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Site Controller III Installation Manual

1. OPTIONAL POWER CONDITIONER BATTERY BACKUP UPS CONTROLLED ENVIRONMENT OPTIONAL POS CONSOLE RS 485 UNCONDITIONED 00 CONDITIONED MODULAR OUTLET OO OUTLETS CABLES E SUPPLIED MONITOR PRINTER BY GASBOY UNCONDITIONED c SERE OUTLET S8 g ner STRIP SITE CIRCUIT SUBML BREAKER CONTROLLER STARTE PANEL iR ICR2 RELAYS RS 232 CABLE TE D AC POWER oO TO MODEM TEL EA JO A CONDITIONER JACK r SUPPLIED Ed E o co WITH MODEM Z ii RS 485 COMMUNICATION 5 a le 18 e 18 MINIMUM MINIMUM AC WIRE TROUGH EIS PAO261 JUNCTION EG D BOX BOX 23 DC AC DC 19 oc AC i J BOX J BOX O J BOX J BOX CABLES SUPPLIED Li WITH INTERFACE KIT TDC 2 WIRE CURRENT LOOP COMMUNICATION LU T DC RS 485 COMMUNICATION S TAC POWER CARD READER AND PUMPS DISPENSERS 1 Fo ne TAC POWER SUBMERSIBLE PUMPS NOTE WHEN USED WITH FUEL POINT AN EXTRA DEDICATED CONDUIT IS REQUIRED SEE THE FUEL POINT READER INSTALLATION MANUAL C35628 FOR DETAILS SUBMERSIBLE SUBMERSIBLE PUMP PUMP Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on POS Consoles Page 26 MDE 4298D CFN Series S
2. T i CONTROLLED ENVIRONMENT POWER CONDITIONER n OPTIONAL BATTERY BACKUP UPS POS CONSOLE pe I I l l UNCONDITIONED OO CONDITIONED RS 485 OUTLET OO OUTLETS I MODULAR CABLES i SUPPLIED i BY GASBOY SUBM CIRCUIT o BREAKER T gt STARTER PANEL CRT PRINTER ler l BEDA TS e I RS 232 CABLE sla TO E ISLAND MOUNT 3 CONDITIONER jus CONTROLLER xi DO l gt D RS 232 CABLE l 7 I MODEM T l l SUPPLIED F8 18 KE WIRE TROUGH WITH MODEM MINIMUM MINIMUM es L i N gt RS 485 23 n I JUNCTION J Box n 9 ex w I BOX i DC RS485 COMMUNICATION l m PULSER amp RS 485 COMMUNICATION e e TAC POWER CARD READER AND PUMPS DISPENSERS Lio AC J BOX J BOX TAC POWER SUBMERSIBLE PUMPS NOTE WHEN USED WITH FUEL POINT AN EXTRA DEDICATED CONDUIT IS REQUIRED CONSULT THE FUEL POINT READER INSTALLATION MANUAL C35628 FOR DETAILS SUBMERSIBLE SUBMERSIBLE PUMP PUMP Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on POS Consoles MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 29 System Layout Conduit Layout Installation Specifications This page is intentionally left blank Page 30 MDE 4298D CEN Series Site Controller III Installation
3. REAR FRONT RIGHT SIDE 4 1 e e 1 N i o o q b E BARRIER y PLATE 8 i I MOUNTING HOLES BOTTOM PLATE A B t 3 4 OR 1 1 gs gt ii jon A 1 11 A A gt i BOTI Page 16 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 ICR System Layout Figure 3 7 ICR with Pump Control Post LEFT SIDE FRONT RIGHT SIDE e 14 16 I Ii NE 10 1 8 BARRIER L PLATE E x I vd A 1 2 MOUNTING Las UA B DUAL KNOCKOUT CONDUIT BARR C HOLE FOR 1 2 e al Ae F a BARRIER VE PLATE N 4 POST I BOTTOM Z i CONE BOTTOM VIEWS MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 17 System Layout ICR2 PA0398X0XXX0 ICR2 PA0398X0XXX0 Description Location Page 18 The ICR2 is a rugged and well designed data entry terminal that gives users access to self service gas pumps The unit is controlled by a microprocessor and communicates to the site controller through Two wire Current Loop communications The unit is available with an ABA Track 2 magnetic stripe card reader A graphic liquid crystal display is used to guide the
4. CFN 3 C06253 DB9 DB25 This section connected according to C05981 Gilbarco s wiring instructions by a qualified Com Adapter Gilbarco installer Port 485 Input Gilbarco Pump C08087 IC 4858 DB9 Distribution Box Pump H IC 485S Power set up for CURRENT LOOP Pump Supply RS 422 RJ11 4 Conn operation TB C05999 Cable Note Refer to MDE 4634 CFN Series Gilbarco Pump PC Interface for information on connecting the Atlas 8800 to a CFN SC III Wayne Pump PC Interface See Figure 5 2 to establish an interface between the SC III and Wayne pumps Use a PC DB9 to DB25 Cable Gasboy Part Number C05907 to connect the selected PC comm port of the SC III to the male DB25 Connector of the Wayne Electronics Central Cabinet Figure 5 2 Wayne Pumps Electronic Interface WAYNE ELECTRONICS CFN3 CENTRAL CABINET C05907 DB9 DB25 CABLE CFN 3 PC PB2S DB2S GABLE WIRING TO WAYNE PUMPS WITH WAYNE PUMP CONTROL s LE UNUSED COM PORT INPUT CONNECTOR SAU es Note Use DB9 DB25 Cable if needed Else remove the DB9 DB25 Cable and use the DB25 DB25 Cable Page 46 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Tokheim Pump PC Interface Pump Remote Dispenser Wiring Tokheim Pump PC Interface See Figure 5 3 and Figure 5 4 to establish an in
5. 44 Gasboy 9800 Pumps Remote Dispensers 44 Wire e ra aea e RR SE TEE SE RA Na sg kc e 44 Wiring Electronic or MechanicalPumps 45 FeetMechanicalPCU teens 45 Gilbarco Pump PC Interface 46 Wayne Pump PC Interface 46 Tokheim Pump PC Interface 2 47 Terminal Block D 1335 rem uba cau Se eh a eae too eri ei e 48 ICR2 Pedestal POU uuu iss ll ERR ERR AR Sea E RR ERE ET ME E d 50 Control Eines ed yes ms RAE EAQUE a dede RENT NAL ici e Raquel eo Dots an qs 51 Grounding o sue cari itunes deva aer Y sbs eu v a Pas Ee tes Tn 51 ResetMotorFeed 0 11 51 PumpMotorFeed 51 Neutial Feed 2r ge eoe ue lk doe m e ig m Ro 52 SubmersibleFeed SubmersibleDrive 52 Reset Complete SwitchDeteci SlowFlow 52 Fasthlows Ls ai berg e ku sn S N elen ia ei k ya s 52 EBM Feed sy ki ate hea ex ec RO sg b sepe 52 Light Neutral 5 5 55143 secre oe E N i ea b RAF eu FAR 52 Phase 2 Feed iotas teaa dere a 52 Pulser i LAE S da pagu ID dtr LOCUS Lu 53 Wiring DIAG rams 2 45 rato a eere ee ee ee eed ee Wd ERR Seo Ve 55 Activating a Gate Controller 76 6 Testing 77 Installation Completion Checklist 77 ManualOverridelest hh 78 Index Index 1 Page ii MDE
6. Internal Diameter Area sq units Fill Area sq units 25 Fill Trade Size in in mm in mm in mm 1 2 0 629 16 0 303 196 0 076 49 3 4 0 826 21 0 532 343 0 133 86 1 1 063 27 0 862 556 0 215 139 1 1 4 1 378 35 1 50 968 0 375 242 1 1 2 1 614 41 2 04 1314 0 509 329 2 2 087 53 3 36 2165 0 839 541 To determine the conduit size required refer to the table THHN THWN Wire Areas on page 23 to find the area for each wire gauge Add up all wire areas Refer to the table Areas of Trade Size Conduit and select the smallest number in the Fill Area sq units 25 Fill column based on NEC 501 1 that comes closest to the total wire area but does not exceed it Conduit Layout Installation Specifications All wiring must be installed and used in accordance with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Canadian users must also comply with the Canadian Electrical Code All peripheral equipment connected to the RS 232 ports must be listed have an Electronics Industries Association EIA standard RS 232 communications protocol and should not be installed in a hazardous location Power for the system components data terminal and modem must come from a separate dedicated circuit breaker rated at no less than 10 Amp All conduits must be made of metal to provide the necessary shielding
7. Motor H P 25 50 100 150 200 250 300 1 4 14 14 12 10 10 8 8 1 3 14 14 12 10 8 8 8 1 2 14 12 10 8 8 8 8 3 4 14 12 10 8 8 6 4 Note For run over 300 feet use relay at motor location 240 Volt Wire Gauge Sizes per Feet of Run see Note Motor H P 25 50 100 150 200 250 300 1 4 14 14 14 12 12 12 12 1 3 14 14 12 12 12 12 12 1 2 14 12 12 12 10 10 10 3 4 14 12 12 10 10 10 8 1 1 2 12 12 10 10 8 8 8 Note For run over 300 feet use relay at motor location Wiring Electronic or Mechanical Pumps The remainder of this section shows wiring schematics for electronic and mechanical pumps All electronic and mechanical pumps must be installed according to the manufacturer s instructions Depending on the type of electronic pump to which you are connecting you may require additional information Contact Gasboy Technical Service for information on various pump interfaces Fleet Mechanical PCU The fleet mechanical PCU does not contain the hardware for controlling fast flow valves It cannot handle auxiliary switch detects for console systems MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 45 Pump Remote Dispenser Wiring Gilbarco Pump PC Interface Gilbarco Pump PC Interface See Figure 5 1 to establish an interface between the SC III and Gilbarco pumps dispensers Figure 5 1 Gilbarco Pumps Dispensers Electronic Interface
8. 23 AreasoflradeSizeConduilt 24 Conduit Layout Installation Specifications 24 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Pagei Table of Contents 4 System Components Wiring 31 General Wiring Precautions LL 31 Power Requirements dei Wale bu eee ei Ate a ec ee ale Vie ee RR ra 32 Wire SIZG is sxe trae at Mere ara ah A i Roa qiia ea es ER D ard etal 32 Communication Requirements 33 RS 485 a A a ei 33 RS 292222 aaa eta 34 n PPP 34 Two wireCurrentlLoop 34 System Components Wiring Diagram 35 ICR2 Communication Wiring 0 00 37 Multiple Console Wining sir Rer eet Me MAA See F baad hi Mee alata d adatte 38 RemoteConsoleWiringg 0 0000 38 Short Haul Modem SHM RS 422 eee eee 39 Phone Modems ss re yustuy ke kei ku eee ele tae eee Nee w ales sy a eS 40 WiringforalankMonitoringSystem 40 Gate Controller WiringusingGateReader 42 5 Pump Remote Dispenser Wiring 43 Wiring PreCAUTIONS 22 ere be ee TRE rai e POR eee 43 Power Requirements a ll m rn 44 Electronic Pumps nune e a 44 Suction Pumps LL 44 RemoteDispensers
9. The line to the motor should be on a separate circuit and fused to carry 20 to 30 Amp depending on the motor size and or the voltage setting nstall an emergency power cutoff switch In addition to circuit breaker requirements of NFPA 70 and NFPA 30A a single control which simultaneously removes AC power from all site dispensing equipment is recommended This control must be readily accessible clearly labeled and in accordance with all local codes In a fuel management system application the Disable Pumps and Stop keys on the console and or the optional Disable Pumps button on the ICR do not remove AC power from the equipment and will not stop product flow under certain conditions In order to provide the highest level of safety to you your employees and customers Gasboy recommends that all employees be aware of the location and be trained on the procedure for turning off power to the entire system A WARNING To reduce the risk of electrical shock when servicing turn off all power to the pump remote dispenser In submersible pump applications turn off all power to the submersible pump and any other remote dispensers that use that submersible pump AC power can feed back into a shut off remote dispenser when dispensers share a common submersible pump or starter relay A AVERTISSEMENT Pour r duire le risque de choc lectrique lors de l entretien r vision coupez totalement le courant la pompe distributeur Dans l
10. Note This diagram illustrates the wiring for the PCU only See Figure 4 4 on page 37 for wiring of the ICR2 Notes 1 All wiring must be installed and used in accordance with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Canadian users must comply with the Canadian Electrical Code also Wiring must also conform to the wiring diagram supplied with the pump remote dispenser 2 All peripheral equipment connected to the RS 232 ports must be UL listed have an EIA standard RS 232 communications protocol and not be installed in a hazardous location 3 This wiring diagram illustrates a CFN System and its components except monitor keyboard and mouse to indicate how they are interconnected Components that are not a part of your system should be ignored 4 When using a shielded cable for the RS 422 RS 485 communication wiring ground the shield to the AC ground used for the system components on one end only 5 Communications to an ICR2 are made through the Two wire Current Loop Refer to ICR2 Communication Wiring on page 37 6 Refer to the applicable section of this manual for specific system installation requirements 7 If you are connecting to Tokheim Insight DPTs refer to MDE 4559 Insight Interface Installation Guide Card Reader IN Dispenser CRIND devices refer to MDE
11. MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Control Lines Pump Remote Dispenser Wiring Control Lines Grounding Descriptions of control lines are provided to familiarize the installer with control inputs and outputs that are used to control a mechanical pump remote dispenser It is recommended that the installer read these descriptions to obtain a better working knowledge of the system to plan the site wiring To ensure proper operation of the equipment and provide the necessary safety factors the unit must be grounded A ground wire preferably green must be connected between the unit s AC junction box ground lug and the main electrical service panel One earth ground connection is required per unit A ground rod must be installed at the main electrical panel in accordance with the National Electrical Code This ground rod must be a solid corrosion resistant conductor It should be properly tied into the ground bus strip of the panel It is recommended that the neutral and ground bus strips be bonded together unless prohibited by local codes Reset Motor Feed Reset Motor Feed is a 120 VAC input that is supplied through the pump handle switch to activate the reset motor This line should be switched through the CFN System and only be on when the pump remote dispenser is authorized or in the manual mode Without power supplied to this line the pump remote dispenser will not reset when the pump
12. The modem should be located in an office like environment However if this is not possible it should be housed in a protective enclosure Do not install the modem in a hazardous location Modems supplied by Gasboy have an operating temperature range of 32 F to 104 F IMPORTANT INFORMATION The AC Surge Protector Power Conditioner and the Voltage Regulator UPS should be installed independently and not combined between the AC outlet and the SC III AC Surge Protector Outlet Strip Description The AC Surge Protector Outlet Strip protects the SC and any equipment directly connected to it printer monitor and so on from line surges and filters out the Electromagnetic Interference EMI Radio Frequency Interference RFI noise Location The AC Surge Protector Outlet Strip should be located within 6 feet of the SC It must be located in an area protected from direct contact with the weather Do not install the Surge Protector in a hazardous location MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 21 System Layout Power Conditioner optional Power Conditioner optional Description Location A UL listed power conditioner should be used when there is an unstable source of power When used the power conditioner helps provide clean power to the SC and other CFN devices located near the SC Poor power condition is a key cause for system malfunction or failure The
13. Mf ry The PCU controls most mechanical pumps and some electronic pumps The unit is controlled by a microprocessor and communicates with the SC through the RS 485 loop Each PCU can control up to four pumps or remote dispensers There are two different versions of the PCU Retail version Weights and Measures Hardware features on the retail version include a battery backup three solid state relays for each pump or remote dispenser slow flow fast flow and submersible pump manual override switches and diagnostic capabilities Fleet version It does not have a battery backup and has only two solid state relays for each pump and remote dispenser Field wiring connections are made to the unit using easy to wire terminal blocks The PCU can be ordered as follows e Mounted in a wall mount box standard or in the ICR s post e Standalone unit to be located on the island The wall mount version of the PCU must be located in an area protected from direct contact with the weather The post and standalone versions of the PCU should be located on the fueling island no closer than 18 from the nearest dispenser The unit is designed for an operating temperature of 40 to 104 F with a relative humidity of 2 to 99 non condensing MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 11 System Layout PCU Figure 3 3 Wall mount PCU A i t
14. o gt TE AC POWER las TO MODEM TEL a JO CONDITIONER JACK essa SUPPLIED E E WITH MODEM DC RS 485 COMMUNICATIO 18 18 gt AC WIRE TROUGH MINIMUM MINIMUM PAO261 JUNCTION j D BOX BOX 7 oc AC 19 19 DC AC J BOX J BOX J BOX J BOX CABLES SUPPLIED WITH INTERFACE KIT O T DC 2 WIRE CURRENT LOOP COMMUNICATION DC PULSER t I TDC RS 485 COMMUNICATION y TAC POWER CARD READER AND PUMPS DISPENSERS T J BOX Box AC POWER SUBMERSIBLE PUMPS NOTE WHEN USED WITH FUEL POINT AN EXTRA DEDICATED CONDUIT IS REQUIRED SEE THE FUEL POINT READER INSTALLATION MANUAL C35628 FOR DETAILS SUBMERSIBLE SUBMERSIBLE PUMP PUMP Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on POS Consoles Page 28 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Conduit Layout Installation Specifications System Layout Figure 3 13 Conduit Layout Standalone Pump Control Post Mechanical Hose Outlets
15. 4298D CFN Series Site Controller III Installation Manual September 2009 Purpose Introduction 1 Introduction Purpose The Gasboy Site Controller SC III Installation Manual is provided to assist you in installing your Cash Flow Network CFN System This manual should be supplied to the electrician prior to conduit and wiring installation to ensure that your CEN System is installed properly Faulty installations are the major cause of system malfunctions The system must be installed as described in this manual to ensure the reliability and proper operation of your Gasboy CEN System Read this entire manual before you begin the installation Gasboy provides a toll free number 1 800 444 5529 for customers and installers who have queries pertaining to the installation Related Documents Document Number C01759 Title CFN Diagnostic Manual GOLD Library CFN Series Controllers and POS C09146 Site Controller Pump Interface Manual CFN Series Networks Card Handlers and Pump Interface C35628 Fuel Point Reader Installation and Retrofit Instructions Manual RFID Wireless and TCP IP MDE 2713 MDE 4255 Universal Distribution Box Installation Manual Gasboy s Warranty Policy Statement G SITE Policy Documents Safety and Warranty MDE 4299 CFN Series Profit Point PLUS Installation Manual CFN Series Controllers and POS MDE 4331 Atlas Installation Manual Gasboy
16. 5 Explosions Preventing 5 F Feed Neutral 52 Phase 2 52 Pump Motor 51 Reset Motor 51 Fires Preventing 5 G gate controller 42 76 l ICR Description 14 Location 14 Installation Completion Checklist 77 M Manual Override Test 78 P PCU Description 11 Location 11 Personnel Emergency informing 6 Power Requirements 32 44 s Safety Information 5 Alert symbol 5 Barricading 5 Emergency electrical shut off 5 Emergency personnel 6 Evacuation 5 NFPA regulations 5 Open flames 6 Preventing explosions and fires 5 Regulations 5 Replacement parts 5 Safety symbols 5 Shut off 5 Signal words 5 Smoking 6 Sparks 6 Warning words 5 Working alone 6 Safety symbols 5 SC HI Description 9 Location 10 Shut off 5 Emergency electrical 5 Signal words Safety 5 T Tokheim Electronic Interface 76 w Warning words 5 Warnings 5 Wire Size 44 Wiring Diagrams 55 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Index 1 Belden is a registered trademark of Belden Inc CRIND and Gilbarco are registered trademarks of Gilbarco Inc Tokheim is a registered trademark of Tokheim Holding B V Corporation UL is a registered trademark of Underwriters Laboratories Inc Wayne is a registered trademark of Dresser Equipment Group Inc Windows NT Windows XPE and Windows are registered trademarks of Microsoft Corporation 2009 GASBOY 7300 West Friendly Avenue Post Office Box 2
17. A GASBOY A CEN Series Site Controller III Installation Manual MDE 4298D Computer Programs and Documentation 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 Federal Communications Commission FCC Warning 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 Gasboy Greensboro is an ISO 9001 2000 registered facility Underwriters Laboratories
18. Atlas Pumps Dispensers MDE 4337 CFN Series Gilbarco CRIND Interface for Site Controller III with Windows CFN Series Networks Card Handlers and Pump Interface MDE 4501 Wayne CAT PC Interface for Site Controller III with Windows NT CFN Series Networks Card Handlers and Pump Interface MDE 4559 Insight Interface Installation Guide CFN Series Networks Card Handlers and Pump Interface MDE 4624 Gasboy CFN Series Tokheim Pump PC Interface CFN Series Networks Card Handlers and Pump Interface MDE 4634 CFN Series Gilbarco Pump PC Interface CFN Series Networks Card Handlers and Pump Interface MDE 4651 Wayne Pump PC Interface for SC III Windows NT CFN Series Networks Card Handlers and Pump Interface MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 1 Introduction Abbreviations and Acronyms Abbreviations and Acronyms Term Description CFN Cash Flow Network CRIND Card Reader IN Dispenser DPT Dispenser Payment Terminal EIA Electronics Industries Association EMI Electromagnetic Interference FPR Fuel Point Reader 1 0 Input Output ICR Island Card Reader PC Personal Computer PCB Printed Circuit Board PCU Pump Control Unit PIN Personal Identification Number POS Point Of Sale RFI Radio Frequency Interference SC Site Controller SHM Short Haul Modem UPS Uninte
19. Manual September 2009 General Wiring Precautions System Components Wiring 4 System Components Wiring General Wiring Precautions The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble free operation of your Gasboy CFN System To ensure a quality installation follow these rules All wiring must be installed and used in accordance with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Canadian users must comply with the Canadian Electrical Code also Wiring must conform to the wiring diagram supplied with the pump remote dispenser Use approved conduits and insulated gasoline and oil resistant wiring of the proper size Wire connections must be tightly spliced and secured with a wire nut Close the open end of the wire nut with an electrical tape Install an emergency power cutoff switch In addition to circuit breaker requirements of NFPA 70 NFPA 30 and NFPA 30A a single control that simultaneously removes AC power from all site dispensing equipment is recommended This control must be readily accessible clearly labeled and must be in accordance with all local codes In a fuel management system application the Disable Pumps and Stop keys on the console and or the optional Disable Pumps button on the ICR do not remove AC
20. SC unit in a dirty environment may cause premature failures The RS 485 junction box must be located within 8 feet of the SC unit The RS 485 junction box must be grounded as specified in Power Requirements on page 32 The SC unit should not be placed on top of any other components and no other equipment should be placed on top of the SC unit Figure 3 1 SC Ill Power In Power Switch PS 2 Mouse PS 2 Keyboard MERE g O Moooooe n COM1 Serial1 25267 ooo oo 2000 DODO coco 00000000000 Monitor dt oss E s sewa 0000000 i U U Ethernet Refer Note 2 Printer USB 3 4 Refer Note 2 USB 1 2 COM2 Serial 2 Speaker Loop1 Island RS 485 Port Loop2 Island RS 485 Port Factory Set to Two wire for Tokheim Loop3 POS High Speed RS 485 Port Port 1 Local RS 232 Port 6 RS 232 Port 5 RS 232 Port 4 RS 232 COM Ports 3 6 Notes 1 Location of PC connectors may differ 2 Ethernet Port and the USB may be disabled depending on Operating System OS and PC settings Port 3 Unused Page 10 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 PCU System Layout PCU Description Location Figure 3 2 RS 485 Junction Box El La B amp h J BACK cacci AIF gih abl
