Gasboy TopKAT PLUS User Manual

Download

TopKAT™ PLUS

Installation Manual

MDE-5013C

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

Non-registered trademarks

Consola

™

Infinity

™

Islander™ PLUS

Registered trademarks

ASTRA

Atlas

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.

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

This document is subject to change without notice.

http://www.gasboy.com

E-mail: literature@gasboy.com · Internet: http://www.gasboy.com

Table of Contents

1 – Introduction 1-1

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

Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TopKAT PLUS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Remote Web Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

TopKAT PLUS Structure . . . . . . . . . . .

Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrical Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Available Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Optional Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Security and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Authorization Security . . . . . . . . . . . . . . . .

Network Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Maintenance Security. . . . . . . . . . . . . . . . .

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Communication Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Security Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

. . . . . . . . . . . . . . . . . . . . . 1-13

. . . . . . . . 1-1

. . . . . . . . . . . 1-1

. . . . . . . . 1-2

. . . . . . . . . 1-11

. . . . . 1-12

. . . . . 1-13

. . . . . . . . . . 1-13

. . . . . . . . . 1-14

. . . . . . . 1-15

. . . . . 1-15

. . . . 1-16

2 – Important Safety Information 2-1

3 – TopKAT PLUS Installation Procedures 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Installation Specifications . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Precautions and Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Types of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Types of TopKAT PLUS Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Head Assembly Dimensions . . . .

Pedestal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Conduit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Barrier Plate Conduit Penetration . . . . . . . . . . . . . . . . .

Sealing Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page i

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

. . . . . . . . . . . 3-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Table of Contents

TopKAT PLUS Pedestal Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Connections to TopKAT PLUS - Pedestal Mounted

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Types of Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Types of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Field Wiring Requirements (LAN/WAN) . . . . . . . . . . . . . . . . . . . . . . . .3-12

AC Power Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Mechanical Pump - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Terminal Block - Pin-out Connections for Mechanical Pumps

Mechanical Pump - Required Connections. . . . . . . . . . . . . . . . . . . . . .3-15

Single Suction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Pump - Pulser Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

RS-485 Electronic - TopKAT PLUS on Gasboy 9800 Atlas 

(Factory Installed) .

Electronic Pump Wiring - TopKAT PLUS on Pedest

Mechanical Pulser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Electronic Pump - Wiring Description (Pedestal Mount)

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

RS-485 Electronic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Electronic Pump - Wiring Description (Atlas Mounted TopKAT PLUS)

Post-installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Completion Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

TopKAT PLUS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manager Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performing a Test Transaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Disabling Test Transaction Option . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Opening Printer Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

. . . . . . . . . . .3-11

. . . .3-14

. . . . . . .3-14

. . . . . .3-18

-19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

al . . . . . . . . . . . . .3-21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

. . . . . . . . . . . . . . . . . . . . . . .3-25

. . . . . . .3-26

. . . . . .3-27

. . . . . . .3-27

4 – Printer 4-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printer Connector Pin-out. .

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Printing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Roll Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal Paper Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Jumpers Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Parameters for Printing . .

Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Printing Status Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Installing Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Installing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Replacing Paper Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Releasing Jammed or Crumpled Paper . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

. . . . . . . . . . . . . . . . . . .4-13

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

. . . . . . .4-3

. . . . . . . . . . . .4-6

. . . . . . . . . .4-6

. . . . . . .4-7

. . . . . . .4-9

. . . . . .4-10

. . . . . . . . .4-13

. . . . . . .4-13

. . . . . .4-14

Page ii MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Table of Contents

5 – Maintenance 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TopKAT PLUS Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

OrPT Troubleshooting . . . . . . . . . . . . . . . .

Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Communication Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Safety Reinforcements. . . . . . .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

. . . . . . . . . . . . . . . . . . . . . . 5-5

. . . . . . . . 5-1

Glossary Glossary-1

FuelOmat Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1

Communication Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glo

ssary-1

Appendix A: Wiring Diagrams A-1

Appendix B: Parts List B-1

Appendix C: TopKAT PLUS Parts Illustrated C-1

Index Index-1

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page iii

Table of Contents

This page is intentionally left blank.

Page iv MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Purpose Introduction

1 – Introduction

Purpose

This manual provides installation instructions for TopKAT™ PLUS, the complete station

automation solution in a dispenser-mounted compact box. The system must be installed in the

factory as described in this manual to ensure its reliability and proper operation.

This manual includes a general and functional

components, installation requirements, and procedures.

Intended Users

This manual is intended for Authorized Service Contractors (ASCs) of TopKAT PLUS and its

components. It is also intended for the factory and island electricians.

Description

T o pKAT PLUS is a fuel control and data acquisition system. The system is self-contained in a

forecourt compatible and weather-resistant cabinet installed on top of Gasboy

mounted on a post.

TopKAT PLUS (see Figu

small home base gas stations. TopKAT PLUS provides the central function of site controller

adequate for a maximum of two nozzles in a single dispenser. It also fulfills other essential

services on the island such as driver identification system, transaction data storage, and so on.

Its ergonomic design, as well as its user-friendly operating program, enables fast and accurate

service for the driver in the refueling site.

description of the product, its main

dispensers or

re 1-1 on page 1-2) is a core component in Gasboy’s solution for

TopKAT PLUS is equipped with the Outdoor Payment Terminal (OrPT), a payment terminal

and communication receptacle. The payment terminal is equipped with an alphanumeric

Liquid Crystal Display (LCD) and a keyboard to interface with the client. This enables

T opKAT PLUS to support all common refueling identification devices such as magnetic cards,

contactless Radio Frequency Identification (RFID) tags (also known as MIFARE

keypad entry.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-1

tags), and

Introduction System Overview

Post Mounted Unit for Mechanical and Electronic Dispensers

TopKAT PLUS mounted on an Atlas

9800 Dispenser

(i)

(ii)

(iii)

TopKAT PLUS - General View

Figure 1-1: TopKAT PLUS - General View

System Overview

TopKAT PLUS System

TopKAT PLUS is an innovative product that enables refueling in home base gas stations for fleet authorized vehicles or drivers. T opKAT PLUS electronically locks the dispenser nozzles, 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  on page 1-3).

The heart of the home base station solution is the SiteOmat automation software. SiteOmat

ns on an embedded operating system on the Orpak

ru embedded hardware platform designed to survive the harsh gas station environment. It uses a solid state flash disk and Real Time Clock (RTC) with backup along with surge suppressors for transient and noise immunity. The system also includes power failure recovery mechanisms.

Remote Web Access

Remote web-based capabilities for monitoring, management, and maintenance are available. A standard PC with Microsoft locally or remotely (secured). A special management software is not required, thanks to the built-in web server technology integrated into the station controller and the large variety of communication links supported.

™

Controller Unit (OrCU). OrCU is an

Internet Explorer® is used for management of the site either

Page 1-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

System Overview Introduction

Head Office

-Site Manager

- Technician

Management & Reporting

Fleet Manager

Home Base

Network

Fleet Head Office Web Server

- Issuing Vehicle Identification

- Authorizing Vehicle Identification

- Setting Limits & Restrictions

- Reporting and Management

- Fuel Management (Optional)

Head Office

Centralized management is provided by the optional Fleet Head Office (FHO) and Fuel

Management Software Server. The head office system 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. In addition, authorized fleet personnel are

able to login 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.

Restrictions and Limits

Control of 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 cases where the system is configured for multiple sites,

the centralized FHO must 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 is able to refuel for a predefined grace period (parameter) using the most

recent limits stored in its database.

Figure 1-2: TopKAT PLUS in Home Base Station - General Configurat ion Diagram

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-3

Introduction TopKAT PLUS Structure

System Workflow Example

Following example depicts the operational workflow for self-service at the home base station:

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 s and approval. The client lifts the nozzle and inserts it in the car inlet. On 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 for future billing.

The client may add more data to the transaction, by manually entering the information using the payment panel keyboard. After the refueling is completed, the motorist replaces the nozzle to pump.

The motorist may print a transaction ticket from the TopKAT PLUS printer (optional).

TopKAT PLUS Structure

Main Components

Following is a short description of the TopKAT PLUS main sub-assemblies:

OrCU

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, RTC with backup, along with surge suppressors for transient and noise immunity.

ite controller (OrCU) for authentication

OrCU features two separate and isolated networks (TCP/IP over Ethernet links the TopKAT PLUS system components. The second network is intended for external remote communication (head office and third-party systems). This network is protected by Secured Socket Layer (SSL) security.

Page 1-4 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

). One network

TopKAT PLUS Structure Introduction

OrCU includes a built-in server for web access through an Internet browser (Internet

Explorer).

Figure 1-3: OrCU

OrPT Panel

The OrPT consists of a 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 such as magnetic

card reader and RFID tag reader. These authorization tools enable TopKA T PLUS to accept all

common authorization methods such as credit cards, magnetic cards, and contactless tags.

tho

OrPT supports keyboard entry for au

such as odometer, engine hours, vehicle plate number, and PIN code.

The OrPT panel is connected to the site controller (OrCU) through a Local Area Network

[LAN (Ethernet)] link.

Figure 1-4: OrPT Panel

rization, and other parameters’ input from the user

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-5

Introduction TopKAT PLUS Structure

Outdoor Printer (Optional)

TopKAT PLUS includes an optional printer for 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.

Printer module G2 is a compact, ruggedized thermal pri of the gas station. It includes two sensors for paper usage alerts:

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

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

The paper usage and receipt indications include a buzzer sound, Light E indicators or the combination of both, dependent on its configuration.

Figure 1-5: Outdoor Printer (Optional)

ter suitable for the harsh environment

the paper roll left

itting Diode (LED)

8-port CommVerter

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

The CommVerter includes an Ethernet switch, RS-485 port for electronic pumps or an Mechanical Pump Interface information, refer to “Printer” on page 4-1. The CommVerter communicates with the site controller (OrCU) through a LAN (Ethernet) link.

Card (MPI-C) for interface to a mechanical pump. For more

Page 1-6 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

TopKAT PLUS Structure Introduction

Figure 1-6: 8-port CommVerter

TopKAT PLUS Internal Configuration - Mechanical Pump

Figure 1-7 shows a general configuration diagram of the TopKAT PLUS up to two mechanical

pumps.

Figure 1-7: Internal Configuration Diagram - Two Mechanical Pumps

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-7

Introduction TopKAT PLUS Structure

TopKAT PLUS Internal Configuration - Electronic Pump

Figure 1-8 shows a general configuration diagram of the TopKAT PLUS up to two electronic

pumps.

Figure 1-8: Internal Configuration Diagram - Two Electronic Pumps

Page 1-8 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

TopKAT PLUS Structure Introduction

OrPT

OrCU

Printer

8-port CommVerter

AC Protective Cover

Terminal Block

Connection Openings

Cover Opening Detection Mechanism

Ground Stud

TopKAT PLUS Main Components Location

Figure 1-9 shows the location of the main components of the TopKAT PLUS.

Figure 1-9: Internal Components Location

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-9

Introduction TopKAT PLUS Structure

5-port Switch

OrCU

8-port CommVerter Heat Sink Cover

Figure 1-10: Internal Components Location - Right Side

Page 1-10 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Electrical Setup Introduction

32 V Regulator (M09680B052)

Line Filter (M09680B008)

24 V Regulator (M09680B083)

Transformer (M09680B022)

Terminal Block (M09680B025)

Electrical Setup

TopKAT PLUS electrical components are protected by a dedicated cover to ensure physical

separation between high voltage and low voltage in the box. The mains cable is first connected

to the terminal block. Between the terminal block and transformer, the system uses a line filter

to attenuate conducted radio frequencies - Radio Frequency Interference (RFI),

Electromagnetic Interference (EMI) - between the line and equipment. AC power is then

supplied to an AC/AC high to low transformer - 110/220 to 25 VAC.

