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MDE-5411A ForeHB Islander Prime Installation Manual · October 2018

Page 3

1.4 Manual Structure

Introduction

1.4 Manual Structure

Section 1: Introduction

This section provides a general description of the system.

Section 2: System Overview

This section provides a general description of the Islander Prime system.

Section 3: Preliminary Guidelines

This section provides the preliminary installation requirements and procedures to be 
performed before installing the Islander Prime system.

Section 4: Installation Procedures

This section provides a detailed description of the Islander Prime installation requirements and 
procedures.

Section 5: Maintenance

This section provides general maintenance instructions for Islander Prime.

Section 6: Troubleshooting

This section provides a comprehensive troubleshooting guide for Islander Prime.

1.5 References

This manual provides installation instructions for the Islander Prime Fuel Island Controller 
and integrated modules.

For specific installation and setup instructions not included in this manual, refer to the 
following manuals:

• MDE-4868 OrPAY1000 Installation and Setup Manual
• MDE-4817 SiteOmat Installation and Maintenance Manual
• G2 Panel Printer Installation and Setup Manual, P/N 800919900

Summary of Contents for Islander Prime

Page 1: ...MDE 5411A Islander Prime Installation Manual ForeHB This document is based on Orpak s ForeHB OrIC Prime Installation Manual P N 817450050 This manual supports released version 6 4 410 XX...

Page 2: ...tion and 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 NFPA30 F...

Page 3: ...evice 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 r...

Page 4: ...This page is intentionally left blank...

Page 5: ...Structure 11 3 3 1 Main Components 11 3 3 2 Internal Configuration 15 3 4 Available Configurations 15 3 4 1 Islander Prime 15 3 4 2 Automatic Vehicle Identification 16 3 4 3 Dispensers 16 3 4 4 Barco...

Page 6: ...lation 37 5 1 General 37 5 2 Installation Guidelines 37 5 2 1 Precautions and Safety Notes 37 5 2 2 Safety Distances 37 5 3 Installing the Pedestal Base 38 5 3 1 Installation Procedure 39 5 3 2 Prelim...

Page 7: ...6 3 3 OrIC Config 73 6 3 4 Log Level 75 6 3 5 Save 76 6 4 Software Upload 78 7 Maintenance 81 7 1 General 81 7 2 OrPAY1000 and Islander Prime 81 7 3 Magnetic Card Reader 81 7 4 Printer 82 8 Troublesho...

Page 8: ...Table of Contents Page iv MDE 5411A ForeHB Islander Prime Installation Manual October 2018 This page is intentionally left blank...

Page 9: ...Pedestal Base Installation 41 Figure 21 Islander Prime Pole Door 42 Figure 22 Barcode Reader Installation Kit 43 Figure 23 Barcode Reader in Islander Prime Pole Door 44 Figure 24 Barcode Reader Wirin...

Page 10: ...m Electronic Interface Wiring Diagram 63 Figure 53 Current Loop Electronic Pump Wiring Diagram 64 Figure 54 RS 485 Electronic Interface 65 Figure 55 RS 485 Device Wiring Diagram 65 Figure 56 RS 232 RS...

Page 11: ...Cellular Modem Installation Kit50 Table 11 MPI C Channels59 Table 12 MPI C Fuses Slot 1 In Use Pump60 Table 13 MPI C Fuses Slot 2 Pump In Use60 Table 14 Tokheim Pinouts63 Table 15 Current Loop Pinout...

Page 12: ...List of Tables Page ii MDE 5411A ForeHB Islander Prime Installation Manual October 2018 This page is intentionally blank...

Page 13: ...ime is a core component of the ForeHB solution for homebase refueling and provides automation and control over all forecourt equipment at the station such as Automatic Vehicle Identification system Tr...

Page 14: ...Architecture Page 2 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 Figure 1 Islander Prime 1 3 System Architecture Figure 2 shows a basic diagram of ForeHB system architecture Figur...

Page 15: ...This section provides a detailed description of the Islander Prime installation requirements and procedures Section 5 Maintenance This section provides general maintenance instructions for Islander P...

Page 16: ...ment respect es peuvent entra ner des blessures ou la mort WARNING An operating procedure practice etc which if not strictly observed could result in damage to or destruction of the equipment Les cons...

Page 17: ...bels or related materials supplied with this equipment If you do not understand a procedure call a Gilbarco Authorized Service Contractor or call the Gilbarco Support Center at 1 800 800 7498 It is im...