21. WITH INTERFACE KIT DC 2 WRE CURRENT LOOP COMMUNICATION TDC PULSER TDC RS 485 COMMUNICATION TAC POWER CARD READER AND PUMPS DISPENSERS Q Box fox TAC POWER SUBMERSIBLE PUMPS NOTE WHEN USED WITH FUEL POINT AN EXTRA DEDICATED CONDUIT IS REQUIRED SEE THE FUEL POINT READER INSTALLATION MANUAL C35628 FOR DETAILS SUBMERSIBLE SUBMERSIBLE PUMP PUMP Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on POS Consoles MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 27 System Layout Conduit Layout Installation Specifications Figure 3 12 Conduit Layout Pump Control Post Mechanical Hose Outlets OPTIONAL POWER CONDITIONER OR BATTERY BACKUP UPS CONTROLLED ENVIRONMENT OPTIONAL POS CONSOLE UNCONDITIONED OO CONDITIONED MODULAR OUTLET OO OUTLETS SABLES SUPPLIED MONITOR PRINTER BY CASBOY oo AC SURGE NEONE NIER O 99 PROTECTOR A OO OUTLET STRIP SITE CIRCUIT j SUBM BREAKER CONTROLLER STARTER PANEL i ICR2 RELA RS 232 CABLE
22. i I P Z I I lt I Page 12 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 PCU System Layout Figure 3 4 Standalone Island mount PCU 4 pra e 2 Q ACCESS a X 2 7 4 2 ja 4 BARRIER TT A PLATE A _ a en lY 7 b 5 T OPENING OPENING 3 3 4 X 12 3 ASA 3 o b le D t 1 4 4121 2 e FRONT d 1 SN 3 T O e 2 Ol 5 v bo I 2 T i DES OY E Lo 4 i POST BOTTOM VIEW BARRIER BOTTOM VIEW BOTTOM OF POST PLATE OF POST 1 INDUIT MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 13 System Layout ICR ICR Description The ICR is a rugged and well designed data entry terminal that gives users access to self service gas pumps The unit is controlled by a microprocessor and communicates with the SC using the RS 485 loop The unit is available with an ABA Track 2 magnetic stripe card reader A 20 character Liquid Crystal Display LCD is used to guide the user through the transaction The display is backlit so that it can be read at night A membrane keypad incorporates easy to read legends and provides the user with means to input data to the system Three different types of posts are available with the ICR The s
23. motor feed are used for 240 VAC motor applications Page 52 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Control Lines Pump Remote Dispenser Wiring Pulser Pulser supplies a DC output that is provided to indicate the quantity dispensed This line must be capped when not in use DC pulser and DC RS 422 and RS 485 communication wires can be combined in the same conduit DC wires must be in a separate metal conduit away from AC wires except as noted in Short Haul Modem SHM RS 422 on page 39 and Pulser Wiring and Configuration Pulser Wiring and Configuration For pulser wiring diagrams see Figure 5 8 on page 54 Pulser wiring requirements are described in Pulser Wiring Requirements on page 55 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 53 Pump Remote Dispenser Wiring Control Lines Figure 5 8 Pulser Wiring and Configuation Diagrams K1 1 O P E a A gt A SREE ouan Sale NOTE 0 S D TO EITHER Sm LSER GROUND POLARITY VR REED SWITCH PULSER 1871 SERIES PULSER x Ki 1 TBP mm x 7 mm LSER y 63 3 P 4 K5 e 9 P 7 m H JUNCTION BO Piojo TAN VR ELECTRONIC PULSER 7671 SERIES 11 F E K1 1 ma RANGE DW BLUE 3 I Calo Lj Le M putser Ae WHITE Ml J BLACK 2 2310 U JUNCTION BO
24. other hoses besides hose 1 should activate Turn off all hoses Place the system override switch for hose 1 in the ON position Repeat steps 4 to 8 for all remaining hoses Substitute the hose under test for hose 1 Turn off the AC power and battery power switches in the PCU Page 78 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Manual Override Test Testing 11 Turn off the breakers for all pumps and or remote dispensers and the SC and other components 12 Replace all wiring connectors green previously removed from the Pump Control I O PCB assembly Note The manual override test will uncover most point to point AC wiring mistakes that can occur The automatic test performed during the system startup will complete the verification of correct AC wiring to the pump remote dispensers The automatic test should only be performed at the startup MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 79 Testing Manual Override Test This page is intentionally left blank Page 80 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Index Index A Alert symbol 5 B Barricading 5 C Caution warnings 5 Communication Requirements RS 232 34 RS 422 34 RS 485 33 Conduit Requirements 23 D Danger warnings 5 E Electrical Shut off 5 Emergency Electrical shut off 5 In Case Of 8 Personnel contacting 6 Evacuation
25. to RS 232 Converter An RS 485 to RS 232 converter is required for communication between the SC III and a modular Profit Point or a tank monitor It converts the format of the data from RS 232 to RS 485 and vice versa Figure 3 9 RS 485 to RS 232 Converter vil ti H Logger Printer Description A printer can be used as a logger for providing hard copy printouts of activities at the site It can be directly connected to the printer port of the PC or to one of the SC s serial ports If connected to the PC printer port LPT 1 the cable length cannot exceed 25 feet Location The printer should be located in a clean office like environment Do not install the printer in a hazardous location Printers supplied by Gasboy have an operating temperature range of 32 F to 104 F and 10 to 95 relative humidity non condensing Locating the printer in a dirty environment may cause premature failure of the printer Page 20 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Modem System Layout Modem Description Modems are used for communicating with the SC when the distance or conditions do not permit direct connection to the unit Various types of modems can be used depending on the maximum baud rate and connection method required Modems used for dial out to a bank network require a dedicated phone line Only Gasboy supplied modems are supported for use with the CFN system Location
26. user through the transaction The display is backlit so that it can be read at night A membrane keypad and soft keys incorporate easy to read legends and provide the user with the means to input data to the system The unit comes standard with a blank post This post is used for mounting the ICR2 to the island The ICR2 is also available with a receipt printer post and or a PCU mounted in the post Communications to the ICR2 is through Two wire Current Loop If the ICR2 has a PCU in the post option both the Two wire Current Loop and four wire RS 485 wiring will need to be installed between the Site Controller III and ICR2 The ICR2 should be located on the fuel island The unit has been designed for an operating temperature range of 40 F to 104 F with a relative humidity of 2 to 99 non condensing Adequate clearance must be provided to allow easy access to the post s access covers An ICR2 with a receipt printer or a pump control mounted in the post requires a minimum of 18 clearance between the post and any of the pumps or remote dispensers on the island MDE 4298D CEN Series Site Controller III Installation Manual September 2009 ICR2 with Standard Post System Layout ICR2 with Standard Post Figure 3 8 ICR2 with Standard Post 2 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 19 System Layout RS 485 to RS 232 Converter RS 485
27. 2087 G AS B OY Greensboro North Carolina 27420 QZ Phone 1 800 444 5529 http www gasboy com Printed in the U S A m MDE 4298D CFN Series Site Controller III Installation Manual September 2009
28. 25DB C05994 All electronic pumps and controls must be installed according to the manufacturer s specifications Figure 4 1 RS 232 1 1 Cable Part Number Q13240 09 6 feet M F DB 25 Male 13 25 For guidelines and restrictions on RS 422 wiring refer to Short Haul Modem SHM RS 422 on page 39 DB 9 Female w 9 0 5 B CT Fm d RS 422 Two wire Current Loop For guidelines and restrictions on the Two wire Current Loop used for ICR2 refer to MDE 2713 Universal Distribution Box Installation manual Page 34 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 System Components Wiring Diagram System Components Wiring System Components Wiring Diagram Figure 4 2 System Components Wiring Diagram Part 1 of 2 Legend D Whenever you see this symbol on the end of a power cord ensure that you plug that power cord into an AC Surge Protector Outlet Strip Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on Profit Point Consoles MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 35 System Components Wiring System Components Wiring Diagram Figure 4 3 System Components Wiring Diagram Part 2 of 2
29. 3 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 27 Single Remote Dispenser Console Gasboy Reset Page 74 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 28 Twin Remote Dispenser Console Gasboy Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 75 Pump Remote Dispenser Wiring Activating a Gate Controller Activating a Gate Controller You can use a relay position in the CFN Mechanical PCU to activate a gate controller This is only available as a Fuel Point transaction and is not using a card console POS terminal or terminal command Figure 5 29 Gate Controller with Relay Position Fuel Point Transaction Notes 1 The CFN PCU can directly switch power to a gate controller The maximum rating of the PCU relay is 3 4 HP 120 VAC If your gate controller uses a different control voltage or exceeds the 3 4 HP rating use an auxiliary mechanical relay with a 120 VAC coil to handle the load 2 Up to four gate controllers can be accessed per PCU You can also combine pumps and gates within the same PCU 3 Once the relay is closed it will remain closed until one pulse is received on the pulser input or until the switch timeout is reached or the Fuel Point rings are separated whichever comes first If the transaction ends by th
30. 33 Short Haul Modem SHM RS 422 on page 39 or Pulser Wiring and Configuration on page 53 Are the CFN system components on a separate dedicated breaker refer to System Components Wiring on page 31 Are pumps over 3 4 HP at 120 240 VAC or 1 1 2 HP at 240 VAC equipped with a starter relay refer to Pump Remote Dispenser Wiring on page 43 Is the correct gauge wire installed for the following System refer to System Components Wiring on page 31 Pumps refer to Pump Remote Dispenser Wiring on page 43 Remote dispensers refer to Pump Remote Dispenser Wiring on page 43 Pulsers refer to Pump Remote Dispenser Wiring on page 43 SHMs refer to System Components Wiring on page 31 Are the communication lines under the maximum allowable distance for the following RS 232 100 feet refer to System Components Wiring on page 31 RS 485 1000 1500 feet refer to System Components Wiring on page 31 RS 422 SHMs 1500 feet refer to System Components Wiring on page 31 If the system has an external modem is the phone line installed refer to System Components Wiring on page 31 Is there fuel in the tanks MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 77 Testing Manual Override Test Manual Override Test 10 Note The manual override test can be performed only on pumps remote dispen
