Gasboy Islander PLUS User manual

Wiring
MDE - 4811F
Islander PLUS and ICR PLUS
INSTALLATION MANUAL
This document is based on Orpak’s Island controller (OrIC)
installation manual P/N 817438050

SAFETY CONSIDERATIONS
Read all warning notes and instructions carefully. They are included to help you installing the Product safely
in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions
could result in serious injury or property damage. It is the installer responsibility to install, operate and
maintain the equipment according to the instructions given in this manual, and to conform to all applicable
codes, regulations and safety measures. Failure to do so could void all warranties associated with this
equipment.
Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure
that actual installation is performed by experienced personnel, licensed to perform work in fuel station and at
a flammable environment, according to the local regulations and relevant standards.
WARNING - EXPLOSION HAZARD
Use separate conduit for the intrinsically safe. Do not run any other wires or cables through this conduit,
because this could create an explosion hazard.
Use standard test equipment only in the non- hazardous area of the fuel station, and approved test equipment
for the hazardous areas.
In the installation and maintenance of the Product, comply with all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for
Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70 “National Electric Code”, federal, state and
local codes and any other applicable safety codes and regulations.
Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work
operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury,
property loss and damage to you and other persons.
CAUTION - SHOCK HAZARD
Dangerous AC voltages that could cause death or serious personal injury are used to power the Product.
Always disconnect power before starting any work. The Product has more than one power supply connection
points. Disconnect all power before servicing.
CAUTION – EXTERNAL WIRING
For supply connections, use wires suitable for at least 90°C.
Signal wiring connected in this box must be rated at least 300 V.
WARNING – PASSING VEHICLES
When working in any open area of fuel station, beware of passing vehicles that could hit you. Block off the
work area to protect yourself and other persons. Use safety cones or other signaling devices.

WARNING
Components substitutions could impair intrinsic safety.
Attaching unauthorized components or equipment will void your warranties.
CAUTION
Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all
warranties related to this equipment.
PROPRIETY NOTICE
This document contains propriety and confidential information. It is the property of ORPAK SYSTEMS
Ltd. It may not be disclosed or reproduced in whole or in part without written consent of ORPAK
SYSTEMS. The information in this document is current as of the date of its publication, but is subject to
change without notice.
DISCLAIMER
This document is provided for reference only. Although every effort has been made to ensure correctness,
ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.
FCC Compliance Statement
The FCC Wants You to Know:
This equipment has been tested and found to comply with the limits for a Class B & C digital device,
pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment generates uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures :
a) Reorient or relocate the receiving antenna.
b) Increase the separation between the equipment and receiver.
c) Connect the equipment to an outlet on a circuit different from that to which the receiver is connected.
d) Consult the dealer or an experienced radio/TV technician.
FCC Warning
Modifications not expressly approved by the manufacturer could void the user authority to operate the
equipment under FCC Rules.

