Smart Fuel Controller

Smart Fuel Controller Troubleshooting Guide Revision: 3

December 19, 2011 VeriFone, Inc. 2099 Gateway Place Suite 600 San Jose, CA 95110 Telephone: 408-232-7800 http://www.verifone.com Printed in the United States of America. 2011 by VeriFone, Inc. No part of this publication covered by the copyrights herein may be reproduced or copied in any form or by any means graphic, electronic, or mechanical, including photocopying, taping, or information storage and retrieval systems without written permission of the publisher. The contents of this document and all features and specifications are subject to change without notice. The information contained herein does not represent a commitment on the part of VeriFone, Inc. Publications are not stocked at the address given above. Requests for VeriFone publications should be made to your VeriFone representative. VeriFone, the VeriFone logo, and Ruby SuperSystem are registered trademarks of VeriFone, Inc. Sapphire, Topaz, HPV-20, Ruby Manager, Everest, EASY ID, Electronic Journal On-site, and Ruby Card are trademarks of VeriFone, Inc. in the U.S. and/or other countries. All other trademarks or brand names are the properties of their respective holders.

Revision History Rev. Date Description 1 August 03, 2010 Initial documentation release. 2 October 20, 2010 Added chapter for Gilbarco Pre-Modular Highline dispensers. 3 December 19, 2011 Added chapter for Dresser Wayne dispensers.

Contents 1. Introduction.......................... 1 2. Gilbarco Advantage, Encore 300 and Encore 500 Dispensers............................ 3 Smart Fuel Controller Configurations................ 3 SPA and SPI: 2-Wire Solution (Gilbarco Advantage & Encore 300)............................... 4 SPA and SPI: 2-Wire Solution (Gilbarco Encore 500).... 5 SPA, SPI, and Secure PumpPAY: 2-Wire Solution....... 6 Smart Fuel Controller Only: 4-Wire Solution......... 7 SFC with SPA and Secure PumpPAY (SPP): 4-Wire Solution 8 Verifying Pump Jumpers and Programming Settings....... 9 Cold Start................................ 9 Addressing the Pumps........................ 9 Addressing the CRIND........................ 9 Gilbarco Encore 500 Pumps.................. 9 Gilbarco Advantage/Encore 300.............. 10 Verify All Other Jumpers on the CRIND Boards in the Pump.................................. 11 Checking Generic CRIND Baud Rate Settings........ 12 Verifying Connections......................... 13 Regulator Board LEDs (SFC with SPA and SPI Solution).. 13 Verify Fuel and CRIND Connections.............. 13 Verify the SFC is Wired Correctly............... 13 Verify the POS is Sending the DCR Poll............ 14 Ping (SFC with SPA and SPI Solution)............. 14 Verifying Application Software................... 15 Telnet into the SFC......................... 15 Verifying that the SFC Application is Running..... 15 Verifying the Software Version on the SFC....... 16 Verifying the Configuration Downloaded to the SFC. 16 Verifying SFC with SPA and SPI Solution......... 17 December 19, 2011

3. Gilbarco Pre-Modular Highline Dispensers..... 21 Smart Fuel Controller Configurations............... 21 Smart Fuel Controller with SPA, SPI, and ispi: 2-Wire Solution................................ 22 Smart Fuel Controller Only: 4-Wire Solution........ 23 How to identify a Modular Versus a Pre-Modular Highline.. 24 Identifying the W01520 Logic Boards............... 25 Verifying the Jumper Setting for W01520 Logic Board.... 26 Addressing the Pump (W01520)................. 26 Grade Assignments (W01520).................. 26 Verifying the Programming of the ispi.............. 27 Verifying 2-Wire Connections for the ispi Connections.... 27 Blinking LEDs on the SFC Expansion Box........... 27 Blinking Transmit (Tx) and Receive (Rx) LEDs on the ispi Unit................................ 28 Verifying 4-Wire Connections in the SFC............. 29 Verifying that the Pre-Modular Highline is Working...... 29 Verifying Application Software................... 30 Telnet into the SFC......................... 30 Verifying the SFC Application is Running........ 30 Verifying the Software Version on the SFC....... 31 Verifying the Config Downloaded to the SFC..... 31 Verifying 4-Wire SFC with Pre-Modular......... 32 Verifying 4-Wire SFC with 32 Fueling Points and One Pre-Modular Highline..................... 33 Verifying 2-Wire SFC with Pre-Modular......... 34 4. Dresser Wayne Dispensers................ 37 Smart Fuel Controller Configurations............... 37 Understanding the Wayne SFC Concept.............. 40 Determing Type for the Dresser Wayne Dispenser....... 40 Verify Configuration on POS for Wayne SFC........... 42 Verify the Wayne FP Configurations for the Site........ 43 Verify Application and Configuration on the Wayne SFC.. 49 Verifying that the SFC Application Is Running....... 50 Verifying the Software Version on the SFC......... 51 Verifying the Configuration Downloaded to the SFC... 51 Verifying the Site Configuration on the SFC......... 52 ii December 19, 2011

