Gasboy Islander PLUS User Manual

Wiring

MDE - 4811F

Islander PLUS and ICR PLUS

INSTALLATION MANUAL

This document is based on Orpak’s Island controller (OrIC)
installation manual P/N 817438050

SAFETY CONSIDERATIONS

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

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

WARNING - EXPLOSION HAZARD

Use separate conduit for the intrinsically safe. Do not run any other wires or cables through this conduit,
because this could create an explosion hazard.
Use standard test equipment only in the non- hazardous area of the fuel station, and approved test equipment
for the hazardous areas.
In the installation and maintenance of the Product, comply with all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for
Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70 “National Electric Code”, federal, state and
local codes and any other applicable safety codes and regulations.
Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work
operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury,
property loss and damage to you and other persons.

CAUTION - SHOCK HAZARD

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

CAUTION – EXTERNAL WIRING

For supply connections, use wires suitable for at least 90°C.

Signal wiring connected in this box must be rated at least 300 V.

WARNING – PASSING VEHICLES

When working in any open area of fuel station, beware of passing vehicles that could hit you. Block off the
work area to protect yourself and other persons. Use safety cones or other signaling devices.

WARNING

Components substitutions could impair intrinsic safety.

Attaching unauthorized components or equipment will void your warranties.

CAUTION

Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all
warranties related to this equipment.

PROPRIETY NOTICE

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

DISCLAIMER

This document is provided for reference only. Although every effort has been made to ensure correctness,
ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.

FCC Compliance Statement

The FCC Wants You to Know:
This equipment has been tested and found to comply with the limits for a Class B & C digital device,
pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment generates uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures :
a) Reorient or relocate the receiving antenna.
b) Increase the separation between the equipment and receiver.
c) Connect the equipment to an outlet on a circuit different from that to which the receiver is connected.
d) Consult the dealer or an experienced radio/TV technician.

FCC Warning

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

This document is the prop erty of:
ORPAK SYSTEMS Ltd.
ISRAEL

TABLE OF CONTENTS

Paragraph Page

GENERAL DESCRIPTION SECTION 1

1-1. SCOPE ................................................................................................................................ 1

1-2. DESCRIPTION .................................................................................................................. 1

1-3. SYSTEM OVERVIEW ...................................................................................................... 3

1-3.1. Islander PLUS System ................................................................................................... 3

1-3.2. Vehicle Identification – FuelPoint PLUS ...................................................................... 3

1-3.3. Remote Web Access ...................................................................................................... 3

1-3.4. Head Office .................................................................................................................... 3

1-3.5. Restrictions and Limits .................................................................................................. 3

1-3.6. Islander PLUS Capabilities for Forecourt Management ................................................ 4

1-3.7. System Workflow Example ........................................................................................... 4

1-3.7.1. Refueling Scenario with FuelPoint PLUS ................................................................. 5

1-3.7.2. Refueling Scenario with Magnetic Cards .................................................................. 5

1-4. ISLANDER PLUS STRUCTURE ..................................................................................... 6

1-4.1. Main Components .......................................................................................................... 6

1-4.2. Islander PLUS Internal Configuration – Mechanical Pump .......................................... 9

1-4.3. Islander PLUS Main Components Location ................................................................... 11

1-5. AVAILABLE CONFIGURATIONS ................................................................................. 16

1-5.1. General ........................................................................................................................... 16

1-5.2. Islander PLUS / ICR PLUS ........................................................................................... 16

1-5.3. Printer Option ................................................................................................................. 16

1-5.4. Vehicle Identification System ........................................................................................ 16

1-5.5. Dispensers ...................................................................................................................... 16

1-5.6. Contactless Tags/Cards .................................................................................................. 17

1-5.6.1. Data Key Sockets – Fleet key ................................................................................... 17

1-5.6.2. HID Device ............................................................................................................... 17

1-5.6.3. Configurations ........................................................................................................... 17

1-6. SECURITY AND PROTECTION ..................................................................................... 20

1-6.1. General ........................................................................................................................... 20

1-6.2. Authorization Security ................................................................................................... 20

1-6.3. Network Security ........................................................................................................... 20

1-6.4. RF Network Security ..................................................................................................... 20

1-6.5. Maintenance Security ..................................................................................................... 20

1-7. HOUSING .......................................................................................................................... 20

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TABLE OF CONTENTS

1-8. SPECIFICATIONS ............................................................................................................. 22

Paragraph Page

1-9. STANDARDS ..................................................................................................................... 23

1-9.1. Communication Standards ............................................................................................. 23

1-9.2. Security Standards .......................................................................................................... 23

1-10. MANUAL STRUCTURE ................................................................................................... 24

1-11. USING THIS MANUAL .................................................................................................... 25

1-12. REFERENCES ................................................................................................................... 26

2-1. GENERAL .......................................................................................................................... 28

2-2. PRELIMINARY INSTALLATION INSTRUCTIONS ..................................................... 28

2-2.1. General ........................................................................................................................... 28

2-2.2. Precautions and Safety Notes ......................................................................................... 28

2-3. CONDUITS LAYOUT/INSTALLATION SPECIFICATIONS ........................................ 29

2-4. CONDUITS ........................................................................................................................ 29

2-4.1. General ........................................................................................................................... 29

2-4.2. Conduit Requirements .................................................................................................... 30

2-4.3. Conduits at Islander PLUS ............................................................................................. 30

2-4.4. Required Conduits in Island ........................................................................................... 32

2-4.5. Required Conduits in Islander PLUS ............................................................................. 32

2-5. CONDUITS INSTALLATION .......................................................................................... 33

2-5.1. General ........................................................................................................................... 33

2-5.2. Installing Conduits in Island .......................................................................................... 33

2-5.3. Sealing Conduits ............................................................................................................ 33

2-6. CABLES INSERTION ....................................................................................................... 36

2-6.1. General ........................................................................................................................... 36

2-6.2. Types of Cables .............................................................................................................. 36

2-6.3. Cables Routing ............................................................................................................... 37

2-7. POWER SETUP ................................................................................................................. 37

2-7.1. General ........................................................................................................................... 37

2-7.2. Islander PLUS for 8 hoses - AC Power Supply Setup ................................................... 38

2-7.3. Connecting the Power Equipment .................................................................................. 40

2-7.4. Grounding....................................................................................................................... 40

2-8. WIRING THE PERIPHERALS ......................................................................................... 41

2-8.1. Pump Wiring .................................................................................................................. 41

2-8.2. TLG wiring ..................................................................................................................... 41

PRELIMINARY INSTALLATION INSTRUCTIONS SECTION 2

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TABLE OF CONTENTS

Paragraph Page

ISLANDER PLUS INSTALLATION PROCEDURES SECTION 3

3-1. GENERAL .......................................................................................................................... 43

3-2. INSTALLATION SPECIFICATIONS .............................................................................. 43

3-2.1. General ........................................................................................................................... 43

3-2.2. Precautions and Safety Notes ......................................................................................... 43

3-2.3. Safety Distances ............................................................................................................. 44

3-3. HOME BASE STATION - OVERVIEW ........................................................................... 44

3-3.1. General ........................................................................................................................... 44

3-3.2. Home Base Station Architecture .................................................................................... 45

3-3.2.1. Main Power Cabinet .................................................................................................. 45

3-3.2.2. Home Base Forecourt ................................................................................................ 45

3-3.2.3. Head Office System (Optional) ................................................................................. 45

3-4. MAPPING THE SITE– EXAMPLE .................................................................................. 49

3-4.1. General ........................................................................................................................... 49

3-4.2. Locating all objects of the site ....................................................................................... 49

3-4.3. Assigning Logical IDs ................................................................................................... 49

3-4.3.1. To each fuel tank ....................................................................................................... 49

3-4.3.2. To each Dispenser Unit ............................................................................................. 49

3-4.3.3. In the Islander PLUS pole ......................................................................................... 49

3-4.4. Mapping ......................................................................................................................... 49

3-5. CONNECTIONS TO ISLANDER PLUS .......................................................................... 50

3-6. INSTALLING THE ISLANDER PLUS PEDESTAL POLE ............................................ 52

3-6.1. General ........................................................................................................................... 52

3-6.2. Installation Procedure Steps ........................................................................................... 52

3-6.3. Pedestal Site Preliminary Setup Procedures .................................................................. 52

3-6.4. Installation Assembly Parts ............................................................................................ 53

3-6.5. Base Plate Installation Procedures ................................................................................. 53

3-6.6. Pedestal Installation Instructions ................................................................................... 56

3-6.7. Base Plate Installation Procedures – Optional ............................................................... 56

3-6.8. Sealing Conduits ............................................................................................................ 57

3-7. WIRING ............................................................................................................................. 58

3-7.1. General ........................................................................................................................... 58

3-7.2. Types of Wiring ............................................................................................................. 58

3-7.3. Wiring Requirement ....................................................................................................... 58

3-7.4. Types of Cable ............................................................................................................... 58

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TABLE OF CONTENTS

3-8. MECHANICAL PUMP – WIRING ................................................................................... 59

Paragraph Page

3-8.1. General ........................................................................................................................... 59

3-8.2. 4 – Mechanical Pump – Terminal Block - Pin-Out Connections ................................... 59

3-8.3. 8-Mechanical Pump – Terminal Block - Pin-Out Connections ..................................... 61

3-8.4. Mechanical Pump - Required Connections .................................................................... 65

3-8.5. Mechanical Pump - Pulser Connections......................................................................... 70

3-8.5.1. Electronic Pulser ........................................................................................................ 70

3-8.5.2. Mechanical Pulser ..................................................................................................... 70

3-9. ELECTRONIC PUMP – WIRING DESCRIPTION .......................................................... 72

3-9.1. General ........................................................................................................................... 72

3-9.2. Tokheim Electronic Pump .............................................................................................. 74

3-9.3. Current Loop Electronic Pump ...................................................................................... 75

3-9.4. RS-485 Electronic Pump ................................................................................................ 76

3-10. WIRING TO GENERAL COMPONENTS ........................................................................ 77

3-10.1. General ........................................................................................................................... 77

3-10.2. Connection to TLG Controller ....................................................................................... 77

3-10.3. Connection to Journal Printer ......................................................................................... 77

3-11. POST-INSTALLATION CHECKLIST ............................................................................. 80

3-12. ISLANDER PLUS SETUP ................................................................................................. 80

4-1. OVERVIEW ....................................................................................................................... 81

4-2. DESCRIPTION ................................................................................................................... 82

4-3. MAIN COMPONENTS ...................................................................................................... 83

4-4. PRINTER CONNECTOR PIN-OUT ................................................................................. 84

4-5. INDICATORS .................................................................................................................... 85

4-6. SPECIFICATIONS ............................................................................................................. 85

4-7. INSTALLATION PRINTING PARAMETERS ................................................................ 86

4-7.1. Jumpers Configuration ................................................................................................... 86

4-7.2. Parameters for Printing................................................................................................... 87

4-7.3. Cutter .............................................................................................................................. 87

4-7.4. Printing the Status Report .............................................................................................. 87

4-8. PAPER ROLL REPLACEMENT ....................................................................................... 88

4-8.1. General ........................................................................................................................... 88

4-8.2. Paper Roll Replacement ................................................................................................. 88

4-8.2.1. Automatic Insertion of Paper ..................................................................................... 90

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PRINTER SECTION 4

TABLE OF CONTENTS

4-8.2.2.

