GILBARCO VEEDER-ROOT PA0261 User manual

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 1
Introduction
Purpose This manual provides instructions to convert the Universal Distribution Box (D-Box):
• From RS-422 to two-wire input for Passport®Point of Sale (POS) systems
• From two-wire to RS-422 for PAM™1000 systems
Intended Users
This manual is intended for Gilbarco-trained and certified Authorized Service Contractors
(ASCs).
Do not install this equipment unless you have proper training for installing equipment in a
hazardous location.
IMPORTANT INFORMATION
Table of Contents
Topic Page
Introduction 1
Important Safety Information 4
Before You Begin 6
Converting D-Box from RS-422 to Two-wire 7
Converting D-Box from Two-wire to RS-422 14
Required Tools and Materials
Following are the tools and materials required for the conversion of the Universal D-Box:
• Multimeter
• Needle Nose Pliers
• Phillips®Screwdriver #2
MDE-3882B
Conversion of the Universal Distribution Box
[D-Box (PA0261XXXXXXX)]: RS-422 to
Two-wire and Two-wire to RS-422
November 2015

Page 2 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Introduction
Parts List Following tables list the parts included in the Conversion Kits:
Item Description Part Number Quantity
1Assembly, Cable Two-wire J905/J102 D-Box R18810-G1 2
2Cable, Work Area Q13850-100 2
3Gender Mender Assembly, Modular Jack to D-Subminiature (D-Sub) Q13180-11B 2
4Assembly, Screw Lock (Connector D-Sub) Q10437-07 4
Conversion Kit Q13241-107
Item Description Part Number Quantity
1Assembly, Cable Two-wire J905/J102 D-Box R18810-G1 2
2Cable, Work Area Q13850-100 2
3Gender Mender Assembly, Modular Jack to D-Sub Q13180-11B 2
4Assembly, Screw Lock (Connector D-Sub) Q10437-07 4
5Cables, PC Q13240-09 1
Conversion Kit Q13241-118
Required Reading
Where fuels are involved, you are working in a dangerous environment of gasoline,
gasoline vapor, and electricity. Failure to install this equipment in accordance with
National Fire Protection Association (NFPA) 30A and NFPA 70®could result in severe
injury or death.
WARNING
Before installing the kits, read, understand, and follow:
•This manual.
•The National Electrical Code [NEC®(NFPA 70)].
•The automotive and marine service code (NFPA 30A).
•Any national, state, and local codes that may apply.
Failure to install the equipment in accordance with NFPA 30A and NFPA 70 may 
adversely affect the safe use and operation of the system.

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 3
Introduction
Related Documents
Document
Number Title GOLDSM Library
MDE-2713 Universal Distribution Box (D-Box) Installation Manual • Advantage®and Legacy®
• POS Peripheral Devices
MDE-3804 Encore®and Eclipse®Start-up/Service Manual • Encore and Eclipse
• Service Manual
MDE-3816 Passport Hardware Start-up and Service Manual • Passport
• Service Manual
MDE-3839 Passport System Installation Addendum Passport
Note: Ensure to read and understand the installation documentation for the dispensers being connected to the D-Box.
Abbreviations and Acronyms
Term Description
CAT-5 Category 5
CRIND®Card Reader in Dispenser
D-Box Distribution Box
D-Sub D-Subminiature
ESD Electrostatic Discharge
GOLD Gilbarco Online Distribution
NEC The National Electrical Code
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Administration
PAM Pump Access Module
PCB Printed Circuit Board
POS Point of Sale
TAC Technical Assistance Center
TWI Two-wire Current Loop Interface

Page 4 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Important Safety Information
Important Safety Information
Notes: 1) Save this Important Safety Information section
in a readily accessible location.
2) Although DEF is non-flammable, Diesel is
flammable. Therefore, for DEF cabinets that are
attached to Diesel dispensers, follow all the
notes in this section that pertain to flammable
fuels.

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 causedeathor serious injury,
if these safe service procedures are not followed.
Preliminary Precautions
You are working in a potentially dangerous environment of
flammable fuels, vapors, and high voltage or 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 pump/dispenser and island. Locate
the switch or circuit breakers that shut off all power to all fueling
equipment, dispensing devices, and Submerged Turbine
Pumps (STPs).
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’s ALL STOP and PUMP STOP or
similar keys.
!
WARNING
!
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 pump/dispenser or
STPs 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)
• A total 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 Technical Assistance Center (TAC) at 
1-800-743-7501. 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 70; National Electrical
Code (NEC), 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.
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.
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 with Alert symbol: Designates a hazard or
unsafe practice which may result in minor injury.
CAUTION without Alert symbol: Designates ahazard 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.
DEF is non-flammable. Therefore, explosion and fire safety
warnings do not apply to DEF lines.
!
!
!

