Gasboy CFN Islander II User Manual

CFN SERIES
ISLANDER II
INSTALLATION MANUAL
C35963
GASBOY INTERNATIONAL LLC
GASBOY CFN SERIES ISLANDER II
INSTALLATION MANUAL
Rev. 03/07/03
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.
Copyright 2003 by Gasboy International LLC All rights reserved.
GASBOY INTERNATIONAL LLC LANSDALE, PA
FCC AND DOC CUSTOMER INFORMATION
Both the US Federal Communications Commission (FCC) and the Canadian Department of Communication (DOC) require specific information be supplied to the users of any equipment which may emit radio frequency energy. Please read the following information.
FCC PART 15
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the device is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interf erence, in which case, the user will be required to correct the interference at his own expense.
FCC PART 68
GENERAL REQUIREMENTS FOR ALL EQUIPMENT
1. This equipment complies with Part 68 of the FCC rules. The GASBOY Internal Modem is contained within a GASBOY Fuel Management System. On the outside of the rear access door of the Fuel Management System is a label that contains, among other information, the FCC registration number and ringer equivalence number (REN) for this equipment. If requested, this information must be provided to the telephone company.
2. The GASBOY Internal Modem should be connected to a USOC RJ-11C jack.
3. An FCC compliant telephone cord and modular plug is provided with the equipment. This equipment is designated to be connected to the telephone network or premises wiring using a compatible modular jack which is Part 68 compliant. See Installation Instructions for details.
4. The REN is used to determine the quantity of devices which may be connected to the telephone line. Excessive RENs on the telephone line may result in the device not ringing in response to an incoming call. In most, but not all areas, the sum of RENs should not exceed five (5.0). To be certain of the number of devices that may be connected to a line, as determined by the total RENs, contact the local telephone company.
5. If the GASBOY Internal Modem causes harm to the telephone network, the telephone company will notify you in advance that temporary discontinuance of service may be required. But if advance notice is not practical, the telephone company will notify the customer as soon as possible. Also, you will be advised of your r ight to file a complaint with the FCC if you believe it is necessary.
6. The telephone company may make changes in it’s facilities, equipment , operations or procedures that could affect the operation of the equipment. If this happens the telephone company will provide advance notice in order for you to make necessary modifications to maintain uninterrupted service.
7. If trouble is experienced with the GASBOY Internal Modem, for repairs or warranty information, please contact GASBOY International LLC at 1-800-444-5529. If the equipment is causing harm to the telephone network, the telephone company may request that you disconnect the equipment until the problem is resolved.
8. The GASBOY Internal Modem does not have any easily repairable or replaceable parts. If you are experiencing trouble please contact GASBOY International LLC.
9. The equipment cannot be used on public coin phone service provided by the telephone company. Connection to party line service is subject to state tariffs. (Contact your state Public Utility Commission, Public Service Commission or Corporation Commission for information.)
DOC CERTIFICATION
The Industry Canada Ringer Equivalence Number Notice
The Canadian Department of Communications label identifies certified equipment. This certification means that the equipment meets certain telecommunications network protective, operational and safety requirements. The Department does not guarantee the equipment will operate to the user’s satisfaction.
Before installing this equipment, users should ensure that it is permissible to be connected to the facilities of the local telecommunications company. The equipment must also be installed using an acceptable method of connection. In some cases, the company’s inside wiring associated with a single line individual service may be extended by means of a certified connector assembly (telephone extension cord). The customer should be aware that compliance with the above condition may not prevent degradation of service in some situations.
Repairs to some certified equipment should be made by an authorized maintenance facility designated by the supplier. Any repairs or alterations made by the user to this equipment, or equipment malfunctions, may give the telecommunications company cause to request the user to disconnect the equipment.
Users should ensure for their own protection that the ground connections of the power utility, telephone lines and internal metallic water pipe system, are connected together. T his precaution may be particularly important in rural areas.
CAUTION Users should not attempt to make such connections themselves, but should contact the appropriate electric inspection authority, or electrician, as appropriate.
