SERIES 1000
FUEL MANAGEMENT SYSTEM
START-UP MANUAL
C08921
GASBOY INTERNATIONAL LLC
GASBOY
SERIES 1000
FUEL MANAGEMENT SYSTEM
START-UP MANUAL
C08921
Rev. 03/07/03
GASBOY INTERNATIONAL LLC
LANSDALE, PA
Copyright 2003 by Gasboy International LLC
All rights reserved
The information in this document is confidential and proprietary. No further disclosure shall be made without permission from Gasboy International LLC.
Gasboy International LLC believes that the information in this document is accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or other rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.
CONTENTS
Section 1: |
STARTING A SERIES 1000 SYSTEM |
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Introduction................................................................................................ |
1-1 |
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Start-Up Overview..................................................................................... |
1-2 |
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What You Need For Testing...................................................................... |
1-2 |
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Filling Out the Start-up Form..................................................................... |
1-2 |
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Using This Book ........................................................................................ |
1-3 |
Section 2: |
SITE INFORMATION................................................................................ |
2-1 |
Section 3: |
BEGIN START-UP FORM |
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Parts 1 Through 4 ..................................................................................... |
3-1 |
Section 4: |
SYSTEM LAYOUT.................................................................................... |
4-1 |
Section 5: |
JUMPERS AND SWITCH SETTINGS...................................................... |
5-1 |
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Series 1000 Jumpers ................................................................................ |
5-1 |
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Auxiliary Communications Port PCB Assembly......................................... |
5-6 |
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Veeder-Root TLS-250 Tank Monitor Switch Settings .......................... |
5-6 |
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Veeder-Root TLS-350 Tank Monitor Switch Settings .......................... |
5-7 |
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Fuel Point Reader Port and Baud Rate Jumpers................................. |
5-7 |
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Gasboy Fuel Point Reader Switch Settings .............................................. |
5-8 |
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Link MC5 Terminal Setup.......................................................................... |
5-9 |
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Okidata 184 Printer Setup......................................................................... |
5-11 |
Section 6: |
PUMP/DISPENSER MANUAL TEST ....................................................... |
6-1 |
Section 7: |
SYSTEM POWER ..................................................................................... |
7-1 |
Section 8: |
DC POWER .............................................................................................. |
8-1 |
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Series 1000.......................................................................................... |
8-1 |
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Fuel Point Reader ................................................................................ |
8-2 |
Section 9: |
COMMUNICATIONS TESTS.................................................................... |
9-1 |
Section 10: |
PUMP/DISPENSER AUTOMATIC TEST ................................................. |
10-1 |
Section 11: |
START-UP COMMANDS ......................................................................... |
11-1 |
Section 12: |
CUSTOMER TRAINING ........................................................................... |
12-1 |
Section 13: |
FINISH START-UP ................................................................................... |
13-1 |
SAMPLE START-UP FORM |
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WARRANTY |
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03/07/03 |
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1-1 |
Section 1
STARTING A SERIES 1000 SYSTEM
INTRODUCTION
This Start-Up Manual is provided to assist you in the start-up of a GASBOY Series 1000 System. As the start-up person, you should already be familiar with all of the Series 1000 manuals. Proper installation is critical to ensure correct and trouble-free operation. The Series 1000 includes a one-year parts warranty against defective material and/or workmanship. See the Warranty page at the back of this book for details.
NOTE: |
Noncompliance with the specifications of the Series 1000 Installation Manual and the |
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checks in the accompanying Start-Up Form could void the warranty. |
As you are performing the start-up process, any deviations from the specifications listed in the Installation Manual should be corrected. If any tests fail, correct the wiring or system problem and perform the test again. If you have any questions, cannot proceed to the next step, or you want authorization for exceptions, please contact GASBOY Customer Service at:
1-800-444-5529
In addition to this manual, the customer should have the following GASBOY Series 1000 Fuel Management System manuals.
●Installation Manual, C08922
Contains instructions, restrictions and guidelines for planning, laying out, and wiring the Series 1000 System.
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Card Encoding Manual, C08924 (Card Systems Only) |
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Describes the process of card encoding, including card layout, field descriptions, and filling |
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out the card encoding form. |
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Operation Manual, C08923 (Card Systems Only) |
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or |
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Cardless Operation Manual, C08926 |
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or |
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FleetKey Operation Manual, C08379 |
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Contains detailed descriptions of system features, data terminal commands, transaction |
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processing and additional system options. |
●Diagnostic Manual, C08925
Contains descriptions of system components, diagnostic tests, troubleshooting procedures, and replacement parts listings.