Figure 1-11 shows the AC setup in electronic pumps configuration without the prot

cover.

Figure 1-11: AC Setup (Electronic Configuration)

ective

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-11

Introduction Available Configurations

Available Configurations

General

TopKAT 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 (refer to “Configurations”). Following paragraphs describe the several configurations and t

Optional Printer

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

Dispensers

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

heir device composition:

Mechanical dispensers require the installation of

an MPIC card on the 8-port CommVerter. Electronic dispensers require installation of an interface card (RS-485) on the 8-port CommVerter.

Configurations

Following table defines all the available product numbers for the different TopKAT PLUS configurations:

PRN

Part Number Name Dispenser

PA040500000 TopKAT PLUS (E) + - PA040501000 TopKAT PLUS (2M) - + PA040500010 TopKAT PLUS (E, PRN)* + - + PA040501010 TopKAT PLUS (2M, PRN)* - + +

*TopKAT PLUS with printer is for inst

allation over class 1, division 2.

Note: TopKAT PLUS does not support Tank Level Gauges (TLG) or additional electronic

dispensers. Those devices require an external box or another solution.

Electronic

Mechanic 2

Printer

In the order form, customers are required

to define the part number for the specific pump card

in use (MPI-C or RS-485, refer to the following table).

No. Pump Card Description Gilbarco® Part Number

1 RS-485 Interface (8P) P.B. M09680B014 2 MPI-C + Sub Interface (8P) P.B. M09680B105

Page 1-12 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Security and Protection Introduction

Security and Protection

General

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

Authorization Security

The contactless tags include Triple-Data Encryption Standard (TDES) encrypted data for user identification and billing. Consequently, TopKAT PLUS includes a special Security Application Module (SAM) for decryption and matching identification. On tag reading, TopKAT PLUS attempts to decrypt the string from the tag. TopKAT PLUS disregards tags whose security scheme does not match the TopKAT PLUS internal SAM.

Network Security

The Ethernet LAN is isolated from the external Wide Area Network (WAN) by the site controller (OrCU). In case of remote maintenance, a firewall must be applied either at the router level or preferably at the home base station level.

Maintenance Security

T opKAT PLUS maintenance and setup procedures require inserting a user name and password for access. For more information, refer to MDE-4817 SiteOmat In-House Station Controller Setup and Maintenance Manual.

Housing

TopKAT PLUS system enclosure is made of a metal cabinet for factory installation on top of the pump. It includes a front plastic panel and a supportive base.

The enclosure is weather-proof to sustain the harsh env TopKAT PLUS payment panel is made of rugged plastic. The devices in its front panel are sealed to prevent humidity and dust penetration.

TopKAT PLUS box is locked by key for safety and security. The key must be kept in a  well-kept, secure, and safe place.

The cabinet also includes an electronic mechanism for preventing unauthorized personnel from opening the TopKAT PLUS box cover. The detection mechanism is set in the SiteOmat application, refer to MDE-4817 SiteOmat In-house Station Contro ller Setu p and Maintenance Manual.

ironment of a home base station.

Note: The top cover and frame are secured by a ground wire. Caution must be taken while

emoving the cover.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-13

Introduction Specifications

Specifications

The physical, electrical, and environmental specifications applicable to the TopKAT PLUS are displayed in the following table.

Description Specification

Supply Voltage 120-240 VAC Power Consumption 1 A max Operating Temperature -40 °F to +104 °F (-40 °C to +40 °C) Storage Temperature -40 °F to +158 °F (-40 °C to +70 °C) Humidity 80% Non-condensing Dimensions W X H X D: 16.26 X 11.24 X 17.224” (413 X 285.5 X 437.5 mm) Communication Interface RS-485 - 9600 bps, Half-duplex 

RS-232 Ethernet RJ-45 - 10 mbps

Pump Control Maximum Current [2 Solid State Relay Channels, (see

Power Supply Output Voltage to Pulser Unit 12 VDC +/- 20% Power Supply Maximum Output Current 30 mA max Pulsar Input High Level Voltage 9 to 15 VDC Pulsar Input High Level Sink Current (at 15 V) 3 mA In Use “On” Level (Input) 100-240 VAC, 50/60 Hz, 2 W (20 mA) In Use “Off” Level (Input) 0 to 20 VAC

Recognition Suitable for Use Over Class 1, Division 2, Group D

Note: When controlling 230 VAC pumps the solid state relay only con

note)]

Motor Maximum: 3/4 HP at 115 VAC or 1-1/2 HP at 230 VAC

trols one leg of the 230 VAC.

Standards

Communication Standards

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

• RS-232 link

• RS-485 link

• TCP/IP over Ethernet

Security Standards

TDES encryption for payment devices (contactless tags, magnetic stripe cards, and so on).

Page 1-14 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Using This Manual Introduction

An operating procedure, practice, and so on, that if not correctly followed, could result in an injury or loss of life.

WARNING

An operating procedure, practice, and so on, that if not strictly observed, could result in damage or destruction of equipment.

CAUTION

More detailed technical/functional information in regard to relevant issue.

IMPORTANT INFORMATION

Using This Manual

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

Abbreviations and Acronyms

Term Description

ANSI American National Standards Institute ASC Authorized Service Contractor AWG American Wire Gauge CAT Category D-Box Distribution Box DES Data Encryption Standard EIA Electronic Industries Alliance EMI Electromagnetic Interference FHO Fleet Head Office GOLD Gilbarco Online Documentation J-box Junction Box LAN Local Area Network LCD Liquid Crystal Display LED Light Emitting Diode MPI Mechanical Pump Interface MPI-C Mechanical Pump Interface Card

NEC NFPA National Fire Protection Association OrCU Orpak Controller Unit OrPT Orpak/Outdoor Payment Terminal PS Pump Server RFI Radio Frequency Interference RFID Radio Frequency Identification RTC Real Time Clock SAM Security Application Module SSE Site Service Equipment SSL Secured Socket Layer STP Submersible Turbine Pump TCP/IP Transmission Control Protocol/Internet Protocol TDES Triple-Data Encryption Standard TIA Telecommunications Industry Association TLG Tank Level Gauges UL Underwriters Laboratories VIT Vehicle Information Transceiver WAN Wide Area Network

National Electrical Code

Page 1-16 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

2 – Important Safety Information

Notes: 1) Save this Important Safety Information section

in a readily accessible location.

2) Although DEF is non-flammable, diesel is flammable. Therefore, for DEF cabine ts 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 o r 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 in formation you must know is how to stop all fuel flow to the pump/dispenser and island. Locate the switch or circuit breakers that shut off all power to all fueling equipment, dispensing devices, and Submerged Turbine Pumps (STPs).

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 th e cas e of an emerge nc y a nd not the console’s ALL STOP and PUMP STOP or similar keys.

WARNING

Total Electrical Shut-Off Before Access

Any procedure that requires access to electrical component s or the electronics of the dispenser requires total elect rical shut off of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gasboy 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 barric ades at the affected unit(s)

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

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 Gasboy Authorized Serv ice Contractor or call the Gasboy Support Center at  1-800-444-5529. It is imperative to your safety and the safe ty of oth

rs 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), Occupatio nal Safety and Health Administrati on

(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 lea d to leg al citation s with penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gasboy replacement p art s and re trofit kits on your pump/dispenser. Using parts other than genuine Gasboy replacement parts could create a safety hazard and violate local regulations.

Safety Symbols and Warning Words

This section provides important information about wa rn ing symbols and boxes.

Alert Symbol

This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prev

ent potential personal safety hazards. Obey 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 followe d to prevent death, injury or damage to the equipment:

DANGER: Al

erts yo

u to a hazard or unsafe practice which will result in death or serious injury. WARNING: Alerts

you to a hazard or unsafe practice that could result in death or serious injury. CAUTION with Alert symbol: Designates a hazard or un

safe practice which may result in minor injury.

CAUTION w

thout Alert symbol: Designates a hazard or unsafe practice which may result in property or equipment damage.

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, expl

osion and fire safety

warnings do not apply to DEF fluid lines.

! !

Important Safety Information

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 2-1

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 ca use 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 cont act 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 ig nite fuels and their vapors. Static electricity, including an electrostatic charge on your body, can cause a spark sufficient to ignite 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 capab l e of rendering first aid be present during servicing. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages. This informa tion 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, address, front/back of building, and so on)

• Nature of accident (for example, possible heart attack, run over by car, burns, and so on)

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

• Whether or not victim has received first aid (for example, stopped bleeding by pressure, and so on)

• Whether or not a victim has vomited (for example, if swallowed or inhaled something, and so on)

Working With Electricity Safely

Ensure that you use safe and established practices in working 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 contrac tors need to understand and comply with this program complete ly 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-5013C TopKAT™ PLUS Installation Manual · February 2015

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

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of machines and equipment in which the unexpecte d energization or sta rt-up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. Lockout/Tagout applies to all mechanical, hydraulic, chemical, or other energy, but does not cover electrical hazards. Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 1910.333 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 . Turn off all system circuit breakers to the island(s).

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

• 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, spilled fuel or exposed wiring.

• Call emergency numbers.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 2-3

Important Safety Information

This page is intentionally left blank.

Page 2-4 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

General TopKAT PLUS Installation Procedures

Before installing or servicing equipment, carefully observe the warnings and precautions provided in “Important Safety Information” on page 2-1.

WARNING

3 – TopKAT PLUS Installation Procedures

General

TopKAT PLUS units can be supplied factory mounted on an Atlas pump/dispenser or with a pedestal for interface to mechanical or electronic register pumps/dispensers. This section provides installation procedures for both types.

These procedures include:

• TopKAT PLUS box installation

• Wiring

• Post installation check

Installation Specifications

General

Installation procedures and requirements depend, to some extent, on the specific fuel dispenser models. Therefore, use the information in this section to develop factory installation plans for each specific dispenser or suction pump.

Precautions and Safety Notes

Before actual installation activities, carefully observe the following precautions and safety notes:

• Ensure that actual installation is performed by experienced personnel as required by the National Fire Protection Association-30 (NFP A-30) “Flammable and Combustible Liquids Code”, NFPA-30A “Code for Motor Fuel Dispensing Facilities and Repair Garages”,

NFPA-70A applicable safety codes and regulations.

• System power may come from more than one source including pumps, before attempting to work on the system.

• Do not connect power to the TopKAT PLUS or pump, until the complete installation is inspected and

, National Electric Code (NEC), federal, state, and local codes, and any other

certified.

. Disconnect all power sources,

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-1

TopKAT PLUS Installation Procedures Installation Specifications

Allow a minimum of 20-inches clearance at rear of the TopKat PLUS head assembly for pedestal and Atlas mounted units.