The RINGER EQUIVALENCE NUMBER (REN) assigned to each terminal device denotes the percentage of the total load to be connected to a telephone loop which is used by the device, to prevent overloading. The termination on a loop may consist of any combination of devices subject only to the requirement that the total of the REN of all devices does not exceed 5.
The REN for the GASBOY Internal Modem is 0.8B.
CONTENTS
Section 1: INTRODUCTION
Purpose..................................................................................................... 1-1
System Overview ...................................................................................... 1-1
Section 2: SYSTEM LAYOUT
Purpose..................................................................................................... 2-1
Islander...................................................................................................... 2-1
Islander With Standard Post or Island Mount Standalone Pump
Control Unit.......................................................................................... 2-2
Islander With Receipt Printer Post ............................................................ 2-3
Pump Control Unit (PCU) (Optional)......................................................... 2-4
Wall-Mount Pump Control Unit (PCU) Dimensions................................... 2-5
Console (Optional) .................................................................................... 2-6
Console..................................................................................................... 2-7
RS-485 Junction Box................................................................................. 2-7
Console Options........................................................................................ 2-8
Customer Display (Optional)..................................................................... 2-9
CRT/Printer (Optional) .............................................................................. 2-10
External Modem (Optional) ....................................................................... 2-10
Power Conditioner (Optional).................................................................... 2-10
Conduit Requirements............................................................................... 2-11
Conduit Layout/Installation Specifications................................................. 2-12
Conduit Layout - Pump Control Post......................................................... 2-13
Conduit Layout - Island-Mount Standalone Pump Control Unit................. 2-14
Conduit Layout - Wall Mount Pump Control.............................................. 2-15
Conduit Layout - Gasboy Electronic Pumps/Remote Dispensers............. 2-16
Section 3: SYSTEM COMPONENTS WIRING
General Wiring Precautions ...................................................................... 3-1
Power Requirements................................................................................. 3-2
System/Peripheral Equipment.............................................................. 3-2
Wire Size................................................................................................... 3-2
Communication Requirements.................................................................. 3-2
RS-485................................................................................................. 3-2
RS-232................................................................................................. 3-4
RS-422................................................................................................. 3-4
RS-232 Cables.......................................................................................... 3-5
RS-232 1:1 Cable (P/N C04549: 8-foot M/M)...................................... 3-5
RS-232 DTE Cross Cable (P/N C05039: 8-foot M/M,
P/N C05928: 8-foot M/F)...................................................................... 3-5
Termination Box................................................................................... 3-5
System Components Wiring Diagram....................................................... 3-6
Checkpoint Console Wiring....................................................................... 3-8
Multiple Checkpoint Console Wiring.......................................................... 3-8
Port Communication Wiring....................................................................... 3-9
Local Port Wiring.................................................................................. 3-9
Remote Port Wiring.............................................................................. 3-10
Short Haul Modems (RS-422)................................................................... 3-12
Installation Requirements..................................................................... 3-12
Wiring For a Link CRT Terminal and Okidata Printer................................ 3-13
03/07/03 Contents-1
CFN Series System
Phone Modems......................................................................................... 3-13
External Modems................................................................................. 3-13
Internal Modems .................................................................................. 3-13
Wiring For a Tank Monitoring System....................................................... 3-14
Gate Controller Wiring Using Gate Reader............................................... 3-15
Section 4: PUMP/REMOTE DISPENSER WIRING
Wiring Precautions.................................................................................... 4-1
Power Requirements................................................................................. 4-2
Suction Pumps..................................................................................... 4-2
Remote Dispensers.............................................................................. 4-2
Wire Size................................................................................................... 4-2
Wiring Electronic or Mechanical Pumps.................................................... 4-3
Connection of Tokheim Pumps............................................................ 4-3
Tokheim Splitter Cabling...................................................................... 4-4
Tokheim 162 Interface, Electronic Interface......................................... 4-5
Tokheim 262 and 262A Interface, Electronic Interface........................ 4-6
