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Gasboy Islander PLUS - User Manual

Gasboy Islander PLUS
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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

Table of Contents

Questions and Answers

Summary

Safety Considerations

Warning - Explosion Hazard

Warns about explosion risks in fuel station environments.

Caution - Shock Hazard

Warns about dangerous AC voltages and the need to disconnect power.

Caution - External Wiring

Specifies wire requirements for supply and signal connections.

Warning - Passing Vehicles

Advises caution regarding passing vehicles in open fuel station areas.

Warning Notices

Caution

Warns against attempting repairs on printed circuit boards.

Propriety Notice

States document confidentiality and property of ORPAK SYSTEMS Ltd.

Disclaimer

States the document is for reference only and may contain errors.

FCC Compliance Statement

Outlines FCC compliance for digital devices and potential interference.

FCC Warning

Warns that unauthorized modifications void user authority to operate equipment.

Section 1 General Description

1-1. Scope

Defines the manual's purpose and target audience for installing Islander PLUS/ICR PLUS.

1-2. Description

Describes Islander PLUS as a fuel control and data acquisition system for home base stations.

1-3. System Overview

Provides an overview of the Islander PLUS system, its components, and functions.

1-5. Available Configurations

Details the various available configurations of the Islander PLUS system.

1-5.1. General

Explains that Islander PLUS is available in several configurations based on use and components.

1-5.2. Islander PLUS; ICR PLUS

Differentiates between Islander PLUS and ICR PLUS configurations and their functionality.

1-5.3. Printer Option

Notes the printer is an optional feature for issuing transaction receipts.

1-5.4. Vehicle Identification System

Lists options for vehicle identification like FuelPoint PLUS and wireless modes.

1-4. Islander PLUS Structure

1-4.1. Main Components

Lists and describes the primary components of the Islander PLUS system.

1-5.6. Contactless Tags;Cards

Discusses options for contactless identification like Data Key Sockets and HID devices.

1-5.6.1. Data Key Sockets - Fleet key

Describes the optional key reader for Data Key Sockets.

1-5.6.2. HID Device

Details the optional HID card reader and its supported formats.

1-5.6.3. Configurations

Refers to Table 1-1 for available product numbers for configurations.

1-6. Security and Protection

Covers security measures for transactions and system access.

1-6.1. General

States that transaction activities are secured and protected.

1-6.2. Authorization Security

Details encryption and security for user identification and billing.

1-6.3. Network Security

Explains network isolation and firewall recommendations for remote access.

1-6.4. RF Network Security

Mentions encryption standards for the RF network.

1-6.5. Maintenance Security

Notes the requirement for username and password for maintenance access.

1-7. Housing

Describes the physical enclosure of the Islander PLUS system.

1-8. Specifications

Lists the physical, electrical, and environmental specifications of the Islander PLUS.

1-9. Standards

Details communication and security standards used by the Islander PLUS.

1-9.1. Communication Standards

Lists standards like RS-232, RS-485, TCP/IP, and EIA 802.15.4.

1-9.2. Security Standards

Lists Triple DES and AES 128 for security.

1-10. Manual Structure

Outlines the structure and sections of the installation manual.

1-11. Using This Manual

Explains how to interpret the manual's alerting comment types (Warning, Caution, Tip, Note, Insight).

1-12. References

Lists related manuals for further information.

Section 3 Islander PLUS Installation Procedures

3-1. General

Outlines the installation procedures for the Islander PLUS.

3-2. Installation Specifications

Details specifications relevant to Islander PLUS installation.

3-2.1. General

Notes that installation depends on dispenser models and site layout.

3-2.2. Precautions and Safety Notes

Advises observing safety notes before commencing installation activities.

3-2.3. Safety Distances

Specifies required safety distances for installing Islander PLUS near dispensers.

3-3. Home Base Station - Overview

Provides an overview of the Home Base Station functional architecture.

3-3.1. General

Emphasizes the need for an overview to draw an architecture diagram.

3-3.2. Home Base Station Architecture

Describes the architecture levels of the Home Base Station.

3-3.2.1. Main Power Cabinet

Lists components within the Main Power Cabinet.

