Gasboy Islander PLUS Bedienungsanleitung

WiringMDE - 4811FIslander PLUS and ICR PLUSINSTALLATION MANUAL This document is based on Orpak’s Island controller (OrIC) installation manual P/N 8174

TABLE OF CONTENTS Paragraph Page INSTALLATION INSTRUCTIONS ...

4-7. INSTALLATION PRINTING PARAMETERS 4-7.1. Jumpers Configuration The Printer includes jumpers that enable setting the RS-485 address and selectin

Figure 4-7. Printer Module– Jumpers Configuration Examples 4-7.2. Parameters for Printing The Printer features two printing modes, as determined

4-8. PAPER ROLL REPLACEMENT 4-8.1. General The Printer Module is a thermal printer and uses thermal printer paper only. The Printer is equipped w

Figure 4-9. Printer - Paper Replacement 5. Press the paper roll pivot (see Figure 4-9) and release pivot 6. Lift the paper roll pivot and re

NOTE Verify that the green paper-lock lever is closed 9. The paper can be inserted into the printer automatically or manually. 4-8.2.1. Automatic

4-9. PRINTER CLEANING 4-9.1. General The Printer should be cleaned periodically at short intervals, due to the harsh environment of the Home Base S

Figure 4-10. Pressing Paper-Lock Lever 4. Remove the cleaning card from its packaging 5. Insert the cleaning card manually into the printer pa

16. If readability is still poor all over the receipt, or even part of it, repeat cleaning procedures with a new Cleaning Card. 4-10. TROUBLESHOOTI

NOTE Do not attempt to release the paper using sharp objects such as a knife or a screwdriver. Doing so will damage the printer paper cutter and void

0 SECTION 5 MAINTENANCE 5-1. GENERAL This section provides general maintenance instructions for the Islander PLUS as well as a comprehensive troub

LIST OF ILLUSTRATIONS Figure Page Figure 1-1 - Islander PLUS / ICR PLUS - General View ...

Table 5-1. Islander PLUS Troubleshooting Fault Probable Cause Checks Corrective Action System is down LCD display is blank Doesn't accept Ke

Table 5-1. Islander PLUS Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action System is down (Continued) Doesn't accep

Table 5-1. Islander PLUS Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action Mechanic pump does not refuel (Continued) Pump

Table 5-1. Islander PLUS Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action Mechanic pump does not refuel (Continued) Pump

Table 5-1. Islander PLUS Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action Mechanic pump does not refuel (Continued) Paym

Table 5-1. Islander PLUS Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action Pump is Authorized and refueling but volume re

5-2.2. OrPT Troubleshooting The OrPT troubleshooting procedure and consequent corrective actions are described in Table 5-2. Table 5-2. OrPT Troub

Table 5-2. OrPT Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action OrPT does not accept RFID tag (Continued) OrPT display

Table 5-2. OrPT Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action OrPT does not accept HID card/key OrPT display does not

Table 5-2. OrPT Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action OrPT displays "No communication" message (Con

Figure 3-19 Mechanical Pump – Twin Dispenser Connections ... 68 Figure 3-20 Islander PLUS and

5-2.3. Printer Troubleshooting The Printer troubleshooting procedure and consequent corrective actions are described in Table 5-3. Table 5-3. Prin

Table 5-3. Printer Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action No communication to Printer (Continued) Incorrect

5-2.4. Communication Troubleshooting The troubleshooting procedure for problems related to communication to peripherals and consequent corrective act

Table 5-4. Communication Troubleshooting Fault Probable Cause Checks Corrective Action No communication to the pumps (8-port CommVerter) (Continued

Table 5-4. Communication Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action No communication to nozzles (Wireless Gateway)

Table 5-4. Communication Troubleshooting (Cont'd) Fault Probable Cause Checks Corrective Action No communication to the TLS (Continued) "

• Remove the cleaning card from its packing • Insert the cleaning card all the way in the Reader, and then pull it out slowly. • Perform the prev

0 SECTION 6 GLOSSARY 6-1. FUELOMAT GLOSSARY ComVerter LAN/232/485/422/C.L./Tokheim Communication Converter DataPass Vehicle Data Transceiver F

VIT Vehicle Information Transceiver VIU Vehicle Identification Unit (VIU3/35/45) WGT Wireless Gateway Terminal μVIT ( = micro VIT) Mini VIT with RF/L

WAN Wide Area Network WEP Wired Equivalent Privacy. The optional cryptographic confidentiality algorithm specified by IEEE 802.11 used to provide data

LIST OF TABLES Table Page Table 1-1. Islander PLUS - Standard Models...

