.
2-6.
2-6.1.
2-6.2.
2-6.3.
2-7.
2-7.1.
2-7.2.
2-7.3.
2-7.4.
2-8.
2-8.1.
2-8.2.
ii
Page
PRELIMINARY INSTALLATION INSTRUCTIONS
GENERAL .......................................................................................................................... 28
PRELIMINARY INSTALLATION INSTRUCTIONS ..................................................... 28
General ........................................................................................................................... 28
Precautions and Safety Notes ......................................................................................... 28
CONDUITS LAYOUT/INSTALLATION SPECIFICATIONS ........................................ 29
CONDUITS ........................................................................................................................ 29
General ........................................................................................................................... 29
Conduit Requirements .................................................................................................... 30
Conduits at Islander PLUS ............................................................................................. 30
Required Conduits in Island ........................................................................................... 32
Required Conduits in Islander PLUS ............................................................................. 32
CONDUITS INSTALLATION .......................................................................................... 33
General ........................................................................................................................... 33
Installing Conduits in Island .......................................................................................... 33
Sealing Conduits ............................................................................................................ 33
CABLES INSERTION ....................................................................................................... 36
General ........................................................................................................................... 36
Types of Cables .............................................................................................................. 36
Cables Routing ............................................................................................................... 37
POWER SETUP ................................................................................................................. 37
General ........................................................................................................................... 37
Islander PLUS for 8 hoses - AC Power Supply Setup ................................................... 38
Connecting the Power Equipment .................................................................................. 40
Grounding....................................................................................................................... 40
WIRING THE PERIPHERALS ......................................................................................... 41
Pump Wiring .................................................................................................................. 41
TLG wiring..................................................................................................................... 41
Islander PLUS Manual
TABLE OF CONTENTS
Paragraph
SECTION 3
Page
ISLANDER PLUS INSTALLATION PROCEDURES
3-1. 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
Islander PLUS Manual
iii
TABLE OF CONTENTS
Paragraph
Page
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
SECTION 4
PRINTER
4-1. 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
iv
Islander PLUS Manual
TABLE OF CONTENTS
Paragraph
Page
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
SECTION 5
MAINTENANCE
5-1. 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
SECTION 6
6-1.
6-2.
GLOSSARY
FUELOMAT GLOSSARY ................................................................................................ 113
COMMUNICATION GLOSSARY ................................................................................... 114
APPENDIX A SITE SURVEY
APPENDIX B WIRING DIAGRAM
APPENDIX C HID ASASEMBLY INSTALLATION
INTRODUCTION .......................................................................................................................... 125
Islander PLUS Manual
v
TABLE OF CONTENTS
Paragraph
Page
INSTALLATION INSTRUCTIONS ............................................................................................. 127
vi
Islander PLUS Manual
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
Islander PLUS Manual
vii
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
viii
Islander PLUS Manual
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
Islander PLUS Manual
ix
0
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
2
Islander PLUS Manual
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.
Islander PLUS Manual
3
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.
4
Islander PLUS Manual
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).
Islander PLUS Manual
5
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.
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Islander PLUS Manual
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.
Islander PLUS Manual
7
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.
8
Islander PLUS Manual
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
Islander PLUS Manual
9
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
10
Islander PLUS Manual
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
Islander PLUS Manual
11
Figure 1-6 - Internal Components Location –8 Mechanical Pumps
12
Islander PLUS Manual
Figure 1-7 – Islander PLUS with Optional Internal Printer (Sectional View)
Islander PLUS Manual
13
Figure 1-8 – Islander PLUS for 8 hoses with Optional Internal Printer (Sectional View)
14
Islander PLUS Manual
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.