IMPORTANT INFORMATION

Types of Cables

Following table lists the types of cable in use for the wiring of the TopKAT PLUS system:

No. Function Type

1 AC Power Power Cable, 3 X 1.5 mm

Control to Pumps (Valves or Engine) In Use Signal

2 Pulser Data Communication Cable, 300 V RMS, 194 ºF (90 ºC), Shielded

3 LAN Category-5E (CAT-5E), Four Conductor Insulator Cable (042GA00007

4 GND Ground Cable 0.4” (10.8 mm

Note: Use the appropriate gauge wire size for the AC power for pump

standards.

isted-pair, Oil-resistant, 24 AWG, Low Capacitance below 

T 60 PF/meter similar to Belden

or 042GALF007 300 V RMS, 194 ºF (90 ºC) similar to Belden 121700A

- Gilbarco part number M12673B001) or Shielded,

NYY (14 AWG), in accordance with local

9729 Cable

)

s, dispensers, and fueling equipment.

Types of TopKAT PLUS Units

There are three types of TopKAT PLUS configurations as follows:

• Electronic TopKAT PLUS mounted on an Atlas 9800 unit

• Electronic TopKAT PLUS mounted on a pedestal

• Mechanical TopKAT PLUS mounted on a pe destal

Head Assembly Dimensions

The T opKat PLUS head assembly that is mounted on a pedestal or Atlas 9800 electronic pump is 116.5 X 11.4 X 18” (W X H X D).

Page 3-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Installation Specifications TopKAT PLUS Installation Procedures

Barrier Plate

11-3/4

11-1/2

1-1/4

9-1/4

5-3/4

11-1/2

2-1/2

5-7/8

11-3/4

Bottom View

A = 1/2” Mounting Holes (Bottom Plate) B = Dual Knockouts For 3/4” or 1” Conduit

(Barrier Plate)

11.4

16.5

Front View

Note: All dimensions are in inches.

9-1/4

Pedestal Dimensions

To ensure a reliable and proper installation it is very important to know the pedestal dimensions. The mechanical and electronic TopKAT PLUS assembly mounted on the pedestals are shown in Figure 3-1.

Figure 3-1: Pedestal Dimensions

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-3

TopKAT PLUS Installation Procedures Conduits

Mechanical Pump/DispenserMechanical Pump/Dispenser

TopKAT PLUS

Optional

Possible Conduits in Pedestal

Office

WAN

MCC

UPS

TCP/IP

CAT-5E

Junction Box

Low Voltage Conduit

TCP/IP

GND

Low Voltage Conduit

High Voltage Conduit

Isle

Junction Box

High Voltage Conduit

Pulser

In Use Control

Conduits

General

The installation of the TopKAT PLUS at 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 TopKAT PLUS. In sites where the infrastructure is already set up, you can use the existing conduits only if they meet the requirements defined in “Conduit Requirements”.

Conduit Requirements

Conduits must comply with:

• All conduits must be made and installed according to loca

• High-voltage AC and low-voltage DC must NOT be combined Junction Box (J-box) or wire through.

• The maximum distance for the LAN communication is 333 feet. Cables must in a separate low voltage conduit, away from AC wires. Communication range can be extended with third-party devices.

• All conduits must be inserted in the TopKAT PL

US pedestal through the holes and

knockouts provided in the lower barrier plate.

• After completing the installation, there must not be any unused conduit openings in the ba

rrier plate. The clearance between conduits and openings in the barrier plate must not be

more than 1/64-inch.

l regulations.

in a common conduit,

be inserted

Figure 3-2: Conduit Layout for Mechanical Pump

Page 3-4 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Barrier Plate Conduit Penetration TopKAT PLUS Installation Procedures

Electronic Pump/DispenserElectronic Pump/Dispenser

TopKAT PLUS

Possible Conduits in Pedestal

Office

WAN

MCC

UPS

Optional

TCP/IP

CAT-5E

J-box

Low Voltage Conduit

TCP/IP

GND

Low Voltage Conduit

High Voltage Conduit

Isle

Figure 3-3: Conduit Layout for Electronic Pump

Barrier Plate Conduit Penetration

The pedestal barrier plate makes the pedestal mounted TopKAT PLUS suitable for installation over a class 1, division 2 hazardous location. Field installed conduit must run completely up through the barrier plate. The conduit must be threaded where it passes through the barrier plate. There must be no unused conduit openings in the barrier plate when installation is completed. Clearance between conduits and openings in the barrier plate through which conduit passes must not be more than 1/64-inch.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-5

TopKAT PLUS Installation Procedures Barrier Plate Conduit Penetration

Approved Location for TopKAT PLUS

TopKAT PLUS

Class 1, Division 2 Safety Area

Dispenser

Ground Level

Isle

20”

18”

18”18”18”

Sealing Conduits

The conduits must 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 3-4).

Figure 3-4: Conduit Fitting

Safety Distance

Figure 3-5 shows the safety distances required for the installation of the TopKAT PLUS

adjacent to the dispensers. When mounting the 18 inches (0.5 m) between the unit and any of the pumps or the dispensers must be maintained. This clearance allows room

T opKAT PLUS is designed and approved for installation and use at a convenient location at or ne

Figure 3-5: TopKAT PLUS - Installation Control Drawing

TopKAT PLUS, a minimum clearance of 

for the wiring and maintenance of the system.

ar fuel island in the appropriate hazardous (classified) location:

• Where hazardous location is classified as class 1, division 2 an

d it does not extend higher

than 18 inches (0.5 m) from surface and

• A minimum safety separation of 18 inches (0.5 m) from any nearest

pump/dispenser.

Page 3-6 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

TopKAT PLUS Pedestal Mounting Instructions TopKAT PLUS Installation Procedures

TopKAT PLUS Pedestal Mounting Instructions

The TopKAT PLUS head assembly and pedestal assembly are packaged in their own boxes and shipped in a large box. After removing them from the large box, the two units must be connected together using the following procedure.

Parts List

Following parts are required for the TopKAT PLUS pedestal mounting:

• Pedestal and Head Assembly

TopKAT PLUS Ped

Description

TopKAT PLUS Pedestal - Electronic D TopKAT PLUS Pedestal - Mechanical Dispenser OrTOP (2M) PA040501000 PA040501100 800938972 TopKAT PLUS Pedestal - Electronic D

with Printer

T opKA T PLUS Pedest al - Mechanical Dispenser

with Printer

TopKAT Pedestal M12706002 - -

spenser OrTOP (E) PA040500000 PA040500100 800938970

spenser

OrTOP (E, PRN) PA040500010 PA040500110 800938971

OrTOP (2M, PRN) PA040501010 PA040501110 800938973

estal

Assembly

TopKAT PLUS Head Part Number

Orpak OrTOP Part Number

• Hardware Kit

•Gasket

• Installation Instructions

To install the TopKAT PLUS pedestal, proceed as follows:

1 Install and secure the pedestal to the island using the four holes at the bottom of the pedestal

with anchor bolts before installing the head assembly. This will prevent the completed assembly from possibly falling over.

Note: To access the four inside bottom mounting holes, re

2 Position the pedestal so that the front side faces the fueling lane. Secure the pedestal to the

move the rear lower door panel.

island using the four mounting holes inside the base of the unit.

3 Install the black rubber gasket on top of the pedestal ensuring that the holes for the wiring are

aligned properly and not blocked.

4 Mount the TopKAT head assembly onto the top of the pedestal using the four threaded studs as

a guide. Secure the head assembly using a flat washer, lockwasher, and 1/4 -20-inch nut onto each of the four post and tighten.

a Remove the TopKAT cover by unlocking the rear key lock and slide the cover to the rear

side of the unit.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-7

TopKAT PLUS Installation Procedures TopKAT PLUS Pedestal Mounting Instructions

Rear View

Side View

Top Mounting Studs

Facing Front

b Ensure that you do not remove the cover completely until the yellow ground wire that

connects the cover to the grounding lug of the unit is removed.

Note: The front of the pedestal has the over hang, an

d the mounting studs are arranged in such a manner that the TopKAT head assembly can only be mounted one way, facing frontwards (see Figure 3-6).

Figure 3-6: TopKAT PLUS Pedestal

Page 3-8 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Connections to TopKAT PLUS - Pedestal Mounted Units TopKAT PLUS Installation Procedures

Connections to TopKAT PLUS - Pedestal Mounted Units

All connections to the post mounted TopKAT PLUS must be performed to the terminal block located at the bottom of the TopKAT PLUS box (see Figure 3-7 and Figure 3-8 on page 3-10). The required connections are:

• Dispenser wiring connections (mechanical

- Pulser (low voltage)

- In use signal (high

- Solenoid valve (high voltage)

• Communications (Atlas 9800 electronic dispensers):

- Pump communication line (RS-485)

• Mains AC power and ground (electronic and mechanical dispensers)

• LAN connection. LAN cable is directly connected to

Figure 3-7: TopKAT PLUS Terminal Block - Mechanical Pump

voltage)

dispensers):

LAN2 connection

on the OrCU.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-9

TopKAT PLUS Installation Procedures Connections to TopKAT PLUS - Pedestal Mounted Units

For the electronic TopKAT factory-installed on top of an Atlas 9800, all the required wiring for the 9800 electronic pumps including the RS-485 communication, the LAN communications, and AC power is pre-wired from the factory. No other connections are made to the terminal blocks.

IMPORTANT INFORMATION

Figure 3-8: TopKAT PLUS Terminal Block - Electronic Pump (Pedestal Mount)

Page 3-10 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Wiring TopKAT PLUS Installation Procedures

Wiring

Types of Wiring

The wiring in the terminal block differs in accordance with the type of pump controlled by the TopKAT PLUS. There are several types of pumps:

• Mechanical pumps

• Electronic pumps

Following section provides the “Wiring Requirements” for ea

Wiring Requirements

Before inserting any wire to the terminal block, proceed as follows:

1 Insert the wire with a terminal lug only (see Figure 3-9).

2 Attach the lug to the wire using the proper terminal crimper.

3 For UL-listing, the terminal lug must be a UL recognized component.

Figure 3-9: Terminal Lug

ch type of pump:

Note: Mark each cable at its both ends with a number or sign that will identify its functionality

in the future.

Types of Cables

Following cables are required for the TopKAT PLUS installation:

• Power cable: In accordance with local regulations

• LAN cable: CAT-5E [refer to “Field Wiring Requirements (LAN/WAN)” on page 3-12]

• RS-485/pulser: Communication cable, twisted-pair, separately For example, Belden 8723 or equivalent.

Note: The shield must be connected to ground on one side of the cable only, preferab ly on the

pKAT PLUS side.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-11

shielded, low capacitance.

TopKAT PLUS Installation Procedures Wiring

Field Wiring Requirements (LAN/WAN)

Wiring must be installed in accordance with ANSI/TIA/EIA 568 B standards and amendments.

Recommendations for CAT-5E Cable

Following are Gasboy recommendations for installing the CAT-5E cable (gas-and oil-resistant) for Site Service Equipment (SSE):

• The Ethernet cable to the pumps/dispensers requirements, for example, gas- and oil-resistant, and vapor-resistant properties.

• CAT-5E cable is viable for typical installations un is not run near the equipment that generates electrical noise such as large motors and power switching equipment. An example of a noise source to avoid is a variable speed Submersible Turbine Pump (STP).

• It is crucial that the installer follows the NEC, Article 501 requiremen outer jacket and spreading the wire pairs at the seal-off points, so that a good vapor seal is achieved. This is required because most CAT-5E cables will conduct vapors inside their outer jacket (see Figure 3-10).