31. 4298D CEN Series Site Controller III Installation Manual September 2009 Conduit Requirements System Layout Conduit Requirements The conduit requirements outlined in this section are relevant to all components that make up the Gasboy system including but not limited to CFN system units pumps remote dispensers submersible pumps submersible starter relays and the circuit breaker panels The Gasboy Warranty will not apply to any system deviating from the requirements outlined in this section All wiring and conduit runs must conform with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Canadian users must also comply with the Canadian Electrical Code All wiring AC and DC connecting the different components of the CFN System and all communication equipment signal wires must be installed underground in threaded rigid metal conduits Poly Vinyl Chloride PVC conduits are not acceptable High voltage AC power wires and low voltage DC signal wires are recommended to be installed in separate conduits However if AC and DC wires share the conduit DC wiring must use the cable specified in the sections Communication Requirements on page 33 Short Haul Modem SHM RS 422 on page 39 and Pulser Wiring and Configuration on page 53 When AC wires and RS 485 or RS 422 wires share the same condui
32. 4337 CFN Series Gilbarco CRIND Interface for SC III with Windows Wayne CATs refer to MDE 4501 Wayne CAT PC Interface for Site Controller III with Windows NT Page 36 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 ICR2 Communication Wiring System Components Wiring ICR2 Communication Wiring Figure 4 4 ICR2 Wiring kn C06253 DB9 DB25 C05981 Com Adapter Ports n Gilbarco 2 Wire C08087 IC 485S di Distribution Box Connection IC 485S Power PA0261X0000X2 blue and RJ11 Supply set up for CURRENT LOOP yellow wires RS 422 Conn operation TB C05999 Cable The Gilbarco Distribution Box PA0261X0000X2 must be installed according to MDE 2713 Universal Distribution Box Installation Manual For more information refer to MDE 4337 CEN Series Gilbarco CRIND Interface for SC III with Windows If the distance between the CFN 3 and the Gilbarco Distribution Box is greater than 8 feet the cable may be extended using an RJ 11 1 1 telephone cable or the pinout see Figure 4 5 This pinout allows you to hard wire the DB9 connector of the D Box to the terminal block of the converter This installation must be done according to RS 485 guidelines refer to RS 485 on page 33 Figure 4 5 Converter to D Box Pinouts CONVERTER D BOX TB POSITION CONNECTION 1 3 2 7 3 6 4 2 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 37 System Compon
33. All conduit should be run underground not overhead DC pulser DC RS 485 and or RS 422 communication wires can be combined in the same conduit It is recommended that the DC pulser RS 485 and or RS 422 wiring be in a separate metal conduit from any AC wires However the DC pulser RS 485 and or RS 422 wires can share the conduit with AC wires if shielded cable is used as specified in Communication Requirements on page 33 Short Haul Modem SHM RS 422 on page 39 and Pulser Wiring and Configuration on page 53 Use the chart in Wire Size on page 44 to determine the wire gauge Refer to Conduit Requirements on page 23 to determine the conduit size according to the number of wires and wire gauge RS 232 communication must not exceed 100 feet RS 232 communication wires must be in a metal conduit separate from any AC wires For communication distances exceeding 100 feet you must use Gasboy Short Haul Modems SHMs In submersible applications starter relays are always recommended however the system can directly drive motors up to 3 4 HP at 120 VAC or 1 1 2 HP at 240 VAC Suction pumps over 3 4 HP at 120 240 VAC or 1 1 2 HP at 240 VAC must use a starter relay Wire the starter relay in place of the motor in the applicable pump wiring drawing A minimum distance of 18 must be maintained between the ICR post and any of the pumps remote dispensers In the conduit layouts disregard the submersible pumps in the draw
34. Repair Garages NFPA 70 National Electrical Code NEC Occupational Safety and Hazard Association OSHA regulations and federal state and local codes All these regulations must be followed Failure to install inspect maintain or service this equipment in accordance with these codes regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment Replacement Parts Use only genuine Gasboy replacement parts and retrofit 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 warning symbols and boxes Alert Symbol A This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent 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 followed to prevent death injury or damage to the equipment DANGER Alerts you 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 Designate
35. UL New York City Fire Department NYFD California Air Resources Board CARB UL File Products listed with UL NYFD C of A Product Executive Order Product MH4314 All dispensers and self contained pumping 4823 9100A 9140A 9152A 9153A G 70 52 AM Balance Vapor Recovery units 9800A 9840A 9850A 9852A G 70 150 AE VaporVac Power operated Transfer Pump Models 25 9853A 9140 MH6418 25C 26 27 28 72 72S 72SP 72X 73 and 4997 9822A 9823A 1820 5046 9100Q 9140Q 9152Q 9153Q MH7404 Hand operated Transfer Pump Models 1230 9800Q 9840Q 9852Q 9853Q Series 1243 Series 1520 and 1720 Series 5087 8753K 8853K 9153K 9853K MH10581 Key control unit Model GKE B Series restricted to diesel and non Card reader terminals Models 1000 1000P retail gasoline sales Site controller Model 2000S CEN Series 5091 8752K 9152K Data entry terminals Model TPK 900 Series 5129 9122K 9123K 9822K 9823K 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 N 9100 Retail Series 8700 ent 9100 Commercial 8700K 8800K IALIA Dispenser Series 9700 Series 2019 Dispenser Series 05 092 Atlas 9100K 9200K 9800K n 4 1000 Series FMS 95 136 Dispenser 9800 Series 91 057 Controller 2000S CFN Series Patents Gas
36. X s c o P E 4 9 VR TOTALIZER PULSER 7874 SERIES 11 gt z A Pq PA EA PR PN EA A A A s E JL J 21212121115 WARNING K TO K4 JUMPERS MUS SET IN THE CONFIGURATION 123 4 5 67 8 SHOWN BEFORE TURI TO THE PUMP CONTROL VR TOTALIZER POWER BRACKET fo I Y a HOSE El B ost 2 km dd es Em HOSE 4 Sd o A 7 z Pa La d BU _ C 4 B M E BOARD EBOUNCE RATE Note All pulsers shown above are connected to the hose 1 position The K1 jumper pins are used to configure the circuitry for hose 1 The jumper pins associated with the other hoses are indicated above Page 54 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Pulser Wiring Requirements 18 AWG wires are required for the installation of a pulser in a separate DC conduit Although it is recommended that DC pulser wires be run in a conduit away from AC wires they can be combined in the same conduit with AC wires if a UL listed cable with the following specifications is used Conductor 18 AWG stranded wire Number of conductors to be determined by the pulser Shield Foil wrapped 100 coverage and or tinned copper braid 90 coverage Drain Wire Stranded tinned copper 20 AWG or larger or braided shield Voltage Rating Maximum operating voltage of 600 V Environmental Gas and oil resistant suitable for wet or dry locations Gasboy c
37. ams Figure 5 21 Twin Suction Pump Single Motor Gasboy Reset Note Solenoid valves must be used on this suction pump to prevent unrecorded dispensing of product Page 68 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 22 Single Remote Dispenser Gasboy Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 69 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 23 Twin Remote Dispenser Gasboy Reset Page 70 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 24 Single Suction Pump Console Gasboy Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 71 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 25 Twin Suction Pump Console Gasboy Reset DI 9 CO d of H O oe I La 1 I L L led LA y J Se e LI Page 72 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 26 Twin Suction Pump Single Motor Console Gasboy Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 7
38. an supply Belden 1063A Part Number C09655 which is a UL listed 4 conductor cable that meets the requirements listed above Note Belden 1063A is UL listed but not CSA listed Wiring Diagrams This section contains the following wiring diagrams Figure 5 9 Single Suction Pump VR Reset on page 56 Figure 5 10 Figure 5 11 Figure 5 12 Figure 5 13 Figure 5 14 Figure 5 15 Figure 5 16 Figure 5 17 Figure 5 18 Figure 5 19 Figure 5 20 Figure 5 21 Figure 5 22 Figure 5 23 Figure 5 24 Figure 5 25 Figure 5 26 Figure 5 27 Figure 5 28 Twin Suction Pump VR Reset on page 57 Twin Suction Pump Single Motor VR Reset on page 58 Single Remote Dispenser VR Reset on page 59 Twin Remote Dispenser VR Reset on page 60 Single Suction Pump Console VR Reset on page 61 Twin Suction Pump Console VR Reset on page 62 Twin Suction Pump Single Motor Console VR Reset on page 63 Single Remote Dispenser Console VR Reset on page 64 Twin Remote Dispenser Console VR Reset on page 65 Single Suction Pump Gasboy Reset on page 66 Twin Suction Pump Gasboy Reset on page 67 Twin Suction Pump Single Motor Gasboy Reset on page 68 Single Remote Dispenser Gasboy Reset on page 69 Twin Remote Dispenser Gasboy Reset on page 70 Single Suction Pump Console Gasboy Reset on page 71 Twin Suction Pump Console Gasboy Reset on page 72 Twin Suction Pump Single Motor Console Gasboy Reset on page 73 Single Remote Dispenser Con
39. boy products are manufactured or sold under one or more of the following US patents Dispensers 5 257 720 Point of Sale Back Office Equipment D335 673 Additional US and foreign patents pending Trademarks Non registered trademarks Registered trademarks Atlas ASTRA Consola Fuel Point Infinity Gasboy Additional US and foreign trademarks pending Keytrol Other brand or product names shown may be Slimline trademarks or registered trademarks of their respective holders This document is subject to change without notice E mail literature gasboy com Internet http www gasboy com 2009 GASBOY All Rights Reserved AQuldd 7 TUTE EUM EQUIPMENT INS Table of Contents Table of Contents 1 Introduction 1 PUTOS ta AZ D e Ut SES Mn tore vix kuy Wad ere ace e RC MN ea dan e ai en daa Eee oe 1 Related Docume Meresaar wine etd eee nem ried un la a tat k a t seeker daly 1 AbbreviatonsandAcronyms hr rs 2 System OVervig Wia a ss ep arde gale gas abd weal gal eal Pala wate pad 2 Wartanty tc SEES peu ie ie AS ve e OR Le UR 3 2 Important Safety Information 5 3 System Layout 9 PUrpoSQ zs soe pu ac eben a Pate de panka Gee pla Stet wees Gale ees Rete x 9 exp XI DEM C 9 Description x 22 eee EU ERR pep eR E e eb et e EO Ed aes 9 Locations tini E iu asas bd ig SU epe d ES 10 PG Li Ata sea wot abu Tn s Ped en e Ve enel x a YARDS TERRE MOX URGE Pon n 11 Descripti
