Gasboy Gilbarco Interface Unit User Manual

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Gasboy® CFN Series

Gilbarco Interface Unit

Installation Manual

Firmware Version 2.1

part number: C01745

Gasboy International LLC

Gasboy CFN Series

Gilbarco Interface Unit

Installation Manual

Firmware Version 2.1

August 7, 2003

C01745

Gasboy International LLC

Lansdale, Pennsylvania

Gasboy International LLC

P. O. Box 309

Lansdale, PA 19446

Printed in the United States of America.

The information in this document is confidential and proprietary. No furth er disclosure thereof 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 i ts use, nor for any infringements of patents or other rights of third parties resulting from its use. We reserve the right to make chang es at any tim e without notice.

REVISION RECORD OF THIS DOCUMENT

Part No. Date Published SC II Release Levels

C01745 April, 1996 Version 2.0 & above C01745 October 2, 1997 Version 2.0 & above C01745 October 19. 2000 Version 2.3 & above C01745 August 7, 2003 Version 2.3 and above

Site Controller II Related Publications

Site Controller - versions 2.3 and 3.3 and above

Part No. Title

C09212 SC II Manager’s Manual, version 2.3 C01918 SC II Installation Manual, version 2.3 C09213 SC II Configur ation Manual, version 2 .3 C09159 SC II Pocket Reference, version 2.3 C35920 CFN3 Manager’s Manual for Windows NT, version 3.3 C09326 CFN3 Configuration Manual for Windows NT, version 3.3 C35921 CFN3 Pocket Reference C09204 Check Point Reference Manual C35745 Profit Point Clerk’s Manual C35746 Profit Point Reference Manual C35923 Point of Sale and Shift Change, version 003

Credit and Debit Card Networks

C35931 Amoco/DataCard C35907 Gascard C35901 Buypass C35909 Generic Dial C35914 ADS-Chicago (formerly SPS/Phillips) C35908 PaymenTech (formerly Gensar) C35902 ADS-CITGO C35910 NaBANCO C35906 ADS-FINA C35911 NDC C35919 ADS-ZION C35913 Sinclair C35904 EDS-CCIS C35915 T-Chek C35903 Comdata C35916 UFDA C35905 FDR C35917 VDOT C35930 Gasboy Dial C35918 VisaNet

Pump Interface

C09146 Pump Interface Manual C01745 Gilbarco Interface Unit C35849 SDI/Wayne CAT Interface C35924 SDI/Unitec Interface C35933 Insight Interface

Card Encoding and Miscellaneous

C09136 CFN Series Clubcard Format C01687 CFN Series Card Encoding Manual

Remote Communications

C09141 PC/SiteControl User’s Manu a l

Technical Public ations

C01759 CFN Diagnostic Manual

Gilbarco Interface Unit v2 .1 Table of Contents iii

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

The Gilbarco interface unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Differences between interface versions 1.2 and 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Differences between interface versions 2.0 and 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Potential problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cash/credit buttons and more than two price levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Many price levels on multiple hose units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Measured totals for blended products not available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cash/credit select and Site Controller I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Gallon cutoffs on multiple hose or fuel units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Large gallon limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Product restriction on multiple hose or fuel units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Volume display at Check Point or Profit Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Advantage version 70.1 firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

MPD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

MPD Pro Blender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Modular MPD-3 version 53.7 firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Multiple price levels on other Gilbarco pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Incompatible pump firmware releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Loading Master Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Network Key Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Contract Prices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

More than 16 CRINDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Blenders and Gascard Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Don’t leave GSM powered down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Broadcast messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Grade restrictions with pre-Advantage MPDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Six-digit money on some pumps, five-digit on others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

What to do first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Things to watch out for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Correct the indicated CRIND two-wire address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Don’t use gallon lim its on multi-fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Use $999 limits only with cash/credit select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Use only grade 1 with Highlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Set correct level at price bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Use reader AUTO YES only with CRINDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Install K5 and K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Do memory reset before checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Starting up the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Determine programming information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gasboy CFN Series

iv Table of Contents Gilbarco Interface Unit v2 .1

Worksheet Heading Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Other configuration in formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CRIND keypad programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Switch settings for interface unit CPU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIP switch bank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIP switch bank 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DIP switch bank 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Site Controller configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Prepare PUMP.BIN data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Prepare READER.BIN data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Program the Site Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Program the dispensers and CRINDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Program the interface unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

CPU board jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Current loop board jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CPU board DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect and test the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Power wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

RS485/422 site wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

RS485/422 CRIND wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Current loop pump wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GSM Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Initial power-up and checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

If the system does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Transferring from Gilbarco console to Gasboy interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

POS says PUMP BUSY on START key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Receipt lines wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pumps work but prices won’t program correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Interface suddenly begins giving unexpected results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Messages on wrong CRIND or wrong pump activates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Single pump won’t come up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Site reports wrong fuel or wrong dollar amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

MPDs will pump only zero-quantity transactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Zero quantity transaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unassigned Transactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Interface to distribution box current loop wiring (pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Interface to distribution box RS485/422 wiring (CRINDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Site controller to interface RS485/422 wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Interface to GSM RS232 wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

AC power inlet and fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Front panel CPU LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Current loop driver board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

P1 and P2 current loop connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Building a dual input mode distribution box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Data monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Data monitor commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Command: h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Gasboy CFN Series

Gilbarco Interface Unit v2 .1 Table of Contents v

Command: w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Command: m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Command: sn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Command: n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Command: <space> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Command: ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Gasboy CFN Series

vi Table of Contents Gilbarco Interface Unit v2 .1

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Introduction 1

1 Introduction

This manual is for technicians and field engineers setting up Gilbarco pumps and CRINDs with Gasboy systems. The equipment discussed here is the Gasboy Gilbarco Interface Unit P/N C05688, with firmware version 2.1.

This Introduction chapter provides a brief description of the Gilbarco interface unit, and

offers a few preliminary thoughts.

The Installation chapter is for setup. Some material here is covered from a different

perspective than in chapter three.

The Hardware chapter describes the hardware, switch settings, and so on. This chapter is for

reference. If you need to understand how to choose switch settings, go to chapter two.

The Data monitor chapter describes in part the data monitor program, which provides

means to diagnose operation of the data ports.

Caution

Please read and understand the Gilbarco installation manuals for your pumps and CRINDs. If you install or service Gilbarco equipment, it is your responsibility to understand and follow Gilbarco’s instructions.

Gilbarco equipment is provided without warranty. We would prefer that you obtain all such information from Gilbarco if possible.

Terms

Dispenser: one enclosure and its contents servicing one or tw o fueling positions. A single-sided dispenser has displays on only one side, or sometimes a hose on one side and identical displays on both sides, but it can serve only one customer at a time, and it appears to the operator as one pump. A dual dispenser has independent displays on two sides, and can serve two customers at the same time. Such a dispenser appears to the operator as two pumps.

GSM: Gilbarco Security Module. Provides DES encryption for up to 16 CRINDs. Pump: equipment that provides fuel to one customer at a time. As used here, one dispenser may

contain more than one pump. This varies from the standard use of pump. However, it is consistent with common usage in the fueling industry.

Main price display: the price display nearest the dollar and volume total displays. This display shows only the single price used in calculating dollar total from volume total. All retail pumps have a main price display.

Price bar: the row of price displays found on some multi- fuel or multi-hose pumps, located near the hoses or the grade selection buttons. Distinguished from the main price display by association with a single fuel grade or hose. Prices on the p rice bar may remain on d isplay during a sale, or may be blanked, except for the price for one fuel or grade.

Any information which might be provided by Gasboy concerning installation or service of

Gasboy CFN Series

2 Introduction Gilbarco Interface Unit v2.1

Dual price bar: a price bar that shows two different prices, for instance cash and credit, at the

same time.

Alternating price bar: a pr ice bar that shows two different prices, for instance cash and credit,

alternately. A dual or alternating price bar may sometimes be required, but it restricts options for

pricing at the site where it is used.

When we mention dual price bar in this manual, the remarks apply equally to alternating

price bars.

Price code: a Gasboy code for a single set of prices, one price per method of payment, that may

be applied to a fuel, grade, or product.

Price level: a Gasboy code that distinguishes between the differ ent prices found in one price code

set. Values of price level are associated with tender types as follows: price level 1 is for cash,

price level 2 is for credit. Price level 3 is for debit, levels 4 and 5 for fleet or club cards, while

level 0 is the standard fallback price that appears on the main price display when the pump is

idle. Levels 0 to 5 will appear on the main price display. Additional price levels may also be used,

but will not appear on any price display.

The Gilbarco interface unit

The Gasboy Gilbarco Interface Unit allows a Gasboy Site Controller II to control up to 8 dual or

16 single-sided Gilbarco dispensers. Cash/credit selection switches m a y be installed on the

pumps, but not delivery selection switches. Each side of each dispenser may have a Generic

CRIND attached. A GSM (Gilbarco Security Module) may be connected to provide DES

encryption services for the CRINDS on an Interface Unit.

No provision is made to support the Major Oil Company (MOC) CRIND. This differs from the Generic CRIND, which we support, in the CRIND firmware and in the electrical connections to the rest of the system. If CRINDs are used, you must use the Gasboy CFN Site Controller II with software revision 2.0B or greater.

CRINDS must contain the Z-180 CPU board, Gilbarco part number T177-64-G1S, revision C or higher, with firmware K93744-02.

One or more Gilbarco Universal Distribution Boxes are required. Pumps are controlled from the interface box using a current loop connection to a distribution box, while CRINDs are controlled using an RS485/422 connection to a distribution box.

For installations w ith eight or fewer pumps, a single di stribu tion box may be asse mbled from parts that controls both pumps and CRINDs. See the discussion near the end of the chapter.

An RS485/422 port connects the interface unit to the Gasboy Site Controller II. The Site Controller senses an array of pump control units, with one or two pumps on each unit, and an array of reader terminals. Switches inside the interface unit determine the pump control unit number and reader terminal number each array begins with.

If there are no cash/credit select b uttons or dual p rice bars on any pumps on an interfa ce box, you may use any number of price l evels, subject to weights and measures cons traints. Onl y levels 0 to 5 will appear at the pump displays.

If there are cash/credit select buttons or dual price bars on any pump, you may use, at most, price levels 0, 1, and 2, and in addition, level 0 (fallback) must be identical with either level 1 (cash) or level 2 (credit).

