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MDE-4813D

INSTALLATION MANUAL

This document is based on Orpak’s Controller Unit (OrCU 3000)

installation manual P/N 817438032

Summary of Contents for ORPAK CFN PLUS

Page 1: ...MDE 4813D C CF FN N P PL LU US S INSTALLATION MANUAL This document is based on Orpak s Controller Unit OrCU 3000 installation manual P N 817438032...

Page 2: ...could create an explosion hazard Use standard test equipment only in the non hazardous area of the fuel station and approved test equipment for the hazardous areas In the installation and maintenance...

Page 3: ...ards residing in the Product as this will void all warranties related to this equipment PROPRIETY NOTICE This document contains propriety and confidential information It is the property of ORPAK SYSTE...

Page 4: ...t occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encourag...

Page 5: ...nt PLUS 5 1 4 CFN PLUS STRUCTURE 5 1 4 1 Main Components 5 1 4 2 CFN PLUS Internal Configuration Mechanical Pump 6 1 4 3 Main Components Location 7 1 5 AVAILABLE CONFIGURATIONS 8 1 5 1 General 8 1 5 2...

Page 6: ...tion 20 2 4 5 Wiring conduits in CFN PLUS 21 2 5 CONDUITS INSTALLATION 21 2 5 1 General 21 2 5 2 Installing Conduits in Station 21 2 5 3 Sealing Conduits 22 2 6 CABLES 25 2 6 1 General 25 2 6 2 Types...

Page 7: ...each Dispenser Unit 38 3 4 3 3 To CFN PLUS 38 3 4 4 Mapping 38 3 5 CONNECTIONS TO CFN PLUS 39 3 6 INSTALLING THE CFN PLUS 40 3 6 1 General 40 3 6 2 Installation Procedure Steps 40 3 6 3 Site Prelimin...

Page 8: ...ENERAL COMPONENTS 59 3 10 1 General 59 3 10 2 Connection to TLG Controller 59 3 11 POST INSTALLATION CHECKLIST 60 3 12 CFN PLUS SETUP 60 SECTION 4 MAINTENANCE 4 1 GENERAL 61 4 2 TROUBLESHOOTING 61 4 2...

Page 9: ...ions Cable Wiring 32 Figure 3 1 CFN PLUS Installation Control Drawing 34 Figure 3 2 Home Base Station with Mechanical Pumps System Diagram 36 Figure 3 3 Home Base Station with Electronic Pumps System...

Page 10: ...N PLUS Wiring Diagram Mechanical Pump 78 Figure B 2 CFN PLUS Wiring Diagram Electronic Pump 79 LIST OF TABLES Table Page Table 1 1 Dispensers Card Definition 9 Table 1 2 CFN PLUS Standard Models 11 Ta...

Page 11: ...ility and proper operation This manual includes a general and functional description of the product its main components installation requirements and procedures This manual is intended for qualified a...

Page 12: ...hicle Driver Identification System FuelPoint PLUS Transaction data storage Forecourt devices control and more Its user friendly operating program enables fast and accurate service for the driver in th...

Page 13: ...e Web Access Remote Web based capabilities for monitoring management and maintenance are available A standard PC with Internet Browser Explorer is used for management of the site either locally or rem...

Page 14: ...g this product has only been evaluated for use with UL Listed Dispensers Advanced electronic support of mechanical dispensers enabling pump with totalized preset and price update Tank Level Gauging Sy...

Page 15: ...N PLUS main sub units see Figure 1 3 and Figure 1 4 Orpak Controller Unit OrCU Orpak Controller Unit OrCU is a complete forecourt controller with its own embedded operating system The unit consists of...

Page 16: ...allation Manual February 2018 6 1 4 2 CFN PLUS Internal Configuration Mechanical Pump The following Figure 1 3 shows a general configuration diagram of the CFN PLUS Figure 1 3 Internal Configuration D...

Page 17: ...components of the CFN PLUS The shown unit includes a terminal block specially set for barriers connection The barriers themselves are grouped in an external box installed separately Figure 1 4 Interna...

Page 18: ...eives DataPass or FuelOPass signals decrypts their information and transmits it to the Station automation system OrCU in a secure manner over an RF signal This setup enables the RF signal to travel th...

