Gasboy Fuel Truck Controller User Manual
This document is based on Orpak’s Truck Controller Unit (OrTC)
installation manual P/N 817438028
MDE-4814C
Fuel Truck Controller
INSTALLATION MANUAL
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.
For UL listing; All peripherals equipment connected to the device must be UL listed and suitable for the
applications.
WARNING - EXPLOSION HAZARD
Install the Product only in the non-hazardous area of the fuel station.
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 NFPA-30 “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
port. Disconnect all power before servicing.
CAUTION – EXTERNAL WIRING
For supply connections, use wires suitable for at least 90°C.
Signal wiring connected in this box must be rated at least 300 V.
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 ORPAK SYSTEMS
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 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 document is the property of:
ORPAK SYSTEMS Ltd.
ISRAEL
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TABLE OF CONTENTS
Paragraph
Page
SECTION 1 GENERAL DESCRIPTION
1-1. SCOPE ................................................................................................................................ 8
1-2. DESCRIPTION .................................................................................................................. 8
1-3. SYSTEM OVERVIEW ...................................................................................................... 9
1-3.1. Fuel Truck Controller System ........................................................................................ 9
1-3.2. Vehicle Identification ..................................................................................................... 9
1-3.3. Remote Web Access ...................................................................................................... 9
1-3.4. Fleet Head Office ........................................................................................................... 9
1-3.5. Restrictions and Limits .................................................................................................. 9
1-3.6. Fuel Truck Controller Capabilities for Mobile Station Management ............................ 10
1-3.7. System Workflow - Example ......................................................................................... 11
1-4. FUEL TRUCK CONTROLLER STRUCTURE ................................................................ 12
1-4.1. Main Components .......................................................................................................... 12
1-4.2. Fuel Truck Controller General Configuration ............................................................... 14
1-4.3. Fuel Truck Controller Main Components Location ....................................................... 15
1-5. AVAILABLE CONFIGURATIONS ................................................................................. 16
1-5.1. General ........................................................................................................................... 16
1-5.2. Vehicle Identification System – FuelPoint PLUS.......................................................... 16
1-5.3. WGT External Box – Optional ...................................................................................... 16
1-5.4. Safety Barriers ............................................................................................................... 17
1-5.5. Modem/Router ............................................................................................................... 18
1-5.6. External TAG Reader (OrTR)........................................................................................ 18
1-5.7. Fuel Truck Controller with OrTR and WGT ................................................................. 19
1-5.8. Fuel Truck Controller - Standard Models ...................................................................... 20
1-6. SECURITY AND PROTECTION ..................................................................................... 21
1-6.1. General ........................................................................................................................... 21
1-6.2. Authorization Security ................................................................................................... 21
1-6.3. Network Security ........................................................................................................... 21
1-6.4. RF Network Security ..................................................................................................... 21
1-6.5. Maintenance Security ..................................................................................................... 21
1-6.6. RTC Backup ................................................................................................................... 21
1-7. HOUSING .......................................................................................................................... 21
1-8. SPECIFICATIONS ............................................................................................................. 23
1-9. STANDARDS .................................................................................................................... 23
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Paragraph
Page
1-9.1. Communication Standards ............................................................................................. 23
1-9.2. Security Standards .......................................................................................................... 24
1-10. MANUAL STRUCTURE ................................................................................................... 25
1-11. USING THIS MANUAL .................................................................................................... 26
1-12. REFERENCES ................................................................................................................... 27
SECTION 2 PRELIMINARY INSTALLATION INSTRUCTIONS
2-1. GENERAL .......................................................................................................................... 28
2-2. PRELIMINARY INSTALLATION INSTRUCTIONS ..................................................... 28
2-2.1. General ........................................................................................................................... 28
2-2.2. Precautions and Safety Notes ......................................................................................... 29
2-3. CONDUITS INSTALLATION .......................................................................................... 29
2-3.1. General ........................................................................................................................... 29
2-3.2. Conduit Requirements .................................................................................................... 29
2-3.3. Type of Conduits in the Truck ....................................................................................... 30
2-3.4. Wiring Openings in Fuel Truck Controller .................................................................... 31