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Islander PLUS Manual
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:
Islander PLUS Manual
17
Table 1-1. Islander PLUS - Standard Models
Name
Islander PLUS for Electric Pumps
Gilbarco P/N
PA039400000
Orpak P/N
800938103
Islander PLUS for Mechanical Pumps - 2 hose
PA039400200
800938105
Islander PLUS for Mechanical Pumps - 4 hose
PA039400400
800938107
Islander PLUS for Mechanical Pumps - 8 hose
PA039400801
800941009
Islander PLUS w/Fleetkey for Electric Pumps
PA039401000
800938167
Islander PLUS w/Fleetkey for Mechanical Pumps - 2 hose
PA039401200
800938169
Islander PLUS w/Fleetkey for Mechanical Pumps - 4 hose
PA039401400
800938171
Islander PLUS w/Fleetkey for Mechanical Pumps - 8 hose
PA039401801
800941073
Islander PLUS w/HID for Electric Pumps
PA039402000
800938231
Islander PLUS w/HID for Mechanical Pumps - 2 hose
PA039402200
800938233
Islander PLUS w/HID for Mechanical Pumps - 4 hose
PA039402400
800938235
Islander PLUS w/HID for Mechanical Pumps - 8 hose
PA039402801
800941137
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
Islander PLUS w/Fleetkey & Printer for Mechanical Pumps 4 hose
PA039401410
ICR PLUS
PA039500000
800938102
ICR PLUS w/Mechanical Pumps - 4 hose
PA039500400
800938106
ICR PLUS w/Fleetkey
PA039501000
800938166
18
800938201
800938203
Islander PLUS Manual
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
Islander PLUS Manual
19
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 wellkept, secure and safe place.
Figure 1-10 shows Islander PLUS/ICR PLUS dimensions in inches.
20
Islander PLUS Manual
Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions
Islander PLUS Manual
21
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)
-40 °F to +104 °F (-40°C to +40 °C)
-4 °F to +113 °F F (-20°C to +45 °C)
(Option with printer)
-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-485 – 9600 bps, Half-Duplex
RS-232
RS-232
Ethernet RJ-45 - 10 Mbps
Ethernet RJ-45 - 10 Mbps
EIA 802.15.4
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
12 VDC +/- 20%
12 VDC +/- 20%
80 mA max
30 mA max
9 to 15 VDC
9 to 15 VDC
Power supply maximum
output current
Pulsar Input High level
voltage
3 mA
Pulsar Input High level
sink current (@15V)
In use "On" level (Input)
3 mA
100 – 240 VAC, 50/60 Hz, 2 W (20
mA)
In use "Off" level (Input) 0 to 20 VAC
22
100 – 240 VAC, 50/60 Hz, 2 W (20
mA)
0 to 20 VAC
Islander PLUS Manual
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
Islander PLUS Manual
23
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.
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Islander PLUS Manual
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.
Islander PLUS Manual
25
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
26
Islander PLUS Manual
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.
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Islander PLUS 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:
•
•
•
•
2-4.
Wire conduits installation
Cables routing within the conduits
Power equipment setup
Forecourt equipment wiring
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.
Islander PLUS Manual
29
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.
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Islander PLUS Manual
Figure 2-1 Islander PLUS Lower Protective Plate
Figure 2-2 Standard Bottom Metal Plate's Knockout –Close View
Islander PLUS Manual
31
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
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Islander PLUS Manual
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.
2.
3.
•
•
Determine the location of the Islander PLUS in the Island.
Dig and prepare passageways for the necessary conduits
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
Islander PLUS Manual
33
Figure 2-4 Conduits Layout for Mechanical Pump
34
Islander PLUS Manual
Figure 2-5 Conduits Layout for Electronic Pump
Islander PLUS Manual
35
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.
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Islander PLUS Manual
Table 2-2. Islander PLUS, Cables Type
No.
1
Function
Type
Power cable, 3x1.5 mm2 NYY (14 AWG),
in accordance with local standards
AC Power from Office
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:
Islander PLUS Manual
37
•
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.
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Islander PLUS Manual
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
Neutral
2
3
4
5
6
~
1
Neutral
2
3
4
5
6
220VAC JUMPER
110VAC JUMPERS
Figure 2-8 VAC Power Supply – Jumpers Setup
Islander PLUS Manual
39
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
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Islander PLUS Manual
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.