Tokheim 330B, 333B-SA, TCS, and Premier Interface, Electronic
Interface.......................................................................................... 4-7
Terminal Block ID...................................................................................... 4-8
Receipt Printer Pedestal ...................................................................... 4-8
Standard Pedestal - Left Side.............................................................. 4-9
Standard Pedestal - Right Side............................................................ 4-10
Wall Mount Pump Control Unit............................................................. 4-11
Control Lines............................................................................................. 4-12
Grounding ............................................................................................ 4-12
Reset Motor Feed................................................................................ 4-12
Pump Motor Feed................................................................................ 4-12
Neutral Feed ........................................................................................ 4-12
Submersible Feed, Submersible Drive................................................. 4-13
Reset Complete (Switch Detect)/Slow Flow......................................... 4-13
Fast Flow ............................................................................................. 4-13
Light Feed............................................................................................ 4-13
Light Neutral......................................................................................... 4-13
Phase 2 Feed....................................................................................... 4-13
Pulser................................................................................................... 4-13
Pulser Wiring and Configuration................................................................ 4-14
Pulser Wiring Requirements ................................................................ 4-15
Single Suction Pump................................................................................. 4-16
Twin Suction Pump ................................................................................... 4-17
Twin Suction Pump, Single Motor............................................................. 4-18
Single Remote Dispenser.......................................................................... 4-19
Twin Remote Dispenser............................................................................ 4-20
Single Suction Pump with Console ........................................................... 4-21
Twin Suction Pump with Console.............................................................. 4-22
Twin Suction Pump, Single Motor with Console........................................ 4-23
Single Remote Dispenser with Console.................................................... 4-24
Twin Remote Dispenser with Console ...................................................... 4-25
Single Suction Pump................................................................................. 4-26
Twin Suction Pump ................................................................................... 4-27
Twin Suction Pump, Single Motor............................................................. 4-28
Single Remote Dispenser.......................................................................... 4-29
Twin Remote Dispenser............................................................................ 4-30
Single Suction Pump with Console ........................................................... 4-31
Contents-2 03/07/03
Contents
Twin Suction Pump with Console.............................................................. 4-32
Twin Suction Pump, Single Motor with Console........................................ 4-33
Single Remote Dispenser with Console.................................................... 4-34
Twin Remote Dispenser with Console ...................................................... 4-35
Using the PCU to Activate a Gate Controller ............................................ 4-36
Section 5: TESTING
Completion Checklist................................................................................. 5-1
Manual Override Test................................................................................ 5-2
03/07/03 Contents-3
Section 1
INTRODUCTION
PURPOSE
The GASBOY CFN Islander II Installation Manual is provided to assist you in installing your CFN Islander System. This manual should be supplied to the electrician prior to the installation of conduit and wiring to ensure your Islander System is installed properly. Faulty installations are the major cause of system malfunctions. The system must be installed as described in this manual to ensure the reliability and proper operation of your Islander System. Please read this entire manual before starting installation.
GASBOY provides a toll-free number for customers and installers having any
SYSTEM OVERVIEW
The CFN Islander II is a microprocessor-based automated fueling system. Consisting of modular components and configurable software, the CFN Islander System can be tailored to meet the needs of government and private fleet owners and retail petroleum marketers. System flexibility allows for debit, credit, club, and fleet cards as well as cash operation through the optional console.
System application determines the components required, therefore, your system may consist of several or all of the following components:
Islander System
RS-485 junction box(es)
Pump control unit(s)
Satellite Islander Reader(s)
Console(s)
Standalone receipt printer(s)
Cash drawer(s)
PIN pad(s)
Data terminal
Modem
Power conditioner
Section 2, System Layout, provides a brief description of each component.
questions pertaining to the installation:
1-800-444-5529
03/07/03 1-1
Section 2
SYSTEM LAYOUT
PURPOSE
Use this section for detailed planning of the installation of your system. This section covers a basic description, location requirements, and the environmental requirements of the CFN components. A dimensional drawing is included for components manufactured by GASBOY. This section also covers conduit requirements and gives conduit layout examples for three basic system configurations. Careful planning for the layout of the site will help eliminate possible problems with the start-up of your system and will help ensure continued, reliable system operation.
