Gasboy PLUS FMS User Manual

FedEx Islander PLUS FMS

Installation Manual

MDE-5067

Computer Programs and Documentation

Gasboy, Greensboro, is an ISO 9001:2000 registered facility. Underwriters Laboratories (UL):

UL File# Products listed with UL

MH4314

All dispensers and self-contained pumping units

MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s

Card reader terminals, Models 1000, 1000P Site Controller, Model 2000S CFN Series Data entry terminals, Model TPK-900 Series Fuel Point Reader System

National Conference of Weights and Measures (NCWM) - Certificate of Compliance (CoC):

Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:

CoC# Product Model # CoC# Product Model # CoC# Product Model #

95-179 Dispenser

9100 Retail Series, 8700 Series, 9700 Series

91-019 Dispenser

9100 Commercial Series

05-002 Atlas

8700K, 8800K, 9100K, 9200K, 9800K

95-136 Dispenser 9800 Series 91-057 Controller

1000 Series FMS, 2000S-CFN Series

California Air Resources Board (CARB):

Executive Order # Product

G-70-52-AM Balance Vapor Recovery G-70-150-AE VaporVac

Registered trademarks

ASTRA

Fuel Point

Gasboy

Keytrol

Slimline

Additional US and foreign trademarks pending.

Other brand or product names shown may be trademarks or registered trademarks of their respective holders.

Non-registered trademarks

Atlas

™

Consola

™

Infinity

™

Federal Communications Commission (FCC) Warning

All Gasboy computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy. Such computer programs and documents may also contain trade secret information. The duplication, disclosure, modification, or unauthorized use of computer programs or documentation is strictly prohibited, unless otherwise licensed by Gasboy.

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate this equipment.

Approvals

Trademarks

Table of Contents

1 – Introduction 1-1

Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 – Important Safety Information 2-1

3 – Installation Procedure 3-1

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Pre-installation Power Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Pre-installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Shutting Down Island. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removing Existing Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Mounting Dry Islander PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Installing FedEx Islander PLUS FMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Downloading Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Installing Islander PLUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Connecting to FedEx Islander PLUS FMS Corporate Network. . . . . . 3-14

4 – SiteOmat Software Set Up 4-1

Software Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Process Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

OrCU Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Setting SiteOmat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pump Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Tank Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Setting Fuel Price . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Unblocking or Activating Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Weights & Measures (W&M) Dongle Activation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Process Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Synchronizing with Fleet Head Office (FHO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

HOCOMM User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Synchronizing FedEx Islander PLUS FMS . . . . . . . . . . . . . . . . . . . . . 4-32

Test Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Testing Procedure for Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Finalizing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Appendix A: Commissioning A-1

Appendix B: Multiple Controller Sites B-1

Installing Multiple Controller FedEx Islander PLUS FMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Gasboy 9800 Series Pumps Business Inventory Reconciliation (BIR) Set Up . . . . . . . . . . . . . . . . . . B-2

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page i

Table of Contents

Appendix C: FedEx Project Site Information Form (Example Only) C-1

Index Index-1

Page ii MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

Purpose Introduction

Verify that you have all the required equipment and software to complete the installation.

IMPORTANT INFORMATION

1 – Introduction

Purpose

This manual provides instructions for installing the FedEx Islander PLUS Fuel Management System (FMS) in the off-site server.

Intended Users

This manual is intended for facility personnel (Operations Manager) who installs the FedEx Islander PLUS FMS.

Required Equipment

Following equipment is required to install the FedEx Islander PLUS FMS:

• FedEx Custom Islander PLUS FMS (PA039400801FX)

• Contents of the FedEx project folder from ftp.gilbarco.com:

- Board Support Package (BSP) - Version 1.08 Service Pack 8

- SiteOmat - Version 6.4.33.098

- Payment Application Interface Service (P

Note: To report any missing or damaged equipment, contact Bob Grif

AIS) - 4.31.1.58

fith at 1-336-547-5654.

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 1-1

Introduction Abbreviations and Acronyms

Abbreviations and Acronyms

Term Description

BIR Business Inventory Reconciliation BSP Board Support Package DEF Diesel Exhaust Fluid DNS Domain Name System FHO Fleet Head Office FMS Fuel Management System GW Gateway HOCOMM Head Office Communicator LAN Local Area Network OrCU Orpak Controller Unit OrPT Orpak Payment Terminal OS Operating System PAIS Payment Application Interface Service POE Power Over Ethernet STP Submersible Turbine Pump WAN Wide Area Network W&M Weights & Measures

Page 1-2 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

2 – Important Safety Information

The EMERGENCY STOP, ALL STOP, and PUMP STOP buttons at the cashier’s station WILL NOT shut off electrical power to the  pump/dispenser. This means that even if you activate these stops, fuel may continue to flow uncontrolled.

