VeriFone Forecourt Controller Interface User manual

Forecourt Controller
Interface
Forecourt Controller Interface
Installation Guide
Date: August 11, 2016

Forecourt Controller Interface Installation Guide
August 11, 2016
Verifone®, Inc.
88 West Plumeria Drive
San Jose, CA 95134
Telephone: [phone]
http://www.verifone.com
Printed in the United States of America.
© 2016 Verifone, Inc. All rights reserved.
No part of this publication covered by the copyrights hereon may be reproduced or copied in
any form or by any means - graphic, electronic, or mechanical, including photocopying, taping,
or information storage and retrieval systems - without written permission of the publisher.
The content of this document is subject to change without notice. The information contained
herein does not represent a commitment on the part of Verifone. All features and
specifications are subject to change without notice.
Verifone, Ruby SuperSystem, and Secure PumpPAY are registered trademarks of Verifone, Inc.
Ruby Card, iOrder, and Commander Site Controller are trademarks of Verifone. All other brand
names and trademarks mentioned in this document are the properties of their respective
holders.

Forecourt Controller Interface Installation Guide
Revision History
Date Description
June 25, 2012 Initial documentation release.
November 2, 2012 Added Warning below. Also, added new part numbers
for the FCI kit and manual.
May 1, 2014 Added references to Commander Site Controller and
current loop board changes.
June 19, 2014 Added Tokheim and Bennett
September 19, 2014 Added information regarding Tokheim and Bennett
RS485 board connections and added Current Loop
Jumper Settings.
March 25, 2015 Added SFC section.
August 11, 2016 Updated the Determing a Location section, Tokheim
TED, added a Megger Test note to the Connecting the
Dispenser Control Cables section, and added Product
Warranty information to the Introduction.

WARNING!
1. This equipment is not intended to be repaired by the user. All
repairs must be performed by an Authorized Service Technician or
a Verifone VASC.
2. The AC Outlet must be within six feet of the Forecourt Controller
Interface unit.
3. The power supply cord must not be attached to the building
surface nor through wall, ceilings, floors, or similar openings in
the building structure.
4. Installation measures must be taken to prevent physical damage
to the power supply cord, including proper routing of the power
supply cord.
5. When replacing the cover on the Forecourt Controller Interface,
tighten the thumbscrews securely with a screwdriver.

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Contents
1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . 1
Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Before You Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Installing the Forecourt Controller Interface Box 7
Determining a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sites required to use the Smart Fuel Controller (SFC) . . . . . . . 8
Gilbarco Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wayne Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tokheim Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bennett Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preparing to Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installing the Forecourt Controller Interface Box. . . . . . . . . . . . 14
Installing the Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connecting the Dispenser Control Cables . . . . . . . . . . . . . . . . . 22
Connecting to Current Loop Boards . . . . . . . . . . . . . . . . . . 23
Connecting to RS485 Boards . . . . . . . . . . . . . . . . . . . . . . . 26
Connecting to a Tokheim TED . . . . . . . . . . . . . . . . . . . . . . . . 29
Completing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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August 11, 2016
1 INTRODUCTION
This guide provides instructions for installing the Verifone®Forecourt Controller
Interface (FCI) Box.
Product Warranty
For Product warranty information, go to
http://global.verifone.com/company/terms-and-conditions/.
Description
The Forecourt Controller Interface allows fuel and DCR communications
between the dispensers and the Commander Site Controller.
Note: The Forecourt Controller Interface is not used for fuel communication
for Tokheim, Bennett, and sites required to use the Smart Fuel
Controller (SFC).
Forecourt Controller Interface Box