APPENDIX A SITE SURVEY STATION INFORMATION FORMS (To be filled during site survey) Home Base Station Date:_______ Prepared by: Name:______ e-ma

• TLS type_________________________ B. STATION MODE OF OPERATION How do the pumps being authorized? o Console o Preset Money, Preset Volume o Fro

• Break Away :  Yes  No Location on the hose:________ • Vapor Recovery:  Yes  No • NOZZLE/HOSE THREAD:  INCH (NPT)  M

Do they use a TLS, what type ?_________________________________________ How do they read tanks today ?_________________________________________ H . S

Islander PLUS Manual 120

0 APPENDIX B WIRING DIAGRAM This appendix provides the wiring diagram of the Islander PLUS, as follows: • Figure B-1 Islander PLUS – Wiring Diagra

Figure B-1 Islander PLUS – Wiring Diagram (Mechanical Pump) Islander PLUS Manual 122

Figure B-2 Islander PLUS – Wiring Diagram (Electronic Pump) Islander PLUS Manual 123

Figure B-3 Islander PLUS for 8 hoses – Wiring Diagram Islander PLUS Manual 124

APPENDIX C HID ASASEMBLY INSTALLATION INTRODUCTION This appendix describes how to install the HID unit in the home base pedestal. Make sure you hav

Figure 1. HID Unit and Connector Figure 2. HID Holder and Nuts Islander PLUS Manual 126

INSTALLATION INSTRUCTIONS CAUTION Only a technician authorized to work on Orpak's pedestals can perform HID installation. The technician must w

2. Cut and remove the rectangular metal plate from the internal side of the pedestal door. Use a cutter to cut the six connecting points holding the

4. Attach the back cover to the HID holder using four screws (P/N 815201300) as shown in Figure 6. Tighten the screws using Phillips type screwdriv

6. Place the unit in the hole while the HID logo faces the front of the pedestal and the cable facing the back. Place the four holder holes on the fo

Figure 10. HID Connector Inserted to OrPT Connector 8. Adjust the cable ties to make sure the cable is fixed in its position. 9. Stick the ellipse

Figure 11. Placing Hand Tag Label on Pedestal Islander PLUS Manual 132

0 SECTION 1 GENERAL DESCRIPTION 1-1. SCOPE This manual is provided to assist you in installing Islander PLUS / ICR PLUS. The system must be insta

Figure 1-1 - Islander PLUS / ICR PLUS - General View Islander PLUS Manual 2

1-3. SYSTEM OVERVIEW 1-3.1. Islander PLUS System Islander PLUS is an innovative product that enables refueling in Home Base stations for fleets autho

1-3.6. Islander PLUS Capabilities for Forecourt Management Islander PLUS provides the following operational features for a comprehensive Forecourt man

1-3.7.1. Refueling Scenario with FuelPoint PLUS A motorist stops for fuel at the station. His authorization device for the fueling transaction is a

SAFETY CONSIDERATIONS Read all warning notes and instructions carefully. They are included to help you installing the Product safely in the highly fl

1-4. ISLANDER PLUS STRUCTURE 1-4.1. Main Components Following is a short description of the Islander PLUS main sub units (see Figure 1-3 and Figu

OrPT Panel The OrPT panel consists of Payment Panel and communication equipment. The Panel is equipped with an alphanumeric LCD (graphic LCD, option

8-Port CommVerter The 8-Port CommVerter consists of a communication board for all Islander PLUS electronic units and for the peripheral equipment inte

1-4.2. Islander PLUS Internal Configuration – Mechanical Pump Figure 1-3 shows a general configuration diagram of the Islander PLUS up to four mechan

Figure 1-4 shows a general configuration diagram of the Islander PLUS for eight mechanical pumps. Figure 1-4 - Internal Configuration Diagram – 8

1-4.3. Islander PLUS Main Components Location The following Figure 1-5 shows the location of the main components of the Islander PLUS, without the P

Figure 1-6 - Internal Components Location –8 Mechanical Pumps Islander PLUS Manual 12

Figure 1-7 – Islander PLUS with Optional Internal Printer (Sectional View) Islander PLUS Manual 13

Figure 1-8 – Islander PLUS for 8 hoses with Optional Internal Printer (Sectional View) Islander PLUS Manual 14

WARNING Components substitutions could impair intrinsic safety. Attaching unauthorized components or equipment will void your warranties. CAUTION Do n

1-5. AVAILABLE CONFIGURATIONS 1-5.1. General Islander PLUS is available in several configurations, in accordance with its intended use and with the

Mechanical dispensers require the installation of MPIC cards on the 8-port Convertor. Electronic dispensers (Tokheim, Current Loop, RS-485) require i

Table 1-1. Islander PLUS - Standard Models Name Gilbarco P/N Orpak P/N Islander PLUS for Electric Pumps PA039400000 800938103 Islander PLUS for Me