Manual Insertion of Paper ......................................................................................... 90

Paragraph Page

4-9. PRINTER CLEANING ...................................................................................................... 91

4-9.1. General ........................................................................................................................... 91

4-9.2. Thermal Printer Head –Cleaning Instructions ............................................................... 91

4-9.2.1. General ...................................................................................................................... 91

4-9.2.2. Cleaning Procedures .................................................................................................. 91

4-10. TROUBLESHOOTING ..................................................................................................... 93

4-10.1. General ........................................................................................................................... 93

4-10.2. Troubleshooting ............................................................................................................. 93

4-10.3. Releasing Jammed or Crumpled Paper .......................................................................... 93

4-11. THERMAL PAPER STORAGE ........................................................................................ 94

MAINTENANCE SECTION 5

5-1. GENERAL .......................................................................................................................... 95

5-2. TROUBLESHOOTING ..................................................................................................... 95

5-2.1. Islander PLUS Troubleshooting .................................................................................... 95

5-2.2. OrPT Troubleshooting ................................................................................................... 102

5-2.3. Printer Troubleshooting ................................................................................................. 106

5-2.4. Communication Troubleshooting .................................................................................. 108

5-3. CLEANING ........................................................................................................................ 111

5-3.1. General ........................................................................................................................... 111

5-3.2. Cleaning ......................................................................................................................... 111

5-3.3. Magnetic Card Reader – Cleaning Instructions ............................................................. 111

5-3.4. Printer – Cleaning Instructions ...................................................................................... 112

6-1. FUELOMAT GLOSSARY ................................................................................................ 113

6-2. COMMUNICATION GLOSSARY ................................................................................... 114

GLOSSARY SECTION 6

APPENDIX A SITE SURVEY

APPENDIX B WIRING DIAGRAM

APPENDIX C HID ASASEMBLY INSTALLATION

INTRODUCTION .......................................................................................................................... 125

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TABLE OF CONTENTS

INSTALLATION INSTRUCTIONS ............................................................................................. 127

Paragraph Page

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LIST OF ILLUSTRATIONS

Figure 1-1 - Islander PLUS / ICR PLUS - General View ................................................................... 2

Figure 3-18 Mechanical Pump – Single Dispenser Connections ..................................................... 67

Figure Page

Figure 1-2 - Islander PLUS in Home Base Station - General Configuration Diagram ....................... 4

Figure 1-3 - Internal Configuration Diagram – 4 Mechanical Pump .................................................. 9

Figure 1-4 - Internal Configuration Diagram – 8 Mechanical Pumps ............................................... 10

Figure 1-5 - Internal Components Location –4 Mechanical Pumps .................................................. 11

Figure 1-6 - Internal Components Location –8 Mechanical Pumps .................................................. 12

Figure 1-7 – Islander PLUS with Optional Internal Printer (Sectional View) .................................. 13

Figure 1-8 – Islander PLUS for 8 hoses with Optional Internal Printer (Sectional View)................ 14

Figure 1-9 – Islander PLUS with Data Key Reader (Optional) ........................................................ 17

Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions .................................................................. 21

Figure 2-1 Islander PLUS Lower Protective Plate ........................................................................... 31

Figure 2-2 Standard Bottom Metal Plate's Knockout –Close View ................................................. 31

Figure 2-3 Conduit Fitting ................................................................................................................ 33

Figure 2-4 Conduits Layout for Mechanical Pump .......................................................................... 34

Figure 2-5 Conduits Layout for Electronic Pump ............................................................................ 35

Figure 2-6 Power Equipment Connections ....................................................................................... 38

Figure 2-7 Power Supply Components and Grounding Studs ......................................................... 39

Figure 2-8 VAC Power Supply – Jumpers Setup ............................................................................. 39

Figure 2-9 Islander PLUS ground description .................................................................................. 40

Figure 2-10 Communications Cable Wiring .................................................................................... 41

Figure 3-1 Islander PLUS– Installation Control Drawing................................................................ 44

Figure 3-2 Home Base Station with 4 Mechanical Pumps – System Diagram ................................ 46

Figure 3-3. Home Base Station with 8 Mechanical Pumps – System Diagram ............................... 47

Figure 3-4 Home Base Station with Electronic Pumps – System Diagram ..................................... 48

Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections ..................................... 51

Figure 3-6 Islander PLUS Terminal Block, Power and LAN Connections (8 pumps) ................... 52

Figure 3-7 Pedestal Pole Installation ................................................................................................ 54

Figure 3-8 Base Plate Installation (Example) ................................................................................... 55

Figure 3-9 Rosette (Upside down view) ........................................................................................... 55

Figure 3-10 Rosette Dimensions ...................................................................................................... 55

Figure 3-11 Expansion Bolt .............................................................................................................. 56

Figure 3-12 Conduit Fitting .............................................................................................................. 57

Figure 3-13 Terminal Lug ................................................................................................................ 58

Figure 3-14 Islander PLUS Terminal Block..................................................................................... 63

Figure 3-15 Islander PLUS - Terminal Block (8 pumps) ................................................................. 64

Figure 3-16 Islander PLUS – Terminal Block –4 Mechanical Pump - Wiring List Label ............... 64

Figure 3-17 Islander PLUS – Terminal Block – 8 Mechanical Pump - Wiring List Label .............. 65

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Figure 3-19 Mechanical Pump – Twin Dispenser Connections ....................................................... 68

Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections .......... 69

Figure 3-21 Terminal Block and 3-Wire Pulser – Wiring Connections ........................................... 70

Figure 3-22 Terminal Block and 2-Wire Pulser – Wiring Connections ........................................... 71

Figure 3-23 Islander PLUS Terminal Block – Wiring List Label .................................................... 73

Figure 3-24 Tokheim Electronic Pump - Wiring Diagram ............................................................... 74

Figure 3-25 Current Loop Electronic Pump - Wiring Diagram........................................................ 75

Figure 3-26 RS-485 Electronic Pump - Wiring Diagram ................................................................. 76

Figure 3-27 Terminal Block – TLG Wiring Link ............................................................................. 77

Figure 3-28 Journal Printer – General View ..................................................................................... 78

Figure 3-29 Journal Printer – Rear Panel.......................................................................................... 79

Figure 4-1. Printer Module in Islander PLUS .................................................................................. 81

Figure 4-2. Printer Module within Islander PLUS ........................................................................... 82

Figure 4-3. Printer Module– Main Components ............................................................................... 83

Figure 4-4. Printer Connector ........................................................................................................... 84

Figure 4-5. Printer Connector – Pin-out Description ........................................................................ 84

Figure 4-6. Printer Module – Jumpers Default Configuration.......................................................... 86

Figure 4-7. Printer Module– Jumpers Configuration Examples ....................................................... 87

Figure 4-8. Door Handle and Paper Lock Lever .............................................................................. 88

Figure 4-9. Printer - Paper Replacement .......................................................................................... 89

Figure 4-10. Pressing Paper-Lock Lever .......................................................................................... 92

Figure B-1 Islander PLUS – Wiring Diagram (Mechanical Pump) ............................................... 122

Figure B-2 Islander PLUS – Wiring Diagram (Electronic Pump) .................................................. 123

Figure B-3 Islander PLUS for 8 hoses – Wiring Diagram ............................................................. 124

Figure 1. HID Unit and Connector ................................................................................................. 126

Figure 2. HID Holder and Nuts ...................................................................................................... 126

Figure 3. OrCU Location in Islander PLUS 8-Hoses ..................................................................... 127

Figure 4. Rectangular Plate Connecting Points Location ............................................................... 128

Figure 5. HID back cover Removal ................................................................................................ 128

Figure 6. Attaching Back Cover to HID Holder ............................................................................. 129

Figure 7. Assembled Back Cover and HID Holder ........................................................................ 129

Figure 8. HID Mounted on Pedestal Door ...................................................................................... 130

Figure 9. Upper Left Corner Spacer ............................................................................................... 130

Figure 10. HID Connector Inserted to OrPT Connector ................................................................. 131

Figure 11. Placing Hand Tag Label on Pedestal ............................................................................. 132

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LIST OF TABLES

Table 1-1. Islander PLUS - Standard Models.................................................................................... 18

Table Page

Table 1-2. Pump Card Definition ..................................................................................................... 19

Table 2-1. Conduits into Islander PLUS .......................................................................................... 32

Table 2-2. Islander PLUS, Cables Type ........................................................................................... 37

Table 2-3. Islander PLUS, Cables Routing ...................................................................................... 37

Table 3-1. Islander PLUS, Assembly Parts ...................................................................................... 53

Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition ........... 59

Table 3-3. Islander PLUS for 8 hoses Terminal Block -8 Mechanical Pump – Connections

Definition ........................................................................................................................................... 61

Table 4-1. Printer Main Components ............................................................................................... 83

Table 4-2. Printer Module Connector – Pin-out Description ........................................................... 84

Table 4-3. Printer Troubleshooting .................................................................................................. 93

Table 5-1. Islander PLUS Troubleshooting ....................................................................................... 96

Table 5-2. OrPT Troubleshooting ................................................................................................... 102

Table 5-3. Printer Troubleshooting ................................................................................................. 106

Table 5-4. Communication Troubleshooting................................................................................... 108

Table 1. HID Installation Kit Items ................................................................................................. 125

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0

SECTION 1

GENERAL DESCRIPTION

1-1. SCOPE

This manual is provided to assist you in installing Islander PLUS / ICR PLUS. The system must be
installed as described in this manual to ensure the system reliability and proper operation.

This manual includes a general and functional description of the products, their main components,
installation requirements and procedures.

This manual is intended for qualified authorized installers of Islander PLUS / ICR PLUS and its
components. It is also intended for the Island electrician.

This document refers to Islander PLUS (including the model with 8 mechanical hoses) and ICR
PLUS. Whenever Islander PLUS is mentioned it also refers to ICR PLUS with the exceptions
mentioned in section 1-5.2 below.

1-2. DESCRIPTION

The Islander PLUS is a fuel control and data acquisition system. Islander PLUS system is
self-contained in a forecourt compatible and weather-resistant cabinet installed on top of a pedestal.

Islander PLUS (see Figure 1-1) is a core component in Gasboy’s solution for Home Base Refueling
Station (Home Base Station). Islander PLUS provides the central function of Site Controller. It
also fulfills other essential services on the Island such as Vehicle/Driver Identification System
(FuelPoint PLUS), Transaction data storage, Forecourt devices control and more. Its ergonomic
design, as well as its user-friendly operating program, enables fast and accurate service for the
driver in the refueling site.

Islander PLUS can control up to 8 mechanical hoses or up to 64 electronic hoses. The hoses may
be linked together or standalone.

Islander PLUS is equipped with the OrPT, a Payment Panel and communication receptacle. The
Payment Panel is equipped with an alphanumeric LCD (graphic LCD, optional) and a keyboard to
interface with the client. This enables the Islander PLUS to support all common refueling
identification devices such as: Vehicle/Driver Identification Unit (FuelPoint PLUS), magnetic
cards, contact-less RFID tags, keypad entry and others.

