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Gasboy Islander PLUS, Installation Manual

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SECTION  2 

PRELIMINARY INSTALLATION INSTRUCTIONS  

 

2-1.

GENERAL 

This section provides the preliminary installation procedures for the Islander PLUS.  

These procedures include:  

•

 

Preliminary instructions  

•

 

Wiring and Wire Conduits requirements  

 

 

2-2.

PRELIMINARY INSTALLATION INSTRUCTIONS  

2-2.1. General  

NOTE 

Perform a site survey of the station prior to 
installation (see Appendix A) 

Installation procedures and requirements depend, to some extent, on the specific fuel dispenser 
models and the site layout.  Therefore, use the information in this section to develop installation 
plans for each specific installation.  Since installation requirements vary widely from case to case, 
no installation hardware is supplied by the equipment manufacturer, and installation planners must 
develop their own requirements. 

The customer should provide an installation plan, designed by an authorized engineer, and 
applicable to all authorities.  This plan design should reflect the existing electric infrastructure of 
the site. 

2-2.2. Precautions and Safety Notes 

Prior to actual installation activities, carefully observe the precautions and safety notes below. 

WARNING 

Before installing or servicing equipment, carefully 
observe the warnings and precautions provided at 
the beginning of this manual. 

 

 

 

 

 

Islander PLUS Manual  

28 

Summary of Contents for Islander PLUS

Page 1: ...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 ...

Page 2: ...nd 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 code...

Page 3: ...ith 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 t...

Page 4: ...This document is the property of ORPAK SYSTEMS Ltd ISRAEL ...

Page 5: ...rds 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 ...

Page 6: ...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...

Page 7: ... 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 Pl...

Page 8: ...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 PRINTER SECTION 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 P...

Page 9: ...4 MAINTENANCE SECTION 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 GLOSSARY SECTION 6 6 1 FUELOMAT GLOSSARY 113 6 ...

Page 10: ...TABLE OF CONTENTS Paragraph Page INSTALLATION INSTRUCTIONS 127 Islander PLUS Manual vi ...

Page 11: ...r Supply Components and Grounding Studs 39 Figure 2 8 VAC Power Supply Jumpers Setup 39 Figure 2 9 Islander PLUS ground description 40 Figure 2 10 Communications Cable Wiring 41 Figure 3 1 Islander PLUS Installation Control Drawing 44 Figure 3 2 Home Base Station with 4 Mechanical Pumps System Diagram 46 Figure 3 3 Home Base Station with 8 Mechanical Pumps System Diagram 47 Figure 3 4 Home Base St...

Page 12: ...ctor 84 Figure 4 5 Printer Connector Pin out Description 84 Figure 4 6 Printer Module Jumpers Default Configuration 86 Figure 4 7 Printer Module Jumpers Configuration Examples 87 Figure 4 8 Door Handle and Paper Lock Lever 88 Figure 4 9 Printer Paper Replacement 89 Figure 4 10 Pressing Paper Lock Lever 92 Figure B 1 Islander PLUS Wiring Diagram Mechanical Pump 122 Figure B 2 Islander PLUS Wiring D...

Page 13: ... Block 4 Mechanical Pump Connections Definition 59 Table 3 3 Islander PLUS for 8 hoses Terminal Block 8 Mechanical Pump Connections Definition 61 Table 4 1 Printer Main Components 83 Table 4 2 Printer Module Connector Pin out Description 84 Table 4 3 Printer Troubleshooting 93 Table 5 1 Islander PLUS Troubleshooting 96 Table 5 2 OrPT Troubleshooting 102 Table 5 3 Printer Troubleshooting 106 Table ...

Page 14: ......

Page 15: ...cabinet installed on top of a pedestal Islander PLUS see Figure 1 1 is a core component in Gasboy s solution for Home Base Refueling Station Home Base Station Islander PLUS provides the central function of Site Controller It also fulfills other essential services on the Island such as Vehicle Driver Identification System FuelPoint PLUS Transaction data storage Forecourt devices control and more It...

Page 16: ...Figure 1 1 Islander PLUS ICR PLUS General View Islander PLUS Manual 2 ...

Page 17: ... management and maintenance are available A standard PC with Internet Browser Explorer is used for management of the site either locally or remotely secured There is no need for special management software thanks to the built in Web server technology integrated into the station controller and a large variety of communication links is supported both wired and wireless 1 3 4 Head Office Centralized ...

Page 18: ...ort of mechanical dispensers enabling pump with totalized preset and price update Tank Level Gauging System TLG available for several brands For UL listing this product has only been evaluated for use with UL Listed TLG s Support of large variety of communication links cellular dial in modem VPN satellite ADSL and more Figure 1 2 Islander PLUS in Home Base Station General Configuration Diagram 1 3...

Page 19: ...on His authorization device for the fueling transaction is a magnetic card The client swipes the card through the magnetic card reader on the Payment Panel The magnetic card information is read and sent to the Site Controller OrCU for authentication and approval The client lifts the nozzle and inserts it in the car inlet Upon approval the fueling transaction starts at the end of which the transact...

Page 20: ...WGT Wireless Gateway Terminal receives both DataPass and FuelOpass vehicle data decrypts the information and transmits it to the Station automation system in a secure manner over an RF signal To obtain maximal grid availability several WGT units are installed at the station to create a robust mesh network This setup enables the RF signal to travel through various routes and bypass possible interfe...

Page 21: ...odes OrPT supports keyboard entry for authorization and other parameters input from the user such as odometer engine hours vehicle plate number and PIN code The OrPT panel is connected to the Site Controller OrCU via a LAN Ethernet link Outdoor Printer Optional The Islander PLUS includes an optional printer for purchase receipts printout as well as data output The printer is linked to the central ...