The Gilbarco interface unit contains battery backed up memory to store transaction information in the event of a power failure. Lamps visible through a window on the front of the unit indicate battery, power, and prog ram status. Lamps in the Gilbarco distribution box indicate current loop port and RS485/422 port status. If more extensive indications of status are needed, an RS-232 port on the back of the interface unit allows connection of a terminal to run diagnostics. A switch and a fuse are located on the back of the cabinet.

Hardware

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Introduction 3

Differences between interface versions 1.2 and 2.0

In version 2 .0, the MPD Pro Blender or other models with six fuels on a side are supported. CRINDs are supported, using the spare RS485/422 port. Current loop port #2 is not used.

Version 2.0 supports a maximum of sixteen fueling positions, while version 1.2 supports 32 fueling positions. In v ersion 1. 2 the spare RS485/422 port is not used, while cur rent loop nu mber 2 supports an extra sixteen fueling positions.

Differences between interface versions 2.0 and 2.1

Version 2.1 supports the same equipment as version 2.0, and in addition, supports one GSM, connected to a serial port.

Version 2.1 supports the six-digit money option in gilbarco pumps. All pumps on an interface must be configured the same.

Potential problems

Cash/credit buttons and more than two price levels

Pumps with cash/credit select buttons may be used only with price levels 0 through 2. The combination of cash/credit buttons and many price levels is not workable.

Level 0 must be the same as level 1 for all such pumps at a site, or it must be the same as level 2 for all such pumps.

Many price levels on multiple hose units

Many price levels on multiple hose units may cause a few customer relations problems at the site, depending on the prices used. A customer awaiting activation will in some cases see a number of different prices in quick succession on the main price display, as the interface downloads new prices to the pump.

MPD, Pro Blender, Salesmaker IV, and so on, without cash/credit select buttons, may be used with price levels 0 through 5.

Measured totals for blended products not available

Product totals for blended products are maintained as totals per blend, not as totals per blended primary fuel.

Reconciliation of these totals with tank inventory must be handl ed by manual methods, outside the system. A program named BLEND.BIN is part of the s oftware fo r Si te Contr oller II , versions 2.0b and later. BLEND.BIN produces a primary fuel report by allocating recorded amounts of blended fuels back to the primary fuels, based on the intended blend ratio. If you need BLEND.BIN and it is not in your Site Controller release, check with your sales representative.

Cash/credit select and Site Controller I

Cash/credit select switches on the pump may not be used with the Site Controller I.

Gallon cutoffs on multiple hose or fuel units

Gallon cutoffs and limits should be set with caution. These are allowed on single-hose pumps, but not on others. MPD cutoff limits must be made in dollars, as the Gasboy equipment cannot arrange for volume presets on Gilbarco multi-fuel pumps. The Site Controller uses dollar limits

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4 Introduction Gilbarco Interface Unit v2.1

internally. Since the hose is not known before fuel is pumped, price is not known, so a dollar limit cannot be calculated from a volume limit.

Large gallon limits

If the activation dollar limit, calculated as activation price times gallon s, exceeds $ 994, the pump may not activate correctly. Sites that use Highlines with various presets, card limits, limitations, and so on, in gallons, have encountered this error condition shortly after price changes. The remedy here is to use a smaller gallon limit, so that the limit times the price gives less than $999 pumped.

Site Controller II version 1.0 may also experience trouble at smaller limits, usually larger than $500. Generally this is seen as sudden inability to activate pumps after a price increase. A PRINT DIAGNOSTICS command shows error counters NB4 incrementing several times per failed transaction. The remedy is to use smaller limits, or upgrade to Site Controller version 2.0.

Product restriction on multiple hose or fuel units

Product restriction can be enforced when using newer Gilbarco multi-hose or multi-fuel units. If you cannot now use product restriction on your Gilbarco MPDs, see if you can upgrade your Gilbarco pumps.

For Gilbarco Highline pumps, product restriction can be enforced , becaus e there is only one product on a pump.

Volume display at Check Point or Profit Point

Volume to be pumped and price are not shown by Check Points or Profit Points at the time of a preset or a prepay on an MPD.

from a few very old pumps. An ongoing transaction viewed on a Check Point or Profit Point will always show zero volume.

Advantage version 70.1 firmware

Gasboy equipment is partially incompatible with Advantage vers ion 70.1 firmware. Replace any Advantage version 70.1 firmware chips with current versions. Failure to do so may cause unexpected results when operating with multiple price levels.

MPD-2

The only Gilbarco Electronic pump that does not interface to the Site Controller II is the Gilbarco MPD-2.

MPD Pro Blender

The Site Controller I does not interface to the MPD Pro Blender or any Gilbarco Cash/Credit pumps.

Modular MPD-3 version 53.7 firmware

Gasboy equipment is partially incompatible with Gilbarco Modular MPD-3 version 53.7 firmware. No upgrade is available for Modular version 53.7 firmware. The problem must be worked around.

Gasboy CFN Series

Only the ongoing dollar amount is available from Gilbarco pumps. Even this is unavailable

• Use price level 1 or 1 and 2, with level 0 set the same as either level 1 or 2.

• Do not use price levels 3, 4, or 5.

• You may use price levels 6 and above.

Gilbarco Interface Unit v2.1 Introduction 5

Failure to follow these restrictions may cause unexpected results when operating with multiple price levels.

Multiple price levels on other Gilbarco pumps

Because irregularities have been found in the interaction of Gilbarco pumps and Gasboy equipment with two different versions of Gilbarco firmware, and because other versions might be affected, a test for the problem has been added to the start-up procedure.

If your site will operate with price levels other than 1 and 2, perform the procedure indicated under Test for multiprice incompatibility, near the end of the next chapter. If your site is adding price levels and you do not know whether this incompatibility exists, you should also perform this procedure.

Incompatible pump firmware releases

The following table lists various Gilbarco pump firmware versions that have potential problems with the Gasboy Gilbarco Interface and the release that corrects the problem.

Pump Affected Versions Corrected Versions

MPD 70.8.0 thru 70.8.2 70.8.3 released 8/96

MPDSH 72.1.7 thru 72.1.9 72.2.10

ASB 75.5.0 thru 75.5.1 75.5.2 released 7/96

AFB 77.4.0 77.4.1 released 7/96

ECAL 84.2.3 thru 84.2.5 84.2.6

B78 75.5.1 75.5.2 released in 7/96

B21 75.8.2 75.8.3 released in 8/96

Loading Master Key

Master Key is factory programmed into Gilbarco GSM un its. No f ield pr ogramming is available.

Network Key Parity

Gilbarco GSM enforces DES working key parity. Not all networks provide working keys with correct parity. The GSM will refuse a working key with incorrect parity.

Contract Prices

Recent versions of Gilbarco pumps incorporate changes that improve Weights and Measures compliance. A side effect of these changes makes it no longer feasible for us to blank contract prices from the main price display following a transaction.

If you use contract prices at Gasboy price levels 3, 4, or 5, be advised these prices will remain on the main display until the pump is started for the next transaction. The Gasboy “Blank after” parameter no longer has its previous effect.

More than 16 CRINDs

Gasboy’ s interface supports only 16 CR INDs per interface. The GSM will support CRINDs only on the same interface connection. Hence, you will need two interfaces and two GSMs if you have more than 16 CRINDs.

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6 Introduction Gilbarco Interface Unit v2.1

Blenders and Gascard Network

Do not use blenders, including three-product fixed blenders, with the Gascard network. This network uses hose number and will not accept hose numbers greater than 4.

Don’t leave GSM powered down

The GSM uses a non-rechargeable battery which will run down if the GSM is left in a power down state for an extended period. Immediately upon receipt of your GSM, power it up, and leave it that way.

Broadcast messages

Currently, Reader Terminal broadcast messages are not displayed on the CRINDS.

Grade restrictions with pre-Advantage MPDs

Grade restrictions, used with some club cards, will not work if you have MPDs older than Advantage MPDs. These will appear to activate under grade restriction, but will return only zeroquantity transactions.

Six-digit money on some pumps, five-digit on others

All pumps on an interface must be configured for fiv e-dig it money and interf ace SW3-6 mus t be OPEN, or else they must all be configured for six-digit money amounts and SW3-6 must be CLOSED. Failure to activate correctly or to complete with the proper amount will result if the interface DIP switch does not agree with a pump’s configuration.

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Gilbarco Interface Unit v2.1 Installation 7

2 Installation

This chapter gives a step by step procedure for installing the Gilbarco interface unit. Switch settings, cables, and so on will be discussed here in a context of their interactions and decisions that must be made. Specific and systematic detail may be found in chapter three.

At the end of chapter two there is a short section on troubleshooting that pertains also to sites that may already be in operation.

What to do first

1. Read and understand the Gilbarco manuals that apply to your pumps and C RINDs.

2. Verify that all CRIND and dispenser wiring is in place and complies with Gilbarco standards.

3. Terminate two-wire loops from the pumps in a distribution box with a current loop connection for the Gasboy CFN Gilbarco interface unit. (The pump loop is part number C06691, and the Gilbarco interface unit is C05688.)

4. Terminate two-wire loops from the CRINDs in a distribution box with an RS485/ 422 connection for the int erface un it. (T he ad aptor i s C066 92; the cabl e is C 06242; both are C06326.)

5. For installations with CRINDS and eight or fewer pumps, you may build a dual distribution box with one current loop input and one RS485/422 input. This is an alternative to using two separate distribution boxes, one with current loop input, one with RS485/422 input. Information on building such a distribution box is found near the end of Chapter 3, page 34, Building a dual input mode distribution box.

6. Install GSM and its power supply, within six feet of the Gilbarco Interface. Use Gasboy cable C07248 to connect the GSM to Gilbarco Interface GSM port, adjacent to the RS485 connectors. This port may be marked “Unused port”.

7. S et up and connect the Site Controller according to the its start-up manual. If you are using CRINDs, you must u se a Site C ontroller I I, and the software v ersion m ust be 2.0B or g reater.

8. Verify that the Gilbarco Interface Unit contains firmware version 2.0 or higher, in sockets U18 through U21.

9. Verify that the Gilbarco CRINDs have the Z-180 CPU board, Gilbarco part numbe r T177-64-G1S, revision C or greater, available as an upgrade for older CRINDs.

Things to watch out for

Correct the indicated CRIND two-wire address

For older CRINDs, CRIND jumper test diagnostic number 6, shows CRIND address applicable to Auto Gas systems only. For all other systems including Gilbarco and Gasboy systems, subtract one from the address shown there. See your CRIND manual for more information.

