Gasboy MDE-5411B Installation Manual

MDE-5411B

ForeHB

Islander PRIME Installation Manual

This manual supports released version 6.4.410.XX

This document is based on Orpak’s ForeHB OrIC PRIME Installation

Manual, P/N 817450050.

SAFETY CONSIDERATIONS

Read all warning notes and instructions carefully. They are included to help you installing the Product safely in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions could result in serious injury or property damage. It is the installer responsibility to install, operate and maintain the equipment according to the instructions given in this manual, and to conform to all applicable codes, regulations and safety measures. Failure to do so could void all warranties associated with this equipment.

Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure that actual installation is performed by experienced personnel, licensed to perform work in fuel station and at a flammable environment, according to the local regulations and relevant standards.

WARNING - EXPLOSION HAZARD

Use separate conduit for the intrinsically safe. Do not run any other wires or cables through this conduit, because this 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 of the Product, comply with all applicable requirements of the National Fire

Protection Association NFPA30 “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 codes and regulations.

Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury, property loss and damage to you and other persons.

CAUTION - SHOCK HAZARD

Dangerous AC voltages that could cause death or serious personal injury are used to power the Product. Always disconnect power before starting any work. The Product has more than one power supply connection points.

Disconnect all power before servicing.

WARNING - PASSING VEHICLES

When working in any open area of fuel 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.

WARNING

Components substitutions could impair intrinsic safety.



Attaching unauthorized components or equipment will void your warranties.

CAUTION

Do not attempt to make any repair on the printed circuit boards 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 Gasboy International Ltd. 

It may not be disclosed or reproduced in whole or in part without written consent of ORPAK SYSTEMS. The information in this document is current as of the date of its publication, but is subject to change without notice.

DISCLAIMER

This document is provided for reference only. Although every effort has been made to ensure correctness, ORPAK

SYSTEMS does not guarantee that there are no errors or omissions in this document.

FCC COMPLIANCE STATEMENT

The FCC Wants You to Know:

This equipment has been tested and found to comply with 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, there is no guarantee that interference will not 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 encouraged to try to correct the interference by one or more of the following measures: a) Reorient or relocate the receiving antenna.

b) Increase the separation between the equipment and receiver.

c) Connect the equipment to an outlet on a circuit different from that to which the receiver is connected. d) Consult the dealer or an experienced radio/TV technician.

FCC WARNING

Modifications not expressly approved by the manufacturer could void the user authority to operate the equipment under FCC Rules.

This page is intentionally left blank.

Table of Contents


1 – Introduction 1

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Solution Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 Manual Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6 Documentation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 – Important Safety Information 5

3 – System Overview 9

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.1 Fuel Point PLUS - Automatic Vehicle Identification . . . . . . . . . . . . . . . . . . . . . 9

3.2.2 Remote Web Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.3 Head Office . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.4 Restrictions and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2.5 Islander PRIME Capabilities for Forecourt Management . . . . . . . . . . . . . . . . 10

3.2.6 System Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Islander PRIME 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 Barcode Reader Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.5 Insert Card Reader Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.6 HID Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.7 Cellular Modem Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.8 Receipt Printer Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4.9 EMV Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.10 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5 Security and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5.1 Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5.2 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5.3 RF Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.6 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.7 Technical Specifications and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.7.1 Islander PRIME Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.7.2 Communication and Security Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4 – Preliminary Guidelines 21

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2 Precautions and Safety Notes 

Précautions et consignes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.3 Station Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020 Page i


4.3.1 Station Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.3.2 Locating All Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.3.3 Assigning Logical IDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.3.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.4 Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.4.1 Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.4.2 Protective Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.4.3 Required Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.4.4 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.4.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4.6 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.5 Cable Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.5.1 Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.5.2 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.6 Power Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.6.1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.6.2 Power Supply Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.6.3 Connecting the Power Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.6.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.7 Wiring the Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.7.1 Pump Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.7.2 TLG Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5 – Installation 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 Preliminary Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.3.3 Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.3.4 Base Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.3.5 Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.3.6 Sealing Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.4 Installing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.4.1 Barcode Reader Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.4.2 HID Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.4.3 Insertion Card Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.4.4 Cellular Modem Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.4.5 G2 Panel Printer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.5 Installing Communication Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.5.1 Adding Communication Interface Blades to the Pedestal . . . . . . . . . . . . . . . 54

5.5.2 Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.5.3 Mechanical Dispenser Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.5.4 Pulser Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.5.5 Electronic Dispenser Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.6 Post-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.7 Islander PRIME Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6 – LAN CommVerter Setup 69

6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.2 Home Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.3.1 Minimal Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Page ii MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020


6.3.2 General Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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 – Troubleshooting 85

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.2 Islander PRIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.2.1 System Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.2.2 Mechanical Pump Does Not Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

8.2.3 No Control Over Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8.3 OrPAY1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8.4 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

8.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

8.6 FuelPoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020 Page iii



Page iv MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020

List of Figures

List of Figures

Figure 1 Islander PRIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Figure 2 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Figure 3 nOrCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 4 OrPAY1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 5 G2 Panel Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 6 Communication Interfaces in the Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 7 Internal Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 8 Islander PRIME Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 9 Installation Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 10 Terminal Block, Power, and LAN Connections (8 Pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 11 Lower Protective Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 12 Conduit Layout for Mechanical Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 13 Conduits Layout for Electronic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Figure 14 Power Equipment Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 15 Power Supply Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 16 Communications Cable Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 17 Base Plate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 18 Base Plate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 19 Base Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 20 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 Wiring to OrPAY1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 25 Barcode Reader Wiring to OrPAY1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 26 HID Reader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 27 HID Reader Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Figure 28 HID Reader on Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Figure 29 HID Reader Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 30 HID Reader in Islander PRIME Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 31 Insertion Card Reader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Figure 32 Insertion Card Reader (Inside Top View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Figure 33 Insertion Card Reader Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 34 Insertion Card Reader Mounted in Islander PRIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 35 Cellular Modem Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Figure 36 Cellular Modem in Islander PRIME Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Figure 37 Cellular Modem Antenna (Left Side Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Figure 38 G2 Panel Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 39 Disconnect Grounding Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 40 Panel Printer in Islander PRIME Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 41 Reconnect Grounding Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 42 Communication Interface Protective Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Figure 43 Communication Interface Slots (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


List of Figures

Figure 44 Communication Interface Blades in Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Figure 45 Communication Interface Protective Panel With Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Figure 46 Mechanical Dispenser Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Figure 47 Mechanical Dispenser Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Figure 48 MPI-C Fuses Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Figure 49 Three-Wire Pulser Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Figure 50 Two-Wire Pulser Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Figure 51 Tokheim Electronic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Figure 52 Tokheim 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-422 Electronic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Figure 57 TLG Wiring Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Figure 58 Islander PRIME CommVerter Setup Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Figure 59 Islander PRIME CommVerter Setup Homepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Figure 60 Minimal Setup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Figure 61 General Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Figure 62 OrIC Config Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Figure 63 Log Level Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Figure 64 Save Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Figure 65 Confirm Save Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Figure 66 Reset Device Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Figure 67 Download Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Figure 68 Software Upload Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Figure 69 Confirm Upload Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Figure 70 Paper Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82


List of Tables

List of Tables

Table 1 Communication Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 2 Islander PRIME Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 3 Conduits into Islander PRIME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 4 Islander PRIME Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 5 Islander PRIME Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 6 Islander PRIME Base Plate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Table 7 Islander PRIME Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Table 8 Barcode Reader Assembly Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table 9 Insertion Card Reader Assembly Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Table 10 Cellular Modem Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Table 11 MPI-C Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Table 12 MPI-C Fuses Slot #1- In Use/Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Table 13 MPI-C Fuses Slot #2 - Pump/In Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Table 14 Tokheim Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Table 15 Current Loop Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Table 16 RS-485 Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Table 17 RS-232/422 Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Table 18 Device Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Table 19 General Setup Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Table 20 OrIC Config Channels Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Table 21 CommVerter Log Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Table 22 Software Upload Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Table 23 System is Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Table 24 Mechanical Pump Does Not Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Table 25 No Control Over Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Table 26 OrPAY1000 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Table 27 Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Table 28 Communication Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Table 29 FuelPoint Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94


List of Tables

This page is intentionally blank.


1.1 General

1 – Introduction

Introduction

1.1 General

This manual describes the Islander PRIME Fuel Island Controller, which is part of the ForeHB solution. It provides a general description of the product, a detailed description of the modules, as well as installation and maintenance guidelines.

1.2 Solution Description

Gasboy ® ’s end-to-end ForeHB homebase fleet fueling solution extends from the station to the head office, giving fleet managers the power and flexibility to monitor fuel levels and authorize fueling activity. All site activity is controlled using Gasboy’s innovative Islander

PRIME Fuel Island Controller, which is an all-in-one weather-resistant cabinet that provides a complete forecourt island solution. Islander PRIME 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

• Transaction data storage

• Control over dispensers

• Reads Automated Tank Gauge (ATG)

Islander PRIME ruggedized pedestal and user-friendly interface, increases fleet operating margins, provides efficient vehicle refueling, offers real-time information on fuel utilization, prevents fuel loss and misuse, and gives homebase managers better control over inventory and delivery. The Islander PRIME is equipped with the following components:

• Embedded Linux controller

• OrPAY1000 Payment Terminal

• Communication interface modules mechanical/electronic/mixed

• Optional outdoor receipt printer

• Modular software licensing allowing different pricing by number of pumps, ATG, Fuel

Point PLUS integration

• Optional EMV ® card reader and PIN Pad

• nOrCU full station automation

• WiFi and/or cellular connectivity with the addition of an optional modem add-on

MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020 Page 1

Introduction

Figure 1: Islander PRIME

1.3 System Architecture

1.3 System Architecture

Figure 2

shows a basic diagram of ForeHB system architecture:

Figure 2: System Architecture

Page 2 MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020

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 FuelPoint ® PLUS Vehicle Installation And Programming Manual

• MDE-4817 SiteOmat In-House Station Controller Setup and Maintenance Manual

• G2 Panel Printer Installation and Setup Manual, P/N 800919900


Introduction 1.6 Documentation Conventions

1.6 Documentation Conventions

This manual uses the following conventions:

!

WARNING

An operating procedure, practice, etc., which if not correctly followed, could result in injury or loss of life.

Les consignes d'avertissement contiennent des informations qui, à moins d'être strictement respectées, peuvent entraîner des blessures ou la mort.

CAUTION

An operating procedure, practice, etc, which if not strictly observed, could result in damage to, or destruction of the equipment.

Les consignes de mise en garde contiennent des informations qui, à moins d'être strictement respectées, peuvent entraîner des dommages ou la destruction de l'équipement ou des risques à long terme pour la santé du personnel.

TIP

A useful guidance, whose purpose is to use the system in a more efficient way.

INSIGHT

More detailed technical/functional information regarding relevant issues.


Important Safety Information

2 – Important Safety Information

Notes: 1) Save this Important Safety Information section in a readily accessible location.

2) Although DEF is non-flammable, Diesel is flammable. Therefore, for DEF cabinets that are attached to Diesel dispensers, follow all the notes in this section that pertain to flammable fuels.

This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death or serious injury, if these safe service procedures are not followed.

Preliminary Precautions

You are working in a potentially dangerous environment of flammable fuels, vapors, and high voltage or pressures. Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment .

Emergency Total Electrical Shut-Off

The first and most important information you must know is how to stop all fuel flow to the pump/dispenser and island. Locate the switch or circuit breakers that shut off all power to all fueling equipment, dispensing devices, and Submerged Turbine

Pumps (STPs).

!

!

WARNING

The EMERGENCY STOP, ALL STOP, and

PUMP STOP buttons at the cashier ’ s station

WILL NOT shut off electrical power to the  pump/dispenser. This means that even if you activate these stops, fuel may continue to flow uncontrolled. 

You must use the TOTAL ELECTRICAL 

SHUT-OFF in the case of an emergency and not the console ’ s ALL STOP and PUMP STOP or similar keys.