Page 22: ...pment interface The CommVerter includes two MPI C cards for interface to the mechanical pumps an Ethernet Switch RS 485 ports and one RS 232 port For electronic pump a different interface card is installed See Chapter 3 for more details The CommVerter communicates with the Site Controller OrCU via a LAN Ethernet link Islander PLUS Manual 8 ...

Page 23: ... Internal Configuration Mechanical Pump Figure 1 3 shows a general configuration diagram of the Islander PLUS up to four mechanical pumps Figure 1 3 Internal Configuration Diagram 4 Mechanical Pump Islander PLUS Manual 9 ...

Page 24: ...Figure 1 4 shows a general configuration diagram of the Islander PLUS for eight mechanical pumps Figure 1 4 Internal Configuration Diagram 8 Mechanical Pumps Islander PLUS Manual 10 ...

Page 25: ...the Islander PLUS without the Printer Figure 1 6 shows the location of the main components of the Islander PLUS for 8 hoses Figure 1 7 and Figure 1 8 show the location of the Printer within the two configurations when it is installed Figure 1 5 Internal Components Location 4 Mechanical Pumps Islander PLUS Manual 11 ...

Page 26: ...Figure 1 6 Internal Components Location 8 Mechanical Pumps Islander PLUS Manual 12 ...

Page 27: ...Figure 1 7 Islander PLUS with Optional Internal Printer Sectional View Islander PLUS Manual 13 ...

Page 28: ...Figure 1 8 Islander PLUS for 8 hoses with Optional Internal Printer Sectional View Islander PLUS Manual 14 ...

Page 29: ......

Page 30: ...icle Identification System Some options are available for vehicle identification in the Islander PLUS ICR PLUS FuelPoint PLUS WGT Wireless Gateway Terminal is Vehicle identification process performed in a wireless mode WGT can be installed on top of the Islander PLUS pedestal or in an external outdoor unit P N PA04000001 WGT receives DataPass or FuelOpass signals decrypts their information and tra...

Page 31: ...cover on the front panel Figure 1 9 Islander PLUS with Data Key Reader Optional 1 5 6 2 HID Device The pedestal can be supplied with an optional HID card reader for payment with specific cards The HID reader supports Track 2 and 26 37 32 bit card formats For further information on HID reader format setup please refer to the OrPT Installation Setup and Operation Manual P N MDE 4819 The HID reader i...

Page 32: ...mps PA039402000 800938231 Islander PLUS w HID for Mechanical Pumps 2 hose PA039402200 800938233 Islander PLUS w HID for Mechanical Pumps 4 hose PA039402400 800938235 Islander PLUS w HID for Mechanical Pumps 8 hose PA039402801 800941137 Islander PLUS w Printer for Electric Pumps PA039400010 800938135 Islander PLUS w Printer for Mechanical Pumps 2 hose PA039400210 800938137 Islander PLUS w Printer f...

Page 33: ...echanical dispensers does not support TLG or additional electronic dispensers from the pedestal Those devices require an external box In the order form you are required to define also the P N for the specific pump card in use MPI C Tokheim Current Loop or RS 485 see Table 1 2 Table 1 2 Pump Card Definition No Pump Card Description Gilbarco P N Orpak P N 1 Tokheim interface 8P P B M09680B028 819223...

Page 34: ...he router level or preferably at the Home Base Station level 1 6 4 RF Network Security Islander PLUS EIA 802 15 4 RF network is encrypted using the AES 128 security standard 1 6 5 Maintenance Security Islander PLUS maintenance and setup procedures require inserting a user name and password for access For further information please refer to the SiteOmat Setup Manual P N MDE 4817 1 7 HOUSING Islande...

Page 35: ...Figure 1 10 Islander PLUS ICR PLUS Dimensions Islander PLUS Manual 21 ...

Page 36: ...D 9 45 x 61 02 x 9 45 24 x 155 x24 cm Communication interface RS 485 9600 bps Half Duplex RS 232 Ethernet RJ 45 10 Mbps EIA 802 15 4 RS 485 9600 bps Half Duplex RS 232 Ethernet RJ 45 10 Mbps EIA 802 15 4 Pump Control Maximum Current 4 Solid State Relay Channels Motor maximum 1 HP at 115 VAC or 2 HP at 230 VAC Additional external relay must be used if pump motor exceeds these limitations Motor maxi...

Page 37: ...s different models over the following standards RS 232 link RS 485 link TCP IP over Ethernet EIA 802 15 4 1 9 2 Security Standards Triple DES encryption for Payment Devices Contact less tags magnetic stripe cards etc AES 128 for RF Network Communication Islander PLUS Manual 23 ...

Page 38: ...Section 4 Printer This section provides a detailed description of the Islander PLUS printer as well as basic troubleshooting instructions Section 5 Maintenance This section provides general maintenance instructions for the Islander PLUS as well as a comprehensive troubleshooting guide Section 6 Glossary This section includes a glossary of terms employed for the Islander PLUS description Appendix A...

Page 39: ...An operating procedure practice etc that if not correctly followed could result in injury or loss of life CAUTION An operating procedure practice etc that if not strictly observed could result in damage to or destruction of equipment TIP This note is aimed for using the system in better efficiently way NOTE This comment is of importance for emphasizing INSIGHT More detailed technical functional in...

Page 40: ... the following manuals OrPT Installation Setup and Operation Manual For Home Base Stations Document No MDE 4819 8 Port CommVerter User s Manual Document No MDE 4812 SiteOmat Station Controller User s Manual Document No MDE 4817 SiteOmat Station Controller Setup Manual Document No MDE 4818 Islander PLUS Manual 26 ...

Page 41: ......

Page 42: ...develop installation plans for each specific installation Since installation requirements vary widely from case to case no installation hardware is supplied by the equipment manufacturer and installation planners must develop their own requirements The customer should provide an installation plan designed by an authorized engineer and applicable to all authorities This plan design should reflect t...