Page 19: ...S 485 Interface 8P P B M09680B017 819223460 5 MPI C Sub Interface 8P P B M09680B019 819223490 1 5 4 OrTR Orpak Tag Reader OrTR P N PA04020001 OrTR Orpak Tag Reader receives tag signals for refuel auth...

Page 20: ...vices The Wireless Gateway Terminal WGT provides vehicle identification process in wireless mode while Orpak Tag Reader OrTR reads Orpak tag signals to complete any transaction WGT communicates with C...

Page 21: ...zation terminal and is intended to ease the system operation in large home base stations In this configuration the station includes a main CFN PLUS and a second unit in Extension Box configuration The...

Page 22: ...Station level 1 6 3 Maintenance Security The CFN PLUS maintenance and setup procedures require inserting a user name and password for access For further information refer to MDE 4817 SiteOmat Setup Ma...

Page 23: ...mm Communication Interface RS 485 9600 bps Half Duplex RS 232 Ethernet RJ 45 10 Mbps Pump Control Maximum Current 4 Solid State Relay Channels Motor maximum HP at 115 VAC or 1 HP at 230 VAC An additio...

Page 24: ...rocedures to be performed in the Home Base Station before installing CFN PLUS Section 3 CFN PLUS Installation Procedures This section provides a detailed description of CFN PLUS installation requireme...

Page 25: ...mment types are used W WA AR RN NI IN NG G An operating procedure practice etc that if not correctly followed could result in injury or loss of life C CA AU UT TI IO ON N An operating procedure practi...

Page 26: ...regarding the CFN PLUS system please refer to the following manuals MDE 4812 8 Port CommVerter User s Manual MDE 4815 WGT Outdoor Unit Installation Manual MDE 4816 Gilbarco s Tag Reader Installation...

Page 27: ...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...

Page 28: ...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 2 3 3 C CO ON ND DU UI IT TS S L LA AY...

Page 29: ...enings provided in the bottom panel see Figure 2 1 Connect the wiring through optional glands or appropriate metal tubing For UL cUL listing this product has only been evaluated for use without the op...

Page 30: ...gh voltage conduit Low voltage conduit The following conduits are required in the station High voltage conduits o AC power for CFN PLUS o Pump control from pumps to CFN PLUS o Pump In use signal from...

Page 31: ...oltage AC power GND control 4 High voltage In use 2 2 5 5 C CO ON ND DU UI IT TS S I IN NS ST TA AL LL LA AT TI IO ON N 2 5 1 General This paragraph describes the infrastructure groundwork necessary t...

Page 32: ...uits 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 liqu...

Page 33: ...MDE 4813D CFN PLUS Installation Manual February 2018 23 Figure 2 3 Conduits Layout for Mechanical Pump...

Page 34: ...MDE 4813D CFN PLUS Installation Manual February 2018 24 Figure 2 4 Conduits Layout for Electronic Pump...

Page 35: ...ower phase N NO OT TE E The type of cable needed to 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 l...

Page 36: ...C similar to Belden 121700 A 4 GND Ground cable 0 4 10 8 mm2 2 6 3 Cables Routing Route the cables from the peripherals and the Office to CFN PLUS as listed in Table 2 3 and shown in Figure 2 3 Procee...

Page 37: ...the Main Power Cabinet of the station office It should include the following Mains Circuit Control Box MCC Uninterruptible Power Supply UPS Online True UPS Power Distribution Box PDB Figure 2 5 shows...

Page 38: ...MDE 4813D CFN PLUS Installation Manual February 2018 28 Figure 2 6 Power Distribution and Grounding in Mechanical Pump Station...

Page 39: ...MDE 4813D CFN PLUS Installation Manual February 2018 29 Figure 2 7 Power Distribution and Grounding in Electronic Pump Station...

Page 40: ...grounding arises ask for a ground test performed by a qualified electrician 2 7 4 AC Power Supply Setup CFN PLUS can be fed either 110 VAC or 220 VAC The Mains cable is first connected to the terminal...

Page 41: ...hich in turn should be grounded to a ground rod A conduit ground does not provide sufficient ground It is recommended that the neutral and ground bus bars be bonded together when it is not prohibited...

Page 42: ...for communication between the TLG and CFN PLUS Follow these installation requirements when installing the RS 232 LAN communications lines N NO OT TE E These requirements shall be compatible with the...