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Figure 1-1 - Islander PLUS / ICR PLUS - General View

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1-3. SYSTEM OVERVIEW

1-3.1. Islander PLUS System

Islander PLUS is an innovative product that enables refueling in Home Base stations for fleets
authorized vehicles or drivers. Islander PLUS electronically locks all dispensers and pumps thereby
ensuring that only appropriately authorized vehicles and plants receive the required fuel. The
system also ensures accurate recording of each transaction (see Figure 1-2).

The heart of the Home Base Station solution is the SiteOmat automation software. SiteOmat runs
on an embedded operating system on the OrCU (Orpak Controller Unit). OrCU is an embedded
hardware platform designed to survive the harsh gas station environment. It uses a solid state Flash
disk and RTC (Real Time Clock) with back-up, along with surge suppressors for transient and noise
immunity. The system also includes power fail recovery mechanisms.

1-3.2. Vehicle Identification – FuelPoint PLUS

Vehicle Identification is an important option for maximal control and savings on fuel expenditure.
The dispenser is authorized to refuel after a positive identification of the vehicle and only while the
nozzle is inside the fuel inlet of the identified vehicle. All transaction information is automatically
recorded. A combined vehicle and driver identification is also possible for tight tracking.

1-3.3. Remote Web Access

Remote Web-based capabilities for monitoring, management and maintenance are available. A
standard PC with Internet Browser (Explorer) is used for management of the site either locally or
remotely (secured). There is no need for special management software; thanks to the built-in Web
server technology integrated into the station controller and a large variety of communication links is
supported – both wired and wireless.

1-3.4. Head Office

Centralized management is provided by the optional Fleet and Fuel Head Office server. The Fleet
and fuel Head Office consolidates the data from multiple sites and generates reports, including
exception reports. It also enables control of the limits and restrictions placed on the various fleet
vehicles. Furthermore, authorized fleet personnel are able to log-in remotely and are always in
control. Head office enables authorized users to control and manage wet stock inventory on all
stations including orders, deliveries and reports.

1-3.5. Restriction s and Limits

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

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1-3.6. Islander PLUS Capabilities for Forecourt Management

Islander PLUS provides the following operational features for a comprehensive Forecourt
management:

• Supports over 50 different types of dispensers in use in many countries. For UL listing; this

product has only been evaluated for use with UL Listed Dispensers.

• Advanced electronic support of mechanical dispensers, enabling pump with totalized, preset

and price update

• Tank Level Gauging System (TLG) available for several brands. For UL listing; this product

has only been evaluated for use with UL Listed TLG’s.

• Support of large variety of communication links: cellular, dial-in modem, VPN, satellite,

ADSL and more.

Figure 1-2 - Islander PLUS in Home Base Station - General Configuration Diagram

1-3.7. System Workflow Example

Following are examples of an operational workflow for self-service at the Home Base Station.

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1-3.7.1. Refueling Scenario with FuelPoint PLUS

A motorist stops for fuel at the station. His authorization device for the fueling transaction is a
FuelPoint PLUS mounted in his car. The client lifts the nozzle and inserts it in the car inlet.

The FuelPoint PLUS information is automatically read and sent to the Site Controller (OrCU)
for authentication and approval. Upon approval, the fueling transaction starts, at the end of
which the transaction data is kept internally and transfer to the Fuel Head Office (FHO) for
future billing. Once the refueling is completed, the motorist replaces the nozzle to pump.

1-3.7.2. Refueling Scenario with Magnetic Cards

A motorist stops for fuel at the station. His authorization device for the fueling transaction is a
magnetic card. The client swipes the card through the magnetic card reader on the Payment
Panel.

The magnetic card information is read and sent to the Site Controller (OrCU) for authentication
and approval. The client lifts the nozzle and inserts it in the car inlet. Upon approval, the
fueling transaction starts, at the end of which the transaction data is kept internally. The data is
transferred to the Fuel Head Office (FHO) for future billing.

The client may add more data to the transaction, by manually entering the information using the
Payment Panel keyboard, or by scanning a barcode in the Barcode Reader (optional) on the front
panel. Once the refueling is completed, the motorist replaces the nozzle to pump.

In both options, the motorist may print a transaction ticket from the Islander PLUS printer
(optional).

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1-4. ISLANDER PLUS STRUCTURE

1-4.1. Main Components

Following is a short description of the Islander PLUS main sub units (see Figure 1-3 and
Figure 1-5):

Orpak Controller Unit (OrCU)

Orpak Controller Unit (OrCU) is a complete
forecourt controller with its own embedded
operating system. The unit consists of an
embedded hardware platform with a solid state
Flash hard disk, Real Time Clock (RTC) with
back up, along with surge suppressors for
transient and noise immunity

OrCU features two separate and isolated networks
(TCP/IP over Ethernet). One network l inks the
Islander PLUS system components. The second
network is intended for external remote
communication (Head Office, 3rd party systems).

This network is protected by SSL security.
OrCU includes a built-in server for Web access trough an internet browser (Explorer).

Wireless Gateway Terminal (WGT) (Optional)

WGT (Wireless Gateway Terminal) receives both
DataPass and FuelOpass vehicle data, decrypts the
information and transmits it to the Station automation
system in a secure manner over an RF signal.

To obtain maximal grid availability, several WGT units

are installed at the station to create a robust 'mesh'
network. This setup enables the RF signal to travel through various routes and bypass possible
interferences (such as a big truck/bus).

The units that provide data to the WGT are:
DataPass - DataPass is a miniature unit that connects to the vehicle bus and captures data from the

vehicle CPU/BUS. It then transmits this data to the nearest Wireless Gateway Terminal (WGT) in
the forecourt.

FuelOpass - FuelOpass is a passive vehicle identification tag for refueling. Its encrypted data
includes the account to be charged and is read by the Nozzle Reader device using RFID contactless
technology.

Nozzle Reader (NR) - Nozzle Reader is a self contained unit installed on the nozzle which reads
the FuelOpass data using contactless technology.

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OrPT Panel

a LAN (Ethernet) link.

Outdoor Printer (Optional)

The Islander PLUS includes an optional printer for purchase receipts
printout, as well as data output. The printer is linked to the central payment
terminal that sends to it the transaction data for printout (see Figure 1-7).

The OrPT panel consists of Payment Panel and communication
equipment. The Panel is equipped with an alphanumeric LCD
(graphic LCD, optional) and a keyboard to interface with the
client. The Payment Panel is equipped with several
authorization options: Magnetic card reader, RFID tag reader
and barcode reader (optional). These authorization tools enable
the Islander PLUS to accept all common authorization methods
such as: Credit cards, magnetic cards, contact-less RFID tags
and Bar Codes.

OrPT supports keyboard entry for authorization, and other
parameters’ input from the user such as odometer, engine hours,
vehicle plate number and PIN code.

The OrPT panel is connected to the Site Controller (OrCU) via

The thermal printer is installed at the center of the Islander PLUS pedestal
door. It includes an integrated paper cutter, paper feeder, paper spool and an
"End of paper" warning sensor.

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8-Port CommVerter

The 8-Port CommVerter consists of a
communication board for all Islander PLUS
electronic units and for the peripheral equipment
interface.

The CommVerter includes two MPI-C cards for
interface to the mechanical pumps, an Ethernet
Switch, RS/485 ports and one RS/232 port. For
electronic pump, a different interface card is
installed. See Chapter 3 for more details.

The CommVerter communicates with the Site
Controller (OrCU) via a LAN (Ethernet) link.

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1-4.2. Islander PLUS Internal Configuration – Mechanical Pump

Figure 1-3 shows a general configuration diagram of the Islander PLUS up to four mechanical
pumps.

Figure 1-3 - Internal Configuration Diagram – 4 Mechanical Pump

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Figure 1-4 shows a general configuration diagram of the Islander PLUS for eight mechanical
pumps.

Figure 1-4 - Internal Configuration Diagram – 8 Mechanical Pumps

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1-4.3. Islander PLUS Main Components Location

The following Figure 1-5 shows the location of the main components of the Islander PLUS, without
the Printer. Figure 1-6 shows the location of the main components of the Islander PLUS for 8 hoses.
Figure 1-7 and Figure 1-8 show the location of the Printer within the two configurations, when it is
installed.

Figure 1-5 - Internal Components Location –4 Mechanical Pumps

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Figure 1-6 - Internal Components Location –8 Mechanical Pumps

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Figure 1-7 – Islander PLUS with Optional Internal Printer (Sectional View)

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Figure 1-8 – Islander PLUS for 8 hoses with Optional Internal Printer (Sectional View)

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1-5. AVAILABLE CONFIGURATIONS

1-5.1. General

Islander PLUS is available in several configurations, in accordance with its intended use and with
the components installed. All configurations are manufactured in accordance with specific
customer request and receive a Part Number.

The following paragraphs describe the several configurations, and their devices composition.

1-5.2. Islander PLUS / ICR PLUS

Islander PLUS is supplied with the OrCU (Orpak Controller Unit) embedded in the unit. In this
configuration, Islander PLUS performs as full station controller, providing functions such as
authorization unit, central forecourt devices controller, linked to the Head Office, etc.

In ICR PLUS configuration, the OrCU is removed from the pedestal. The ICR PLUS operates as an
authorization terminal in order to ease the use of the system in large home base stations. ICR PLUS
is linked to another Islander PLUS or CFN PLUS in order to connect to the Head Office. In this
configuration, the OrCU in the Islander PLUS pedestal is shared by both units.

1-5.3. Printer Option

The printer in the Islander PLUS /ICR PLUS is provided as an option. The printer issues a printout
of the transaction to the driver.

1-5.4. Vehicle Identification System

Some options are available for vehicle identification in the Islander PLUS /ICR PLUS:

• FuelPoint PLUS - WGT (Wireless Gateway Terminal) is Vehicle identification process

performed in a wireless mode. WGT can be installed on top of the Islander PLUS pedestal
or in an external outdoor unit (P/N PA04000001). WGT receives DataPass or FuelOpass
signals, decrypts their information and transmits it to the Station automation system (OrCU)
in a secure manner over an RF signal. This setup enables the RF signal to travel through
various routes and bypass possible interferences (such as a big truck/bus). The transmission
signal range is 10 meters. The WGT is designed to be installed in a designated external box
on the station wall or in a pedestal. The WGT should be connected to the OrCU box using
CAT5E cable.
More than one WGT outdoor unit can be mounted in one station to ensure improved RF area
coverage. In this case one WGT box is Master and the other(s) are routers. For further
details, refer to WGT outdoor unit Installation Guide, document no. MDE-4815.

• No vehicle identification unit: The vehicle identification process will be done

manually by the driver with any accepted authorization devices such as cards, tags or
manual entry.

1-5.5. Dispensers

Islander PLUS can support either mechanical or electronic dispensers, in accordance with its
configuration.

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Mechanical dispensers require the installation of MPIC cards on the 8-port Convertor. Electronic
dispensers (Tokheim, Current Loop, RS-485) require installation of interface relevant cards on the
8-port Convertor.