Page 43: ...ld ignite fuel vapors and flammable liquids resulting in death serious personal injury property loss and damage to you and other persons When working in any open area of Home Base 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 2 3 CONDUITS LAYOUT INSTALLATION SPECIFICATIONS The installa...

Page 44: ...away from AC wires All conduits must be inserted in the Islander PLUS pedestal through the holes and knockouts provided in the lower protective plate see Figure 2 1 Do not make any other hole in this unit If you must make holes at locations other than those provided contact Gasboy for approval After completing the installation all open holes should be sealed 2 4 3 Conduits at Islander PLUS Islande...

Page 45: ...Figure 2 1 Islander PLUS Lower Protective Plate Figure 2 2 Standard Bottom Metal Plate s Knockout Close View Islander PLUS Manual 31 ...

Page 46: ... line from TLG at office to Islander PLUS o RS 485 422 C L or Tokheim o Pulser from pumps to Islander PLUS Grounding o At least 10 mm OOO AWG Grounding cable to pump chassis o At least 10 mm OOO AWG Grounding cable to Islander PLUS pole Connected to the external chassis grounding post o Grounding cable to TLG in accordance with TLG manufacturer instructions Tank conduit o TLG probe 2 4 5 Required ...

Page 47: ...ow voltage cables inspection box o One conduit to Office control room o One conduit to each pump o Two conduits to Islander PLUS High voltage cables inspection box o One conduit to Office control room o One conduit to each pump o Two conduits to Islander PLUS 2 5 3 Sealing Conduits The conduits shall be sealed in accordance with NFPA requirements and local regulations to prevent the passage of gas...

Page 48: ...Figure 2 4 Conduits Layout for Mechanical Pump Islander PLUS Manual 34 ...

Page 49: ...Figure 2 5 Conduits Layout for Electronic Pump Islander PLUS Manual 35 ...

Page 50: ...eded vary in accordance with the device it connects The wire used must be stranded and not a solid core Select a cable specification in accordance with local environment conditions CAUTION For supply connections use wires suitable for at least 90 C Signal wiring connected in this box must be rated at least 300 V 2 6 2 Types of Cables Table 2 2 lists the types of cable in use for the wiring of the ...

Page 51: ...from the peripherals and the Office to Islander PLUS as listed in Table 2 3 and shown in Figure 2 4 Proceed as follows Table 2 3 Islander PLUS Cables Routing No Functional Description From Through Insert Cable Type 1 Power AC Office High voltage conduit 1 2 GND Office High voltage conduit 4 3 TLG Office Low voltage conduit 2 4 LAN Office Low voltage conduit 3 5 Control Pump A Pump A High voltage c...

Page 52: ...he power supply can be fed either 110 VAC or 220 VAC The Mains cable is first connected to the terminal block Between the terminal block and transformer the system uses a Line Filter in order to attenuate conducted radio frequencies RFI electromagnetic interference EMI between the line and the equipment see Figure 2 7 AC power is then supplied to an AC AC High to Low Transformer 110 220 VAC to 25 ...

Page 53: ...figured for 110 VAC Mains power supply Take care to set it accordingly to your local Mains power supply specifications Failure to do so may result in damages 1 3 2 4 5 6 220VAC JUMPER 1 3 2 4 5 6 110VAC JUMPERS Neutral Neutral Figure 2 8 VAC Power Supply Jumpers Setup Islander PLUS Manual 39 ...

Page 54: ... part of the system installation As with the AC power the grounds for all system components should return to the same circuit breaker panel This helps you to assure a common ground throughout the system which is necessary for protection of the RS 485 data loop circuitry Ground for all system devices should be wired to the breaker panel ground bus bar which in turn should be grounded to a ground ro...

Page 55: ...d Wire one 0 4 10 mm ground cable from the Mains ground connection to the pump chassis The communication cable shield must be connected to ground at one end side only preferably at the controller installation side see Figure 2 10 Figure 2 10 Communications Cable Wiring 2 8 2 TLG wiring RS 232 LAN is used for communication between the TLG and Islander PLUS Follow these installation requirements whe...

Page 56: ...cable must be in a low voltage conduit away from any AC wires Cable The type of cable required should be according to the device it is connected to The wire used must be stranded and not a solid core Select a cable specification in accordance with local environment conditions Islander PLUS Manual 42 ...

Page 57: ... use the information in this section to develop installation plans for each specific installation Since installation requirements vary widely from case to case no installation hardware is supplied by the equipment manufacturer and installation planners must develop their own requirements The customer should provide an installation plan designed by an authorized engineer This plan design should ref...

Page 58: ...on is classified as Class 1 Division 2 and it does not extend higher than 18 inches 0 5m from surface and A minimum safety separation of 18 inches 0 5m from any nearest pump dispenser Figure 3 1 Islander PLUS Installation Control Drawing 3 3 HOME BASE STATION OVERVIEW 3 3 1 General Prior to installation you are required to obtain an overview of the Home Base Station functional architecture This ov...

Page 59: ...er s up to four nozzles for each Islander PLUS ICR PLUS For UL listing this product has only been evaluated for use with UL Listed Dispensers One or more Underground gas tanks TLG probe for each gas tank For UL listing this product has only been evaluated for use with UL Listed TLG s 3 3 2 3 Head Office System Optional The Head Office system consists of fully integrated management hardware and sof...

Page 60: ...Figure 3 2 Home Base Station with 4 Mechanical Pumps System Diagram Islander PLUS Manual 46 ...

Page 61: ...Figure 3 3 Home Base Station with 8 Mechanical Pumps System Diagram Islander PLUS Manual 47 ...

Page 62: ...Figure 3 4 Home Base Station with Electronic Pumps System Diagram Islander PLUS Manual 48 ...