A. Verifying Voltage Measurements........... 53 AC Voltage on 2-Wire Sets.................... 53 Open Circuit Voltage........................ 53 Closed Circuit Voltage....................... 53 AC Voltage with RS232 Unplugged............... 53 December 19, 2011 iii

iv December 19, 2011

1 INTRODUCTION This guide provides Smart Fuel Controller (SFC) troubleshooting solutions, including setup verification methods. Chapter 2 provides troubleshooting solutions for Gilbarco Advantage, Encore 300, and Encore 500 dispensers. Chapter 3 provides solutions for Gilbarco Pre-Modular Highline dispensers. Chapter 4 provides troubleshooting solutions fro Dresser Wayne dispensers. December 19, 2011 1

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2 GILBARCO ADVANTAGE, ENCORE 300 AND ENCORE 500 DISPENSERS Smart Fuel Controller Configurations The following diagrams show the possible Smart Fuel Controller configurations using the Smart Pump Access (SPA) and Smart Pump Interface (SPI) devices. December 19, 2011 3

SPA and SPI: 2-Wire Solution (Gilbarco Advantage & Encore 300) 4 December 19, 2011

SPA and SPI: 2-Wire Solution (Gilbarco Encore 500) December 19, 2011 5

SPA, SPI, and Secure PumpPAY: 2-Wire Solution 6 December 19, 2011

Smart Fuel Controller Only: 4-Wire Solution December 19, 2011 7

SFC with SPA and Secure PumpPAY (SPP): 4-Wire Solution 8 December 19, 2011

ATTENTION Before installing the Smart Fuel Controller Solutions Verify that the PUMP FIRMWARE is updated to at least the POS application release note version and that the pumps are ADDRESSED and the CRINDs are JUMPERED correctly. Gilbarco Certified Pump Technician For verification of any modifications or updates to the Gilbarco dispenser, please consult with a Gilbarco certified pump technician. Verifying Pump Jumpers and Programming Settings Cold Start After making any jumper/crind changes, a cold start must be performed for any effect to take place. Gilbarco Encore 500 Swipe the Gilbarco Diagnostic Card and follow the Cold Start procedure. Gilbarco Advantage/Encore 300 Put in the Cold Start jumper (J11) and power-cycle the pump. Then, follow the instructions on the screen. Addressing the Pumps A Gilbarco trained technician must go into the pump programming using the keypad and verify that the pumps are addressed correctly. At the G-Site, the pumps are addressed 7/11. When the site switches over to VeriFone equipment, the pumps need to be addressed - FP: 1, 2, 3. Note: The addressing will start over when there are more than 16 fueling points. Addressing the CRIND Example: FP01 FP16 Addressed as 1 16 FP17 FP32 Addressed as 1 16 Gilbarco Encore 500 Pumps The CRINDs are programmed with a Diagnostic card. A Gilbarco certified technician will have this card. December 19, 2011 9

Gilbarco Advantage/Encore 300 Verify the CRINDs are addressed/jumped correctly on the CRIND boards. JP4 JP8: CRIND address... the addresses are in Binary form. For addressing FP32 all the jumpers are OUT. Note: The addressing will continue for more than 16 fueling points. Example: FP01 FP16 Addressed as 1 16 FP17 FP32 Addressed as 17 32 Address JP8 (1) JP7 (2) JP6 (4) JP5 (8) JP4 (16) 1 IN OUT OUT OUT OUT 2 OUT IN OUT OUT OUT 3 IN IN OUT OUT OUT 4 OUT OUT IN OUT OUT 5 IN OUT IN OUT OUT 6 OUT IN IN OUT OUT 7 IN IN IN OUT OUT 8 OUT OUT OUT IN OUT 9 IN OUT OUT IN OUT 10 OUT IN OUT IN OUT 11 IN IN OUT IN OUT 12 OUT OUT IN IN OUT 13 IN OUT IN IN OUT 14 OUT IN IN IN OUT 15 IN IN IN IN OUT 16 OUT OUT OUT OUT IN 17 IN OUT OUT OUT IN 18 OUT IN OUT OUT IN 19 IN IN OUT OUT IN 20 OUT OUT IN OUT IN 21 IN OUT IN OUT IN 22 OUT IN IN OUT IN 10 December 19, 2011