1-5.6. Contactless Tags/Cards 1-5.6.1. Data Key Sockets – Fleet key

The pedestal can be supplied with an optional key reader for payment with Data Key
Sockets (see Figure 1-9). The key reader is installed behind the printer door cover on the
front panel.

Figure 1-9 – Islander PLUS with Data Key Reader (Optional)

1-5.6.2. HID Device

The pedestal can be supplied with an optional HID card reader for payment with specific
cards. The HID reader supports Track 2 and 26/37/32 bit card formats. For further
information on HID reader format setup, please refer to the OrPT Installation, Setup and
Operation Manual, P/N MDE-4819.

The HID reader is installed behind the decorative black cover of the front panel (Refer to
Appendix C).

1-5.6.3. Configurations

Table 1-1 define all the available product numbers for the different configurations of Islander
PLUS:

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Name

Gilbarco P/N

Orpak P/N

Table 1-1. Islander PLUS - Standard Models

Islander PLUS for Electric Pumps PA039400000 800938103
Islander PLUS for Mechanical Pumps - 2 hose PA039400200 800938105
Islander PLUS for Mechanical Pumps - 4 hose PA039400400 800938107
Islander PLUS for Mechanical Pumps - 8 hose PA039400801 800941009
Islander PLUS w/Fleetkey for Electric Pumps PA039401000 800938167

Islander PLUS w/Fleetkey for Mechanical Pumps - 2 hose
Islander PLUS w/Fleetkey for Mechanical Pumps - 4 hose

PA039401200

PA039401400

800938169

800938171

Islander PLUS w/Fleetkey for Mechanical Pumps - 8 hose PA039401801 800941073
Islander PLUS w/HID for Electric Pumps PA039402000 800938231

Islander PLUS w/HID for Mechanical Pumps - 2 hose
Islander PLUS w/HID for Mechanical Pumps - 4 hose

PA039402200
PA039402400

800938233
800938235

Islander PLUS w/HID for Mechanical Pumps - 8 hose PA039402801 800941137
Islander PLUS w/Printer for Electric Pumps PA039400010 800938135

Islander PLUS w/Printer for Mechanical Pumps - 2 hose
Islander PLUS w/Printer for Mechanical Pumps - 4 hose
Islander PLUS w/Fleetkey & Printer for Electric Pumps

Islander PLUS w/Fleetkey & Printer for Mechanical Pumps ­2 hose

PA039400210
PA039400410
PA039401010

PA039401210

800938137
800938139
800938199
800938201

Islander PLUS w/Fleetkey & Printer for Mechanical Pumps ­4 hose

ICR PLUS PA039500000 800938102
ICR PLUS w/Mechanical Pumps - 4 hose PA039500400 800938106
ICR PLUS w/Fleetkey PA039501000 800938166

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PA039401410

800938203

ICR PLUS w/Fleetkey & Mechanical Pumps - 4 hose PA039501400 800938170
ICR PLUS w/HID PA039502000 800938230
ICR PLUS w/HID & Mechanical Pumps - 4 hose PA039502400 800938234
ICR PLUS w/Printer PA039500010 800938134
ICR PLUS w/Printer & Mechanical Pumps - 4 hose PA039500410 800938138
ICR PLUS w/Fleetkey & Printer PA039501010 800938198
ICR PLUS w/Fleetkey, Printer & Mechanical Pumps - 4

hose

PA039501410

800938202

NOTE

Islander PLUS with 8 mechanical dispensers does
not support TLG or additional electronic dispensers
from the pedestal. Those devices require an external
box.

In the order form, you are required to define also the P/N for the specific pump card in use (MPI-C,
Tokheim, Current Loop or RS-485 – see Table 1-2).

Table 1-2. Pump Card Definition

No. Pump Card Description Gilbarco P/N Orpak P/N

1 Tokheim interface (8P) P.B. M09680B028 819223420
2 Current Loop interface (8P) P.B. M09680B029 819223431
3 RS232 Interface (8P) P.B. M09680B016 819223451
4 RS485 Interface (8P) P.B. M09680B017 819223460
5 MPI-C + Sub Interface (8P) P.B. M09680B019 819223490

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1-6. SECURITY AND PROTECTION

1-6.1. General

The transaction activities of the Islander PLUS are secured and protected for transmission and
authorization activities.

1-6.2. Authorization Security

The contact-less tags include Triple DES encrypted data for user identification and billing.
Consequently, Islander PLUS includes a special Security Application Module (SAM) for
decryption and matching identification. Upon tag reading, Islander PLUS attempts to decrypt the
string from the tag. Islander PLUS disregards Tags whose security scheme does not match the
Islander PLUS internal SAM.

1-6.3. Network Security

The Ethernet LAN is isolated from the external WAN by the Site Controller (OrCU). In case of
remote maintenance, a firewall should be applied either at the router level or preferably at the Home
Base Station level.

1-6.4. RF Network Security

Islander PLUS EIA 802.15.4 RF network is encrypted, using the AES 128 security standard.

1-6.5. Maintenance Se cu ri t y

Islander PLUS maintenance and setup procedures require inserting a user name and password for
access. For further information, please refer to the SiteOmat Setup Manual. P/N MDE-4817

1-7. HOUSING

Islander PLUS system enclosure is made of a metal cabinet, with plastic panels, in the form of a
pedestal. The enclosure is weather-proof in order to sustain the harsh environment of a Home Base
Station. The Payment Panel of the Islander PLUS is made of rugged plastic. The devices in its
front panel are sealed to prevent humidity and dust penetration.

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

Figure 1-10 shows Islander PLUS/ICR PLUS dimensions in inches.

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Figure 1-10 - Islander PLUS / ICR PLUS - Dimensions

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1-8. SPECIFICATIONS

Dimensions:

W x H x D: 9.45 x 61.02 x 9.45 " (24 x

W x H x D: 9.45 x 61.02 x 9.45 " (24 x

Power supply output

12 VDC +/- 20%

12 VDC +/- 20%

In use "Off" level (Input)

0 to 20 VAC

0 to 20 VAC

The following physical, electrical and environmental specifications are applicable to the Islander
PLUS:

Islander PLUS - Pedestal with up to 4

mechanical pumps

Islander PLUS - Pedestal with up to 8

mechanical pumps
Name Islander PLUS Islander PLUS
Supply voltage: 100 – 240 VAC 120 / 240 VAC
Power consumption: 2A max. 2A - 1A max. (Accordingly)
Operating temperature:

Storage temperature: -40 °F to +158 °F (-40°C to +70 °C)

-22 °F to +113 °F (-30°C to +45 °C)

-4 °F to +113 °F F (-20°C to +45 °C)
(Option with printer)

-40 °F to +104 °F (-40°C to +40 °C)

-4 °F to +104 °F (-20°C to +40 °C)

(Option with printer)

-40 °F to +158 °F (-40°C to +70 °C)

Humidity: 80% Non-condensing 80% Non-condensing

Communication
interface:

155 x24 cm)
RS-485 – 9600 bps, Half-Duplex

RS-232
Ethernet RJ-45 - 10 Mbps

155 x24 cm)

RS-485 – 9600 bps, Half-Duplex

RS-232

Ethernet RJ-45 - 10 Mbps

EIA 802.15.4

Pump Control Maximum
Current
(4 Solid State Relay
Channels):

voltage to Pulsar unit

Motor maximum: 1 HP at 115 VAC or
2 HP at 230 VAC. Additional external
relay must be used if pump motor
exceeds these limitations.

80 mA max
Power supply maximum
output current

Pulsar Input High level
voltage

9 to 15 VDC

3 mA
Pulsar Input High level
sink current (@15V)

In use "On" level (Input) 100 – 240 VAC, 50/60 Hz, 2 W (20

mA)

EIA 802.15.4
Motor maximum: 3/4 HP at 115 VAC

or 1.5 HP at 230 VAC. Additional
external relay must be used if pump
motor exceeds these limitations.

30 mA max

9 to 15 VDC

3 mA

100 – 240 VAC, 50/60 Hz, 2 W (20
mA)

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1-9. STANDARDS

1-9.1. Communication Standards

Islander PLUS communicates, in its different models, over the following standards:

• RS-232 link

• RS-485 link

• TCP/IP over Ethernet

• EIA 802.15.4

1-9.2. Security Standards

• Triple DES encryption for Payment Devices (Contact-less tags, magnetic stripe cards, etc.)

• AES 128 for RF Network Communication

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1-10. MANUAL STRUCTURE

This manual comprises of the following sections:
Section 1: General Description
This section provides a general description of the Islander PLUS system.
Section 2: Preliminary Installation Procedures
This section provides the preliminary installation requirements and procedures to be performed

before installing Islander PLUS.
Section 3: Islander PLUS Installation Procedures
This section provides a detailed description of Islander PLUS installation requirements and

procedures.
Section 4: Printer
This section provides a detailed description of the Islander PLUS printer, as well as basic

troubleshooting instructions.
Section 5: Maintenance
This section provides general maintenance instructions for the Islander PLUS as well as a

comprehensive troubleshooting guide.
Section 6: Glossary
This section includes a glossary of terms employed for the Islander PLUS description.
Appendix A: Station Survey
This section includes instructions for conducting gas station survey.
Appendix B: Wiring Diagram
This section includes the Wiring Diagram of the Islander PLUS.
Appendix C: HID Assembly Installation
This section includes the description of HID device installation.

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1-11. USING THIS MANUAL

This manual includes alerting comments inserted along the document, in order to draw the reader’s
attention to important issues. The comments are accompanied by symbols for ease of reference.
The following comment types are used:

WARNING

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

CAUTION

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

TIP

This note is aimed for using the system in better
efficiently way.

NOTE

This comment is of importance for emphasizing.

INSIGHT

More detailed technical/ functional information in
regard relevant issue.

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1-12. REFERENCES

For additional and complementary information regarding the Islander PLUS system, please refer to
the following manuals:

 OrPT - Installation, Setup and Operation Manual For Home-Base Stations, Document No.

MDE-4819

 8-Port CommVerter User’s Manual, Document No. MDE-4812
 SiteOmat Station Controller User’s Manual, Document No. MDE-4817
 SiteOmat Station Controller Setup Manual, Document No. MDE-4818

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26

0

SECTION 2

PRELIMINARY INSTALLATION INSTRUCTIONS

2-1. GENERAL

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

• Preliminary instructions

• Wiring and Wire Conduits requirements

2-2. PRELIMINARY INSTALLATION INSTRUCTIONS

2-2.1. General

NOTE

Perform a site survey of the station prior to
installation (see Appendix A)

Installation procedures and requirements depend, to some extent, on the specific fuel dispenser
models and the site layout. Therefore, use the information in this section to develop installation
plans for each specific installation. Since installation requirements vary widely from case to case,
no installation hardware is supplied by the equipment manufacturer, and installation planners must
develop their own requirements.

The customer should provide an installation plan, designed by an authorized engineer, and
applicable to all authorities. This plan design should reflect the existing electric infrastructure of
the site.