Customers having the Fuel Point option should also have the following manuals:
●Fuel Point Reader Installation Manual, C35628
●Fuel Point Dispenser and Hose Retrofit Manual, C35593
●Fuel Point Vehicle Module Installation Manual, C35699
●Fuel Point Vehicle Module Programming Manual, C35629
03/07/03 |
1-1 |
GASBOY Series 1000
START-UP OVERVIEW
Start-up for the Series 1000 System consists of:
•verifying the system layout
•making sure the system complies with the guidelines and restrictions outlined in the system
Installation Guide and this manual.
•testing the system
•helping the system user execute the commands needed to start the system
•making sure the customer understands how the system works
•filling out the GASBOY Series 1000 Start-up Form, 55F065
WHAT YOU NEED FOR TESTING
To perform the testing portion of start-up, you will need:
•a digital voltmeter
•a 1/4 inch flat blade screwdriver
•a Phillips head #1 screwdriver
•a Phillips head #2 screwdriver
•a plastic 1/8 inch or smaller flat blade screwdriver
•a tape measure
We recommend that you bring all your tools and spare parts when doing a start-up.
FILLING OUT THE START-UP FORM
A sample filled-out Start-Up form appears at the end of this manual. You should already have blank copies of the Start-up form; however, if you do not, you can obtain more by calling GASBOY Office Services Department. Throughout the procedures in this manual, you will find doubleoutlined boxes preceded by this symbol . This writing hand symbol tells you to "fill in" the start-up information for the entries contained in the box.
When you encounter a box, fill in all the information requested. If an option is not used or does not apply, fill in N/A (not applicable) in that space. It may be helpful to have the terminal operator review the Series 1000 Operation Manual, if he has not already done so, while you are starting up the system.
The Start-Up Form must be filled out completely and sent to:
Gasboy International LLC
Customer Service Dept.
707 N. Valley Forge Rd.
P.O. Box 309
Lansdale, Pa 19446
1-2 |
03/07/03 |
Starting a Series 1000 System
USING THIS BOOK
This book is designed to be followed from start to finish. The procedures are listed in a logical order and correspond to the layout of the Start-up form. Please follow the step-by-step procedures in this manual.
The following symbols are used in this manual:
Means fill in the Start-up form entries explained in the box.
Means mail the form to GASBOY.
Means press the RETURN key.
03/07/03 |
1-3 |
Section 2
SITE INFORMATION
Before you can use the Series 1000, you must load in certain operating information. This section provides a template for you to fill in the information needed to perform the start-up commands in Section 11. Do not perform the commands at this time. Confirm with the customer the information that he will be using (e.g., fuel authorizations, limitations, etc.). Successful start-up requires coordination between separate components of the system: installation, card or key encoding, and operation. Each item listed contains a manual reference where you can find additional information.
For mag and optical card and FleetKey systems, the system identification, product authorization and product limitation codes are encoded on the access cards or keys and then entered into the system via commands. The commands you enter must match what is encoded on the cards. The
Series 1000 Card Encoding Manual and the FleetKey Operation Manual explain the encoding of these items.
For cardless systems, the authorization and limitation codes are stored in the vehicle record. The commands you enter must match what is stored in the vehicle record. See Fueling Restriction Commands in the Series 1000 Cardless Operation Manual for more information.
1.COMMUNICATION PORT SETTINGS (Reference: Operation Manual: Communicating
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with the Series 1000) |
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Port 1 |
RS-232/RS-422 |
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Baud rate |
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Port 2 |
RS-232/RS-422 |
______ |
Baud rate |
______ |
Aux. Port 1 |
RS-232/RS-422 |
______ |
Baud rate |
______ |
Aux. Port 2 |
RS-232 |
______ |
Baud rate |
______ |
NOTE: If you have a tank monitoring system, receipt printer, or Fuel Point Reader (FPR), you also have the auxiliary communications port PCB. Port 1 is configurable for RS-232 or RS-422; Port 2 is RS-232 only. If the system does not have a FPR, Port 1 is always used for a tank monitor; port 2 is for the receipt printer. If a FPR is used, it is always Port 1, RS-422, 1200 Baud; port 2 can be used for a tank monitor or receipt printer. In all cases, the receipt printer must be set for 9600 baud.