Address JP8 (1) JP7 (2) JP6 (4) JP5 (8) JP4 (16) 23 IN IN IN OUT IN 24 OUT OUT OUT IN IN 25 IN OUT OUT IN IN 26 OUT IN OUT IN IN 27 IN IN OUT IN IN 28 OUT OUT IN IN IN 29 IN OUT IN IN IN 30 OUT IN IN IN IN 31 IN IN IN IN IN 32 OUT OUT OUT OUT OUT Verify All Other Jumpers on the CRIND Boards in the Pump Note: For Gilbarco Encore 300, the CRIND boards are mounted on pump walls. After the pump door is opened, pull out the tray with the boards. There are three boards in the tray: the two outside boards are the CRIND board and one in the middle is the Regulator board. The jumpers are located on the top side of the CRIND boards. Jump Jack Setting Function JP1 IN IN = Watch Dog Enable OUT = Watch Dog Disabled JP4 JP8 IN/OUT CRIND Addresses JP10 OUT Sets Baud Rate Settings (See table below) JP11 IN/OUT IN - Cold start. (Pump will always have to be cold started for the jumper change to take effect.) JP13 IN SIDE A OUT SIDE B IN Sets CRIND as side A (Master.) This jumper must be set to IN on least one of the two CRIND board, but not on both of them. JP14 IN Generic IN Sets CRIND fro Generic. Use JP14 only with BIOS v2.x or higher. JP16 IN Sets Baud Rate Settings (See table below) December 19, 2011 11

Jump Jack Setting Function JP19 IN BIOS selector, IN Generic Bios only. Part No.: T17764-G# G1 & G2 Does not have JP19 G3 & G4 Has JP19 The boards that do not have the JP19, this is addressed by the CRIND firmware. P267 Pin 3-4 IN Use for G1 Boards only Checking Generic CRIND Baud Rate Settings Baud Rate should be set for 4800. JP10 JP16 Baud Rate OUT OUT 1200 IN OUT 2400 OUT IN 4800 IN IN 9600 Note: After making any jumper changes, a cold start (JP11) must be performed for any effect to take place. 12 December 19, 2011

Verifying Connections Regulator Board LEDs (SFC with SPA and SPI Solution) Verify that the Transmit (TX) and Receive (RX) LEDS are blinking on the REGULATOR BOARD Check to see if the TX and RX LEDs are blinking on the Regulator board (middle board.) The Green LED is the SFC transmitting messages to the dispenser. The Red LED is the dispenser transmitting messages to the SFC. If both Red and Green LEDs are blinking, then the SPI is communication with the dispenser. If ONLY the Green LED is blinking, it indicates that the dispenser is not responding. Refer to the sections Addressing the Pumps and Telnet into the SFC in this guide. If the LEDs are NOT blinking, then check the connection on the SPI to see whether the 2-wire connections have any LEDs blinking. Verify Fuel and CRIND Connections Verify that the Fuel and CRIND connections are made to the correct connector in the pumps. See the installation manual for correct connection. Verify the SFC is Wired Correctly COM1 Fuel from POS COM2 DCR from POS SFC Ethernet Master SPA See the Smart Fuel Controller Installation Guide for more detailed connection information. December 19, 2011 13

Verify the POS is Sending the DCR Poll 1. Disconnect the RS232 cable from COM2 of the SFC and connect to the laptop with a RED NULL modem. 2. Start Hyper Terminal: Port Settings Bits per second 4800 Date bits 8 Parity Even Stop bits 1 Flow control None 3. The Hyper Terminal example below shows two fueling points. Depending on number of fueling points available, the Hyper Terminal will display A, B, C (FP 1, 2, 3 ) Ping (SFC with SPA and SPI Solution) 1. Connect a laptop Ethernet with a crossover cable into one of the available Ethernet ports on the Master SPA. 2. Start the SFC installer. 3. Select Site Configuration. 4. Select the SPI tab. 5. Select OPEN LIST (The VASC should have saved this list one setting up all the SPIs.) 6. Make sure that your SPI configuration settings are all filled in, then select PING ALL. 14 December 19, 2011

