Tokheim Crypto VGA User manual
Crypto VGA
Document Ref 942179-001
Rev - 1
09/2007
Component
Technical Manual
Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
Issue A
Great care has been taken in the preparation of this manual however Tokheim
shall not be liable for any misunderstanding, errors and/or loss or defect
arising from the use of this manual.
Tokheim shall not be liable for damage to the product, nor for personal or
third party injury, caused by incorrect use of the product or by attempts to
maintain or to repair the product by parties other than those fully trained by
Tokheim or by its accredited third party representatives.
Please contact your nearest service department, at the relevant address printed
on the back cover of this manual, should any aspect of this manual be unclear.
© Copyright by Tokheim. All intellectual rights arising from, accruing
to,and residing in this manual belong to Tokheim. No part of this document
may be reproduced in any form without the express written permission of
Tokheim.
Tokheim reserves the right to apply changes to this document and the
equipment without further notice.
Document Ref 942179-001 Rev 1 1
Component Technical Manual Crypto VGA
REVISION RECORD
Date Revision Page Issue Reason
13/09/2007 1 All A Original Issue
2 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
This page is intentionally blank
Issue A
Document Ref 942179-001 Rev 1 3
Technical Component Manual Crypto VGA
Issue A
(CONT.)
CONTENTS
1 INTRODUCTION........................................................................................................ 1-2
1.1 How to Use this Manual ......................................................................................1-2
1.2 Product Scope ...................................................................................................... 1-2
1.3 Authorised Technicians ........................................................................................ 1-2
1.4 Contact Information .............................................................................................1-3
1.5 Health & Safety ...................................................................................................1-3
1.5.1 Safety Checklist ...................................................................................1-3
1.5.2 Duties of the Employees ......................................................................1-3
1.5.3 Hazards................................................................................................1-4
1.5.4 Warning Signs ......................................................................................1-4
1.5.5 Personal Protective Equipment (PPE) ................................................1-6
1.6 Standards & Certificates ...................................................................................... 1-7
2 PRODUCT INFORMATION .................................................................................... 2-2
2.1 System Description ..............................................................................................2-2
2.2 Key Characteristics..............................................................................................2-2
2.2.1 Crypto VGA Hardware ....................................................................... 2-3
2.2.2 Environmental Conditions ....................................................................2-3
2.3 Configuration ........................................................................................................ 2-3
2.3.1 Receipt Printer .....................................................................................2-4
2.3.2 VGA / Touch Sensor ........................................................................... 2-4
2.3.3 Manual Card Reader ........................................................................... 2-4
2.4 Crypto VGA Terminal Dimensions ...................................................................... 2-5
2.4.1 Crypto VGA Standalone Island Terminal ........................................... 2-5
2.4.2 Crypto VGA add on unit ...................................................................... 2-6
2.4.3 Crypto VGA DIT ................................................................................. 2-7
2.4.4 Crypto VGA BNA ...............................................................................2-8
3 INSTALLATION OF THE CRYPTO VGA.............................................................. 3-2
3.1 General .................................................................................................................3-2
3.2 Retrofitting the Crypto VGA ................................................................................ 3-2
3.3 Communication Connections ................................................................................ 3-2
3.4 Crypto VGA Connections across the Forecourt .................................................. 3-2
3.4.1 Panduit Connector Instructions ............................................................ 3-4
3.5 Installation of the OPT IQ BNA .......................................................................... 3-5
3.5.1 Ground Frame Installation Procedure .................................................. 3-5
3.5.2 Lifting and Placement Procedure ........................................................3-6
4 CRYPTO VGA WIRING DIAGRAMS ..................................................................... 4-2
4.1 Wiring Overview - Crypto VGA ..........................................................................4-2
5 CRYPTO VGA PARTS LIST ...................................................................................... 5-2
5.1 Crypto OPT Assembly .........................................................................................5-2
5.2 Crypto DIT Assembly .......................................................................................... 5-4
5.3 Crypto VGA PSU & Lamp Assembly ................................................................. 5-6