You must use the TOTAL ELECTRICAL  SHUT-OFF in the case of an emergency and not the console’s ALL STOP and PUMP STOP or similar keys.

WARNING

Important Safety Information

Note: Although DEF is non-flammable, Diesel is

flammable. Therefore, for DEF cabinets that are attached to Diesel dispensers, follow all the notes in this section that pertain to flammable fuels.

This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death or serious injury, if these safe service procedures are not followed.

Preliminary Precautions

You are working in a potentially dangerous environment of flammable fuels, vapors, and high voltage or pressures. Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment.

Emergency Total Electrical Shut-Off

The first and most important information you must know is how to stop all fuel flow to the pump/dispenser and island. Locate the switch or circuit breakers that shut of f all p ower to all fueling equipment, dispensing devices, and Submerged Turbine Pumps (STPs).

Read the Manual

Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand a procedure, call a Gilbarco Authorized Se rvice Contractor or call the Gilbarco Support Ce nte r at  1-800-800-7498. It is imperative to your safety and the sa fety of ot

hers to understand the procedures before beginning work.

Follow the Regulations

Applicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Fuel Dispensing

Facilities and Repair Garages, NFPA 70; National Electrical Code (NEC), Occupational Safety and Health Administration

(OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operat ion of the equipment.

Replacement Parts

Use only genuine Gilbarco replacement parts and retrofit kits on your pump/dispenser. Using parts other than genuine Gilbarco replacement parts could create a safety hazard and violate local regulations.

Safety Symbols and Warning Words

This section provides important information about warn ing symbols and boxes.

Alert Symbol

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical co mponent s or the electronics of the dispenser requires total electrical shut off of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gilbarco equipment.

Evacuating, Barricading and Shutting Off

Any procedure that requires access to the pump/dispenser or STPs requires the following actions:

• An evacuation of all unauthorized persons and vehicles from

the work area

• Use of safety tape, cones or barrica

• A total electrical shut-off of the affected unit(s)

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 2-1

des at the affected unit(s)

This safety alert symbol is used in this manual and on

warning labels to alert you to a precaution which must be

ed to prevent potential personal safety hazards. Obey

follow safety directives that follow this symbol to avoid possible injury or death.

Signal Words

These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions below must be followed to prevent death, injury or damage to the equipment:

DANGER: Alert

which will result in death or serious injury.

WARNING: A

that could result in death or serious injury.

CAUTION with Alert

unsafe practice which may result in minor injury. CAUTION without Alert symbol: Designates a hazard or un

safe practice which may result in property or

equipment damage.

you to a hazard or unsafe practice

lerts you to a hazard or unsafe practice

mbol: Designates a hazard or

Working With Fuels and Electrical Energy

Prevent Explosions and Fires

Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island.

DEF is non-flammable. Therefore, explosion and fire safety

rnings do not apply to DEF fluid lines.

Important Safety Information

The pump/dispenser contains a chemical known to the State of California to cause cancer.

WARNING

The pump/dispenser contains a chemical known to the State of California to cause birth defects or other reproductive harm.

WARNING

Gasoline/DEF ingested may cause unconsciousness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately.

DEF generates ammonia gas at high er temperatures. When opening enclosed panels, allow the unit to air out to avoid breathing vapors. If respiratory difficulties develop, move victim away from source of exposure and into fresh air. If symptoms persist, seek medical attention.

WARNING

Gasoline inhaled may cause unconsciousness and burns to lips, mouth and lungs. Keep airway open. Seek medical advice immediately.

WARNING

Gasoline/DEF spilled in eyes may cause burns to eye tissue. Irrigate eyes with water for approximately  15 minutes. Seek medical advice immediately.

WARNING

Gasoline/DEF spilled on skin may cause burn s. Wash area thoroughly with clear water. Seek medical advice immediately.

WARNING

DEF is mildly corrosive. Avoid contact with eyes, skin, and clothing. Ensure that eyewash stations and safety showers are close to the work location. Seek medical advice/recommended treatment if DEF spills into eyes.