CFN ISLANDER
Description
The CFN Islander II is the heart of the CFN System at the fueling site. The Islander consists of a Site Controller II, which controls and allows interaction between all your automated fueling equipment including pump control devices and satellite Islander readers. In the Islander, the Site Controller II comes standard with two PCMCIA car d slots and two PCMCIA SRAM cards for mass storage of data and loading in of oper ating system programs. The Islander II can be ordered to provide magnetic or optical card or cardless oper ation. A built-in keyswitch can be used to limit access to specified commands. The Islander can control up to 32 hoses and up to 7 satellite readers (Islander readers).
The Islander comes in two post configurations, a standard post and a receipt printer post. If pump control units are required, the standard pedestal can accommodate two pump control
units controlling up to eight hoses. The receipt printer pedestal can accommodate one pump control unit controlling up to four hoses. Remote wall-mount pump control unit(s) can also be used.
The Islander contains four asynchronous ports for terminals, modems and/or computer communications. The ports can be set for either RS-232 or RS-422 communications to meet individual requirements. Port 0 is used for communications to a data terminal (logger ). Port 2 is used for communication through a modem or to a computer. Ports 1 and 3 are additional por ts which can be programmed according to the application.
Two RS-485 ports are provided for communications with other CFN devices at the fueling site.
Location The Islander should be located on the fuel island. The unit has been designed for an operating temperature range of -40 Adequate clearance must be provided to allow easy access to the post’s access covers.
The Islander requires a minimum of 18 inches clearance between the post and any of the pumps/remote dispensers on the island.
o
F to 104oF with a relative humidity of 2% to 99% non-condensing.
03/07/03 2-1
CFN Series System
ISLANDER WITH STANDARD POST OR ISLAND-MOUNT STANDALONE PUMP CONTROL UNIT
NOTE: Drawing shows standard Islander II unit. Island-Mount Standalone unit has the same footprint, but does not have a head. Pedestal height is 48 inches.
2-2 03/07/03
System Layout
ISLANDER WITH RECEIPT PRINTER POST
03/07/03 2-3
CFN Series System
PUMP CONTROL UNIT (PCU) (OPTIONAL)
Description
The pump control unit (PCU) controls most mechanical pumps and some electronic pumps. The unit is controlled by a microprocessor and communicates to the Islander via the RS-485 loop. Each pump control unit can control up to four pumps or remote dispensers.
Hardware features include a battery backup for Weights and Measures requirements, three solid state relays for each pump or remote dispenser (slow flow, fast flow and pump), manual override switches, and diagnostic capabilities. Field wiring connections are made to the unit via easy-to­wire terminal blocks.
Pump control units, can be accommodated within the pedestal of the Islander (a standard pedestal can accommodate two pump control units, a receipt printer pedestal can accommodate only one), can be remote from the Islander (wall-mount), or can be a standalone unit located on the island.
Location The pedestal version of the pump control unit is located within the Islander. The wall mount version of the pump control unit must be located in an area protected from direct contact with weather. The standalone version is located on the island. Do not install over a hazardous location. All pump control units are designed for an operating temperature of -40 a relative humidity of 2% to 99% non-condensing.
o
F to 104oF with
2-4 03/07/03
System Layout
WALL-MOUNT PUMP CONTROL UNIT (PCU) DIMENSIONS
03/07/03 2-5
CFN Series System
CONSOLE (OPTIONAL)
Description
The Checkpoint console is used in retail applications to initiate and monitor sales at the Islander. The unit is controlled by a microprocessor and communicates to the Islander via a direct RS-485 connection that requires an RS-485 junction box. The RS-485 junction box provides a means for hard-wire connection while incorporating protection circuitry to prevent electrostatic sur ges (which may occur on the field wiring) from reaching the console.
Each Checkpoint console can control up to 16 pumps or remote dispensers. A 20-character alphanumeric display along with pump status LEDs are used to provide the operator with current information regarding the site. Full-travel keys are used in the operation of the unit. An ABA Track 2 magnetic stripe reader is provided for use in reading magnetic stripe cards for credit or club card purchases.
An optional standalone receipt printer, a PIN (personal identification number) pad, a cash drawer , and a customer display are available for use with the console. The optional standalone receipt printer is used for generating receipts in the building where the console is located. T he optional PIN pad can be used to allow customers to secretly enter their PINs for console transactions. The optional cash drawer is used for storage of cash at the site. The customer display allows you to display console sales so they are visible to the customer.