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical components or the electronics of the dispenser requires total electrical shut off of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gilbarco equipment.

Evacuating, Barricading and Shutting Off

Any procedure that requires access to the pump/dispenser or

STPs requires the following actions:

• An evacuation of all unauthorized persons and vehicles from the work area

• Use of safety tape, cones or barricades at the affected unit(s)

• A total electrical shut-off of the affected unit(s)

Read the Manual

Read, understand and follow this manual and any other labels or related materials supplied with this equipment. Replace with the following information: If you do not understand a procedure, call the Gasboy Technical Support at 1 800-444-5529. It is imperative to your safety and the safety of others to understand the procedures before beginning work.

Follow the Regulations

Applicable information is available in National Fire Protection

Association (NFPA) 30A; Code for Motor Fuel Dispensing

Facilities and Repair Garages , NFPA 70; National Electrical

Code (NEC) , Occupational Safety and Health Administration

(OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gilbarco replacement parts and retrofit kits on your pump/dispenser. Using parts other than genuine Gilbarco replacement parts could create a safety hazard and violate local regulations.

Safety Symbols and Warning Words

This section provides important information about warning symbols and boxes.

Alert Symbol

This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death.

Signal Words

These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions below must be followed to prevent death, injury or damage to the equipment:

!

!

DANGER : Alerts you to a hazard or unsafe practice which will result in death or serious injury.

WARNING : Alerts you to a hazard or unsafe practice that could result in death or serious injury.

!

CAUTION with Alert symbol: Designates a hazard or unsafe practice which may result in minor injury.

CAUTION without Alert symbol: Designates a hazard or unsafe practice which may result in property or equipment damage.

Working With Fuels and Electrical Energy

Prevent Explosions and Fires

Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island.

DEF is non-flammable. Therefore, explosion and fire safety warnings do not apply to DEF fluid lines.



No Open Fire

Open flames from matches, lighters, welding torches, or other sources can ignite fuels and their vapors.

No Sparks - No Smoking

Sparks from starting vehicles, starting, or using power tools, burning cigarettes, cigars, or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic charge on your body, can cause a spark sufficient to ignite fuel vapors.

Every time you get out of a vehicle, touch the metal of your vehicle, to discharge any electrostatic charge before you approach the dispenser island.

Working Alone

It is highly recommended that someone who is capable of rendering first aid be present during servicing. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages. This information is available from the American Red Cross. Always advise the station personnel about where you will be working, and caution them not to activate power while you are working on the equipment. 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

Ensure that you use safe and established practices in working with electrical devices. Poorly wired devices may cause a fire, explosion, or electrical shock. Ensure that grounding connections are properly made. Take care that sealing devices and compounds are in place. Ensure that you do not pinch wires when replacing covers. Follow OSHA Lockout/Tagout requirements. Station employees and service contractors need to understand and comply with this program completely to ensure safety while the equipment is down.

Hazardous Materials

Some materials present inside electronic enclosures may present a health hazard if not handled correctly. Ensure that you clean hands after handling equipment. Do not place any equipment in the mouth.

!

The pump/dispenser contains a chemical known to the

State of California to cause cancer.

!

The pump/dispenser contains a chemical known to the

State of California to cause birth defects or other reproductive harm.

Page 6

WARNING

WARNING

Gilbarco Veeder-Root encourages the recycling of our products. Some products contain electronics, batteries, or other materials that may require special management practices depending on your location.

Please refer to your local, state, or country regulations for these requirements.

In an Emergency

Inform Emergency Personnel

Compile the following information and inform emergency personnel:

• Location of accident (for example, address, front/back of building, and so on)

• Nature of accident (for example, possible heart attack, run over by car, burns, and so on)

• Age of victim (for example, baby, teenager, middle-age, elderly)

• Whether or not victim has received first aid (for example, stopped bleeding by pressure, and so on)

• Whether or not a victim has vomited (for example, if swallowed or inhaled something, and so on)

!

WARNING

Gasoline/DEF ingested may cause unconsciousness and burns to internal organs.

Do not induce vomiting. Keep airway open.

Oxygen may be needed at scene. Seek medical advice immediately.

!

WARNING

DEF generates ammonia gas at higher temperatures.

When opening enclosed panels, allow the unit to air out to avoid breathing vapors. If respiratory difficulties develop, move victim away from source of exposure and into fresh air. If symptoms persist, seek medical attention.

!

WARNING

Gasoline inhaled may cause unconsciousness and burns to lips, mouth, and lungs. Keep airway open. Seek medical advice immediately.

!

!

WARNING

Gasoline/DEF spilled in eyes may cause burns to eye tissue. Irrigate eyes with water for approximately 15 minutes. Seek medical advice immediately.

WARNING

Gasoline/DEF spilled on skin may cause burns.

Wash area thoroughly with clear water.

Seek medical advice immediately.

!

WARNING

DEF is mildly corrosive. Avoid contact with eyes, skin, and clothing. Ensure that eyewash stations and safety showers are close to the work location. Seek medical advice/recommended treatment if DEF spills into eyes.

IMPORTANT : Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or  start-up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. 

Lockout/Tagout applies to all mechanical, hydraulic, chemical, or other energy, but does not cover electrical hazards. 

Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR

Part 1910.333 contains specific Lockout/Tagout provision for electrical hazards.

MDE-5411B ForeHB Islander PRIME Installation Manual · February 2020


Hazards and Actions

!

WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a serious hazard.

Fire or explosion may result, causing serious injury or death.

Follow established emergency procedures.

DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.

The following actions are recommended regarding these hazards:

Collision of a Vehicle with Unit Fire at Island Fuel Spill

• Do not go near a fuel spill or allow anyone else in the area.

• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).

• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not remove AC power and do not always stop product flow.

• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow open flames, smoking or power tools in the area.

• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.

• Call emergency numbers.





3.1 General

3 – System Overview

System Overview

3.1 General

This section provides a detailed description of the Islander PRIME system, as well as the available configurations, system specifications, and communication standards.

3.2 System Description

The following describes the modules that make up the Islander PRIME Fuel Island Controller.

Islander PRIME is an innovative controller that enables refueling in homebase stations for fleets authorized vehicles or drivers. Islander PRIME electronically locks all dispensers and pumps thereby ensuring that only authorized vehicles receive the required fuel. The system also ensures accurate recording of each transaction.

The heart of the ForeHB solution is the SiteOmat automation software. SiteOmat runs on an embedded operating system on the nOrCU (Gasboy Controller Unit). nOrCU is an embedded hardware platform designed to withstand the harsh gas station environment. It uses a solid state Flash disk and RTC (Real Time Clock) with back up, along with surge suppressors for transient and noise immunity. The system also includes power fail recovery 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 expenditures. The dispenser is authorized to fuel after a positive identification of the vehicle and only while the nozzle is inside the fuel inlet of the identified vehicle. All transaction information is automatically recorded. Combined vehicle and driver identification is also possible for more detailed tracking.

3.2.2 Remote Web Access

Remote Web-based capabilities for monitoring, management and maintenance are available. A standard PC with an Internet browser is used for management of the site either locally or remotely (secured). A software license is provided with the Islander PRIME system in order to access these features.

3.2.3 Head Office

Centralized management is provided by the optional Fleet and Fuel Head Office server. The

Fleet and Fuel Head Office consolidates the data from multiple sites and generates reports. It also enables control over limits and restrictions placed on the various fleet vehicles.

Furthermore, authorized fleet personnel are able to log in remotely and have full control over the forecourt. Head Office enables authorized users to control and manage wet stock inventory on all stations including orders, deliveries, and reports.


System Overview 3.2 System Description

3.2.4 Restrictions and Limits

Control of a fleet’s fuel expenses can be controlled by defining limits (day, week, month), maximum number of fuel transactions (day, week, month), and setting restrictions (days of the week, fuel type, stations, time intervals). In case of system configuration for multiple sites, the centralized Fleet Head Office needs to synchronize the data between all sites so that the limits can be applied to a whole system rather than to an individual site. In case of communication failure, the specific site will be able to refuel for a predefined period using the most recent limits stored in the database.

3.2.5 Islander PRIME Capabilities for Forecourt Management

Islander PRIME provides the following operational features for comprehensive forecourt management:

• Supports over 50 different types of dispensers used around the world. This product has only been evaluated for use with Underwriters’ Laboratories (UL ® ) Listed Dispensers.

• Advanced electronic support for mechanical dispensers, enabling pump with totalizer, preset and price update.

• Tank Level Gauging System (TLG) available for several brands. This product has only been evaluated for use with UL Listed TLGs.

• Support for a wide variety of communication links: cellular, dial-in modem, VPN, satellite, ADSL, and more.

3.2.6 System Workflow

The following provide 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).

3.2.6.1 Refueling Scenario with Fuel Ring

A driver stops for fuel at the station. The authorization device for the refueling transaction is a

Fuel Ring mounted in the vehicle. The driver lifts the nozzle and inserts it in the car inlet.

The Fuel Ring information is automatically read and sent to the Site Controller (nOrCU) for authentication and approval. Upon approval, the fueling transaction starts. At the end of the transaction, the data is stored internally and transfer to the Fuel Head Office (FHO) for future billing. Once the refueling is completed, the driver replaces the nozzle.

Page 10

3.2.6.2 Refueling Scenario with Magnetic Cards

A driver stops for fuel at the station. The authorization device for the fueling transaction is a magnetic card. The driver inserts the card through the magnetic card reader on the payment panel.

The magnetic card information is read and sent to the site controller (nOrCU) for authentication and approval. The driver lifts the nozzle and inserts it in the car inlet. Upon approval, the fueling transaction starts. At the end of the transaction, the data is stored internally and transfer to the FHO for future billing.

The client may add more data to the transaction by manually entering the information using the payment panel keyboard, or by scanning a barcode using the barcode reader (optional) on the front panel. Once the refueling is completed, the driver replaces the nozzle.


3.3 Islander PRIME Structure System Overview

3.3 Islander PRIME Structure

The following describes the components that are part of the Islander PRIME structure, including their location and configuration.

3.3.1 Main Components

The following provides a description of Islander PRIME’s main sub units.

3.3.1.1 Gasboy Controller 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 storage, Real Time Clock (RTC) with a backup. nOrCU features two separate and isolated networks (TCP/IP over Ethernet

®

). One network links the Islander PRIME system components. The second network is intended for external remote communication (Head

Office, third-party systems). This network is protected by SSL security.

nOrCU includes a built-in server for Web access through an Internet browser.

Figure 3: nOrCU


System Overview 3.3 Islander PRIME Structure

3.3.1.2 OrPAY1000

OrPAY1000 is Gasboy’s cost-effective outdoor payment terminal installed directly onto the dispenser or wall mounted next to it for both attended and unattended activities. 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 management, and more.

The OrPAY1000 terminal is small enough to fit in any standard pump head or pedestal, yet provides an efficient and advanced user interface with its 4.3-inch multimedia color Liquid

Crystal Display (LCD) display, four addressable screen keys, and a full alphanumeric  vandal-proof 40-key keyboard.

Figure 4: OrPAY1000


3.3 Islander PRIME Structure System Overview

3.3.1.3 G2 Panel Printer

Islander PRIME includes an optional 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 the center of the Islander PRIME pedestal door. It includes an integrated paper cutter, paper feeder, paper spool, and an “End of paper” warning sensor.

Figure 5: G2 Panel Printer


System Overview 3.3 Islander PRIME Structure

3.3.1.4 Communication Interfaces

Islander PRIME contains three slots for the various optional 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 electronic communication interfaces, and slot 3 can only house an electronic communication interface.

The mechanical interfaces contain up to four onboard bypass switches.