Note: This is not required if Four Conductor Insulator Cable (042GA00007 or

042GALF007 - Gilbarco part number M12673B001) is used. This cable will not conduct vapors inside the outer jacket.

is designed to comply with forecourt wiring

der 280 feet of cable length, if the cable

ts by removing the



Figure 3-10: CAT-5E Cable Installation

• CAT-5E cable must not share the conduit with AC, but can share the conduit with pulsers or other CAT-5E cables.

• If an Ethernet hub is used, it must be of commercial quality

. Commercial Ethernet switches are a family of fixed configuration standalone devices that provide desktop. 10/100 fast Ethernet and 10/100/1000 Gigabit Ethernet connectivity for entry level enterprise

, medium-sized, and branch office networks to enable enhanced LAN services.

• The recommended CAT-5E cable is Fou r Con ductor Insulator Cable (042GA00007 or 042GALF0

07 - Gilbarco part number M12673B001) or an equivalent. The CAT-5E qualified cable has gas and oil-resistant inner and outer insulation, and vapor resistant properties.

• A patch panel is recommended (optional) to connect the CAT

-5E cable to the network  RJ-45. The patch panel and LAN wiring must be LAN-certified and follow TIA/EIA LAN 568-

B wiring standards.

Page 3-12 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Wiring TopKAT PLUS Installation Procedures

TopKAT PLUS is shipped configured for 115 VAC po wer supply. Ensure care to set it accordingly to your local AC power supply specifications. Failure to do so may result in damages.

WARNING

AC Power Connection

The AC power input is connected to the terminal block. Between the terminal block and transformer, the system uses a line filter to attenuate conducted RFI and EMI - between the line and equipment. AC power is then supplied to an AC/AC high to low  transformer -110/220 to 25 VAC. T ransformer can be fed either to 1 10 or 2 20 VAC. The power supply setup jumpers shown in Figure 3-11 must be set to match the AC power input to the TopKAT PLUS. A settings label is also found beside the terminal block. For dispenser mounted T op KAT PLUS, the power supply setup jumpers must be set to match the micro feed input to the Atlas pump/dispenser.

• For 115 VAC input (default setting), there must be a jumper wire from position 1 of the setup jumper to position 5 and from posi

• For 230 VAC input, there must be a jumper wire from position 5 position 2.

tion 2 to position 6.

of the setup jumper to

Figure 3-11: Power Supply Setup Jumpers

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-13

TopKAT PLUS Installation Procedures Mechanical Pump - Wiring

Dangerous AC voltages that can cause death or serious personal injury are used to power the product. Always disconnect power before starting any work.

WARNING

Mechanical Pump - Wiring

General

This device is intended to be connected to UL-listed dispensers equipped with a J-box of sufficient volume. These connections are not suitable for direct connection to intrinsically safe devices. All wiring is to be in compliance with NFPA 70 and NFPA 30A.

The wiring for mechanical pumps

is provided in two modes:

• Following table lists the wiring in the sequential order of the terminals. This table provides signal name and a functional description of the signal.

the

• Figure 3-12 on page 3-15 shows the wiring list for connection to the terminal,

in the wiring label attached to the inner side of the unit. The wiring l physical location of the wires in the terminal block.

Terminal Block - Pin-out Connections for Mechanical Pumps

Following table lists the TopKAT PLUS terminal block connections for mechanical pumps:

Terminal No. Signal Name Functional Description

1 LINE_IN_(115/230 V) Line Connection, TopKAT PLUS Power Input 2 NEUTRAL_IN_(115/230 V) Neutral Connection, TopKAT PLUS Power Input 3 GROUND_IN_(115/230 V) Ground Connection, TopKAT PLUS Power Input 4 LINE_1 Pump Control 220/110 VAC Input - Nozzle 1 5 LOAD_1 Pump Control Output - Nozzle 1 6 LINE_2 Pump Control 220/110 VAC Input - Nozzle 2 7 LOAD_2 Pump Control Output - Nozzle 2 8 IN_USE_1_ A(AC) Handle Up - In Use Signal Input - Nozzle 1 9 IN_USE_1_ B(RETURN) Handle Up - AC In Use Signal Return - Nozzle 1 10 IN_USE_2_ A(AC) Handle Up - In Use Signal Input - Nozzle 2 11 IN_USE_2_ B(RETURN) Handle Up - AC In Use Signal Return - Nozzle 2 12 -DC OUT FOR BY-PASS_2 Connection to External Bypass Nozzle 2 13 BY-PASS_2_IN Connection to External Bypass Nozzle 2 14 PULSER_1 Pulser Input - Nozzle 1 15 PULSER_2 Pulser Input - Nozzle 2 16 +12 V_2_P +12 VDC Output to Pulser - Nozzle 2 17 -DC OUT FOR BY-PASS_1 Connection to External Bypass Nozzle 1 18 BY-PASS_1_IN Connection to External Bypass Nozzle 1 19 GND_1_P Nozzle Grounding - Nozzle 1 20 GND_2_P Nozzle Grounding - Nozzle 2 21 +12 V_1_P +12 VDC Output to Pulser - Nozzle 1

as published

abel follows the

Page 3-14 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Mechanical Pump - Wiring TopKAT PLUS Installa tio n Pro cedures

Figure 3-12: TopKAT PLUS - Mechanical Pump Wiring List Label

Mechanical Pump - Required Connections

This paragraph describes the required wiring connections between the mechanical pump and TopKAT PLUS. Figure 3-13 and Figure 3-14 on page 3-16 show a schematic diagram of the connections between the TopKAT PLUS an on page 3-17 shows a detailed wiring diagram between the TopKAT PLUS terminal block and pump components.

Pulse Input

Wir

Handle Status Input Wi

res

Authorization Output Wi

TopKAT PLUS ratings for above signals are as follows:

The dispenser outputs pulses to the system by means of the pulser unit, installed in accordance with the manufacturer instructions. The pulse rate per volume (liter/gallon) is determined by the pulser unit. It is programmed as a “factor” in the SiteOmat.

The handle signal is used to signal the system that the pump is “In Use” mode. When the dispenser handle is lifted, this contact closes. This signals the system that the pump is “In Use” or that the transaction ended.

The dispenser requires an authorization signal from the TopKAT PLUS to

res

start a sale transaction. Without this authorization signal, the electric valve (or pump) does not open and the sale transaction does not begin. The TopKAT PLUS switches the AC power signal to the valve. When the dispenser receives the authorization signal, fuel starts to flow. This signal is also referred to as the LOAD.

d the mechanical pump components. Figure 3-15

Signal TopKAT PLUS Rating

Pulser Input 3 mA, 15 VDC max. Pulser Power Output 12 VDC, 30 mA max. In Use Input 100-240 VAC, 50/60 Hz, 2 W (20 mA) Load 3/4 HP @115 V

1.5 HP @ 240 V

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-15

TopKAT PLUS Installation Procedures Mechanical Pump - Wiring

Figure 3-13: Mechanical Pump - Single Dispenser Connections

Figure 3-14: Mechanical Pump - Twin Dispenser Connections

Page 3-16 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Mechanical Pump - Wiring TopKAT PLUS Installa tio n Pro cedures

Figure 3-15: TopKAT PLUS and Mechanical Pump - Terminal Block Detailed

Connections

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-17

TopKAT PLUS Installation Procedures Single Suction Pump

Single Suction Pump

Figure 3-16 shows the connections to the single suction pump.

Figure 3-16: Single Suction Pump 1 HP 115 VAC/230 VAC

GASBOY MECHANICAL PUMP

with VR/TOK Reset Color Codes

Islander Load-1 (TB-31)

SOLENOID

VALVE

OPTIONAL LIGHT ASSEMBLY

ELECTRIC RESET

120 VAC

RESET

RED

MOTOR

NO NC

WHT

HANDLE

BRN

BLU

YEL/WHT

BRN/WHT

BLK

SUBM FEED

LIGHT FEED

LIGHT NEUTRAL

RESET MOTOR FEED

TO SUBMERSIBLE

STARTER RELAY

OF PUMP

1 HP AT 120/240 VAC

SUBM DRIVE

FEED NEUTRAL

ORG

RESET COMPLETE

Islander In-use 1A and Line-1 (TB-19 and TB27)

Neutral to In-use 1B (TB-23)

BREAKERS

DISPENSER

Page 3-18 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

HOT NEUT

Mechanical Pump - Pulser Connections TopKAT PLUS Installation Procedures

Mechanical Pump - Pulser Connections

This paragraph describes the required wiring connections between the pulser in the mechanical pump and TopKA T PLUS. The sy stem can accept many types of pulsers. For more information, contact Gasboy. Two types of pulsers can be found in the pumps:

• Electronic pulser

• Mechanical pulser

Connect the TopKAT PLUS to the pulser in a

ccordance with its characteristics.

Following are the TopKAT PLUS ratings for above signals:

Signal TopKAT PLUS Rating

Pulser Input 3 mA, 15 VDC max. Pulser Power Output 12 VDC, 30 mA max. In Use Input 100-200 VAC, 50/60 Hz, 2 W (20 mA) Load 3/4 HP @115 V

1.5 HP @ 240 V

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-19

TopKAT PLUS Installation Procedures Mechanical Pump - Pulser Connections

RS-485 Electronic - TopKAT PLUS on Gasboy 9800 Atlas  (Factory Installed)

Figure 3-17 shows the internal wiring connections between TopKAT PLUS and the RS-485

pump nozzle.

Figure 3-17: RS-485 Electronic Pump - Wiring Diagram - 1

Page 3-20 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Mechanical Pump - Pulser Connections TopKAT PLUS Installation Procedures

Electronic Pump Wiring - TopKAT PLUS on Pedestal

Figure 3-18 shows the external wiring connections between TopKAT PLUS and Gasboy Atlas

9800 unit(s).

Figure 3-18: RS-485 Electronic Pump - Wiring Diagram - 2

In Gasboy electronic J-box for pump 1, connect the red Tx+ to white Rx+ and connect the green Tx- to black Rx- as shown in Figure 3-18.

Connect one wire from “+” and one wire from “-” to proper terminal blocks in the Islander PLUS unit. For proper pump location, refer to Figure 3-18.

™

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-21

TopKAT PLUS Installation Procedures Mechanical Pump - Pulser Connections

Mechanical Pulser

The two-wire pulser is powered by the TopKAT PLUS. Figure 3-19 shows a schematic diagram of the connections between the terminal block

Figure 3-19: Terminal Block and Two-wire Pulser - Wiring Connections

and two-wire pulser.

Page 3-22 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Electronic Pump - Wiring Description (Pedestal Mount) TopKAT PLUS Installation Procedures

Electronic Pump - Wiring Description (Pedestal Mount)

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 required for the following pumps is described below:

•RS-485

For the wiring list label attached to the i

• The rows are the connection ports in the terminal

• Each column is dedicated for a specific pump. Each cell defines the signal attached to the terminal block port.

•

Figure 3-20: TopKAT PLUS Terminal Block - Wiring List Label

nner side of the unit, see Figure 3-20.

block in an ascending order.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-23

TopKAT PLUS Installation Procedures Electronic Pump - Wiring Description (Pedestal Mount)

Note: On the RS-485 interface board in the 9800 head assembly, the positive pins are



1 and 3 (jumper) and negative pins are 2 and 4 (jumper).