3-3.2.2. Home Base Forecourt

Lists components in the Home Base Forecourt.

3-3.2.3. Head Office System (Optional)

Describes the optional Head Office system for management.

3-4. Mapping the Site- Example

Provides an example procedure for mapping a site.

3-4.1. General

Outlines steps for site mapping: locating objects, assigning IDs, etc.

3-4.2. Locating all objects of the site

Lists items to locate for site mapping.

3-4.3. Assigning Logical IDs

Details assigning logical IDs to tanks, dispensers, and the Islander PLUS pole.

3-5. Connections to Islander PLUS

Explains how to perform all connections to the Islander PLUS.

3-6. Installing the Islander PLUS Pedestal Pole

Details the steps for installing the Islander PLUS pedestal pole.

3-6.1. General

Describes how the pedestal is mounted on a base plate.

3-6.2. Installation Procedure Steps

Lists the general steps for pedestal installation.

3-6.3. Pedestal Site Preliminary Setup Procedures

Outlines preliminary setup procedures for the pedestal site.

3-7. Wiring

Covers the wiring procedures after installation.

3-7.1. General

States wiring is performed in the Islander PLUS Terminal Block.

3-7.2. Types of Wiring

Notes wiring differs based on pump type (mechanical or electronic).

3-7.3. Wiring Requirement

Specifies requirements for inserting wires with terminal lugs.

3-7.4. Types of Cable

Lists the types of cables required for installation.

Section 4 Printer

4-1. Overview

Introduces the optional printer, its characteristics, and operation.

4-2. Description

Describes the printer as a compact, ruggedized thermal printer for gas stations.

4-3. Main Components

Identifies the main components of the printer module.

4-4. Printer Connector Pin-Out

Details the pin-out configuration of the printer connector.

4-5. Indicators

Explains the printer's buzzer and LED indicators for status.

4-6. Specifications

Lists the physical, electrical, and environmental specifications of the printer.

4-7. Installation Printing Parameters

Covers jumper configuration for RS-485 address and copy selection.

4-7.1. Jumpers Configuration

Explains how jumpers set the RS-485 address and number of copies.

4-7.2. Parameters for Printing

Details printing modes: print only when door lifted or print always.

4-7.3. Cutter

Describes the three modes for the paper cutter: No Cut, Full Cut, Partial Cut.

4-7.4. Printing the Status Report

Outlines steps to print a printer status report.

4-8. Paper Roll Replacement

Provides instructions for replacing the printer paper roll.

4-8.1. General

Mentions paper sensors for low paper and out of paper alerts.

4-8.2. Paper Roll Replacement

Details the procedure for replacing the printer paper roll.

Section 5 Maintenance

5-1. General

Provides general maintenance instructions and a troubleshooting guide.

5-2. Troubleshooting

Lists common problems and corrective actions for the system and peripherals.

5-2.1. Islander PLUS Troubleshooting

Describes troubleshooting procedures and corrective actions for the Islander PLUS.

5-2.2. OrPT Troubleshooting

Outlines troubleshooting for the OrPT module.

5-2.3. Printer Troubleshooting

Details troubleshooting steps for printer issues.

5-2.4. Communication Troubleshooting

Covers troubleshooting for communication problems with peripherals.

5-3. Cleaning

Provides instructions for cleaning system components.

5-3.1. General

Mentions periodic cleaning for the Islander PLUS unit.

5-3.2. Cleaning

Gives cleaning instructions for the OrPT front panel and pedestal.

5-3.3. Magnetic Card Reader - Cleaning Instructions

Provides instructions for cleaning the magnetic card reader.

Section 2 Preliminary Installation Instructions

2-1. General

Introduces the preliminary installation procedures for the Islander PLUS.

2-2. Preliminary Installation Instructions

Details preliminary installation requirements and procedures.

2-2.1. General

Emphasizes performing a site survey before installation.

2-2.2. Precautions and Safety Notes

Advises observing safety notes before actual installation activities.

2-3. Conduits Layout;Installation Specifications

2-4. Conduits

Details requirements for conduit installation.