WARNING

No Open Fire

Open flames from matches, lighters, welding torches or

other sources can ignite fuels and their vapors.

No Sparks - No Smoking

Sparks from starting vehicles, starting or using power tools, burning cigarettes, cigars or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic charge on your body , can ca use a sp ark su f ficient to ign ite fuel vapors. Every time you get out of a vehicle, touch the metal of your vehicle, to discharge any electrostatic charge before you approach the dispenser island.

Working Alone

It is highly recommended that someone who is capable of rendering first aid be present during servicing. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages. This information is available from the American Red Cross. Always advise the station personnel about where you will be working, and caution them not to activate power while you are working on the equipment. Use the OSHA Lockout/Tagout procedures. If you are not familiar with this requirement, refer to this information in the service manual and OSHA documentation.

In an Emergency

Inform Emergency Personnel

Compile the following information and inform emergency personnel:

• Location of accident (for example, addres building, and so on)

• Nature of accident (for example, poss over by car , burns, and so on)

• Age of victim (for example, baby, teenager, middle-age, elderly

)

• Whether or not victim has receiv

ed f

stopped bleeding by pressure, and so on)

• Whether or not a victim has vomited (for example, if swal

lowed or inhaled something, and so on)

s, front/back of

ible heart attack, run

irst aid (for example,

Working With Electricity Safely

Ensure that you use safe and established practices in workin g with electrical devices. Poorly wired devices may cause a fire, explosion or electrical shock. Ensure that grounding connections are properly made. Take care that sealing devices and compounds are in place. Ensure that you do not pinch wires when replacing covers. Follow OSHA Lockout/Tagout requirements. Station employees and service con tra ctors need to understand and comply with this program completely to ensure safety while the equipment is down.

Hazardous Materials

Some materials present inside electronic enclosures may present a health hazard if not handled correctly. Ensure that you clean hands after handling equipment. Do not place any equipment in the mouth.

Page 2-2 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/Tagout

Lockout/Tagout covers serv icing and maintenance o f machines and equipment in which the unexpected energization or 

ipme

start-up of the machine(s) or equ

nt or release of stored energy could cause injury to employ ee s or personnel.  Lockout/Tagout applies to all mechanical, hydraulic, chemical, or o

ther energy , but does not cover electrical hazards.  Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 19

10.333 contains specific Lockout/Tagout provision for

electrical hazards.

Hazards and Actions

WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a serious hazard. Fire or explosion may result, causing serious injury or death. Follow established emergency procedures.

DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.

Collision of a Vehicle with Unit Fire at Island Fuel Spill

The following actions are recommended regarding these hazards:

Important Safety Information

• Do not go near a fuel spill or allow anyone else in the area.

• Use station EMERGENCY CUTOFF immediately. T urn of f all

• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not ve AC power and do not always stop product flow.

remo

• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow

open flames, smoking or power tools in the area.

• Do not expose yourself to hazardous conditions such as fire, spil

• Call emergency numbers.

system circuit breakers to the island(s).

led fuel or exposed wiring.

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 2-3

Important Safety Information

This page is intentionally left blank.

Page 2-4 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

3 – Installation Procedure

AC power is present on the Terminal Blocks in the pedestal. Electrical shock may occur if the operator comes in contact with these connections.

WARNING

If any readings are NOT within the acceptable ranges, then STOP. For further instructions, call Gasboy TAC at 1-800-444-5529.

IMPORTANT INFORMATION

Before You Begin

Use the following checklist to verify you have all the required equipment to complete the installation.

Pre-installation Power Inspection

Installation and reliability issues during the initial roll out of the FedEx project have revealed a high number of sites with electrical issues, excessive noise, due to improper system and panel grounding, and other issues. These issues have made it necessary to verify the quality of the AC power at the island before removing the existing equipment and checking again post installation to verify no issues have been introduced during the installation process.

These checks/tests are simple to complete and must not add entire installation.

Following checks/tests pre-install are designed to identify additional work required, not currently part of the installation scope.

1 Verify that the AC Power for the Islander PLUS System comes from a separate, dedicated

circuit breaker. No other equipment must be powered from this breaker. The system’s pumps or dispensers must not be on this breaker. Power for the system must be 115 VAC + 10%,  47-63 HZ. The system draws 135 watts

Before You Begin

more than 10-15 minutes to the

maximum.

Locate the SYSTEM POWER Terminal Block in the pedestal on the existing system. Use a digital AC voltmeter to measure the following voltages.

