Gasboy Islander Prime Manual

MDE-5411A
Islander Prime Installation Manual
ForeHB
This document is based on Orpak’s ForeHB OrIC Prime Installation Manual,
P/N 817450050.
This manual supports released version 6.4.410.XX

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 NFPA30 “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.
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.
This document is the property of:
ORPAK SYSTEMS Ltd.
ISRAEL
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 page is intentionally left blank.

MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page i
Table of Contents
Table of Contents
1 – Introduction 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Solution Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Manual Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.6 Documentation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 – Important Safety Information 5
3 – System Overview 9
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.1 Fuel Point PLUS - Automatic Vehicle Identification . . . . . . . . . . . . . . . . . . . . .9
3.2.2 Remote Web Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.3 Head Office . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.4 Restrictions and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.5 Islander Prime Capabilities for Forecourt Management . . . . . . . . . . . . . . . . .10
3.2.6 System Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3 Islander Prime Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3.1 Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3.2 Internal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.4 Available Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.4.1 Islander Prime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.4.2 Automatic Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.3 Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.4 Barcode Reader Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.5 Insert Card Reader Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.6 HID Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.7 Cellular Modem Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.8 Receipt Printer Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.9 EMV Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.4.10 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.5 Security and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.5.1 Authorization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.5.2 Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.5.3 RF Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.5.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.6 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.7 Technical Specifications and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.7.1 Islander Prime Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.7.2 Communication and Security Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4 – Preliminary Guidelines 21
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2 Precautions and Safety Notes
Précautions et consignes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3 Station Survey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Table of Contents
Page ii MDE-5411A ForeHB Islander Prime Installation Manual · October 2018
4.3.1 Station Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.2 Locating All Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.3 Assigning Logical IDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4.1 Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4.2 Protective Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.3 Required Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4.4 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.6 Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Cable Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.1 Cable Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5.2 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6 Power Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6.1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.6.2 Power Supply Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.6.3 Connecting the Power Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7 Wiring the Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7.1 Pump Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7.2 TLG Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 – Installation 37
5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2.1 Precautions and Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2.2 Safety Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Installing the Pedestal Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.2 Preliminary Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.3 Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.4 Base Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3.5 Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.6 Sealing Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4 Installing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4.1 Barcode Reader Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4.2 HID Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4.3 Insertion Card Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4.4 Cellular Modem Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4.5 G2 Panel Printer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.5 Installing Communication Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5.1 Adding Communication Interface Blades to the Pedestal . . . . . . . . . . . . . . . 54
5.5.2 Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5.3 Mechanical Dispenser Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.4 Pulser Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5.5 Electronic Dispenser Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6 Post-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.7 Islander Prime Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page iii
Table of Contents
6 – LAN CommVerter Setup 69
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
6.2 Home Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
6.3 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.3.1 Minimal Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.3.2 General Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
6.3.3 OrIC Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
6.3.4 Log Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
6.3.5 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
6.4 Software Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
7 – Maintenance 81
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
7.2 OrPAY1000 and Islander Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
7.3 Magnetic Card Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
7.4 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
8 – Troubleshooting 85
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.2 Islander Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.2.1 System Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.2.2 Mechanical Pump Does Not Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
8.2.3 No Control Over Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
8.3 OrPAY1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
8.4 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
8.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
8.6 FuelPoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Table of Contents
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MDE-4818G MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page i
List Of Figures
List Of Figures
Figure 1 Islander Prime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 3 nOrCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 4 OrPAY1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 5 G2 Panel Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 6 Communication Interfaces in the Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 7 Internal Configuration Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 8 Islander Prime Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 9 Installation Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 10 Terminal Block, Power, and LAN Connections (8 Pumps). . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 11 Lower Protective Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 12 Conduit Layout for Mechanical Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 13 Conduits Layout for Electronic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 14 Power Equipment Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 15 Power Supply Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 16 Communications Cable Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 17 Base Plate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 18 Base Plate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 19 Base Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 20 Pedestal Base Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 21 Islander Prime Pole Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 22 Barcode Reader Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 23 Barcode Reader in Islander Prime Pole Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 24 Barcode Reader Wiring to OrPAY1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 25 Barcode Reader Wiring to OrPAY1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 26 HID Reader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 27 HID Reader Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 28 HID Reader on Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 29 HID Reader Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 30 HID Reader in Islander Prime Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 31 Insertion Card Reader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 32 Insertion Card Reader (Inside Top View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 33 Insertion Card Reader Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 34 Insertion Card Reader Mounted in Islander Prime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 35 Cellular Modem Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 36 Cellular Modem in Islander Prime Pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 37 Cellular Modem Antenna (Left Side Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 38 G2 Panel Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 39 Disconnect Grounding Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 40 Panel Printer in Islander Prime Pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 41 Reconnect Grounding Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 42 Communication Interface Protective Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 43 Communication Interface Slots (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