RS-485 Electronic Pump

Figure 3-21 shows the specific internal wiring connections between the TopKAT PLUS and

RS-485 interface board in the Atlas

Figure 3-21: RS-485 Electronic Pump - Internal Wiring Diagram

electronic head assembly.

Page 3-24 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Electronic Pump - Wiring Description (Atlas Mounted TopKAT PLUS) TopKAT PLUS Installation Procedures

Product Inlet

AC Power Connection

Optional DC  Power Connection

Electronic Pump - Wiring Description (Atlas Mounted TopKAT PLUS)

Atlas pumps/dispensers must be installed and wired according to MDE-4331 Atlas Fuel Systems Installation Manual. When the TopKAT PLUS is factory mounted on an Atlas unit,

all required wiring including RS-485 communications to the pump, device interconnection, and AC power (it receives its power from the Atlas micro feed lines) is prewired from the factory. The only external connections required to the TopKAT PLUS are the LAN connections. For more information on the LAN connections, refer to “Field Wiring

Requirements (LAN/WAN)” on page 3-12.

Electronic Pump - External wiring

The J-box located on side A in the bottom of the unit allows the installer to make all the required AC wiring connection including the low voltage LAN communication. For AC wiring connections, refer to MDE-4331 Atlas Fuel Systems Installation Manual.

Figure 3-22: Atlas 9800 J-box Connections - AC/DC Connections

• AC Power connections - AC voltage with two separate circuits, pump power and micro feed in rigit metal conduit from the circuit breaker panel.

• DC Power connections - CAT-5 LAN communication cable from a netw

ork jack from the

FHO, ran in separate rigit metal conduit.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-25

TopKAT PLUS Installation Procedures Post-installation Checklist

Post-installation Checklist

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

In particular, pay attention to the following issues:

Correct wiring

• Check if all the wiring is inserted in metal conduits.

• Check if the system is grounded properly.

• Check if the cables are correctly routed in the dispenser.

Clean dirt and wire remnant

Verify if power supply setup jumpers (see Figure 3-11 on page 3-13) are properly set BEFORE applying power to the TopKAT PLUS. In case problems are detected after installation or during operation, repeat the post-installation checks listed above.

Completion Checklist

Following information will help in verifying if the TopKAT PLUS is properly installed. Review it before testing the pumps and/or dispensers in the manual override position.

Check if all the conduit is metal conduit (refer to the “Reference Information” section in MDE-4331 Atlas Fuel Systems Installation Manual).

Check if AC and DC wirings are in separate conduits and troughs.

Check if the systems/peripheral equipment is there on a separate dedicated breaker.

Check if the system is grounded properly (refer to the “Reference Information” section in MDE-4331 Atlas Fuel Systems Installation Manual).

Check if the correct wire gauge wire is installed (refer to the “Reference Information” section in MDE-4331 Atlas Fuel Systems Installation Manual).

Check if the communication lines are under the maximum allowable distance - LAN:280’, RS-485 = 1500’ MAX, and RS-232 = 100’.

Check if the AC power for the systems and pumps is on the same phase in the breaker panel.

Page 3-26 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

TopKAT PLUS Setup TopKAT PLUS Installation Procedures

TopKAT PLUS Setup

For TopKAT PLUS setup, refer to MDE-4817 SiteOmat In -House Station Controller Setup and Maintenance Manual.

Manager Tag

Following paragraphs describe the manager tag provided with TopKAT PLUS controllers. The manager tag (see Figure 3-23) enables technicians to perform test transactions proper integration of the controller and pump. In addition, the manager front panel for maintenance purposes such as paper roll replacement.

Figure 3-23: TopKAT PLUS Manager Tag

to verify the

tag opens the printer

Performing a Test Transaction

To perform a test transaction, proceed as follows:

1 The OrPT We lcome screen is displayed (see Figure 3-24). Present the tag to the OrPT reader.

Figure 3-24: OrPT Welcome Screen

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-27

TopKAT PLUS Installation Procedures Manager Tag

The manager screen is displayed (see Figure 3-25).

Figure 3-25: OrPT Manager Screen

2 Press 2 on the keypad and press OK. Figure 3-26 is displayed.

Figure 3-26: OrPT Pump Selection Screen

3 Enter the pump number and press OK. The fueling is authorized and the Figure 3-27 appears.

Figure 3-27: OrPT Refueling Screen

Page 3-28 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Manager Tag TopKAT PLUS Installation Procedures

4 Lift the nozzle and refuel. 5 Verify if the transaction details on SiteOmat Pump Status screen matches to the actual

transaction.

Note: For more information on SiteOmat, refer to

Controller User’s Manual.

Disabling Test Transaction Option

After testing the unit, the technician may disable the test transaction option. In this case, the system cleans all test transactions, initializes all counters in the database and deactivates the test transaction option.

If the manager tag is presented after disabling the option, printer door (refer to “Opening Printer Front Panel”).

To disable the test transaction option, proceed as follows:

1 Present the tag to the OrPT reader. The manager screen is displayed (see Figure 3-25 

on page 3-28).

2 Press 3 on the keypad and press OK. The OrPT welcome screen is displayed (see Figure 3-24

on page 3-28).

Note: The manager screen o n the OrPT may b e reactivated by selecting the activate manager

tag check box Mode > Global > Advanced. For more information on SiteOmat, refer to MDE-4817 SiteOmat In-House Station Controller Setup and Maintenance Manual.

on SiteOmat’s station parameters dialog box. Go to Setup > Advanced

MDE-4818 SiteOmat In House Station

the system automatically opens the

Opening Printer Front Panel

To open the printer front panel for maintenance purposes such as paper roll replacement, proceed as follows:

Note: In cases where the test transaction option was

Transaction Option”), the printer front panel is automatically unlocked after pr

the tag.

1 Present the tag to the OrPT reader. The manager screen is displayed (see Figure 3-25 

on page 3-28).

2 Press 1 on the keypad and press OK.

3 The front panel lock is unlocked and buzzer provides sound feedback.

4 Press in on the top of the receipt printer panel and pull to open.

disabled (refer to“Disabling Test

esenting

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 3-29

TopKAT PLUS Installation Procedures Manager Tag

This page is intentionally left blank.

Page 3-30 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

General Printer

The receipt printer comes factory-installed per order in the T opKA T PLUS assembly and there are no provisions to add one to an existing unit.

IMPORTANT INFORMATION

4 – Printer

General

This section provides a general overview of the optional printer module G2. It includes general information regarding the printer module G2, its components, and functionality.

It describes the printer module G2, its instructions on replacing the printer paper roll as well as instructions regarding several recommended steps for checking the printer operability.

Figure 4-1: Printer Module G2 Unit

technical characteristics, and its operation. It includes

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-1

Printer Description

Green LED Indicator

Printer Case

Door

Receipt Aperture (Paper Slice)

Green LED Indicator

Description

The printer module G2 is a compact, ruggedized thermal printer suitable for the harsh environment of the gas station. It uses thermal printer paper only (55 gr., 40 X 57 mm).

The printer module G2 is connected

to the station controller through an RS-485 link and it

requires a 24-26 VDC power supply input.

The printer module G2 is packed in a compact aluminum enclosure designed to survive the harsh forecourt environment. It uses spark gaps protection for the links and 1.5 KV isolation between the forecourt devices.

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, LED indicators or the combination of both, dependent on the station controller.

Figure 4-2 and Figure 4-3 on page 4-3 sho

respec

tively.

Figure 4-2: Printer Module G2 Unit - General View

w front and rear view of the printer module G2,

Page 4-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Main Components Printer

Front Panel Lock Level

Printer Connector

Door

Printer Enclosure

Figure 4-3: Printer Module G2 Unit - Rear View

Main Components

The printer module G2 consists of the following main items (refer to the following table, 

Figure 4-4, and Figure 4-5 on page 4-4):

Item Functionality

Advance Paper Push Button Advances the paper into the printer. Printer Cutter Lock Unlocks the cutter lock. Printer Cutter Cuts the paper. Thermal Printer Prints the text on the thermal paper by means of the thermal head. Paper Lock Lever Unlocks the paper lock by pushing the lock down. Paper Roll Pivot Pawl Releases the paper pivot and enables insertion of a new paper roll. Front Panel Lock Lever Bypasses the solenoid lock (for Electronic Board Printer controller.

nician use only).

tech

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-3

Printer Main Components

Cutter Lock

Electronic Board

Advance Paper Push Button

Paper Roll Pivot Pawl

Front Panel

Door Locker Pin

Paper Roll Pivot

Paper Lock Lever

Printer

Cutter

Door Locker

Printer

Jumpers

Flash Memory AVR Connector

Door

Printer Head (M09680B102)

Figure 4-4: Printer Module G2 Unit - Main Components

Item Functionality

Jumpers Enables to determine the RS-485 address and number of copies. Flash Memory Device Stores the printer software. AVR Connector Enables to download/upload printer software/data.

Note: These components are intended for maintenance purposes only.

Figure 4-5: Printer Module G2 Unit - Internal Components

Page 4-4 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Printer Connector Pin-out Printer

Front door sense/paper  advance

User door advance

Printer

Paper

Paper Reel

Low Paper Sense

Buzzer

Paper Receipt

Lift door for printing

Service Door

Manual/Emergency release lock

Power Ground

RS-485

Door Locker

Board with control software and Orpak protocol

Internal status of LEDs Internal Jumpers

Flash Memory

AVR Connector

Figure 4-6 shows an internal diagram of the printer module G2, indicating the sensors, paper

path within the printer, and internal electronic components.

Figure 4-6: Printer Module G2 Unit - Internal View

Printer Connector Pin-out

The printer connector is located on the printer rear panel. It provides the printer both the communication link and power supply input (24-26 VDC). The power is supplied through an external power supply.

following table show the G2 printer connector pin-out description.

front p

the

Figure 4-7 and the

Figure 4-7: Printer Module G2 Connector - Pin-out Description

Pin Number Functionality Description

1 VIN - DC Power Supply GND 2 VIN + DC Plus Voltage 3 SLN For technician use, when connected to ground, opens

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

anel - optional external key for maintenance

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-5

Printer Housing

Housing

The printer module enclosure is made of aluminum. The front panel includes two green LED indicators and receipt aperture, protected behind a metal lid, see Figure 4-2 on page 4-2.

Indicators

Protection

The rear panel includes the printer co

nnector and front panel lock, see Figure 4-3 on page 4-3. The printer lock is an electro-mechanic lock (solenoid type) controlled by the station controller.

The printer module includes two green LED indi cators l ocat ed on its fro nt pan el an d a b uzzer. The printer indicators provide visual and audio display on the following events:

• Printing is in progress

• Paper alerts - paper run out or approximately 25% left (refer to “Genera

l” on page 4-10)

• Receipt ready

Note: The indicators activation is cont

rolled by the station controller.

The printer also includes LEDs under its front door for monitoring communication.

At turn

on, the LEDs and buzzer are activated for a short period of time.

Two types of protections are included in the printer module:

• Isolation of 1.5 KV DC to protect against galvanic connection

between the host side and

printer side.

• The printer side is protected against high voltage transient and l

ightning by using spark gaps and transorbs for RS-485 communication. This allows the use of long communication cables.

