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.
This document is subject to change without notice.
http://www.gasboy.com
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com
2014 GASBOY. All Rights Reserved.
2015 GASBOY. All Rights Reserved.
Table of Contents
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
. . . . . . . . . . . . . . . . . . . . . 1-13
. . . . . . . . 1-1
. . . . . . . . . . . 1-1
. . . . . . . . 1-2
. . . . . . . . . 1-11
. . . . . 1-12
. . . . . 1-13
. . . . . . . . . . 1-13
. . . . . . . . . 1-14
. . . . . . . . . 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
. . . . . . . . . . . .4-6
. . . . . . . . . .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.
n
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
m
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.
r
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
UL
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:
Related Documents
Document
Number Description GOLD
MDE-4331 Atlas Fuel Systems Installation Manual • Gasboy Atlas
MDE-4333 Atlas Fuel Systems Site Preparation Manual • Gasboy Atlas
MDE-4334 Commercial and Retail Series Atlas Start-up/Service Manual • Gasboy Atlas
MDE-4817 SiteOmat In-House Station Controller Setup and Maintenance Manual Gasboy Fleet PLUS
MDE-4818 SiteOmat In-House Station Controller User’s Manual Gasboy Fleet PLUS
MDE-4819 OrPT Gasboy’s Payment Terminal Inst
Manual for Home-base Stations
MDE-4820 8-port CommVerter Operation and Installation Manual Gasboy Fleet PLUS
PT-1963 Illustrated Spare Parts Manual Gasboy Fleet PLUS System
allation, Setup and Oper
ation
SM
Library
• Pumps/Dispensers
• Pumps/Dispensers
• Pumps/Dispensers
t
ems
Sys
ems
Syst
Gasboy Fleet PLUS
Systems
t
ems
Sys
MDE-5013C TopKAT™ PLUS Installation Manual · February 2015 Page 1-15
Introduction Abbreviations and Acronyms
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
e
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
i
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
!
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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