Page 63: ...tion of each ICR PLUS Draw a basic map of the site with all the objects 3 4 3 Assigning Logical IDs 3 4 3 1 To each fuel tank Assign the tank sequential number coordinated with the station manager Assign its fuel code and name Assign its TLG Probe AP Id 3 4 3 2 To each Dispenser Unit Assign an id to every dispenser name and Pump Server Assign an id to every dispenser pump P Assign an id to every p...

Page 64: ...igure 3 5 Figure 3 6 The required connections are 1 Dispenser wiring connections Pulser Low Voltage In Use signal High voltage Valve High voltage 2 Communications RS 232 LAN to TLG Controller to Gas Tank RS 485 for Orpak peripheral device Pump communication line e g Current Loop RS485 Tokheim RS422 3 Mains AC Power and Ground 4 LAN connection Islander PLUS Manual 50 ...

Page 65: ...Figure 3 5 Islander PLUS Terminal Block Power and LAN Connections Islander PLUS Manual 51 ...

Page 66: ...se Station concrete floor 3 6 2 Installation Procedure Steps Installation of the Islander PLUS pedestal consists of the following general steps Running conduits to the pedestal site Installing the Base Plate Installing the Pedestal Base Installing the Pedestal Running the cable conduits to the installation hole and filling all open holes Installing the Rosettes to firmly lock the Islander PLUS ped...

Page 67: ...1 lists the assembly parts for the installation of the Islander PLUS Table 3 1 Islander PLUS Assembly Parts Item No Orpak Part Number Description Qty 1 Islander PLUS 1 2 814906200 Bolt ICU 4 3 815103000 Nut M10 8 4 815300200 Washer Flat M10 8 5 814908400 Bottom Plate 1 6 814982200 Rosette Islander PLUS 1 3 6 5 Base Plate Installation Procedures Proceed as follows see Figure 3 7 1 Prepare the Botto...

Page 68: ...ottom Plate is on a same level as the ground asphalt pedestal on which it is installed Check repeatedly that the Bottom Plate is leveled Otherwise make the necessary adjustments so the plate is perfectly leveled 6 Wait the necessary time for the concrete to harden and dry as per local practice Check anew that the Bottom Plate is leveled Islander PLUS Manual 54 ...

Page 69: ...Figure 3 8 Base Plate Installation Example Figure 3 9 Rosette Upside down view Figure 3 10 Rosette Dimensions Islander PLUS Manual 55 ...

Page 70: ...nd M10 nuts 1 in Figure 3 8 3 in Table 3 1 3 6 7 Base Plate Installation Procedures Optional The Base Plate can be attached to the spot ground by four expansion bolts as an option Proceed as follows 1 Set the Bottom Plate 1 in Figure 3 7 5 in Table 3 1 in the spot and mark the four holes location for drilling 2 Drill four holes in the installation spot 3 Insert four expansion bolts see Figure 3 11...

Page 71: ...on the Pedestal Base and secure it to Pedestal Pole with four M10 flat washers 4 in Table 3 1 and M10 nuts 1 in Figure 3 8 3 in Table 3 1 3 6 8 Sealing Conduits The conduits shall be sealed in accordance with NFPA requirements and local regulations to prevent the passage of gases through conduits cables and conductors The fittings are requested wherever volatile liquids or gases are present in the...

Page 72: ...es of pumps Mechanical Pump Electronic Pumps The following paragraphs provide the wiring requirements for each type of pump 3 7 3 Wiring Requirement For any type of wire prior to inserting it to the terminal block proceed as follows 1 Insert any wire with a terminal lug only 2 Use the proper Terminal Crimper to attach the lug to the wire 3 For UL Listing The Terminal Lug must be a UL recognized co...

Page 73: ...rminals This table provides the signal name and a functional description of the signal Figure 3 16 and Figure 3 17 show the wiring list for connection to the Terminal as published in the Wiring Label added to the inner door The Wiring Label follows the physical location of the wires in the Terminal Block as shown in Figure 3 14 and Figure 3 15 3 8 2 4 Mechanical Pump Terminal Block Pin Out Connect...

Page 74: ...9 IN USE 1 A Handle Up In Use signal input Nozzle 1 20 IN USE 2 A Handle Up In Use signal input Nozzle 2 21 IN USE 3 A Handle Up In Use signal input Nozzle 3 22 IN USE 4 A Handle Up In Use signal input Nozzle 4 23 IN USE 1 B Handle Up AC In Use signal return Nozzle 1 24 IN USE 2 B Handle Up AC In Use signal return Nozzle 2 25 IN USE 3 B Handle Up AC In Use signal return Nozzle 3 26 IN USE 4 B Hand...

Page 75: ...AN 2 CONNECTOR RJ45 separate LAN connector for connection to external network 3 8 3 8 Mechanical Pump Terminal Block Pin Out Connections The Islander PLUS Terminal Block connections for an 8 Mechanical Pump are listed in Table 3 3 Table 3 3 Islander PLUS for 8 hoses Terminal Block 8 Mechanical Pump Connections Definition Terminal No Signal Name Functional Description 1 GND_1_P Nozzle Grounding Noz...

Page 76: ...E 3 B Handle Up AC In Use signal Return Nozzle 3 36 IN USE 4 B Handle Up AC In Use signal Return Nozzle 4 37 IN USE 5 B Handle Up AC In Use signal Return Nozzle 5 38 IN USE 6 B Handle Up AC In Use signal Return Nozzle 6 39 IN USE 7 B Handle Up AC In Use signal Return Nozzle 7 40 IN USE 8 B Handle Up AC In Use signal Return Nozzle 8 41 LINE 1 Pump control 220 110 VAC Input Nozzle 1 42 LINE 2 Pump c...