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8 Installation Gilbarco Interface Unit v2.1

Don’t use gallon limits on multi-fuel pumps

Multiple hose/fuel pumps may use only dollar limits. The Gasboy equipmen t does not provide volume limits for Gilbarco multiple fuel pumps, such as MPDs or blenders. This implies that a site with any such pumps may not use gallon limits as card limits.

Use $999 limits only with cash/credit select

On pumps with five-dight money configuration, use $999 as a limit only for pumps with cash/ credit buttons. Cash/credit buttons are the flashing buttons located on the pump, not the tender keys on CRINDs. Never use $995 and above as a card limit.

On pumps with six-dight money configuration, use $9990 as a limit only for pumps with cash/credit buttons. Cash/credit buttons are the flashing buttons located on the pump, not the tender keys on CRINDs. Never use $9950 and above as a card limit.

Use only grade 1 with Highlines

Program the pump grade as a Gasboy hose numb er . P er pump, pr ogram the pump assig ning grade 1 to hose 1, grade 2 to hose 2, etc.

Set correct level at price bars

If there is cash/credit pricing, make price bars sh ow pr ice level 2. This rule h as some excep tions . See Price level for price bars, below.

Use reader AUTO YES only with CRINDs

Don’t set READER.BIN program menu 3 Auto column (auto pump select) to YES for any reader that is not a CRIND, CAT, or a DPT. Auto pump select set to YES on an ICR may cause its representative pump to shut off almost immediately after activation.

Install K5 and K6

Make sure interface unit CPU board K5 and K6 are installed. Everything will seem to work fine with these missing, until the lights flicker. At that time many unexpected things can happen.

Do memory reset before checkout

Be sure to do a memory reset on the interface after you have all dispensers programmed and before you try to bring them up.

Starting up the site

Complete each of the following sections. You do not need to complete them in order, but you should make sure you have considered or performed each item mentioned.

Determine programming information

In this phase you make decisions on programming, options, switch settings, and so on. Some issues here have consequences with respect to other issues, and you may find you have to backtrack and change earlier decisions, in order to make later ones work out.

You may need Gilbarco manuals and additional Gasboy manuals to help determine exactly how to program the things discussed here.

Here is a worksheet. Make copies, and fill out one line per fueling position.

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Gilbarco Interface Unit v2.1 Installation 9

Pump Number

Pump/CRIND Worksheet

Pump type (H111, MPD-3, etc.)

Two-wire address

(individual headings discussed on the following page)

PCU number PCU slot

Number o f hoses

CRIND address

Reader number

Price levels used at site: 012345 (circle all levels used) Price at level 0 is same as price at level: 1 2 both neither (circle one) Price level for price bars: 1 2 both neither (circle one)

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10 Installation Gilbarco Interface Unit v2.1

Worksheet Heading Description

Pump number

Enter the number of a fueling position posted on the pump and shown at the Check Point or Profit Point terminal. You may assign the pump number in a way that makes s ense to the custo mers and clerks, in terms of the physical layout of the site. Pumps are often numbered so that opposite sides of the same dispenser ha ve cons ecutive num bers , b ut ot her arran gemen ts ar e also p ractical. Or, using adjacent pump numbers on the opposite sides of the same dispenser may make other site configuration simpler.

Pump type

The Gilbarco model name, such as Highline, Salesmaker II, Salesmaker IV, MPD, Advantage Blender, and so on.

Two-wire address

The pump’s two-wire address, from 01 to 16. Always assign two-wire addresses starting from number 01.

If you assign addresses 13 through 16, remember that you will need to use a non-default setting for one of the DIP switch bank 4 positions, below.

Sometimes the two-wire address is not the same as the pu mp number, though like the pump number there is one two-wire address per fueling position. Dual or double-sided units should always have consecutive two-wire address pairs, with the odd address smaller than the even address, for example 01 and 02 (not 02 and 03), or 09 and 10 (not 10 and 11).

If you can, reserve odd-even pairs of two-wire addresses for single-sided disp ensers, using the odd address and skipping the even. F or instance, you might give a single-side dispenser twowire address 09, and skip address 10, assigning address 11 to the next pump. If this is not practical you may double up single units, giving one the odd address and the other unit the even address.

Avoid splitting dual dispensers across two pump control units. This happens if you assign even-odd pairs such as 10 and 11 to the opposite sides of the same dispenser, or if the two-wire addresses you assign to a dispenser are not consecutive—for instance 9 and 12.

If you need more than 16 addresses and you are using interface firmware version 2.0 or above, you need a second interface unit. With two units, put roughly half of the pumps on each interface unit, remembering not to split any dual dispenser. Start over at two-wire address 01 for the first side of the first pump on the second unit.

Pump control unit (PCU) number

Pumps are paired onto PCUs to save line bandwidth on the Gasboy RS485/422 local loop. The two-wire address determines the PCU number, at least in part. Where all pumps at a site are Gilbarco and there are less than 16 fueling positions, pumps with the two-wire addresses 01 and 02 form PCU #1, two-wi re 03 and 0 4 form P CU #2, an d so on through t he la st pump f oun d on an interface unit.

PCU number. For instance, if you have PCU numbers 01 through 05 on the first interface unit, assign PCU 06 as the starting PCU for the second interface unit.

PCU slot

Each PCU has two slots, numbered 1 and 2. Assign each pump a PCU slot. Assign the pump with the odd address to slot 1 on its PCU, the even address, slot 2.

Gasboy CFN Series

If you have a second interface unit, assign the next available PCU number as its starting

The starting_PCU is the starting PCU number set on DIP switch bank 2, position 8-4.

Gilbarco Interface Unit v2.1 Installation 11

Number of hoses

For Highlines, multi-hose MPDs, and so on, this is the same as the number of physical hoses. For pumps that dispense different kinds or blends of fuel at different times from the same hose, this is the number of distinct kinds of fuel dispensed from the unit.

Fixed blenders may appear to have five hoses, thought they actually dispense only three products, two unblended and one blended.

CRIND address

For older CRINDs, regarding the two-wire CRIND address, you must subtract 1 from the CRIND address shown in CRIND diagnostic test number 6 to get the real CRIND two-wire address.

The real address is shown in the address jumper tables for MOC and generic CRINDs in Gilbarco publications MDE-2562 and MDE-2377. Ignore the Auto Gas Only tables you may find there.

CRINDs may be set to addresses from 1 to 32. Use addresses from 1 to 16 with Gasboy equipment.

If you can, use the pump number (the number painted on the pump, not the pump two-wire address, where they differ) as the two-wire address for the CRIND. For instance, give pump 1, CRIND 1. This will simplify maintenance later.

If you have more than sixteen fueling positions, this won’t work. You will need a second interface unit, and you will have to start over at C RIND two-wire address #1 on the second interface unit.

This second interface unit will have DIP switch bank 2, positions 4-8 set to put its first two pumps, with p ump two- wire addresse s 01 and 02, on a PCU number other than PCU number 1. Usually you start with the next PCU number not used on the first interface box.

For example, if your first interface bo x u ses PCUs 1 through 8, for sixteen fueling positions with two per PCU, then the second interface box will usually be switched to start at PCU 9.

To find the reader number of the CRIND addressed as 01 on the second interface unit:

• Begin with the interface unit’s starting PCU number, as set in DIP switch bank 2, positions 4-8.

• Take that starting PCU number and double it.

• Then subtract one.

Supposing the first PCU on the second interface unit is PCU number 9. If you double that, you have 18. Then subtract one, leaving 17. From this, the CRIND addressed as two-wire address 01 on the second interface box will appear as reader terminal number 17.

Sometimes it is desired to offset the CRIND numbers to allow island reader terminals or indoor receipt printers to answer as low-numbered reader terminals. This works at sites with only a few readers, but can run into problems at sites with many.

It is better to assign the CRIND reader numbers first, and then to assign r eceipt printer s and Gasboy Island Card Readers after that.

Reader number

This is the reader terminal number to be used by the Site Controller. As mentioned previously, this is determined by the CRIND two-wire address and the starting PCU number for the interface unit on which the CRIND is found.

The formula for determining the reader number is:

• Step 1: multiply the starting PCU number (which is set in DIP switch bank 2, positions 4-8) by 2.

• Step 2: subtract 2 from the real CRIND two-wire address (as pointed out els ewhere, the

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12 Installation Gilbarco Interface Unit v2.1

real CRIND two-wire address is one smaller than the address reported by the CRIND self-test).

• Step 3: add the result of step 1 to the result of step 2. The resulting total is the reader number.

Price levels used at site

Circle the levels used. Only the prices to be used with Gilbarco pumps, and only levels 0 through 5, count here.

Price at level 0 is same as price

Circle Level 1 or Level 2 or Neither or Both according to the way the prices are set up at the site.

If you circle Neither you must determine whether your pumps will operate correctly in this mode. Perform the procedure under Test for multiprice incompatibility, page 23. If any level 1 price differs from the corres ponding level 0 price the two levels must be treated as having different prices. Likewise for levels 0 and 2.

Price level for price bars

Price bars are the displays over the hoses, as distinct from the main price display. MPDs, blenders, and so on may have price bars. Unless only one price is used at the site, all price bars must show the same price level.

If you have no price bars on any pumps, circle None.

If levels 1 and 2 are always the same, circle 2 even if you have dual level price bars.

If levels 1 and 2 are different and you have dual level price bars, circle Both.

Other configuration information

There is some other configuration information that affects the setup of Gilbarco pumps and CRINDs with Gasboy equipment.

Fuel grade assignment for each hose

Use Gilbarco fuel grade to indicate hose number to Gasboy equipment. Thus, any pump that has only one grade on a side gets grade 1 regardless of which fuel it really pumps.

Pumps with more than one grade on a side have their grades numbered consecutively, from 1 to whatever number of hoses or grades are located on a side.

Some pumps, such as blenders and single-hose MPDs, have more than one grade per hose. These pumps are treated by the Gasboy equipment as though they had one hose per grade. Thus, a five-product blender looks to the Gasboy equipment like a five-hose MPD.

Assign a grade number to each hose. For each pump, list the hoses, with the fuels pumped and the grade (hose) numbers assigned. You may use copies of the table on the following page.