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 the American 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.
The pump/dispenser contains a chemical known to the
State of California to cause cancer.
WARNING
!
The pump/dispenser contains a chemical known to the
State of California to cause birth defects or other
reproductive harm.
WARNING
!
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)
Gasoline/DEF ingested may cause
unconsciousness and burns to internal organs.
Do not induce vomiting. Keep airway open.
Oxygen may be needed at scene. Seek medical
advice immediately.
WARNING
!
DEF generates ammonia gas at higher temperatures.
When opening enclosed panels, allow the unit to air out to
avoid breathing vapors.
If respiratory difficulties develop, move victim away from
source of exposure and into fresh air. If symptoms persist,
seek medical attention.
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth, and lungs. Keep airway
open. Seek medical advice immediately.
WARNING
!
Gasoline/DEF spilled in eyes may cause burns to
eye tissue. Irrigate eyes with water for
approximately 15 minutes. Seek medical advice
immediately.
WARNING
!
Gasoline/DEF spilled on skin may cause burns.
Wash area thoroughly with clear water.
Seek medical advice immediately.
WARNING
!
DEF is mildly corrosive. Avoid contact with eyes, skin, and
clothing. Ensure that eyewash stations and safety
showers are close to the work location. Seek medical
advice/recommended treatment if DEF spills into eyes.
WARNING
!
IMPORTANT: Oxygen may be needed at scene if gasoline has
been ingested or 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.
MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 5
Important Safety Information

Page 6 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Before You Begin
Before You Begin
Before you begin, read and understand “Important Safety Information” on page 4.
A properly grounded Electrostatic Discharge (ESD) wrist strap must be worn
while servicing any electronic devices or components. Failure to use
electrostatic precautions may damage electronic components and void
warranty.
CAUTION
1Inform the manager.
2Barricade the unit to be worked on.
3
Failure to turn off the unit during the installation of the kit may cause injury or bodily harm
from electrical shock. Ensure that all power to the unit is switched off before opening the
door to the unit and during kit installation.
WARNING
Remove power to the unit at the breaker panel. Follow OSHA lockout/tagout procedures.
4Match the parts received in the kit with “Parts List” on page 2.

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 7
Converting D-Box from RS-422 to Two-wire
Converting D-Box from RS-422 to Two-wire
To convert a D-Box from RS-422 to two-wire, proceed as follows:
1Loosen the two screws on the bottom front of the D-Box, and lift the lid.
2
Working on Printed Circuit Boards (PCBs) without connecting to a ground or discharging
static can damage electronic parts. Use a wrist strap and store parts in antistatic storage
bags.
CAUTION
Disconnect the cable(s) at ports P101 and P103 of T17651 Board and ports P101 and P103A/B
of M14301 Board.
3Remove the two screws that secure the 9-pin D-Sub connectors to the D-Box case; then,
remove and discard the cable assembly.
4Install the R18810-G1 Two-wire Cables at the D-Sub positions. Secure the cable with the
standoffs.
5Connect the other end of the R18810-G1 Cable(s) to port P102 (for T17651) and 
port P102A/B (for M14301) on the PCBs. Note the orientation of the cable.
6Change and verify the jump jack settings.
Configuration 8 Loops/1 Input 16 Loops/1 Input 16 Loops/2 Inputs
Two-wire Current Loop Interface
(TWI): Dispensers or CRIND
devices
Figure 1 on page 8 and
Figure 2 on page 9 Figure 3 on page 10 and Figure 4 on page 11 Figure 5 on page 12 and Figure 6 on page 13
Following table lists the correct jump jack configurations:
7Reconnect the cable at the port P101.
8Connect the Q13850-100 Data Cables and Q13180-11B Gender Menders from the Passport
CPU or Passport Dispenser Hub.
Note: In case of D-Box with M14301 Board, Q13850-100 Cable can be directly connected to
RJ-45 input connectors P1 and P2 of the board so steps 4to 6are not required. An
additional step is to open the knockouts of box for P1 and P2, if they are not opened
already.
9Plug in the AC power cord.
10 Replace the D-Box cover, and secure with screws.
11 Verify the operation of card readers and/or dispensing units.
Converting the D-Box from RS-422 to two-wire is now complete.