Verifying Application Software Telnet into the SFC 1. Connect a laptop into the Master SPA using an Ethernet cable. Note: For sites without SPA and SPI (SFC 4-wire solution), connect the Ethernet cable straight into the Ethernet ports on the SFC. 2. Ping the SFC using the SFC Installer. 3. On the laptop, open a DOS CMD window and enter the following: CMD Telnet 169.254.196.207 Login As usr1 Password 166831 This will bring you to the CMD $ prompt. Verifying that the SFC Application is Running At the CMD $ prompt: CMD ps o This will list what is running If you see Sleep No. that means that the SFC APP has not fully started. Wait few min. and then enter cmd ps again. If the SFC app was loaded correctly and running, then there will be several PamCtrl; GilbCtrl; and DCR Ctrl files listed. December 19, 2011 15

Verifying the Software Version on the SFC At the CMD $ prompt: CMD cd /tmp o This will change the directory to /var/tmp CMD ls o This will list all the files that are in the tmp folder CMD cat version.txt o This will display the software version on the SFC o In this example, the SFC version is 2.02.11c Verifying the Configuration Downloaded to the SFC At the CMD $ prompt: CMD cd SFC/config o This cmd will get you to the config folder CMD ls o This cmd will list all the files in that directory o SFC with SPA and SPI: There should be three files spi.config; dcr.config; and sfc.config o SFC without SPA and SPI: There should be only two files dcr.config and sfc.config 16 December 19, 2011

Verifying SFC with SPA and SPI Solution spi.config: At the CMD $ prompt: CMD cat spi.config o This cmd will display the SPI configurations SPI Enabled should be 1 IP address should be correct. Two per dispenser. 1 at the end of the IP address means that there is a DCR Present. 0 means NO DCR Present. Also, Notice that each dispenser has SAME two IP address. December 19, 2011 17

dcr.config: At the CMD $ prompt CMD cat dcr.config o This cmd will display the DCR configurations Make sure that 2_WIRE = 1 sfc.config: At the CMD $ prompt CMD cat sfc.config o This cmd will display the SFC configurations Verify that the 2_WIRE = 1 The Fuel configs are correct. 18 December 19, 2011

Verifying SFC Without the SPA and SPI Solution dcr.config: At the CMD $ prompt CMD cat dcr.config o This cmd will display the DCR configurations Verify that the 4_wire = 1 Verify the DCR configs are correct. sfc.config: At the CMD $ prompt CMD cat sfc.config o This cmd will display the SFC configurations Verify that the 2_WIRE = 0 Verify the Fuel configs are correct. December 19, 2011 19

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3 GILBARCO PRE-MODULAR HIGHLINE DISPENSERS Attention High Voltage High voltage on the display board. Follow all precautions. Gilbarco Certified Pump Technician For verification of any modifications or updates to the Gilbarco Pre- Modular Highline dispenser, please consult with a Gilbarco certified pump technician. Smart Fuel Controller Configurations The following diagrams show the possible Smart Fuel Controller configurations using the Smart Pump Access (SPA) and Smart Pump Interface (SPI) devices. December 19, 2011 21

Smart Fuel Controller with SPA, SPI, and ispi: 2-Wire Solution 22 December 19, 2011

Smart Fuel Controller Only: 4-Wire Solution December 19, 2011 23

How to identify a Modular Versus a Pre-Modular Highline Modular Highline pumps: These pumps have a numeric keypad and use modular electronics. The keypad is in the pump behind SIDE A of the access door. Modular Numeric Keypad Pre-Modular Highline pumps: These pumps have a command module jack behind the access door. These units need an external command module to program the pump. Pre-Modular Command Module Jack 24 December 19, 2011

Identifying the W01520 Logic Boards The logic board is located behind the display board. Warning: High voltage on the display board. There are two different styles of logic board one with dials and one with jumpers. W01520 Logic Board (See exploded view below) W01520 Logic Board with Dials W01520 Logic Board with Jumpers December 19, 2011 25