This document is the property of:
ORPAK SYSTEMS Ltd.
ISRAEL

TABLE OF CONTENTS
Paragraph Page
GENERAL DESCRIPTIONSECTION 1
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
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TABLE OF CONTENTS
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1-8.
SPECIFICATIONS.............................................................................................................22
1-9. STANDARDS.....................................................................................................................23
1-9.1. Communication Standards .............................................................................................23
1-9.2. Security Standards..........................................................................................................23
1-10. MANUAL STRUCTURE................................................................................................... 24
1-11. USING THIS MANUAL....................................................................................................25
1-12. REFERENCES ...................................................................................................................26
PRELIMINARY INSTALLATION INSTRUCTIONSSECTION 2
2-1. GENERAL..........................................................................................................................28
2-2. PRELIMINARY INSTALLATION INSTRUCTIONS ..................................................... 28
2-2.1. General ........................................................................................................................... 28
2-2.2. Precautions and Safety Notes......................................................................................... 28
2-3. CONDUITS LAYOUT/INSTALLATION SPECIFICATIONS........................................29
2-4. CONDUITS ........................................................................................................................29
2-4.1. General ........................................................................................................................... 29
2-4.2. Conduit Requirements....................................................................................................30
2-4.3. Conduits at Islander PLUS............................................................................................. 30
2-4.4. Required Conduits in Island........................................................................................... 32
2-4.5. Required Conduits in Islander PLUS.............................................................................32
2-5. CONDUITS INSTALLATION ..........................................................................................33
2-5.1. General ........................................................................................................................... 33
2-5.2. Installing Conduits in Island .......................................................................................... 33
2-5.3. Sealing Conduits ............................................................................................................33
2-6. CABLES INSERTION.......................................................................................................36
2-6.1. General ........................................................................................................................... 36
2-6.2. Types of Cables..............................................................................................................36
2-6.3. Cables Routing............................................................................................................... 37
2-7. POWER SETUP ................................................................................................................. 37
2-7.1. General ........................................................................................................................... 37
2-7.2. Islander PLUS for 8 hoses - AC Power Supply Setup...................................................38
2-7.3. Connecting the Power Equipment..................................................................................40
2-7.4. Grounding.......................................................................................................................40
2-8. WIRING THE PERIPHERALS .........................................................................................41
2-8.1. Pump Wiring.................................................................................................................. 41
2-8.2. TLG wiring.....................................................................................................................41
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TABLE OF CONTENTS
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ISLANDER PLUS INSTALLATION PROCEDURESSECTION 3
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
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TABLE OF CONTENTS
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3-8.
MECHANICAL PUMP – WIRING ...................................................................................59
3-8.1. General ........................................................................................................................... 59
3-8.2. 4 – Mechanical Pump – Terminal Block - Pin-Out Connections...................................59
3-8.3. 8-Mechanical Pump – Terminal Block - Pin-Out Connections .....................................61
3-8.4. Mechanical Pump - Required Connections.................................................................... 65
3-8.5. Mechanical Pump - Pulser Connections.........................................................................70
3-8.5.1. Electronic Pulser........................................................................................................70
3-8.5.2. Mechanical Pulser ..................................................................................................... 70
3-9. ELECTRONIC PUMP – WIRING DESCRIPTION..........................................................72
3-9.1. General ........................................................................................................................... 72
3-9.2. Tokheim Electronic Pump.............................................................................................. 74
3-9.3. Current Loop Electronic Pump ......................................................................................75
3-9.4. RS-485 Electronic Pump................................................................................................ 76
3-10. WIRING TO GENERAL COMPONENTS........................................................................ 77
3-10.1. General ........................................................................................................................... 77
3-10.2. Connection to TLG Controller.......................................................................................77
3-10.3. Connection to Journal Printer.........................................................................................77
3-11. POST-INSTALLATION CHECKLIST .............................................................................80
3-12. ISLANDER PLUS SETUP.................................................................................................80
PRINTERSECTION 4
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
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4-8.2.2.
Manual Insertion of Paper......................................................................................... 90
4-9. PRINTER CLEANING ...................................................................................................... 91
4-9.1. General........................................................................................................................... 91
4-9.2. Thermal Printer Head –Cleaning Instructions ............................................................... 91
4-9.2.1. General ...................................................................................................................... 91
4-9.2.2. Cleaning Procedures.................................................................................................. 91
4-10. TROUBLESHOOTING ..................................................................................................... 93
4-10.1. General........................................................................................................................... 93
4-10.2. Troubleshooting............................................................................................................. 93
4-10.3. Releasing Jammed or Crumpled Paper.......................................................................... 93
4-11. THERMAL PAPER STORAGE........................................................................................ 94
MAINTENANCESECTION 5
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
GLOSSARYSECTION 6
6-1. FUELOMAT GLOSSARY ................................................................................................ 113
6-2. COMMUNICATION GLOSSARY ................................................................................... 114
APPENDIX A SITE SURVEY
APPENDIX B WIRING DIAGRAM
APPENDIX C HID ASASEMBLY INSTALLATION
INTRODUCTION.......................................................................................................................... 125
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INSTALLATION INSTRUCTIONS .............................................................................................127
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