Specifications

Following table lists the printer physical, electrical, and environmental specifications:

Printer Specification

Power Consumption: Maximum Current Without Heater Maximum Current with Heater

Operating Temperature -4 °F (-20 °C) to 158 °F (70 °C) 

Storage Temperature -4 °F (-20 °C) to 158 °F (70 °C) Humidity 80% Non-condensing Communication Interface RS-485 - 9600 bps Half-duplex

Dimensions H 197 X W 179 X D 162 mm, W: 950 g

Page 4-6 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

10 W Without Heater (21 W with Heater on)

0.7 A

1.4 A

[Optional -40 °F (-40 °C) to 158 °F (70 °C) with Internal Heater)]

Ethernet RJ-45 10 mbps (X2) RS-232 (X2) GPIO (DB9)

Setting Printing Parameters Printer

On a single RS-485 bus, each device must be assigned a different address.

CAUTION

Top

Bottom

5 Jumpers determine the  RS-485 address

3 Jumpers determine the  number of copies in a printout

Setting Printing Parameters

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 eight jumpers, where the first five jumpers determine the  RS-485 address. The last three jumpers determine the number of copies. Figure 4-8 shows the jumpers default configuration, where the RS-485 address = 70 Hex. Figure 4-9 on page 4-8 provides examples of jumpers configuration and corresponding RS-485 address.

Figure 4-8: Printer Module - Jumpers Default Configuration

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-7

Printer Setting Printing Parameters

1st Jumper short =  71 Hex

2nd Jumper short =  72 Hex

1st and 2nd Jumpers short =  73 Hex

3rd Jumper short =  74 Hex

Figure 4-9: Printer Module - Example Jumpers Configuration

Parameters for Printing

The printer features two printing modes, as determined by the controller:

• Print only when the door is lifted - Paper save mode

•Print always

Cutter

The paper cutter may be set to one of the following three modes, as determined by the controller:

•No Cut

• Full Cut

• Partial Cut

Printing Status Report

The G2 printer enables producing a printer status report. To produce a printer status report, proceed as follows:

1 Turn off the printer.

2 Open the printer’s service door.

3 Turn on power to the printer.

4 The G2 printer prints a status report.

Page 4-8 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Replacement - Installation Printer

Housing Clamp

Wing Screw

Replacement - Installation

Following table lists the items required for the printer installation (see Figure 4-10):

No. Description Part Number Quantity

1 Connector Screw MC1.5/6-STF-3.81 mm 813326106 1 2 Clamp Housing, Printer Module 814935500 1 3 Wing Screw M6 X 12 815200100 2

Installing Printer

To install the printer in the TopKAT PLUS dedicated aperture, proceed as follows:

1 Shut down any power source at the installation and working area.

2 Insert the printer into the designated aperture.

3 Secure the printer using the clamp housing, two flat washers, two spring washers, and two

wing screws as shown in the above table.

4 Prepare the power and communication cables to be connected as described in the following

paragraph.

Figure 4-10: Installation Clamp

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-9

Printer Paper Roll Replacement

Green Locking Handle

Installing Cable

Note: Use shielded twisted-pair cable, designated for RS-485 communication, such as Belden

9729/8723.

To connect the power and communication cables to the printer

1 Connect the power and communication cables to the connector in accordance with the pin-out

description in the table in “Printer Connector Pin-out” on page 4-5 and Figure 4-7 on page 4-5.

2 Connect the connector to the printer connector located on the printer rear panel (see Figure 4-3

on page 4-3).

, proceed as follows:

Paper Roll Replacement

General

The printer module is a thermal printer and uses thermal printer paper only. The printer is equipped with two sensors for paper usage alerts as follows:

• Low paper sensor - warns when there is approximately 25% of the paper roll left

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

Replacing Paper Roll

This procedure applies when the printer is online and connected to a power source. In that state, the printer pulls the paper automatically and cuts it when paper feeding is completed.

To replace the printer paper roll, proceed as follows:

1 Open the printer front panel. The front panel lock is an electro mechanic lock (solenoid type)

that can be opened from the station controller.

2 Release the green locking handle (see Figure 4-11) and release the printer (see Figure 4-12 

on page 4-11).

Figure 4-11: Locking Handle

Page 4-10 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Paper Roll Replacement Printer

Attached Paper Printer

Pivot Handle

Pivot Pawl

Pivot

3 Lift the printer and release the attached paper (see Figure 4-12).

Figure 4-12: Released Printer

4 Press the paper roll pivot handle (see Figure 4-12) and release the handle.

5 Lift the paper roll pivot (see Figure 4-13).

6 Press the paper roll pivot pawl (see Figure 4-13) and remove the paper roll.

Figure 4-13: Paper Roll Pivot Handle

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-11

Printer Paper Roll Replacement

7 Prepare a new paper roll facing down. 8 Press the paper roll pivot pawl (see Figure 4-13 on page 4-11) and slide back the new paper

roll when it is facing down.

Note: Insert the paper as shown in Figure 4-12 on page 4-11, with the thermal (shining) side

facing out.

9 Lock the paper roll pivot back (see Figure 4-12 on page 4-11).

The paper can be inserted into the printer auto

matically or manually.

Automatic Insertion of Paper

To insert the paper automatically, proceed as follows:

Note: Ensure that the green locking handle is closed.

1 Slide the paper gently along the grooves until the printer motor starts pulling the paper. At the

end of the process, the paper will exit from the cutter

Note: Do not pull the paper. The printer pulls the paper automatically and cuts it.

2 Slide the paper from the printer door slice (see Figure 4-14).

Manual Insertion of Paper

To insert the paper manually, proceed as follows:

1 Release the green locking handle (see Figure 4-11 on page 4-10).

2 Slide the paper gently along the grooves until the paper exits from the cutter.

3 Lock back the green locking handle and let the printer fall back in its place.

4 Slide the paper from the printer door slice and close the door (see Figure 4-14).

Figure 4-14: Protruding Paper from Slice in Door

Page 4-12 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Cleaning Printer Printer

DO NOT use any solvents such as thinner or benzene to clean the printer front panel.

CAUTION

If the problem persists, contact Gasboy. Do not attempt to dismantle the printer under any circumstances. The printer module G2 unit repair must be performed at Gasboy laboratories only.

CAUTION

Cleaning Printer

The printer must be cleaned periodically at short intervals due to the harsh environment of the home base station.

Clean the printer front panel with a damp cloth only.

Troubleshooting

In case problems are detected after installation or during operation, repeat the installation procedures listed in “Replacement - Installation” on pag

e 4-9.

The G2 printer module indicates a faulty operation by means of its LEDs on the front panel. For the recommended corrective actions to troubleshoot and repair the unit, refer to the following table:

No. Failure Indication Probab le Cause of Failure

1 Left-hand green LED flickers constantly. The printer unit is stuck. 1 Check paper roll.

2 Right-hand green LED flickers constantly. The printer module G2 unit is stuck. 1 C heck paper roll.

Releasing Jammed or Crumpled Paper

This procedure applies when a paper is crumpled or jammed inside the printer. In this case, the printer is disabled and all actions must be performed manually. To release the paper, proceed as follows:

Notes: 1) Do not attempt to release the paper using sharp objects such as a k

screwdriver. Doing so might damage the printer paper cutter and void your warranty.

2) Do not attempt to pull the paper from the printer.

3) Doing so might damage the printer.

To release the paper when a paper jam occurs, proceed as follows:

1 Open the printer front panel. The front panel lock is an electro mechanic lock (solenoid type)

that can be opened from the controller.

Recommended Corrective A

2 Replace unit.

ction

nife or a

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 4-13

2 Pull up the printer cover and release the green locking handle (see Figure 4-11 on page 4-10).

Printer Thermal Paper Storage

3 Pull out any crumpled paper.

4 Clean the printer area from any paper remnants.

5 Push the green locking handle to its original state.

6 Slide the new paper roll into the pivot handle 2 in Figure 4-12 on page 4-11. Ensure that the

paper roll to be inserted is not crumpled.

7 Insert the paper into the printer either automatically (refer to “Automatic Insertion of Paper”

on page 4-12) or manually (refer to “Manual Insertion of Paper” on page 4-12).

Thermal Paper Storage

The thermal paper is sensitive to the environmental conditions. Printer module operation is sensitive to the type of paper inserted. To store the thermal paper, proceed as follows:

• Use the right paper, as specified.

• Insert the paper edge to the printer.

• Insert the paper in the correct side.

• Store the paper in a dry, shaded area, at 64 º

• During paper replacement, avoid dust, moisture, and rain.

F (18 ºC) to 68 ºF (20 ºC).

Note: Dispose of wet or damp paper

. It may jam in the printer.

Page 4-14 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

General Maintenance

5 – Maintenance

General

This section provides general maintenance instructions for the TopKAT PLUS.

The TopKAT PLUS cabinet is specially designed for the ease malfunction, unlock the lock located on the rear part of the box and pull out the cover. The cabinet layout (refer to “TopKAT PLUS Main Components Location” on page 1-9) is intended to grant the technician full and fast access to any defective component.

Note: Only Gasboy certified technicians must perf

PLUS cabinets.

Troubleshooting

Following paragraphs provide a list of common pump/system prob lems which may be encountered when using the TopKAT PLUS system, as well as corrective action instructions, covering the following problems related to the system and its peripherals:

• TopKAT PLUS (refer to “TopKAT PLUS Troubleshooting” on page 5-2)

• OrPT (refer to “OrPT Troubleshooting” on

• Printer (refer to “Printer Troubleshooting” on

• Communication (refer to “Communication Troubleshooting” on

of maintenance. In case of

orm maintenance tasks on the TopKAT

page 5-5)

page 5-6)

page 5-7)

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 5-1

Maintenance Troubleshooting

TopKAT PLUS Troubleshooting

TopKAT PLUS troubleshooting procedure and consequent corrective actions are described in the following table:

Fault Probable Cause Checks Corrective Action

System is down

LCD display is blank



Does not accept key/card/keypad input



No communication



OrCU LEDs are not lit

Does not accept  key/card/keypad input No

mmunication

No magnetic card response Dirty or faulty magnetic

No key response Loose cable faulty key

Customer display is blank Faulty customer display

T o pKAT PLUS main switch

off

is No 115 VAC feed to the

unit

Power failure Does the unit shut down immediately after

External circuit breaker is

Internal fuse blown Check the two fuses inside the protective

Power supply failure Check the power supply using an

OrPT setup is incorrect Login to OrPT and check communication

OrCU setup is incorrect Check OrCU setup:

d reader faulty

car magnetic cards

acle

recept

Faulty Or

1 Check power at the 

Distribution Box (D-Box). 2 Check cabling from D-Box to the unit. 3 Ensure that power cable is properly

nnected to unit terminal block.

co 4 Is 115 V measured at the power input

terminal blo

being turne

Is breaker off or tripped? Turn breaker on, if off. Is 115 V being switched through breaker? Replace breaker if 115 V is not being

Is 115 V measured at the power input terminal blo

Does the breaker turn off immediately after being turne

ver using an ohmmeter.

ltmeter.

rameters.

• OrPT bus

• OrPT parameters

• OrCU administrator parameters

1 Visually check magnetic card reader. 2 Present several magnetic cards.

1 Visually check key receptacle. 2 Insert several keys.

Ensure that the customer display board is properly connected to OrPT interface board.

ck?

d on?

ck?

d on?

Turn main switch on.

Correct wiring problems if 115 VAC is not measured.

1 Check for shorts in the power line

cable.

2 Check grounding.

switched. Correct wiring problems if 115 V is

not measured. Check for loads or shorts in the

power line. Replace the fuse if it is blown.