2-2.2. Precautions and Safety Notes

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

WARNING

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

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28

 Remember that the Home Base Gas Station environment is highly flammable and

combustible. Therefore, make sure that actual installation is performed by experienced
personnel, licensed to perform work in Home Base Station and capable of implementing all
applicable requirements of the National Fire Protection Association NFPA-30 “Flammable
and Combustible Liquids Code”, NFPA-30A “Code for Motor Fuel Dispensing Facilities
and Repair Garages”, NFPA-70A “National Electric Code”, federal, state and local codes
and any other applicable safety codes and regulations.

 System power may come from more than one source. Disconnect all power sources,

including pumps, before attempting to work on the system.

 Install the Islander PLUS in an area in accordance with the safety restrictions as shown in

Figure 3-1.

 Islander PLUS site preparation is in the customer’s responsibility.
 Do not connect power to the Islander PLUS and other peripherals in the whole system,

including pumps, until complete installation is inspected and certified.

 Do not perform any metal work in the hazardous area. Sparks generated by drilling,

tapping and metal work operations could ignite fuel vapors and flammable liquids, resulting
in death, serious personal injury, property loss and damage to you and other persons.

 When working in any open area of Home Base Station, beware of passing vehicles that

could hit you. Block off the work area to protect yourself and other persons. Use safety
cones or other signaling devices.

2-3. CONDUITS LAYOUT/INSTALLATION SPECIFICATIONS

The installation of the Islander PLUS requires preparing beforehand the cables layout in the Home
Base Station. This procedure consists of installing conduits within the Island, inserting the proper
cables and setting the proper power equipment and sensors.

This chapter provides the procedures for infrastructure groundwork. These procedures consist of, in
a descending order of performance:

• Wire conduits installation

• Cables routing within the conduits

• Power equipment setup

• Forecourt equipment wiring

2-4. CONDUITS

2-4.1. General

The installation of the Islander PLUS in the Island requires digging and setting several conduits in
the Station ground. The conduits are required for the routing and protection of the different types of
cables in use in a Home Base Station with Islander PLUS. In sites where the infrastructure is
already setup, you can use the existing conduits only if they meet the requirements defined below.

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2-4.2. Conduit Requirements

Conduits must comply with:

• All conduits must be made and installed according to local regulations.

• High-voltage AC and low-voltage DC must NOT be combined in a common conduit,

junction box or wire through.

• RS-485 or LAN communication must not exceed 330 feet (100 m). Cables must be

inserted in a separate low voltage conduit, away from AC wires. Communication
range can be extended with 3rd party devices.

• RS-232 communication must not exceed 50 feet (15 m). RS-232 communication

shielded cable must be inserted in a separate low voltage conduit, away from AC
wires. Communication range can be extended with 3rd party devices.

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

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

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

knockouts provided in the lower protective plate (see Figure 2-1). Do not make any
other hole in this unit. If you must make holes at locations other than those provided,
contact Gasboy for approval.

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

2-4.3. Conduits at Islander PLUS

Islander PLUS includes a protective plate below the Terminal Block in the installation pole. The
plate is perforated with circles that enable to insert four conduits (see Figure 2-1, Figure 2-2):

• Four conduits of 1" diameter

• Four conduit of 1/2" diameter

The conduits are in use for:

• Two conduits of 1" diameter are intended for high voltage cables

• One conduit of 1" is intended for low voltage conduit

The cables and wires to/from the other units in the forecourt are connected to the Terminal Block.
The cables and wires are inserted through the conduits in accordance with their types and routed to
their sources.

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Figure 2-1 Islander PLUS Lower Protective Plate

Figure 2-2 Standard Bottom Metal Plate's Knockout –Close View

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31

2-4.4. Required Conduits in Island

1

Low voltage

Pulser, TLG, LAN

The types of conduits in the Island are a function of the different equipment, and their location in
the Island. Basically, there are two functional conduit s:

• High voltage conduits

• Low voltage conduits

The following conduits are required in the Island:

• High voltage conduits

o AC power for Islander PLUS
o Pump control from pumps to Islander PLUS
o Pump In-use signal from pumps to Islander PLUS

• Low voltage conduits

o Internet line from LAN at Office to Islander PLUS
o RS-232 communication line from TLG at office to Islander PLUS
o RS-485/422/C.L. or Tokheim
o Pulser from pumps to Islander PLUS

• Grounding

o At least 10 mm (OOO AWG) Grounding cable to pump chassis
o At least 10 mm (OOO AWG) Grounding cable to Islander PLUS pole

(Connected to the external chassis grounding post)

o Grounding cable to TLG – in accordance with TLG manufacturer

instructions.

• Tank conduit

o TLG probe

2-4.5. Required Conduits in Islander PLUS

Four conduits can be inserted in the Islander PLUS, each carrying specific wires, as listed in
Table 2-1 and shown in Figure 2-4.

Table 2-1. Conduits into Islander PLUS

No. Conduit Type Type

2 High voltage AC power, GND , In-use
3 High voltage Control

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2-5. CONDUITS INSTALLATION

2-5.1. General

This paragraph describes the infrastructure groundwork necessary to install the conduits in the
Island (see Figure 2-1).

2-5.2. Installing Conduits in Island

Proceed as follows:

1. Determine the location of the Islander PLUS in the Island.

2. Dig and prepare passageways for the necessary conduits

3. Take care to route the following conduits to the inspection boxes:

• Low voltage cables inspection box:

o One conduit to Office (control room)
o One conduit to each pump
o Two conduits to Islander PLUS

• High voltage cables inspection box:

o One conduit to Office (control room)
o One conduit to each pump
o Two conduits to Islander PLUS

2-5.3. Sealing Conduits

The conduits shall be sealed in accordance with NFPA requirements and local regulations, to
prevent the passage of gases through conduits, cables and conductors. The fittings are requested
wherever volatile liquids or gases are present in the surroundings (see Figure 2-3).

Figure 2-3 Conduit Fitting

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Figure 2-4 Conduits Layout for Mechanical Pump

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34

Figure 2-5 Conduits Layout for Electronic Pump

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35

2-6. CABLES INSERTION

2-6.1. General

This paragraph describes the requirements and procedures for the insertion of cables in the conduits.

NOTE

All devices in the system must be connected to the
same electric power phase.

NOTE

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

CAUTION

For supply connections, use wires suitable for at
least 90°C.

Signal wiring connected in this box must be rated at
least 300 V

2-6.2. Types of Cables

Table 2-2 lists the types of cable in use for the wiring of the Islander PLUS system.

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36

Table 2-2. Islander PLUS, Cables Type

Power cable, 3x1.5 mm2 NYY (14 AWG),
in accordance with local standards

Control to pumps (valves or engine)

In-use signal

similar to Belden 9729 cable

4

GND

Ground cable 0.4" (10.8 mm2)

No.

Functional Description

From

Through Insert

Cable Type (*)

No.

Function Type

1 AC Power from Office

2 Pulser Data communication cable, 300 V RMS,

90ºC, shielded twisted pair, oil resistant, 24
AWG, low capacitance below 60 PF/meter

TLG (RS -232)
3 LAN CAT5E, Shielded, 300 V RMS, 90ºC

similar to Belden 121700A

2-6.3. Cables Routing

Route the cables from the peripherals and the Office to Islander PLUS as listed in Table 2-3 and
shown in Figure 2-4. Proceed as follows:

Table 2-3. Islander PLUS, Cables Routing

1 Power AC Office High voltage conduit 1
2 GND Office High voltage conduit 4
3 TLG Office Low voltage conduit 2
4 LAN Office Low voltage conduit 3
5 Control, Pump A Pump A High voltage conduit 1
6 In-use, Pump A Pump A High voltage conduit 1
7 Pulser, Pump A Pump A Low voltage conduit 2
(*) Refer to Table 2-2.

2-7. POWER SETUP

2-7.1. General

The power equipment shall be installed in the Main Power Cabinet of the station office. It should
include the following:

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37

• Mains Circuit Control Box (MCC)

• Uninterruptible Power Supply (UPS) – Online ("True") UPS

Figure 2-6 shows the requested connections of the power equipment.

Figure 2-6 Power Equipment Connections

Beside the power equipment, other components shall be connected to the power supply such as the
TLG and the dispensers.

2-7.2. Islander PLUS for 8 hoses - AC Power Supply

Setup

In Islander PLUS for 8 hoses the power supply can be fed either 110 VAC or 220 VAC. The Mains
cable is first connected to the terminal block. Between the terminal block and transformer the
system uses a Line Filter in order to attenuate conducted radio frequencies - RFI, electromagnetic
interference (EMI) - between the line and the equipment (see Figure 2-7). AC power is then
supplied to an AC/AC High to Low Transformer – 110/220 VAC to 25 VAC. The transformer
requires jumpers' setup for either 110 VAC or 220 VAC Mains input, as shown in Figure 2-8. A
settings label is also found on top of the transformer.

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38

1

32 4 5 6

220VAC JUMPER

1

32 4 5 6

110VAC JUMPERS

~

Neutral

~

Neutral

Figure 2-7 Power Supply Components and Grounding Studs

WARNING

Islander PLUS is shipped configured for 110 VAC
Mains power supply. Take care to set it accordingly
to your local Mains power supply specifications.
Failure to do so may result in damages.

Figure 2-8 VAC Power Supply – Jumpers Setup

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39

2-7.3. Connecting the Power Equipment

Proceed as follows:

• External Mains

o Connect Mains power to the Mains Circuit Control Box (MCC)
o Wire one 0.4" (10mm) ground cable from the Mains ground

connection to the MCC.

• Uninterruptible Power Supply (UPS)
o Connect the MCC to the UPS.

• If any doubt concerning grounding arises, ask for a ground test performed by a

qualified electrician.

2-7.4. Grounding

Proper system grounding is an extremely important part of the system installation. As with the AC
power, the grounds for all system components should return to the same circuit breaker panel. This
helps you to assure a common ground throughout the system, which is necessary for protection of
the RS-485 data loop circuitry. Ground for all system devices should be wired to the breaker panel
ground bus bar, which in turn should be grounded to a ground rod. A conduit ground does not
provide sufficient ground. It is recommended that the neutral and ground bus bars be bonded
together when it is not prohibited by local codes.

Figure 2-9 Islander PLUS ground description

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2-8. WIRING THE PERIPHERALS

2-8.1. Pump Wiring

Islander PLUS is capable of directly driving pump motors up to 3/4 HP at 115 VAC or 1-1/2 HP at
230 VAC. Additional external relay must be used if pump motor exceed this limitations. A separate
circuit breaker should be supplied for each dispenser. Wire the pump as follows:

• Wire one Mains AC cable from the UPS-MCC to the pump enclosure, intended for

the pump motor.

• For an electronic pump, wire RS485 / Current Loop / Tokheim communication cable

from the Islander PLUS to the pump head.

• Wire one 0.4" (10 mm) ground cable from the Mains ground connection to the pump

chassis.

• The communication cable shield must be connected to ground at one end-side only,

preferably at the controller installation side (see Figure 2-10).

Figure 2-10 Communications Cable Wiring

2-8.2. TLG wiring

RS-232/LAN is used for communication between the TLG and Islander PLUS. Follow these
installation requirements when installing the RS-232/LAN communications lines:

NOTE

These requirements shall be compatible with the
recommendations of the TLG manufacturer.