Verifying the Jumper Setting for W01520 Logic Board Addressing the Pump (W01520) The Pre-Modular Highline with W01520 Logic board will only support fueling positions addressed from 01 to 12. Note: The PAM 1000 will not support grade restricted prepay transactions on a Pre-Modular Highline with a W01520 Logic board. (See ISD Engineering Bulletin 0196) Options if Pre-Modular Highline is address higher than FP12 Re-address the highline to be fueling post ion from 01 to 12 (See the following Pump Addressing table.) The Pre-Modular Highline can be isolated to a dedicated channel on the SFC (Expansion box P/N P063-090-03-R.) Hose A Hose B Jumper JPA-1 JPA-2 JPA-4 JPA-8 JPB-1 JPB-2 JPB-4 JPB-8 Functions Hose #01 IN OUT OUT OUT IN OUT OUT OUT Hose #02 OUT IN OUT OUT OUT IN OUT OUT Hose #03 IN IN OUT OUT IN IN OUT OUT Hose #04 OUT OUT IN OUT OUT OUT IN OUT Hose #05 IN OUT IN OUT IN OUT IN OUT Hose #06 OUT IN IN OUT OUT IN IN OUT Hose #07 IN IN IN OUT IN IN IN OUT Hose #08 OUT OUT OUT IN OUT OUT OUT IN Hose #09 IN OUT OUT IN IN OUT OUT IN Hose #10 OUT IN OUT IN OUT IN OUT IN Hose #11 IN IN OUT IN IN IN OUT IN Hose #12 OUT OUT IN IN OUT OUT IN IN Grade Assignments (W01520) Grade settings are made on JP-C or S2. (See Logic Board diagram above.) Hose B Hose A Jumper JPC-1 JPC-2 JPC-3 JPC-4 JPC-5 JPC-6 Functions Grade #1 OUT OUT IN OUT OUT IN Grade #2 OUT IN OUT OUT IN OUT Grade #3 IN OUT OUT IN OUT OUT Grade #4 IN OUT IN IN OUT IN 26 December 19, 2011

Verifying the Programming of the ispi See the ispi installation manual for programming the unit. Verifying 2-Wire Connections for the ispi Connections Blinking LEDs on the SFC Expansion Box Verify that the following LEDs are blinking: On the SPI where the Dispenser connector (28472-01-R) is connected On the Port board where the other end of the Dispenser connection is made from the SPI On the Port board where the existing two wires from the premodular pumps are connected Ethernet connection from the SPA (Master) to the SPI December 19, 2011 27

Blinking Transmit (Tx) and Receive (Rx) LEDs on the ispi Unit Verify that the transmit and receive LEDs are blinking. On the SPI: If both Red and Green are blinking, then the SPI is communicating with the dispenser. If ONLY the Green LED is blinking, it indicates that the dispenser is not responding. Verify that the pump is address correctly and the SPI is programmed correctly. SPI connection on the port board: If both Red and Green are blinking, then the SPI is communicating with the dispenser. If ONLY the Green LED is blinking, it indicates that the dispenser is not responding. Verify that the pump is address correctly and the SPI is pro ga mm ed correctly. If the LED is SOLID Green, it indicates that there is no SPI connection Verify that the Dispenser cable (P/N 28472-01-R) is being used and connected correctly Pump connection on the port board: There is only one RED blinking LED. If it is blinking, then pump communication is good. If the Red LED is solid, then there is no pump communication. Verify that the polarity of the 2-wire connection from the pump is correctly connected. On the port board, the pin closer to the power supply is the (+) pin. Ohm out the cables to make sure that there is no short in the cable. Telnet into the SFC and verify that the sfc.config and spi.config is correct. 28 December 19, 2011

Ethernet connection on SPI: There are two LEDS on the Ethernet connection. The left Green LED indicates POWER and right Amber blinking LED indicates communication. If NO LEDS are blinking on the SPI Dispenser port and on the SFC Expansion box port board, verify that the Ethernet cable from the SPA (Master) is plugged in. Verifying 4-Wire Connections in the SFC Pump connection on the port board: The Pre-Modular Highline for the 4-wire is directly connected to the SFC port board along with the fuel communication lines from all the dispensers. Note: The Pre-Modular dispenser does not have CRINDS/DCR; therefore, there will be only one pair of two wires. The pair of two wires will be connected to the SFC port board that is configured for FUEL. There is only one RED blinking LED. If it is blinking, then pump communication is good. If the Red LED is solid, then there is no pump communication. Verify that the polarity of the 2-wire connection from the pump is correctly connected. On the port board, the pin closer to the power supply is + pin. Ohm out the cables to make sure that there is no short in the cable. Telnet into the SFC and verify that the sfc.config is correct. Verifying that the Pre-Modular Highline is Working Check to see if the prices go down to the pump. If the prices do not go down correctly, then check the following: Connection on the SFC or the ispi box Polarity of the cables coming from the pump There should be no Voltage on the line Hose assignment in the POS is correct December 19, 2011 29