Figure 6: Communication Interfaces in the Slots


3.4 Available Configurations System Overview

3.3.2 Internal Configuration

The following is an example of the Islander PRIME internal configuration (see

Figure 7 ).

Figure 7: Internal Configuration Diagram

3.4 Available Configurations

Islander PRIME is available in several configurations, in accordance with its intended use and 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 composition.

The following describes the configurations available for the Islander PRIME Fuel Island

Controller.

3.4.1 Islander PRIME

Islander PRIME is supplied with the nOrCU (the Gasboy Controller Unit) embedded in the unit. In this configuration, nOrCU acts as a full station controller, providing functions such as authorization unit, central forecourt devices controller, linked to the Head Office, etc.


System Overview 3.4 Available Configurations

3.4.2 Automatic Vehicle Identification

The following options are available for automatic vehicle identification in Islander PRIME:

• Fuel Point PLUS: The software license embedded in the OrPAY1000 is a vehicle identification process performed in a wireless mode. The software receives DataPass  and/or Fuel Ring data, decrypts their information and transmits it to the nOrCU in a secure manner over an RF signal. This setup enables the RF signal to travel through various routes and bypass possible interferences (such as large trucks).

• No vehicle identification unit: The vehicle identification process will be done manually by the driver with any accepted authorization devices such as cards, tags, or manual data entry.

3.4.3 Dispensers

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 dispensers (Tokheim ® , Current Loop, RS-485, RS-422, RS-232) require installation of relevant interface blades.

3.4.4 Barcode Reader Option

The pedestal can be supplied with an optional barcode reader (P/N M15778B009) for reading barcodes.

3.4.5 Insert Card Reader Option

The pedestal is designed to support an optional standard insert card reader (P/N M15778B007) tointerface with magnetic cards, such as loyalty and fuel cards.

3.4.6 Human Interface Device (HID) Option

The pedestal is designed to support an optional HID Reader (P/N M09680B134) set for payment with HID cards.

3.4.7 Cellular Modem Option

The pedestal is designed to support an optional AvaLAN (model: AW-NetdropLTE) cellular modem for remote access communication.

3.4.8 Receipt Printer Option

The pedestal is designed to support the G2 Panel Printer (P/N M15778B008). The printer issues a printout of transactions to the driver.


3.5 Security and Protection System Overview

3.4.9 EMV Option

The pedestal can be supplied with an optional EMV reader set for payment with bank cards.

This feature is not currently offered, but will be available at a future date.

3.4.10 Communication Interfaces

Islander PRIME comes equipped with three slots to house communication interfaces embedded in slot blades. Slots 1 and 2 may house either mechanical or electronic interfaces, and slot 3 may only house electronic interfaces. In the order form, it is also required to define the part number for the specific communication interface blades in use. The following

communication interfaces are available (see Table 1

):

Table 1: Communication Interfaces

4

5

6

2

3

No. Pump Interface Blade

1 Islander PRIME 2M Blade

Islander PRIME 4M Blade

Islander PRIME 4x 485 Blade

Islander PRIME 4x Tokheim Blade

Part Number

M15778B001

M15778B001

M15778B001

M15778B001

Islander PRIME 4x Current Loop Blade M15778B001

Islander PRIME 2x 422 + 2x 232 Blade M15778B001

3.5 Security and Protection

All transactions performed in Islander PRIME are secured and protected. The following describes the security features of Islander PRIME in detail.

3.5.1 Authorization

The contactless tags include Triple DES encrypted data for user identification and billing.

Consequently, Islander PRIME includes a special Security Access Module (SAM) for decryption and matching identification. Upon tag reading, Islander PRIME attempts to decrypt the string from the tag and disregards tags whose security scheme does not match the Islander

PRIME internal SAM.

3.5.2 Network

The Ethernet LAN is isolated from the external Wide Area Network (WAN) by the nOrCU. In case of remote maintenance, a firewall should be applied either at the router level or preferably at the homebase station level.

3.5.3 RF Network

Islander PRIME IEE 802.15.4 RF network is encrypted, using the AES 128 security standard.


System Overview 3.6 Housing

3.5.4 Maintenance

Islander PRIME maintenance and setup procedures require inserting a user name and password for access. For more information, refer to the

MDE-4817 SiteOmat In-House Station

Controller Setup and Maintenance Manual .

3.6 Housing

The Islander PRIME system enclosure is made of a metal cabinet, with plastic panels, in the form of a pedestal. The enclosure is weather resistant in order to sustain the harsh environment of a homebase Station. It is also waterproof with 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.

Note: Do not pressure wash the Islander PRIME.

Islander PRIME pedestal is locked by key for safety and security. The key should be kept in a secure and safe place.

The following displays the Islander PRIME dimensions (see

Figure 8

):

Figure 8: Islander PRIME Dimensions

Page 18

The left side and right side pedestals display the standard Islander PRIME height, the center pedestal displays the ADA accessible Islander PRIME height. The width and depth are identical in both configurations. For detailed internal dimensions, see

“5.3 Installing the

Pedestal Base” on page 38 .


3.7 Technical Specifications and Standards System Overview

3.7 Technical Specifications and Standards

The following details the technical specifications, as well as the communication and security standards for the Islander PRIME.

3.7.1 Islander PRIME Technical Specifications

The following details the physical, electrical, and environmental specifications of the Islander

PRIME (see Table 2 ):

Table 2: Islander PRIME Technical Specifications

Parameter

Dimensions (H x W x D)

Supply Voltage

Power Consumption

Operating Temperature

Storage Temperature

Humidity

Communication Interface

Value

Standard: 158 x 30 x 29 cm | 62.2-inch x 11.8-inch x 29.2-inch in.

ADA accessible : 128 x 30 x 29 cm | 50-inch x 11.8-inch x 29.2-inch.

100 - 240 VAC

2A max

Without Printer : -40° to +65°C | -40° to +149°F 

With Printer : -40° to +50°C | -40° to +122°F 

With Barcorde : -30° to +60°C | -22° to +140°F

-40° to +70°C | -40° to +158°F

80% Non-condensing

• RS-485

• RS-232

• RS-422

• LAN

Pump Communication Interface

Wireless Communication

Pump Control Maximum Current 

(4 Solid State Relay Channels)

Power supply output voltage to Pulser unit

Power Supply Maximum Output

Current

Pulser Input High level Voltage

Pulser Input Low level sink current

(@15V)

In use “On” level (Input)

In use “Off” level (Input)

Certifications

Optional Accessories

• RS-485

• RS-422

• Current Loop

• MPI-C

• Tokheim

Optional wireless communication IEEE802.15.4 with proprietary mesh network (License)

Maximum of 380mA current for each channel, either for driving the external relay of the pump motor or for driving the solenoid valve

12 VDC +/- 20% 50mA

8 A max

9 to 15 VDC

3mA max.

100 – 240 VAC, 50/60 Hz, 5mA

0 to 10 VAC

ETL, CE, FCC, cETLus

• Printer

• EMV Card Reader and Payment

• Insert Card Reader

• HID Card Reader

• Barcode Reader

• ADA (Americans with Disabilities Act) Pedestal

• Stainless Steel Pedestal


System Overview 3.7 Technical Specifications and Standards

3.7.2 Communication and Security Standards

Islander PRIME communicates over the following standards:

• RS-232 link

• RS-485 link

• TCP/IP over Ethernet

• IEEE 802.15.4

• AES 128 for RF Network Communication


4.1 General

4 – Preliminary Guidelines

Preliminary Guidelines

4.1 General

This section provides preliminary guidelines for Islander PRIME. These include:

• Preliminary instructions

• Wiring and wire conduits requirements

• Installation procedures and requirements depend 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 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 provide an installation plan designed by an authorized engineer, and ensure that it adheres to all local standards. This plan design should reflect the existing electric infrastructure of the site.

TIP

Perform a site survey of the station prior to installation.

4.2 Precautions and Safety Notes



Précautions et consignes de sécurité

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

Avant toute activité d'installation, observez avec soin les précautions et les consignes de sécurité ci- dessous.


Preliminary Guidelines 4.2 Precautions and Safety Notes Précautions et consignes de sécurité

!

WARNING

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

Avant l'installation ou l'entretien de l'équipement, observez avec soin les avertissements et les précautions mentionnés au début de ce manuel.

The homebase environment is highly flammable and combustible. Therefore, make sure that the installation is performed by experienced personnel, licensed to perform work in a homebase station and capable of implementing 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-70A “National

Electric Code”, federal, state, local codes, and any other applicable safety codes and regulations.

L'environnement de base est hautement inflammable et combustible. Par conséquent, assurez-vous que l'installation soit réalisée par un personnel expérimenté, autorisé à travailler dans une station de base et capable de mettre en œuvre toutes les exigences applicable du “Code sur les liquides inflammables et combustibles” NFPA-30, le “Code for Motor Fuel Dispensing

Facilities and Repair Garages” NFPA-30A et le “National Electric Code” 

NFPA-70 de la National Fire Protection Association, les codes fédéraux, nationaux et locaux et tous autres codes et réglementations de sécurité.

System power may come from more than one source. Disconnect all power sources, including pumps, before attempting to work on the system.

L'alimentation du système peut provenir de plus d'une source. Débranchez toutes les sources d'alimentation, les pompes comprises, avant de travailler sur le système.

Install Islander PRIME in an area in accordance with the safety restrictions 

(see

Figure 9

).

Installez Islander PRIME dans une zone conforme aux restrictions en matière de sécurité (voir

Figure 9 ).

Figure 9: Installation Control


4.3 Station Survey Preliminary Guidelines

!

WARNING

The Islander PRIME site preparation is the customer’s responsibility.

La préparation du site d’Islander PRIME est de la responsabilité du client.

Do not connect power to Islander PRIME and other peripherals, including pumps, until complete installation is inspected and certified.

Ne branchez pas l’alimentation électrique d’Islander PRIME et d’autres périphériques, les pompes comprises, tant que toute l’installation n’a pas été contrôlée et certifiée.

Do not perform any metal work in the hazardous area. Sparks generated by drilling, tapping, and metal work operations could ignite fuel vapors and flammable liquids. This may result in death, serious personal injury, property loss, and damage to you and other persons.

N'exécutez aucun travail sur des métaux dans la zone dangereuse. Les

étincelles générées par le perçage, l'entaillage et d'autres opérations du travail des métaux peuvent enflammer les vapeurs de carburant et les liquides inflammables, entraînant la mort, des blessures sérieuses, des pertes ou des dégâts de matériel pour vous ou d'autres personnes.

When working in any open area of the homebase station, beware of passing vehicles. Block off the work area to protect yourself and other persons using safety cones or other signaling devices.

Lors du travail dans une zone ouverte de la station de base, faites attention aux véhicules de passage. Délimitez la zone de travail pour vous protéger vous et les autres personnes à l'aide de cône de sécurité ou d'autres dispositifs de signalisation.

4.3 Station Survey

Prior to installation, you are required to perform a survey of the homebase station functional architecture. This survey is required in order to draw an architecture diagram with all components and their communication links.

4.3.1 Station Architecture

The homebase station functional architecture consists of the following levels:

• Main Power Cabinet and homebase station forecourt

• FHO

4.3.1.1. Main Power Cabinet

The Main Power Cabinet includes the following components:

• Mains Circuit Control Box (MCC)

• Uninterruptible Power Supply [UPS (when required)]

• TLG Controller


Preliminary Guidelines 4.3 Station Survey

4.3.1.2 Homebase Forecourt

The Homebase Forecourt includes the following components:

• Islander PRIME

• Electronic or mechanical dispensers. This product has only been evaluated for use with

UL Listed Dispensers.

• One or more fuel tanks

• TLG probe for each fuel tank. This product has only been evaluated for use with UL

Listed TLGs.

