Gasboy TopKAT PLUS User Manual

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

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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

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