• Distance: the following distances must be adhered to when installing the

communication lines:

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

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41

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

• Conduit: All direct connect RS-232/LAN cable must be in a low voltage conduit

away from any AC wires.

• Cable: The type of cable required should be according to the device it is connected

to. The wire used must be stranded and not a solid core. Select a cable specification
in accordance with local environment conditions.

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42

0

SECTION 3

ISLANDER PLUS INSTALLATION PROCEDURES

3-1. GENERAL

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

• Islander PLUS Pedestal installation

• Wiring

• Post installation check.

3-2. INSTALLATION SPECIFICATIONS

3-2.1. General

NOTE

Perform a site survey of the station prior to
installation

Installation procedures and requirements depend, to some extent, on the specific fuel dispenser
models and the site layout. Therefore, use the information in this section to develop installation
plans for each specific installation. Since installation requirements vary widely from case to case,
no installation hardware is supplied by the equipment manufacturer, and installation planners must
develop their own requirements.

The customer should provide an installation plan, designed by an authorized engineer. This plan
design should reflect the existing electric infrastructure of the site.

3-2.2. Precautions and Safety Notes

Prior to actual installation activities, carefully observe the precautions and safety notes detailed in
paragraphs 2-2.2 and 2-4.2, and at the opening pages.

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3-2.3. Safety Distances

Figure 3-1 shows the safety distances required for the installation of the Islander PLUS adjacent
to the dispensers. When mounting the Islander PLUS, a minimum clearance of 18 inches
(0.5m) between the unit and any of the pumps or the dispensers must be maintained. This
clearance allows room for the wiring and maintenance of the system.

Islander PLUS is designed and approved for installation and use at a convenient location at or near
fuel Island in the appropriate hazardous (classified) location:

• Where hazardous location is classified as Class 1, Division 2 and it does not extend higher

than 18 inches (0.5m) from surface and

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

Figure 3-1 Islander PLUS– Installation Control Drawing

3-3. HOME BASE STATION - OVERVIEW

3-3.1. General

Prior to installation, you are required to obtain an overview of the Home Base Station functional
architecture. This overview is required in order to draw an architecture diagram with all
components and their communication links.

Figure 3-2 shows a functional diagram of the links within the Home Base Station with 4 mechanical
pumps.

Figure 3-3 shows a functional diagram of the links within the Home Base Station with 8 mechanical
pumps.

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44

Figure 3-4 shows a functional diagram of the links within the Home Base Station with electronic
pumps.

3-3.2. Home Base Station Architecture

The Home Base Station functional architecture consists of the following levels:

• Main Power Cabinet and Home Base Station forecourt

• Head Office Center

3-3.2.1. Main Power Cabinet

The Main Power Cabinet includes the following components:

• Mains Circuit Control Box (MCC)

• Uninterruptible Power Supply (UPS)

• TLG Controller

3-3.2.2. Home Base Forecourt

The Home Base Forecourt includes the following components:

• Islander PLUS/ICR PLUS

• Dispenser(s) – up to four nozzles for each Islander PLUS/ ICR PLUS. Fo r UL

listing; this product has only been evaluated for use with UL Listed Dispensers.

• One or more Underground gas tanks

• TLG probe for each gas tank. For UL listing; this product has only been

evaluated for use with UL Listed TLG’s.

3-3.2.3. Head Office System (Optional)

The Head Office system consists of fully integrated management hardware and software tool that
supports Home Base Station and small gas stations with their sale management of products
including inventory management and reporting.

The Head Office system is a remote control center that stores, processes and analyzes all the
transactions at the Home Base Station. The Head Office Station provides an integrated retail
solution.

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45

Figure 3-2 Home Base Station with 4 Mechanical Pumps – System Diagram

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46

Figure 3-3. Home Base Station with 8 Mechanical Pumps – System Diagram

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47

Figure 3-4 Home Base Station with Electronic Pumps – System Diagram

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48

3-4. MAPPING THE SITE– EXAMPLE

3-4.1. General

This paragraph shows an example of the mapping of a site. This procedure consists of the
following steps:

• Locating and mapping all objects of the site

• Assigning logical identifications (Id.) to the devices

• Assigning the Ethernet and Serial addresses of devices linked to the network

• Obtaining a functional and physical map of the devices in the site.

3-4.2. Locating all objects of the site

• Locate the roads around the site

• Locate the islands and their dispensers

• Locate the fuel tanks

• Locate the intended position of the Islander PLUS pole

• Locate the intended position of each ICR PLUS

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

3-4.3. Assigning Logical IDs 3-4.3.1. To each fuel tank

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

• Assign its fuel code and name

• Assign its TLG Probe (AP) Id.

3-4.3.2. To each Dispenser Unit

• Assign an id. to every dispenser name and Pump Server

• Assign an id. to every dispenser pump (P)

• Assign an id. to every pump CPU addresses if any

• Assign an id. to its nozzles (N)

• Assign to each nozzle the tank (T) Id. to whom it is linked.

3-4.3.3. In the Islander PLUS pole

• Assign the Islander PLUS its id.

• Assign the panel printer (PP) its Id.

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

3-4.4. Mapping

• Draw a map of the site.

• Use the map methodology and Ids. for later setup configuration.

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3-5. CONNECTIONS TO ISLANDER PLUS

All connections to the Islander PLUS must be performed to the Terminal Block located at the
bottom of the Islander PLUS pedestal (see Figure 3-5, Figure 3-6). The required connections are:

1. Dispenser wiring connections:

• Pulser (Low Voltage)

• In Use signal (High voltage)

• Valve (High voltage)

2. Communications

• RS-232/LAN to TLG Controller to Gas Tank

• RS-485 for Orpak peripheral device

• Pump communication line (e.g. Current Loop, RS485, Tokheim, RS422)

3. Mains AC Power and Ground

4. LAN connection

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Figure 3-5 Islander PLUS Terminal Block, Power and LAN Connections

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51

Figure 3-6 Islander PLUS Terminal Block, Power and LAN Connections (8 pumps)

3-6. INSTALLING THE ISLANDER PLUS

PEDESTAL POLE

3-6.1. General

The Islander PLUS pedestal is mounted in the Home Base Station (see Figure 3-7) on a base
plate that is fastened to the Home Base Station concrete floor. The base plate upper side
includes 4 holding screws immersed in the Home Base Station concrete floor.

3-6.2. Installation Pro ced ure Steps

Installation of the Islander PLUS pedestal consists of the following general steps:

• Running conduits to the pedestal site

• Installing the Base Plate

• Installing the Pedestal Base

• Installing the Pedestal

• Running the cable conduits to the installation hole and filling all open holes

• Installing the Rosettes to firmly lock the Islander PLUS pedestal.

3-6.3. Pedestal Site Preliminary Setup Procedures

Proceed as follows:

1. Determine the spot for the Islander PLUS pedestal installation

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52

2. Run cable conduits for each type of cables to the spot:

1 Islander PLUS

1

2

814906200

Bolt, ICU

4 3 815103000

Nut, M10

8 4 815300200

Washer, Flat, M10

8 5 814908400

Bottom Plate

1 6 814982200

Rosette, Islander PLUS

1

• One High Voltage conduit from the dispenser

• One Low Voltage conduit from the dispenser

• One Low Voltage conduit from the Office

• One High Voltage conduit from the Mains Distribution Box

3. In the installation spot, dig a hole on the ground of the following dimensions:

• Width: 11.8" (300 mm)

• Length: 11.8" (300 mm)

• Depth: 15.75" (400 mm)

4. Run the cable conduits to the hole.

5. All holes in this panel must be filled when the unit is installed.

3-6.4. Installation Assembly Parts

Table 3-1 lists the assembly parts for the installation of the Islander PLUS.

Table 3-1. Islander PLUS, Assembly Parts

Item No. Orpak Part Number Description Qty

3-6.5. Base Plate Installation Procedures

Proceed as follows (see Figure 3-7):

1. Prepare the Bottom Plate (5 in Table 3-1) with four ICU bolts (2 in Table 3-1) attached to it

with M10 nuts (3 in Table 3-1). Check that the bolts protrude from the plate
by 1.4" (35 mm).

2. Insert the Bottom Plate in the hole

3. Take care that all power and communication conduits pass through the central hole in the

Bottom Plate

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4. Pour concrete type B200 in the hole as a support base for the pole

Figure 3-7 Pedestal Pole Installation

5. Take care that, as the concrete fills the hole, the Bottom Plate is on a same level as the

ground (asphalt, pedestal) on which it is installed. Check repeatedly that the Bottom Plate is
leveled. Otherwise make the necessary adjustments so the plate is perfectly leveled

6. Wait the necessary time for the concrete to harden and dry (as per local practice), Check

anew that the Bottom Plate is leveled.

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Figure 3-8 Base Plate Installation (Example)

Figure 3-9 Rosette (Upside down view)

Figure 3-10 Rosette Dimensions

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55

3-6.6. Pedestal Installation Instructions

Proceed as follows:

1. Remove the four M10 nuts (1 in Figure 3-8) from the four bolts attached to the Bottom

Plate.

2. Insert the Pedestal Base (3 in Figure 3-7) (1 in Table 3-1) on top of the Bottom Plate.

3. Insert the Pedestal Pole (4 in Figure 3-7) (1 in Table 3-1) on top of the Pedestal Plate.

4. Anchor the Pedestal Pole onto the Pedestal Plate with the four bolts (1 in Figure 3-7)

protruding from the inner ground.

5. Secure the Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in

Figure 3-8) (3 in Table 3-1)

6. Insert the Rosette (see Figure 3-9) (6 in Table 3-1) on the Pedestal Base, and secure it to

Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in Figure 3-8)
(3 in Table 3-1).

3-6.7. Base Plate Installation Procedures – Optional

The Base Plate can be attached to the spot ground by four expansion bolts as an option.
Proceed as follows:

1. Set the Bottom Plate (1 in Figure 3-7) (5 in Table 3-1) in the spot and mark the four holes

location for drilling

2. Drill four holes in the installation spot

3. Insert four expansion bolts (see Figure 3-11) in the holes. Check that the bolts protrude

from the Bottom Plate by 1.4" (35 mm).

4. Insert the Bottom Plate on the spot so that its installation holes fit with the protruding bolts.

5. Take care that all power and communication conduits pass through the central hole in the

Bottom Plate

Figure 3-11 Expansion Bolt

7. Insert the Pedestal Base (3 in Figure 3-7) (1 in Table 3-1) on top of the Bottom Plate.

8. Insert the Pedestal Pole (4 in Figure 3-7) (1 in Table 3-1) on top of the Pedestal Plate.

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56

9. Anchor the Pedestal Pole onto the Pedestal Plate with the four expansion bolts protruding

from the inner ground.

10. Secure the Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts

(1 in Figure 3-8) (3 in Table 3-1)

11. Insert the Rosette (see Figure 3-9) (6 in Table 3-1) on the Pedestal Base, and secure it to

Pedestal Pole with four M10 flat washers (4 in Table 3-1) and M10 nuts (1 in Figure 3-8) (3
in Table 3-1).