40. cturer s documentation for installation instructions before connecting a tank gauge to your CFN system For EECO monitors use a C07476 Cable in place of the C04549 Cable Figure 4 8 Wiring for a Tank Monitoring System 8 feet or less Page 40 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring for a Tank Monitoring System System Components Wiring Figure 4 9 Wiring for a Tank Monitoring System over 8 feet 5 Ton Fo LAND J le S Figure 4 10 Serial Wiring for a TLS 350 with RS 232 Module MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 41 System Components Wiring Gate Controller Wiring using Gate Reader Gate Controller Wiring using Gate Reader The CEN system can activate a gate controller by using the CEN Gate Island Reader or Gate Satellite Reader Both the Gate Readers allow activation by card Fuel Point or terminal command but not using the console or POS terminal Figure 4 11 CFN Gate Controller Wiring The CEN Gate ICR can directly switch power to a gate controller The maximum ratings of the switched power should not exceed 5 Amp 30 VDC or 1 8 HP 120 VAC If the gate controller switch control exceeds these ratings an auxiliary relay must be installed to handle the load The auxiliary relay coil should not exceed the ratings mentioned abov
41. devices PCUs ICRs and so on must connect to this port Loop 2 It is an alternate island RS 485 port The factory setting for this loop is Two wire RS 485 half duplex which enables communication to Tokheim Dispenser Payment Terminals DPT For additional information on Tokheim DPT wiring refer to C09146 Site Controller Pump Interface Manual If a Two wire device for example DPT is connected to a loop that is set for Four wire the SC will not operate correctly Four wire devices on a Two wire loop may not communicate with the SC Refer to C01759 CFN Diagnostic Manual for appropriate jumper settings for two or Four wire operation of these ports Loop 3 It is the POS high speed port It is the only port to which a modular POS terminal can be connected MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 9 System Layout SC Ill In addition to SC ports Personal Computer PC peripherals monitor mouse and so on are connected as per the manufacturer s instructions Figure 3 1 shows SC ports as installed on a representative PC your actual PC layout may differ Location The SC II should be located in an office like environment and in an area protected from direct contact with the weather Do not install the SC unit in a hazardous location The unit is designed for an operating temperature range of 40 F to 95 F with a relative humidity of 20 to 80 non condensing Placing the
42. dispenser This means that even if you activate these stops fuel may continue to flow uncontrolled You must use the TOTAL ELECTRICAL SHUT OFF in the case of an emergency and not the console s ALL STOP and PUMP STOP or similar keys Total Electrical Shut Off Before Access Any procedure that requires access to electrical components or the electronics of the dispenser requires total electrical shut off of that unit Understand the function and location of this switch or circuit breaker before inspecting installing maintaining or servicing Gasboy equipment Evacuating Barricading and Shutting Off Any procedure that requires access to the pump dispenser or STPs requires the following actions ONAGA An evacuation of all unauthorized persons and vehicles from the work area Use of safety tape cones or barricades 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 Service Contractor or call the Gasboy Service Center at 1 800 444 5529 It is imperative to your safety and the safety of others 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
43. e The CEN system allows a loadable timeout value up to 2 minutes during which time the relays are energized The selected time depends on the gate controller manufacturer s specification Instead of a timed closure the system also allows relays to stay energized indefinitely until a signal returns to turn them off The signal is 120 VAC only and is connected to the Input Output I O Board s Switch Detect connector Page 42 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Precautions Pump Remote Dispenser Wiring 5 Pump Remote Dispenser Wiring Wiring Precautions The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble free operation of your Gasboy CEN System To ensure a quality installation follow the rules below All wiring must be installed and used in accordance with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Canadian users must comply with the Canadian Electrical Code also Wiring must also conform to the wiring diagram supplied with the pump remote dispenser Use approved conduits and insulated gasoline and oil resistant wiring of the proper size Wire connections must be tightly spliced and secured with a wire nut close the open end of the wire nut with electrical tape
44. e a sufficient ground It is recommended that the neutral and ground bus bars be bonded together when it is not prohibited by local codes While most of the CFN system components operate on 120 VAC the ICR2 without a pedestal PCU PA039810X0X0 will accept 120 240 VAC 10 47 63 Hz The AC wire size for power to the CFN system components must be 14 AWG or larger This gauge of wire is sufficient for runs of up to 300 feet from the breaker panel to the system Components with distances over 300 feet must use 12 AWG wire or larger All wiring should be stranded The specifications for the RS 485 data loop and RS 232 communication wire cable size can be found in Communication Requirements on page 33 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Communication Requirements System Components Wiring Communication Requirements The CFN System utilizes RS 485 RS 232 RS 422 and Two wire Current Loop modes of communication for communicating to other CFN system components and peripheral equipment Phone line modem communication may also be used when remote communication to the site is preferred The specific requirements for each of these modes of communication are listed below RS 485 RS 485 wiring is used for communication between the CFN system components This communication takes place over RS 485 modular cables provided with system components and the RS 485 data loop field wiring The following in
45. e pulse the transaction is stored in memory If the transaction ends by timeout or ring separation a message is logged However nothing is stored in the memory 4 The pulser signal can come from a dry contact switch with no other voltage or circuits connected or it can be a 12 VDC signal Ensure that you set the appropriate pulser input jumper as shown The jumpers are K1 through K4 and correspond to gates I through 4 respectively 5 Receipts are not available for these transactions Page 76 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Installation Completion Checklist Testing 6 Testing Installation Completion Checklist The information below should be reviewed to help verify proper installation of the CFN system prior to testing pumps and or remote dispensers in the manual override position Are the CEN system components located in the proper environment as described in Purpose on page 9 Is there adequate clearance around the ICRs refer to Purpose on page 9 ICR on page 14 and ICR2 PA0398X0XXX0 on page 18 Is all the wiring inside the metal conduit except as noted in Short Haul Modem SHM RS 422 on page 39 Is the AC and DC wiring in separate conduits troughs and so on If they are not and if the AC and DC wires share the conduit a shielded cable must be used as specified in Communication Requirements on page 33 RS 485 on page
46. entionally left blank Page 8 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Purpose System Layout 3 System Layout Purpose The purpose of this section is as follows It provides a basic description location and environmental requirements of the CEN components Dimensional drawings are included for the components manufactured by Gasboy It covers conduit requirements and provides conduit layout examples for basic system configurations Careful planning for the layout of the site will help you eliminate possible problems with the startup of your system and will ensure continued reliable system operation SC Ill Description The SC III is the heart of the CFN System present at the fueling site It controls and allows interaction between the automated fueling equipment including electronic pumps pump control devices card readers registers tank monitors and customer activated terminals The unit uses advanced microprocessor technology and incorporates multiple hardware and software safeguards The standard SC III unit consists of a hard disk drive for mass storage of data a 3 1 2 disk drive and a CD ROM drive The SC III provides the following ports Ports 1 4 5 and 6 These are local RS 232 ports They can accept a modem printer or other devices Port 3 Currently this port is not used Loop 1 It is an island port and connects to the RS 485 junction box All Gasboy
47. ents Wiring Multiple Console Wiring Multiple Console Wiring Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on multiple Profit Point Consoles Remote Console Wiring Consoles are located within 8 feet of the SC and are wired using the supplied cables You can however place your console up to 1000 feet away from the SC To do this you must use two additional junction boxes and wire the site as shown below All wiring must be installed according to the RS 232 and RS 485 wiring specifications Figure 4 6 Remote Console Wiring A di FAN POS Terminal i MRIN Coni N 4 Note Refer to MDE 4299 CFN Series Profit Point PLUS Installation Manual for information on Profit Point Consoles Page 38 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Short Haul Modem SHM RS 422 System Components Wiring Short Haul Modem SHM RS 422 A Gasboy SHM and the appropriate interconnect cable must be used when the RS 422 communication mode is being used It should be used for distances between 100 and 1500 feet It can be used for distances under 100 feet in place of RS 232 wiring One SHM is required at each end of the communication line Figure 4 7 SHM Connections All wiring must be installed and used in accordance with all building fire codes all Federal State and Local codes National Elec
48. es applications de pompe immersible coupez totalement le courant la pompe immersible et tous autres distributeurs qui utilisent la pompe immersible Le courant alternatif peut alimenter de nouveau un distributeur l arr t quand les distributeurs partagent une pompe immersible commune ou un relais de d marrage MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 43 Pump Remote Dispenser Wiring Power Requirements Power Requirements Electronic Pumps All electronic register pumps remote dispensers must be installed according to the manufacturer s instructions Suction Pumps The CFN PCU is capable of directly driving pump motors up to 3 4 HP at 120 240 VAC or 1 1 2 HP at 240 VAC A starter relay must be used with pump motors exceeding these limitations A separate circuit breaker should be supplied for each pump to meet the current requirements and to allow for isolated control with the circuit breaker panel in case of problems Remote Dispensers The CFN PCU is capable of directly driving submersible pumps up to 3 4 HP at 120 240 VAC or 1 1 2 HP at 240 VAC A remote dispenser with a submersible pump exceeding these limitations requires the use of a submersible starter relay A separate circuit breaker should be supplied for each remote dispenser in cases where it will directly drive the submersible pump Remote dispensers may be grouped together on a single breaker when the submersible pum