Page 18: ...uipment Use the OSHA Lockout Tagout procedures If you are not familiar with this requirement refer to this information in the service manual and OSHA documentation Working With Electricity Safely Ensu...

Page 19: ...witch These devices switch power off inside the dispenser automatically in a hazardous fault condition and send a signal that can be utilized to switch off the site automatically However the above rec...

Page 20: ...Page 8 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 Important Safety Information This page is intentionally left blank...

Page 21: ...very mechanisms 3 2 1 Fuel Point PLUS Automatic Vehicle Identification Gasboy s Fuel Point PLUS Automatic Vehicle Identification is an optional feature for maximal control and savings of fuel expendit...

Page 22: ...rovide examples of an operational workflow for self service at the homebase station Note In both options the driver may print a transaction ticket from the Islander Prime G2 Panel Printer optional 3 2...

Page 23: ...ler Unit nOrCU Gasboy Controller Unit nOrCU is a complete forecourt controller with its own embedded operating system The unit consists of an embedded hardware platform with a solid state flash storag...

Page 24: ...vities The terminal s features suit both retail and commercial fleet markets as a pay at the pump solution for fuel card purchases forecourt promotions local accounts loyalty programs attendant manage...

Page 25: ...tional printer for receipts printout as well as data output The printer is linked to the central payment terminal that sends to it the transaction data for printout The thermal printer is installed at...

Page 26: ...nal communication interfaces 1 2 and 3 There are two types of communication interfaces that can be inserted into the slots mechanical and electronic Slots 1 and 2 can house both mechanical and electro...

Page 27: ...the components installed All the configurations are manufactured in accordance with the specific customer request The following section describes the several configurations and the specific device co...

Page 28: ...s Islander Prime can support either mechanical or electronic dispensers in accordance with its configuration Mechanical dispensers require the installation of an MPI C interface blade Electronic dispe...

Page 29: ...778B001 3 Islander Prime 4x 485 Blade M15778B001 4 Islander Prime 4x Tokheim Blade M15778B001 5 Islander Prime 4x Current Loop Blade M15778B001 6 Islander Prime 2x 422 2x 232 Blade M15778B001 3 5 Secu...

Page 30: ...a certified Ingress Protection IP rating of IP54 The payment panel of the Islander Prime is made of rugged plastic The devices in the front panel are sealed to prevent humidity and dust penetration No...

Page 31: ...122 F WithBarcorde 30 to 60 C 22 to 140 F Storage Temperature 40 to 70 C 40 to 158 F Humidity 80 Non condensing Communication Interface RS 485 RS 232 RS 422 LAN Pump Communication Interface RS 485 RS...

Page 32: ...20 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 3 7 2 Communication and Security Standards Islander Prime communicates over the following standards RS 232 link RS 485 link TCP IP o...

Page 33: ...ents vary from case to case no installation hardware is supplied by the equipment manufacturer and installation planners must develop their own requirements It is the customer s responsibility to prov...

Page 34: ...l codes and any other applicable safety codes and regulations L environnement de base est hautement inflammable et combustible Par cons quent assurez vous que l installation soit r alis e par un perso...

Page 35: ...ation lectrique d Islander Prime et d autres p riph riques les pompes comprises tant que toute l installation n a pas t contr l e et certifi e Do not perform any metal work in the hazardous area Spark...

Page 36: ...transactions at the homebase station The Head Office Station provides an integrated retail solution 4 3 2 Locating All Objects Locate the roads around the site Locate the islands and their dispensers...

Page 37: ...he Ethernet port located at the bottom of the Islander Prime pedestal see Figure 10 Figure 10 Terminal Block Power and LAN Connections 8 Pumps The required connections are as follows Dispenser wiring...

Page 38: ...rastructure is already set up you can use the existing conduits only if they meet the requirements defined below Conduits must comply with the following requirements All conduits must be made and inst...

Page 39: ...te Islander Prime includes a protective plate below the terminal block in the installation pole The plate is perforated enabling the insertion of four conduits Four conduits of 1 inch diameter Four co...

Page 40: ...Prime Low voltage conduits Internet line from LAN at Office to Islander Prime RS 232 communication line from TLG at office to Islander Prime RS 485 422 C L or Tokheim Pulser from pumps to Islander Pri...

Page 41: ...e Installation Manual October 2018 Page 29 4 4 Conduits Preliminary Guidelines The following is a diagram of the conduit layout for Islander Prime using a mechanical pump see Figure 12 Figure 12 Condu...