Location The console and optional equipment should be located in an office-type environment. The unit must be located in an area protected fr om direct contact with the weather. Do not install over a hazardous location. The unit is designed for an operating temperature range of 4 a relative humidity of 5% to 95% non-condensing. The operative temperature range for the optional standalone receipt printer is 40
o
F to 104oF.
You can locate the console in a location up to 1000 feet away from the Islander. The RS-485 junction box must be located within eight feet of the console. See Console Wiring in Section 3.
o
F to 120oF with
2-6 03/07/03
System Layout
CONSOLE
RS-485 JUNCTION BOX
03/07/03 2-7
CFN Series System
CONSOLE OPTIONS
Standalone Receipt Printer
PIN Pad
Cash Drawer
2-8 03/07/03
System Layout
CUSTOMER DISPLAY (OPTIONAL)
Install the customer display as follows:
1. Remove the protective tape holding the connecting cable to the tube.
2. Thread the connecting cable from the tube down through the tube fitting in the base, under the base and up through the opening in the base plate (Figure A). Be careful not to drop display.
3. Install the tube in the tube fitting, position the display, and tighten the set screw in the tube fitting.
4. Take the strain relief bushing and, using pliers, squeeze the bushing onto the wire. Snap the bushing into the retaining plate (Figure B).
5. Screw the retaining plate to the base as shown in Figure A.
03/07/03 2-9
CFN Series System
CRT/PRINTER (OPTIONAL)
Description
The CRT terminal is used for communication to and from the Islander. A CRT/printer combination can be used as a logger for providing hard-copy printouts of action at the site or as an interrogation device to extract information from the system via the system’s commands. A CRT can be directly connected to the Islander, connected via short haul modems, or connected via telephone modems.
Location The CRT/printer should be located in a clean, office-type environment. Do not install over a hazardous location. CRT/printer combinations supplied by GASBOY have an operating temperature range of 32
o
F to 104oF, 10% to 95% relative humidity, non-condensing. Locating the
CRT/printer in a dirty environment may cause premature failures.
MODEMS (OPTIONAL)
Description
There are two types of modems (internal and external) that can be used for communication to the Islander where distance or conditions will not permit direct connection to the unit. When an internal modem is installed, remote port communication is routed through the modem in place of being wired at the terminal block in the post. See Section 3, Phone Modems for details. Modems to be used for dial-out to a bank network require a dedicated phone line.
Location When an external modem is used with the system, it is recommended the modem be located in an office-type environment. However, if this is not possible, it should be housed in a protective enclosure. Do not install over a hazardous location. External modems supplied by GASBOY have an operating temperature range of 32
o
F to 104oF.
When ordered, the internal modem is mounted inside the Islander at the factory. Power for the modem is supplied by the Islander.
POWER CONDITIONER (OPTIONAL)
Description
A Listed power conditioner should be used when there is an unstable source of power. Poor power conditions are a key cause to system malfunction or failure. When used, the power conditioner helps provide clean power to the Islander and other CFN devices. The power conditioner provides transient and common mode protection for the CFN system, although it cannot totally compensate for extremely poor power conditions.
Location
The power conditioner should be located near (within 50 feet of) the Islander, but not in or above a hazardous area. It must be located in an area protected from direct contact with weather (typically near the system circuit breakers). The unit is designed for an operating temperature range of 0
o
to 104
F.
o
F
2-10 03/07/03
System Layout
CONDUIT REQUIREMENTS
The conduit requirements outlined in this section are relevant to all components making up the GASBOY system including, but not limited to, CFN system units, pumps, remote dispensers, submersible pumps, submersible starter relays and the circuit breaker panels. The GASBOY Warranty will not apply to any system deviating from the requirements outlined in this section.
All wiring and conduit runs must conform with all building/fire codes, all Federal, State, and Local codes, National Electrical Code, (NFPA 70), NFPA 30, and Automotive and Marine Service Station Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code.