4.3.1.3 Head Office System (Optional)

The Head Office system consists of a fully integrated management hardware and software tool that supports homebase stations and small fuel stations with their sale management of products including inventory management and reporting.

The Head Office system is a remote control center that stores, processes, and analyzes all the 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

• Locate the fuel tanks

• Locate the intended position of the Islander PRIME pedestal

• Draw a basic map of the site with all the objects

4.3.3 Assigning Logical IDs

When performing a station survey, assign Logical IDs as described below

Page 24

4.3.3.1 Fuel Tanks

• Assign the tank sequential number (coordinated with the station manager)

• Assign its fuel code and name

• Assign its TLG Probe (AP) ID

4.3.3.2 Dispenser Units

• Assign an ID to every dispenser name and pump server

• Assign an ID to every dispenser pump (P)

• Assign an ID to every pump CPU addresses if any

• Assign an ID to its nozzles (N)

• Assign to each nozzle the tank (T) ID to which it is linked

4.3.3.3 Islander PRIME Pedestal

• Assign the Islander PRIME its ID

• Assign the Panel Printer (PP) its ID

• Assign their IDs in an ascending order with the dispenser unit IDs


4.3 Station Survey Preliminary Guidelines

4.3.3.4 Mapping

• Draw a map of the site.

Note: The map methodology and IDs will be used for setup configuration.

4.3.4 Connections

All connections to Islander PRIME must be performed to the terminal block and to the

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 connections

- Pulser (Low Voltage)

- In Use signal (High voltage)

- Valve (High voltage)

• Communications

- RS-232/LAN to TLG console to fuel tank

- RS-485 for Gasboy peripheral device

- Pump communication line (e.g. Current Loop, RS-485, Tokheim, RS-422)

• Mains AC Power and Ground

• LAN connection

• ETH1 for technician and maintenance

• ETH2 secured WAN



4.4 Conduits

4.4 Conduits

The installation of Islander PRIME requires preparing the cable layout in the homebase station in advance. This procedure consists of installing conduits within the island, inserting the proper cables, and setting the power equipment and sensors.

This section provides the procedures for infrastructure groundwork. These procedures are presented in the order in which they should be performed:

• Wire conduits installation

• Cable routing within the conduits

• Power equipment setup

• Forecourt equipment wiring

4.4.1 Requirements

The installation of Islander PRIME in the island requires digging and setting several conduits in the station ground. The conduits are required for the routing and protection of the different types of cables used in a homebase station with Islander PRIME.

In sites where the infrastructure 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 installed according to local regulations.

• High-voltage AC and low-voltage DC must NOT be combined in a common conduit, junction box, or wire trough.

• RS-485 or LAN communication must not exceed 330 feet (100 m). Cables must be inserted in a separate low voltage conduit, away from AC wires. Communication range can be extended using third party devices.

• RS-232 communication must not exceed 50 feet (15 m). RS-232 communication shielded cable must be inserted in a separate low voltage conduit, away from AC wires.

Communication range can be extended using third party devices.

• Antenna wires must not exceed 330 feet (100 m) in case the VIU is in use, and 50 feet 

(15 m) in case the Fuel Ring is used. Antenna wires must be inserted in a separate low voltage conduit, away from AC wires.

• All conduits must be inserted in the Islander PRIME pedestal through the holes and

knockouts provided in the lower protective plate (see Figure 11

on

page 27 ).


4.4 Conduits

Figure 11: Lower Protective Plate


• Do not make any holes in the unit other than the ones available as knockout plates. If you must make holes at locations other than those provided, contact Gasboy Customer Support for approval.

• After completing the installation, all open holes should be resealed.

4.4.2 Protective Plate

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 conduits of 1/2-inch diameter

The following explains what the conduits are used for:

• Two conduits of 1-inch diameter are intended for high voltage cables.

• One conduit of 1-inch is intended for low voltage conduit.

The cables and wires to/from the other units in the forecourt are connected to the terminal block.

The cables and wires are inserted through the conduits in accordance with their types and routed to their sources.


Preliminary Guidelines 4.4 Conduits

4.4.3 Required Conduits

The types of conduits in the island are a function of the different equipment and location in the island. There are two functional conduits:

• High voltage conduits

• Low voltage conduits

The following conduits are required in the Island:

• High voltage conduits

- AC power for Islander PRIME

- Pump control from mechanical pumps to Islander PRIME

- Pump In-use signal from mechanical pumps to Islander 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 PRIME

• Grounding

- At least 10 mm (OOO AWG) Grounding cable to pump chassis

- At least 10 mm (OOO AWG) Grounding cable to Islander PRIME pole (Connected to the external chassis grounding post)

- Grounding cable to TLG – in accordance with TLG manufacturer instructions

• Tank conduit

- TLG Probe

4.4.4 Layout

Four conduits can be inserted in Islander PRIME, each carrying specific wires (see Table 3 ).

Table 3: Conduits into Islander PRIME

2

3

No.

Conduit Type Type

1 Low voltage Pulser, TLG, LAN

High voltage

High voltage

AC power, GND, In-use

Control


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: Conduit Layout for Mechanical Pump


Preliminary Guidelines 4.4 Conduits

The following is a diagram of the conduit layout for Islander PRIME using an electronic pump

(see

Figure 13

):

Figure 13: Conduits Layout for Electronic Pump


4.5 Cable Insertion Preliminary Guidelines

4.4.5 Installation

To install conduits in the island, proceed as follows:

1 Determine the location of the Islander PRIME pedestal in the island.

2 Dig and prepare passageways for the necessary conduits.

3 Take care to route the following conduits to the junction boxes (J-box):

• Low voltage cables J-box:

- One conduit to the office (control room)

- One conduit to each pump

- Two conduits to Islander PRIME

• High voltage cables J-box:

- One conduit to the office (control room)

- One conduit to each pump

- Two conduits to Islander PRIME

4.4.6 Sealing

The conduits must be sealed in accordance with NFPA requirements and local regulations, to prevent the passage of gases 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 protruding through the knockout opening.

4.5 Cable Insertion

The following describes the requirements and procedures for the insertion of cables in the conduits.

Notes:1) All devices in the system must be connected to the same electric power phase.

2) The type of cable needed varies in accordance with the device it connects to. The wire used must be stranded and not a solid core. Select a cable specification in accordance with local environment conditions.

!

WARNING

For supply connections, use wires suitable for at least 90°C / 194°F. Signal wiring connected in this box must be rated at least 300V.

Avertissement : Pour les raccordements d'alimentation, utilisez des fils convenant à au moins 90°C / 194°F. Le câblage de signal raccordé dans cette doit être conçu pour au moins 300V.


Preliminary Guidelines 4.6 Power Setup

4.5.1 Cable Types

The following are the types of cables used for the wiring of the Islander PRIME system 

(see

Table 4

):

Table 4: Islander PRIME Cable Types

3

4

No .

Function

1 AC Power from

Office

Control to pumps

(valves or engine)

2

In-use signal

Coil (Barrier)

Pulser

TLG (RS-232)

LAN

GND

Type

Power cable, 3x1.5 mm

2

0.118 x 0.06-inch

2

/ NYY (14 AWG), in accordance with local standards.

Data communication cable, 300 V RMS, 90°C /194°F, shielded twisted pair, oil resistant, 24

AWG, low capacitance below 60 PF/meter (3.3') similar to Belden 9729 cable.

CAT5E, Shielded, 300 V RMS, 90°C/194°F similar to Belden 121700A.

Ground cable 0.4-inch (10.8-mm

2

).

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 Cable Routing

6

7

4

5

2

3

No.

Functional Description From

1 Power AC Office

GND

TLG

Office

Office

LAN

Control, Pump A

In-use, Pump A

GND

Office

Through Insert

High voltage conduit

High voltage conduit

Low voltage conduit

Low voltage conduit

Pump A High voltage conduit

Pump A High voltage conduit

Pump A Low voltage conduit

1

2

3

1

4

2

Cable Type

1

Note: The cable type number refers to the table in the above section (see Table 4 ).

4.6 Power Setup

The power equipment must be installed in the main power cabinet. It should include the following:

• Mains Circuit Control (MCC) Box includes dedicated circuit breaker for the pedestal

• Uninterruptible Power Supply (UPS) - Online (“True”) UPS


4.6 Power Setup Preliminary Guidelines

4.6.1 Connection Diagram

The following diagram shows the requested connections of the power equipment 

(see

Figure 14

):

Figure 14: Power Equipment Connections

Apart from the power equipment, 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 cable is first connected to the terminal block. Between the terminal block and power supply, 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 15

).

Figure 15: Power Supply Components


Preliminary Guidelines 4.7 Wiring the Peripherals

4.6.3 Connecting the Power Equipment

To connect the power equipment, proceed as follows:

• External Mains

1 Connect Mains power to the Mains Circuit Control Box (MCC).

2 Wire one 0.4-inch (10-mm) ground cable from the mains ground connection to the

MCC.

• Uninterruptible Power Supply (UPS)

Connect the MCC to the UPS.

Note: If there is any doubt concerning grounding, ask for a ground test, which must be performed by a qualified electrician.

4.6.4 Grounding

Proper system grounding is an extremely important 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 assure a common ground throughout the system, which is necessary for protection 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 not provide sufficient grounding. It is recommended that the neutral and ground bus bars be bonded together when it is not prohibited by local codes.

4.7 Wiring the Peripherals

The following describes the wiring procedures for Islander PRIME peripherals.

4.7.1 Pump Wiring

Islander PRIME is capable of driving pump motors through an additional external relay. A separate circuit breaker should be supplied for each dispenser.

Note: The protection in communication circuits is part of the operator’s responsibility.

To wire the pump, proceed as follows:

1 Wire one mains AC cable from the UPS MCC to the pump enclosure, intended for the pump motor.

• For an electronic pump, wire RS-485/Current Loop/Tokheim communication cable from

Islander PRIME to the pump head.

2 Wire one 0.4-inch (10-mm) ground cable from the mains ground connection to the pump chassis.


4.7 Wiring the Peripherals Preliminary Guidelines

The communication cable shield must be grounded at one end-side only, preferably at the controller installation side (see

Figure 16 ).

Figure 16: Communications Cable Wiring

4.7.2 TLG Wiring

RS-232/LAN is used for communication between the TLG and Islander PRIME.

Follow these installation requirements when installing the RS-232/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 communication lines:

- RS-232: 1 - 50 feet (1 - 15 m) for direct connection to a TLG device

- LAN: 1- 330 feet (100 m) for direct connection to a TLG device

• Conduit : All direct connect RS-232/LAN cable must be in a low voltage conduit away from any AC wires.

• Cable : The type of cable used is determined by the device to which it is connected. The wire used must be stranded and not a solid core. Select a cable specification in accordance with local environment conditions.


Preliminary Guidelines 4.7 Wiring the Peripherals



5.1 General

5 – Installation

Installation

5.1 General

This section provides the installation procedures for Islander PRIME. These procedures include:

•

5.2 Installation Guidelines on page 37

•

5.3 Installing the Pedestal Base on page 38

•

5.4 Installing Options on page 42

•

5.5 Installing Communication Interfaces on page 54

•

5.6 Post-Installation Checklist

on

page 67

•

5.7 Islander PRIME Setup

on

page 68

5.2 Installation Guidelines

Installation procedures and requirements depend 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 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 reflect the existing electric infrastructure of the site.

5.2.1 Precautions and Safety Notes

Prior to actual installation activities, carefully observe the precautions and safety notes detailed in Precautions and Safety Notes and Requirements.

5.2.2 Safety Distances

The following shows the safety distances required for the installation of Islander PRIME adjacent to the dispensers (see

Figure 17

).