Page 42: ...uits Page 30 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 The following is a diagram of the conduit layout for Islander Prime using an electronic pump see Figure 13 Figure 13 Condu...

Page 43: ...through conduits cables and conductors Fittings are required wherever volatile liquids or gases are present in the surroundings Note Install the seal under the barrier plate with the threaded end prot...

Page 44: ...round cable 0 4 inch 10 8 mm2 Islander Prime Cable Types 4 5 2 Cable Routing Route the cables from the peripherals and the office to Islander Prime as shown below see Table 5 Table 5 Islander Prime Ca...

Page 45: ...quipment other components should be connected to the power supply such as the TLG and dispensers 4 6 2 Power Supply Setup The Islander Prime power supply can be connected 110 VAC 220 VAC The mains cab...

Page 46: ...tection of the RS 485 data loop circuitry Grounding for all system devices should be wired to the breaker panel ground bus bar which in turn should be grounded to a ground rod A conduit ground does no...

Page 47: ...32 LAN communication lines Note These requirements must be compatible with the recommendations of the TLG manufacturer Distance The following distances must be adhered to when installing the communica...

Page 48: ...Preliminary Guidelines 4 7 Wiring the Peripherals Page 36 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 This page is intentionally blank...

Page 49: ...e the information in this section to develop installation plans for each specific installation Since installation requirements vary from case to case no installation hardware is supplied by the equipm...

Page 50: ...propriate hazardous classified location Where hazardous location is classified as Class 1 Division 2 and it does not extend higher than 18 inches 0 5 m from surface A minimum safety separation of 18 i...

Page 51: ...Islander Prime location One High Voltage conduit from the dispenser One Low Voltage conduit from the dispenser One Low Voltage conduit from the office One High Voltage conduit from the Mains Distribu...

Page 52: ...plate in the hole 3 Take care that all power and communication conduits pass through the central hole in the bottom plate step 2 in Figure 19 3 in Figure 20 4 Pour concrete type B200 in the hole as a...

Page 53: ...e bottom plate step 2 in Figure 20 Figure 20 Pedestal Base Installation 2 Remove the front panel of the pedestal base to enable you to reach the bolts inside 3 Install the pedestal base on top of the...

Page 54: ...Install the seal under the barrier plate with the threaded end protruding through the knockout opening 5 4 Installing Options Islander Prime can be provided in a number of configurations that include...

Page 55: ...to the G2 Panel Printer User Manual for setup details for the G2 Panel Printer 5 4 1 Barcode Reader Installation The barcode reader P N M15778B009 is provided with the following assembly kit componen...

Page 56: ...up against the glass window in the door of the Islander Prime pole see Figure 23 Figure 23 Barcode Reader in Islander Prime Pole Door 3 Use the screws provided in the installation kit to secure the ba...

Page 57: ...he OrPAY1000 as follows see Figure 25 Figure 25 Barcode Reader Wiring to OrPAY1000 7 Wire barcode reader harness P3 to the OrPAY1000 HID harness 5 4 2 HID Reader Installation The HID Reader P N M09680...

Page 58: ...cket to the Islander Prime pole door 2 Remove the back plate from the HID Reader 3 Fasten the HID Reader back plate to the HID Bracket using the flat head screws provided in the installation kit as fo...

Page 59: ...the OrPAY1000 HID Reader harness When installing both a Barcode Reader and an HID Reader connect the Barcode Reader harness to the HID Reader harness as follows see Figure 29 Figure 29 HID Reader Wiri...

Page 60: ...ation The insertion card reader P N M15778B007 is provided with the following assembly kit components see Table 9 Figure 31 Figure 32 and Figure 33 Table 9 Item No Description Qty 1 Barcode Reader 1 2...

Page 61: ...he screws affixing the front panel to the Islander Prime pole 2 Place the insertion card reader into the opening light stripe side up 3 Use the screws provided in the installation kit to secure the in...

Page 62: ...components see Table 10 Table 10 Item No Description Qty P N 1 Bracket 1 819250100 2 Screw M4x10 SST 2 Washers 4 815228200 Cellular Modem Installation Kit To install a Cellular Modem in the Islander...

Page 63: ...installation kit 5 Anchor the modem antennas in the designated apertures as follows see Figure 37 Figure 37 Cellular Modem Antenna Left Side Example 6 Use the modem harness provided in the installati...