Islander PLUS Manual
41
•
•
42
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.
Islander PLUS Manual
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.
Islander PLUS Manual
43
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.
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Islander PLUS Manual
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.
Islander PLUS Manual
45
Figure 3-2 Home Base Station with 4 Mechanical Pumps – System Diagram
46
Islander PLUS Manual
Figure 3-3. Home Base Station with 8 Mechanical Pumps – System Diagram
Islander PLUS Manual
47
Figure 3-4 Home Base Station with Electronic Pumps – System Diagram
48
Islander PLUS Manual
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:
•
•
•
•
3-4.2.
•
•
•
•
•
•
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.
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.
Islander PLUS Manual
49
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
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Islander PLUS Manual
Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections
Islander PLUS Manual
51
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
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Islander PLUS Manual
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
1
Description
Qty
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
Islander PLUS Manual
53
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.
54
Islander PLUS Manual
Figure 3-8 Base Plate Installation (Example)
Figure 3-9 Rosette (Upside down view)
Figure 3-10 Rosette Dimensions
Islander PLUS Manual
55
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.
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Islander PLUS Manual
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
Islander PLUS Manual
57
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:
•
58
Power cable – In accordance with local regulations
Islander PLUS Manual
•
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.
•
3-8.
Antenna cable - Communication cable, Twisted pair, separately shielded, low
capacitance (example – Belden 9729/30)
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 /
Islander PLUS Manual
59
Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition
Terminal No.
60
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
Islander PLUS Manual
Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition
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
3
GND_3_P
Nozzle Grounding – Nozzle 3
4
GND_4_P
Nozzle Grounding – Nozzle 4
5
GND_5_P
Nozzle Grounding – Nozzle 5
6
GND_6_P
Nozzle Grounding – Nozzle 6
7
GND_7_P
Nozzle Grounding – Nozzle 7
8
GND_8_P
Nozzle Grounding – Nozzle 8
17
+12V_1_P
+12 VDC Output to Pulser – Nozzle 1
18
+12V_2_P
+12 VDC Output to Pulser – Nozzle 2
19
+12V_3_P
+12 VDC Output to Pulser – Nozzle 3
20
+12V_4_P
+12 VDC Output to Pulser – Nozzle 4
21
+12V_5_P
+12 VDC Output to Pulser – Nozzle 5
Islander PLUS Manual
61
Terminal No.
62
Signal Name
Functional Description
22
+12V_6_P
+12 VDC Output to Pulser – Nozzle 6
23
+12V_7_P
+12 VDC Output to Pulser – Nozzle 7
24
+12V_8_P
+12 VDC Output to Pulser – Nozzle 8
25
IN USE 1 A
Handle Up – AC In Use signal input - Nozzle 1
26
IN USE 2 A
Handle Up – AC In Use signal input - Nozzle 2
27
IN USE 3 A
Handle Up – AC In Use signal input - Nozzle 3
28
IN USE 4 A
Handle Up – AC In Use signal input - Nozzle 4
29
IN USE 5 A
Handle Up – AC In Use signal input - Nozzle 5
30
IN USE 6 A
Handle Up – AC In Use signal input - Nozzle 6
31
IN USE 7 A
Handle Up – AC In Use signal input - Nozzle 7
32
IN USE 8 A
Handle Up – AC In Use signal input - Nozzle 8
33
IN USE 1 B(-)
Handle Up – AC In Use signal Return - Nozzle 1
34
IN USE 2 B(-)
Handle Up – AC In Use signal Return - Nozzle 2
35
IN USE 3 B(-)
Handle Up – AC In Use signal Return - Nozzle 3
36
IN USE 4 B(-)
Handle Up – AC In Use signal Return - Nozzle 4
37
IN USE 5 B(-)
Handle Up – AC In Use signal Return - Nozzle 5
38
IN USE 6 B(-)
Handle Up – AC In Use signal Return - Nozzle 6
39
IN USE 7 B(-)
Handle Up – AC In Use signal Return - Nozzle 7
40
IN USE 8 B(-)
Handle Up – AC In Use signal Return - Nozzle 8
41
LINE 1
Pump control 220/110 VAC Input - Nozzle 1
42
LINE 2
Pump control 220/110 VAC Input - Nozzle 2
43
LINE 3
Pump control 220/110 VAC Input - Nozzle 3
44
LINE 4
Pump control 220/110 VAC Input - Nozzle 4
45
LINE 5
Pump control 220/110 VAC Input - Nozzle 5
46
LINE 6
Pump control 220/110 VAC Input - Nozzle 6
47
LINE 7
Pump control 220/110 VAC Input - Nozzle 7
48
LINE 8
Pump control 220/110 VAC Input - Nozzle 8
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
Islander PLUS Manual
Terminal No.