Figure 17: Base Plate Dimensions


Installation 5.3 Installing the Pedestal Base

When mounting Islander PRIME, a minimum clearance of 18-inches (0.5-m) between the unit and any of the pumps or the dispensers must be maintained. This clearance ensures that a safe amount of room is available for the wiring and maintenance of the system, and that the system complies with fire codes.

Islander PRIME is designed and approved for installation and use at a convenient location at or near the 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 surface.

• A minimum safety separation of 18 inches (0.5-m) from any nearest pump or dispenser.

5.3 Installing the Pedestal Base

The Islander PRIME pedestal is mounted in the homebase station on a base plate that is

fastened to the homebase station concrete floor (see Figure 18 , Table 6

). The upper side of the base plate includes four holding screws set in the homebase station concrete floor.

Figure 18: Base Plate Dimensions

Page 38

Table 6: Islander PRIME Base Plate Dimensions

Measurement

Anchor Bolt Holes

Base Plate Central Opening

Dimension

10 .

5 0 mm x 4 | 0.

41 in .

x 4

200 x 200 mm | 7.87 x 7.87 inch


5.3 Installing the Pedestal Base Installation

5.3.1 Installation Procedure

Installation of the Islander PRIME 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

5.3.2 Preliminary Setup

To perform the preliminary setup procedures for the pedestal site, proceed as follows:

1 Determine the exact location for the Islander PRIME pedestal installation.

2 Run cable conduits for each type of cables to the 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 Distribution Box

3 Run the cable conduits to the hole.

Notes:1) All conduits must be sealed when the unit is installed.

2) Ensure that the conduits are the right length to reach above the pedestal base into the pedestal itself. Various pedestal base heights are available; refer to the specifications of the configuration that you have ordered to determine how far the conduits must reach.

5.3.3 Assembly Parts

The following table lists the assembly parts required for the Islander PRIME installation 

(see

Table 7

):

Table 7: Islander PRIME Assembly Parts

3

4

Item No.

Description

1 Bolt, ICU

2 Nut, M10

Washer, Flat, SM10

Base plate

8

1

Qty P/N

4 814904200

8 815103000

815300200

814353700


Installation 5.3 Installing the Pedestal Base

5.3.4 Base Plate

To install the base plate, proceed as follows:

1

Prepare the bottom plate with four ICU bolts attached to it with M10 nuts (step 1 in Figure 19

and

Figure 20 ). Check that the bolts protrude from the plate by 1.4-inch (35-mm).

Figure 19: Base Plate Installation

Page 40

2 Insert the bottom 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 support base for the pole.

5 Take care that as the concrete fills the hole, the bottom plate is on a same level as the ground

(asphalt, pedestal) on which it is installed. Check that the bottom plate is leveled. Otherwise make the necessary adjustments so the plate is leveled.

6 Wait the necessary time for the concrete to harden and dry (as per local practice), and then check again that the bottom plate is leveled.


5.3 Installing the Pedestal Base

5.3.5 Pedestal

To install the pedestal, proceed as follows:

1 Remove the four M10 nuts from the four bolts attached to the bottom plate 

(step 2 in Figure 20

).

Figure 20: Pedestal Base Installation

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 bottom plate (step 4 in Figure 20

).

4 Anchor the pedestal base onto the base plate with the four bolts protruding from the inner ground.

5 Secure the pedestal base to the base plate with four M10 flat washers and M10 nuts 

(step 5 in Figure 20

).


Installation 5.4 Installing Options

6 Mount the pedestal on top of the pedestal base, using the 4 sets of bolts provided with the pedestal to fasten the pedestal to the base.

7 Fasten the front panel to the pedestal base.

5.3.6 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 required wherever volatile liquids or gases are present in the surroundings.

Note: 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 a variety of optional add-ons. The following optional add-ons are available:

• Barcode reader

• HID Reader

• Card reader

• Cellular modem

• Receipt printer

Depending upon customer requirements, the Islander PRIME may be delivered pre-assembled with all add-ons installed offsite, or it may be delivered empty, with all openings on the front

of the pole covered by removable panels (see Figure 21

). If the add-ons shall be assembled on site, the panels are removed as needed to install each add-on. Installation directions for each add-on are detailed below.

Figure 21: Islander PRIME Pole Door


5.4 Installing Options Installation

Note: Refer to the MDE-5415 SiteOmat360 User Manual for setup details for each add-on; refer 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

components (see Table 8 , Figure 22 ).

Table 8: Barcode Reader Assembly Kit

Item # Description

1 Barcode Reader

2 Barcode Reader Harness

3 Screw, M4x10 SST+2 Washers 2

Qt y

1

1

Figure 22: Barcode Reader Installation Kit



To install a barcode reader in the Islander PRIME, proceed as follows:

1 Remove the opaque panel covering the glass window in the Islander PRIME pole door.

2 Place the barcode reader inside the pole door lined 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 barcode reader to the Islander

PRIME.

4 Connect barcode harness P1 to the socket in the barcode reader.

5 Remove the power harness from the OrPAY1000, and wire the barcode reader harness P2 to the respective pins 7 and 8 in the OrPAY1000 power harness as follows (see

Figure 24 ).

Figure 24: Barcode Reader Wiring to OrPAY1000



6

Place the connector in the aperture behind the 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 M09680B134) is provided alone, without an assembly kit; it is installed using components already in the Islander PRIME pole door (see

Figure 29

).

Figure 26: HID Reader



To install an HID Reader in the Islander PRIME, proceed as follows:

1 Remove the screws affixing the HID Bracket 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 follows (see Figure 27 ).

Figure 27: HID Reader Back Plate

4 Pull the HID connector harness cable through the HID bracket, and mount the HID Reader to the bracket as follows (see

Figure 28 ).

Figure 28: HID Reader on Back Plate



5 Connect the HID Reader harness to 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 Wiring

6 Use the screws provided to secure the HID Reader to the Islander PRIME as follows 

(see

Figure 30

).

Figure 30: HID Reader in Islander PRIME Pole



5.4.3 Insertion Card Reader Installation

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: Insertion Card Reader Assembly Kit

Item No.

Description

1 Barcode Reader


Qty

1

Figure 31: Insertion Card Reader

Figure 32: Insertion Card Reader (Inside Top View)


5.4 Installing Options

Figure 33: Insertion Card Reader Label

Installation

To install an insertion card reader in the Islander PRIME, proceed as follows:

1 Remove the 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 insertion card reader to the Islander

PRIME pole door.

4 Connect the insertion card reader cable from the OrPAY1000 to the socket on the insertion card reader device (see

Figure 34

).

Figure 34: Insertion Card Reader Mounted in Islander PRIME



5.4.4 Cellular Modem Installation

Users have the option to install their own Cellular Modem in the Islander PRIME pole door.

Gasboy provides a bracket that can be used to mount the Cellular Modem in the pole door. 

The Cellular Modem installation kit (P/N 819250110) includes the following components 

(see

Table 10 ).

Table 10: Cellular Modem Installation Kit

Item No.

Description

1 Bracket


Qty P/N

1 819250100

815228200

To install a Cellular Modem in the Islander PRIME, proceed as follows:

1

Remove the original small plastic bracket from the modem as follows (see Figure 35 ).

Figure 35: Cellular Modem Back Plate

2 Slide the modem into the metal bracket provided in the installation kit.

3 Use the screws provided in the installation kit to secure the cellular modem to the Islander

PRIME as follows (see

Figure 36

).

Figure 36: Cellular Modem in Islander PRIME Pole



4 Connect the two modem antennae to the cellular modem using cables provided in the 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 installation kit to connect the cellular modem to the

Islander PRIME.

7 Use the Ethernet cable provided in the installation kit to connect the cellular modem to the

Islander PRIME 5-port Ethernet switch.



5.4.5 G2 Panel Printer Installation

The G2 Panel Printer (P/N M15778B008) is provided with the following assembly kit

components (see Figure 38

):

Figure 38: G2 Panel Printer

Page 52

To install a G2 Panel Printer in the Islander PRIME, proceed as follows:

1 Disconnect the grounding wire connection in the Islander PRIME pole door as follows 

(see

Figure 39

):

Figure 39: Disconnect Grounding Cable



2 Remove the screws affixing the panel covering the printer opening to the Islander PRIME pole door.

3 Place 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 Printer in Islander PRIME Pole

5 Connect the printer ground cable to the ground stud in the Islander PRIME pole door together with the main grounding cable as follows (see

Figure 41

):

Figure 41: Reconnect Grounding Cable


Installation 5.5 Installing Communication Interfaces

5.5 Installing Communication Interfaces

The Islander PRIME pedestal pole has three slots in which communication interface cards can be added. Each communication interface card is embedded into a blade, which slides into the slot. Slot 1 and Slot 2 can support either mechanical or electronic interfaces, and Slot 3 supports only electronic interfaces.

Detailed below are instructions on how to insert communication interface blades into the slots, followed by wiring procedures for each specific type of interface. The wiring 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 the device in the homebase station.

The maximum load for each bus is 8 devices/pumps.

TIP

For optimum configuration, each line should be connected to up to 6 devices.

5.5.1 Adding Communication Interface Blades to the Pedestal

To add a communication interface blade to the Islander PRIME pedestal, proceed as follows:

1 Turn off all power to the pedestal and the pumps, and fully disconnect all power sources.

CAUTION

Caution : Risk of electric shock. Disconnect all power before servicing; there may be more than one disconnect switch.

Attention : Risque de choc électrique. Débrancher toute l'alimentation avant l'entretien, il peut y avoir plus d'un sectionneur.


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 Protective Panel

Figure 43: Communication Interface Slots (Empty)



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 you are adding a mechanical interface, it may be inserted into slot 1 or

 slot 2 only.

5 Tighten the front screws in each blade.



6 Replace the protective panel in front of the slots (see

Figure 45

).

Figure 45: Communication Interface Protective Panel With Interface

Installation

5.5.2 Wiring Requirements

TIP

Mark each cable at both ends with a number or sign that will identify its functionality.



5.5.3 Mechanical Dispenser Connections

Mechanical dispenser interfaces (see 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.

Figure 46: Mechanical Dispenser Interface

The following is a detailed wiring diagram between Islander PRIME terminal block and the

pump components (see Figure 47 ):

Figure 47: Mechanical Dispenser Wiring Diagram



5.5.3.1 Pulse Input Wires

The dispenser outputs pulses to the system by means of the pulser unit, installed in accordance with manufacturer instructions. The pulse rate per volume (liter/gallon) is determined by the pulser unit. It is programmed as a “factor” by the Head Office controller.

5.5.3.2 Handle Status Input Wires

The handle signal is used to signal to the system that the pump is in “In Use” mode. When the dispenser handle is lifted this contact will close. This should signal to the system that the pump is “In Use” or that the transaction has ended.

5.5.3.3 Authorization Output Wires

The dispenser requires an authorization signal from Islander PRIME to start a sales transaction. 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 dispenser receives the authorization signal, it enables the fuel flow.

5.5.3.4 MPI-C Pinouts

The following tables provide MPI-C pinout connection details, based on the Terminal Block

Map found on the power supply protective panel (see

Table 11

, Table 12 , and Table 13

). The tables are laid out as follows:

• The pin number for each cell corresponds with the pin numbers displayed in the Terminal

Block Map found on the inner wall of the Islander PRIME unit.

• Each block of cells shows the channels for that configuration, as follows:

- (Green): Channel #1

- (Peach): Channel #2

- (Purple): Channel #3

- (Beige): Channel #4

Each cell defines the signal that is sent over that pin in the terminal block port.

Table 11: MPI-C Channels

PLS_V1 PLS_V2 CHSS

PLS_G1 PLS_G2 n.c.

PLS_IN1 PLS_IN2 n.c.

