Gasboy Islander PLUS - Maintenance; General; Troubleshooting; 5-2.1. Islander PLUS Troubleshooting

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SECTION 5

MAINTENANCE

5-1. GENERAL

This section provides general maintenance instructions for the Islander PLUS as well as a

comprehensive troubleshooting guide.

5-2. TROUBLESHOOTING

The next paragraphs provide a list of common pump/system problems which may be encountered

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 corrective actions are described in

Table 5-1.

Islander PLUS Manual

Main Page

Table of Contents5
General Description15
Scope15
Description15
Figure 1-1 - Islander PLUS / ICR PLUS - General View16
System Overview17
1-3.1. Islander PLUS System17
1-3.2. Vehicle Identification - Fuelpoint PLUS17
1-3.3. Remote Web Access17
1-3.4. Head Office17
1-3.5. Restrictions and Limits17
1-3.6. Islander PLUS Capabilities for Forecourt Management18
1-3.7. System Workflow Example18
Figure 1-2 - Islander PLUS in Home Base Station - General Configuration Diagram18
1-3.7.1. Refueling Scenario with Fuelpoint PLUS19
1-3.7.2. Refueling Scenario with Magnetic Cards19
Islander Plus Structure20
1-4.1. Main Components20
1-4.2. Islander PLUS Internal Configuration - Mechanical Pump23
Figure 1-3 - Internal Configuration Diagram - 4 Mechanical Pump23
Figure 1-4 - Internal Configuration Diagram - 8 Mechanical Pumps24
1-4.3. Islander PLUS Main Components Location25
Figure 1-5 - Internal Components Location -4 Mechanical Pumps25
Figure 1-6 - Internal Components Location -8 Mechanical Pumps26
Figure 1-7 - Islander PLUS with Optional Internal Printer (Sectional View)27
Figure 1-8 - Islander PLUS for 8 Hoses with Optional Internal Printer (Sectional View)28
Available Configurations30
1-5.1. General30
1-5.2. Islander PLUS / ICR PLUS30
1-5.3. Printer Option30
1-5.4. Vehicle Identification System30
1-5.5. Dispensers30
1-5.6. Contactless Tags/Cards31
1-5.6.1. Data Key Sockets - Fleet Key31
1-5.6.2. HID Device31
1-5.6.3. Configurations31
Figure 1-9 - Islander PLUS with Data Key Reader (Optional)31
Table 1-1. Islander PLUS - Standard Models32
Table 1-2. Pump Card Definition33
Security and Protection34
1-6.1. General34
1-6.2. Authorization Security34
1-6.3. Network Security34
1-6.4. RF Network Security34
1-6.5. Maintenance Security34
Housing34
Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions35
Specifications36
Standards37
1-9.1. Communication Standards37
1-9.2. Security Standards37
1-10. Manual Structure38
1-11. Using this Manual39
1-12. References40
Preliminary Installation Instructions42
General42
2-2.2. Precautions and Safety Notes42
Conduits Layout/Installation Specifications43
Conduits43
2-4.1. General43
2-4.2. Conduit Requirements44
2-4.3. Conduits at Islander PLUS44
Figure 2-1 Islander PLUS Lower Protective Plate45
Figure 2-2 Standard Bottom Metal Plate's Knockout -Close View45
2-4.4. Required Conduits in Island46
2-4.5. Required Conduits in Islander PLUS46
Table 2-1. Conduits into Islander PLUS46
2-5. Conduits Installation47
2-5.1. General47
2-5.2. Installing Conduits in Island47
2-5.3. Sealing Conduits47
Figure 2-3 Conduit Fitting47
Figure 2-4 Conduits Layout for Mechanical Pump48
Figure 2-5 Conduits Layout for Electronic Pump49
Cables Insertion50
2-6.1. General50
2-6.2. Types of Cables50
2-6.3. Cables Routing51
2-7. Power Setup51
2-7.1. General51
Table 2-2. Islander PLUS, Cables Type51