1 Replace fuse. 2 Replace power supply.

1 Set communication parameters. 2 Submit and check again.

1 Set communication parameters. 2 Save and reload check again.

1 Clean magnetic card reader. 2 Replace magnetic card reader. 3 Replace OrPT.

1 Replace Key receptacle. 2 Replace OrPT.

1 Replace customer display. 2 Replace OrPT.

Page 5-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Troubleshooting Maintenance

Fault Probable Cause Checks Corrective Action

Mechanic pump does not refuel

Pump does not supply fuel Device is not allowed to

Pump is authorized but call

ate is not detected (nozzle

st icon in SiteOmat status screen does not display Call state)

Pump is authorized, pump

is running, but no fuel

motor is supplied

refuel

Pump setup is incorrect Check pump setup:

Faulty connection to pump Check control cables from TopKAT PLUS

8-port failure Ensure that power LED is lit. If it is off, use a voltmeter to check

Pump malfunction Turn the external bypass switch on, lift the

Handle-on switch problem Is the In Use red LED in MPI-C board lit

Faulty in use switch in pump

Faulty connections Check In Use cable

Faulty in use terminal block Replace in use terminal block. Faulty MPI-C board Ensure that the call red LED is lit when

Faulty 8-port Replace 8-port. Faulty solenoid valve

Faulty pump

1 Open the pump from SiteOmat status

een.

scr

2 Ensure that the vehicle/device has no

ation in FHO setup.

limit

• Pump Server

•Buses

•Prices

• Pulse rate

to pump.

Ensure that control red LED on MPI-C

d is lit.

boar

nozzle, and check that the pump fuel.

ozzle is lifted?

when n

Power off the pump using a ohmmeter, measure the

Check In Use terminal block connections.

nozzle is lif

Does the pump solenoid valve produce a clicking sound?

switch in on and off states.

ted.

supplies

Enable the device to refuel.

1 Set pump parameters. 2 Save and reload. 3 Check again.

Make good electrical connection.

supply to the unit: If power

power supply is OK, then replace the 8-port board. If power supply is faulty, replace the power supply.

1 Replace MPI-C board. 2 Replace 8-port.

If the problem persists: 1 Check Handle-On switch. 2 Repair pump.

1 Check in use cable and repair, if

required.

2 Check terminal wires and repair, if

required.

3 Check the in ise switch in the pump

Replace pump switch in cases where no short was detected.

Make good electrical connection if fault

If the red LED is not lit, replace  MPI-C board. If the LED is lit, the problem is exter

1 Replace valve. 2 Repair pump.

and rep

y one exists.

air, if required.

nal to the controller.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 5-3

Maintenance Troubleshooting

Fault Probable Cause Checks Corrective Action

Payment device (card, key, tag, and fuel ring) is not accepted

Pump is refueling but

olume remains zero

Pump is refueling without any cont

rol

Communication fault between

Device was not  defined/incorrectly defined in F

Device limit was passed Ensure that the device is within the limits of

Device was set as driver 1 Login to FHO and go to devices

Device is blocked 1 Login to FHO and go to devices

Pulse factor is zero Check SO pump setup. Change pump settings to correct the

Faulty MPI-C board

Faulty pulser

Pump is in bypass Ensure that external bypass switch is off. Turn bypass switch off, if on. Faulty SSR Replace the relevant SSR unit inside

If an external relay is used to control the pump it may be stuck due to a small current leak

OrPT and SO

FHO and SO

Pump is Authorized and refueling but volume remains zero

/valve,

1 Check LAN cable. 2 Check OrPT setup. 3 Check SO setup.

1 Check connection path with FHO 2 Ensure that the station is available and

synchronized with FHO in FH status screen.

1 Login to FHO as Fleet manager. 2 Check that the device is defined. 3 Check device parameters. 4 Check that device rules does not limit

ling.

refue

its r

ule.

managemen 2 Select the specific device and check if it

was co

managemen 2 Check the status of the device in the

atus column in the devices grid

st (blocked/unblocked).

Disconnect the pulser and short the  pulse-in wires to simulate pulses.

No control on refueling

nfigured as driver.

O stations

1 Replace LAN cable, if required. 2 Set OrPT parameters properly. 3 Set SO parameters properly.

Repair communication between FHO and SO, provid communication line.

Define the device parameters in FHO proper

ly.

For testing only, remove any rule associated to this device.

Change the device setting to

hicle.

Change device status to U

factor for the relevant pump. If pulses are received during

refueling, replace pump pulser If not, replace MPI-C board.

opKAT PLUS.

the T Add a snubber (capacitor + resistor)

arallel to relay input.

in p

ing a reliable

nblocked.

Page 5-4 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Troubleshooting Maintenance

OrPT Troubleshooting

The OrPT troubleshooting procedure and consequent corrective actions are described in the following table:

Fault Probable Cause Checks Corrective Action

OrPT display is not lit

OrPT display is blank. Internal fuse blown. Check the mini fuse at the bottom of

e power supply using an

th ohmmeter.

Power supply failure. Ensure that green LED on power

Faulty OrPT. Replace OrPT.

OrPT display does not respond corr

Pressing the keypad buttons does not gene any sound and does not affect the display.

5-LAN switch is dead. No power to 8-port. Are 8-port LEDs lit/blinking? 1 Check power connector to 8-port.

ectly to cards.

ectly to tags.

Bad card. Present several cards to see if

Dirty card reader. Ensure that the card reader is clean. Clean the card reader using a cleaner card

OrPT is busy performing

task.

another

Faulty card reader. Replace OrPT.

Bad tag. Replace tag and test again. Tag is not close to the

PT antenna.

Or OrPT is busy performing

task.

another

Faulty OrPT. Replace OrPT.

OrPT does not respond to keypad entries

Dirty keyboard. Clean the keyboard.

rate

Damaged keypad. Visually check the keypad surface

OrPT is busy performing another

task.

Faulty OrPT. Replace OrPT.

OrPT displays “No communication” message

Communication disconnected.

OrPT displays “No communication” message

supply is lit.

OrPT does not accept card

problem is consistent.

Ensure that the display presents the idle message.

OrPT does not accept RFID tag

Ensure that the display presents the idle message.

r any damage.

fo Ensure that the display presents the

idle message.

Open TopKAT PLUS cabinet and

LAN cable from OrPT to 

check 5-LAN switch.

Is 5-LAN switch LEDs are  lit/blinking?

Replace the fuse if it is blown.

Replace power supply.

Replace card and test again.

and tr

y again.

1 Press Cancel. 2 Present the card while the idle message is

displayed.

Bring the key close to the antenna located on the red circle.

1 Press Cancel. 2 Present the tag while the idle message is

displayed.

Replace keypad if any damage is found.

1 Press Cancel. 2 Present the tag while the idle message is

displayed.

Make correct and good connection if it was

correct.

2 Replace 8-port. 1 Check connection of LAN switch on 

8-port. It must be inserted in a socket on

port main board.

the 8-

2 Replace 5-LAN switch board.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 5-5

Maintenance Troubleshooting

Fault Probable Cause Checks Corrective Action

OrCU problem Faulty connection Check power to OrCU. Ensure that the white power connector is

plugged into the OrCU POWER socket.

Power supply failure Is power supply on? 1 Replace fuse.

2 Replace power supply. Faulty OrCU Replace OrCU. Incorrect SiteOmat setup Ensure that OrPT parameters

Incorrect OrCU setup Login to OrPT and ensure that all

fined

in SiteOmat match the

de values presented in OrPT display at power on.

parameters ma

tch OrCU setup.

Set the OrPT bus and parameters

ding to OrPT values presented in

accor

OrPT display at power on.

OrCU setup.

Printer Troubleshooting

Following table describes printer troubleshooting procedure and consequent corrective actions:

Fault Probable Cause Checks Corrective Action

No printing at the end of transaction

No printing, printer does not

ce a b

produ power on

Paper is not being cut at the end of the

eep sound at

printing

Printer does not print

Printer is out of paper Check paper roll. Replace paper roll. Paper lock (green) switch

is open Jammed paper Release paper. Incorrect SiteOmat setting Check SiteOmat printer settings. Set printer parameters properly. Faulty printer Replace printer.

Power cable is disconnected

Faulty power supply Check power supply outputs using a

Faulty printer Replace printer.

RS-485 cable is

sconnected

di LAN cable is

sconnected

d Incorrect address settings Check printer address jumpers (no

Faulty printer Replace printer.

ncorrect SiteOmat setting Check SiteOmat printing settings. Set SiteOmat printing settings

Faulty printer cutter Replace printer cutter. Faulty printer Replace printer.

Check paper lock switch position. Close paper lock switch.

No power to Printer

Check power cable connections between the printer and OrPT.

gital Voltmeter. The output voltage

d must be 24 VDC.

No Communication to Printer

Check the RS-485 cable connections between the printer and OrPT.

Check the OrPT LAN cable. Make correct and good connection if it

jumper means addre

Paper is not automatically cut

ss is 70 HEX).

Make correct and good connection if it was incorrect.

Replace power supply.

Make correct and good connection if it was incorrect.

was incorrect. Set the correct Hex address in

SiteOmat.

accordingly.

Page 5-6 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Troubleshooting Maintenance

Communication Troubleshooting

The troubleshooting procedure for problems related to communication to peripherals and consequent corrective actions are described in the following table:

Fault Probable Cause Checks Corrective Action

No communication between FHO and SO controller

No connection to the

ation

from FHO

st stations screen

A “Warning” sign for the pump is di the SiteOmat status screen

OrPT displays the message, “No H Communication”

splayed on

ost

Cabling issue Visually inspect the

No communication to the pump (8-port CommVerter)

Incorrect 8-port

ommVerter setup

Incorrect OrPT communication physical network setup

and/or

network cable to LAN2.

Check the physical connection of the 8-port CommVerter to the local network (5-port switch activity).

Check network connectivity by p a “ping” command locally or remotely, through PuTTY application.

communication to OrPT

Check the network cable

r activity on 5-port

fo switch.

Ping the OrPT to confirm

oper settings in the

p controller.

erfor

1 Verify if LAN2 port LED is blinking. 2 Unplug the cable and plug it back in. 3 Replace LAN cable, if required. 4 If the cable is in good condition, contact the IT

artment to confirm that the switch/router connected

de to the LAN cable is properly set.

5 Check the controller network settings (IP addresses,

mask, gateway

1 If no activity on the LAN port connected to the 8-port

ommV

C change the LAN port to confirm normal operation.

2 Check the status of the LEDs on the 8-port (upper right

er of the

corn to confirm power and network connection, while second LED must blink to confirm network activity. The last two

ming

LEDs (from left to right) must blink constantly to confirm communication with controller.

3 In cases where all LEDs are lit periodically, (every 30

seconds), the unit is resettin the controller.

4 Reset the IP and reconfigure the Pump Server (PS) in

oller setup.

contr

1 If no activity on the LAN port, check the cable and/or

change the port o

2 Reset the OrPT and follow the main screen messages

r the IP addr

3 Change the configuration of the OrPT according to the

site setup (contro

, an

d so on).

erter, replace the short Ethernet cable or/and

board): the first and third LED must be lit

due to connection loss to

n the 5-port switch.

ess.

ller).