List Of Figures
Page ii MDE-4818G MDE-5411A ForeHB Islander Prime Installation Manual · October 2018
Figure 44 Communication Interface Blades in Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 45 Communication Interface Protective Panel With Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 46 Mechanical Dispenser Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 47 Mechanical Dispenser Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 48 MPI-C Fuses Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 49 Three-Wire Pulser Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 50 Two-Wire Pulser Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 51 Tokheim Electronic Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 52 Tokheim Electronic Interface - Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 53 Current Loop Electronic Pump - Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 54 RS-485 Electronic Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 55 RS-485 Device - Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 56 RS-232/RS-422 Electronic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 57 TLG Wiring Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 58 Islander Prime CommVerter Setup Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 59 Islander Prime CommVerter Setup Homepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 60 Minimal Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 61 General Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 62 OrIC Config Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 63 Log Level Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 64 Save Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 65 Confirm Save Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 66 Reset Device Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 67 Download Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 68 Software Upload Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 69 Confirm Upload Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 70 Paper Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page i
List of Tables
List of Tables
Table 1 Communication Interfaces17
Table 2 Islander Prime Technical Specifications19
Table 3 Conduits into Islander Prime28
Table 4 Islander Prime Cable Types32
Table 5 Islander Prime Cable Routing32
Table 6 Islander Prime Base Plate Dimensions38
Table 7 Islander Prime Assembly Parts39
Table 8 Barcode Reader Assembly Kit43
Table 9 Insertion Card Reader Assembly Kit48
Table 10 Cellular Modem Installation Kit50
Table 11 MPI-C Channels59
Table 12 MPI-C Fuses Slot #1- In Use/Pump60
Table 13 MPI-C Fuses Slot #2 - Pump/In Use60
Table 14 Tokheim Pinouts63
Table 15 Current Loop Pinouts64
Table 16 RS-485 Pinouts66
Table 17 RS-232/422 Pinouts67
Table 18 Device Information70
Table 19 General Setup Fields72
Table 20 OrIC Config Channels Fields74
Table 21 CommVerter Log Levels75
Table 22 Software Upload Fields78
Table 23 System is Down85
Table 24 Mechanical Pump Does Not Fuel86
Table 25 No Control Over Fueling88
Table 26 OrPAY1000 Troubleshooting88
Table 27 Printer Troubleshooting90
Table 28 Communication Troubleshooting92
Table 29 FuelPoint Troubleshooting94