Signal Name
Functional Description
10
PULSER_2
Pulser Input – Nozzle 2
11
PULSER_3
Pulser Input – Nozzle 3
12
PULSER_4
Pulser Input – Nozzle 4
13
PULSER_5
Pulser Input – Nozzle 5
14
PULSER_6
Pulser Input – Nozzle 6
15
PULSER_7
Pulser Input – Nozzle 7
16
PULSER_8
Pulser Input – Nozzle 8
49
LOAD 1
Pump control output - Nozzle 1
50
LOAD 2
Pump control output - Nozzle 2
51
LOAD 3
Pump control output - Nozzle 3
52
LOAD 4
Pump control output - Nozzle 4
53
LOAD 5
Pump control output - Nozzle 5
54
LOAD 6
Pump control output - Nozzle 6
55
LOAD 3
Pump control output - Nozzle 7
56
LOAD 8
Pump control output - Nozzle 8
Figure 3-14 Islander PLUS Terminal Block
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63
Figure 3-15 Islander PLUS - Terminal Block (8 pumps)
Figure 3-16 Islander PLUS – Terminal Block –4 Mechanical Pump - Wiring List Label
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Islander PLUS Manual
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:
Islander PLUS Manual
The dispenser outputs pulses to the system by means of the Pulser unit,
installed in accordance with the manufacturer instructions. The Pulse rate
65
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.
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Islander PLUS Manual
Figure 3-18 Mechanical Pump – Single Dispenser Connections
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67
Figure 3-19 Mechanical Pump – Twin Dispenser Connections
68
Islander PLUS Manual
Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections
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69
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
•
70
2-Wire Pulser - powered by the Islander PLUS.
Islander PLUS Manual
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
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71
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.
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Islander PLUS Manual
Figure 3-23 Islander PLUS Terminal Block – Wiring List Label
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73
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
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Islander PLUS Manual
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 3-23 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 3-25 Current Loop Electronic Pump - Wiring Diagram
NOTE
Recommended maximum distance is 2600'.
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75
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 3-23 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 3-26 RS-485 Electronic Pump - Wiring Diagram
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Islander PLUS Manual
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.
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77
Figure 3-28 Journal Printer – General View
The Journal Printer is connected to the 8-Port Commverter through one of the channels of the RS485 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).
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Islander PLUS Manual
Figure 3-29 Journal Printer – Rear Panel
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79
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
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Islander PLUS Manual
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
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81
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.
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Islander PLUS Manual
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
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83
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
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Islander PLUS Manual
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
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85
4-7.
4-7.1.
INSTALLATION PRINTING PARAMETERS
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
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Islander PLUS Manual
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.
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87
4-8.
4-8.1.
PAPER ROLL REPLACEMENT
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
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Islander PLUS Manual
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.
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89
NOTE
Verify that the green paper-lock lever is closed
9.
4-8.2.1.
The paper can be inserted into the printer automatically or manually.
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.
4-8.2.2.
Slide the paper from the printer door slice.
Manual Insertion of Paper
Proceed as follows:
90
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.
Islander PLUS Manual
4-9.