2-3.5. Conduits Installation Procedures .................................................................................... 31
2-4. CABLES ............................................................................................................................. 31
2-4.1. General ........................................................................................................................... 31
2-4.2. Cable Types .................................................................................................................... 32
2-4.3. Cables Routing ............................................................................................................... 32
2-5. Electrical System ................................................................................................................ 33
2-5.1. External Fuse .................................................................................................................. 33
2-5.2. Fuel Truck Controller Power System ............................................................................. 33
2-6. GROUNDING AND SHIELDING .................................................................................... 34
2-7. CONNECTIONS TO FUEL TRUCK CONTROLLER ..................................................... 35
SECTION 3 INSTALLATION PROCEDURES
3-1. GENERAL .......................................................................................................................... 37
3-2. INSTALLATION SPECIFICATIONS ............................................................................... 37
3-2.1. General ........................................................................................................................... 37
3-2.2. Precautions and Safety Notes ......................................................................................... 37
3-3. FUEL TRUCK - OVERVIEW ........................................................................................... 38
3-3.1. General ........................................................................................................................... 38
3-4. MAPPING THE TRUCK ................................................................................................... 39
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3-4.1. General ........................................................................................................................... 39
3-4.2. Locating all objects of the fuel truck ............................................................................. 39
3-4.3. Assigning Logical IDs ................................................................................................... 39
3-5. INSTALLING THE FUEL TRUCK CONTROLLER ....................................................... 40
3-5.1. Installation Assembly Parts ............................................................................................ 40
3-5.2. Preliminary Procedures .................................................................................................. 41
3-5.3. Fuel Truck Controller Installation in Driver's Cabin ..................................................... 41
3-5.4. Determining the Spot Installation Fuel Truck Controller with Shock Absorber Assembly41
3-5.5. Shock Absorbers Assembly - Installation Procedures ................................................... 42
3-5.6. Fuel Truck Controller Installation Assembly ................................................................ 43
3-6. INSTALLATION OF FUEL TRUCK CONTROLLER WITH WALL MOUNT KIT ..... 44
3-6.1. Installation Assembly Parts ............................................................................................ 44
3-6.2. Installation Procedures ................................................................................................... 44
3-7. WIRING ............................................................................................................................. 46
3-7.1. General ........................................................................................................................... 46
3-7.2. Wiring Requirement ....................................................................................................... 46
3-7.3. Wiring Procedures ......................................................................................................... 46
3-7.4. General ........................................................................................................................... 46
3-7.5. Mechanical Pump – Terminal Block - Pin-Out Connections ........................................ 47
3-8. PUMP - REQUIRED CONNECTIONS ............................................................................. 51
3-9. WIRING THE PERIPHERALS ......................................................................................... 52
3-9.1. Valve Wiring .................................................................................................................. 52
3-9.2. Pulser Wiring ................................................................................................................. 53
3-9.2.1. Electronic Pulser ....................................................................................................... 54
3-9.2.2. Mechanical Pulser ..................................................................................................... 54
3-9.3. In-Use Switch ................................................................................................................. 55
3-9.4. Nozzle Installation ......................................................................................................... 56
3-10. WIRING TO GENERAL COMPONENTS ....................................................................... 56
3-10.1. Connection to Barrier Set within the Pump (Optional).................................................. 56
3-11. ONGOING TRANSACTION INDICATION .................................................................... 57
3-12. POST-INSTALLATION CHECKLIST ............................................................................. 57
3-13. FUEL TRUCK CONTROLLER SETUP ........................................................................... 57
SECTION 4 PRINTER
4-1. GENERAL .......................................................................................................................... 58
4-2. DESCRIPTION .................................................................................................................. 58
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4-3. SPECIFICATIONS ............................................................................................................. 59
4-4. PRINTER INSTALLATION .............................................................................................. 59
4-5. PRINTER SETUP ............................................................................................................... 61
4-6. MAINTENANCE ............................................................................................................... 65
4-6.1. Paper Roll Replacement ................................................................................................. 65
4-6.2. Cleaning ......................................................................................................................... 65
