Gasboy WGT Outdoor Unit User Manual

MDE-4815B

WWGGTT OOuuttddoooorr UUnniitt

INSTALLATION MANUAL

This document is based on Orpak’s WGT outdoor unit installation
manual P/N 817439300

SAFETY CONSIDERATIONS

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

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

WARNING - EXPLOSION HAZARD

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

CAUTION - SHOCK HAZARD

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

WARNING – PASSING VEHICLES

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

WARNING

Components substitutions could impair intrinsic safety.

Attaching unauthorized components or equipment will void your warranties.

CAUTION

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

PROPRIETY NOTICE

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

DISCLAIMER

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

This document is the property of:

ORPAK SYSTEMS Ltd.

ISRAEL

TABLE OF CONTENTS

Paragraph Page

SECTION 1 GENERAL DESCRIPTION

1-1. WGT – WIRELESS GATEWAY TERMINAL................................................................. 1-1

1-2. WGT OUTDOOR BOX..................................................................................................... 1-1

1-3. INSTALLATION OPTIONS............................................................................................. 1-2

1-4. INSTALLATION REQUIREMENTS............................................................................... 1-2

. IInnssttaallllaattiioonn LLooccaattiioonn ...................................................................................................... 1-2

11--44..11.

. IInnssttaallllaattiioonn IInnssttrruuccttiioonnss.................................................................................................. 1-3

11--44..22.

. PPoowweerr SSuuppppllyy................................................................................................................. 1-4

11--44..33.

. CCaabbllee IInnssttaallllaattiioonnss.......................................................................................................... 1-4

11--44..44.

. DDeeddiiccaatteedd PPoollee OOrr PPeeddeessttaall............................................................................................ 1-7

11--44..55.

. BBaatttteerryy............................................................................................................................ 1-7

11--44..66.

1-5. WGT OUTDOOR BOX SPECIFICATIONS.................................................................... 1-8

1-6. TROUBLESHOOTING ..................................................................................................... 1-12

WGT Manual

i

LIST OF ILLUSTRATIONS

Figure Page

Figure 1-1. WGT - General View.......................................... ... ..... ...... .. ...... ..... ... ..... ..... ... ..... .........1-1

Figure 1-2. WGT, Outdoor Installation Control Drawing................................................ ..... ... ..... .1-2

Figure 1-3. WGT Box Cable Installation........................................................................................1-4

Figure 1-4. WGT Outdoor Box Dimensions.................................................... ..............................1-9

Figure 1-5. WGT Outdoor Box, Inside View.............................................. ...................................1-10

Figure 1-6. WGT Outdoor Box, External View.............................................................................1-11

ii

WGT Manual

LIST OF TABLES

Table Page

Table 1-1. Pin Assignment For Input Power - C n 8, 4 Pin Connector, Molex............................... 1-5

Table 1-2. Pin Assignment For RS485 Communication Connector – Cn 1 2, Conn,

Type D9p Male.................................... ..... ... ..... ...... .. ...... ..... ... ..... ..... ... ..... ...... .. ...... ..... ... ................ 1-5

Table 1-3. Pin Number Assignment, Communication Lan – Cn2 Conn.Rj45..............................1-6

Table 1-4. Pin Assignment For Rs232 Communication Connector – Cn11Conn,

Type D9s Female...................................................... ...... .. ...... ..... ..... ... ..... ...... .. ...... ..... ... ................ 1-6

Table 1-5. Jumpers (Factory Assembly) .......................................................................................1-6

Table 1-6. Indication Leds On The Left Side Of Pcb (Left To Right).......................................... 1-6

Table 1-7. Indication Leds On The Right Side Of Pcb (Left To Right)........................................ 1-7

Table 1-8. Wgt, Troubleshooting Procedures................................................................................ 1-12

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iii

0

SSEECCTTIIOONN 11

GGEENNEERRAALL DDEESSCCRRIIPPTTIIOONN

11--11.. WWGGTT –– WWIIRREELLEESSSS GGAATTEEWWAAYY TTEERRMMIINNAALL

The Wireless Gateway Terminal (WGT) is an electroni c unit, part of FuelPoint PLUS Solution for
vehicle identification based fueling solution for gas stations.

As part of the solution, one or several WGT units are i ns talled in gas stations to form a wireless
network communication da ta from the vehicle units to the station contr oller through short range RF
communication (very low power) in the ISM 2.4 GHz band. The number of WGT units mainly
depends on station size and number of dispensers covered. In each station one of the WGTs is set to
be Master WGT and it will be connected to the forecourt controller (FCC) via LAN. The re st of the
WGTs in the station will be “routers” with no LAN connection.

The WGT can be installed in several locations:

• In enclosed and non explosive environment inside the station controller box (Islander PLUS

or ICR PLUS) or in the station office.

• On a pole or wall mounted config uration which requires using the WGT outdoor b o x.

This guide describes in details the second option- outdoor installation.

1-2. WWGGTT OOUUTTDDOOOORR BBOOXX
The WGT outdoor box is made of plastic to allow for uninterrupted passage of the RF signal.