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 5-7

Maintenance Troubleshooting

Safety Reinforcements

To comply with UL and cUL safety standards, the connectors and components enumerated in the following table are secured by tie-wraps. These reinforcements must be replaced, if removed when performing maintenance tasks.

Reinforcement Description

CN13 - P/S connector on 8-port board

CN6 - Cover opening detection sensor connector on 8-port board

CN1 - Illumination panel connectors (X2)

Page 5-8 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Troubleshooting Maintenance

DO NOT use any solvents such as thinner or benzene.

CAUTION

Reinforcement Description

Fuse boxes on 24 V and 32 V regulators located inside the protective cover

Cleaning

General

The TopKAT PLUS itself as a standalone unit must be cleaned periodically at short intervals, due to the harsh environment of the home base station where they operate.

Cleaning

Following instructions are valid for the OrPT front panel and TopKAT PLUS pedestal.

• Clean the OrPT front plastic panel with a cloth lightly mois similar lubricant.

• Clean the pedestal metallic enclosure using a damp clot

tened with WD-40 or any other

h and cleaning spray.

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 5-9

Maintenance Troubleshooting

Magnetic Card Reader - Cleaning Instructions

The card reader must be cleaned periodically, preferably once in every two weeks to ensure proper operation. The cleaning purpose is to remove any dust or foreign body that may harm the reader and consequently prevent the completion of a sale.

To clean the magnetic card reader, proceed as follows:

1 Remove the cleaning card from its packing.

2 Insert the cleaning card all the way in the reader and then pull it out slowly.

3 Perform the previous procedures several times, until the card gets dry.

4 Insert any magnetic card and ensure that its stored data is read by the magnetic card reader.

Printer - Cleaning Instructions

Refer to “Cleaning Printer” on page 4-13.

Page 5-10 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

FuelOmat Glossary

Glossary

FuelOmat

Term Description

CommVerter LAN/232/485/422/C.L./Tokheim OrCU Orpak embedded Controller Unit

OrPT Orpak/Outdoor Payment Terminal (display, keyboard, key reader, magnetic

SAM Security Application Module (security card in the

Communication

Term Description

Data Encryption

andard (DES)

St Ethernet A popular local area data communications network, originally developed by

TCP/IP Communication protocol used in Ethernet/Internet. Triple DES Triple-Data Encryption Standard. A method of data encryption.

d reade

car

r, LEDs, buzzer; install in fueling area)

LANs with high level of security. A method of data encryption.

Xerox Corpor terminals. Ethernet operates on 10/100 Mbps transmission rate over shielded coaxial cable or over shielded twisted-pair telephone wire.

ation, which accepts transmission from computers and

Communication Converter

VIT/UPI)

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Glossary-1

Glossary Communication

This page is intentionally left blank.

Glossary-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Appendix A: Wiring Diagrams

This appendix provides the wiring diagrams of the TopKAT PLUS, as follows:

• TopKAT PLUS - Wiring Diagram (Mechanical Pump)

• TopKAT PLUS - Wiring Diagram (Electronic Pump)

Figure A-1: TopKAT PLUS - Wiring Diagram (Mechanical Pump)

Appendix A: Wiring Diagrams

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page A-1

Appendix A: Wiring Diagrams

Figure A-2: TopKAT PLUS - Wiring Diagram (Electronic Pump)

Page A-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Appendix B: Parts List

Following table lists the TopKAT PLUS parts (for TopKAT PLUS parts illustrations, refer to

“TopKAT PLUS Parts Illustrated” on page C-1):

Description Part Number

Printer Head M09680B102 PCB Card for Printer M09680B033 Mechanical Printer Module M09680B107 Line Filter M09680B008 32 V Regulator M09680B052 24 V Regulator M09680B083 Transformer M09680B022 Terminal Block M09680B025 Printer G2 M09680B101 OrCU-N M09680B004 Kit 5-port + Heat Sink M09680B103 (see note 1) 8-port CommVerter M09680B123 (see note 1) RS485 P.B TopKAT PLUS M09680B104 (see note 1) OrPT M09680B124 (see note 1) MPI + SUB P.B TopKAT PLUS M09680B105 (see note 1) Paper TopKAT Printer M09680B100 Lock M09680B106 Sensor Islander Kit M09680B096 Manual Override Switch M09680B048 Relay SS 250 V 25 A M09680B044

Notes: 1) New PCB per UL specifications with same

functionality without jumpers.

2) The T opKA T PLUS system is NOT compatible with current loop pump communication and Tank Monitor™.

Appendix B: Parts List



MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page B-1

Appendix B: Parts List

This page is intentionally left blank.

Page B-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Appendix C: TopKAT PLUS Parts Illustrated

8-port CommVerter (M09680B123)

Kit 5-port + Heat Sink (M09680B103)

OrCU-N (M09680B004)

Printer G2  (M09680B101)

Line Filter (M09680B008)

32 V Regulator (M09680B052)

24 V Regulator (M09680B083)

Transformer (M09680B022)

Terminal Block (M09680B025)

Appendix C: TopKAT PLUS Parts Illustrated

Figure C-1: TopKAT PLUS - Right Side Parts

Figure C-2: TopKAT PLUS - Left Side Parts

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page C-1

Appendix C: TopKAT PLUS Parts Illustrated

Printer Head (M09680B102)

PCB Card for Printer (M09680B033)

Mechanical Printer Module (M09680B107)

Figure C-3: TopKAT PLUS Receipt Printer

Page C-2 MDE-5013C TopKAT™ PLUS Installation Manual · February 2015

Index

attenuate 1-11, 3-13 Authorized Service Contractors 1-1

Barrier Plate 3-5 black rubber gasket 3-7

Communication range 3-4 CommVerter 1-6, 1-12, 5-7, c-1, 1-1 compact box 1-1 conductors 3-6 conduit 3-5, 3-12, 3-25, 3-26 contactless tags 1-5, 1-13, 1-14

data acquisition system 1-1

Electromagnetic Interference 1-11 Electronic pulser 3-19 electronic pumps 1-6, 1-8, 3-10, 3-23 electronic pumps configuration 1-11 End paper sensor 1-6, 4-2, 4-10 environmental specifications 1-14 Ethernet 1-4, 1-13, 1-14, 4-6, c-1

factory installation 1-13, 3-1 flash disk 1-2 flat washer 3-7 Fleet Head Office 1-3 forecourt compatible 1-1 forecourt wiring 3-12 Fuel Management Software Server 1-3

gases 3-6 grace period 1-3 grounding lug 3-8

hazardous location 3-5, 3-6 Head Assembly 3-2 Head office 1-3 High voltage 3-9 home base gas stations 1-2

installation requirements 1-1 internal SAM 1-13 Internet Explorer 1-2, 1-5 island electrician 1-1

jumper wire 3-13

Line Filter 1-1 Liquid Crystal Display 1-1 LOAD 3-15 LOAD_1 3-14 LOAD_2 3-14 Local Area Network 1-5 lockwasher 3-7 Low Capacitance 3-2 Low paper sensor 1-6, 4-2, 4-10 Low voltage 3-9

magnetic cards 1-1, 1-5, 5-2 magnetic stripe cards 1-14 Manual Override Switch 1-1 Mechanical dispensers 1-12 Mechanical pulser 3-19 metal cabinet 1-13 motorist 1-4 MPIC card 1-12

operational workflow 1-4 Outdoor Payment Terminal 1-1, c-1 outer jacket 3-12

Paper TopKAT Printer 1-1 parameters 5-2 pedestal 3-2, 3-3 Pedestal Assembly 3-7 Post installation check 3-1 power failure recovery mechanisms 1-2 power supply setup jumpers 3-13, 3-26 Printer Head 1-1 proper operation 1-1, 5-10 pump nozzle 3-20

Radio Frequency Identification 1-1 Real Time Clock 1-2 reliability 1-1 RS-232 link 1-14 RS-485 link 1-14

Secured Socket Layer 1-4 self-service 1-4 Sensor Islander Kit 1-1 shielded 3-11, 4-9 SiteOmat automation software 1-2 Solid State 1-14 station automation 1-1

TCP/IP over Ethernet 1-14 TCP/IP TCP/IP over Ethernet 1-4 TDES encryption 1-14 terminal blocks 3-10, 3-21 third-party systems 1-4 TopKAT PLUS box installation 3-1 TopKAT PLUS cabinets 5-1 Transformer 1-1 Triple-Data Encryption Standard 

1-13, c-1

twisted-pair 3-11, 4-9, c-1

volatile liquids 3-6 voltmeter 5-2

weather-resistant cabinet 1-1 Wide Area Network 1-13 wiring 3-2, 3-6, 3-9, 3-11, 3-14, 3-19

MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Index-1

Belden® is a registered trademark of Belden Inc. Ethernet® is a registered trademark of Xerox Corporation. Gilbarco® is a registered trademark of Gilbarco Inc. GOLD Microsoft Corporation. MIFARE

is a service mark of Gilbarco Inc. Internet Explorer® and Microsoft® are registered trademarks of

is a registered trademark of NXP Semiconductors N.V. NEC® and NFPA 70® are registered trademarks of the National Fire Protection Association. Orpak™ is a trademark of Orpak Systems Ltd. Tank Monitor™ is a trademark of Gilbarco Inc. Tokheim

is a registered trademark of Tokheim Holding B.V. Corporation. UL® is a registered trademark of Underwriters Laboratories Inc.

© 2015 GASBOY 7300 West Friendly Avenue · Post Office Box 22087 Greensboro, North Carolina 27420 Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A. MDE-5013C TopKAT™ PLUS Installation Manual · Februa ry 2015

Gasboy TopKAT PLUS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 – Introduction

Purpose

Intended Users

Description

System Overview

TopKAT PLUS System

Remote Web Access

Head Office

Restrictions and Limits

System Workflow Example

Refueling Scenario with Magnetic Cards

TopKAT PLUS Structure

Main Components

OrCU

OrPT Panel

Outdoor Printer (Optional)

8-port CommVerter

TopKAT PLUS Internal Configuration - Mechanical Pump

TopKAT PLUS Internal Configuration - Electronic Pump

TopKAT PLUS Main Components Location

Electrical Setup

Available Configurations

General

Optional Printer

Dispensers

Configurations

Security and Protection

General

Authorization Security

Network Security

Maintenance Security

Housing

Specifications

Standards

Communication Standards

Security Standards

Using This Manual

Related Documents

Abbreviations and Acronyms

2 – Important Safety Information

3 – TopKAT PLUS Installation Procedures

General

Installation Specifications

General

Precautions and Safety Notes

Types of Cables

Types of TopKAT PLUS Units

Head Assembly Dimensions

Pedestal Dimensions

Conduits

General

Conduit Requirements

Barrier Plate Conduit Penetration

Sealing Conduits

Safety Distance

TopKAT PLUS Pedestal Mounting Instructions

Parts List

Connections to TopKAT PLUS - Pedestal Mounted Units

Wiring

Types of Wiring

Wiring Requirements

Types of Cables

Field Wiring Requirements (LAN/WAN)

Recommendations for CAT-5E Cable

AC Power Connection

Mechanical Pump - Wiring

General

Terminal Block - Pin-out Connections for Mechanical Pumps

Mechanical Pump - Required Connections

Single Suction Pump

Mechanical Pump - Pulser Connections

Electronic Pump Wiring - TopKAT PLUS on Pedestal

Mechanical Pulser

Electronic Pump - Wiring Description (Pedestal Mount)

General