Page 8 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Converting D-Box from RS-422 to Two-wire
Jumper Settings
Following are the diagrams for jumper settings for T17651 and M14301 Boards:
Figure 1: Jumper Settings - TWI, Single T17651 Board, Single Input, 8 Loops

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 9
Converting D-Box from RS-422 to Two-wire
Figure 2: Jumper Settings - TWI, M14301 Board, Single Input, 8 Loops

Page 10 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Converting D-Box from RS-422 to Two-wire
Figure 3: Jumper Settings -TWI, Dual T17651 Boards, Single Input, 16 Loops Total

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 11
Converting D-Box from RS-422 to Two-wire
Figure 4: Jumper settings - TWI, M14301 Board, Single Input, 16 Loops Total

Page 12 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Converting D-Box from RS-422 to Two-wire
Figure 5: Jumper Settings - TWI, Dual T17651 Boards, Two Inputs, 8 Loops Each

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 13
Converting D-Box from RS-422 to Two-wire
Figure 6: Jumper Settings - TWI, M14301 Board, Two Inputs, 8 Loops Each

Page 14 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Converting D-Box from Two-wire to RS-422
Converting D-Box from Two-wire to RS-422
To convert a D-Box from two-wire to RS-422, proceed as follows:
1Loosen the two screws on the bottom front of D-Box, and lift the lid.
2
Working on PCBs without connecting to a ground or discharging static can damage
electronic parts. Use a wrist strap and store parts in antistatic storage bags.
CAUTION
Disconnect the cables at ports P101 and P102 of T17651 Board and ports P102A/B of M14301
Board.
3Remove the two screws that secure the 9-pin D-Sub connector(s) to the D-Box case; then,
remove and discard the cable assembly.
4For T17651 Board, install the R19249-G1 Two-wire Cables at the D-Sub position(s). For
M14301 Board, install shorter R19249-G1 Cable near the board at D-Sub position and longer
R19249-G2 Cable at D-Sub position away from board. Secure the cable with standoffs.
5For T17651 Board, connect the other end of the R19249-G1 Cable(s) to port P103. For
M14301 Board, connect R19249-G1 Cable to port P103A and R19249-G2 Cable to port
P103B. Note the orientation of the cable.
6
Configuration 8 Loops/1 input 16 Loops/1 Input 16 Loops/2 Inputs
RS-422: Dispensers or
CRIND Devices Figure 7 on page 15 and
Figure 8 on page 16 Figure 9 on page 17 and Figure 10 on page 18 Figure 11 on page 19 and Figure 12 on page 20
Change and verify the jump jack settings.
Following table lists the correct jump jack configurations:
7Reconnect the cable at the port P101.
8Connect the Q13850-100 Data Cables and Q13180-11B Gender Menders from the Passport
dispenser hub.
9Plug in the AC power cord.
10 Replace the D-Box cover, and secure with screws.
11 Verify the operation of card readers and/or dispensing units.
Converting the D-Box from two-wire to RS-422 is now complete.

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 15
Converting D-Box from Two-wire to RS-422
Jumper Settings
Following are the diagrams for jumper settings for T17651 and M14301 Boards:
Figure 7: Jumper Settings - RS-422 Interface, Single T17651 Board, Single Input, 
8 Loops

Page 16 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Converting D-Box from Two-wire to RS-422
Figure 8: Jumper Settings - RS-422 Interface, M14301 Board, Single Input, 8 Loops

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 17
Converting D-Box from Two-wire to RS-422
Figure 9: Jumper Settings - RS-422 Interface, Dual T17651 Board, Single Input, 
16 Loops Total

Page 18 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Converting D-Box from Two-wire to RS-422
Figure 10: Jumper Settings - RS-422 Interface, M14301 Board, Single Input, 16 Loops
Total

MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 19
Converting D-Box from Two-wire to RS-422
Figure 11: Jumper Settings - RS-422 Interface, Dual T17651 Board, Two Inputs of 
8 Loops Each

© 2015 Gilbarco Inc.
7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone [phone] · http://www.gilbarco.com · Printed in the U.S.A.
MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and
Two-wire to RS-422 · November 2015
The Advantage®Series, CRIND®, Encore®, Eclipse®, Legacy®, and Passport®are registered trademarks of Gilbarco Inc. GOLDSM is a
service mark of Gilbarco Inc. PAM™is a trademark of Gilbarco Inc. Phillips®is a registered trademark of Phillips Screw Company.
Converting D-Box from Two-wire to RS-422
Figure 12: Jumper Settings - RS-422 Interface, M14301 Board, Two Inputs of 8 Loops 
Each