4-9.1.
PRINTER CLEANING
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
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91
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.
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Islander PLUS Manual
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.
1
2
Failure Indication
Probable Cause of Failure
Left-hand green Led
flickers constantly
The Printer Unit is stuck
Right-hand green Led
flickers constantly
The Printer Unit is stuck
Recommended Corrective
Action
1. Check paper roll
2. Replace unit
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.
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93
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
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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.
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95
Table 5-1. Islander PLUS Troubleshooting
Fault
Probable Cause
Checks
Corrective Action
System is down
LCD display is
blank
Islander PLUS main
switch is off
Doesn't accept
No 115 VAC feed
Key/Card/Keypad to the unit
input
No
communication
OrCU LEDs are
not lit
Turn main switch on
1. Check power at
Distribution Box
Correct wiring problems if
115VAC is not measured
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?
Does the unit shut down
immediately after being
turned on?
1. Check for shorts in the
power line cable
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
Power failure
Circuit breaker is
off
96
2. Check grounding
2. Replace power supply
Islander PLUS Manual
Table 5-1. Islander PLUS Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
System is down (Continued)
Doesn't accept
OrPT setup is
Key/Card/Keypad incorrect
input
No
OrCU setup is
communication
incorrect
No Magnetic
Card response
Dirty or faulty
Magnetic Card
reader
Faulty Magnetic
Cards
No Key response
1. Set communication
parameters
Check OrCU setup:
1. Set communication
parameters
•
OrPT bus
•
OrPT parameters
•
OrCU Administrator
parameters
2. Submit and check again
2. Save and reload
3. Check again
1. Visually check
Magnetic Card reader
1. Clean Magnetic Card
reader
2. Present several
Magnetic Cards
2. Replace Magnetic Card
reader
3. Replace OrPT
1. Visually check Key
receptacle
Loose cable
Faulty key
receptacle
Customer display
is blank
Login into OrPT and
check communication
parameters
1. Replace Key receptacle
2. Replace OrPT
2. Insert several keys
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
Enable the device to refuel
2. Verify that the
vehicle/device has no
limitation in FHO
setup
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97
Table 5-1. Islander PLUS Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
Mechanic pump does not refuel (Continued)
Pump does not
supply fuel
Pump setup is
incorrect
Check pump setup:
1. Set pump parameters
•
Pump server
2. Save and reload
•
Buses
3. Check again
•
Prices
•
Pulse rate
Faulty connection to Check Control cables
pump
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 If the problem persist:
bypass switch on, lift the
1. Check Handle-On Switch
nozzle and check that
the pump supplies fuel
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
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Islander PLUS Manual
Table 5-1. Islander PLUS Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
Mechanic pump does not refuel (Continued)
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 Replace pump switch in
a ohmmeter measure the
cases where no short was
switch in on and off states detected
Faulty connections
Check In Use cable
Check In Use terminal
block connections
Faulty In Use
terminal block
Faulty MPI-C board
Replace In-use terminal
block
Verify that the Call red
LED is lit when nozzle is
lifted
Faulty 8-Port
Pump is
authorized, pump
motor is running,
but no fuel is
supplied
Faulty solenoid
valve
Payment device
(card, key, tag,
Fuel Ring) is not
accepted
Communication
fault between OrPT
and SO
Faulty pump
Make good electrical
connection if faulty one
exists
If the red LED is not lit,
replace MPI-C board.
If the led is lit, the problem
is external to the controller
Replace 8-Port
Does the pump solenoid
valve produce a clicking
sound?