SECTION 5 MAINTENANCE
5-1. GENERAL .......................................................................................................................... 66
5-2. TROUBLESHOOTING ...................................................................................................... 66
5-2.1. Fuel Truck Controller Troubleshooting ......................................................................... 66
5-2.2. Communication Troubleshooting ................................................................................... 72
5-3. CLEANING ........................................................................................................................ 75
SECTION 6 GLOSSARY
6-1. FUELOMAT GLOSSARY ................................................................................................. 76
6-2. COMMUNICATION GLOSSARY .................................................................................... 77
APPENDIX A WIRING DIAGRAM
APPENDIX B SITE SURVEY FORM - EXAMPLE
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LIST OF ILLUSTRATIONS
Figure
Page
Figure 1-1. Fuel Truck Controller - General View with Shock Absorber Assembly .......................... 8
Figure 1-2. Fuel Truck Controller on a Fuel Truck - General Configuration Diagram .................... 10
Figure 1-3. Internal Configuration Diagram – Mechanical Pump..................................................... 14
Figure 1-4. Fuel Truck Controller Internal Components Location ................................................... 15
Figure 1-5. Wireless Gateway Terminal (WGT) ............................................................................... 17
Figure 1-6. Tag Reader (OrTR) ......................................................................................................... 18
Figure 1-7. Fuel Truck Controller with OrTR ................................................................................... 19
Figure 1-8. Fuel Truck Controller with OrTR and WGT ................................................................. 19
Figure 1-9. Fuel Truck Controller - General View with Shock Absorber Assembly ........................ 22
Figure 1-10. Shock Absorber - Detail ............................................................................................... 22
Figure 2-1. Fuel Truck Controller Wiring Openings ......................................................................... 30
Figure 2-2 Power Supply – Block Diagram ..................................................................................... 34
Figure 2-3 Cables Shielding ............................................................................................................. 34
Figure 2-4 Fuel Truck Controller Terminal Block, Power and LAN Connections .......................... 35
Figure 3-1. Fuel Truck Controller with Mechanical Pumps – System Diagram .............................. 38
Figure 3-2 Shock Absorber Assembly – Installation Holes ............................................................. 42
Figure 3-3 Fuel Truck Controller with Shock Absorber Assembly – Installation Holes ................. 43
Figure 3-4 Installing Fuel Truck Controller on Shock Absorber Brackets – Installation Holes ...... 43
Figure 3-5 Rear Panel Support Holes ............................................................................................... 45
Figure 3-6 Wall Bracket, Installation Example ................................................................................ 45
Figure 3-7 Wall Bracket, Dimensions (mm) .................................................................................... 45
Figure 3-8 Terminal Lug .................................................................................................................. 46
Figure 3-9 Terminal Block ............................................................................................................... 49
Figure 3-10 Terminal Block – Mechanical Pump - Wiring List Label ............................................ 49
Figure 3-11 Terminal Block – Mechanical Pump - Wiring List Label Installed ............................. 50
Figure 3-12. Fuel Truck Controller Mechanical Pump - Terminal Block Detailed Connections ..... 53
Figure 3-13 Terminal Block and 3-Wire Pulser – Wiring Connections ........................................... 54
Figure 3-14 Terminal Block and 2-Wire Pulser – Wiring Connections ........................................... 55
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LIST OF ILLUSTRATIONS
Figure
Page
Figure 3-15. In-Use Switch ................................................................................................................ 55
Figure 3-16 Terminal Block – Barrier Inside Pump Wiring Link (Axial Barrier) ........................... 56
Figure 4-1. Mobile Printer – Main Components............................................................................... 58
Figure 4-2. Printer Harnesses ........................................................................................................... 60
Figure 4-3. OrCUAdministrator – Serial/Modem Settings Screen ................................................... 61
Figure 4-4. OrCUAdministrator – System Information Screen ........................................................ 62
Figure 4-5. SiteOmat – Buses Dialog Box ....................................................................................... 63
Figure 4-6. SiteOmat – Printers Dialog Box..................................................................................... 64
Figure 4-7. Paper Roll Direction....................................................................................................... 65
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LIST OF TABLES
Table
Page
Table 2-1. Conduits into Fuel Truck Controller ............................................................................... 31
Table 2-2. Fuel Truck Controller, Cables Type................................................................................ 32
Table 2-3. Fuel Truck Controller, Cables Routing ........................................................................... 33
Table 2-4. Nozzles to Fuel Truck Controller, Cables Routing ......................................................... 33
Table 3-1. Fuel Truck Controller, Installation Assembly Parts ........................................................ 40
Table 3-2. Fuel Truck Controller, Assembly Parts ........................................................................... 44
Table 3-3. Fuel Truck Controller Terminal Block - Mechanical Pump – Connections Definition .. 47
Table 4-1. Mobile Printer Specifications .......................................................................................... 59
Table 4-1. Fuel Truck Controller Troubleshooting ........................................................................... 66
Table 4-2. Communication Troubleshooting..................................................................................... 73
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SECTION 1
GENERAL DESCRIPTION
This manual is provided to assist you in installing – Gasboy’s Fuel Truck Controller. The system
must be installed as described in this manual to ensure the system reliability and proper operation.