Page 77: ...ulser Input Nozzle 7 16 PULSER_8 Pulser Input Nozzle 8 49 LOAD 1 Pump control output Nozzle 1 50 LOAD 2 Pump control output Nozzle 2 51 LOAD 3 Pump control output Nozzle 3 52 LOAD 4 Pump control output Nozzle 4 53 LOAD 5 Pump control output Nozzle 5 54 LOAD 6 Pump control output Nozzle 6 55 LOAD 3 Pump control output Nozzle 7 56 LOAD 8 Pump control output Nozzle 8 Figure 3 14 Islander PLUS Termina...

Page 78: ...Figure 3 15 Islander PLUS Terminal Block 8 pumps Figure 3 16 Islander PLUS Terminal Block 4 Mechanical Pump Wiring List Label Islander PLUS Manual 64 ...

Page 79: ...3 18 and Figure 3 19 show a schematic diagram of the connections between the Islander PLUS and the mechanical pump components Figure 3 20 to Figure 3 22 show a detailed wiring diagram between the Islander PLUS terminal block and the pump components Pulse Input Wires The dispenser outputs pulses to the system by means of the Pulser unit installed in accordance with the manufacturer instructions The...

Page 80: ...e transaction ended Authorization Output Wires The dispenser requires an authorization signal from the Islander PLUS to start a sale transaction Without this authorization signal the electric valve or pump will not open and the sale transaction will not begin The Islander PLUS switches the AC power signal to the valve When the dispenser receives the authorization signal fuel is flowing NOTE All te...

Page 81: ...Figure 3 18 Mechanical Pump Single Dispenser Connections Islander PLUS Manual 67 ...

Page 82: ...Figure 3 19 Mechanical Pump Twin Dispenser Connections Islander PLUS Manual 68 ...

Page 83: ...Figure 3 20 Islander PLUS and Mechanical Pump Terminal Block Detailed Connections Islander PLUS Manual 69 ...

Page 84: ...s characteristics NOTE Pulser should be installed in accordance with the pulser manufacturer s instructions Some pulsers do not have a barrier in that case you must add a pulser barrier Barriers are not provided with Islander PLUS 3 8 5 1 Electronic Pulser 3 Wire Pulser requires an external power source 12V in order to operate Figure 3 21 shows a schematic diagram of the connections between the Te...

Page 85: ...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 Pulser Wiring Connections Islander PLUS Manual 71 ...

Page 86: ... 485 RS 422 See Figure 3 23 for the wiring list label applied within the inner wall of the unit This label consists of a wiring list table for the Terminal block You are requested to connect the Forecourt equipment to OrIC in accordance with this table The rows are the connection ports in the Terminal Block in an ascending order Each column is dedicated for a specific pump Each cell defines the si...

Page 87: ...Figure 3 23 Islander PLUS Terminal Block Wiring List Label Islander PLUS Manual 73 ...

Page 88: ...eim pump nozzle and the terminals that differ from the Mechanical Pump Figure 3 23 shows the wiring list for connection to the Terminal as published in the Wiring Label added to the inner door The Wiring Label follows the physical location of the wires in the Terminal Block as shown in Figure 3 14 Figure 3 24 Tokheim Electronic Pump Wiring Diagram Islander PLUS Manual 74 ...

Page 89: ...al Pump The figure shows the serial connection between two Current Loop pumps and the Terminal Block Figure 3 23 shows the wiring list for connection to the Terminal as published in the Wiring Label added to the inner door The Wiring Label follows the physical location of the wires in the Terminal Block as shown in Figure 3 14 Figure 3 25 Current Loop Electronic Pump Wiring Diagram NOTE Recommende...

Page 90: ... from the Mechanical Pump The figure shows the prallel connection between two RS 485 pumps and the Terminal Block Figure 3 23 shows the wiring list for connection to the Terminal as published in the Wiring Label added to the inner door The Wiring Label follows the physical location of the wires in the Terminal Block as shown in Figure 3 14 Figure 3 26 RS 485 Electronic Pump Wiring Diagram Islander...

Page 91: ...ical or electronic pump 3 10 2 Connection to TLG Controller Figure 3 27 shows the required connection between the TLG controller in the site and the Islander PLUS Terminal Block Figure 3 27 Terminal Block TLG Wiring Link 3 10 3 Connection to Journal Printer A journal printer P N M09680B090 see Figure 3 28 is available for journaling important operations such as all transactions on hard copy Island...

Page 92: ...d to the 8 Port Commverter through one of the channels of the RS 485 Module P N M09680B017 with a shielded twisted pair cable maximum length 100m The Printer is provided with the SPRN interface board which includes an RS 485 connector see Figure 3 29 Islander PLUS Manual 78 ...

Page 93: ...Figure 3 29 Journal Printer Rear Panel Islander PLUS Manual 79 ...

Page 94: ...parate dedicated breaker o Is the system grounded properly o Are the cables correctly routed in the Island o Are the communication lines under the maximum allowable distance RS 232 50 feet 15m RS 485 330 feet 100m Antenna wire 330 feet 100m for VIU 50 feet 15m for FuelOpass Clean dirt and wire remnants In case problems are detected after installation or during operation repeat the post installatio...

Page 95: ...80B034 provides the customer a receipt once a refueling action is completed This section provides as well as instructions It includes instructions on replacing the printer paper roll In addition this section includes several recommended steps for checking the printer operability Figure 4 1 Printer Module in Islander PLUS Islander PLUS Manual 81 ...

Page 96: ... It uses thermal printer paper only 55 gr 57 mm width 101 mm diameter The Printer is connected to the OrPT via an RS 485 link The Printer requires a 24 26 VDC power supply input The Printer enclosure is designed to survive the harsh forecourt environment It uses Spark Gaps protection for the links and 1 5 KV isolation The printer includes two sensors for paper usage alerts Low paper sensor activat...