ICR PLUS w/Fleetkey & Mechanical Pumps - 4 hose PA039501400 800938170 ICR PLUS w/HID PA039502000 800938230 ICR PLUS w/HID & Mechanical Pum

1-6. SECURITY AND PROTECTION 1-6.1. General The transaction activities of the Islander PLUS are secured and protected for transmission and authoriz

Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions Islander PLUS Manual 21

1-8. SPECIFICATIONS The following physical, electrical and environmental specifications are applicable to the Islander PLUS: Islander PLUS - Pedes

1-9. STANDARDS 1-9.1. Communication Standards Islander PLUS communicates, in its different models, over the following standards: • RS-232 link • RS

1-10. MANUAL STRUCTURE This manual comprises of the following sections: Section 1: General Description This section provides a general description o

1-11. USING THIS MANUAL This manual includes alerting comments inserted along the document, in order to draw the reader’s attention to important issu

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

1-12. REFERENCES For additional and complementary information regarding the Islander PLUS system, please refer to the following manuals:  OrPT - I

0 SECTION 2 PRELIMINARY INSTALLATION INSTRUCTIONS 2-1. GENERAL This section provides the preliminary installation procedures for the Islander PLUS

 Remember that the Home Base Gas Station environment is highly flammable and combustible. Therefore, make sure that actual installation is performe

2-4.2. Conduit Requirements Conduits must comply with: • All conduits must be made and installed according to local regulations. • High-voltage

Figure 2-1 Islander PLUS Lower Protective Plate Figure 2-2 Standard Bottom Metal Plate's Knockout –Close View Islander PLUS Manual 31

2-4.4. Required Conduits in Island The types of conduits in the Island are a function of the different equipment, and their location in the Island.

2-5. CONDUITS INSTALLATION 2-5.1. General This paragraph describes the infrastructure groundwork necessary to install the conduits in the Island (s

Figure 2-4 Conduits Layout for Mechanical Pump Islander PLUS Manual 34

Figure 2-5 Conduits Layout for Electronic Pump Islander PLUS Manual 35

TABLE OF CONTENTS Paragraph Page GENERAL DESCRIPTION SECTION 11-1. SCOPE ...

2-6. CABLES INSERTION 2-6.1. General This paragraph describes the requirements and procedures for the insertion of cables in the conduits. NOTE Al

Table 2-2. Islander PLUS, Cables Type No. Function Type 1 AC Power from Office Power cable, 3x1.5 mm2 NYY (14 AWG), in accordance with local s

• Mains Circuit Control Box (MCC) • Uninterruptible Power Supply (UPS) – Online ("True") UPS Figure 2-6 shows the requested connections

Figure 2-7 Power Supply Components and Grounding Studs WARNING Islander PLUS is shipped configured for 110 VAC Mains power supply. Take care to

2-7.3. Connecting the Power Equipment Proceed as follows: • External Mains o Connect Mains power to the Mains Circuit Control Box (MCC) o Wire o

2-8. WIRING THE PERIPHERALS 2-8.1. Pump Wiring Islander PLUS is capable of directly driving pump motors up to 3/4 HP at 115 VAC or 1-1/2 HP at 230

o LAN: 1- 330 feet (100m) for direct connection to a TLG device • Conduit: All direct connect RS-232/LAN cable must be in a low voltage conduit awa

0 SECTION 3 ISLANDER PLUS INSTALLATION PROCEDURES 3-1. GENERAL This section provides the installation procedures for the Islander PLUS. These pro

3-2.3. Safety Distances Figure 3-1 shows the safety distances required for the installation of the Islander PLUS adjacent to the dispensers. When mo

Figure 3-4 shows a functional diagram of the links within the Home Base Station with electronic pumps. 3-3.2. Home Base Station Architecture The Hom

TABLE OF CONTENTS Paragraph Page 1-8. SPECIFICATIONS ...

Figure 3-2 Home Base Station with 4 Mechanical Pumps – System Diagram Islander PLUS Manual 46

Figure 3-3. Home Base Station with 8 Mechanical Pumps – System Diagram Islander PLUS Manual 47

Figure 3-4 Home Base Station with Electronic Pumps – System Diagram Islander PLUS Manual 48

3-4. MAPPING THE SITE– EXAMPLE 3-4.1. General This paragraph shows an example of the mapping of a site. This procedure consists of the following st

3-5. CONNECTIONS TO ISLANDER PLUS All connections to the Islander PLUS must be performed to the Terminal Block located at the bottom of the Islander

Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections Islander PLUS Manual 51

Figure 3-6 Islander PLUS Terminal Block, Power and LAN Connections (8 pumps) 3-6. INSTALLING THE ISLANDER PLUS PEDESTAL POLE 3-6.1. General The

2. Run cable conduits for each type of cables to the spot: • One High Voltage conduit from the dispenser • One Low Voltage conduit from the dispe

4. Pour concrete type B200 in the hole as a support base for the pole Figure 3-7 Pedestal Pole Installation 5. Take care that, as the concrete

Figure 3-8 Base Plate Installation (Example) Figure 3-9 Rosette (Upside down view) Figure 3-10 Rosette Dimensions Islander PLUS Manual

TABLE OF CONTENTS Paragraph Page ISLANDER PLUS INSTALLATION PROCEDURES SECTION 33-1. GENERAL ...