2.SIGN ON PASSWORD (Reference: Operation Manual: LS Command) Password (up to 10 characters)________________
3.SYSTEM CONFIGURATION (Reference: Operation Manual: SC Command)
Site Number: |
_________ (0000-9999) |
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Idle Message: |
____________________ (20 characters maximum) |
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Number of pumps: ____ (1-8) |
Number of tanks: ____ (1-8) |
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Receipt Printer?: ____ |
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03/07/03 |
2-1 |
GASBOY Series 1000
Pump |
Pulser Type |
Pulses Per |
Tank Number |
Fuel Code |
No. |
(Reed, Elec.) |
Gallon |
(1-8) |
(1-99) |
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($, 1000, 500, |
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100, 10, 1) |
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1
2
3
4
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7
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Price Data Format: _____ |
No Data |
_____ |
Unit Price Only (valid option for $ pulsing only) |
_____ |
Unit and Total Price |
System ID: |
________ (Card or FleetKey Systems) |
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Number of zero quantity transactions to disable a pump: _____ (01-99) |
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Card (Key) Expiration Date: ______ Enable |
______ Disable (Card or FleetKey Systems) |
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Auto PIN lock out: ______ Enable ______ Disable (Card or FleetKey Systems) |
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PIN Entry: ______ Enable ______ Disable |
(Cardless Systems Only) |
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4.SITE SHUT DOWN (Reference: Operation Manual: SC and SD Commands)
Site Shut Down: Enable |
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Disable ____________ |
Begin Time |
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End Time ____________ |
2-2 |
03/07/03 |
Site Information
5.PRODUCT AUTHORIZATION TABLE (Reference: Operation Manuals: LF Command)
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Card Encoding Manual: Product Authorization |
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Code |
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Auth. |
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Allowable Fuel Types (01-99) Per Code |
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Code |
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1
2
3
4
5
6
7
8
9
6.PRODUCT LIMITATION TABLE (Reference: Operation Manuals: LL Command)
Card Encoding Manual: Product Limitation Code)
Limit Cutoff (0-99999)
Limitation Code |
Limit Cutoff |
1
2
3
4
5
6
7
8
9
03/07/03 |
2-3 |
GASBOY Series 1000
7.LOCKOUT TYPE (Reference: Operation Manual: VA and IA Commands)
Check type of lockout desired: |
Negative ______ |
Positive _____ |
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NOTE: |
If you use the second account field, you may wish to use positive lockout for more |
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security. |
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After you have obtained this information, have the contact person provide you with the system’s keys and, if applicable, the user cards or data keys. If actual user cards or data keys are not available, test cards or data keys are provided with the system.
CARDLESS SYSTEMS ONLY
8.VEHICLE FILE (Reference: Operation Manual: Vehicle File Commands)
If the system is cardless, you must identify each record in the vehicle file that you wish to be active. Use this chart to get started, photocopy it if you need to define unique data for each record.
VEH. NO. |
LIM. CODE |
AUTH. CODE |
CHECK DIGIT |
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2-4 |
03/07/03 |
Site Information
9.SECOND ACCOUNT FIELD AND PIN DATA (Reference: Operation Manual)
Use of the second account field is optional and is determined by the check digit in the vehicle file. If you use the second account field and PIN entry is enabled in the SC command, all entries must have a PIN number. Use this chart to enter your second account field data and associated PIN data. You may wish to photocopy it if you need additional space.
2nd Account ________________ |
PIN |
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03/07/03 |
2-5 |
GASBOY Series 1000
FLEETKEY SYSTEMS ONLY
10. MAINTENANCE TABLE (Reference: FleetKey Operation Manual: Maintenance Option)
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MAINT A |
MAINT B |
MAINT C |
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Class |
Miles |
Days |
Miles |
Days |
Miles |
Days |
1
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2-6 |
03/07/03 |
Section 3
BEGIN START-UP FORM
PARTS 1 THROUGH 4
This section covers Parts 1 through 4 of the Start-up form. Parts 5 through 12 are covered in subsequent sections. A sample filled-out Start-up form appears at the end of this book.