All wiring (AC and DC) connecting the different components of the CFN System and all communication equipment signal wires must be installed underground in threaded, rigid, metal conduit. PVC IS NOT ACCEPTABLE. It is recommended that high voltage AC power wires be installed in separate conduit from the low voltage DC signal wires. However, if AC and DC wires share conduit, DC wiring must use the cable specified in Section 3, Communication
Requirements (RS-485), Short Haul Modems (RS-422), and Section 4, Pulser Wiring and Configuration. When AC and RS-485 or RS-422 wires are combined in the same conduit, only
AC wires for the system and pumps may be in that conduit. All conduit must be connected to the CFN components through the holes and knockouts provided
by the factory. Do not make any other holes in these units. If alternate holes are required, contact GASBOY for approval first.
Use the charts below as a guideline to determine the proper conduit sizes for the GASBO Y CFN Series system. When planning the orientation of the wiring runs, follow the applicable GASBOY wiring diagram and consider the layout of the components at the site. Long runs or a large number of bends may require you to increase conduit size over what is listed.
To determine conduit size needed, use the THHN/THWN Wire Areas table (left) to find the area for each wire gauge. Add up all wire areas. Use the Areas of Tr ade Size Conduit Table (right) to select the smallest number in the 25% fill area (based on NEC 501-1) that comes closest without exceeding the total wire area.
03/07/03 2-11
CFN Series System
CONDUIT LAYOUT/INSTALLATION SPECIFICATIONS
1. All wiring is to be installed and used in accordance with all building/fire codes, all Federal, State, and Local codes, National Electrical Code (NFPA 70), NFPA 30, and Automotive and Marine Service Station Code (NFPA 30A) codes and regulations. Canadian users must also comply with the Canadian Electrical Code.
2. All peripher al equipment connected to the RS-232 ports must be Listed, have an Electronics Industrial Association (EIA) standard RS-232 communications protocol and not be installed over a hazardous location.
3. Power for the system components, data terminal, and modem must come from a separ ate dedicated circuit breaker rated at no less than 10 AMPS.
4. All conduit must be metal to provide the necessary shielding.
5. All conduit must be run underground, not overhead.
6. DC pulser and DC RS-485 and RS- 422 communication wires can be combined in the same conduit. It is recommended that the DC pulser, RS-485 and/or RS-422 wiring be in a separate metal conduit from any AC wires. However, the DC pulser, RS-485 and/or RS-422 wires can share conduit with AC wires if shielded cable is used as specified in Section 3, Communication Requirements (RS-485), Short Haul Modems (RS-422), and/or Section 4, Pulser Wiring and Configuration.
7. Use the wire size chart (Table 4-1) to determine the wire gauge.
8. Use the conduit size char ts to determine the size according to the number of wires and wire gauge.
9. RS-232 communication must not exceed 100 feet. RS- 232 communication wires must be in a metal conduit separate from any AC wires.
10. For communication distances exceeding 100 feet, you must use a GASBOY short haul modem.
11. In submersible applications, starter relays are always recommended; however, the system can directly drive motors up to 3/4 HP at 120/240 VAC or 1-1/2 HP at 240 VAC.
12. Suction pumps over 3/4 HP at 120/240 VAC or 1-1/2 HP at 240 VAC must use a starter relay. Wire the starter relay in place of the motor in the applicable pump wiring drawing.
13. A minimum distance of 18 inches must be maintained between the Islander post and any of the pumps/remote dispensers.
14. Disregard the submersible pump in the drawing if the hose outlets are suction pumps.
15. Consult the applicable section of this manual for specific system installation requirements.
16. When used with Fuel Point, an extra dedicated junction box is supplied to be installed in the pump/dispenser. A separate dedicated conduit is to be run between the junction box and the Fuel Point Reader. Consult the Fuel Point Reader Installation Manual C35628 for details.
2-12 03/07/03
System Layout
CONDUIT LAYOUT-PUMP CONTROL POST
Mechanical Hose Outlets
03/07/03 2-13
CFN Series System
CONDUIT LAYOUT-ISLAND-MOUNT STANDALONE PUMP CONTROL
Mechanical Hose Outlets
2-14 03/07/03
Loading...
+ 57 hidden pages