Page 97: ...lity Printer Cutter Lock Shifts away from the printer and unlocks the cutter lock Printer Cutter Cuts the paper Thermal Printer Prints the text on the thermal paper by means of the thermal head Paper Lock Lever Push down to unlock the paper lock Electronic Board Printer controller Figure 4 3 Printer Module Main Components Islander PLUS Manual 83 ...

Page 98: ...l power supply Figure 4 5 and Table 4 2 show the Printer connector pin out description Figure 4 4 Printer Connector Figure 4 5 Printer Connector Pin out Description Table 4 2 Printer Module Connector Pin out Description Pin Number Functionality Description 1 VIN DC Power Supply GND 2 VIN DC Plus Voltage 3 SLN Not Applicable 4 GND RS 485 GND 5 485 RS 485 Communication Line 6 485 RS 485 Communicatio...

Page 99: ...onitoring At turn on the LEDs and the buzzer are activated for a short period of time 4 6 SPECIFICATIONS This section lists the physical electrical and environmental specifications of the printer as follows Supply Voltage 24 26 VDC Power Consumption Standby 15 W Typical 60 W Communication Interface RS 485 9600 bps Half Duplex Paper Type Thermal 57 mm W 55 gr 101 mm diameter Paper Maximum Printing ...

Page 100: ... jumpers where the five first jumpers determine the RS485 address The last three jumpers determine the number of copies Figure 4 6 shows the jumpers default configuration where the RS485 Address 70 Hex Figure 4 7 provides examples of jumpers configuration and the corresponding RS485 address CAUTION On a single RS485 bus each device must be assigned a different address Figure 4 6 Printer Module Jum...

Page 101: ...ve mode Print always 4 7 3 Cutter The paper cutter may be set to one of three modes as determined by the controller in the Head Office No Cut Full Cut Partial Cut 4 7 4 Printing the Status Report The G2 Printer enables producing a printer status report Proceed as follows 1 Turn off the printer 2 Open the printer s service door 3 Turn on power to the printer 4 The G2 Printer prints a status report ...

Page 102: ...uns out completely 4 8 2 Paper Roll Replacement This procedure applies when the printer is on line and connected to a power source In that state the printer pulls the paper automatically and cuts it when paper feeding is completed Perform the following procedures to replace the printer paper roll 1 Open the Islander PLUS front panel with the key 2 Lift the printer door and hold 3 Release the green...

Page 103: ...vot 6 Lift the paper roll pivot and remove the paper roll 7 Prepare a new paper roll facing down 8 Press the paper roll pivot pawl and slide back the new paper roll when it is facing down NOTE Insert the paper as shown in Figure 4 9 with the thermal shining side facing out Islander PLUS Manual 89 ...

Page 104: ... end of the process the paper will exit from the cutter NOTE Do not pull the paper The printer pulls the paper automatically and cuts it 11 Slide the paper from the printer door slice 4 8 2 2 Manual Insertion of Paper Proceed as follows 1 Release green paper lock lever see Figure 4 9 2 Slide the paper gently along the grooves until the paper exits from the cutter 3 Lock back the green locking hand...

Page 105: ...ith the Printer Cleaning Card The Printer Cleaning Card is provided in a protective package to prevent dryness The cleaning procedure shall be performed whenever the Print Fade Away is observed all over any receipt and even when observed in some areas of the receipt NOTE The cleaning procedure must be done quickly as the substance in the cleaning card may fade away in a short time 4 9 2 2 Cleaning...

Page 106: ...t the cleaning card should be tilted to the far right of the printer paper slot Next the cleaning card should be tilted to the left 9 Verify that the cleaning card rolls out from the paper slot 10 Pull the cleaning card gently and repeat procedures 5 to 9 with the same cleaning card now tilted to the left 11 Repeat procedures several times right and left in order to obtain the best cleaning result...

Page 107: ...orm the recommended corrective actions to troubleshooting the failure and to repair the unit Table 4 3 Printer Troubleshooting No Failure Indication Probable Cause of Failure Recommended Corrective Action 1 Left hand green Led flickers constantly The Printer Unit is stuck 1 Check paper roll 2 Replace unit 2 Right hand green Led flickers constantly The Printer Unit is stuck 1 Check paper roll 2 Rep...

Page 108: ...lock lever to its original state 6 Slide the new paper roll into the Pivot Handle Make sure the paper roll you insert is not crumpled 7 Insert the paper into the printer either automatically or manually 4 11 THERMAL PAPER STORAGE The thermal paper is sensitive to the environmental conditions where it is stored Just as well the Printer Module operation is sensitive to the type of paper inserted Pro...

Page 109: ...ncountered when using the Islander PLUS system as well as corrective action instructions covering the following problems related to the system and its peripherals Islander PLUS see paragraph 5 2 1 OrPT see paragraph 5 2 2 Printer see paragraph 5 2 3 Communication to peripherals see paragraph 5 2 4 5 2 1 Islander PLUS Troubleshooting The Islander PLUS troubleshooting procedure and consequent correc...

Page 110: ... Does the unit shut down immediately after being turned on 1 Check for shorts in the power line cable 2 Check grounding Circuit breaker is off Is breaker off or tripped Turn breaker on if off Is 115V being switched through breaker Replace breaker if 115V is not being switched Is 115V measured at the power input terminal block Correct wiring problems if 115V is not measured Does the breaker turn of...

Page 111: ...gnetic Cards 1 Visually check Magnetic Card reader 2 Present several Magnetic Cards 1 Clean Magnetic Card reader 2 Replace Magnetic Card reader 3 Replace OrPT No Key response Loose cable Faulty key receptacle 1 Visually check Key receptacle 2 Insert several keys 1 Replace Key receptacle 2 Replace OrPT Customer display is blank Faulty Customer display Faulty OrPT Verify that customer display board ...