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Gilbarco Interface Unit v2.1 Installation 13

Hose/grade wo rksheet

Pump Hose Grade Fuel Pump Hose Grade Fuel

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14 Installation Gilbarco Interface Unit v2.1

CRIND keypad programming

The keys on the CRIND keypad can be configured for dif ferent fu nctions with the Tokheim DPT/ Gilbarco CRIND keyboard layout item on page 4 of the SC II’s SYS_PAR program. The characters that select different functions are shown below. Note that these characters are casesensitive:

Character Function

0-9 Numeric digits 0 through 9

. Decimal Point EENTER CCLEAR Yyes NNo $Cash inside

c Cash outside DDebit inside d debit outside B Credit (bank card) inside b Credit (bank card) outside XCancel x CLEAR/CANCEL (CLEAR if data entry started; else CANCEL) HHelp h Help/Decimal (Decimal if data started; else Help) n No/CANCEL (No if in yes / n o state; else CANCEL) SStart u unused key

The numbers of the keypad keys on the CRIND are:

12345 678910 11 12 13 14 15 16 17 18 19 20

Note that keys on the left half of the keyboard—that is, 1, 2, 3, 6, 7, 8, 11, 12, 13, 16, 17, and 18—cannot be programmed.

The default function arrangement of the CRIND keypad is:

123ub 456$B 789NY C0EHX

The string that would be typed into the Tokheim DPT/Gilbarco CRIND keyboard layout item in SYS_PAR to give the CRIND keypad function arrangement shown above is:

123ub456$B789NYC0EHX

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Gilbarco Interface Unit v2.1 Installation 15

Switch settings for interface unit CPU board

The Hardware chapter lists all switches and jumpers but does not discuss details or interactions. Choose appropriate switch settings and write them down.

DIP switch bank 2

Positions 1-3 are ordinarily all CLOSED. At certain times during startup you will be asked to open position 2 momentarily while you press RESET or cycle the power. This erases the memory in the interface unit. Positions 4-8 set the starting PCU number for the interface, as shown here:

Starting PCU Number

01 CL CL CL CL CL 02 CL CL CL CL OP 03 CL CL CL OP CL 04 CL CL CL OP OP 05 CL CL OP CL CL 06 CL CL OP CL OP 07 CL CL OP OP CL 08 CL CL OP OP OP 09 CL OP CL CL CL 10 CL OP CL CL OP 11 CL OP CL OP CL 12 CL OP CL OP OP 13 CL OP OP CL CL 14 CL OP OP CL OP 15 CL OP OP OP CL 16 CL OP OP OP OP 17 OP CL CL CL CL 18 OP CL CL CL OP 19 OP CL CL OP CL 20 OP CL CL OP OP 21 OP CL OP CL CL 22 OP CL OP CL OP 23 OP CL OP OP CL 24 OP CL OP OP OP 25 OP OP CL CL CL 26 OP OP CL CL OP 27 OP OP CL OP CL 28 OP OP CL OP OP 29 OP OP OP CL CL 30 OP OP OP CL OP 31 OP OP OP OP CL 32 OP OP OP OP OP

45 6 7 8

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16 Installation Gilbarco Interface Unit v2.1

DIP switch bank 3

Position Function 1, 2 Debug port baud rate:

OPEN, OPEN = 9600 OPEN, CLOSED = 2400 CLOSED, OPEN = 1200 CLOSED, CLOSED = 300

3 OPEN = CRINDs are on spare RS485/422 port.

CLOSED = CRINDs are on second current loop: Requires board

modifications in current loop box. Do not use.

4 OPEN = Report all events during activate. Use with SCII V 2.0B or later.

CLOSED = Hide some events during activate. Use with SCI, SCII V 2.0A and earlier.

5 OPEN = No grade restrictions

CLOSED = Restrict grades

6 OPEN = Money amounts are five digits

CLOSED = Money amounts are six digits

7-8 Reserved. All positions are normally OPEN. Position 5 is CLOSED if you wish to enable grade restrictions for fleet or club cards. This option

is available only at sites where all multi-fuel pumps are Advantage Position 6 setting must agree with the configuration of every pump on an interface.



DIP switch bank 4

Position 2 should be OPEN if you are using two-wire addresses 01 up to 12 or less on this unit, and CLOSED if you are using addresses from 01 to more than 12. The limit is 16. Positions 1 and 4 interact, and should be set according to the rules below. Apply the first rule that matches there, and skip the rest.

Note: if your site is operating with different prices loaded to levels 1 and 2, with level 0 the

same as one of the others, and you are using any multihose or multigrade pumps, you should ascertain the compatibility of your pumps with this mode of operation. Perform the procedure under Test for multiprice incompa tibility, page 23.

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Installation 17

Here is the table for positions 1 and 4; use the first rule in the table that matches your

situation:

Positions

Rule 1 4 NOTE

Only one price is used at the site OP OP There are no pump cash/credit select buttons or dual level price

bars at the site, and:(4)

Price level 0 is the same as price level 2 OP OP (1) Price level 0 is the same as level 1 OP CL (2) Price levels 0, 1, and 2 are all different, and:

There are no price bars CL OP Level 2 is on price bars CL OP Level 1 is on price bars CL CL

There are some pumps with cash/credit select buttons at the site or there are some pumps with dual level price bars, and: (4)

Any price at price levels 3, 4, or 5 differs from price at level 0

(3)

Price leve ls 0, 1, and 2 all have different prices

Price level 0 is the same as level 2 OP OP (1) Price level 0 is the same as level 1 OP CL (2)

Notes:

All

(1)

price bars must show price level 2.

All

(2)

price bars must show price level 1. (3) This won’t work, change some previous choices. (4) Pump cash/credit select buttons are the lighted buttons on pumps, not to be confused with

the payment buttons on CRINDs.

Site Controller configuration

Certain data must be loaded into the Site Controller using the PUMP.BIN or READER.B IN programs, or the Site Controller commands.

• For Site Controller II version 2.0, the Gasboy P/N C09213, and the be helpful.

• For Site Controller II version 1.0, see the Gasboy P/N C09132, and the

• For Site Controller I, see manuals C09149, C01917, and C01900. As mentioned previously, you can use pumps with Site Controller II version 1.0 but not CRINDs, and likewise for Site Controller I.

(3)

Site Controller II Configuration Manual

Site Controller II Manager’s Manual

Site Contr o ller I I Confi gurat ion Ma nual

Site Controller II System Administrator’s Manual.

, P/N C09212, will

(2.0),

(1.0),

Gasboy CFN Series

18 Installation Gilbarco Interface Unit v2.1

Prepare PUMP.BIN data

In PUMP.BIN program menu 3, pump options should be set according to the following chart. Some prepackaged sets of options may exist there, but many sites will have to add or subtract options to account for the many variations that may be found. You may have to create some new pump types to accommodate. Combine all options from this table that apply to give the set of options for a pump.

Pump, Model or Configuration Set option(s)

Pump is MPD, Blender, or Salesmaker IV 1 and 5 Pump has cash/credit select buttons 3 Pump is Gilbarco electronic pump 9 Pump is single-sided 15 Pump has press-to-start kit 17 Alert beep is desired before customer presses

payment type key on CRIND 18

Pump has grade select buttons 19

For an ordinary Highline, all you need is option 9. With cash/credit select buttons, you must add option 3, so that your list is 3 and 9.

For an ordinary MPD, the required options are 1, 5, and 9. With cash/credit select buttons,

you must add option 3, so that your list is 1, 3, 5, and 9.

If you have cash/credit select options installed on any pumps, you must set their fill limits to $999 and maximum limit to 0. This must be set in pump configuration, and also with the LOAD CUTOFF command.

Option 6 is also mentioned in PUMP.BIN. You will not need this option.

Advantage Super High special settings

Advantage Super High (model BD1) has the following PUMP.BIN configuration requirements. Side ‘B’ of the pump must have 2 hoses assigned as illustrat ed.

In Pump type - submenu 1:

# Pump type Cl Slow Fill Max Pulse Hoses

1. GILBARCO MPD 1 0.250 $50 0 1000/G 1

2. GILBARCO MPD 1 0.250 $50 0 1000/G 2

In Pump Control Units - submenu 2:

1. ELECTRONIC PCU 1:1 2:2

2. ELECTRONIC PCU 1:3 2:4

3. ELECTRONIC PCU 1:5 2:6

In Add Pump types - submenu 3:

#. GILBARCO MPD (2) 1,5,7,9

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Installation 19

Prepare READER.BIN data

In READER.BIN Menu 3, you must set Rep-pump to the pump number associated with a CRIND. Set Auto to Y es for all CRINDS, to No for any ICR, printer, or anything else that is not a CRIND DPT, or a CAT. Setting Auto to Yes for an ICR will cause unexpected deactivation of the representative pump.

Also, set the device type.

Program the Site Controller

You will need to use the LOAD TANK, LOAD PRODUCT, LOAD PUMP, LOAD FUEL, LOAD PRICE, and LOAD CUTOFF commands, in addition to configuration programs PUMP and READER. You may examine the data you have loaded using PRINT TANK, PRINT PRODUCT, PRINT PUMP, and PRINT PRICE commands, and PUMP - P and READER -P.

When loading cutoff and other limits for Highlines, be sure that if you load a gallon cutoff, the cutoff limit times the highest price that could ever be used does not give a dollar amount greater than $995, or $9950 for pumps operating with six-digit money. The pump may not activate properly if you allow gallon limit times price to exceed this.

You may also need to load your encrypted network key, using the LOAD KEY command. Consult your network provider about this.

If you are using DES for debit, you must arrange for key management.

If the CRIND is the only unit at which you take debit, you will not need to load a master key. The master key is pre-injected into the GSM at the Gilbarco factory.

If you are using Gasboy Isl an d C ard R eaders or Verifo ne PIN pad s, you w ill n eed t o ar rang e for master key injection into these units. How you do this will depend on your bank and your bank card network.

Encrypted working (network ) keys will be necessary in any case. How you load working keys will depend on your network. Y ou may be required to use the Site Controller's LOAD KEY command, or the network may supply the keys directly to the Site Controller. Consult the specific manual for your network for more information.

Program the dispensers and CRINDS

Set fuel grades, two-wire addresses, and price levels for price bars, according to the determinations made previously. You may also need to set pump cutoff limits and other information not discussed here. See Gilbarco publication MDE-2531 The

Start-up/Service Manual

instructions in MDE-2377 CRIND Electronic CD Module Installation. The two-wire address should be set as determined previously, and all other settings will be according to the generic CRIND indications there.