3-6.8. Sealing Conduits

The conduits shall be sealed in accordance with NFPA requirements and local regulations, to
prevent the passage of gases through conduits, cables and conductors. The fittings are requested
wherever volatile liquids or gases are present in the surroundings (see Figure 3-12).

Figure 3-12 Conduit Fitting

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3-7. WIRING

3-7.1. General

After completing the installation procedure, perform the following wiring procedures. The wiring is
performed in the Islander PLUS Terminal Block only.

The wires should be pulled from the conduits that protrude from the Installation Base, or in the
opposite direction, from the Terminal Block to the device in the Home Base Station.

3-7.2. Types of Wiring

The wiring in the Terminal Block differs in accordance with the type of pump installed in the Home
Base Station. There are several types of pumps:

• Mechanical Pump

• Electronic Pumps

The following paragraphs provide the wiring requirements for each type of pump.

3-7.3. Wiring Requirement

For any type of wire, prior to inserting it to the terminal block, proceed as follows:

1. Insert any wire with a terminal lug only.

2. Use the proper Terminal Crimper to attach the lug to the wire.

3. For UL Listing; The Terminal Lug must be a UL recognized component.

Figure 3-13 Terminal Lug

TIP

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

3-7.4. Types of Cable

The following cables are in required for the Islander PLUS installation:

• Power cable – In accordance with local regulations

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58

• LAN cable – CAT5e

• RS232/485/422/Tokheim/Pulser – Communication cable, twisted pair, separately

shielded, low capacitance, e.g. Belden 8723 or equivalent.

NOTE

The shield should be connected to Ground in one
side of the cable only, preferably on the Islander
PLUS side.

• Antenna cable - Communication cable, Twisted pair, separately shielded, low

capacitance (exampl e – Belden 9729/30)

3-8. MECHANICAL PUMP – WIRING

3-8.1. General

The wiring for mechanical pumps is provided in two modes:

• Table 3-2 and Table 3-3 list the wiring in the sequential order of the terminals. This

table provides the signal name and a functional description of the signal.

• Figure 3-16 and Figure 3-17 show the wiring list for connection to the Terminal, as

published in the Wiring Label added to the inner door. The Wiring Label follows
the physical location of the wires in the Terminal Block, as shown in Figure 3-14
and Figure 3-15.

3-8.2. 4 – Mechanical Pump – Terminal Block - Pin-Out Connections

The Islander PLUS Terminal Block connections for a 4-Mechanical Pump are listed in Table 3-2.

Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition

Terminal No. Signal Name Functional Description

1 TX-RS232 Data link to TLG Con troller
2 GND-RS232 Transmit / Transmit/Receive Data Return /

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59

Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition

Terminal No.

Signal Name

Functional Description

8

PULSER_2

Pulser Input – Nozzle 2

13

GND_3_P

Nozzle Grounding – Nozzle 3

18

+12V_4_P

+12 VDC Output to Pulser – Nozzle 4

23

IN USE 1 B(-)

Handle Up – AC In Use signal return - Nozzle 1

28

LINE 2

Pump control 220/110 VAC Input - Nozzle 2

33

LOAD 3

Pump control output - Nozzle 3

3 RX-RS232 Receive Data interface
4 RS-485 GND Data link to Density Probes Console Box /
5 RS-485_+ Density Display
6 RS-485_- Chassis / Positive / Negative connections
7 PULSER_1 Pulser Input – Nozzle 1

9 PULSER_3 Pulser Input – Nozzle 3
10 PULSER_4 Pulser Input – Nozzle 4
11 GND_1_P Nozzle Grounding – Nozzle 1
12 GND_2_P Nozzle Grounding – Nozzle 2

14 GND_4_P Nozzle Grounding – Nozzle 4
15 +12V_1_P +12 VDC Output to Pulser – Nozzle 1
16 +12V_2_P +12 VDC Output to Pulser – Nozzle 2
17 +12V_3_P +12 VDC Output to Pulser – Nozzle 3

19 IN USE 1 A Handle Up - In Use signal input - Nozzle 1
20 IN USE 2 A Handle Up - In Use signal input - Nozzle 2
21 IN USE 3 A Handle Up - In Use signal input - Nozzle 3
22 IN USE 4 A Handle Up - In Use signal input - Nozzle 4

24 IN USE 2 B(-) Handle Up – AC In Use signal return - Nozzle 2
25 IN USE 3 B(-) Handle Up – AC In Use signal return - Nozzle 3
26 IN USE 4 B(-) Handle Up – AC In Use signal return - Nozzle 4
27 LINE 1 Pump control 220/110 VAC Input - Nozzle 1

29 LINE 3 Pump control 220/110 VAC Input - Nozzle 3
30 LINE 4 Pump control 220/110 VAC Input - Nozzle 4
31 LOAD 1 Pump control output - Nozzle 1
32 LOAD 2 Pump control output - Nozzle 2

34 LOAD 4 Pump control output - Nozzle 4
35 LINE IN (115/230v) Line Connection, Islander PLUS power input
36 NEUTRAL IN (115/230v) Neutral Connection, Islander PLUS power input

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Table 3-2. Islander PLUS Terminal Block -4 Mechanical Pump – Connections Definition

Terminal No.

Signal Name

Functional Description

38

BARRIER 1

Connection to Safety Barrier for Nozzle 1 (1st wire)

43

BARRIER 2

Connection to Safety Barrier for Nozzle 2 (2nd wire)

2

GND_2_P

Nozzle Grounding – Nozzle 2

8

GND_8_P

Nozzle Grounding – Nozzle 8

37 GROUND IN Ground Connection, Islander PLUS power input

39 BARRIER 2 Connection to Safety Barrier for Nozzle 2 (1st wire)
40 BARRIER 3 Connection to Safety Barrier for Nozzle 3 (1st wire)
41 BARRIER 4 Connection to Safety Barrier for Nozzle 4 (1st wire)
42 BARRIER 1 Connection to Safety Barrier for Nozzle 1 (2nd wire)

44 BARRIER 3 Connection to Safety Barrier for Nozzle 3 (2nd wire)
45 BARRIER 4 Connection to Safety Barrier for Nozzle 4 (2nd wire)
46 LAN 2 CONNECTOR

RJ45, separate LAN connector for connection to external
network

3-8.3. 8-Mechanical Pump – Terminal Block - Pin-Out Connections

The Islander PLUS Terminal Block connections for an 8-Mechanical Pump are listed in Table 3-3.

Table 3-3. Islander PLUS for 8 hoses Terminal Block -8 Mechanical Pump – Connections

Definition

Terminal No. Signal Name Functional Description

1 GND_1_P Nozzle Grounding – Nozzle 1

3 GND_3_P Nozzle Grounding – Nozzle 3
4 GND_4_P Nozzle Grounding – Nozzle 4
5 GND_5_P Nozzle Grounding – Nozzle 5
6 GND_6_P Nozzle Grounding – Nozzle 6
7 GND_7_P Nozzle Grounding – Nozzle 7

17 +12V_1_P +12 VDC Output to Pulser – Nozzle 1
18 +12V_2_P +12 VDC Output to Pulser – Nozzle 2
19 +12V_3_P +12 VDC Output to Pulser – Nozzle 3
20 +12V_4_P +12 VDC Output to Pulser – Nozzle 4
21 +12V_5_P +12 VDC Output to Pulser – Nozzle 5

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Terminal No.

Signal Name

Functional Description

22 +12V_6_P +12 VDC Output to Pulser – Nozzle 6

25

IN USE 1 A

Handle Up – AC In Use signal input - Nozzle 1

26

IN USE 2 A

Handle Up – AC In Use signal input - Nozzle 2

32

IN USE 8 A

Handle Up – AC In Use signal input - Nozzle 8

38

IN USE 6 B(-)

Handle Up – AC In Use signal Return - Nozzle 6

39

IN USE 7 B(-)

Handle Up – AC In Use signal Return - Nozzle 7

45

LINE 5

Pump control 220/110 VAC Input - Nozzle 5

59

GROUND IN

Ground Connection, OrIC power input

9

PULSER_1

Pulser Input – Nozzle 1

23 +12V_7_P +12 VDC Output to Pulser – Nozzle 7
24 +12V_8_P +12 VDC Output to Pulser – Nozzle 8

27 IN USE 3 A Handle Up – AC In Use signal input - Nozzle 3
28 IN USE 4 A Handle Up – AC In Use signal input - Nozzle 4
29 IN USE 5 A Handle Up – AC In Use signal input - Nozzle 5
30 IN USE 6 A Handle Up – AC In Use signal input - Nozzle 6
31 IN USE 7 A Handle Up – AC In Use signal input - Nozzle 7

33 IN USE 1 B(-) Handle Up – AC In Use signal Return - Nozzle 1
34 IN USE 2 B(-) Handle Up – AC In Use signal Return - Nozzle 2
35 IN USE 3 B(-) Handle Up – AC In Use signal Return - Nozzle 3
36 IN USE 4 B(-) Handle Up – AC In Use signal Return - Nozzle 4
37 IN USE 5 B(-) Handle Up – AC In Use signal Return - Nozzle 5

40 IN USE 8 B(-) Handle Up – AC In Use signal Return - Nozzle 8
41 LINE 1 Pump control 220/110 VAC Input - Nozzle 1
42 LINE 2 Pump control 220/110 VAC Input - Nozzle 2
43 LINE 3 Pump control 220/110 VAC Input - Nozzle 3
44 LINE 4 Pump control 220/110 VAC Input - Nozzle 4

46 LINE 6 Pump control 220/110 VAC Input - Nozzle 6
47 LINE 7 Pump control 220/110 VAC Input - Nozzle 7
48 LINE 8 Pump control 220/110 VAC Input - Nozzle 8
57 NEUTRAL IN (115/230v) Neutral Connection, OrIC power input
58 LINE IN (115/230v) Line Connection, OrIC power input

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Terminal No.

Signal Name

Functional Description

10 PULSER_2 Pulser Input – Nozzle 2

13

PULSER_5

Pulser Input – Nozzle 5

14

PULSER_6

Pulser Input – Nozzle 6

52

LOAD 4

Pump control output - Nozzle 4

11 PULSER_3 Pulser Input – Nozzle 3
12 PULSER_4 Pulser Input – Nozzle 4

15 PULSER_7 Pulser Input – Nozzle 7
16 PULSER_8 Pulser Input – Nozzle 8
49 LOAD 1 Pump control output - Nozzle 1
50 LOAD 2 Pump control output - Nozzle 2
51 LOAD 3 Pump control output - Nozzle 3

53 LOAD 5 Pump control output - Nozzle 5
54 LOAD 6 Pump control output - Nozzle 6
55 LOAD 3 Pump control output - Nozzle 7
56 LOAD 8 Pump control output - Nozzle 8

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Figure 3-14 Islander PLUS Terminal Block

63

Figure 3-15 Islander PLUS - Terminal Block (8 pumps)

Figure 3-16 Islander PLUS – Terminal Block –4 Mechanical Pump - Wiring List Label

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64

installed in accordance with the manufacturer instructions. The Pulse rate

Figure 3-17 Islander PLUS – Terminal Block – 8 Mechanical Pump - Wiring List Label

3-8.4. Mechanical Pump - Required Connections

This paragraph describes the required wiring connections between the mechanical pump and the
Islander PLUS. Figure 3-18 and Figure 3-19 show a schematic diagram of the connections between
the Islander PLUS and the mechanical pump components. Figure 3-20 to Figure 3-22 show a
detailed wiring diagram between the Islander PLUS terminal block and the pump components.