Hot to Neutral measured at: ____________ (fill in value) measured by: ____________ (print name) This voltage must be 115 VAC + 10% (104 VAC to 126 VAC). Hot to Ground measured at: ____________ (fill in value) measured by: ____________ (print name) This voltage must be 115 VAC + 10% (104 VAC to 126 VAC). Neutral to Ground measured at: ____________ (fill in value) measured by: ____________ (print name) This voltage must be 0 VAC + 500 millivolts (-500 mV to 500 mV).

Note: If power is not within these specifications,

Put ALL PUMPS into manual override and activate the pumps [ensure Submersible Turbine

correct it before continuing.

Pumps (STPs)/pumping units are ON]. Use a digital AC voltmeter to measure the following voltages

Note: If power is not within these specifications, correct it before continuing.

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 3-1

Before You Begin

DO NOT remove existing system before verifying that there are NO BARRIERS to complete the Islander PLUS installation. If issues are found, call Bob Griffith at 336-547-5654 IMMEDIATELY to discuss optio ns.

WARNING

4 Grounding Method: Proper system grounding is an extremely important part of the system

installation. Grounds for all system devices must be wired to the breaker panel ground bus bar which, in turn, must be grounded to a ground rod. A conduit ground does not provide a sufficient ground. It is recommended that the neutral and ground bus bars be bonded together unless prohibited by local codes.

Pre-installation Checklist

Following pre-installation checklist is designed to ensure proper installation:

Description Checkbox

Check that you have the correct Gasboy Supplied parts:

• PA093400810FX - Islander PLUS FedEx CUSTOM.

• Stage 2 FedEx Islander PLUS Install Guide.

Check the conduit layout, and ensure you have the proper supplies and clearances to complete the installation.

Check all fueling positions for proper operation.

Check all hose reels for proper operation - All hose reels connected to the existing system MUST be connected and controlled by the Gasboy Fleet PLUS system.

Check the E-STOP system for proper operation.

Find the circuit controlling the current FMS. Verify this is a dedicated circuit.

Trace and identify control wires in the existing system.

Know the function of the control wires.

Identify and label the handle switch (in-use), if available.

Identify and label the (line/load) or authorize wires.

Identify and label the pulser wires.

Identify and label the LAN/WAN connections.

Mark all control wires for use when installing the Islander PLUS system.

Page 3-2 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

Shutting Down Island

For issues locating the FedEx Fleet Manager, contact Travis Langston at 1-870-704-5230.

IMPORTANT INFORMATION

The circuit panel must be locked out, tagged out as per normal Gilbarco® safety procedures found in the Gilbarco LMS training module http://wise.gilbarco.com. For more information, refer to GVRSAFEUS50-012 GVR Fueling Site Safety.

CAUTION

Ensure that the facility personnel (Operations Manager) is aware of these steps before the old equipment is removed. Name and contact information for the Operations Manager and site installation parameters will be sent to you by Bob Griffith (1-336-547-5654).

FedEx Project Site Information Form, includes the following [for an example, refer to “FedEx

Project Site Information Form (Example Only)” on page C-1]:

• Operations Manager’s Name and Phone Number.

• Fipay Server IP Address, Subnet Mask, and Gateway IP Address.

• SiteOmat Wide Area Network [WAN Local Area Network (LAN2)] IP Address, Subnet

Mask, a

• FedEx Alpha code - SiteOmat St

• Site Number - SiteOmat Station Code.

Before You Begin

nd Gateway IP Address.

ation Name or Description.

Removing Existing Equipment

The Gasboy Fleet PLUS system will use some of the same control and communication wiring as other third-party FMS. To aid in efficient installation, all control wiring in an existing system must be labeled before disconnection.

Mounting Dry Islander PLUS

To mount the Islander PLUS in the facility, proceed as follows:

1 When installing the Gasboy Islander PLUS at a facility with existing conduits at the fuel

island, it is important to note the dimensions of the pedestal to determine if special fabrication is required for the conduits (see Figure 3-1 on page 4).

2 The pedestal can be cut within UL parameters from the base plate up to 18 inches. Any holes

drilled in the pedestal must only be large enough to fit conduit elbows and must not be inserted above the IS Barrier Plate.

3 Following conduits are required for the Gasboy Islander PLUS pedestal:

• High Voltag e (AC power, pump control, ground, in-use for me

• Low Volta ge (pulser, tank gauge, and LAN).

chanical dispensers).