This manual includes a general and functional description of the Fuel Truck Controller and its main
components. It also provides the installation procedures for the Fuel Truck Controller.
This manual is intended for qualified authorized installers of the Fuel Truck Controller and its
components.
Fuel Truck Controller is a fuel control and data acquisition system. Fuel Truck Controller system is
a self-contained weather-resistant cabinet installed on fuel trucks used as mobile refueling station.
Fuel Truck Controller (see Figure 1-1) is a core component in Gasboy’s solution for mobile
refueling stations. Fuel Truck Controller provides the central function of the mobile site controller.
It also fulfills other essential services on site such as Vehicle/Driver Identification System,
Transaction data storage, devices control and more.
Figure 1-1. Fuel Truck Controller - General View with Shock Absorber Assembly
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Fuel Truck Controller system is a mobile Fleet Management System. The system controls, monitors
and stores on-the-spot refueling data by tanker truck for customers with large land moving
equipment. The system is suitable for a large range of home base customers.
The system consists of a Controller mounted on the truck and Vehicle Identification Units (VIU)
installed on the fleet vehicles.
Fuel Truck Controller enables refueling of vehicles equipped with VIUs only. The vehicles fuel
inlet must be positioned in the proximity of the fuel pump nozzle, ensuring end-to-end
authentication of the vehicle, meaning that only authorized vehicles get fuel. After providing fuel,
the system registers the transaction data (see Figure 1-2).
The heart of the mobile solution is the Orpak Controller Unit (OrCU) operating with the SiteOmat
automation software. SiteOmat runs on an embedded operating system. OrCU is a hardware
platform designed to survive 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 transients and noise
immunity. The system also includes power fail recovery mechanisms.
Vehicle Identification is an essential feature for maximal control and savings on fuel expenditure.
The dispenser is authorized to refuel 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. A combined vehicle and driver identification is also possible for tight tracking.
Remote Web-based capabilities for monitoring, management and maintenance are available. A
standard PC with Internet Browser (Explorer) is used for remote management of Fuel Truck
Controller. There is no need for special purpose management software thanks to the built-in Web
server technology integrated into Fuel Truck Controller.
Centralized management is provided by the optional Fleet Head Office server. The Fleet Head
Office consolidates the data from multiple sites and generates reports, including exception reports.
It also enables control of the limits and restrictions placed on the various fleet vehicles.
Furthermore, authorized fleet personnel are able to log-in remotely and are always in control.
Control of a fleet’s fuel consumption can be maximized by defining limits. Optional limits include:
volume per day/week/month, fuel type. In case of communication failure, the specific site will be
able to refuel for a predefined grace period (parameter) using the most recent limits stored in its
database.
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The Fuel Truck Controller provides features for a comprehensive mobile refueling station
management by enabling a large variety of communication links: Cellular, dial-in modem, WiFi,
radio modem and satellite.
Figure 1-2. Fuel Truck Controller on a Fuel Truck - General Configuration Diagram
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An example of an operational workflow for self-service at the Fuel Truck Controller site is provided
below:
The Fuel Truck Controller equipped fuel truck arrives at the construction site to refuel its fleet
vehicles. All fleet vehicles equipped with FuelPoint PLUS devices. The operator inserts the nozzle
into a vehicle fuel inlet and waits for authorization. Truck data is automatically read and stored in
the Controller for authentication and authorization. Upon approval, the fueling transaction starts, at
the end of which the transaction data is kept internally until transferred to the Head Office (HO) for
future billing.
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Following is a short description of the Fuel Truck Controller main sub units:
Orpak Controller Unit (OrCU)
Orpak Controller Unit (OrCU) is a complete controller with its
own embedded operating system. The unit consists of an
embedded hardware platform with a solid state Flash hard disk,
Real Time Clock (RTC) with backup, along with surge
suppressors for transient and noise immunity
It features two separate and isolated networks (TCP/IP over
Ethernet). One network links the Fuel Truck Controller system
components. The second network is intended for external
remote communication (Head Office, 3rd party systems). This
network is protected by SSL security.