The WGT outdoor box includes the WGT as shown in Figure 1-1.

Figure 1-1. WGT - General View

WGT Manual

1-1

11--33.. IINNSSTTAALLLLAATTIIOONN OOPPTTIIOONNSS

The preferred installation method depends on the layout and conf igura ti o n of the gas station.
There are three installation options for the WGT Box:

1. Unit mounted on a wall or a pole in the island

2. On a dedicated pole or pedestal

3. Under the station roof (not recom mended due to maintenance con ve nience).

Any of the above selected methods must comply with UL and EU requirements.

11--44.. IINNSSTTAALLLLAATTIIOONN RREEQQUUIIRREEMMEENNTTSS

Due to safety requirements, it is not allowed to install a WGT box withi n hazardous location as
shown in the control drawing (see Figure 1-2).

11--44..11.. IINNSSTTAALLLLAATTIIOONN LLOOCCAATTIIOONN

The WGT box must be installed at n o n hazardous area / non classified ar ea , which means:

1. Above 18” (0.5 meter) from the island floor

2. At least 18” (0.5 meter) away from the dispenser

Figure 1-2 presents various possible WGT Box installation locations.

Figure 1-2. WGT, Outdoor Installation Control Drawing

1-2

WGT Manual

11--44..22.. IINNSSTTAALLLLAATTIIOONN IINNSSTTRRUUCCTTIIOONNSS

The following paragraph provides step by step instructions for installation of the outdoor WGT.
a. Install the WGT in a non hazardous area according to Figure 1-2 .
b. Install a Master WGT and a Router WGT (one or more) in each station according to station

topology.

• The Master WGT, as opposed to the Rou ter WGT, is connected to the FCC controller using

shielded S-CAT5E LAN cable. Install the master WGT as close as possible to the FCC
controller.

• Install the Router(s) WGT in a line of sight with the Master WGT, within a distance not

exceeding 15 meters (approximately 50 feet).

• The Master unit and the Router unit activate the RF mesh network in the station.

• For ease of maintenance, it is recommended not to install the WGT higher than two meters from

the ground. However, the higher will be the unit, the better will be the RF cover.

• The installation procedures must meet all safety regulations according to local state regulations.

• Mechanical Installation

- Remove the WGT cover and install the unit on a smooth surface using four screws via holes

located at the four corners of the unit.

- Refer to Figure 1-4 for the location of the four holes.

- Install the WGT vertically where the two cable holes are located at the bottom section of the

unit (see Figure 1-5).

- Connect a 12-28 VDC (stabilized), 500 mA ( maximum) power suppl y, for the Master and

Router WGTs.

- For the master WGT, connect a shielded S-CAT5E cable using RJ-45 connector.

- Connect the wiring through UL liste d glands or appropriate metal tubing. The large hole can

host a gland for cables in diameter betwee n 0.230” to 0.530” (5.8 to 13.9 mm) and the small
hole can host a gland for cables in diameter between 0.114” to 0.250” (2.9 to 6.4 mm).
Tighten the glands in order to prevent leak of water or gass e s throu gh con dui ts, cables and
conductors.

- In case you are not using one of the two wiring holes be sure to seal it properly.

- When installing cables into the WGT bo x, do not damage unit sealing (IP66 protection).

- Assemble the unit cover using the four coarse pitch screws and than install the four screw

clip-on knobs.

• Perform Router and Master unit setup prior to installation according to instructions provided in

the Setup Sections.

WGT Manual

1-3

Figure 1-3. WGT Box Cable Installation

11--44..33.. PPOOWWEERR SSUUPPPPLLYY

An external AC to DC or DC to DC switching power supply shall be use to operate the WGT. This
power supply should be 12V to 28V DC output. The adaptor should be approved according to the
local regulation. In North America use a AC to DC NEC Class 2 power supply, low voltage and
low current maximum 100 VA even under fault conditions. The power supply can be installed in
the office, in the pedestal, in the tanker truck cabin (DC to DC powe r supply) or in a separate box.
DC cable will be connected to the DC input in the WGT box.

Note: If power supply installed far from WGT box, make sure the WGT get a correct voltage due to
power fail on the lines!

11--44..44.. CCAABBLLEE IINNSSTTAALLLLAATTIIOONNSS

The WGT Box has power input and optional data (LAN or other) input/output. The LAN cable will
be connected to the station network LAN onl y in case the WGT is a master WGT. The other I/O
plugs (RS-232 and RS-485) will be connec te d only by certified technician for ma intenance use
only.

The cables must be placed in dedicated tubes which comply with UL/EU regulations and any other
local regulations. The cables enter the WGT box from the sealing adapters which used to ensure the
box sealing as shown in Figur e 1-3.

1-4

WGT Manual

Table 1-1. Pin Assignment for Input Power - CN8, 4 pin connector, Molex

Pin No. Assignment Wire color Remarks

4 DC INPUT +V Red
2 DC INPUT -V Black

1

Ground Yellow/Green Ground connection to be

connected to nearest ground.