Table 2-3. Islander PLUS, Cables Routing51
2-7.2. Islander PLUS for 8 Hoses - AC Power Supply Setup52
Figure 2-6 Power Equipment Connections52
Figure 2-7 Power Supply Components and Grounding Studs53
Figure 2-8 VAC Power Supply - Jumpers Setup53
2-7.3. Connecting the Power Equipment54
2-7.4. Grounding54
Figure 2-9 Islander PLUS Ground Description54
2-8. Wiring the Peripherals55
2-8.1. Pump Wiring55
2-8.2. TLG Wiring55
Figure 2-10 Communications Cable Wiring55
Islander Plus Installation Procedures57
General57
Installation Specifications57
3-2.2. Precautions and Safety Notes57
3-2.3. Safety Distances58
3-3. Home Base Station - Overview58
3-3.1. General58
Figure 3-1 Islander PLUS- Installation Control Drawing58
3-3.2. Home Base Station Architecture59
3-3.2.1. Main Power Cabinet59
3-3.2.2. Home Base Forecourt59
3-3.2.3. Head Office System (Optional)59
Figure 3-2 Home Base Station with 4 Mechanical Pumps - System Diagram60
Figure 3-3. Home Base Station with 8 Mechanical Pumps - System Diagram61
Figure 3-4 Home Base Station with Electronic Pumps - System Diagram62
3-4. Mapping the Site- Example63
3-4.1. General63
3-4.2. Locating All Objects of the Site63
3-4.3. Assigning Logical Ids63
3-4.3.1. to each Fuel Tank63
3-4.3.2. to each Dispenser Unit63
3-4.3.3. in the Islander PLUS Pole63
3-4.4. Mapping63
Connections to Islander Plus64
Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections65
Installing the Islander Plus Pedestal Pole66
3-6.1. General66
3-6.2. Installation Procedure Steps66
3-6.3. Pedestal Site Preliminary Setup Procedures66
Figure 3-6 Islander PLUS Terminal Block, Power and LAN Connections (8 Pumps)66
3-6.4. Installation Assembly Parts67
3-6.5. Base Plate Installation Procedures67
Table 3-1. Islander PLUS, Assembly Parts67
Figure 3-7 Pedestal Pole Installation68
Figure 3-8 Base Plate Installation (Example)69
Figure 3-9 Rosette (Upside down View)69
Figure 3-10 Rosette Dimensions69
3-6.6. Pedestal Installation Instructions70
3-6.7. Base Plate Installation Procedures - Optional70
Figure 3-11 Expansion Bolt70
3-6.8. Sealing Conduits71
Figure 3-12 Conduit Fitting71
Wiring72
3-7.1. General72
3-7.2. Types of Wiring72
3-7.3. Wiring Requirement72
3-7.4. Types of Cable72
Figure 3-13 Terminal Lug72
Mechanical Pump - Wiring73
3-8.1. General73
3-8.2. 4 - Mechanical Pump - Terminal Block - Pin-Out Connections73
Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump - Connections Definition73
3-8.3. 8-Mechanical Pump - Terminal Block - Pin-Out Connections75
Table 3-3. Islander PLUS for 8 Hoses Terminal Block -8 Mechanical Pump - Connections Definition75
Figure 3-14 Islander PLUS Terminal Block77
Figure 3-15 Islander PLUS - Terminal Block (8 Pumps)78
Figure 3-16 Islander PLUS - Terminal Block -4 Mechanical Pump - Wiring List Label78
3-8.4. Mechanical Pump - Required Connections79
Figure 3-17 Islander PLUS - Terminal Block - 8 Mechanical Pump - Wiring List Label79
Figure 3-18 Mechanical Pump - Single Dispenser Connections81
Figure 3-19 Mechanical Pump - Twin Dispenser Connections82
Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections83
3-8.5. Mechanical Pump - Pulser Connections84
3-8.5.1. Electronic Pulser84
3-8.5.2. Mechanical Pulser84
Figure 3-21 Terminal Block and 3-Wire Pulser - Wiring Connections84
Figure 3-22 Terminal Block and 2-Wire Pulser - Wiring Connections85
Electronic Pump - Wiring Description86
3-9.1. General86