OrCU includes a built-in server for Web access trough an internet browser (Explorer).
8-Port CommVerter
The 8-Port CommVerter is the communication interface
to the peripheral pumps. It consists of communication
modules for the mechanical pump elements. The
CommVerter includes one MPI-C card and sub card for
interface to two mechanical pumps, an Ethernet Switch.
The CommVerter communicates with the Site Controller
(OrCU) via a LAN (Ethernet) link.
Micro Vehicle Identification Transceiver (uVIT) (Optional):
The uVIT reads Orpak’s vehicle identification
components through the VIRO Receivers (Receiver
coil) installed on the hose nozzle equipment. The uVIT
supports up to eight VIRO Receivers. The connection
to the VIRO receiver must be done through an
intrinsically safety barrier. The uVIT performs the first
level of authentication by decrypting the string
transmitted from the vehicle. As an option for several
applications, the uVIT includes some capabilities for
peripheral equipment interface.
The uVIT is connected to the system via a LAN (Ethernet) link.
Optional Mobile Printer
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Fuel Truck Controller includes an optional Mobile Printer. Installed in
the driver's cabin and directly connected to the Controller Unit viva
RS-232 link, this compact device prints out all fueling transactions.
The Mobile Printer includes two LED indicators on the front panel:
Green: Power On
Red: Out of paper
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Figure 1-3 shows a general configuration diagram of Fuel Truck Controller.
Figure 1-3. Internal Configuration Diagram – Mechanical Pump
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Figure 1-4 shows the location of the main components of Fuel Truck Controller.
Figure 1-4. Fuel Truck Controller Internal Components Location
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The Fuel Truck Controller is available in several configurations, in accordance with its intended use
and with the components installed. All configurations are manufactured in accordance with specific
customer request.
The following paragraphs describe the several configurations, and their devices composition.
The following options are available for vehicle identification:
Wireless Gateway Terminal (WGT) – with this terminal, the vehicle identification process
is performed in a wireless mode.
Micro Vehicle Identification Transceiver (uVIT) – Orpak’s wired vehicle authorization
system.
No vehicle identification unit: The vehicle identification process will be done manually by
the truck driver with any accepted authorization devices such as cards, or tags. This option
will require external tag reader connected to Fuel Truck Controller (refer to paragraph1-5.6).
The Wireless Gateway Terminal (WGT) receives DataPass, FuelOpass and VIU signals, decrypts
their information and transmits it to the Station automation system (OrCU) 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 a big truck/bus). The transmission signal range is 10 meters.
The WGT is designed to be installed in a designated external box on the truck on the side facing the
fueling elements. The WGT will be connected to the Fuel Truck Controller box using CAT5E
cable. More than one WGT external boxes can be mounted on one truck for better RF area
coverage. In this case one WGT box will be Master and the other(s) will be routers. For further
details, see WGT External Installation Guide, document no. MDE-4815
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Figure 1-5. Wireless Gateway Terminal (WGT)
The units that provide data to the WGT are:
DataPass - DataPass is a miniature unit that connects to the vehicle bus and captures data
from the vehicle CPU/BUS. It then transmits this data to the nearest Wireless Gateway
Terminal (WGT) in the forecourt.
FuelOpass - FuelOpass is a passive vehicle identification tag for refueling. Its encrypted
data includes the account to be charged and is read by the Nozzle Reader device using RFID
contactless technology.
VIU - VIU is an active Vehicle Identification Unit for refueling. The data includes odometer
and engine hour meter.
Nozzle Reader (NR) - Nozzle Reader is a self contained unit installed on the nozzle which
reads the FuelOpass data using contactless technology.
To obtain maximal grid availability, several WGT units can be installed to create a robust 'mesh'
network.
Safety Barriers are required in the truck whenever the Fuel Truck Controller includes an uVIT.
uVIT is electrically connected to the transceiver coil of the nozzle. This coil is intended for use in
potentially explosive atmosphere. Therefore the connection between these devices must be done
via an intrinsically safe barrier. Consequently, the truck must be equipped with an external Barriers
Box. The barriers in use depend on the geographical location of the installation:
Barriers and nozzle rings must be installed on dispensers as UL Listed by Report Retrofit
kits prior to the installation of the Fuel Truck Controller.