PLS_V3 PLS_V4

PLS_G3 PLS_G4

PLS_IN3 PLS_IN4

CHSS n.c.

n.c.



5.5.3.5 Fuses

Mechanical pumps are supplied with power via fuses located below the pump slots 

(see

Figure 48

,

Table 12

,

Table 13 ):

Figure 48: MPI-C Fuses Diagram

Table 12: MPI-C Fuses Slot #1- In Use/Pump

In Use Pump

INUSE1_A INUSE2_A INUSE3_A INUSE4_A LINE1 LINE2 LINE3 LINE4

INUSE1_B INUSE2_B INUSE3_B INUSE4_B LOAD1 LOAD2 LOAD3 LOAD4

Table 13: MPI-C Fuses Slot #2 - Pump/In Use

In Use

LINE1 LINE2 LINE3 LINE4

Pump

INUSE1_A INUSE2_A INUSE3_A INUSE4_A

LOAD1 LOAD2 LOAD3 LOAD4 INUSE1_B INUSE2_B INUSE3_B INUSE4_B

5.5.4 Pulser Connections

The following describes the required wiring connections between the pulser in the mechanical pump and Islander PRIME. The system can accept many types of pulsers; contact Gasboy for more information. There are two types of pulser:

• Electronic pulser

• Mechanical pulser

Connect Islander PRIME to the pulser in accordance to its characteristics.

Note: Pulsers 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 PRIME.



5.5.4.1 Electronic Pulser - Three-Wire Pulser

Note: A three-wire pulser requires an external 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 Connections

5.5.4.2 Mechanical Pulser - Two-Wire Pulser

The following is a schematic diagram of the connections between the terminal block and a two-wire pulser (see

Figure 50

):

Figure 50: Two-Wire Pulser Wiring Connections



5.5.5 Electronic Dispenser Connections

The wiring in the terminal block differs in accordance with the type of electronic pump installed in the homebase station. There are several types of electronic pumps. Electronic dispenser interfaces may be installed in any of the three slots in the Islander PRIME. The following describes 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 the pin numbers displayed in the Terminal

Block Map found on the inner wall of the Islander PRIME unit.

• Each block of cells shows the channels for each interface type, as follows:

- (Green): Channel #1

- (Peach): Channel #2

- (Purple): Channel #3

- (Beige): Channel #4

• Each cell defines the signal that is sent over that pin in the terminal block port.

5.5.5.1 Tokheim

The Tokheim electronic interface appears as follows (see Figure 51 ):

Figure 51: Tokheim Electronic Interface



The following shows the specific wiring connections between Islander 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 interface is wired according to the following pinout

scheme (see Table 14

):

Table 14: Tokheim Pinouts

GND1 GND2 CHSS

TTD_1 TTD_2 n.c.

TTC_1 TTC_2 n.c.

GND3 GND4 CHSS

TTD_3 TTD_4 n.c.

TTC_3 TTC_4 n.c.



5.5.5.2 Current Loop

The following shows the specific wiring connections between Islander PRIME and the

Current Loop pump 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 Diagram

The Current Loop electronic communication interface is wired according to the following

pinout scheme (see Table 15

):

Table 15: Current Loop Pinouts

GND1 GND2 CHSS

CLI_1 CLI_2 n.c.

CLO_1 CLO_2 n.c.

GND3 GND4 CHSS

CLI_3 CLI_4 n.c.

CLO_3 CLO_4 n.c.



5.5.5.3 RS-485

The RS-485 electronic interface appears as follows (see

Figure 54

):

Figure 54: RS-485 Electronic Interface

Installation

The following show the parallel connection between two Gasboy RS-485 pumps and the

terminal block (see Figure 55

):

Figure 55: RS-485 Device - Wiring Diagram



• In the junction box for the Gasboy electronic pump, connect the Red Tx+ to the White

Rx+, and connect the Green Tx- to the Black Rx.

• Run one wire from the + and one wire 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 Pinouts

GND1 GND2 CHSS

485_1485_2n.c.

485_1+ 485_2+ n.c.

GND3 GND4 CHSS

485_3485_4n.c.

485_3+ 485_4+ n.c.

5.5.5.4 TLG Controller

The following is an example of an RS-232/RS-422 electronic interface, which is used by the

TLG Controller (see

Figure 56

):

Figure 56: RS-232/RS-422 Electronic Interface


5.6 Post-Installation Checklist Installation

The following shows the required connection between the TLG controller at the site and the

Islander PRIME terminal block (see Figure 57 ):

Figure 57: TLG Wiring Link

The TLG controller communicates via RS-232/422 channels. The RS-232/422 electronic

communication interface is wired according to the following pinout scheme (see Table 17

):

Table 17: RS-232/422 Pinouts

RX_1+ RX_2

TX_1TX_2

TX_1+ GND1

CHSS

GND2

RX_1-

RX_3+ RX_4

TX_3TX_4

TX_3+ GND3

CHSS

GND4

RX_3+

5.6 Post-Installation 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 following:

• Correct wiring

- Is all of the wiring inserted within metal conduits?

- Is the AC and the DC wiring inserted in separate conduits, troughs, etc.?

- Is the system / peripheral equipment powered on a separate dedicated 20 Amp breaker?

- Is the system grounded properly?

- Are the cables correctly routed in the island?

- Are the communication lines under the maximum allowable distance?

o RS-232: 50 feet (15 m) o RS-485: 330 feet (100 m)


Installation 5.7 Islander PRIME Setup o Antenna wire:

> 330 feet (100 m) for VIU

> 50 feet (15 m) for Fuel Ring

• Clean dirt and wire remnants

In case problems are detected after installation or during operation, repeat the post-installation checks listed above.

CAUTION

The OrPAY1000 display should not be exposed to direct sunlight. It is therefore highly recommended to add an awning.

5.7 Islander PRIME Setup

For information on how to set up Islander PRIME once installed, refer to the 

MDE-4817 SiteOmat In-House Station Controller Setup and Maintenance Manual .


6.1 General

6 – LAN CommVerter Setup

LAN CommVerter Setup

6.1 General

This section provides instructions for setting up the Islander PRIME LAN CommVerter.

To 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 (see

Figure 58 ).

Figure 58: Islander PRIME CommVerter Setup Login

Enter the Username and Password provided by Gasboy and click Sign In . The following

screen is displayed (see Figure 59 ):

Figure 59: Islander PRIME CommVerter Setup Homepage

MDE-5411B ForeHB Islander PRIME Installation Manual February 2020 Page 69

LAN CommVerter Setup 6.2 Home Page

The CommVerter settings page has the following navigation buttons on the left side of the screen:

• Home Page: Basic device information

• Setup: Main device settings

• Software Upload: Uploads configuration files and software/firmware updates

6.2 Home Page

The Home page displays current device information (see

Figure 59 ,

Table 18 ):

Table 18: Device Information

Field

Ethernet IP

Ethernet MAC

SW Version

Description

Ethernet IP address

Ethernet MAC address

Software version installed on the device

HW Version Hardware version installed on the device

Boot Loader Version Boot Loader Version installed on the device

Pump 1 Version

Pump 2 Version

Pump software version for the PI in Slot 1


Pump 3 Version

Location


Location of the Islander PRIME

Page 70 MDE-5411B ForeHB Islander PRIME Installation Manual February 2020

6.3 Setup LAN CommVerter Setup

6.3 Setup

The Setup page is comprised of five tabs: Minimal Setup, General Setup, OrIC Config, Log

Level, and Save. Click Setup to view and define the parameters in each tab.

6.3.1 Minimal Setup

The Setup page opens with the Minimal Setup tab selected (see

Figure 60

).

Figure 60: Minimal Setup Tab

The following actions 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 downloaded setup to apply to the current configuration; then, click Upload

(optional).

• Click Restore Factory Setup to reset the device to the factory defaults (optional).

CAUTION

All previously defined settings will be overwritten.

• Click Submit to save the changes locally.

Note: Clicking Submit saves the configuration temporarily on a local level. To commit the changes permanently, ensure to save everything via the Save tab.



6.3.2 General Setup

Click the General Setup tab. The following screen opens (see

Figure 61

):

Figure 61: General Setup Tab

6.3 Setup

Page 72


• Define the General Setup fields (see

Table 19 ).


Note: Clicking Submit saves the configuration temporarily on a local level. To commit the changes permanently, ensure to save everything via the Save tab.

Table 19: General Setup Fields

Field

Ethernet Configuration

IP Address

Subnet Mask

Gateway

DHCP

MAC

RTC

Date (dd/mm/yyyy)

Time (hh:mm:ss)

FCC Communication

NoData Reset

Description

Device IP Address

Subnet Mask address

Gateway

Not currently available

MAC address

Date

Time

NoData Timeout (sec)

Enable : The controller checks the TCP/IP at regular intervals; if no communication is detected within the timeout interval, the device will automatically reset.

Disable : Device will not automatically reset.

No Data Timeout timeout interval, in seconds.

Note: Make sure that no pumps at the station are actively fueling before changing the date or time.

MDE-5411B ForeHB Islander PRIME Installation Manual February 2020

6.3 Setup LAN CommVerter Setup

6.3.3 OrIC Config

Click the OrIC Config tab. The following screen opens (see

Figure 62

):

Figure 62: OrIC Config Tab

The following additional actions 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 channel on the list.

• Define the channel fields (see

Table 20 ).


Note: Clicking Submit saves the configuration temporarily on a local level. To commit the changes permanently, make sure to save everything via the Save tab.


LAN CommVerter Setup 6.3 Setup

Table 20: OrIC Config Channels Fields

Field

Host

TCP/IP Port

Description

Host TCP/IP Port

Device Name Device Name (Ideally should reflect the corresponding destination, i.e. “CL” for Current Loop destinations)

Destination

OrIC Number Channel number between 1-12 (up to 4 per PI)

Comm. Type Communication protocol for the interface Current Loop

• RS-232

• RS-422

• RS-485

• Tokheim

• MPI-Primary

• MPI-Secondary

RS-232 and RS-422 channels are configured on the same PI- channels 1/2 are RS-232 and channels 3/4 are RS-422

MPI-Primary and -Secondary are used for mechanical PIs; MPI-Secondary is used for channels

3/4 in configurations that enable 4 MPI-C channels.

Communication Interface details Baud Rate

Data Bits

Parity

Stop Bits

RS-485 Echo (RS-485 channels only)

Current Select (Current Loop channels only) Type of current used by the channel

Frame Timeout Longest pause in milliseconds between received bits before destination interface interprets the pause as the end of one message, and interprets further transmissions as a new message (0 = 4 bytes of silence).

No Data

Timeout

The controller checks communication at regular intervals. If no communication is detected within the timeout interval, the channel will automatically reset. If set to 0, the channel will not reset.

Note: If the channel configuration is not displayed properly after saving all changes and resetting the device, clear your browser cache and reload the page.


6.3 Setup

6.3.4 Log Level

Click the Log Level tab. The following screen opens (see

Figure 63

):

Figure 63: Log Level Tab


The Log Levels section defines settings for logs that are sent to Gasboy .

Note: Consult with Gasboy’s Customer Services prior to defining the Log Levels settings.


• Define the Log Level fields (see

Table 21 ).

• In the Debug Port 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 Submit button to save the changes locally.

Note: Clicking Submit saves the configuration temporarily on a local level. To commit the changes permanently, ensure that you save everything via the Save tab.