Page 112: ...er to check power supply to the unit If power supply is OK then replace the 8 port board If power supply is faulty replace the power supply Verify that Control red LED on MPI C board is lit 1 Replace MPI C board 2 Replace 8 port Pump malfunction Turn the Islander PLUS bypass switch on lift the nozzle and check that the pump supplies fuel If the problem persist 1 Check Handle On Switch 2 Repair pum...

Page 113: ...it when nozzle is lifted If the red LED is not lit replace MPI C board If the led is lit the problem is external to the controller Faulty 8 Port Replace 8 Port Pump is authorized pump motor is running but no fuel is supplied Faulty solenoid valve Faulty pump Does the pump solenoid valve produce a clicking sound 1 Replace valve 2 Repair pump Payment device card key tag Fuel Ring is not accepted Com...

Page 114: ...eling Define the device parameters in FHO properly Device limit was passed Verify that the device is within the limits of its rule For testing only remove any rule associated to this device Device was set as Driver 1 Login into FHO and go Devices Management 2 Select the specific device and check if it was configured as Driver Change the device setting to Vehicle Device is blocked 1 Login into FHO ...

Page 115: ...pulser and short the pulse in wires to simulate pulses If pulses are received during refueling replace pump pulser If not replace MPI C board No control on refueling Pump is refueling without any control Pump is in bypass Verify that Islander PLUS bypass switch is off Turn bypass switch off if on Faulty SSR Replace the relevant SSR unit inside the Islander PLUS If an external relay is used to cont...

Page 116: ... not accept card OrPT display does not respond correctly to cards Bad card Present several cards to see if problem is consistent Replace card and test again Dirty card reader Verify that the card reader is clean Clean the card reader using a cleaner card and try again OrPT is busy performing another task Verify that the display presents the idle message 1 Press Cancel 2 Present the card while the ...

Page 117: ... connects key reader to the OrPT terminal Make good electrical connection if faulty one exists OrPT is busy performing another task Verify that the display presents the idle message 1 Press Cancel 2 Present the tag while the idle message is displayed Faulty OrPT Replace OrPT OrPT does not respond to keypad entries Pressing the keypad buttons does not generate any sound and does not affect the disp...

Page 118: ...place OrPT OrPT displays No communication message Communication disconnected Open Islander PLUS door and check LAN cable from OrPT to 5 LAN switch Make correct and good connection if it was incorrect 5 LAN switch is dead No power to 8 Port Are 8 Port LEDs lit blinking 1 Check power connector to 8 Port 2 Replace 8 Port Is 5 LAN switch LEDs are lit blinking 1 Check connection of LAN switch on 8 Port...

Page 119: ...etup Verify that OrPT parameters defined in SiteOmat match the values presented in OrPT display at power on Set the OrPT bus and parameters according to OrPT values presented in OrPT display at power on Incorrect OrCU setup Login into OrPT and verify that all parameters match OrCU setup Login into OrPT and change setup so it suits OrCU setup Islander PLUS Manual 105 ...

Page 120: ...rs properly Faulty Printer Replace Printer No power to Printer No printing printer doesn t produce a beep sound at power on Power cable is disconnected Check power cable connections between the printer and OrPT Make correct and good connection if it was incorrect Faulty power supply Check power supply outputs using a digital Voltemeter the output voltage should be 24 VDC Replace power supply Fault...

Page 121: ... Jumper means address is 70HEX Set the correct Hex address in SiteOmat Faulty Printer Replace Printer Paper is not automatically cut Paper is not being cut at the end of the printing Incorrect SiteOmat setting Check SiteOmat printing settings Set SiteOmat printing settings accordingly Faulty Printer cutter Replace Printer cutter Faulty Printer Replace Printer Islander PLUS Manual 107 ...

Page 122: ... plug it back in 3 Replace LAN cable if necessary 4 If the cable is in good condition contact the IT department to confirm that the switch router connected to the LAN cable is properly set 5 Check the Controller network settings IP addresses mask gateway etc No communication to the pumps 8 port CommVerter Warning signs displayed for all pumps on the SiteOmat Status screen Incorrect 8 port CommVert...

Page 123: ...to right should be blinking constantly to confirm communication with controller 3 In cases where all LEDs are lit periodically every 30 seconds the unit is resetting due to connection loss to the controller 4 Reset the IP and reconfigure the Pump Server PS in controller setup No communication to nozzles Wireless Gateway Can t read the vehicles and or no authorization at the pumps 1 No communicatio...

Page 124: ...to confirm proper settings in the controller 1 If no activity on the LAN port check the cable and or change the port on the 5 port switch 2 Reset the OrPT and follow the main screen messages for the IP address 3 Change the configuration of the OrPT according to the site setup controller No communication to the TLS Warning signs displayed for all tanks on the SiteOmat Tank Status screen Incorrect T...

Page 125: ...e cleaned periodically at short intervals due to the harsh environment of the Home Base Station where they operate 5 3 2 Cleaning The following instructions are valid for the OrPT front panel and the Islander PLUS pedestal Clean the OrPT front plastic panel with a cloth lightly moistened with WD 40 or any other similar lubricant Clean the pedestal metallic enclosure using a damp cloth and cleaning...

Page 126: ...the Reader and then pull it out slowly Perform the previous procedures several times until the card gets dry Insert any magnetic card and verify that its stored data is read by the Magnetic Card Reader 5 3 4 Printer Cleaning Instructions Refer to paragraph 4 9 Islander PLUS Manual 112 ...