5.3.1 Crypto VGA PSU Assembly ............................................................. 5-8
5.4 Crypto VGA Assembly ...................................................................................... 5-10
5.5 Crypto VGA Printer Assembly .......................................................................... 5-12
4Document Ref 942179-001 Rev 1
Crypto VGA Technical Component Manual
Issue A
5 CRYPTO VGA PARTS LIST /
5.6 Crypto VGA Bracket Assembly (Single-Sided) ................................................. 5-14
5.7 Crypto VGA Bracket Assembly (Double-Sided) ............................................... 5-16
5.8 Crypto VGA Lock Assembly ............................................................................. 5-18
5.9 Euro Lock Assembly .......................................................................................... 5-20
6 CRYPTO VGA BASIC MAINTENANCE ............................................................... 6-2
6.1 Accessing the Crypto VGA .................................................................................6-2
6.2 Cleaning Cards ..................................................................................................... 6-2
6.2.1 Magnetic Stripe Cleaning Cards ..........................................................6-2
6.2.2 Chipcard Cleaning Cards .....................................................................6-2
6.3 Replacing a Paper Roll ......................................................................................... 6-3
6.4 Paper Jams ........................................................................................................... 6-4
6.5 Printer Cutter Units/Blades ..................................................................................6-5
6.6 Cleaning the Display Screen ................................................................................6-5
6.7 Bank Note Acceptors (BNA) ..............................................................................6-6
6.8 Changing a bulb (Crypto VGA OPTs only)..........................................................6-7
6.9 Changing the battery pack (Crypto VGA OPTs only) .........................................6-8
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 1-1
Issue A
CONTENTS
1 INTRODUCTION........................................................................................................ 1-2
1.1 How to Use this Manual ......................................................................................1-2
1.2 Product Scope ...................................................................................................... 1-2
1.3 Authorised Technicians ........................................................................................ 1-2
1.4 Contact Information .............................................................................................1-3
1.5 Health & Safety ...................................................................................................1-3
1.5.1 Safety Checklist ...................................................................................1-3
1.5.2 Duties of the Employees ......................................................................1-3
1.5.3 Hazards................................................................................................1-4
1.5.4 Warning Signs ......................................................................................1-4
1.5.5 Personal Protective Equipment (PPE) ................................................1-6
1.6 Standards & Certificates ...................................................................................... 1-7
Page 1-2 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
1 INTRODUCTION
1.1 How to Use this Manual
It is recommended that all relevant persons familiarise themselves with the contents of this
manual prior to carrying out any operations or procedures.
This manual is divided into sections which are described as follows: -
Section 1 - Introduction
This section contains information on how to use the manual, the scope of equipment covered,
recommendations on qualified technicians and contact information. It also includes relevant
health and safety information required for the safe installation of the product.
Section 2 - Product Information
This section contains the system descriptions and operating principles of Tokheim’s Crypto
VGA payment system.
Section 3 - Installation of the Crypto VGA unit
This section provides the necessary information for the installation and connection of the
Crypto VGA unit.
Section 4 - Crypto VGA Wiring Diagrams
This section details the wiring diagrams for the Crypto VGA.
Section 5 - Crypto VGA Parts List
This section details the assembly drawings and part identification lists for the Crypto VGA.
1.2 Product Scope
This manual is designed to cover the Crypto VGA in Quantium T-range dispensers and
later models.
1.3 Authorised Technicians
Only qualified technicians familiar with the contents of this manual should carry out the
procedures contained herein.
WARNING : ANY ATTEMPTS TO CARRY OUT THE PROCEDURES OF THIS
MANUAL, BY UNQUALIFIED OR UNAUTHORISED PERSONS, MAY
RESULT IN SERIOUS INJURY OR LOSS OF LIFE.
NOTE : THIS MANUAL IS NOT INTENDED TO REPLACE THE SERVICES
OF A FULLY QUALIFIED TECHNICIAN.
Issue A
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 1-3
1.4 Contact Information
For information relating to the contents of this manual please contact: -
Technical Author
Tokheim UK Ltd.
Dundee, Scotland
For technical assistance please contact the appropriate service division listed on the back
cover of this manual.
1.5 Health & Safety
1.5.1 SAFETY CHECKLIST
•It is obligatory that this checklist be fully complied with during all work at the
petrol station, particularly construction or repair work.
•It is the duty of the contractor to ensure that all workers employed by him obey
each and all of the relevant laws, directives and other regulations.