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The FCI box can hold up to four current loop or RS485 boards (or a combination
of both). Each board can support up to 16 fueling positions. The FCI box comes
with one current loop board installed. Additional boards must be ordered
separately.
• Current Loop Board (Kit # 29721-01) — Supports both current loop and
RS232 communications.
• RS485 Board (Kit # 29376-01) — Supports RS485 communications and must
be used for Dresser Wayne CAT/Ovation, Tokheim DPT, Bennett Secure
Payment Module (SPM), and Verifone Secure PumpPAY installations.
Before You Install
This section describes the components supplied with the Forecourt Controller
Interface box.
Unpacking
Carefully inspect the shipping carton and its contents for any damage that might
have occurred during shipment. If anything appears damaged, immediately file
a claim with the shipping company or carrier and notify your Verifone
representative.
Never use damaged equipment. A shock or fire hazard may exist if equipment is
energized in a damaged condition.
Contents
Remove the components from the packaging and place them on a table or
counter top. Make certain you have all the parts listed in Table 1 before you
begin. Contact the Verifone Technical Support Center if you are missing
anything.
Note: Keep the shipping carton and any packing material in case it is necessary
to move components from one location to another or to return the
equipment for service.
Note: One FCI box supports up to 32 fueling positions.

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General Requirements
Before you start, read the following important information:
1. Changes or modifications not expressly approved by Verifone, Inc., could
void the user’s authority to operate this equipment.
2. This equipment is not intended to be repaired by the user. All repairs
must be performed by an Authorized Service Technician or a Verifone
VASC .
3. All installations must comply with the requirements of the National
Electrical Code (NFPA 70), the Code for Fuel Dispensing Facilities and
Repair Garages (NFPA 30 and 30A), OSHA regulations, including Standard
29 CFR 1910.147, and all other applicable national and local codes.
Table 1: Forecourt Controller Interface Box (P/N M149-901-01-R)
Quantity Item Verifone Part Number
(1) unit Forecourt Controller Interface
Box
Includes:
- Locking ribbon cables (4)
- AC Power Cable
- Current Loop Board
M149-901-01-R
(1) per unit Forecourt Controller Interface
Installation Guide
DOC149-901-01-R,
Revision C00
Table 2: Materials Provided by Installer
Quantity Item
Various lengths 18 AWG plenum rated twisted-pair cable (for example,
Belden P/N 88760). Lengths depend on configuration.
(20) per unit Wire nuts for splicing 18 AWG wires
(3) per unit 1-inch metallic conduit fittings
(1) per unit 1/2-inch Romex cable clamp
(4) per unit #8, 1-1/2 inch wood screws
(4) per unit 1/8 inch toggle bolts. 3 inches long

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4. The circuit providing power to the Forecourt Controller Interface unit
must not power other devices. The AC outlet must be within six feet of
the Forecourt Controller Interface unit. Do not use extension cords.
5. The power supply cord must not be attached to the building surface nor
through walls, ceilings, floors, or similar openings in the building
structure.
6. Installation measures must be taken to prevent physical damage to the
power supply cord, including proper routing of the power supply cord.
7. Do not connect the Forecourt Controller Interface unit to the AC power
until the installation is complete.
8. Always wear an electrostatic wrist strap. Working on console electronics
without connecting to a ground or discharging static can damage
electronic parts.
9. When replacing the cover on the Forecourt Controller Interface
enclosure, tighten the screws securely with a Phillips screwdriver.
Safety Instructions
For safe disassembly and installation of this equipment, read and understand all
safety notices.
WARNING: You must be a Verifone Authorized Service Contractor
(VASC) with training in the installation, service, or
maintenance of this equipment before working on it.
DANGER means: If you do not follow the instructions, severe injury or
death will occur.
WARNING means: If you do not follow the instructions, severe injury or
death can occur.
CAUTION means: If you do not follow the instructions, damage to the
equipment can occur.
CAUTION: High voltage. To be serviced by authorized service
personnel only.
CAUTION: There is a risk of explosion if the battery is replaced by
an incorrect type. Dispose of used batteries according to
the instructions.

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DANGER: Disconnect all power to this equipment during
installation, service, or maintenace. Tag breakers to
prevent others from reconnecting power.
DANGER: This equipment is to be installed in an indoor location
only. Do not install this equipment in a hazardous
location.
WARNING: Make sure this equipment is correctly grounded. Failure
to do so can cause injury or damage to the equipment.