Some jumpers found on the CRIND CPU board when you receive it may be docum ented as Spare. These may set CRIND two-wire loop baud rate. This must be 4800 baud. Consult your Gilbarco service manual for appropriate settings.

, among other manuals. CRINDS will need jumpers set accor ding to the

Program the interface unit

If you have not done so, take a moment now and browse through chapter three of this manual, then turn back here and continue reading. There you will find illustrations to go with many of the things we discuss here.

Advantage Series

Gasboy CFN Series

20 Installation Gilbarco Interface Unit v2.1

CPU board jumpers

Make sure that K5 and K6 on the CPU board are inserted. An AC power failure will cause unexpected behavior if these jumpers are absent. Insert also K3, on the pair of K3 terminals closest and parallel to P9, and K7. CPU board jumpers K1, K2, K4, and K8 must be absent.

Current loop board jumpers

On the current loop board, t he l ower of the two boards, K1 should be in position 1 . K2 sho ul d be present. This is done at the factory, and does not need to be checked unless there are indications that this needs to be done. If you should remove the interface CPU board, when you replace the screws holding it on its standoffs, be sure that the insulated washer, if loose, is replaced on the screw at the front center of the board, near C36.

CPU board DIP switches

DIP switches should be set as follows, except as noted previously. DIP switch bank 2, position — All switches CLOSED. DIP switch bank 3 and DIP switch bank 4 — All switches OPEN.

Connect and test the installation

Power wiring

The interface unit power cord must be plugged into a grounded outlet referenced to the same earth ground as any RS485/422 j un ctio n bo xes and all other RS485/4 22 eq uipment at the site, as described in the Site Controller II Installation Manual.

The Gasboy warranty may be invalidated if wiring requirements described are not met.

RS485/422 site wiring

Make the RS485/422 wiring from the Gilbarco interface to the Site Controller ready, but do not insert the RS485/422 connector into the port on the interface unit at this time. Use cross cable C04500.

To connect two interface units to the Site Controller, use an extra Gasboy RS485/422 junction box. Connect its terminal block in parallel with the terminal block of the first junction box using a short piece of your field wiring cable. Also connect the external ground stud of the second box to the ground stud of the first or to the ground screw on the power protection unit.

RS485/422 CRIND wiring

The Gilbarco interface unit is connected to th e distribution box responsible for the CRINDs using Gasboy cable assembly C06242 and adaptor C06692, RJ-11 to DB-9P.

Current loop pump wiring

The interface unit is connected to the distribution box responsible for the pumps using Gasboy cable assembly C06691. This cable connects to P1 at the back of the Gilbarco Interfact unit.

GSM Wiring

Connect GSM to its power supply. Connect Gasboy cable P/N C07248 from the GSM to interface GSM port, which may be marked “Unused port” or “GSM port”.

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Installation 21

Initial power-up and checkout

Perform each step in order. If you get an incorrect result at any time, correct the cause before proceeding to the next step.

Power up

With the interface unit connected to the pumps and the pumps turned on, apply power to the interface unit and observe the lamps visible through the window on the front of the interface unit.

Lamp check

Two green lamps (DC and BOK) on the lower board in the interface unit should be lit. The red lamp (BAD) on the lower board should not be lit.

If no lamps are lit, the power supply is not delivering correct power. If the red lamp (BAD)

is lit, wait about a minute.

If it does not go out, the battery on the lower board is bad, the battery jumper is out, or the

battery fuse is blown. Correct the condition and try again.

Now the red light should be out, and the green light next to it should be on.

DC power check

The DC power OK lamp, to the left of the battery OK lamp, should also be lit. Even if it is, check the DC voltage at CPU board P9 pins 1 and 64. This should be 5.00 to 5.05 volts. If the voltage is not within these limits return to the factory.

If the leftmost green lamp still does not light, adjust the DC power fail potentiometer on the lower board. This adjustment may be facilitated by powering down the unit, removing the three screws on the bottom that secure the circuit boards, and raising the two boards as a unit until a screwdriver may be inserted into the adjusting shaft. Take care not to short the bottom of the current loop board to the case when you apply power. Alternately, you may use a small offset screwdriver.

Turn the potentiometer clockwise 1/4 turn then cycle power ten times using the switch on the back panel of the unit. The green LED should come on eight or nine out of ten tries. Repeat the adjustment until it does.

If the LED comes on at each of the ten tries, back the potentiometer off a little until you are able to get it to come on just eight or nine out of ten tries.

When you have completed the preceding, turn the screwdriver shaft 1/3 of a turn clockwise. Remove power and fasten the boards back into the unit, then apply power again.

Remaining interface lamp check

L9 to L12 should now all be off. If L12 alone of these is on, you have omitted K7 on the CPU board, or else U8, MID400, is burned out. Correct this. If lamps from L9 to L11 are on, the current loop interface needs repair.Note which of L9 to L12 were lit and report this to phone support. Chapter 3 Hardware, has some information about the meanings of lamps L9 to L12, under "Front panel CPU LEDs" on page 32.

At this point, you should see blinks on L1 and L5, nothing on L2-L4, L6 lit, and L7 and L8 indicating current loop status. A connected current loop will cause its associated lamp to blink.

Universal distribution box lamp check

Check the lamps in the Gilbarco distribution boxes according to Gilbarco instructions.

Gasboy CFN Series

22 Installation Gilbarco Interface Unit v2.1

GSM Lamp check

Power lamp should be on. Status l amp should show either a steady o n-off flash, or it should be on but interrupted at intervals by sequences of three or four flashes.

The GSM should NOT show a status lamp that is:

Steady off Steady on On, interrupted at intervals by ten or more flashes On, interrupted at intervals by a single flash.

If any of these patterns are observed, contact Gilbarco.

Erase interface unit memory

All checks up to this point should have succeeded. If not, go back, find the error conditions, and correct them now.

The current loop wiring to the pumps and CRINDs should be connected and set to

NORMAL at the distribution box or boxes.

Set interface unit CPU board DIP switch bank 2, position 2 OPEN and press the RESET button or cycle power off then on again. This will erase memory in the interface unit. Restore DIP switch bank 2, position 2 to CLOSED and allow the interface to operate for about three minutes with all pumps and CRINDs connected. It will then determine the arrangement of devices it is connected to. This information will ordinarily be retained indefinitely.

If it is necessary to re-address any pump s, repeat the erase in terface u nit memo ry pro cedur e.

Connect to Site Controller

You are now ready to connect the interface unit to the RS485/422 loop. Insert the modular connector on cable C04500 into the site RS485/422 PORT jack on the interface unit, then observe the interface unit lamps. You should see some activity on lamps L3 and L4 within about thirty seconds.

If neither L3 nor L4 light, there is a Ga s bo y data l oo p RS4 85/422 problem. If L3 flashes but not L4, the Site Controller is talking on the loop but the interface is not answering. Check configuration, and re-check other things up to here.

You should now see some messages about pump control units and reader terminals on the logger. PRINT DIAGNOSTICS should indicate that the expected pump control units are up.

Verify system operat io n

If you have a Check Point or a Profit Point on the system, lift each pump handle in turn, and verify the offhook indication. Us e the START key to activate each pump after you have verified switch detect for each hose on a pump.

Verify that each CRIND is up according to the diagnostics, and then verify that each C RIND keypad responds as appropriate.

A CRIND that has powered up successfully should say PLEASE PAY INSIDE on the CRIND display. When the interface successfully polls the CRIND, this message changes to <PLEASE PAY INSIDE> including the brackets. If the CRIND goes f or fifteen seconds without communicating with the interface, the brackets disappear.

With all CRINDS programmed correctly and DES working key loaded, you should be able to swipe a card that requires DES encryption. The CRIND should say, “Enter your PIN” or something similar. If instead it goes back to its initial message, for example “Press payment key” or if it says “DES not ready”, the GSM is not connected correctly or the working key is not loaded.

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Installation 23

It may take up to several minutes after the CRINDs and the GSM are connected before the CRINDs are ready to perform DES encryption. Transactions that do not require DES may proceed during this time.

Test for multiprice incompatibility

You may skip this procedure at your si te if:

• all pumps are either Highline or Salesmaker-2, or

• all pumps are Advantage with firmware 70.5 or greater, or

• every pump is one of the preceding types.

If you are changing over from single price or cash/credit pricing to additional prices at levels 3, 4, or 5, and you have not previously performed this procedure, you should perform it now.

If your site will operate with only one price level, or with cash and credit pricing and level 0 same as either cash or credit, you may skip this procedure. For this decision, prices at level 6 and above do not count.

Do not perform this test while the site is open for business.

1. On the interface CPU board note the settings of DIP switch bank 4, positions 1 and 4, then change them to position 1 CLOSED and position 4 OPEN. Press RESET on the interface unit.

2. For one pump of each multihose or multigrade variety , load price levels 0, 1, and 2 each with different and unique prices.

3. S elect a pump under test and press START on the Check Point or Profit Point.

4. Raise the leftmost pump handle. Pump a very small amount of fu el. Lower t he handle.

5. Press CASH then START on the Check Point or Profit Point.

6. Raise a different pump handle and pump a small amount of fuel. Note whether the price shown on the pump is the expected cash price for the fuel pu mped. If not, you may not operate this pump in multiprice mode, except for cash and credit prices.

7. Lower the handle and print a receipt.

8. Determine whether the total amount shown on the receipt agrees with what was shown on the pump. If not, you may not operate this pump in multiprice mode, except for cash and credit prices.

9. Restore DIP switch bank 4, positions 1 and 4 to their previous settings and press RESET on the Current Loop Interface CPU board.

If you find a pump that does not operate correctly in this mode, please determine the pump model and firmware revision number, and report them to Gasboy Technical Service (by fax, if possible). We will attempt to maintain a list of models known not to work in this mode, for the benefit of our customers.

Troubleshooting

This section is a collection of known problems not necessarily discussed elsewhere in this manual. It pertains more to sites that have started successfully, but either fail to become fully functional, or develop subsequent problems. This section is not exhaustive, but instead attempts to mention some of the more common problems reported.

If you find a problem you think should be included, contact your Gasboy sales or service

representative.

Gasboy CFN Series

24 Installation Gilbarco Interface Unit v2.1

If the system does not operate

One or more pump control units may fail to come up or stay up. Messages may print on the log about pump control units going up and down. You may see PUMP OUT OF SERVICE error messages when you hit START on the Check Point or Profit Point, or CAN’T ACTIVA TE if yo u use the ACTIVATE PUMP command. PRINT DIAGNOSTICS may reveal that a pump control unit is down.