Pulse Input Wires: The dispenser outputs pulses to the system by means of the Pulser unit,

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65

per volume (liter/gallon) is determined by the Pulser unit. It is

programmed as a "factor" by the Head Office controller.

Handle Status Input
Wires:

Authorization Output
Wires:

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

The dispenser requires an authorization signal from the Islander PLUS to
start a sale transaction. Without this authorization signal, the electric valve
(or pump) will not open and the sale transaction will not begin. The
Islander PLUS switches the AC power signal to the valve. When the
dispenser receives the authorization signal, fuel is flowing.

NOTE

All terminal block references and numbers in the
following drawings (up to figure 3.27) refer to
Islander PLUS with 4 pumps only.

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Figure 3-18 Mechanical Pump – Single Dispenser Connections

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67

Figure 3-19 Mechanical Pump – Twin Dispenser Connections

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Figure 3-20 Islander PLUS and Mechanical Pump - Terminal Block Detailed Connections

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69

3-8.5. Mechanical Pump - Pulser Connections

This paragraph describes the required wiring connections between the pulser in the mechanical
pump and the Islander PLUS. The system can accept many types of pulsers, please contact Gasboy
for more information. Two types of pulser can be found in trucks:

- Electronic pulser

- Mechanical pulser
Connect the Islander PLUS to the Pulser in accordance to its characteristics.

NOTE

Pulser should be installed in accordance with the
pulser manufacturer's instructions. Some pulsers do
not have a barrier, in that case you must add a pulser
barrier! Barriers are not provided with Islander
PLUS.

3-8.5.1. Electronic Pulser

• 3-Wire Pulser - requires an external power source (12V) in order to operate

Figure 3-21 shows a schematic diagram of the connections between the Terminal Block and a
3-wire Pulser.

Figure 3-21 Terminal Block and 3-Wire Pulser – Wiring Connections

3-8.5.2. Mechanical Pulser

• 2-Wire Pulser - powered by the Islander PLUS.

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Figure 3-22 shows a schematic diagram of the connections between the Terminal Block and a
2-wire Pulser.

Figure 3-22 Terminal Block and 2-Wire Pulser – Wiring Connections

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3-9. ELECTRONIC PUMP – WIRING DESCRIPTION

3-9.1. General

The wiring in the Terminal Block differs in accordance with the type of electronic pump installed in
the Home Base Station. There are several types of electronic pumps. The wiring of some of the
major one are described below. The major pumps are:

• Tokheim

• Current Loop

• RS-485

• RS - 422

See Figure 3-23 for the wiring list label applied within the inner wall of the unit. This label consists
of a wiring list table for the Terminal block. You are requested to connect the Forecourt equipment
to OrIC in accordance with this table:

• The rows are the connection ports in the Terminal Block, in an ascending order.

• Each column is dedicated for a specific pump.

• Each cell defines the signal attached to the Terminal Block port.

The wiring of some of the major pumps is described below.

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Figure 3-23 Islander PLUS Terminal Block – Wiring List Label

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3-9.2. Tokheim Electronic Pump

The wiring for the Tokheim electronic pump is provided as follows:

• Figure 3-24 shows the specific wiring connections between OrIC and the Tokheim

pump nozzle, and the terminals that differ from the Mechanical Pump.

• Figure 3-23 shows the wiring list for connection to the Terminal, as published in the

Wiring Label added to the inner door. The Wiring Label follows the physical
location of the wires in the Terminal Block, as shown in Figure 3-14.

Figure 3-24 Tokheim Electronic Pump - Wiring Diagram

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3-9.3. Current Loop Electronic Pump

The wiring for the Current Loop electronic pump is provided as follows:

• Figure 3-25 shows the specific wiring connections between OrIC and the Current

Loop pump nozzle, and the terminals that differ from the Mechanical Pump. The
figure shows the serial connection between two Current Loop pumps and the
Terminal Block.

• Figure 3-23 shows the wiring list for connection to the Terminal, as published in the

Wiring Label added to the inner door. The Wiring Label follows the physical
location of the wires in the Terminal Block, as shown in Figure 3-14.

Figure 3-25 Current Loop Electronic Pump - Wiring Diagram

NOTE

Recommended maximum distance is 2600'.

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3-9.4. RS-485 Electronic Pump

The wiring for the RS-485 electronic pump is provided as follows:

• Figure 3-26 shows the specific wiring connections between OrIC and the RS-485

pump nozzle, and the terminals that differ from the Mechanical Pump. The figure
shows the prallel connection between two RS-485 pumps and the Terminal Block.

• Figure 3-23 shows the wiring list for connection to the Terminal, as published in the

Wiring Label added to the inner door. The Wiring Label follows the physical
location of the wires in the Terminal Block, as shown in Figure 3-14.

Figure 3-26 RS-485 Electronic Pump - Wiring Diagram

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3-10. WIRING TO GENERAL COMPONENTS

3-10.1. General

The following paragraphs show the specific wiring between the Islander PLUS Terminal Block and
components common in both types of Home Base Stations, either with mechanical or electronic
pump.

3-10.2. Connection to TLG Controller

Figure 3-27 shows the required connection between the TLG controller in the site and the Islander
PLUS Terminal Block.

Figure 3-27 Terminal Block – TLG Wiring Link

3-10.3. Connection to Journal Printer

A journal printer (P/N M09680B090, see Figure 3-28) is available for journaling important
operations such as all transactions on hard copy.

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Figure 3-28 Journal Printer – General View

The Journal Printer is connected to the 8-Port Commverter through one of the channels of the RS­485 Module (P/N M09680B017) with a shielded twisted- pair cable (maximum length 100m). The
Printer is provided with the SPRN interface board which includes an RS-485 connector (see
Figure 3-29).

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Figure 3-29 Journal Printer – Rear Panel

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3-11. POST-INSTALLATION CHECKLIST

After completing the installation procedure, inspect carefully the connection between the Islander
PLUS and the external power mains and the data sources.

In particular, pay attention to the following issues:

• Correct wiring

o Is all the wiring inserted in metal conduits?
o Is the AC and the DC wiring inserted in separate conduits, throughs and so

on?

o Is the system/peripheral equipment powered on a separate dedicated breaker?
o Is the system grounded properly?
o Are the cables correctly routed in the Island?
o Are the communication lines under the maximum allowable distance?

 RS-232: 50 feet (15m)
 RS-485: 330 feet (100m)
 Antenna wire:

• 330 feet (100m) for VIU

• 50 feet (15m) for FuelOpass

• Clean dirt and wire remnants

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

CAUTION

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

3-12. ISLANDER PLUS SETUP

Please refer to the SiteOmat Setup Manual P/N MDE-4817

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0

SECTION 4

PRINTER

4-1. OVERVIEW

This section describes the (optional) Printer, its technical characteristics and its operation. The
Printer (, P/N M09680B034) provides the customer a receipt once a refueling action is completed.

This section provides as well as instructions. It includes instructions on replacing the printer paper
roll. In addition, this section includes several recommended steps for checking the printer
operability.

Figure 4-1. Printer Module in Islander PLUS

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The Printer provides visual and audio indications of its activities by means of two green LEDs and a
buzzer. The visual and audio indications are used to indicate whether the printer runs out of paper
or when there is approximately 25% of the paper roll left or when the receipt is ready.

Figure 4-2. Printer Module within Islander PLUS

4-2. DESCRIPTION

The Printer is a compact, ruggedized thermal printer suitable for the harsh environment of the gas
station. It uses thermal printer paper only (55 gr., 57 mm width, 101 mm diameter).

The Printer is connected to the OrPT via an RS-485 link. The Printer requires a 24 – 26 VDC power
supply input.

The Printer enclosure is designed to survive the harsh forecourt environment. It uses Spark Gaps
protection for the links and 1.5 KV isolation.

The printer includes two sensors for paper usage alerts:

• Low paper sensor - activated when there is approximately 25% of the paper

roll left

• End paper sensor - activated when printer paper runs out completely

The paper usage and receipt indications include a buzzer sound and LED indicators or the
combination of both.

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4-3. MAIN COMPONENTS

Printer Cutter Lock

Shifts away from the printer and unlocks the cutter lock

Thermal Printer

Prints the text on the thermal paper by means of the thermal head

The Printer consists of the following main items (see Table 4-1 and Figure 4-3).

Table 4-1. Printer Main Components

Item Functionality

Printer Cutter Cuts the paper

Paper Lock Lever Push down to unlock the paper lock
Electronic Board Printer controller

Figure 4-3. Printer Module– Main Components

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4-4. PRINTER CONNECTOR PIN-OUT

4

GND

RS-485 GND

The printer connector is located on the printer rear panel (see Figure 4-4). It provides the printer
both the communication link and the power supply input (24 – 26 VDC). The power is supplied via
an external power supply.Figure 4-5 and Table 4-2 show the Printer connector pin-out description.

Figure 4-4. Printer Connector

Figure 4-5. Printer Connector – Pin-out Description

Table 4-2. Printer Module Connector – Pin-out Description

Pin Number Functionality Description

1 VIN - DC Power Supply GND
2 VIN + DC Plus Voltage
3 SLN Not Applicable

5 485 - RS-485 Communication Line
6 485 + RS-485 Communication Line

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4-5. INDICATORS

The printer module includes a buzzer to provide audio display on the following events:

• Printing is in progress

• Paper alerts – paper run out or approximately 25% left (see paragraph 4-8.1)

• Receipt ready

The printer also includes LEDs (see Figure 4-3) in its front panel for communication monitoring.
At turn on, the LEDs and the buzzer are activated for a short period of time.

4-6. SPECIFICATIONS

This section lists the physical, electrical and environmental specifications of the printer, as follows:
Supply Voltage: 24 - 26 VDC
Power Consumption: Standby 15 W

Typical 60 W
Communication Interface: RS-485 – 9600 bps Half-Duplex
Paper Type: Thermal, 57 mm (W), 55 gr., 101 mm diameter
Paper Maximum Printing

54 mm
Area Width:

Maximum Printing Speed: 120 mm/sec.
Autocutter: Integrated

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4-7. INSTALLATION PRINTING PARAMETERS

4-7.1. Jumpers Configuration

The Printer includes jumpers that enable setting the RS-485 address and selecting the number of
copies automatically produced during each printout.

The jumpers are set in a matrix of 8 jumpers, where the five first jumpers determine the RS485
address. The last three jumpers determine the number of copies. Figure 4-6 shows the jumpers
default configuration, where the RS485 Address = 70 Hex. Figure 4-7 provides examples of
jumpers configuration and the corresponding RS485 address.

CAUTION

On a single RS485 bus, each device must be
assigned a different address.

Figure 4-6. Printer Module – Jumpers Default Configuration

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