Table 21: CommVerter Log Levels

Field

General

Debug Port Interface

Description

Log Levels: Select Debug Information

Source Logs:

• TcpS

• TcpC

• DIAG

• ADMIN

• ORIC

Log Levels

None : Logs are not transferred

Com : Transfers logs via RS-232

TCP IP : Transfers logs via LAN

• Data

• Debug

• Info


LAN CommVerter Setup 6.3 Setup

6.3.5 Save

After you have completed and submitted all configuration 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 Save tab. The following screen opens (see

Figure 64

):

Figure 64: Save Tab

2 Click Apply

. The following dialog box opens (see Figure 65 ):

Figure 65: Confirm Save Dialog Box


6.3 Setup

3 Click OK to continue. The following dialog box opens (see

Figure 66

):

Figure 66: Reset Device Dialog Box


4 Click OK to complete the save 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: Download Setup File

6 Click OK to confirm.

Note: The dialog box screenshots in this procedure are for demonstration purposes only, including the IP address in the headers. Use the IP address provided to you by Gasboy when performing this procedure.


LAN CommVerter Setup 6.4 Software Upload

6.4 Software Upload

Click Software Upload

navigation button. The following screen opens (see Figure 68 ):

Figure 68: Software Upload Screen

Page 78

The Software Upload screen enables uploading the newest software and firmware versions

provided by Gasboy (see Table 22

).

Table 22: Software Upload Fields

Field

File Type

Update Options

Choose File

Force Update

Description

• Wireless Gateway-ST

• Boot Loader

• Pump Mezzanine

Currently only Update Immediate is available.

Opens a browser to select a file for upload.

When enabled, forces a software update.

To upload a file to the device, proceed as follows:

1 From the File Type drop-down, select the file type that you want to upload.

2 Click Choose File to launch a browser window, and browse to the file path of the software version to upload.

3 Select the file and click Open .

MDE-5411B ForeHB Islander PRIME Installation Manual February 2020

6.4 Software Upload

4 Click Upload

. The following dialog box opens (see Figure 69

):

Figure 69: Confirm Upload Dialog Box


5 Click OK to confirm and upload the file.


LAN CommVerter Setup 6.4 Software Upload



7.1 General

7 – Maintenance

Maintenance

7.1 General

Islander PRIME itself as a standalone unit should be cleaned periodically at short intervals, due to the harsh environment of the homebase station where it operates.

7.2 OrPAY1000 and Islander PRIME

The following instructions are valid for the OrPAY1000 front panel and the Islander PRIME pedestal.

• Clean the OrPAY1000 front plastic panel with a lightly moistened cloth with WD-40 or any other similar lubricant.

• Clean the pedestal metallic enclosure using a damp cloth and cleaning spray.

CAUTION

Caution:

• DO NOT 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 benzène.

• Ne pas utiliser un lavage sous pression pour nettoyer le piédestal.

7.3 Magnetic Card Reader

The Card Reader should be cleaned periodically, preferably once every two weeks, in order to ensure proper operation. The purpose of cleaning is to remove any dust that may harm the reader and consequently prevent the completion of a sale.

To clean the magnetic card reader, proceed as follows:

1 Remove the cleaning card from its packing.

2 Insert the cleaning card all the way in the reader, and then pull it out slowly.

3 Perform steps 1 and 2 several times until the card is dry.

4 Insert any magnetic card and verify that its stored data is read by the magnetic card reader.


Maintenance 7.4 Printer

7.4 Printer

Due to the harsh environment of the homebase station, the printer should be cleaned periodically.

Note: Clean the printer front panel with a damp cloth only. DO NOT use any solvents such as thinner or benzene to clean the printer front panel.

The following describes the cleaning procedures for the thermal printer head in the printer.

The cleaning is performed with the printer cleaning card. The printer cleaning card is provided in a protective package to prevent dryness.

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 of time.

To clean the thermal printer head, proceed as follows:

1 Turn on the printer.

2 Insert paper in the printer slot, and make sure that the printer guillotine cuts the paper protruding from the printer.

Note: This procedure ensures that the guillotine will not cut the cleaning card.

3

Press the green paper-lock lever and pull out the paper from the printer (see Figure 70 ).

Figure 70: Paper Lock Lever

Page 82

4 Remove the cleaning card from its packaging.

5 Insert the cleaning card manually into the printer paper slot.

6 Press the green paper-lock lever back to its initial position.


7.4 Printer Maintenance

7 Push and pull the cleaning card so that the printer head is cleaned.

8 Verify that the cleaning card has been removed from the printer guillotine without being affected.

9 Verify that the cleaning card rolls out from the paper slot.

10 Pull the cleaning 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 card is dry.

13 Press the green paper-lock lever and insert thermal paper in the printer from the paper roll.

14 Press the green paper-lock lever back.

15 Print a receipt with at least ten rows of text.

16 Check readability and verify the text font is clear.

Note: If readability is still poor, repeat the cleaning procedure with a new cleaning card.


Maintenance 7.4 Printer



8.1 General

8 – Troubleshooting

Troubleshooting

8.1 General

This section provides a list of common pump/system problems that may be encountered when using the Islander PRIME system, as well as corrective actions for problems related to the system and its peripherals.

8.2 Islander PRIME

The following describes Islander PRIME troubleshooting procedures and appropriate corrective actions.

8.2.1 System Down

The following table describes the Islander PRIME troubleshooting procedure and appropriate

corrective actions when the system is down (see Table 23

):

Table 23: System is Down

Fault

• LCD display is blank.

• Doesn't accept 

Key/ Card/Keypad input.

• No communication.

• nOrCU LEDs are not lit.

Probable Cause Checks

Islander PRIME main switch is off

No 115 VAC feed to the unit

Power failure

1

2

Check power at breaker panel.

Check cabling from breaker panel to the unit.

3 Verify that the power cable is properly connected to unit terminal block.

4 Verify 115 V measured at the power input terminal block.

Corrective Action

Turn on the main switch.

Correct wiring problems if

115VAC is not measured.

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 the breaker off or tripped?

Is 115 V being switched through breaker?

Internal fuse blown

Power supply failure

OrPAY1000 is incorrectly set up nOrCU is incorrectly set up

Is 115 V measured at the power input terminal block?

Correct wiring problems if

115 V is not measured.

Does the breaker turn off immediately after being turned on?

Check for loads or shorts in the power line.

Check the pico fuse using an ohmmeter.

Verify that green LED on power supply is lit.

Check communication parameters.

Check bus and parameters setup.

Turn the breaker on, if off.

Replace breaker if 115 V is not being switched.

Replace the fuse if it is blown.

Replace power supply.

Set communication parameters.

Set communication parameters.


Troubleshooting 8.2 Islander PRIME

8.2.2 Mechanical Pump Does Not Fuel

The following table describes the Islander PRIME troubleshooting procedure and appropriate corrective actions when the mechanical pump does not fuel (see

Table 24 ):

Table 24: Mechanical Pump Does Not Fuel

Fault

Pump does not supply fuel.

Pump is authorized but call state is not detected (nozzle icon in SiteOmat Status screen does not display call state).

Pump is authorized, pump motor is running, but no fuel is supplied.

Probable Cause Check s

Pump setup is incorrect

Check pump setup:

• Pump server Buses

• Prices Pulse Rate

Faulty connection to pump

LAN to 3x 485

CommVerter


1 Set pump parameters.

2 Save and reload.

3 Check again.

Check Control cables from Islander PRIME to pump.

Make a secure electrical connection.

Verify that Power LED is lit.

If it is off, use a voltmeter to check power supply to the unit: If power supply is OK, then replace the LAN to 3x 485

CommVerter board. If power supply is faulty, replace the power supply.

1 Replace MPI-C board.

1 Replace LAN to 3x 485 CommVerter.

Verify that the Control red LED on MPI-C board is lit.

Pump malfunction Turn the Islander

PRIME bypass switch on; lift the nozzle, and check that the pump supplies fuel.

Handle-on switch problem

Is the In Use red LED

MPI-C board lit when nozzle is lifted?

Faulty in-use switch in pump

If the problem persists:

1

2

1

2

Check Handle-on switch.

Repair pump.

Check In Use cable and repair (if necessary).

Check terminal wires and repair (if necessary).

3 Check In Use switch in the pump and repair (if necessary).

Replace pump switch in cases where no short was detected.

Faulty connections

Power off the pump; then, using an ohmmeter, measure the switch in on and off states.

• Check In Use cable.

• Check In Use terminal block connections.

Make good electrical connection if faulty one exists.

Faulty In Use terminal block

Faulty MPI-C board

Verify that the Call red

LED is lit when nozzle is lifted.

Replace In-use terminal block.

• If the red LED is not lit, replace the

MPI-C board.

• If the LED is lit, the problem is external to the controller.

Faulty LAN to 3x

485 CommVerter

• Faulty solenoid valve

• Faulty pump

Does the pump solenoid valve produce a clicking sound?

Replace the LAN to 3x 485 CommVerter.

• Replace valve

• Repair pump


8.2 Islander PRIME Troubleshooting

Fault

Payment device (card, key, tag, Fuel Ring) is not accepted.

Pump is refueling but volume remains zero.


Communication fault between

OrPAY1000 and

SiteOmat.

1

2

3

Check LAN cable.

Check OrPAY1000 setup.

Check SiteOmat setup.

Communication fault between

FHO and

SiteOmat.

1 Check connection path with FHO.

2 Verify that the station is available and synchronized with FHO in FHO

Stations Status screen.

Device was not defined or is defined incorrectly in

FHO.

Device limit was passed.

1

2

Log into FHO as

Fleet Manager.

Check that the device is defined.

3 Check device parameters.

4 Check that the device rules do not limit refueling.

Verify that the device is within the limits of its rule.


1 Replace LAN cable, if necessary.

2 Set OrPAY1000 parameters properly.

3 Set SiteOmat parameters properly.

Repair communication between FHO and

SiteOmat, providing a reliable communication line.

Define the device parameters in FHO properly.

For testing only, remove any rule associated to this device.

Device was set as

Driver.

1 Log into FHO and go to Device

Management.

2 Select the specific device and check it was configured as a Driver.

Change the device setting to vehicle.

Device is blocked. Log into FHO and go to

Devices Management.

Check the status of the device in the Status column in the Devices grid (blocked/ unblocked).

Change device status to Unblocked.

Pulse factor is zero.

• Faulty MPI-C board

• Faulty pulser

Check SO pump setup. Change Pump Settings to correct the factor for the relevant pump.

Disconnect the 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.


Troubleshooting 8.3 OrPAY1000

8.2.3 No Control Over Fueling

The following table describes the Islander PRIME troubleshooting procedure and appropriate

corrective actions when there is no control over fueling (see Table 25

):

Table 25: No Control Over Fueling

Fault

Pump is refueling without any control.

Probable Cause

Pump is in bypass

Faulty SSR

If an external relay is used to control the pump / valve, it may be stuck due to a small current leak.

Checks

Verify that the

Islander PRIME bypass switch is off.


Turn bypass switch off, if it is on.

Replace the relevant SSR unit inside Islander PRIME.

Add a snubber (capacitor

+ pull up resistor) in parallel to relay input.

8.3 OrPAY1000

Page 88

The following table describes the OrPAY1000 troubleshooting procedure and appropriate

corrective actions (see Table 26

):

Table 26: OrPAY1000 Troubleshooting

Fault

OrPAY1000 display is blank.

OrPAY1000 display does not respond correctly to cards.

Fault

OrPAY1000 display does not respond correctly to tags.

Probable Cause

Internal fuse blown


Faulty

OrPAY1000

Checks

OrPAY1000 Display Is Not Lit

Check the mini fuse at the bottom of the power supply using an ohmmeter.


Replace the fuse if it is blown.

Verify that the green LED on the power supply is lit.


Does the unit shut down immediately after being turned on?

Replace OrPAY1000.

Bad card

OrPAY1000 Does Not Accept 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.

OrPAY1000 is busy performing another task.

Verify that the display presents the idle message.

Clean the card reader using a cleaner card and try again.

Press Cancel.

Present the card while the idle message is displayed.