Try a memory loss at the interface. Setting DIP switch bank 2, position 2 to OPEN momentarily while you cycle the AC power or press the reset button. Disconnect the interface from its RS485/422 line to the Site Controller and wait for five minutes, then reconnect the line.

If there is still a problem, try putting all pumps in ISOLATE at the distribution box. Switch pumps back to NORMAL one at a time, waiting for the associated pump con t rol un it to come u p each time. Sometimes you will see a pump control unit that has been up for a while suddenly go down when you switch some pump to NORMAL.

• If a pump newly switched in always takes down the same other pump, the pump just switched in may be set to the wrong poll address.

• If a newly switched in pump takes down more t han one other pump, it may have a faulty circuit board in it, or the current loop field wiring may be faulty. If there are still problems, go back and re-check all preceding parts of setup. If the problem still remains after that, you will need to obtain further technical assistance from Gasboy.

If CRINDs do not operate at all, first check the CRIND displays. They will say either PLEASE PAY INSIDE or <PLEASE PAY INSIDE>. In the first case, the CRIND is not seeing any communication with the interface unit. In the second case (the message with the brackets), the CRIND is communicating with the interface unit, but the Site Controller is not.

If the CRINDS operate but the keys on the keypad do not get the proper responses, check

the CRIND keypad programming.

Transferring from Gilbarco console to Gasboy interface

During setup it is sometimes useful to check out th e pu mps using a Gilbarco con so le, s uch as the Transac T-12. If you do this, make sure all pumps are deauthorized before disconnecting the current loop wiring from the Gilbarco console and connecting it to the Gasboy interface.

Failure to follow this precaution will cause the Gasboy unit to take an excessive amount of time before the pumps are fully operational. Unassigned transactions may also result, causing the Site Controller to disable pumps. The Site Controller command ENABLE PCU must be used to bring the pumps back to operating status if this happens.

POS says PUMP BUSY on START key

This is a normal message if a transaction has gone payable due to pulser timeout or operator intervention, and the handle on the pump has not yet been lowered. Lowering the handle on the pump should restore normal operation.

Rarely, Gilbarco pumps in this condition do not respond to the handle. Remove power from the pump briefly. In most cases this cures the problem.

If the problem persists, and if you have a Site Controller II version 2.0B or greater, and Gilbarco interface firmware 1.2L or 2.0, or greater, you may use the Site Controller TEST PCU command to restore normal operation.

If the message results from a Site Controller malfunction, try the ENABLE PUMP;A command. Otherwise, a Gilbarco service representative must master reset and reprogram the pump, or a Gilbarco console must be connected to the pump and the START or AUTHORIZE key used.

This problem has been observed in several different models of Gilbarco pumps, including very old models, but appears to be more common in newer (The Advantage) models.

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Installation 25

Receipt lines wrap

Sometimes the CRIND receipt printer may stick in its normal typeface, which has characters too wide to allow the Gasboy receipt to print correctly . The Gilbarco interface s ends the command to put the printer in narrow typeface mode at the beginning of each receipt. However, the CRIND may sometimes cease to respond to this. Remove power from the CRIND briefly.

Pumps work but prices won’t program correctly

Every instance of this problem observed to date has been due to incorrect grade p rogramming, or incorrect price bar programming, or to the SYS_PAR.BIN on page 9: Miscellany: “Blank pump display after” parameter being set longer than the time between sales.

Prices will not load while the Site Controller is waiting to blank the display after a sale, as

loading the prices will blank the display. Set the wait to 30 seconds in the parameter.

If you have checked Blank aft er and that is not the problem, rev iew the materials concerning grade and price bar programming earlier in this chapter, and if that does not help, call Gasboy service for assistance.

Some sites with nonstandard arrangements of multiple price levels may require more insight than we offer here to make the price programming work as desired, within the limits of what is possible with the equipment.

Interface suddenly begins giving unexpected results

This includes sudden failure to function at all, or other serious misbehavior.

If K5 and K6 are out, replace them and do an interface memory clear by opening DIP switch bank 2, position 2 and pres si n g t he res et but ton . B e s ure to restore DIP switch bank 2, position 2 to the CLOSED position.

If the interface is entirely dead, check the lamps as in

power-up and checkout.

Lamp check

, above, under

Initial

Messages on wrong CRIND or wrong pump activates

The CRINDs are not responding as the same reader terminal numbers the Site controller thinks they should be. Messages might change on the wrong CRIND when you raise a pump handle. Also, the wrong pump activates after a card approval.

Possibly the CRIND two-wire addresses are off by one. Did you take into account the discrepancy between actual two- wire address and the one reported by the CRIND in its diagnostic test number 6? As mentioned elsewhere, actual is one address less than the reported number.

Did you enter the wrong “representative pump” in the reader configuration menu 3?

If the site has two interface boxes, did you work out the starting reader number on the second box correctly? Power down the lowest-numbered r eader o n the seco nd in terface, an d s ee if the Site Controller reports that the reader you expected went down.

Single pump won’t come up

If everything else works fine but a single pump will not come up, it is possible the interface needs a RAM clear.

While you are changing pump addresses, if the interface sees even a single poll response from the even-numbered two-wire address for a PCU, it will not bring up that PCU unless it is talking to a pump at the even-numbered address.

Singles are usually set up as an odd two-wire address with no matching even address. This leaves the interface waiting for a pump it will never see.

Gasboy CFN Series

26 Installation Gilbarco Interface Unit v2.1

To solve this, make the interface forget about the even- numbered pump by clearing its memory. For the procedure see Erase interface unit memory under Connect and test the installation, earlier in this chapter.

Site reports wrong fuel or wrong dollar amount

If a transaction or the receipt shows the wrong fuel or an incorrect dollar total, check the pump firmware version.

If your pump is an Advan tage v e rsio n 7 0.1 , s ee Adva ntag e versio n 7 0.1 firmware in the first chapter.

If your pump is a Modul ar MP D-3 vers i on 53. 7, s ee M odular MPD-3 versi on 53.7 firm ware in the first chapter.

Also refer to other incompatible pump versions in “Incompatible pump firmware releases” on page 5.

If your pump is of any other type or has any other firmware version, contact Gasboy T echn ical Service immediately.

MPDs will pump only zero-quantity transactions

Older (pre-Advantage) MPDs will pump only zero-quantity transactions if they are activated using grade restrictions. The grade restriction feature is enabled using SW3-5 CLOSED. See “DIP switch bank 3” on page 16, for more information.

Zero quantity transaction

Pumps activate when START is pressed on POS but the transaction completes as a zero-quantity when handle is raised on pump.

Make sure you are not sending too large a money limit. Count the digits, including any fractional digits. Five-di git money pump s must have a money li mit of five dig its or less. S ix-digit pumps accept money limits to six digits or less. In either case, the leading three digits of the money limit must be less than “995” and should not be “980” or “981” for five-d igit money pumps.

Make sure interface SW3-6 agrees with the money digit setting for the pumps: OPEN for pumps configured for five-digit money, CLOSED for pumps that have six-digit money. All pumps on an interface must be configured the same way.

Unassigned Transactions

Every reader configuration must have a “select pump” program step prior to the “activate pump” step. Failure to include the select pump step will cause warnings about unassigned transactions, with pumps becoming disabled after the transaction.

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Hardware 27

3 Hardware

This chapter is about the electrical parts of the interface. Ratings, jumper positions, and switch settings are described in detail. The purpose of this chapter is to give specific detail in a systematic fashion.

Cabinet

The interface unit cabinet is shown in figure below. The cabinet is three inches high, 12 inches wide, and eight inches deep. It contains a power supply, the interface unit CPU board, and the current loop driver board.

A short cable connects current l oop driver board P1 to the up per two po sitions on a ter minal block, which provides for connection to the pump port on a distribution box (also called a Dbox).

The RS485/422 port on the right, shown in the figure with legend SC II Port above it, provides for connection to the Site Controller.

The RS485/422 port on the left in the figure below, labeled CRIND PORT, provides for connection to the CRIND port on a di stributi on box. A s tandard pow er entry mo dule, label ed AC POWER, provides for an instrument cord to supply power to the interface.

Front of Gilbarco Interface Unit

GSM

CURRENT LOOP

Back of Gilbarco Interface Unit

Gasboy CFN Series

28 Hardware Gilbarco Interface Unit v2.1

External connections

The interface unit is connected to the power mains, the Site Contro ller, and to one or two Gilbarco distribution boxes.

Island Card Reader w/ Receipt Printer

Gilbarco

Salesmaker2

Dist. Box Gilbarco Security Module

Customer Display

Check Point POS

Gilbarco Crind

RS232

MPD

RS422

Receipt Printer

Modem to Host Computer

Modem to Bank Networ k

Mechanical Dispenser

CRT or Back Room PC

Gilbarco

Pro Blender

Gilbarco

Pump

Dist. Box

Current

Loop

Gilbarco

Interface

Scanner

ABC

DEF

GHI

JKL

MNO

PRS

TUV

WXY

ENTERCLEAR

PIN Pad

Site Controller II

Profit Point POS

logpumpspay 7actoff

$43.68Total

Gasboy CFN II

Mon Mar 4 11:04 AM John Smith: Shift 1

$$7

payable

$9.80

cigarettes 6 pack Coke$1.98 Reg Fritos$2.09

$42.24

Subtotal . .

$1.44

Sales tax . .

$43.68Total . . . .

Customer Display

Electronic Commercial Dispenser

Site Log Printer

Pump Control Unit

Mechanical Dispenser

Interconnection of Site Equipment with Interface Unit

Interface to distribution box current loop wiring (pumps)

The current loop wiring for the pump loop from the Gilbarco interface to the distribution box is shown in figure below. Interface Terminal is the terminal on the current loop board.

Cable C06691, interface to D-box, pump

Interface Terminal P1-1 P1-2 Wire color black red DB-9S to D-box pin 7 pin 6

This uses eight-foot cable, Ga sboy P/N C06691, with wedge con nector and a DB-9S, whic h may be extended by any 1:1 9-pin D connector extension cable with at least pins 6 and 7 connected.

Interface to distribution box RS485/422 wiring (CRINDs)

The RS485/422 wiring for the CRIND loop from the interface to the distribution box is shown below.