List of Tables
Page ii MDE-5411A ForeHB Islander Prime Installation Manual · October 2018
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MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page 1
1.1 General Introduction
1 – Introduction
1.1 General
This manual describes the Islander Prime Fuel Island Controller, which is part of the ForeHB
solution. It provides a general description of the product, a detailed description of the modules,
as well as installation and maintenance guidelines.
1.2 Solution Description
Gasboy®’s end-to-end ForeHB homebase fleet fueling solution extends from the station to the
head office, giving fleet managers the power and flexibility to monitor fuel levels and
authorize fueling activity. All site activity is controlled using Gasboy’s innovative Islander
Prime Fuel Island Controller, which is an all-in-one weather-resistant cabinet that provides a
complete forecourt island solution. Islander Prime is a core component of the ForeHB solution
for homebase refueling and provides automation and control over all forecourt equipment at
the station such as:
• Automatic Vehicle Identification system
• Transaction data storage
• Control over dispensers
•ReadsATGs
Islander Prime ruggedized pedestal and user-friendly interface, increases fleet operating
margins, provides efficient vehicle refueling, offers real-time information on fuel utilization,
prevents fuel loss and misuse, and gives homebase managers better control over inventory and
delivery. The Islander Prime is equipped with the following components:
• Embedded Linux controller
• OrPAY1000 Payment Terminal
• Communication interface modules mechanical/electronic/mixed
• Optional outdoor receipt printer
• Modular software licensing allowing different pricing by number of pumps, ATG, Fuel
Point PLUS integration
• Optional EMV card reader and PIN pad
• nOrCU full station automation
• WiFi and/or cellular connectivity with the addition of an optional modem add-on

MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page 3
1.4 Manual Structure Introduction
1.4 Manual Structure
Section 1: Introduction
This section provides a general description of the system.
Section 2: System Overview
This section provides a general description of the Islander Prime system.
Section 3: Preliminary Guidelines
This section provides the preliminary installation requirements and procedures to be
performed before installing the Islander Prime system.
Section 4: Installation Procedures
This section provides a detailed description of the Islander Prime installation requirements and
procedures.
Section 5: Maintenance
This section provides general maintenance instructions for Islander Prime.
Section 6: Troubleshooting
This section provides a comprehensive troubleshooting guide for Islander Prime.
1.5 References
This manual provides installation instructions for the Islander Prime Fuel Island Controller
and integrated modules.
For specific installation and setup instructions not included in this manual, refer to the
following manuals:
• MDE-4868 OrPAY1000 Installation and Setup Manual
• MDE-4817 SiteOmat Installation and Maintenance Manual
• G2 Panel Printer Installation and Setup Manual, P/N 800919900

Introduction 1.6 Documentation Conventions
Page 4 MDE-5411A ForeHB Islander Prime Installation Manual · October 2018
1.6 Documentation Conventions
This manual uses the following conventions:
An operating procedure, practice, etc., which if not correctly followed, could
result in injury or loss of life.
Les consignes d'avertissement contiennent des informations qui, à moins
d'être strictement respectées, peuvent entraîner des blessures ou la mort.
WARNING
!
An operating procedure, practice, etc, which if not strictly observed, could result in
damage to, or destruction of the equipment.
Les consignes de mise en garde contiennent des informations qui, à moins d'être
strictement respectées, peuvent entraîner des dommages ou la destruction de
l'équipement ou des risques à long terme pour la santé du personnel.
CAUTION
A useful guidance, whose purpose is to use the system in a more efficient way.
TIP
More detailed technical/functional information regarding relevant issues.
INSIGHT

MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page 5
Important Safety Information
2 – Important Safety Information
Notes: 1) Save this Important Safety Information section
in a readily accessible location.
2) Only trained, qualified, and certified specialists
are authorized to perform work on the Gilbarco
Encore CNG Dispenser.
This section introduces the hazards and safety precautions
associated with installing, inspecting, maintaining or servicing
this product. Before performing any task on this product, read
this safety information and the applicable sections in this
manual, where additional hazards and safety precautions for
your task will be found. Fire, explosion, electrical shock or
pressure release could occur and cause death or serious
injury, if these safe service procedures are not followed.
Preliminary Precautions
You are working in a potentially dangerous environment of
flammable fuels, vapors, high voltage and high pressures. Only
trained or authorized individuals knowledgeable in the related
procedures should install, inspect, maintain or service this
equipment.
Emergency Total Electrical Shut-Off
The first and most important information you must know is how to
stop all fuel flow to the dispenser and island. Locate the switch or
circuit breakers that shut off all power to all fueling equipment,
dispensing devices, and compressors associated.
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical components or the
electronics of the dispenser requires total electrical shut off of that
unit. Understand the function and location of this switch or circuit
breaker before inspecting, installing, maintaining, or servicing
Gilbarco equipment.
Evacuating, Barricading and Shutting Off
Any procedure that requires access to the dispenser or
associated equipment requires the following actions:
• An evacuation of all unauthorized persons and vehicles from the
work area
• Use of safety tape, cones or barricades at the affected unit(s)
• Atotal electrical shut-off of the affected unit(s)
Read the Manual
Read, understand and follow this manual and any other labels
or related materials supplied with this equipment. If you do not
understand a procedure, call a Gilbarco Authorized Service
Contractor or call the Gilbarco Support Center at
1-800-800-7498. It is imperative to your safety and the safety
of others to understand the procedures before beginning
work.
Follow the Regulations
Applicable information is available in National Fire Protection
Association (NFPA) 30A; Code for Motor Fuel Dispensing
Facilities and Repair Garages, NFPA 52, NFPA 70®, ANSI
NGV4.1 (CSA12.5); National Electrical Code (NEC), EPO 28,
Occupational Safety and Health Administration (OSHA)
regulations and federal, state, and local codes. All these
regulations must be followed. Failure to install, inspect,
maintain or service this equipment in accordance with these
codes, regulations and standards may lead to legal citations
with penalties or affect the safe use and operation of the
equipment.
Location
System Siting
Dispenser to only be located above ground and away from
electrical power lines. A minimum of 10 feet (3 m).
Installation of Emergency Shutdown Equipment
An emergency manual shutdown device shall be provided
within 10 feet (3 m) of the dispensing area and also greater
than 25 feet (7.6 m) from the dispensing area.
Fire Protection
A portable fire extinguisher having a rating of not less than
20 B:C shall be provided at the dispensing area.
Replacement Parts
Use only genuine Gilbarco replacement parts and retrofit kits
on your pump/dispenser. Using parts other than genuine
Gilbarco replacement parts could create a safety hazard and
violate local regulations.
The EMERGENCY STOP, ALL STOP, and
PUMP STOP buttons at the cashier’s station
WILL NOT shut off electrical power to the
pump/dispenser. This means that even if you
activate these stops, fuel may continue to flow
uncontrolled.
You must use the TOTAL ELECTRICAL
SHUT-OFF in the case of an emergency and not
the console’sALL STOP and PUMP STOP or
similar keys.
!
WARNING
!
Adaptors are not to be used at or be used at or in the
vehicle fueling connection.
WARNING
!
Depressure system before pneumatic maintenance
and service.
Any procedure that requires work on pneumatic system
parts and components require the total depressurization of
the dispenser after total electrical shut off.
Refer to MDE-5055 Encore CNG Start up and Service
Manual.
!
WARNING
!