Page 43: ...on 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 provi...

Page 44: ...ation at or near fuel Island in the appropriate 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 surfa...

Page 45: ...wer Cabinet includes the following components Mains Circuit Control Box MCC Uninterruptible Power Supply UPS Power Distribution Box PDB TLG Controller 3 3 2 2 Home Base Forecourt The Home Base Forecou...

Page 46: ...MDE 4813D CFN PLUS Installation Manual February 2018 36 Figure 3 2 Home Base Station with Mechanical Pumps System Diagram...

Page 47: ...MDE 4813D CFN PLUS Installation Manual February 2018 37 Figure 3 3 Home Base Station with Electronic Pumps System Diagram...

Page 48: ...e islands and their dispensers Locate the fuel tanks Locate the intended position of the CFN 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 tan...

Page 49: ...he CFN PLUS pedestal by see Figure 3 4 The required connections are 1 Dispenser wiring connections Pulser Low Voltage In Use signal High voltage Valve High voltage 2 Communications RS 232 to TLG Contr...

Page 50: ...he following general steps Installing CFN PLUS on a wall Running cables through the conduits to CFN PLUS Wiring CFN PLUS 3 6 3 Site Preliminary Setup Procedures Proceed as follows 1 Determine the spot...

Page 51: ...drilling Select a place that allows you to open completely the CFN PLUS door 5 Drill four holes in the installation spot fit for M4 screws 6 Insert four wall anchors or equivalent in the holes 7 Set t...

Page 52: ...g 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 whe...

Page 53: ...n the Home Base Station There are two types of pumps Mechanical Pump Electronic Pumps The following paragraphs provide the wiring requirements for each type of pump 3 7 3 Wiring Requirements For any t...

Page 54: ...bel added to the power protective window see Figure 3 12 The Wiring Label follows the physical location of the wires in the Terminal Block as shown in Figure 3 11 3 8 2 Mechanical Pump Terminal Block...

Page 55: ...12 VDC Output to Pulser Nozzle 1 24 12 V 2 P 12 VDC Output to Pulser Nozzle 2 25 12 V 3 P 12 VDC Output to Pulser Nozzle 3 26 12 V 4 P 12 VDC Output to Pulser Nozzle 4 27 IN USE 1 A AC Handle Up AC I...

Page 56: ...Terminal Block Mechanical Pump Connections Definition Terminal No Signal Name Functional Description 42 LINE 4 Pump control 120 240 VDC Input Nozzle 4 43 LINE IN 115 230 V Input AC voltage 44 NEUTRAL...

Page 57: ...MDE 4813D CFN PLUS Installation Manual February 2018 47 Figure 3 11 Terminal Block Mechanical Pump Wiring List Label Figure 3 12 Terminal Block Wiring List Label Installed on Protective Cover...

Page 58: ...per volume liter gallon is determined by the Pulser unit It is programmed as a factor by the Head Office controller Handle Status Input Wires The handle signal is used to signal the system that the p...

Page 59: ...MDE 4813D CFN PLUS Installation Manual February 2018 49 Figure 3 13 Mechanical Pump Single Dispenser Connections...

Page 60: ...MDE 4813D CFN PLUS Installation Manual February 2018 50 Figure 3 14 Mechanical Pump Twin Dispenser Connections BREAKERS...

Page 61: ...MDE 4813D CFN PLUS Installation Manual February 2018 51 Figure 3 15 CFN PLUS and Mechanical Pump Terminal Block Detailed Connections...

Page 62: ...N NO OT TE E 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 and nozzle rin...

Page 63: ...2018 53 3 8 4 2 Mechanical Pulser Two Wire Pulser powered by the CFN PLUS Figure 3 17 shows a schematic diagram of the connections between the Terminal Block and a two wire Pulser Figure 3 17 Termina...

Page 64: ...ajor one are described below The major pumps are Tokheim Current Loop RS 485 RS 422 See Figure 3 18 for the wiring list label applied within the inner wall of the unit This label consists of a wiring...

Page 65: ...MDE 4813D CFN PLUS Installation Manual February 2018 55 Figure 3 18 CFN PLUS Terminal Block Wiring List Label...