3-6.6. Pedestal Installation Instructions Proceed as follows: 1. Remove the four M10 nuts (1 in Figure 3-8) from the four bolts attached to the Bo

9. Anchor the Pedestal Pole onto the Pedestal Plate with the four expansion bolts protruding from the inner ground. 10. Secure the Pedestal Pole wit

3-7. WIRING 3-7.1. General After completing the installation procedure, perform the following wiring procedures. The wiring is performed in the Isl

• LAN cable – CAT5e • RS232/485/422/Tokheim/Pulser – Communication cable, twisted pair, separately shielded, low capacitance, e.g. Belden 8723 or eq

Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition Terminal No. Signal Name Functional Description 3 RX-RS232

Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition Terminal No. Signal Name Functional Description 37 GR

Terminal No. Signal Name Functional Description 22 +12V_6_P +12 VDC Output to Pulser – Nozzle 6 23 +12V_7_P +12 VDC Output to Pulser – Nozz

Terminal No. Signal Name Functional Description 10 PULSER_2 Pulser Input – Nozzle 2 11 PULSER_3 Pulser Input – Nozzle 3 12 PULSER_4 Puls

Figure 3-15 Islander PLUS - Terminal Block (8 pumps) Figure 3-16 Islander PLUS – Terminal Block –4 Mechanical Pump - Wiring List Label Isla

Figure 3-17 Islander PLUS – Terminal Block – 8 Mechanical Pump - Wiring List Label 3-8.4. Mechanical Pump - Required Connections This paragraph d

TABLE OF CONTENTS Paragraph Page 3-8. MECHANICAL PUMP – WIRING ... 59

per volume (liter/gallon) is determined by the Pulser unit. It is programmed as a "factor" by the Head Office controller. Handle Status I

Figure 3-18 Mechanical Pump – Single Dispenser Connections Islander PLUS Manual 67

Figure 3-19 Mechanical Pump – Twin Dispenser Connections Islander PLUS Manual 68

Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections Islander PLUS Manual 69

3-8.5. Mechanical Pump - Pulser Connections This paragraph describes the required wiring connections between the pulser in the mechanical pump and t

Figure 3-22 shows a schematic diagram of the connections between the Terminal Block and a 2-wire Pulser. Figure 3-22 Terminal Block and 2-Wire Pul

3-9. ELECTRONIC PUMP – WIRING DESCRIPTION 3-9.1. General The wiring in the Terminal Block differs in accordance with the type of electronic pump in

Figure 3-23 Islander PLUS Terminal Block – Wiring List Label Islander PLUS Manual 73

3-9.2. Tokheim Electronic Pump The wiring for the Tokheim electronic pump is provided as follows: • Figure 3-24 shows the specific wiring connectio

3-9.3. Current Loop Electronic Pump The wiring for the Current Loop electronic pump is provided as follows: • Figure 3-25 shows the specific wiring

TABLE OF CONTENTS Paragraph Page 4-8.2.2. Manual Insertion of Paper ...

3-9.4. RS-485 Electronic Pump The wiring for the RS-485 electronic pump is provided as follows: • Figure 3-26 shows the specific wiring connections

3-10. WIRING TO GENERAL COMPONENTS 3-10.1. General The following paragraphs show the specific wiring between the Islander PLUS Terminal Block and

Figure 3-28 Journal Printer – General View The Journal Printer is connected to the 8-Port Commverter through one of the channels of the RS-485 Modu

Figure 3-29 Journal Printer – Rear Panel Islander PLUS Manual 79

3-11. POST-INSTALLATION CHECKLIST After completing the installation procedure, inspect carefully the connection between the Islander PLUS and the ex

0 SECTION 4 PRINTER 4-1. OVERVIEW This section describes the (optional) Printer, its technical characteristics and its operation. The Printer (

The Printer provides visual and audio indications of its activities by means of two green LEDs and a buzzer. The visual and audio indications are use

4-3. MAIN COMPONENTS The Printer consists of the following main items (see Table 4-1 and Figure 4-3). Table 4-1. Printer Main Components Item

4-4. PRINTER CONNECTOR PIN-OUT The printer connector is located on the printer rear panel (see Figure 4-4). It provides the printer both the commu

4-5. INDICATORS The printer module includes a buzzer to provide audio display on the following events: • Printing is in progress • Paper alerts –