Figure 3-23 Islander PLUS Terminal Block - Wiring List Label87
3-9.2. Tokheim Electronic Pump88
Figure 3-24 Tokheim Electronic Pump - Wiring Diagram88
3-9.3. Current Loop Electronic Pump89
Figure 3-25 Current Loop Electronic Pump - Wiring Diagram89
3-9.4. RS-485 Electronic Pump90
Figure 3-26 RS-485 Electronic Pump - Wiring Diagram90
3-10. Wiring to General Components91
3-10.1. General91
3-10.2. Connection to TLG Controller91
3-10.3. Connection to Journal Printer91
Figure 3-27 Terminal Block - TLG Wiring Link91
Figure 3-28 Journal Printer - General View92
Figure 3-29 Journal Printer - Rear Panel93
3-11. Post-Installation Checklist94
3-12. Islander Plus Setup94
Printer95
Overview95
Figure 4-1. Printer Module in Islander PLUS95
Description96
Figure 4-2. Printer Module Within Islander PLUS96
Main Components97
Figure 4-3. Printer Module- Main Components97
Table 4-1. Printer Main Components97
Printer Connector Pin-Out98
Figure 4-4. Printer Connector98
Figure 4-5. Printer Connector - Pin-Out Description98
Table 4-2. Printer Module Connector - Pin-Out Description98
Indicators99
Specifications99
Installation Printing Parameters100
4-7.1. Jumpers Configuration100
Figure 4-6. Printer Module - Jumpers Default Configuration100
4-7.2. Parameters for Printing101
4-7.3. Cutter101
4-7.4. Printing the Status Report101
Figure 4-7. Printer Module- Jumpers Configuration Examples101
Paper Roll Replacement102
4-8.1. General102
Figure 4-8. Door Handle and Paper Lock Lever102
Figure 4-9. Printer - Paper Replacement103
4-8.2.1. Automatic Insertion of Paper104
4-8.2.2. Manual Insertion of Paper104
Printer Cleaning105
4-9.1. General105
4-9.2. Thermal Printer Head -Cleaning Instructions105
4-9.2.2. Cleaning Procedures105
Figure 4-10. Pressing Paper-Lock Lever106
4-10. Troubleshooting107
4-10.1. General107
4-10.3. Releasing Jammed or Crumpled Paper107
Table 4-3. Printer Troubleshooting107
4-11. Thermal Paper Storage108
Maintenance109
General109
Troubleshooting109
5-2.1. Islander PLUS Troubleshooting109
Table 5-1. Islander PLUS Troubleshooting110
5-2.2. Orpt Troubleshooting116
Table 5-2. Orpt Troubleshooting116
5-2.3. Printer Troubleshooting120
Table 5-3. Printer Troubleshooting120
5-2.4. Communication Troubleshooting122
Table 5-4. Communication Troubleshooting122
Cleaning125
5-3.1. General125
5-3.3. Magnetic Card Reader - Cleaning Instructions125
5-3.4. Printer - Cleaning Instructions126
Glossary127
Fuelomat Glossary127
Communication Glossary128
Appendix Asite Survey130
Appendix Bwiring Diagram135
Figure B-1 Islander PLUS - Wiring Diagram (Mechanical Pump)135
Figure B-2 Islander PLUS - Wiring Diagram (Electronic Pump)135
Figure B-3 Islander PLUS for 8 Hoses - Wiring Diagram138
Appendix Chid Asasembly Installation139
Introduction139
Table 1. HID Installation Kit Items139
Figure 1. HID Unit and Connector140
Figure 2. HID Holder and Nuts140
Figure 3. Orcu Location in Islander PLUS 8-Hoses141
Figure 4. Rectangular Plate Connecting Points Location142
Figure 5. HID Back Cover Removal142
Figure 6. Attaching Back Cover to HID Holder143
Figure 7. Assembled Back Cover and HID Holder143
Figure 8. HID Mounted on Pedestal Door144
Figure 9. Upper Left Corner Spacer144
Figure 10. HID Connector Inserted to Orpt Connector145
Figure 11. Placing Hand Tag Label on Pedestal146

Gasboy Islander PLUS - Maintenance; General; Troubleshooting; 5-2.1. Islander PLUS Troubleshooting

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