Page 64: ...on The G2 Panel Printer P N M15778B008 is provided with the following assembly kit components see Figure 38 Figure 38 G2 Panel Printer To install a G2 Panel Printer in the Islander Prime proceed as fo...

Page 65: ...ce the printer into the opening from the outside 4 Use the screws provided to secure the printer to the inside of the Islander Prime in the provided bracket as follows see Figure 40 Figure 40 Panel Pr...

Page 66: ...is performed in the Islander Prime terminal block only The wires should be pulled from the conduits that protrude from the installation base or in the opposite direction from the terminal block to th...

Page 67: ...18 Page 55 5 5 Installing Communication Interfaces Installation 2 Remove the protective panel covering the communication interface slots see Figure 42 and Figure 43 Figure 42 Communication Interface P...

Page 68: ...3 Hold the blade by the front screws that are provided pre inserted into the front of the blade 4 Slide the blade into the slot see Figure 44 Figure 44 Communication Interface Blades in Slots Note If...

Page 69: ...Communication Interfaces Installation 6 Replace the protective panel in front of the slots see Figure 45 Figure 45 Communication Interface Protective Panel With Interface 5 5 2 Wiring Requirements Mar...

Page 70: ...Figure 46 may be installed in either Slot 1 or Slot 2 of the Islander Prime The following describes the required wiring connections between the mechanical dispenser interface and Islander Prime Figur...

Page 71: ...ansaction Without this authorization signal the electric valve or pump will not open and the sales transaction will not begin Islander Prime switches the AC power signal to the valve When the dispense...

Page 72: ...USE1_A INUSE2_A INUSE3_A INUSE4_A LOAD1 LOAD2 LOAD3 LOAD4 INUSE1_B INUSE2_B INUSE3_B INUSE4_B MPI C Fuses Slot 2 Pump In Use 5 5 4 Pulser Connections The following describes the required wiring connec...

Page 73: ...l power source 12 V in order to operate The following is a schematic diagram of the connections between the terminal block and a three wire pulser see Figure 49 Figure 49 Three Wire Pulser Wiring Conn...

Page 74: ...ribes the wiring connections of the available pumps Each interface wiring description includes a pinout scheme The pinout schemes are laid out as follows The pin number for each cell corresponds with...

Page 75: ...nder Prime and the Tokheim pump nozzle and the terminals that differ from the mechanical pump see Figure 52 Figure 52 Tokheim Electronic Interface Wiring Diagram The Tokheim electronic communication i...

Page 76: ...p nozzle the terminals that differ from the mechanical pump and the serial connection between two Current Loop pumps and the terminal block see Figure 53 Figure 53 Current Loop Electronic Pump Wiring...

Page 77: ...tion Interfaces Installation 5 5 5 3 RS 485 The RS 485 electronic interface appears as follows see Figure 54 Figure 54 RS 485 Electronic Interface The following show the parallel connection between tw...

Page 78: ...ire from the to the proper terminal blocks in the Islander Prime unit The RS 485 electronic communication interface is wired according to the following pinout scheme see Table 16 Table 16 RS 485 Pinou...

Page 79: ...Checklist After completing the installation procedure carefully inspect the connection between Islander Prime and the external power mains and the data sources In particular pay attention to the foll...

Page 80: ...ants In case problems are detected after installation or during operation repeat the post installation checks listed above 5 7 Islander Prime Setup For information on how to set up Islander Prime once...

Page 81: ...access the setup site for Islander Prime proceed as follows Open an Internet browser and enter the default IP address provided by Gasboy The CommVerter Setup homepage opens with a login dialog box se...

Page 82: ...me page displays current device information see Figure 59 Table 18 Table 18 Field Description Ethernet IP Ethernet IP address Ethernet MAC Ethernet MAC address SW Version Software version installed on...

Page 83: ...ions are available In the Location field enter a description for the location of the device optional In Upload Setup From File click Choose File to launch a file browser and select a previously downlo...

Page 84: ...save everything via the Save tab Table 19 Field Description Ethernet Configuration IP Address Device IP Address Subnet Mask Subnet Mask address Gateway Gateway DHCP Not currently available MAC MAC add...

Page 85: ...are available Click Add Channel to add another channel Click Remove Channel to remove the last channel from the list Click Copy Channel to add another channel with the same settings as the last channe...