Page 127: ... embedded Controller Unit OrCU 3000 Orpak site Controller Unit OrIC Orpak Island Controller OrIT Orpak Island Terminal OrPT Orpak Outdoor Payment Terminal display Keyboard key reader magnetic card reader LED s buzzer install in fueling area OrTC Orpak Tanker Controller OrTR Orpak Tag Reader POS Point Of Sale SAM Security Application Module security card in the VIT UPI TLS Tank Level System measuri...

Page 128: ...an Extended Service Set An ESS is basically a roaming domain ESSID Extended Service Set Identifier The length of the ESSID information is between 0 and 32 octets A zero length identifier indicates the broadcast SSID Ethernet A popular local area data communications network originally developed by Xerox Corp which accepts transmission from computers and terminals Ethernet operates on 10 100 Mbps tr...

Page 129: ...ntiality algorithm specified by IEEE 802 11 used to provide data confidentiality that is subjectively equivalent to the confidentiality of a wired local area network LAN medium that does not employ cryptographic techniques to enhance privacy WG Wireless Gateway Islander PLUS Manual 115 ...

Page 130: ..._ A STATION INFORMATION Power line 110VAC 220VAC Other____ Power stabilizer UPS available ______________ Spec _________________ Station name __________________________ Location _________________________ FCC Tel No _____________ Direct connect _____________ Internet connectivity method Modem GPRS cable frame relay SAT ADSL etc ______________ Number of dispensers to be connected to FCC ______ Number...

Page 131: ... Mechanical have electronic pulse out _____ Pulses liter factor_________ Electronic protocol communication ____________ Pump link Current Loop RS 485 Other ___________________ Type of wire used for pump link is it shielded ______________ Number of CPU Heads per dispenser ______________________ Number of Nozzles __________________ Decimal Point Price________ Volume _______ Total _______ How many di...

Page 132: ..._____ Break Away Yes No Location on the hose ________ Vapor Recovery Yes No NOZZLE HOSE THREAD INCH NPT MILLIMETER DSP HOSE THREAD Male Female MANUFACTURER ___________________ MODEL ___________________________ DIAMETER OF NOZZLE SPOUT ________ G CONDUIT Exists _________ Can be used ____________ Sealed ______________ Need new conduit _____________Type of surface ________________ Tanks Is tank gage ...

Page 133: ...the station and attach photos Pay attention to the following Photos of Nozzle Hose Pump Isle Station Distances Location of office to install FCC Pumps Tanks Isles etc Broadcast antennas Power line cables tower Generators etc Color scheme and Graphics that may affect the appearance of our equipment at the station like the color of OrPT Box Islander PLUS Manual 119 ...

Page 134: ...Islander PLUS Manual 120 ...

Page 135: ...des the wiring diagram of the Islander PLUS as follows Figure B 1 Islander PLUS Wiring Diagram Mechanical Pump Figure B 2 Islander PLUS Wiring Diagram Electronic Pump Figure B 3 Islander PLUS 8 Wiring Diagram Mechanical Pump Islander PLUS Manual 121 ...

Page 136: ...Figure B 1 Islander PLUS Wiring Diagram Mechanical Pump Islander PLUS Manual 122 ...

Page 137: ...Figure B 2 Islander PLUS Wiring Diagram Electronic Pump Islander PLUS Manual 123 ...

Page 138: ...Figure B 3 Islander PLUS for 8 hoses Wiring Diagram Islander PLUS Manual 124 ...

Page 139: ... HID installation kit P N M09680B040 The installation kit includes the following items Table 1 HID Installation Kit Items P N Name Quantity 813118001 HID Assy 1 814982600 HID Holder 1 815102500 NUT M3 4 815201300 SCREW M3x8 FLAT HD CROSS RECE 4 815302200 WASHER SPRING M3 4 817310940 LABEL HAND TAG 1 817418000 INSTL INSTR HID KIT SET 1 Islander PLUS Manual 125 ...

Page 140: ...Figure 1 HID Unit and Connector Figure 2 HID Holder and Nuts Islander PLUS Manual 126 ...

Page 141: ...tallation manual MDE 4811 1 In cases where installing the HID unit in Islander PLUS 8 hoses pedestals remove the OrCU module from the internal side of the pedestal door see Figure 3 as follows a Unscrew four 4X10 screws and washers securing the OrCU module to the holder b Remove the OrCU holder by unscrewing three M3 flat screws and spacers Figure 3 OrCU Location in Islander PLUS 8 Hoses Islander ...

Page 142: ...door See arrows Figure 4 for location of the connecting points that need to be broken Make sure no sharp edges remained after cutting and the surface is smooth Discard the metal plate Figure 4 Rectangular Plate Connecting Points Location 3 Remove the HID back cover by opening the side screw see Figure 5 Figure 5 HID back cover Removal Islander PLUS Manual 128 ...

Page 143: ...using Phillips type screwdriver Figure 6 Attaching Back Cover to HID Holder 5 Run the connector cable through the hole in the holder from inside out as shown in Figure 8 Install the back cover with the holder in the HID unit using the side screw Figure 7 Assembled Back Cover and HID Holder Islander PLUS Manual 129 ...

Page 144: ...uts and washers excluding the nut in the upper left corner b Place a spacer on the upper left corner stud see Figure 9 c Place the two remaining spacers and install the OrCU holder d Secure the OrCU holder utilizing three M3 flat screws e Install and secure the OrCU module to the holder utilizing four 4X10 screws and washers Figure 8 HID Mounted on Pedestal Door Figure 9 Upper Left Corner Spacer 7...

Page 145: ...position 9 Stick the ellipse hand tag label P N 817310940 on the front black decorative panel see Figure 11 The hand tag label should be placed horizontally in the middle of the pedestal 115 mm 4 528 inches away from the side end 53 mm 2 087 inches away from the bottom line of the OrPT line Islander PLUS Manual 131 ...

Page 146: ...Figure 11 Placing Hand Tag Label on Pedestal Islander PLUS Manual 132 ...

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