3 PF Not used

Table 1-2. Pin Assignment for RS485 Communication connector – CN12,

CONN, type D9P male

Pin No. Assignment

Channel 1
1 +485
2 -485
6 G485

Channel 2
3 +485
4 -485
8 G485

7,9, case Ground

5 N.C.

WGT Manual

1-5

Table 1-3. Pin number assignment, Communication LAN – CN2

CONN.RJ45

Pin No. Assignment Wire color Remarks

Standard cable S-CAT5E For master WGT application

only

Table 1-4. Pin assignment for RS232 Communication connector – CN11

CONN, TYPE D9S female

Pin No. Assignment Remarks

2 TXD_232
3 RXD_232
5 Ground_232
8 MONITOR Refer to monitor jumpers (Rev C only)
4 MONITOR Refer to monitor jumpers (Rev D only)
7 CAN_H (Rev D only)
8 CAN_L (Rev D only)
9 CAN_Ground (Rev D only)

, 4, 6, 9 N.C. (Rev C only)

1 N.C.

Table 1-5. Jumpers (Factory assembly)

Jumper No. Name Description

J4
Pins1-2 3.3V SAM power is 3.3V
Pins2-3 5V SAM power is 5V
J6 Switches the battery (BT1) to circuit

Table 1-6. Indication LEDs on the Left side of PCB (left to right)

LED No. Name Description

DL2 100 Indicates communication rate:

Light on: 100 BPS

1-6

WGT Manual

Light off: 10 BPS

DL3 ACT Blinks during active communication
DL4 LNK Illuminates constantly when Ether ne t

communication is connected

Table 1-7. Indication LEDs on the Right side of PCB (left to right)

LED No. Name Description

DL9 GP Illuminates constantly.

Blinks during data transfer via external
communication (Ethernet, RS-232 or

RS-485)
DL(not shown) TAG Not used
DL(not shown) RST Reset LED. Illuminates during reset.
DL(not shown) 5V Indicates +5V active

DL7 3V Indicates +3.3V active
DL8 1V8 Indicates +1.8V active

11--44..55.. DDEEDDIICCAATTEEDD PPOOLLEE OORR PPEEDDEESSTTAALL

If no suitable walls or poles are available, the WGT can be placed on a dedicated pole. In that case,
setting the pole in the island must comply with th e UL/EU or any local regulations requirements ­cementing the pole to the island floor, cable laying and keeping the WGT Box outside Class I zone,
as described in the “installation location” section.

11--44..66.. BBAATTTTEERRYY

The WGT includes Lithium battery (BT1) for RTC backup. (Orpak P/N 812502030).
To remove battery for disposal:

− WGT's battery is designed for easy removal and replacement by customers.

− Read and use any precautions published by battery manufacturer in datasheet/website

concerning battery stor a ge, use and disposal.

WGT Manual

1-7

− Make sure the POWER is in OFF position before removing battery.

− Remove WGT cover by loosening the screws.

− Remove the battery from the soc ke t and replace it with a new one. New batterie s must be

approved by Gasboy or Orpak.

− Discharged Lithium and Lithium Ion batterie s are currently designated to be disposed off in

normal trash.

− However, users should contact their municipal waste disposal facility prior to discarding any

used battery in normal trash.

11--55.. WWGGTT OOUUTTDDOOOORR BBOOXX SSPPEECCIIFFIICCAATTIIOONNSS

Physical

• Height – 241 mm

• Width – 194 mm

• Depth – 87 mm

• Weight – 815 gram

Power

• Operating voltage - 12 - 28 V DC.

• Operating current - 0.5 A

Environmental

• Operating temperature : -13 °F to +158 °F (-25° C- +70° C)

• Storage temperature : -13 °F to +158 °F (-25° C- +70° C)

• Humidity – 95% RH

• Degrees of Protection - IP66

Communication

• AES 128 for RF Network Communic ation

• TCP/IP over Ethernet

• EIA 802.15.4

Order informati on

• P/N – 800939351

• Name – WGT outdoor unit

1-8

WGT Manual

Figure 1-4. WGT Outdoor Box Dimensions

WGT Manual

1-9

Figure 1-5. WGT Outdoor Box, Inside View

1-10

WGT Manual

Figure 1-6. WGT Outdoor Box, External View (Glands are optional)

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1-11

11--66.. TTRROOUUBBLLEESSHHOOOOTTIINNGG

Table 1-8 lists the recommended procedures for troubleshooting the WGT.

Table 1-8. WGT, Troubleshooting Procedures

No. Symptom Troubleshooting Procedure Recommended Action

1 LEDs are inactive Check DC Voltage power supply

output

Replace DC Voltage

power supply
Check AC and DC output Replace power supply
Check the proper connection between

Wire the units anew.

the Power Supply and the WGT

2 No communication

between the Master WGT
and the FCC

Check CAT-5E cable connecti on
between the Master WGT and the
FCC

Replace one unit, then

other units if necessary

3 No RF communication Check Nozzle Reader setup Replace Nozzle

Reader
Check WGT setup Set WGT anew
4 Wrong date and time in

log’s after electricity
failure.

Check WGT battery Replace battery as

describe in

paragraph 1-4.6.

1-12

WGT Manual