1. Replace valve
1. Check LAN cable
1. Replace LAN cable, if
necessary
2. Check OrPT setup
3. Check SO setup
2. Repair pump
2. Set OrPT parameters
properly
3. Set SO parameters
properly
Communication
fault between FHO
and SO
Islander PLUS Manual
1. Check connection path Repair communication
with FHO
between FHO and SO,
2. Verify that the station providing a reliable
communication line
is available and
synchronized with
FHO in FHO Stations
Status screen
99
Table 5-1. Islander PLUS Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
Mechanic pump does not refuel (Continued)
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
Define the device
parameters in FHO
properly
3. Check device
parameters
4. Check that device
rules does not limit
refueling
Device limit was
passed
Verify that the device is
For testing only, remove
within the limits of its rule any rule associated to this
device
Device was set as
Driver
1. Login into FHO and
go Devices
Management
Change the device setting
to Vehicle
2. Select the specific
device and check if it
was configured as
Driver
Device is blocked
1. Login into FHO and
go to Devices
Management
Change device status to
Unblocked
2. Check the status of the
device in the Status
column in the Devices
grid
(blocked/unblocked)
100
Islander PLUS Manual
Table 5-1. Islander PLUS Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
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
Disconnect the pulser and
short the pulse-in wires to
simulate pulses
If pulses are received
during refueling, replace
pump pulser
Faulty 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
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101
5-2.2. OrPT Troubleshooting
The OrPT troubleshooting procedure and consequent corrective actions are described in Table 5-2.
Table 5-2. OrPT Troubleshooting
Fault
Probable Cause
Checks
Corrective Action
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
Power supply
failure
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
Faulty card reader
2. Present the card while
the idle message is
displayed
Replace OrPT
OrPT does not accept RFID tag
OrPT display
does not respond
correctly to tags
102
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
Islander PLUS Manual
Table 5-2. OrPT Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
OrPT does not accept RFID tag (Continued)
OrPT display
does not respond
correctly to tags
OrPT is busy
performing another
task
Verify that the display
presents the idle message
Faulty OrPT
1. Press Cancel
2. Present the tag while
the idle message is
displayed
Replace OrPT
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
Make good electrical
connection if faulty one
exists
OrPT is busy
performing another
task
Verify that the display
presents the idle message
1. Press Cancel
Faulty OrPT
2. Present the tag while
the idle message is
displayed
Replace OrPT
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
OrPT is busy
performing another
task
Verify that the display
presents the idle message
1. Press Cancel
Faulty OrPT
Islander PLUS Manual
2. Present the tag while
the idle message is
displayed
Replace OrPT
103
Table 5-2. OrPT Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
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
Make good electrical
connection if faulty one
exists
OrPT is busy in
another task
check that dsplay present
the idle message
1. Press Cancel
Faulty OrPT
2. Present the card/key
while the idle message
is displayed
Replace OrPT
OrPT displays "No communication" message
5-LAN switch is
dead
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
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
Power supply
failure
Is power supply on?
1. Replace fuse
Faulty OrCU
104
2. Replace power supply
Replace OrCU
Islander PLUS Manual
Table 5-2. OrPT Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
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
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105
5-2.3. Printer Troubleshooting
The Printer troubleshooting procedure and consequent corrective actions are described in Table 5-3.