Cable C06242/C06692, interface to D-box, CRIND

This uses two Gasboy parts: an eight-foot cable, C06242, and adaptor C06692, RJ-11 to 9-pin DB-9P. (The combined part number for both C0624 2 and C066 92 is C063 26 .) The cabl e may be extended using an RJ-11 or RJ-12 1:1 telephone extensi on cable.

Gasboy CFN Series

Interface to DB-9P Signal

Modular Connector D-Box Name

Pin 1 Pin 2 Rx+ Pin 2 Pin 6 RxPin 3 Pin 3 TxPin 4 Pin 7 Tx+

Gilbarco Interface Unit v2.1 Hardware 29

Site controller to interface RS485/422 wiring

The cable to the Gilbarco interface RS485/422 connection is a modular handset connector cross cable assembly with the transmit and receive pairs reversed, Gasboy part nu mber C 04500 . The connections are:

Cable C04500, RS-485/422 junction box to interface

Junction Box Pin Current Loop Interface Pin

1 (Rx+) 3 (Tx+) 2 (Rx-) 4 (Tx-) 3 (Tx+) 1 (Rx+) 4 (Tx-) 2 (Rx-)

This cable runs from an RS485/422 junction box to the interface unit.

Should you need a second interface unit, use a second junction box connected in parallel with the first, using a short piece of field wiring cable connecting the terminal blocks of the two junction boxes in parallel. Also connect the external ground terminals together using approved grounding wire. The second interface bo x then uses another C04500 cross cable from the second junction box to its SC II Port.

This drawing shows two connected interface units:

GSM to Interface Cable

To 422 Loop 2

Site Contro ll er II

RS422/485 Cable

(C05670)

GSM

RS-422

J-Box

Gilbarco 422 Cable

(C07248)

(C04500)

Current Loop Interface Box

Current Loop 1

C05688

(Cable C06691)

(Cable C06326)

CRIND D-Box

(from Gilbarco)

To 422 Loop 2

Gilbarco D-Box

(from Gilbarco)

CRINDS 1-16

PUMPS 1-16

Interface to GSM RS232 wiring

The cable from Gilbarco Interface to GSM is a custom RS232 cable, Gasboy P/N C07248, with a 25-pin “D” connector on the Interface end and a 9-pin “D” connector for the GSM. The connections are:

Cable C07248, GSM to interface

GSM Pin Interface Pin

2 (TxD) 3 (RxD) 3 (RxD) 2 (TxD) 7 (GND) 7 (GND) 9 (RESET) 4 (RTS)

5 (CTS) 6 (DSR) 8 (DCD) 20 (DTR)

Do not substitute any other cable or you may damage the GSM.

Pins 5, 6, 8, and 20 on Gilbarco Interface end connected together

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30 Hardware Gilbarco Interface Unit v2.1

AC power inlet and fuse

The interface unit has the same power requirements as the Site Controller, as given in the Site Controller (I or II, as appropriate) installation manu al.

Jumpers

The CPU board (part number C0483 5) has jumpers and switches that must b e set correctl y. Some settings never change. The ones that do may also be d iscuss ed in chapt er two of this manual. The jumper positions labeled K1 through K8 are below:

CPU Board Jumpers K1 to K8 Jumper Function and/or normal setting

K1 All K1 jumpers are absent. K2 All K2 jumpers are absent. K3 Position 1. Enables the dead man timer . K3 -1 jump er mus t be

installed. K3-1 is the pair of K3 terminals closest to P9, the long double-row offboard connector at the edge of the board. Position 2. K3-2 jumper is absent. K3-2 is the pair of K3 ter-

minals farthest from P9. K4 K4 does not exist. K5, K6 Provide battery backup power to the devices in U31 and U32

respectively. K5 and K6 jumpers must be installed. K7 Enables the AC power fail circuit. K7 jumper must be

installed. K8 K8 jumper is absent.

Jumpers K5 and K6 are normally present but not installed when the unit is shipped. They must be installed by the startup technician. Make sure the jumpers are set as shown here. The interface will seem to work well even though some of these jumpers are set wrong, until you get a momentary power failure. Transaction data can be lost and pumps can go out of service for extended periods.

DIP switches

There are 24 DIP switches in the front right hand corner of the interface unit CPU bo ard. When a switch is closed, it grounds the logic signal, which is then read as a 0. When the switch is open, the logic signal goes to +5 volts or logic 1. The normal setting of the switches is:

DIP switch bank 2, positions 1-8: all closed DIP switch bank 3, positions 1-8: all open DIP switch bank 4, positions 1-8: all open

Unless there is a specific reason, the switches should be set as described above. The individual switches and their settings are described below.

DIP switch bank 2

DIP switch bank 2, position sets PCU poll address and allows clearing memory.

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Gilbarco Interface Unit v2.1 Hardware 31

Position Function

1 CLOSED = Normal mode.

OPEN = Debug mode. Do not use.

2 OPEN = Erase all memory on reset.

CLOSED = Do not erase memory on reset.

3-8 Interface unit base address: see chapter two.

In most cases, the unit base address is 1, so that positions 3 to 8 are all CLOSED.

DIP switch bank 3

Position Function

1, 2 Debug port baud rate:

OPEN, OPEN = 9600 OPEN, CLOSED = 2400 CLOSED, OPEN = 1200 CLOSED, CLOSED = 300

3 OPEN = CRINDs are on spare RS485/422 port.

CLOSED = CRINDs are on second current loop: Requires board modifications in current loop box. Do not use.

4 OPEN = Report all events during activate. Use with SCII V 2.0B or later.

CLOSED = Hide some events during activate. Use with SCI, SCII V 2 .0A and earlier.

5 OPEN = No grade restrictions

CLOSED = Restrict grades

6 OPEN = Money amounts are five digits

CLOSED = Money amounts are six digits

7-8 Reserved. All positions are normally OPEN. Position 5 is CLOSED if you wish to enable grade restrictions for fleet or club cards. This option

is available only at sites where all multi-fuel pumps are Advantage



Position 6 setting must agree with the configuration of every pump on an interface.

DIP switch bank 4

Position 4 selects certain price level options and allows either twelve or sixteen pumps (six or eight double-sided units) on a loop.

Position Function

1 OPEN = Price level 0 same as either price level 1 or 2.

CLOSED = Price level 0 not same as level 1 or 2.

2 OPEN = 12 fueling positions on this interface.

CLOSED = 16 fueling positions on this interface.

3 OPEN = Site RS485/422 deadman timer enabled.

CLOSED = Sit e RS485/422 deadma n timer disabled.

4 OPEN = Map transient prices to level 1.

CLOSED = Map transient prices to level 2.

5-8 Reserved Positions 1 and 4 interact. See chapter two for discussion. Unless there is a reason to do

otherwise, set all positions to OPEN.

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32 Hardware Gilbarco Interface Unit v2.1

Front panel CPU LEDs

The two rows of LEDs visible through the front panel window are shown in figure and their functions are listed in the figure after that. The upper row LEDs, left to right, are named L1, L2, and so on through L12. The lower row LEDs, left to right, are named DC, BOK, and BAD.

Lamp Indication

L1 CRIND RS485/422 Transmit data L2 C RIND RS485/422 Receive data L3 Site Controller RS485/422 transmit data L4 Site Controller RS485/422 receive data L5 Deadman timer refresh L6 Current loop power enabled L7 Current loop #1 active if flashing L8 Current loop #2 active if flashing L9 Program fail code bit 1 L10 Program fail code bit 2 L11 Program fail code bit 3 L12 Program fail code bit 4 DC DC 5V power OK (green) BOK Battery OK (green) BAD Battery bad (red)

Examination of these lamps allows quick evaluation of the state of the interface. They are discussed in the Installation chapter.

Lamp

L9 L10 L11 L12 Code Meaning

OFF OFF OFF OFF 0 Normal. Other lamps should blink. OFF OFF OFF ON 1 Po wer fail. Problem with AC power detect OFF OFF ON OFF 2 Internal program error. OFF OFF ON ON 3 Internal program error. OFF ON OFF OFF 4 ROM checksum bad. Pin bent on U18-

U21? OFF ON OFF ON 5 RAM bad. Replace chips U31 and U32. OFF ON ON OFF 6 Program failure. Replace U18-U20. OFF ON ON ON 7 Internal program error.

ON OFF OFF OFF 8 Internal program error

The "Internal program error" conditions indicate severe hardware failure or software defects which must be fixed by the developers. Note which lamps were on, and the circumstances such as what was being done and how often this is seen. If internal program error is not a frequent event, you may temporarily restore a site to ope rating condition by cycling po wer to the interf ace box after carefully gathering information. Report any internal program error conditions to Gasboy Development.

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Gilbarco Interface Unit v2.1 Hardware 33

Current loop driver board

The current loop driver board (part number C05374 or kit C07249) contains two current loop ports, a 5V to 40V dc-to-dc converter that supplies power for two of the current loops, a battery to back up CPU board RAM, battery trickle charger, battery fail detect, and DC power fail detect. The board draws 5V power for battery and control through P3, and 5V power for the current loop supply through P4. Signals are passed through P3. Current loops plug into P1 and P2. Board ratings are shown below:

Power: +5v, .3A nominal, .6A Maximum at P3

5v, .9A nominal, 1.2A Maximum at P4

Current Loop Outputs: 40 mA nominal at idle, 45V maximum open loop voltage.

Baud rate is 5800. Current loop will endure short circuit operation indefinitely with 40 degree C rise in current source transistor temperature.

Battery: 3.6V nominal, 110 mA-hours charge. Backup time at .1 mA

nominal exceeds two weeks.

Battery fail: Indicates failure if battery fails shorted, battery fuse is blown

or battery jumper is missing.

Powerfail detect: RESET asserted if DC power falls below 4. 65V nominal. Trip

level is screwdriver adjustable.

Status LEDs: LED #1, red, on if battery low or fuse blown or jumper

omitted. LED #2, green, on if battery OK. LED #3, green, on if 5V DC OK.

The interface board has under gone three revisions. The only boa rds that should be continued

in service if difficulties are observed are the revision 3 boards.

Jumpers

These are the functions and settings of current loop driver board jumper positions K1 and K2:

Jumper Function

K1 Baud rate clock source. Must be installed in position 1. K2 Battery backup enable. Boards should be stored with this jumper out. It should

be installed at assembly time. The red battery fail lamp will light if K2 is omitted.

Fuses

Fuses F1 and F2 protect the current loops. These are 1/8 amp picofuses. A blown F1 or F2 indicates a blown transistor Q12 or Q13, or other serious circuit malfunction.