Page 86: ...l PIs MPI Secondary is used for channels 3 4 in configurations that enable 4 MPI C channels Baud Rate Communication Interface details Data Bits Parity Stop Bits RS 485 Echo RS 485 channels only Curren...

Page 87: ...ort Interface drop down select the port that the log will be transferred through None Logs are not transferred Com Transfers the logs via RS 232 TCP IP Transfers the logs via LAN connection Click the...

Page 88: ...nfiguration details you must save all changes in the Save tab in order to write the changes to the flash memory and save the configuration permanently To save changes proceed as follows 1 Click the Sa...

Page 89: ...process 5 To download an XML file containing all of the settings defined on the Setup page to the local machine click Download Setup to PC The following dialog box opens see Figure 67 Figure 67 Downlo...

Page 90: ...see Table 22 Table 22 Software Upload Fields Field Description File Type Wireless Gateway ST Boot Loader Pump Mezzanine Update Options Currently only Update Immediate is available Choose File Opens a...

Page 91: ...Prime Installation Manual October 2018 Page 79 6 4 Software Upload LAN CommVerter Setup 4 Click Upload The following dialog box opens see Figure 69 Figure 69 Confirm Upload Dialog Box 5 Click OK to co...

Page 92: ...LAN CommVerter Setup 6 4 Software Upload Page 80 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 This page is intentionally blank...

Page 93: ...use any solvents such as thinner or benzene Do not pressure wash the pedestal Mise en garde NE PAS utiliser de solvants tels qu un diluant ou du benz ne Ne pas utiliser un lavage sous pression pour n...

Page 94: ...ness The cleaning procedure shall be performed whenever ink is faded on a receipt Note The cleaning procedure must be done quickly as the substance in the cleaning card evaporates over a short period...

Page 95: ...leaning card gently and repeat steps 5 to 9 with the same cleaning card now tilted to the left 11 Repeat the above several times in order to obtain the best cleaning results 12 Stop when the cleaning...

Page 96: ...Maintenance 7 4 Printer Page 84 MDE 5411A ForeHB Islander Prime Installation Manual October 2018 This page is intentionally blank...

Page 97: ...r panel 2 Check cabling from breaker panel to theunit 3 Verify that the power cable is properly connected to unit terminal block 4 Verify 115 V measured at the power input terminal block Correct wirin...

Page 98: ...n lift the nozzle and check that the pump supplies fuel If the problem persists 1 Check Handle on switch 2 Repair pump Handle on switch problem Is the In Use red LED MPI C board lit when nozzle is lif...

Page 99: ...ine the device parameters in FHO properly Device limit was passed Verifythat the device is within the limits of its rule For testing only remove any rule associated to this device Device was set as Dr...

Page 100: ...ternal fuse blown Check the mini fuse at the bottom of the power supply using an ohmmeter Replace the fuse if it is blown Power supply failure Verify that the green LED on the power supply is lit Repl...

Page 101: ...which connects theOrPAY EMV reader to the OrPAY1000 terminal Make a secure electrical connection if faulty one exists OrPAY1000 is busy performing another task Verify that the display presents the idl...

Page 102: ...in OrPAY1000 display at power on Incorrect nOrCU setup Log into OrPAY1000 and verify that all parameters match the nOrCU setup LogintoOrPAY1000andamend the setup so that it matches the nOrCU setup Fa...

Page 103: ...Cable is disconnected Check the OrPAY1000 LAN cable Make correct and good connection if it was incorrect Incorrect Address settings Check printer address jumpers no jumper means that the address is 70...

Page 104: ...N to 3x 485 CommVerter to the local network 5 port switch activity Check network connectivity by performing a ping command locally or remotely through PuTTY application 1 If there is no activity on th...

Page 105: ...screen Incorrect TLS communication and or physical network setup Ping the TLS from controller PuTTY Check network RS 232 port on the TLS 1 If no response to the ping command from controller check the...

Page 106: ...is connected Connect the wire from J13 to DFI CPU board Replace CPU CommVerter board is off Power to the board Power harness from main board J23 is connected Connect harness from J23 to commVerter boa...

Page 107: ...MDE 5411A ForeHB Islander Prime Installation Manual October 2018 Page 95 8 6 FuelPoint Troubleshooting This page is intentionally blank...

Page 108: ...336 547 5000 http www gilbarco com Printed in the U S A MDE 5411A ForeHB Islander Prime Installation Manual October 2018 Ethernet is a registered trademark of Xerox Corporation Gasboy is a registered...

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