Areas where special caution is required
•The insides of tanks, tubes, dome shafts, filling shafts, change over shafts, vessels
and dispensers.
•All areas in which fuel vapour that is heavier than air can accumulate, e.g. fuel
separator, draining shafts, low located rooms, cellars, excavations, pipe trenches
etc.
•The areas around the outlets of tank ventilation pipes, especially during the filling
phase.
•All areas near dispensers, tanker lorries and other vehicles while they are being
tanked up, and particularly when there is a lack of wind.
•A radius of 1.0 metres around petrol carrying pipes, as well as pipes that are not
vapour free.
•Silt traps.
1.5.2 DUTIES OF THE EMPLOYEES
•To ensure optimal accident prevention in our company, in addition to general
rules applying to worker’s protection, it is necessary to take into account all the
national protection of workers legislation and to actively support all measures
which enhance safety standards.
•It is an employee’s duty to follow all company directives regarding the prevention
of accidents, unless such directives can be proved to be unfounded.
•Employees should not follow any instructions that go against safety standards.
•Employees are only permitted to use equipment for its original purpose, and this
is defined by the company alone.
•If an employee detects equipment that is deficient in terms of safety, he shall
eliminate this deficiency immediately. If such safety rectification is not part of
his defined area of activities, or if his knowledge is insufficient to carry out such
work he must immediately inform his superior about the detected safety
deficiency.
Issue A
Page 1-4 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
This equally applies to:
1) Work Materials which have not been correctly packed or correctly marked in
order to meet safety requirements.
2) Work Methods or work processes which have not been correctly coordinated
or controlled in order to meet safety requirements.
3) Where dangerous activities are carried out by several persons, the need
for a permanent faultless communication between them in order to avoid
dangerous events shall require the appointing of one person in order to carry out
overall supervision.
1.5.3 HAZARDS
Prior to starting work, the dispenser must be isolated (i.e. entirely disconnected
from the mains supply) and the mains supply switch locked in the OFF position.
The submerged pump (if applicable) and control signals from the dispenser must
also be isolated. This is done to provide safety for the technician. As a further
precaution, switch off the mains supply in the service station shop and place a
clear notice on the switch to avoid it being turned on again inadvertently.
WARNING : THE CONNECTION AND DISCONNECTION OF
ELECTRICAL CONNECTIONS MAY ONLY BE CARRIED OUT BY
QUALIFIED PERSONNEL AUTHORISED FOR SUCH ACTIVITIES.
WORK IN DANGEROUS AREAS MUST BE MADE SAFE BY
OBSERVING ALL THE NATIONAL SAFETY REQUIREMENTS IN
FORCE.
It is not permitted to put a fuel dispenser into operation before an authorised
official has inspected it and released it. This depends upon the national regulations
in force.
Dismantled packaging and cladding must be stored in such a way as to avoid
damage to components or injuries to persons. Covers that can be opened, such
as the calculator housing, should be handled with care. Ensure that the retaining
catch is placed in the correct position to prevent the cover falling onto the head
of the service engineer or other persons in the area.
At unattended service stations, every end-user should be able to read the User
Instructions. They should be visible on a notice board or integrated into the DIT
and should be sufficiently well lit so that they can be read at night.
At unattended service stations break away couplings must always be used to
reduce the danger caused by a motorist driving off with the nozzle still in the
tank.
1.5.4 WARNING SIGNS
The following warning signs are fitted as standard, on the dispenser, however
they may vary according to individual country requirements or customer
specifications.
Issue A
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 1-5
Issue A
Do not use mobile
phones
SIGN
Naked flames and
smoking forbidden
Visible from both
sides of dispenser
Visible from both
sides of dispenser
MEANING POSITION
Do not spill fuel on the
ground
Stop vehicle engine
At Diesel high speed
dispensers near the
nozzle boots
Visible from both
sides of dispenser
Visible from both
sides of dispenser
Trucks only
Do not drive away with
nozzle in tank
Next to User
Instructions near the
nozzle boot
Visible from both
sides of dispenser
Page 1-6 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
1.5.5 PERSONAL PROTECTIVE EQUIPMENT (PPE)
PROTECTIVE CLOTHING
The following clothing should be worn at all times during installation and
maintenance procedures:-
•Protective helmet.