Table 5-3. Printer Troubleshooting
Fault
Probable Cause
Checks
Corrective Action
Printer does not print
No printing at the Printer is out of
end of transaction paper
Paper Lock(green)
switch is open
Check paper roll
Replace paper roll
Check Paper Lock switch
position
Close Paper Lock switch
Jammed paper
Incorrect SiteOmat
setting
Release paper
Check SiteOmat printer
settings
Faulty Printer
Set printer parameters
properly
Replace Printer
No power to Printer
No printing,
printer doesn't
produce a beep
sound at poweron
Power cable is
disconnected
Check power cable
connections between the
printer and OrPT
Make correct and good
connection if it was
incorrect
Faulty power supply Check power supply
Replace power supply
outputs using a digital
Voltemeter. the output
voltage should be 24 VDC
Replace Printer
Faulty Printer
No communication to Printer
106
RS485 cable is
disconnected
Check the RS485 cable
connections between the
printer and OrPT
Make correct and good
connection if it was
incorrect
LAN Cable is
disconnected
Check the OrPT LAN
cable
Make correct and good
connection if it was
incorrect
Islander PLUS Manual
Table 5-3. Printer Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
No communication to Printer (Continued)
Incorrect Address
settings
Check printer address
jumpers (no Jumper
means address is 70HEX)
Faulty Printer
Set the correct Hex address
in SiteOmat
Replace Printer
Paper is not automatically cut
Paper is not being Incorrect SiteOmat
cut at the end of
setting
the printing
Faulty Printer cutter
Faulty Printer
Islander PLUS Manual
Check SiteOmat printing
settings
Set SiteOmat printing
settings accordingly
Replace Printer cutter
Replace Printer
107
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
Fault
Probable Cause
Checks
Corrective Action
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
108
Incorrect 8-port
CommVerter setup
Check the physical
connection of the 8port CommVerter to
the local network (5port 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
Islander PLUS Manual
Table 5-4. Communication Troubleshooting
Fault
Probable Cause
Checks
Corrective Action
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
Islander PLUS Manual
Check the physical
connection of the
Wireless Gateway to
the local network (5port 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
109
Table 5-4. Communication Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
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/RS232 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)
110
Islander PLUS Manual
Table 5-4. Communication Troubleshooting (Cont'd)
Fault
Probable Cause
Checks
Corrective Action
No communication to the TLS (Continued)
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
"Warning" signs
displayed for all
tanks on the
SiteOmat Tank
Status screen
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:
Islander PLUS Manual
111
•
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.
112
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0
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
Islander PLUS Manual
113
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.
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Islander PLUS Manual
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
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115
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 __________________
Contact person:
Fax:
Tel: ____________
__________________ Mobile Phone:_____
____________
A. STATION INFORMATION
•
Power line
•
Power stabilizer/UPS available? ______________ Spec _________________
•
Station name
•
Location
•
FCC Tel. No._____________ / Direct connect _____________
•
Internet connectivity method (Modem, GPRS, cable, frame relay,
110VAC
220VAC
Other____
__________________________
_________________________
SAT,ADSL etc) ______________
•
Number of dispensers (to be connected to FCC): ______
•
Number of nozzles (to be connected to FCC): ______
•
Number of Authorizers required _____
116
Islander PLUS Manual
•
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 :
•
Hose Length ___________________
3/4”
Islander PLUS Manual
1”
other________
117
•
Break Away :  Yes
•
Vapor Recovery:
•
NOZZLE/HOSE THREAD:
INCH (NPT)
•
HOSE THREAD :
Female
•
MANUFACTURER: ___________________
•
MODEL: ___________________________
•
DIAMETER OF NOZZLE SPOUT: ________
 No
Location on the hose:________
 Yes
 No
Male
MILLIMETER (DSP)
•
F. NOZZLE EQUIPMENT-2
•
HOSE SIZE :
•
Hose Length ___________________
•
Break Away :  Yes
•
Vapor Recovery:
•
NOZZLE/HOSE THREAD:
INCH (NPT)
•
HOSE THREAD :
Female
•
MANUFACTURER: ___________________
•
MODEL: ___________________________
•
DIAMETER OF NOZZLE SPOUT: ________
3/4”
other________
1”
 No
Location on the hose:________
 Yes
 No
Male
MILLIMETER (DSP)
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 ?_______________________________________
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Islander PLUS Manual
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)
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119
120
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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)
Islander PLUS Manual
121
Figure B-1 Islander PLUS – Wiring Diagram (Mechanical Pump)
122
Islander PLUS Manual
Figure B-2 Islander PLUS – Wiring Diagram (Electronic Pump)
Islander PLUS Manual
123
Figure B-3 Islander PLUS for 8 hoses – Wiring Diagram
124
Islander PLUS Manual
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
Islander PLUS Manual
125
Figure 1. HID Unit and Connector
Figure 2. HID Holder and Nuts
126
Islander PLUS Manual
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
Islander PLUS Manual
127
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
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Islander PLUS Manual
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
Islander PLUS Manual
129
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.
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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).
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Figure 11. Placing Hand Tag Label on Pedestal
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