Page 66: ...connections between CFN PLUS and the Tokheim pump nozzle and the terminals that differ from the Mechanical Pump Figure 3 18 shows the wiring list for connection to the Terminal as published in the Wir...

Page 67: ...op pump nozzle and the terminals that differ from the Mechanical Pump The figure shows the serial connection between two Current Loop pumps and the Terminal Block Figure 3 18 shows the wiring list for...

Page 68: ...ump nozzle and the terminals that differ from the Mechanical Pump The figure shows the parallel connection between two RS 485 pumps and the Terminal Block Figure 3 18 shows the wiring list for connect...

Page 69: ...g paragraphs show the specific wiring between the CFN PLUS Terminal Block and components common in both types of Home Base Stations either with mechanical or electronic pump 3 10 2 Connection to TLG C...

Page 70: ...wiring inserted in separate conduits throughs and so on o Is the system peripheral equipment powered on a separate dedicated breaker o Is the system grounded properly o Are the cables correctly route...

Page 71: ...lated to the system and its peripherals CFN PLUS see paragraph 4 2 1 Communication to peripherals see paragraph 4 2 2 4 2 1 CFN PLUS Troubleshooting The CFN PLUS troubleshooting procedure and conseque...

Page 72: ...r being turned ON Check for loads or shorts in the power line Internal fuse blown Check the two pico fuses red wires at the bottom of the power supply using an ohmmeter Replace the fuse if it is blown...

Page 73: ...place MPI C board 2 Replace 8 port board Pump malfunction Turn the CFN PLUS bypass switch on lift the nozzle and check that the pump supplies fuel If the problem persists 1 Check Handle On Switch 2 Re...

Page 74: ...ound 1 Replace valve 2 Repair pump Payment device card key tag Fuel Ring is not accepted Communication fault between OrTR and SO 1 Check LAN cable 2 Check OrTR setup 3 Check SO setup 1 Replace LAN cab...

Page 75: ...Devices grid blocked unblocked Change device status to Unblocked Pump is Authorized and refueling but volume remains zero Pump is refueling but volume remains zero Pulse factor is zero Check SO pump...

Page 76: ...LED is blinking 2 Unplug the cable and 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 th...

Page 77: ...rk activity The last two LEDs from left 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 rese...

Page 78: ...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 IP address of the...

Page 79: ...cally at short intervals due to the harsh environment of the Home Base Station where they operate The following instructions are valid for the CFN PLUS box and for OrTR Optional Clean the OrTR front p...

Page 80: ...MDE 4813D CFN PLUS Installation Manual February 2018 70 This page is intentionally left blank...

Page 81: ...der unit OrCU Orpak 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 reade...

Page 82: ...ID 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 accep...

Page 83: ...e __________________ Tel ____________ Contact Person __________________ Mobile Phone _____ Fax ____________ A STATION INFORMATION Power line 110VAC 220VAC Other____ Power stabilizer UPS available ____...

Page 84: ...ufacturer_________________ MODEL___________________________ TYPE Mechanical have electronic pulse out _____ Pulses liter factor_________ Electronic protocol communication ____________ Pump link Curren...

Page 85: ..._________________________ DIAMETER OF NOZZLE SPOUT ________ E NOZZLE EQUIPMENT 2 HOSE SIZE 3 4 1 other________ Hose Length ___________________ Break Away Yes No Location on the hose ________ Vapor Rec...

Page 86: ...se a TLS what type _________________________________________ How do they read tanks today _________________________________________ H Site inspection draw the station and attach photos Pay attention t...

Page 87: ...018 77 0 A AP PP PE EN ND DI IX X B B W WI IR RI IN NG G D DI IA AG GR RA AM M This appendix provides the wiring diagram of the CFN PLUS as follows Figure B 1 CFN PLUS Wiring Diagram Mechanical Pump F...

Page 88: ...MDE 4813D CFN PLUS Installation Manual February 2018 78 Figure B 1 CFN PLUS Wiring Diagram Mechanical Pump...

Page 89: ...MDE 4813D CFN PLUS Installation Manual February 2018 79 Figure B 2 CFN PLUS Wiring Diagram Electronic Pump...

Page 90: ...MDE 4813D CFN PLUS Installation Manual February 2018 80 This page is intentionally left blank...

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