•Protective shoes (conductive).
•Protective gloves and/or protective hand cream.
•Anti static clothing.
•Eye protection.
SAFETY EQUIPMENT FOR WORKING IN HAZARDOUS AREAS
The following safety equipment is required for working in hazardous areas:-
•Only spark free tools are permitted for work on dispensers.
•Work on bearings is only permitted using the standard workshop tools authorised
for this kind of work.
•The use of all electrical tools is strictly prohibited.
•Only the use of explosion protected work lights is permitted.
•The use of telecommunications equipment in hazardous areas is strictly prohibited.
SAFETY INSTRUCTIONS
The following safety instructions must be adhered to during installation and
maintenance procedures:-
•Inhalation of petrol vapour must be avoided. Suitable precautions must be taken
and where necessary respirators used.
•Avoid direct contact of fuel with the skin.
•Use suitable protective clothing, protective gloves and/or protective hand cream.
•Avoid fuel spills.
•No smoking, no naked flames are permitted.
•Long hair and ties can get caught in moving parts. Hair must be suitably covered.
Issue A
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 1-7
Issue A
1.6 Standards & Certificates
Tokheim Crypto VGA standalone and integrated units are constructed in conformity with
the requirements of all the applicable European Directives (Machinery 98/37/EC; EMC
89/336/EEC; ATEX 94/9/EC) and compliant with OIML R177.
Dispenser integrated terminals are incorporated into Tokheim fuel dispensers which conform
to the essential requirements of the Machinery Directive 98/37/EC.
The components used within the OPTimum, including connection facilities, are selected in
accordance with the European Standard EN BS 60079-0 (Electrical Apparatus for explosive
gas atmospheres) and the supplementary Standards listed therein.
The Crypto VGA payment terminal is also EMV 2000 approved and PCI POS AFD
approved. Compliant with Anti Fishing Anti Skimming (AFAS) requirements in France.
The production and end test is controlled through the Quality Assurance systems within
the Tokheim Manufacturing Centres.
Page 1-8 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
Issue A
This page is intentionally blank
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 2-1
Issue A
CONTENTS
2 PRODUCT INFORMATION....................................................................................... 2-2
2.1 System Description ............................................................................................. 2-2
2.2 Key Characteristics ............................................................................................. 2-2
2.2.1 Crypto VGA Hardware ....................................................................... 2-3
2.2.2 Environmental Conditions .................................................................. 2-3
2.3 Configuration ...................................................................................................... 2-3
2.3.1 Receipt Printer .................................................................................... 2-4
2.3.2 VGA / Touch Sensor........................................................................... 2-4
2.3.3 Manual Card Reader........................................................................... 2-4
2.4 Crypto VGA Terminal Dimensions..................................................................... 2-5
2.4.1 Crypto VGA Standalone Island Terminal .......................................... 2-5
2.4.2 Crypto VGA Add On Units ................................................................ 2-6
2.4.3 Crypto VGA DIT ................................................................................ 2-7
2.4.4 Crypto VGA BNA .............................................................................. 2-8
Page 2-2 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
Issue A
2.2 Key Characteristics
The Crypto VGA has the following key characteristics:-
• Modular micro-processor hardware
• Off-the-shelf real-time operating system
• Modular design harmonised with dispenser design
• Audio-signal/feedback
• Battery Back-up
• Alarm Contacts
•Card reader for magnetic stripe cards and/or chip cards
• EMV and PCI approval
Additional Crypto VGA characteristics:-
•VGA touchscreen
•Touchscreen based security PIN pad to allow all data to be read and entered within the
same screen e.g. PIN code, pump number, mileage etc.
•Anti-intrusion protection integrated into the design
•Controlled through the Fuel POS enables the provision of a variety of additional
functionality such as remote diagnostics, audio/visual instructions, advertising etc.
2 PRODUCT INFORMATION
2.1 System Description
Tokheim’s Crypto VGA payment terminal incorporates advanced colour touchscreen
technology enclosed in a fraud protective housing to provide secure pay-at-the-pump
facilities with an up-to-date and secure user interface.