1. SITE IDENTIFICATION
Customer: |
The name of the company that owns the system. |
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Location: |
The address of the site where the system is located. |
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Contact: |
The name of a responsible contact person at the site. |
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Customer Phone No.: |
The phone number where the contact person can be reached. |
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Date: |
Today’s date (date of the start-up). |
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Distributor: |
The distributor involved with the sale and/or installation of the |
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system. |
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Distributor Phone No.: |
The phone number where the distributor can be reached. |
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Start-up Person: |
The name of the person performing the start-up. |
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Installer: |
The firm that installed the system. |
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2. PUMPS/DISPENSERS
Fuel Type: |
The type of fuel dispensed by that pump or dispenser (e.g., No- |
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Lead, Regular, etc.). |
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Fuel Code: |
The product code number assigned to that fuel type. |
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Pump Make: |
The name of the manufacturer of the pump or dispenser. |
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Pump Model #: |
The model number of the pump or dispenser. |
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Pump Serial #: |
The serial number of the pump or dispenser. |
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Motor Size: |
The size of the motor used (e.g., 3/4HP, 1 1/2HP). |
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Pump Type: |
The type of pump used to dispense the fuel. Is it a submersible |
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pump (Sub) located in the tank or is it a suction pump (Suc) |
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located in the pump housing? Circle one. |
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Starter Relay: |
Is an external starter relay used to supply power to the pump. |
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Circle Y for yes or N for no. |
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Pulser Rate: |
The pulser rate of the pulser used by that pump or dispenser |
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(e.g., $, 10:1, 100:1). |
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03/07/03 |
3-1 |
GASBOY Series 1000
3. COMMUNICATION
Data Terminal: |
The make and model number of the data terminal connected to |
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the system. If a data terminal is not being used, indicate not |
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applicable (N/A). |
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External Modem: |
The make and model number of the external modem that is |
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connected to the system. This can include Short Haul Modems |
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used for distances over 1500 feet. If no external modems are |
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used, indicate not applicable (N/A). |
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Modem Phone No: |
The area code and phone number for the internal or external |
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phone modem connected to the system. If a modem is not used, |
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indicate not applicable (N/A). |
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Port 1: |
The method of communication used for Port 1 (direct printout |
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port). Circle either RS-232 or RS-422. Indicate the baud rate. |
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Port 2: |
The method of communication used for Port 2 (secondary port). |
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Circle either RS-232, RS-422, or internal modem (Int. Modem). |
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Internal modem should be circled when the internal modem is |
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connected to Port 2 via the ribbon cable directly above the Port 2 |
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RS-232 and RS-422 connectors. Nothing should be connected |
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to the RS-232 or RS-422 ports when the ribbon cable is |
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connected. Indicate the baud rate. |
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Aux. Port 1: |
If auxiliary port 1 is used with a tank monitor, indicate the method |
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of communication. Circle either RS-232 or RS-422. Auxiliary |
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port 2 is always RS-232. Indicate the baud rate. |
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4. BREAKERS
Enter the breaker number for each of the items listed. When multiple breakers are used for 
powering a device (e.g., a breaker for the dispenser and a breaker for the submersible pump), list 
both breakers. All breakers pertaining to the system should be in the OFF position at this time. 
3-2 |
03/07/03 |
Section 4
SYSTEM LAYOUT
1.Verify that the system is installed with a minimum clearance of 18 inches between the post and any of the pumps or dispensers. This clearance meets the NFPA 30A and NFPA 70 requirements and allows room for wiring and maintenance of the system. Adequate clearance around the head of the unit is important to provide room for maintenance of the system. A minimum of 14 inches of clearance from the rear of the unit must be provided to allow the rear door to open.
2.Remove the 10 screws from the upper side pedestal cover. Unlock and remove the cover. Remove the 10 screws from the lower side pedestal cover and remove the cover (same side of post as the upper pedestal cover).
3.Verify that the conduit is installed according to the following specifications:
All wiring (AC and DC) connecting the different components of the Series 1000 System must be installed in metal conduit. PVC IS NOT ACCEPTABLE. Components of the system include pumps, dispensers, submersible pumps, submersible starter relays, Series 1000 System, and circuit breaker panels. Communications equipment signal wires should also be run in metal conduit, (except for RS-422 wiring as noted below).
High voltage AC power wires must be installed in separate conduit from the low voltage DC signal wires. The AC power wires and DC signal wires must not be run in any sort of common conduit or trough (except for RS-422 wiring as noted below). All conduits should be connected to the Series 1000 pedestal through the holes and knockouts provided by the factory. No other holes should be made in either of these units unless previously approved by GASBOY.
All wiring and conduit runs must conform with the National Electrical Code (NFPA 70), the Automotive and Marine Service Stations Code (NFPA 30A), and State and Local Electrical Codes.
Conduits for the system port wiring must be as follows:
RS-232 wires must be installed in a metal conduit separate from any AC wires.
RS-422 wires should be installed in a metal conduit separate from any AC wires. The use of shielded two twisted pair cable (Belden 8102 or equivalent - GASBOY P/N C08728) allows for the following exceptions:
•The cable can be run with AC wires in metal conduit. The shield drain wire must be connected to the system AC ground.
•The cable can be run indoors without the use of metal conduit. The shield drain wire must be connected to the system AC ground. In no case should the cable be run outdoors without the use of metal conduit. Whenever possible the conduit should be run underground and not overhead.
•A short haul modem (SHM) must be used for RS-422 communications.
03/07/03 |
4-1 |
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