49. et Complete is a 120 VAC output that is used to indicate that the reset is complete and the pump remote dispenser is ready to dispense the product Two lines are provided for twins This line should only be used when monitoring of the pump remote dispenser is desired such as with a fuel management system This line must be capped when not in use This line is connected to the slow flow stage of the solenoid in the pump Fast Flow Fast Flow is a 120 VAC input that controls the fast flow valve of the pump remote dispenser when a slow fast flow valve is available If slow fast flow control is not desired this line should be tied to the Reset Complete slow flow line This line should be switched through the CEN System and be on only if the pump remote dispenser is authorized and the pump remote dispenser is in the fast flow mode This line will also be turned on when the pump remote dispenser is in the manual mode Light Feed Light Feed is a 120 VAC input required to power optional fluorescent lights that may be available in a pump remote dispenser In a site configuration using multiple remote dispensers or pumps the power for lights of up to 8 units can be supplied by one breaker The light feed is not controlled by the CFN System Light Neutral Light Neutral is a return line for AC current from lights to the breaker panel Phase 2 Feed Phase 2 Feed is a hot feed that is the opposite phase of the pump motor feed This line and the pump
50. handle is turned on Two feed lines are provided for twins This feed is also connected to the input of one of the internal switches of the electric reset When the reset finishes its cycle the 120 VAC input to the switch should be passed through as an output which causes the solenoid valve optional in some models to open and the Reset Complete line to indicate 120 VAC Note This line is also used to sense the closing of the pump handle for console operation A low current 120 VAC is supplied through this line in order to sense the condition of the handle This low current voltage is not capable of driving the reset motor or operating a solenoid valve Pump Motor Feed Pump Motor Feed is a 120 VAC input that is supplied to the input side of one of the internal switches of the electric reset This line should be switched through the CFN System and should only be turned on when the pump remote dispenser is authorized or in the manual mode When the reset finishes its cycle the 120 VAC input to the switch is passed through as an output causing the pump motor to receive power and begin running Without power to this line the unit will reset However it will not be able to fuel Two feed lines are provided in twins which contain two motors The gauge of this wire and its neutral wire should be determined according to the size of the motor the voltage at which the motor will be powered 120 VAC or 240 VAC and the distance from the breaker panel t
51. hield drain wire must be connected to the system AC ground Only AC wires for the system and pumps can be installed in the AC conduit Do not run the cable outdoors without the use of a metal conduit Do not run this cable overhead when outdoors The cable can be run indoors without the use of a metal conduit The shield drain wire must be connected to the system AC ground If you are using a cable other than the one recommended above the RS 485 field wires must be installed in a metal conduit away from any AC wires Distance The following distances must be adhered to when installing the RS 485 field wiring Wiring over 100 feet must follow the specifications outlined above The distance from the RS 485 junction box to the farthest CFN component is limited to 1000 feet The total length of the RS 485 field wiring to all the CFN components cannot exceed 1500 feet MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 33 System Components Wiring Communication Requirements RS 485 Modular Cable The RS 485 modular cables required are supplied with the system These cables are not compatible with standard phone cables that are obtained from other sources Gasboy supplied cables are 8 feet long If you need to connect a CFN component with a modular connector console that is more than 8 feet from the system you must use an RS 485 junction box to connect the device to the RS 485 communication wiri
52. ings if the hose outlets are suction pumps Page 24 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Conduit Layout Installation Specifications System Layout Consult the applicable section of this manual for specific system installation requirements The RS 485 junction box must be grounded as specified in Power Requirements on page 32 When used with Fuel Point an extra dedicated junction box is supplied and should be installed in the pump dispenser A separate dedicated conduit should be run between the junction box and the FPR Refer to C35628 Fuel Point Reader Installation and Retrofit Instructions Manual for details When using an ICR2 refer to MDE 2713 Universal Distribution Box Installation Manual for conduit layout installation requirements of the Two wire Current Loop communications For an overview of ICR2 Communication wiring refer to ICR2 Communication Wiring on page 37 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 25 System Layout Conduit Layout Installation Specifications Figure 3 10 Conduit Layout Electronic Pumps Remote Dispensers Electronic Hose Outlets
53. ite Controller III Installation Manual September 2009 Conduit Layout Installation Specifications System Layout Figure 3 11 Conduit Layout Wall mount Pump Control Mechanical Hose Outlets OPTIONAL POWER CONDITIONER n HER OR aj UPS CONTROLLED BATTERY B P UPS ENVIRONMENT SEL POS CONSOLE RS 485 UNCONDITIONED 00 CONDITIONED ODULAR OUTLET OO OUTLETS CABLES sai SUPPLIED MONITOR PRINTER BY GASBOY AC SURGE UNCONDITIONED oo 00 PROTECTOR L r OUTLET Y S9 Gomer STRIP CIRCUIT ANTO E CONTROL SUBM BREAKER DUE CONTROLLER STARTER PANEL 5 fo i ICR2 RELAYS 1 RS 232 CABLE EE AC POWER 2 TO MODEM TEL cL Ju cc CONDITIONER LL JACK SUPPLIED E e E WITH MODEM DC RS 485 COMMUNICATION ETTE I 18 4 I 18 4 i MINIMUM MINIMUM AC WIRE TROUGH r e PAO261 JUNCTION D BOX BOX 23 DC AC 19 DC AC I J BOX J BOX J BOX J BOX CABLES SUPPLIED 4 H
54. ng Connections Refer to System Components Wiring Diagram on page 35 for proper connection of the RS 485 field wiring to the CFN system components RS 232 RS 232 wiring can be used for communication between the CFN SC and EIA RS 232 compatible peripheral devices printer modem and so on The remote end of the wiring can be terminated with either an RS 232D connector or a Gasboy termination box You must follow these installation requirements when installing the CFN RS 232 communication lines All peripheral equipment connected to the RS 232 ports must be listed have an EIA standard RS 232 communication protocol and should not be installed in a hazardous location Distance The following distances must be adhered to when installing the RS 232 communication lines 1 100 feet RS 232 can be directly connected to a peripheral device 101 1500 feet An RS 422 Cable and a Gasboy SHM are required refer to Short Haul Modem SHM RS 422 on page 39 Conduit All direct connect RS 232 Cables over 15 feet must be in a metal conduit away from any AC wires For conduit requirements of SHMs see the installation sheet that applies to the device being used Cables RS 232 Cables can be purchased from Gasboy The type of cable required will vary according to the devices it connects Connection Cable Type Gasboy Part Number Port 1 4 5 and 6 to modem MiniDIN to 25DB C05995 Port 1 4 5 and 6 to terminal MindDIN to
55. nsers MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 47 Pump Remote Dispenser Wiring Terminal Block ID Terminal Block ID All mechanical pump remote dispenser wiring for the CFN System is terminated in the PCU Terminal connectors should be used on the stranded wire when connecting to the pump power and power input terminal blocks of the system Connections made to the smaller screw terminal blocks Pump Control I O Printed Circuit Board PCB Assembly do not require terminal connectors The wire to these connectors must not be larger than 14 AWG The orientation of the chassis assembly is shown in Figure 5 5 and Figure 5 6 on page 49 Figure 5 5 Pedestal or Wall mount PCU Terminal Block ID Page 48 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Terminal Block ID Pump Remote Dispenser Wiring Figure 5 6 Island mounted Standalone PCU Terminal Block ID BATTERY POWER SWITCH AC POWER SWITCH FUSE SWITCH DETECT TBS 485 COMMUNICATION LEFT SIDE VIEW RIGHT SIDE VIEW MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Page 49 Pump Remote Dispenser Wiring ICR2 Pedestal PCU ICR2 Pedestal PCU Figure 5 7 ICR2 Pedestal PCU ww CIA ral ew 6699 E n 669096969999 Page 50
56. nual September 2009 Page 61 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 15 Twin Suction Pump Console VR Reset Page 62 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 16 Twin Suction Pump Single Motor Console VR Reset Note Solenoid valves must be used on this suction pump di BED SERI ET to prevent unrecorded dispensing of product MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 63 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 17 Single Remote Dispenser Console VR Reset 4 o 0000 OO Page 64 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 18 Twin Remote Dispenser Console VR Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 65 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 19 Single Suction Pump Gasboy Reset Page 66 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 20 Twin Suction Pump Gasboy Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 67 Pump Remote Dispenser Wiring Wiring Diagr
57. o the pump It is possible to combine the pump motor feeds for twins and supply them from one breaker However the gauge of the wire must be adjusted to handle the load of two motors Note 240 VAC is developed across a motor when the other leg of the motor is connected to a Phase 2 Feed MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 51 Pump Remote Dispenser Wiring Conirol Lines Neutral Feed Neutral Feed is the AC current return line back to the breaker panel for all attached devices pump motor reset motor solenoid valves The gauge of this wire must be equal to that of the Pump Motor Feed suction pumps or Submersible Feed remote dispensers Submersible Feed Submersible Drive Submersible Feed is a 120 VAC input that is supplied to the input side of one of the internal switches of the electric reset This line should be switched through the CFN System and only be on when the pump remote dispenser is authorized or in the manual mode When the reset finishes its cycle the 120 VAC input to the switch is passed through as an output submersible drive to drive a starter relay or to directly drive a submersible motor up to 3 4 HP at 120 240 VAC or 1 1 2 HP at 240 VAC Any submersible motor exceeding these limitations must use a starter relay Note 240 VAC is developed across a motor when the other leg of the motor is connected to a Phase 2 Feed Reset Complete Switch Detect Slow Flow Res