2-4.1. General

Explains the need for conduits in the station ground for routing and protection.

2-4.2. Conduit Requirements

Lists compliance requirements for conduits, including separation of voltage types.

2-4.3. Conduits at Islander PLUS

Describes the conduits available at the Islander PLUS pedestal for cable entry.

2-5. Conduits Installation

2-5.1. General

Describes the groundwork for installing conduits in the island.

2-5.2. Installing Conduits in Island

Provides step-by-step instructions for installing conduits in the island.

2-5.3. Sealing Conduits

Explains the importance and procedure for sealing conduits as per regulations.

2-8. Wiring the Peripherals

2-8.1. Pump Wiring

Details the wiring procedures for pump motors connected to the Islander PLUS.

2-8.2. TLG wiring

Explains installation requirements for TLG RS-232/LAN communication lines.

3-8. Mechanical Pump - Wiring

3-8.1. General

Explains the two modes for mechanical pump wiring.

3-8.2. 4 - Mechanical Pump - Terminal Block - Pin-Out Connections

Lists terminal block connections for a 4-mechanical pump setup.

3-8.3. 8-Mechanical Pump - Terminal Block - Pin-Out Connections

Nozzle Grounding - Nozzle 1

Grounding connection for Nozzle 1.

Nozzle Grounding - Nozzle 2

Grounding connection for Nozzle 2.

Nozzle Grounding - Nozzle 3

Grounding connection for Nozzle 3.

Nozzle Grounding - Nozzle 4

Grounding connection for Nozzle 4.

Nozzle Grounding - Nozzle 5

Grounding connection for Nozzle 5.

Nozzle Grounding - Nozzle 6

Grounding connection for Nozzle 6.

Nozzle Grounding - Nozzle 7

Grounding connection for Nozzle 7.

Nozzle Grounding - Nozzle 8

Grounding connection for Nozzle 8.

+12 VDC Output to Pulser - Nozzle 1

+12 VDC output for Pulser on Nozzle 1.

+12 VDC Output to Pulser - Nozzle 2

+12 VDC output for Pulser on Nozzle 2.

+12 VDC Output to Pulser - Nozzle 3

+12 VDC output for Pulser on Nozzle 3.

+12 VDC Output to Pulser - Nozzle 4

+12 VDC output for Pulser on Nozzle 4.

+12 VDC Output to Pulser - Nozzle 5

+12 VDC output for Pulser on Nozzle 5.

3-9. Electronic Pump - Wiring Description

3-9.1. General

States wiring differs based on electronic pump type (Tokheim, Current Loop, RS-485).

3-9.2. Tokheim Electronic Pump

Wiring Connections

Provides wiring connections for the Tokheim electronic pump.

3-9.3. Current Loop Electronic Pump

Wiring Connections

Details wiring connections for the Current Loop electronic pump.

3-9.4. RS-485 Electronic Pump

Wiring Connections

Shows wiring connections for the RS-485 electronic pump.

3-10. Wiring to General Components

3-10.1. General

Covers wiring between Islander PLUS and common components.

3-10.2. Connection to TLG Controller

Shows the connection between the TLG controller and the Islander PLUS.

3-10.3. Connection to Journal Printer

Describes the journal printer for journaling operations.

3-11. Post-Installation Checklist

Correct Wiring

Checks for proper wiring, conduit use, dedicated breakers, grounding, and cable routing.

Clean Dirt and Wire Remnants

Instruction to clean dirt and wire remnants after installation.

Section 6 Glossary

6-1. FuelOmat Glossary

Defines terms related to the FuelOmat system.

6-2. Communication Glossary

Defines terms related to network and communication protocols.

Appendix B Wiring Diagram

Appendix C HID Assembly Installation

Introduction

Describes how to install the HID unit in the home base pedestal.

Gasboy Islander PLUS Specifications

General IconGeneral
CategoryController
ManufacturerGasboy
ModelIslander PLUS
Power SupplyExternal power supply
Enclosure RatingNEMA 4X
CompatibilityGasboy Dispensers
DisplayLCD
KeypadNumeric
CommunicationRS-232, RS-485
MemoryNon-volatile

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