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August 11, 2016
2 INSTALLING THE FORECOURT
CONTROLLER INTERFACE BOX
This chapter provides instructions for installing the Forecourt Controller
Interface (FCI) box.
You can install the FCI box with
• Up to four current loop boards
• Up to four RS485 boards
• Any combination of current loop boards and RS485 boards (up to four
boards)
Warning:Before you begin to install the Forecourt Controller Interface box,
be sure all power to the existing distribution box and PAM or
Electronics Cabinet is disconnected at the main panel. Multiple
disconnects may be required to de-energize these devices. (Refer to
the General Requirements section in Chapter 1.)
Determining a Location
The Forecourt Controller Interface box must be mounted in an indoor location.
Locate the box at least 18 inches above the floor in an area where liquids will
not be spilled onto it.
Note: The Forecourt Controller Interface box is to be mounted in an indoor
location only. The box is not to be used in a hazardous location. Do not
mount the Forecourt Controller Interface in a fuel dispenser.
Avoid the following locations:
• DO NOT install less than six inches near or inside electrical panels
• DO NOT install less than six inches near submersible pump controllers or
along side wiring to these devices
• DO NOT install less than six inches near submersible pump relays

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Existing Equipment
Note: Dispose of all removed components in an appropriate manner as
approved by the site owner.
Sites required to use the Smart Fuel Controller (SFC)
Note: The Commander Site Controller application must be at base 32 or higher
OR supports POP Discounts and loyalty using the Smart Fuel Controller.
If the site is required to use the Smart Fuel Controller for fuel, then the Current
Loop boards are not needed in the FCI box. The FCI box and RS-485 boards are
still needed for the DCRs. A RS-232 cable is required from the Commander Site
Controller to the SFC box. See the Smart Fuel Controller Installation Guide on
the Verifone Premier Portal at Petro Downloads > Verifone Fuel Controllers >
Smart Fuel Controller for more information.
Gilbarco Sites
If there is an existing distribution box at the site, disconnect the cables from the
box and remove it. It is not used with the Forecourt Controller Interface. The
Forecourt Controller Interface box can be mounted in the same location.
The dispenser control cables will be reconnected to the Forecourt Controller
Interface.
Also, disconnect and remove the PAM. It is not used with the FCI box.
Distribution Box
Dispenser Communications Cables

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Wayne Sites
If there is a Wayne distribution box, disconnect all the dispenser control cables.
The terminals on the distribution box are marked (+) and (–); mark the positive
(+) wires. The dispenser control cables will be reconnected to the FCI. Also,
disconnect the cables that go to the Electronics Cabinet.
Remove the distribution box. It is not used with the FCI. The FCI box can be
mounted in the same location.
Remove the Electronics Cabinet and all the cables connected to it. It is not
reused.
PAM
Dispenser Control Cables
Cables to Electronics
Cabinet
Outside of Distribution Box

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Wayne Electronics Cabinet

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To k h e i m S i t e s
The FCI Box does not control Tokheim fuel communications. Tokheim sites
require a VXDHC or DHC box. Use a RS-232 cable (P/N 13836-XX) and red null
modem connector (P/N 13581-01) to connect the Commander Site Controller to
the VXDHC or DHC.
Note: If the Verifone Site Controller is being replaced rather than a new
installation, use the existing VXDHC/DHC box, cable and connector as
described above.
Tokheim DHC/VXDHC

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Bennett Sites
The FCI Box does not control Bennett fuel communications. Bennett sites
require a 515 Box. Use a RS-232 cable (P/N 13836-XX) and black straight through
connector (P/N 13641-01) to connect the Commander Site Controller to the 515
Box.
Note: If the Verifone Site Controller is being replaced rather than a new
installation, use the existing 515 box, cable and connector as described
above.
Bennett 515 Box