P/N 808012500 Barrier4 (Atex – For all regions except North America)
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Please consult your local cellular service provider for the type of router supported in your area. The
router will be provided from your service provider with proper installation instructions. The router
will be connected to the LAN input in OrCU box.
OrTR (P/N 800910910) - OrTR (Orpak Tag Reader) receives Orpak tag signals for refuel
authorization purpose. OrTR transmits the information to the Station automation system (OrCU)
over a CAT5E or RS-485 cable. OrTR contain LCD with 2 lines display. OrTR is designed to be
installed in a non hazardous, convenient and secured area in accordance with local state regulations.
In the vehicle two installation alternatives are available:
External box in any non hazardous area. This installation mode requires a dedicated
mounting bracket. Such an installation shall be performed within safety distances required
for any installation adjacent to dispensers.
Installed beneath Fuel Truck Controller box with mounting bracket (P/N 814930300)
For further details, see OrTR Installation Guide, document no. MDE - 4816.
Figure 1-6. Tag Reader (OrTR)
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Figure 1-7. Fuel Truck Controller with OrTR
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In this configuration (see Figure 1-8), the Fuel Truck Controller encompasses most types of
authorization devices. The Wireless Gateway Terminal (WGT) provides vehicle identification
process in wireless mode while Orpak Tag Reader (OrTR) reads Orpak tag signals to complete any
transaction.
WGT communicates with Fuel Truck Controller over the LAN (CAT5E cable) and is powered
directly by Fuel Truck Controller. RF transmission of data from WGT enables sending data of all
transactions to the Station controller.
Figure 1-8. Fuel Truck Controller with OrTR and WGT
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Table 1-1. Fuel Truck Controller - Standard Models
Name
Gilbarco P/N
Orpak P/N
Fuel Truck Control Unit for 2 hose
PA039600200
800938901
Fuel Truck Control Unit for 4 hose
PA039600400
800938902
Table 1-1 define all the available product numbers for the different configurations of Fuel Truck
Controller:
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11--66.. SSEECCUURRIITTYY AANNDD PPRROOTTEECCTTIIOONN
11--66..11.. GGeenneerraall
11--66..22.. AAuutthhoorriizzaattiioonn SSeeccuurriittyy
11--66..33.. NNeettwwoorrkk SSeeccuurriittyy
11--66..44.. RRFF NNeettwwoorrkk SSeeccuurriittyy
11--66..55.. MMaaiinntteennaannccee SSeeccuurriittyy
11--66..66.. RRTTCC BBaacckkuupp
11--77.. HHOOUUSSIINNGG
The transaction activities of the Fuel Truck Controller are secured and protected for transmission
and authorization activities.
The contact-less tags include Triple DES encrypted data for user identification and billing.
Consequently, the Fuel Truck Controller includes a special Security Application Module (SAM) for
decryption and matching identification. Upon tag reading, the Fuel Truck Controller attempts to
decrypt the string from the tag. The Fuel Truck Controller disregards Tags whose security scheme
does not match the Fuel Truck Controller internal SAM.
The Ethernet LAN is isolated from the external WAN by the Site Controller (OrCU). In case of
remote maintenance, a firewall should be applied either at the router level or preferably at the Home
Base Station level.
The Fuel Truck Controller EIA 802.15.4 RF network is encrypted, using the AES 128 security
standard.
The Fuel Truck Controller maintenance and setup procedures require inserting a user name and
password for access. For further information, please refer to the SiteOmat station controller Setup
Manual, P/N MDE-4817
Fuel Truck Controller is locked by key to prevent unauthorized access to the bypass switches and
controller electronics.
The Real Time Clock backup is based on a maintenance free 1 Farad supercapacitor. Backup time is
3 to 6 days before time and date loss.
Fuel Truck Controller enclosure is a weather-proof metal cabinet, able to sustain the harsh
environment of the Island. The Fuel Truck Controller is installed with a rear shock absorber
assembly that dampens vibrations from truck and road (see Figure 1-9).
The overall structure is installed vertically on any flat surface and secured with eight screws. See
anti-vibration shock absorbers in Figure 1-10.
Fuel Truck Controller is locked by key for safety and security. The key should be kept in a wellkept, secure and safe place.
Fuel Truck Controller Manual
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