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 3-3

Before You Begin

61.728

I/S Barrier Plate

Note: Dimensions are in inches.

4 Depending on the installation, you may need to modify the existing conduit wiring to

accommodate the required feeds.

Figure 3-1: Installing Gasboy Islander PLUS

Page 3-4 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

Before You Begin

φ 11 (X4) With Knockout Cover

φ Insert PEM CLS-M4X1 From Other Side (X4)

A3 φ 28.5 (X4) With Knockout Cover

Front of Base - Wide Side

Wide Side

5 Make a template of the conduit configuration for the cutouts in the barrier plate. The cutouts in

the plate must only be cut large enough for the wiring to be pulled through. You will also want to install conduit gaskets to prevent wire damage (see Figure 3-2).

Figure 3-2: Conduit Configuration in Barrier Plate

6 After the pedestal and conduit needs are addressed, place the base plate over the conduits,

wider side faced towards the front of the unit, and mark the island along the outside edge of the base plate as well as the inside holes for the lag bolt placement (see Figure 3-3).

Figure 3-3: Base Plate on Conduits

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 3-5

Installing FedEx Islander PLUS FMS

To install the FedEx Islander PLUS FMS, proceed as follows:

Downloading Software

To download the software, proceed as follows:

1 Download all software and documents required for installation:

•Site: ftp.gilbarco.com

• ID: -

• Password: -

Note: If the ID and Password are not known, contact Gasboy TAC at 1-800-444-5529.

2 Navigate to the FedEx folder and download the entire contents of this folder.

3 Click the Page button and select Open FTP Site in Internet Explorer

Figure 3-4: Opening FTP Site in Internet Explorer

Page 3-6 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

Installing Islander PLUS

To install the Islander PLUS, proceed as follows:

1 After lag bolts are inserted in the island, position the base plate over the lag bolts, wide-side

facing front. The pedestal is then placed over conduit and into the base plate. To avoid pinching wires, two technicians are required for this step. Tighten the nuts over the lag bolts to secure to the island (see Figure 3-5).

Figure 3-5: Installing Islander PLUS

Installing FedEx Islander PLUS FMS

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 3-7

Installing FedEx Islander PLUS FMS

PCB Assembly P.S-24 VDC [8-hose (M09680B083)]

PCB Assembly, SSR [8-hose (M09680B084)]

(i)

(ii)

2 The control wiring must be attached to the Terminal Block after the pedestal is secure 

(see Figure 3-6). System power, dispenser communication, connected based on the Terminal (see Figure 3-8 on page 10).

Figure 3-6: Connecting Control Wiring to Terminal Block

LAN, and so on, must be

Block diagram on the inside door of the pedestal 

Page 3-8 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

Figure 3-7: Terminal Block Connection

Installing FedEx Islander PLUS FMS

3 For pumps that are NOT Gasboy 9800’s, follow the wiring diagrams for electronic and

mechanical per your specific application.

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 3-9

Installing FedEx Islander PLUS FMS

4 Mechanical dispenser: Note that instead of the solenoid lead tying to the Reset Complete wire;

it now connects directly to Terminal Block for the Gasboy PLUS. Also, note that the Reset Motor and Submersible Feeds tie together in the junction box of the dispenser (see Figure 3-8).

Figure 3-8: Wiring Diagram - Mechanical Dispenser

Note: Reset Complete is the in-use line, this jumpers to line and the load line, which comes

back and run the solenoid valves. Pulse wires are polarized.

Page 3-10 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

Figure 3-9: Mechanical Pump without Solenoid Valve

Disconnect from motor feed and cap wire. Islander IN_Use_1A and Line (TB-25 and

TB-41)

Islander Load 1 (TB-49)

Pump Control Maximum Current Pedestal with up to 4-hose mechanical pumps: Motor Max: 1 HP @ 115 VAC ~OR~ 2 HP @ 230 VAC Additional relay must be used if pump motor exceeds these limitations.

Pedestal with up to 8-hose mechanical pumps: Motor Max: 3/4 HP @ 115 VAC ~OR~

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

Neutral to IN_Use 1B (TB-33)

Installing FedEx Islander PLUS FMS

MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013 Page 3-11

Installing FedEx Islander PLUS FMS

Figure 3-10: Mechanical Pumps On Stick - PMC Pumps

Page 3-12 MDE-5067 FedEx Islander PLUS FMS Installation Manual · March 2013

+ 50 hidden pages