58. on etti hi eee iR ee rae ici Ua EHE 11 Location xia iranica imamla mim rotti 11 Checa inte ideali ia ne Ai 14 Description rare Der REOR aa Raina Xe XS 14 SpecallORforCNG 14 LOCATION si cdd etc e ka isi in Pete ilani bati lr gli 14 ICRA PADBBROXXXO hn hs 18 Descriptions i pria farai a ya dd BERE Ra pet 18 Location iue ze ue e Miren Vu it ERE ue Pee UR vase 18 ICR2 with Standard Posts iletime Lex rr eee eed sas aa 19 RS 485 to RS 232 Converter 2 20 Logger Printer rue an lr ex a pele ub Ner RYE RR XN EET Lea 20 Description aie AA ee ayi VER CEDERE EMEXS 20 Localtlon cda etr the et tee beu E de ru pele wee aur 20 Modeli ani ie bele ie iii ete B lado lede eee 21 Descriptions decise pee eki aa 21 Location elio es tg e ERR NUR NE Dae te e Dane d 21 AC Surge Protector Outlet Strip aaa e aaa a a a iaaa 21 Description trio e Sisa de EEA CRAE a 21 Locations siii ken sma AE ERN km E N 21 Power Conditioner optional 45004800 22 Description 1435 ayam tS uQ apa edi eu ae eue La EE S 22 Location crea EY EM EY 22 Voltage Regulator Backup Power Supply UPS 22 Description etcetera y e ee ana aii a Gicik s 22 Location vcro wat newer hewn a Riis pews tada 22 ConduitReguiremenis 2 0 aaa 23 THHN THWN WireAreas
59. p has its own breaker It is recommended that no more than two remote dispensers be powered from one breaker to maintain isolated control with the circuit breaker panel in case of problems Gasboy 9800 Pumps Remote Dispensers Wire Size Page 44 Gasboy 9800 Series pumps and remote dispensers do not use the CFN PCU They are wired as standalone units Refer to MDE 4331 Atlas Installation Manual for wiring diagrams and instructions The table below lists the required AC wire size for suction and submersible pumps based on the HP rating of the pump motor and the distance from the circuit breaker to the pump remote dispenser for both 120 and 240 V units Use this table as a guide for selecting the proper size wire for your installation All wiring should be stranded The wire size for the switch detect from the pump should be 14 AWG The wire size for control lines of a remote dispenser should be 12 AWG These control lines are used to supply power for the reset mechanism solenoid valve and submersible starter relay when the submersible pump is not directly powered by the remote dispenser The wire size for DC pulsers should be 18 AWG and must meet the wiring requirements outlined in Pulser Wiring and Configuration on page 53 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Electronic or Mechanical Pumps Pump Remote Dispenser Wiring 120 Volt Wire Gauge Sizes per Feet of Run see Note
60. 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 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 contractors need to understand and comply with this program completely to ensure safety while the equipment is down Hazardous Materials Some materials present inside electronic enclosures may present a health hazard if not handled correctly Ensure that you clean hands after handling equipment Do not place any equipment in the mouth A WARNING The pump dispenser contains a chemical known to the State of California to cause cancer AN WARNING The pump dispenser contains a chemical known to the State of California to cause birth defects or other reproductive harm In an Emergency Inform Emergency Personnel Compile the following information and inform emergency personnel Location of accident for example addres
61. plies 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 Page 6 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Important Safety Information Hazards and Actions serious hazard Fire or explosion may result causing serious injury or death Follow established emergency procedures amp Spilled fuels accidents involving pumps dispensers or uncontrolled fuel flow create a The following actions are recommended regarding these hazards Collision of a Vehicle with Unit Fire at Island Fuel Spill 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 4298D CFN Series Site Controller III Installation Manual September 2009 Page 7 Important Safety Information This page is int
62. power conditioner provides a transient and common mode of protection to the CFN system although it cannot totally compensate for extremely poor power conditions IMPORTANT INFORMATION If present the power conditioner should be used in place of the AC Surge Protector Outlet Strip The power conditioner should be located within 50 feet of the SC but not in a hazardous location It must be located in an area protected from direct contact with the weather typically the system circuit breakers The unit is designed for an operating temperature range of 0 to 104 F Voltage Regulator Backup Power Supply UPS Description Location The voltage regulator backup power supply protects line operated equipment from low line voltage brownout and total line power failure by providing emergency power almost instantaneously The voltage regulator backup power supply also protects line operated equipment from potentially dangerous voltage spikes coming in on the commercial AC power Although it helps in conditioning the power to the CFN system it cannot totally compensate for extremely poor power conditions The voltage regulator backup power supply should be located in an area protected from direct contact with the weather typically near the system circuit breakers and should be located within 50 feet of the CFN system for optimum protection The unit is designed for an operating temperature range of 0 to 50 C Page 22 MDE
63. power from the equipment and will not stop product flow under certain conditions In order to provide the highest level of safety to you your employees and customers Gasboy recommends that all employees be aware of the location and are trained on the procedure for turning off power to the entire system A WARNING To reduce the risk of electrical shock when servicing turn off all power to the pump remote dispenser In submersible pump applications turn off all power to the submersible pump and any other remote dispensers that use the submersible pump AC power can feed back into a shut off remote dispenser when dispensers share a common submersible pump or starter relay N AVERTISSEMENT Pour r duire le risque de choc lectrique lors de l entretien r vision coupez totalement le courant a la pompe distributeur Dans les applications de pompe immersible coupez totalement le courant a la pompe immersible et tous autres distributeurs qui utilisent la pompe immersible Le courant alternatif peut alimenter de nouveau un distributeur l arr t quand les distributeurs partagent une pompe immersible commune ou un relais de d marrage MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 31 System Components Wiring Power Requirements Power Requirements Wire Size Page 32 AC Power for the CFN system components data terminal and external modem must come from a separate dedicated circ
64. rruptible Power Supply System Overview The Gasboy CFN System is a microprocessor based automated fueling system It consists of modular components and configurable software The CFN System can be tailored to meet the needs of retail petroleum marketers unattended or self service government fleets or private fleet owners The system flexibility allows for debit credit club and fleet card usage as well as cash operation The system application determines the components required Therefore your system may consist of several or all of the following components e RS 485 Junction Box es Pump Control Unit s PCUs Island Card Reader s ICRs Island Card Reader 2 ICR2 sland Receipt Printer s Point Of Sale POS console s e Standalone Receipt Printer s Cash Drawer s Personal Identification Number PIN Pad s Scanner RS 485 to RS 232 Converter Data Terminal Printer Page 2 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Warranty Introduction Modem Power Conditioner Voltage Regulator Backup Uninterruptible Power Supply UPS System Layout on page 9 provides a brief description of each component Warranty For information on warranty refer to MDE 4255 Gasboy s Warranty Policy Statement If you have any warranty related questions contact Gasboy s Warranty Department at its Greensboro location MDE 4298D CFN Series Site Controller III Ins
65. s 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 AX WARNING 4p Gasoline ingested may cause unconsciousness aS and burns to internal organs Do not induce vomiting Keep airway open Oxygen may be needed at scene Seek medical advice immediately AN WARNING 3 Gasoline inhaled may cause unconsciousness AN and burns to lips mouth and lungs Keep airway open Seek medical advice immediately AN WARNING lt Gasoline spilled in eyes may cause burns to eye tissue Irrigate eyes with water for approximately 15 minutes Seek medical advice immediately A WARNING e Gasoline spilled on skin may cause burns Wash area thoroughly with clear water Seek medical advice immediately 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 unexpected energization or start up of the machine s or equipment or release of stored energy could cause injury to employees or personnel Lockout Tagout ap
66. s a hazard or unsafe practice which may result in minor injury CAUTION without 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 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 5 Important Safety Information No Open Fire S Open flames from matches lighters welding torches or other sources can ignite fuels and their vapors No Sparks No Smoking Sparks from starting vehicles starting or using power tools burning cigarettes cigars or pipes can also ignite fuels and their vapors Static electricity including an electrostatic charge on your body can 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 capable of rendering first aid be present during servicing Familiarize yourself with Cardiopulmonary Resuscitation CPR methods if you work with or around high voltages This information is available from the American Red Cross Always advise the station
67. sers that are connected to CFN PCUs For testing of electronic pumps remote dispensers refer to manuals supplied with the pumps remote dispensers The pumps and or remote dispensers should be tested to verify AC wiring Note Only PCUs should be powered up during these tests The steps below list the testing procedures and expected results If any of these tests fail correct the wiring and repeat the test See the Terminal Block ID diagram in Pump Remote Dispenser Wiring on page 43 for the location of override switches Remove all wiring connectors green from the Pump Control I O PCB assembly located in the front of the card cage This will prevent damage to PCBs if the wiring is incorrect Ensure that connectors are not touching any metal surfaces Turn on the breakers for all pumps and or remote dispensers If the SC and other components are powered from the same breaker as the PCU ensure that they are turned off before proceeding A WARNING AC power is present on the terminal blocks of relay modules Electrical shock may occur if the operator comes in contact with these connections In the PCU turn the AC power and battery power switches to the ON position up These switches are located in the upper righthand corner of the power supply Place the system override switch for hose 41 in the MAN position Turn on hose 1 After completing reset the hose should be able to dispense the product Turn on all other hoses No
68. sole Gasboy Reset on page 74 Twin Remote Dispenser Console Gasboy Reset on page 75 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 55 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 9 Single Suction Pump VR Reset Page 56 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 10 Twin Suction Pump VR Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 57 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 11 Twin Suction Pump Single Motor VR Reset Note Solenoid valves must be used on this suction pump to prevent unrecorded dispensing of product 1 Page 58 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 12 Single Remote Dispenser VR Reset MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 59 Pump Remote Dispenser Wiring Wiring Diagrams Figure 5 13 Twin Remote Dispenser VR Reset Page 60 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Wiring Diagrams Pump Remote Dispenser Wiring Figure 5 14 Single Suction Pump Console VR Reset MDE 4298D CFN Series Site Controller III Installation Ma