Faulty card reader

Replace OrPAY1000.

Probable Cause Checks Corrective Action

OrPAY1000 Does Not Accept RFID Tag

Bad tag Replace tag and test again.

Bring the key close to the antenna located on the red circle.

Tag is not close enough to the

OrPAY1000 antenna.


Faulty

OrPAY1000

1 Press Cancel.

2 Present the tag while the idle message is displayed.

Replace OrPAY1000.


8.3 OrPAY1000 Troubleshooting

Pressing the keypad buttons does not generate any sound and does not affect the display.

OrPAY1000 display does not respond correctly to EMV cards.

5-port LAN switch is not functional

OrPAY1000 Does Not Respond to Keypad Entries

Dirty keyboard Clean the keyboard.

Replace keypad if any damage is found.

Damaged keypad Check the keypad surface for any damage.



1

2

Press Cancel.

Use the keypad while the idle message is displayed.

Faulty

OrPAY1000

Replace OrPAY1000.

Bad card

OrPAY1000 Does Not Accept EMV Card

Faulty connection Open the Islander PRIME door and check the cable which connects the OrPAY

EMV reader to the

OrPAY1000 terminal.

Replace the card and test again.

Make a secure electrical connection if faulty one exists.


Faulty

OrPAY1000


1

2

Press Cancel.

Present the card while the idle message is displayed.

Replace OrPAY1000.

OrPAY1000 Displays “No Communication” Message

Communication disconnected

Open the Islander PRIME door and check the LAN cable from the OrPAY1000 to the 5-LAN switch.

Make a secure connection if it was setup incorrectly.

No power to LAN to 3x 485

CommVerter.

Are the LAN to 3x 485

CommVerter LEDs  lit / blinking?

Are the 5-LAN switch LEDs are lit/blinking?

1 Check power connector to the LAN to 3x 485 CommVerter.

2 Replace the LAN to 3x 485

CommVerter.

1 Check the connection of the LAN switch on the LAN to 3x 485

CommVerter. It should be inserted in a socket on the LAN to 3x 485

CommVerter main board.

2 Replace the 5-LAN switch.


Troubleshooting 8.4 Printer

Fault

Problem with the nOrCU


Faulty connection Check power to the nOrCU.

Verify that the white power connector is plugged into the nOrCU power socket.


Is the power supply on?

1 Replace the fuse.

2 Replace the power supply.

Faulty nOrCU

Incorrect

SiteOmat setup

Incorrect nOrCU setup

Verify that the OrPAY1000 parameters defined in

SiteOmat match the values presented in OrPAY1000 display at power-on.

Log into OrPAY1000 and verify that all parameters match the nOrCU setup.

Replace the nOrCU.

Set the OrPAY1000 bus and parameters according to the

OrPAY1000 values presented in

OrPAY1000 display at power-on.

Log into OrPAY1000 and amend the setup so that it matches the nOrCU setup.

8.4 Printer

The following table describes the printer troubleshooting procedure and appropriate corrective

actions (see Table 27

):

Table 27: Printer Troubleshooting

Fault

No printed summary at the end of transaction.

No printing; printer doesn't produce a beep sound at power on.


Printer Does Not Print

Printer is out of paper.

Check paper roll.

Paper Lock switch is open.

Paper jam

Check Paper Lock switch position.

Incorrect SiteOmat setting.

Faulty printer

Check SiteOmat printer settings.

Power cable is disconnected.

No Power to the Printer

Check power cable connections between the printer and OrPAY1000.

Faulty power supply

Check power supply outputs using a digital voltmeter. The output voltage should be 24 VDC.

Faulty printer


Replace paper roll.

Close Paper Lock switch.

Release paper.

Set printer parameters properly.

Replace printer.

Make correct and good connection if it was incorrect.


Replace the printer.


8.4 Printer Troubleshooting

Fault Probable Cause Checks

No Communication with the Printer

RS-485 cable is disconnected.

Check the RS-485 cable connections between the printer and OrPAY1000.

LAN Cable is disconnected.

Check the OrPAY1000 LAN cable.




Set the correct Hex address in SiteOmat.

Incorrect Address settings

Check printer address jumpers (no jumper means that the address is

70HEX).

Faulty printer

Paper is Not Automatically Cut

Paper is not being cut at the end of the printing.

Incorrect SiteOmat setting

Faulty printer cutter

Check SiteOmat printing settings.

Faulty printer

Replace the printer.

Set SiteOmat printing settings accordingly.

Replace printer cutter.

Replace printer.


Troubleshooting 8.5 Communication

8.5 Communication

The following table describes problems related to communication to peripherals and consequent corrective actions (see

Table 28 ):

Table 28: Communication Troubleshooting

Fault

No connection to the station from

FHO Stations screen.

Probable Cause Check s Corrective Action

No Communication between FHO and SO Controller

Cabling issue Inspect the network cable to LAN2.

1 Verify that the LAN2 Port LED is blinking.

2 Unplug the cable and plug it back in.

3 Replace the LAN cable (if necessary).

4 If the cable is in a good condition; contact the IT department to confirm that the switch/router connected to the LAN cable is installed properly.

5 Check the controller network settings (IP addresses, mask, gateway, etc.).

No Communication with the Pumps (LAN to 3x 485 CommVerter)

Warning signs displayed for all pumps on the

SiteOmat Status screen.

Incorrect LAN to 3x 485

CommVerter setup.

• Check the physical connection of the

LAN 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 the LAN port connected to the LAN to 3x

485 CommVerter, replace the short Ethernet cable and /or change the LAN port to confirm normal operation.

2 Check the status of the LEDs on the LAN to 3x 485 CommVerter

(upper right corner of the board): the first and the third LED should be lit to confirm power and network connection, while second

LED should blink to confirm network 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 resetting due to connection loss to the controller.

4 Reset the IP and reconfigure the

Pump Server (PS) in controller setup.

No Communication with the Nozzles

Can’t read the vehicles and/or no authorization at the pumps.

No communication with the FHO.

Incorrect nozzle reader setup.

• Check the software license is correct.

• Check the programming of the

WNRs.

1 Re-enter the software license.

2 If no activity on the LAN port, check the cable and/or change the port on the 5-port switch.


8.5 Communication Troubleshooting

Fault

OrPAY1000 displays “No Host

Communication” message.

“Warning” signs displayed for all tanks on the

SiteOmat Tank

Status screen.

Probable Cause Check s Corrective Action

No Communication with OrPAY1000

Incorrect OrPAY1000 communication and/or physical network setup.

• Check the network cable for activity on 

5-port switch.

• Ping the

OrPAY1000 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 OrPAY1000 and follow the main screen messages for the IP address.

3 Change the configuration of the

OrPAY1000 according to the site setup (controller).

No Communication with the TLS

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 IP address of the TLS.

Contact the IT department in cases where there is no communication to the unit (if connected over the WAN).

2 Check the physical layer

(Ethernet cable) and port activity to the TLS (if connected over the

LAN).

3 Connect to the TLS network interface through telnet (“telnet

XXX.XXX.XXX.XXX 9999”) and check the configuration. Confirm proper network settings and serial port settings (should be

9600, 8, None, 1, None and D6 as connection type). By default the port is set to 10001 – confirm similar setting for the TLS bus in the controller setup.


Troubleshooting 8.6 FuelPoint

8.6 FuelPoint

The following table describes the printer troubleshooting procedure and appropriate corrective

actions (see Table 29

):

Table 29: FuelPoint Troubleshooting

Fault

FuelPoint does not Power Up

Probable Cause

OrPAY1000 is off internal

LEDs are off.

No power

Loose cable

Checks

• Check that unit is getting 220/110Vac from mains.

• Check that power is going to the correct terminals on the unit.

• Check power cable & socket.

• Check if power wires are loose in the terminal block.

• Check that all wires are firmly connected on the terminal block.


Apply power to the unit.

Firmly insert all connecters into their sockets.

CPU board is off.

CommVerter board is off.

Power switch is off.

Bad power supply Check that power supply in and out wires are firmly connected.

Turn on power switch.


Power to CPU Check that the power wire from main board J13 is connected.

Connect the wire from J13 to DFI

CPU board.

Replace CPU.

Power to the board Power harness from main board J23 is connected.

Connect harness from J23 to commVerter board.

Replace commVerter board.

OrPAY1000 is off, and internal devices are on.

Power wire Check power cable from main board J4 is connected.

Connect harness from J4.

Replace OrPAY1000.

No Communication from Outside PC to the nOrCU

Can't communicate with nOrCUor other devices. No ping.

LAN cables are loose.

Bad 5-port LAN switch

Bad CPU

Check that all LAN cables are firmly connected.

Check whether the LEDs on the board are  on/blinking.

Check network setup.

If LEDs are not on: Replace switch board.

If LEDs are on: Check connection between the PC and the CPU directly using a LAN cable.

Replace CPU.

Adapt network setup to PRIME network setup.


8.6 FuelPoint Troubleshooting

Fault

None of the devices connected are able to communicate with the CPU.


No Communication to Devices (Pumps, OrTR, etc.)

Cable Check LAN cables:

• From CPU to LAN switch

• From OrPAY1000 to

• LAN switch

• From main board

ETH1/2 to LAN switch

• From LAN to PC

• From com card to LAN switch

• From com card to main board J23

Replace cable/harness.


FuelPoint® and Gasboy ® are trademarks of Gasboy International. Gilbarco ® is a trademark of Gilbarco Inc. EMV ® is a registered trademark of EMVCo LLC. Ethernet ® is a registered trademark of Xerox Corporation. NEC ® and NFPA 70 ® are registered trademarks of the National Fire Protection Association. Tokheim ® is a registered trademark of Tokheim Holding B.V. Corporation. UL ® is a registered trademark of Underwriters Laboratories Inc.

© 2020 Gilbarco Inc.

7300 West Friendly Avenue · Post Office Box 22087

Greensboro, North Carolina 27420

Phone (336) 547-5000 · http://www.gilbarco.com

· Printed in the U.S.A.


Gasboy MDE-5411B Installation Manual

ForeHB

Islander PRIME Installation Manual

Table of Contents

List of Figures

1 – Introduction

1.1 General

1.2 Solution Description

1.3 System Architecture

1.4 Manual Structure

1.5 References

1.6 Documentation Conventions

2 – Important Safety Information

3 – System Overview

3.1 General

3.2 System Description

3.3 Islander PRIME Structure

3.4 Available Configurations

3.5 Security and Protection

3.6 Housing

3.7 Technical Specifications and Standards

4 – Preliminary Guidelines

4.1 General

4.2 Precautions and Safety Notes

Précautions et consignes de sécurité

4.3 Station Survey

4.4 Conduits

4.5 Cable Insertion

4.6 Power Setup

4.7 Wiring the Peripherals

5 – Installation

5.1 General

5.2 Installation Guidelines

5.3 Installing the Pedestal Base

5.4 Installing Options

5.5 Installing Communication Interfaces

n.c.

5.6 Post-Installation Checklist

5.7 Islander PRIME Setup

6 – LAN CommVerter Setup

6.1 General

6.2 Home Page

6.3 Setup

6.4 Software Upload

7 – Maintenance

7.1 General

7.2 OrPAY1000 and Islander PRIME

7.3 Magnetic Card Reader

7.4 Printer

8 – Troubleshooting

8.1 General

8.2 Islander PRIME

8.3 OrPAY1000

8.4 Printer

8.5 Communication

8.6 FuelPoint

Related manuals

Gasboy

MDE-4820K

Orpak Systems

W8F800939105

Hembry Creek

M-ISLANDER-30BN

Gasboy

C35294

Gasboy

C08921

Gasboy

MDE-4707

Gasboy

MDE-4816

Gasboy

MDE-4530

Table of contents