Fuse F3 protects BATT1. A blown F3 usually indicates a momentary short from the positive side of the battery to ground. Lamp I1 will not go out while power is applied if fuse F3 is blown. F3 is a 1.25 amp Picofuse. Smaller values may be used, as maximum working current is less than 20 milliamps.

P1 and P2 current loop connectors

These connectors each provide an active current loop port. The loops expect less than 20 milliamps for an active state, and up to 48 mA for an idle state. Current loop power and ground are fully isolated from logic power and ground. T ransient s uppressors prevent excessive voltag es being generated across loops. This table shows the pinout on P1 and P2:

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34 Hardware Gilbarco Interface Unit v2.1

Pin # Signal Name Description P1-1 1 + Current loop sink P1-2 1 - Current loop source

P2-1 2 + Current loop sink

P2-2 2 - Current loop source Note that the signal names are confusing. The signal P1-1 + is negative, and the P1-2 - is positive. Interface unit with firmware version 2.0 uses only P1. Some early beta versions also used P2, as

the CRIND interface loop. Released version 2.0 uses the spare RS485/422 port for CRIND communication. The later firmware is compatible with the earlier, modified, units. These may continue to use the second current loop port when they are upgraded, if switch DIP switch bank 3, position 3 is set to CLOSED.

Building a dual input mode distribution box

The dual input mode distribution box, with one input RS485/422 and one input current loop, is not a standard Gilbarco offering, nor do their installation manuals show any diagrams of such. However, it is easy to construct one of these, starting either with two distribution boxes, or with one box and a kit.

If you have two dual distribu tion boxes, one set up for current loop inp ut, one for RS4 85/422 input, you can construct two dual input mode distribution boxes by swapping two cables and moving some jumpers.

You can also build a dual input mode distribut ion box from a sin gle distr ibution box o f either the current loop or RS485/422 input variety, and on e K93717 expansion kit. The K93717 kit contains both input cables, a T17651 distribution box circuit board and some other cables.

The result in either case is the same, as illustrated in figure below. This is a dual RS485/422 input distribution box, exce pt th at the second i nput has been change d into a curre nt loop inp ut by moving the jumpers JP10 and JP12, and by exchanging the second R19249-G1 cable plugged into P103 for an R18810-G1 cable plugged into P102.

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Gilbarco Interface Unit v2.1 Data monitor 35

4 Data monitor

Once all connections have been made and all switches set correctly, the system still does not always function correctly. As an aid to diagnosing remaining problems, the interface unit is equipped with a data monitor program.

The monitor program is accessed by connecting a terminal to the local port. The baud rate must agree with the rate switched in on interface unit switches DIP switch bank 3, positions 1 and 2.

The data monitor command m or just ENTER is used to determine whether communication has been established.

Data monitor commands

The monitor commands are discussed below:

Monitor Commands

Key Modifier Effect

h — Show list of commands and status w — Show monitor status m — Monitor next data port p — Monitor pump data port c — Monitor CRIND data port g — Monitor GSM data port s <space> Monitor all devices on port s 0-f Monitor only one device n — Toggle display all/new messages <space> — Halt or restart display ? — Display device status and counters * — Reset counters r — Toggle display raw/cooked mode

Command: h

Print help menu. The commands are listed, with a brief explanation of each . The key also elicits this.

ENTER

Command: w

Print status. The monitor shows its print mode (off or on), whether it is printing all messages or just new ones (verbose or ters e), which data por t it is watch ing (l ine 1 or line 2 ), and wh at device or devices it is watching.

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36 Data monitor Gilbarco Interface Unit v2.1

Command: m

Monitor next data port. If monitoring pumps, monitor CRINDs; if CRINDs, monitor GSM; if GSM, monitor pumps.

Command: sn

Show device n, where n is a number from 0 to 9 or a letter f rom a to f to in dicate a dev ice from 0 to 15, or g to indicate all devices. When using a slow terminal, it will most likely be necessary to watch only one device at a time, unless the station is not very busy.

Command: n

New/all messages. If displaying only new messages, display all messages; if all, display new messages only .

Command: <space>

T oggle prin t. If prin ting, stop . If not, prin t. No scrol ling is pos sible with t he monitor, so you must stop anything you want to look at before it disappears off the top of the screen. There is a discussion of the print format below.

Command: ?

Print device status. Prints a table for all devices that have answered a data request since last time the interface unit cleared memory. Here is what the output of this command might look like:

pump up status pcom scom | CRND up status ccom scom 01 yes 61 21 CC | 02 yes 95 94 WW

The first line may also show:

GSM down

GSM up, no key

GSM up, key loaded

The columns are discussed on the next page. A pump and a CRIND on the same row does not mean they are connected in any way. Pump 16 appears in the table at address 00, while CRIND 16 appears at address 10, which is base 16 for decimal 16. Note that many of the numbers of the table are in base 16, with letters A through F used as digits having values of 10 through 15.

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Gilbarco Interface Unit v2.1 Data monitor 37

Column Meaning

pump Pump two-wire address. up If yes, the device is talking to the interface. status Last pump status. pcom Last command sent by interface to pump. scom Last command sent by Site Controller to interface. CRND CRIND two-wire address. up CRIND is talking to the interface. status Last CRIND status. ccom Last command from interface to CRIND. scom Last command from Site Controller to interface.

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38 Data monitor Gilbarco Interface Unit v2.1

Gasboy CFN Series

Gilbarco Interface Unit v2.1 Index i

Index

Advantage Super High pump

;

CRIND

two-wire loop baud rate CRIND address CRIND keypad

;

Data monitor commands DC and BOK lamps DC power check Differences bet w een interface versions DIP switches Dual input mode distribution box

;

Erase interface unit memory

;

Finding the CRIND re ader number Finding the Termi nal reader number Five-digit money

;

Gilbarco

keypad string Gilbarco Cash/Credit pumps

Problem interface with SCI Gilbarco Interface Unit Gilbarco Security Module GSM Lamp check GSM Wiring

;

Hardware

Cabinet Hose/grade worksheet

;

Incompatible Interfa ce s Interface lamp check Interface to GSM RS232 wiring

;

Jumpers

;

K5 and K6 jumpers Keypad string

Gilbarco

;

LEDs

;

Loop driver board

;

Money amounts

Five-digits

;

Six-digits

switch setting MPD Pro Blender MPD-2

;

Non-defaul t s etting Number of hoses

P1 and P2 current loop connector s PCU slot Potential Problems

Potential problems

Price Levels

;

Blenders and Gascard Network

Broadcast messages

Contract Prices

Don’t leave GSM powered down

Grade restrictions with pre-Advantage MPDs

Loading Master Key

More than 16 CRINDs

Multiple price levels on other Gil ba rco pumps

Network Key Parity

Six-digit money on some pumps, five-digit on others

Cash/credit buttons and more than two price levels

Cash/credit select and SC I

Gallon cutoffs on multiple hose or fuel units

Large gallon limits

Many price levels on multiple hose units

Measured totals for blended products not available

Product restriction on multiple hose or fuel units

Volume display at Check Point or Profi t Poi nt

Cash/credit select buttons

No cash/credit select butt ons

;

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ii Index Gilbarco Interface Unit v2 .1

Pump control unit (PCU) number Pump number Pump type Pump/CRIND Worksheet

;

Reader number

;

Six-digit money Sucessful power up

;

Terms

Alternating price bar Dispenser Dual price bar GSM Main price display Price bar Price code Price level

Pump Test for multiprice Troubleshooting

If the system does not operate

Interface suddenly begins giving unexpected results

Messages on wrong CRIND or wrong pu mp ac tiva te s

MPDs will pump only zero-qua nt it y tr ansa ctions

POS says PUMP BUSY on START key

Pumps work but prices won’t program correctly

Receipt lines wrap

Single pump won’t come up

Site reports wrong fuel or wrong dollar amount

Transferring from Gilbarco console to Gasboy interface

Unassigned Transactions

Zero quantity trans ac tion Two-wire loop baud rat e

;

Unassigned transaction Universal distribution lamps

;

Wiring

Interface to distribution bo x

Interface to distribution box RS 485/422 (CRINDS)

Site Controll er to in terface RS 482/422

Gasboy CFN Series

;

Gasboy Gilbarco Interface Unit User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 Introduction

Caution

Terms

The Gilbarco interface unit

Differences between interface versions 1.2 and 2.0

Differences between interface versions 2.0 and 2.1

Potential problems

Cash/credit buttons and more than two price levels

Many price levels on multiple hose units

Measured totals for blended products not available

Cash/credit select and Site Controller I

Gallon cutoffs on multiple hose or fuel units

Large gallon limits

Product restriction on multiple hose or fuel units

Volume display at Check Point or Profit Point

Advantage version 70.1 firmware

MPD-2

MPD Pro Blender

Modular MPD-3 version 53.7 firmware

Multiple price levels on other Gilbarco pumps

Incompatible pump firmware releases

Loading Master Key

Network Key Parity

Contract Prices

More than 16 CRINDs

Blenders and Gascard Network

Don’t leave GSM powered down

Broadcast messages

Grade restrictions with pre-Advantage MPDs

Six-digit money on some pumps, five-digit on others

2 Installation

What to do first

Things to watch out for

Correct the indicated CRIND two-wire address

Don’t use gallon limits on multi-fuel pumps

Use $999 limits only with cash/credit select

Use only grade 1 with Highlines

Set correct level at price bars

Use reader AUTO YES only with CRINDs

Install K5 and K6

Do memory reset before checkout

Starting up the site

Determine programming information

Worksheet Heading Description

Other configuration information

CRIND keypad programming

Switch settings for interface unit CPU board

DIP switch bank 2

DIP switch bank 3

DIP switch bank 4

Site Controller configuration

Prepare PUMP.BIN data

Prepare READER.BIN data

Program the Site Controller

Program the dispensers and CRINDS

Program the interface unit

CPU board jumpers

Current loop board jumpers

CPU board DIP switches

Connect and test the installation

Power wiring

RS485/422 site wiring

RS485/422 CRIND wiring

Current loop pump wiring

GSM Wiring

Initial power-up and checkout

Troubleshooting

If the system does not operate

Transferring from Gilbarco console to Gasboy interface

POS says PUMP BUSY on START key

Receipt lines wrap

Pumps work but prices won’t program correctly

Interface suddenly begins giving unexpected results

Messages on wrong CRIND or wrong pump activates

Single pump won’t come up