69. stallation requirements must be followed when installing CFN RS 485 communication lines All wiring must be installed and used in accordance with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Canadian users must comply with the Canadian Electrical Code also Cable A twisted pair shielded cable is highly recommended for RS 485 wiring Although it is recommended that wires be run in a conduit away from AC wires they can be combined in the same conduit with AC wires if a UL listed cable with the following specifications is used Conductor 18 AWG stranded wire 2 twisted pairs Shield Foil wrapped 100 coverage and or tinned copper braid 90 coverage Drain Wire Stranded tinned copper 20 AWG or larger or braided shield Voltage Rating Maximum operating voltage of 600 V Environmental Gas and oil resistant suitable for wet or dry locations Gasboy can supply Belden 1063A Part Number C09655 which is a UL listed 4 conductor cable that meets the requirements listed above Note Belden 1063A is UL listed but not CSA listed When a cable with a voltage rating of less than 600 V is used it must be installed in a conduit separate from all AC wires Conduit When you use the recommended shielded twisted pair cable described above the cable can be run with AC wires in a metal conduit The s
70. t only the AC wires for the system and pumps can be used in that conduit Wiring between the Fuel Point Reader FPR and the Pre amp junction box is intrinsically safe and must be run in a conduit with only other intrinsically safe wiring It cannot be run ina conduit with AC DC RS 485 or pulser wiring regardless of the cable type used Refer to C35628 Fuel Point Reader Installation and Retrofit Instructions Manual for details All conduits must be connected to the CFN components through the holes and knockouts provided by the factory Do not make any other holes in these units If alternate holes are required contact Gasboy for approval first Refer to MDE 2713 Universal Distribution Box Installation Manual for conduit and wire requirements of the Two wire Current Loop communications to the ICR2 For an overview of ICR2 Communication wiring refer to ICR2 Communication Wiring on page 37 THHN THWN Wire Areas Diameter Area sq units Gauge in mm in mm 18 0 090 2 29 0 007 4 1 16 0 104 2 64 0 009 5 5 14 0 118 2 95 0 011 6 8 12 0 135 3 43 0 014 9 2 10 0 169 4 29 0 022 14 5 8 0 216 5 49 0 037 23 7 6 0 259 6 60 0 053 34 2 4 0 331 8 41 0 086 55 5 3 0 359 9 14 0 102 65 6 2 0 394 10 01 0 122 78 7 1063A 0 417 10 59 0 137 88 4 MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 23 System Layout Conduit Layout Installation Specifications Areas of Trade Size Conduit
71. tallation Manual September 2009 Page 3 Introduction Warranty This page is intentionally left blank Page 4 MDE 4298D CEN Series Site Controller III Installation Manual September 2009 Important Safety Information 2 Important Safety Information This section introduces the hazards and safety precautions associated with installing inspecting maintaining or servicing this product Before performing any task on this product read this safety information and the applicable sections in this manual where additional hazards and safety precautions for your task will be found Fire explosion electrical shock or pressure release could occur and cause death or serious injury if these safe service procedures are not followed Preliminary Precautions You are working in a potentially dangerous environment of flammable fuels vapors and high voltage or pressures Only trained or authorized individuals knowledgeable in the related procedures should install inspect maintain or service this equipment Emergency Total Electrical Shut Off The first and most important information you must know is how to stop all fuel flow to the pump dispenser and island Locate the switch or circuit breakers that shut off all power to all fueling equipment dispensing devices and Submerged Turbine Pumps STPs The EMERGENCY STOP ALL STOP and A PUMP STOP buttons at the cashier s station WILL NOT shut off electrical power to the pump
72. tandard unit has a blank post This post is used for mounting the ICR to the island The ICR is also available with a receipt printer post or a pump control post Special ICR for CNG Location Page 14 A special version of the CFN ICR is available for use in the Class 1 Division 2 area of CNG sites Model DETC The dimensions of this unit are the same as those mentioned in Figure 3 5 on page 15 This unit is not available with an internal receipt printer or a PCU The ICR should be located on the fuel island The unit has been designed for an operating temperature range of 40 to 104 F with a relative humidity of 2 to 99 non condensing Adequate clearance must be provided to allow easy access to the post s access covers An ICR with a receipt printer post or a pump control post requires a minimum of 18 clearance between the post and any of the pumps remote dispensers on the island MDE 4298D CEN Series Site Controller III Installation Manual September 2009 ICR System Layout Figure 3 5 ICR with Blank Post I L bud TENERO m J i i I PLATE 48 i rot 000 11 10 I TING HOLES BOTTOM PLATE la B D KOUTS FOR 3 R 1 nl la BARRIER PLA i TT ot Mr A I MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 15 System Layout ICR Figure 3 6 ICR with Receipt Printer Post
73. te lines and will not work if connected into a telephone network Conduit When using the recommended shielded twisted pair cable described in Short Haul Modem SHM RS 422 on page 39 RS 422 wires can be run with AC wires in a metal conduit The shield drain wire must be connected to the system AC ground Only AC wires for the system and pumps can be installed in the AC conduit Do not run the cable outdoors without the use of metal conduit Do not run this cable overhead when outdoors The cable can be run indoors without the use of a metal conduit The shield drain wire must be connected to the system AC ground If you are using a cable other than the one recommended previously the RS 422 field wires must be installed in a metal conduit separate from any AC wires This cable must also meet the other previously specified requirements Distance The maximum field wiring cable length must not exceed 1500 feet Phone Modems The type of phone line required for remote communication using a modem depends on the type of modem used and the method of communication preferred Consult the manual provided with the modem for specific requirements Wiring for a Tank Monitoring System The following diagrams show the wiring schemes when connecting the SC to a Tank Monitoring System All wiring must be installed according to the RS 232 and RS 485 wiring specifications described in Communication Requirements on page 33 Consult the manufa
74. terface between the SCII and Tokheim pumps dispensers Use the C05578 CEN to Tokheim 67 98 D Box Cable Assembly and see Figure 5 3 to connect the selected PC COMM port of the SC III to a single Tokheim 67 or 98 Interface Box If there are more than 16 dispensers connected through two Tokheim 67 boxes another COMM port on the PC must be used and the wiring connections must be duplicated as shown in Figure 5 3 Figure 5 3 Tokheim Pumps Electronic Interface One Tokheim 67 or 98 Interface Box 9 pin PC COMM Port M07493A001 Barrel Connector Cable Tokheim 67 or 98 Interface Box Signal Converter P C05851 ower Supply Use the C05577 CFN to Tokheim 98 D Box Cable Assembly and see Figure 5 4 to connect the selected PC COMM port of the SC III to two Tokheim 98 Interface Boxes Figure 5 4 Tokheim Pumps Electronic Interface Two Tokheim 98 Interface Boxes 9 pin PC COMM Port M07493A001 Cable Barrel Connector Tokheim 98 Interface Box Tokheim 98 Interface Box Signal Converter C05851 Power Supply If there are more than two Tokheim 98 Interface Boxes the site will be required to use another COMM port on the SC HI PC and the connections must be duplicated as shown in Figure 5 4 depending on whether there are three or four Tokheim 98 Interface Boxes Refer to the manufacturer s instructions to connect Tokheim 67 or 98 Interface Boxes to the Tokheim pumps dispe
75. trical Code NFPA 70 NFPA 30 and Automotive and Marine Service Station NFPA 30A codes and regulations Wiring must conform to the wiring diagram supplied with the pump remote dispenser also Canadian users must also comply with the Canadian Electrical Code Power The AC power for the SHM should come from the same breaker that supplies the peripheral device or the system Cable Twisted pair shielded cable is highly recommended for RS 422 wiring Although it is recommended that wires be run in a conduit separate from AC wires they can be combined in the same conduit with AC wires if a UL listed cable with the following specifications is used Conductor 18 AWG stranded wire 2 twisted pairs Shield Foil wrapped 100 coverage and or tinned copper braid 90 coverage Drain Wire Stranded tinned copper 20 AWG or larger or braided shield Voltage Rating Maximum operating voltage of 600 V Environmental Gas and oil resistant suitable for wet or dry locations Gasboy can supply Belden 1063A Part Number C09655 which is a UL listed 4 conductor cable that meets the requirements listed above Note Belden 1063A is UL listed but not CSA listed If a cable with a voltage rating of less than 600 V is used it must be installed in a conduit away from all AC wires MDE 4298D CFN Series Site Controller III Installation Manual September 2009 Page 39 System Components Wiring Phone Modems These modems must be connected with priva
76. uit breaker No other equipment including the system s pumps or remote dispensers may be powered from this breaker Whenever possible a single breaker should be used to supply the CFN system components data terminal and modem However it is acceptable to supply power to the different CFN system components and accessories from multiple breakers within the same breaker panel and the same phase of power When necessary power for the data terminal or modem may be supplied from a separate dedicated breaker located in a different breaker panel The system requires 120 VAC 10 47 63 Hz for power An SC and its attached components printer monitor and so on must draw power from an AC Surge Protector Outlet Strip that cannot be plugged into the optional power conditioner A power conditioner may be used in place of the AC Surge Protector Whenever possible the AC Surge Protector Outlet Strip or optional power conditioner must draw their power from the same source Proper system grounding is an extremely important part of the system installation As with the AC power the grounds for all CFN system components should return to the same breaker panel This ensures that there is a common ground throughout the system which is necessary for the protection of the RS 485 data loop circuitry Grounds for all system devices should be wired to the breaker panel ground bus bar which in turn should be grounded to a ground rod A conduit ground does not provid

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