Page 6 MDE-5411A ForeHB Islander Prime Installation Manual · October 2018
Important Safety Information
Safety Symbols and Warning Words
This section provides important information about warning
symbols and boxes.
Alert Symbol
This safety alert symbol is used in this manual and on
warning labels to alert you to a precaution which must be
followed to prevent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible injury
or death.
Signal Words
These signal words used in this manual and on warning labels
tell you the seriousness of particular safety hazards. The
precautions below must be followed to prevent death, injury or
damage to the equipment:
DANGER:Alerts you to a hazard or unsafe practice
which will result in death or serious injury.
WARNING: Alerts you to a hazard or unsafe practice
that could result in death or serious injury.
CAUTION withAlert symbol: Designates a hazard or
unsafe practice which may result in minor injury.
CAUTION withoutAlert symbol: Designates a hazard or
unsafe practice which may result in property or
equipment damage.
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will explode or burn, if ignited. Spilled or
leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors in the vicinity of the
dispenser or island.
No Open Fire
Open flames from matches, lighters, welding torches or
other sources can ignite fuels and their vapors.
No Sparks - No Smoking
Sparks from starting vehicles, starting or using power tools,
burning cigarettes, cigars or pipes can also ignite fuels and their
vapors. Static electricity, including an electrostatic charge on
your body, can cause a spark sufficient to ignite fuel vapors.
Every time you get out of a vehicle, touch the metal of your
vehicle, to discharge any electrostatic charge before you
approach the dispenser island.
Working Alone
It is highly recommended that someone who is capable of
rendering first aid be present during servicing. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods, if
you work with or around high voltages. This information is
available from theAmerican Red Cross.Always advise the
station personnel about where you will be working, and caution
them not to activate power while you are working on the
equipment. Use the OSHA Lockout/Tagout procedures. If you
are not familiar with this requirement, refer to this information in
the service manual and OSHA documentation.
Working With Electricity Safely
Ensure that you use safe and established practices in working
with electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure that grounding
connections are properly made. Take care that sealing devices
and compounds are in place. Ensure that you do not pinch
wires when replacing covers. Follow OSHA Lockout/Tagout
requirements. Station employees and service contractors need
to understand and comply with this program completely to
ensure safety while the equipment is down.
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Ensure that you
clean hands after handling equipment. Do not place any
equipment in the mouth.
Barrier
It is recommended that the Encore CNG Dispenser be
protected with safety guard railing and posts to prevent
vehicular damage to the dispenser.
Maintenance and Repair
The owner/operator of the dispensing system is required to
keep it in proper condition, operate it professionally. Comply
with all maintenance instructions and required servicing.
In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
personnel:
• Location of accident (for example, address, front/back of
building, and so on)
• Nature of accident (for example, possible heart attack, run
over by car, burns, and so on)
• Age of victim (for example, baby, teenager, middle-age,
elderly)
• Whether or not victim has received first aid (for example,
stopped bleeding by pressure, and so on)
• Whether or not a victim has vomited (for example, if
swallowed or inhaled something, and so on)
IMPORTANT: Oxygen may be needed at scene if natural gas
has been inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of machines
and equipment in which the unexpected energization or start-up
of the machine(s) or equipment or release of stored energy
could cause injury to employees or personnel. Lockout/Tagout
applies to all mechanical, hydraulic, chemical, or other energy,
but does not cover electrical hazards. Subpart S of 29 CFR Part
1910 - Electrical Hazards, 29 CFR Part 1910.333 contains
specific Lockout/Tagout provision for electrical hazards.
Notifications
To comply with NFPA clause 8.3.1 where systems are served
by a gas utility, the utility shall be notified of all CNG
installations.
!
!
!

MDE-5411A ForeHB Islander Prime Installation Manual · October 2018 Page 7
Important Safety Information
Hazards and Actions
The following actions are recommended regarding these hazards:
• Do not go near a fuel spill or allow anyone else in the area.
• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOPto shut off power. These keys do not remove
AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow open
flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
Encore CNG Automatic Safety Systems
Unique automatic disconnect functions are included in the Encore CNG dispenser which contains a
hydrocarbon sensor and impact detector/tilt switch. These devices switch power off inside the dispenser
automatically in a hazardous fault condition and send a signal that can be utilized to switch off the site
automatically. However, the above recommended actions (regarding collision of vehicle on island or site or
gas leak) are still applicable and these automatic devices should not be relied upon to ensure the site is
made safe and the manual intervention described above must be enacted.
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
WARNING
Collision of a Vehicle with Unit Fire at Island or Site Gas Leak
WARNING
CNG dispenser in collision with vehicles damaged with fire or explosions must be removed from
service and replaced.
WARNING
Breakaways must be installed to provide safety protection in the event of a drive-off while the
nozzle is connected. CNG dispenser MUST NOT be used in service without approved
breakaways being installed.
Adapters are not to be used at the vehicle fuel connection.

Page 8 MDE-5411A ForeHB Islander Prime Installation Manual · October 2018
Important Safety Information
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