The Crypto VGA is available as:-
•Dispenser-integrated payment terminal (DIT) which can be delivered pre-installed in a
new dispenser or integrated at a later date into Quantium T and 10 series dispensers (single
or double-sided)
•Standalone island terminal (single-sided only)
•Add-on unit for third party dispensers (single or double-sided)
•Optionally with the Bank Note Acceptor (BNA)
ISLAND
TERMINAL
DIT WITH
MULTIMEDIA
ADD-ON
UNIT
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 2-3
Issue A
2.2.1 CRYPTO VGA HARDWARE
• Manual card reader for magnetic stripe cards and/or chip cards
• High speed thermal ticket printer with automatic cutter and “drop down” ticket
bin with paper-end/low detection
• Full colour 6.4” VGA touchscreen with NFI touch panel
• Touchscreen based security PIN-pad
• TCP/IP interface for high speed, high bandwidth data streams
• LAN connection to Fuel POS system
• Mains : single phase 230V AC
2.2.2 ENVIRONMENTAL CONDITIONS
• Ambient temperature : -25oC to +60oC for standard configuration
• Relative humidity : 5% to 95% non-condensing
2.3 Configuration
The Crypto VGA is only available in a single secure unit configuration with no user-
defined or country specific parts.
The main components of the OPT are:-
• Receipt Printer (refer to section 1.3.1)
•VGA / Touch sensor (refer to section 1.3.2)
• Manual Card Reader (refer to section 1.3.3)
DISPLAY
SCREEN &
TOUCHSCREEN
PIN-PAD
MANUAL
CARD
READER
RECEIPT
PRINTER
Page 2-4 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
Issue A
2.3.1 RECEIPT PRINTER
All OPTimum IQ units are fitted with the standard receipt printer, automatic
cutter and printer controller board. A drop-down ticket bin is also supplied to
avoid the risk of paper jams caused by customers removing the ticket prior to
completion of cutting.
The basic characteristics of the receipt printer are as follows:-
• Printing Method : Thermal dot line printing (448 dots per line)
• Effective Printing Width : 56mm
• Printing Speed : 400 dot lines per second
• Paper Feed Method : Friction - Pitch 0.125mm per minute force 100g
• Motor : 4 phase step motor 24V DC (+/- 5%)
• Printing Head Circuit : 5V DC (+/- 5% 100mA)
• Printing Head Driving : 5V DC (+/- 5% 1.7A at 25% duty)
• Paper Width : 59.5mm (+/- 5mm)
• Paper Roll Diameter : <160mm
• Temperature Detector : By thermistor
• Head Open Detection : By Mechanical Switches
• Paper End Detection : By Photo Interruptor
•Paper Low Detection : Optional - by Photo Interruptor
• Paper Replacement : Auto Feed (once new roll in position)
•Ambient Temperature -25oC to +50oC
Range : (with direct sun radiation the printer can temporarily
stop working at an ambient temperature of 45oC)
2.3.2 VGA / TOUCH SENSOR
The touchscreen based security PIN-pad allows all data to be read and entered
within the same screen e.g. PIN code, pump number, mileage etc. Control via
the Fuel POS provides the means for a variety of added functionality such as
remote diagnostics, audio/visual instructions, advertising etc.
• Capacitive touch sensor with toughened anti-glare glass
2.3.3 MANUAL CARD READER
The EMV 2000 compatible manual operated card reader is available for magnetic
stripe cards and/or chip cards. The main characteristics are:-
• Magnetic Cards : Read track 1,2,3 with ISO conformity
• Recording Method : FM decoding (F2F)
• Card Feeding Method : Manual (push/pull)
• Card Feeding Speed : 8-127cm per second
• Service Life : >500,000 passes
•PCI POS AFD offline and online compatible
Component Technical Manual Crypto VGA
Document Ref 942179-001 Rev 1 Page 2-5
Issue A
2.4 Crypto VGA Terminal Dimensions
2.4.1 CRYPTO VGA STANDALONE ISLAND TERMINAL
1449
350
336
70
340
1003
1350
Page 2-6 Document Ref 942179-001 Rev 1
Crypto VGA Component Technical Manual
Issue A
2.4.2 CRYPTO VGA ADD ON UNITS
CRYPTO VGA PAYMENT ASSEMBLY
CRYPTO VGA PRINTER ASSEMBLY
Table of contents