Verifying Application Software Telnet into the SFC SFC 2-wire solution (SPA & SPI or ispi) Connect a laptop into the Master SPA using an Ethernet cable. SFC 4 wire solution (No SPA & SPI) Connect the Ethernet cable straight into the Ethernet port of the SFC. Ping SFC using the SFC installer Open up a DOS CMD window CMD Telnet 169.254.196.207 Login As usr1 Password 166831 This will bring you to a $ CMD prompt Verifying the SFC Application is Running At the CMD $ prompt CMD ps This will list what is running If you see Sleep No, that means that the SFC APP has not fully started. Wait a few minutes and then enter cmd ps again. If the SFC app was loaded correctly and running, then there will be several PamCtrl; GilbCtrl; and DCRCtrl files listed. 30 December 19, 2011

Verifying the Software Version on the SFC At the CMD $ prompt CMD cd /tmp This will change the directory to /var/tmp CMD ls This will list all the files that are in the tmp folder CMD cat version.txt This will display the software version on the SFC In this example, the SFC version is 2.02.11c Verifying the Config Downloaded to the SFC At the CMD $ prompt CMD cd SFC/config This cmd will get you to the config folder CMD ls This cmd will list all the files in that directory SFC with SPA and SPI: There should be three files spi.config; dcr.config; and sfc.config SFC without SPA and SPI: There should be only two files dcr.config and sfc.config December 19, 2011 31

Verifying 4-Wire SFC with Pre-Modular sfc.config: At the CMD $ prompt CMD cat sfc.config This cmd will display the SFC configurations Verify that the 2_WIRE = 0 Verify that the Fuel configs are correct. Note: For the Pre-Modular Highline line pumps a MAX DELAY = 50 must be set when configuring fuel. dcr.config: At the CMD $ prompt CMD cat dcr.config This cmd will display the DCR configurations Make sure that 2_WIRE = 0 Make sure that 4_WIRE = 1 32 December 19, 2011

Verifying 4-Wire SFC with 32 Fueling Points and One Pre-Modular Highline sfc.config: At the CMD $ prompt CMD cat sfc.config This cmd will display the SFC configurations If the site has more than 16 Fueling points there will be two Driver Data lines. The Port Board on the SFC with the Pre-Modular Highline is the only one that needs to have the MAX DELAY = 50. The delay does not need to be on the second Port Board if the Pre-Modular Highline is not connected. dcr.config: At the CMD $ prompt CMD cat dcr.config This cmd will display the DCR configurations If the site has DCR present on more than 16 fueling points, then there should be two DCRPORT DATA lines. December 19, 2011 33

Verifying 2-Wire SFC with Pre-Modular sfc.config: At the CMD $ prompt CMD cat sfc.config This cmd will display the SFC configurations Verify that the 2_WIRE = 1 Verify that the Fuel configs are correct. NOTE: For the Pre-Modular Highline line pumps a MAX DELAY = 50 must be set when configuring fuel. dcr.config: At the CMD $ prompt CMD cat dcr.config This cmd will display the DCR configurations Make sure that 2_WIRE = 1 Make sure that 4_WIRE = 0 Note: NOTE: Because this is a 2-Wire configuration, the DCRPORT DATA will not be there. 34 December 19, 2011

spi.config: At the CMD $ prompt CMD cat spi.config This cmd will display the SPI configurations SPI Enabled should be 1 IP address should be correct. Two per dispenser. Notice that each dispenser has SAME IP address twice. 1 at the end of the IP address means that there is a DCR Present. 0 means NO DCR Present. In the Example: FP12 is a Pre-Modular Highline. Pre-Modular Highlines do not have a DCRs. December 19, 2011 35

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4 DRESSER WAYNE DISPENSERS Smart Fuel Controller Configurations The following diagrams show the possible Smart Fuel Controller configurations with Dresser Wayne Dispensers. December 19, 2011 37

Table 1: Solution 1: SFC with 485-Board and Dresser Wayne Dispenser 38 December 19, 2011

Table 2: Solution 2: SFC with RS232/RS485 Converter (BnB) and Dresser Wayne Dispenser December 19, 2011 39

Understanding the Wayne SFC Concept POS will communicate to all SFC controlled dispensers with the Gilbarco fuel interface. The SFC will need the appropriate dispenser manufacturer (Gilbarco, Wayne, Tokheim) driver installed to interface to the corresponding manufacturer dispensers. The SFC gets the blend ratio from the Dresser Wayne dispensers; therefore, all the blend ratios are set to 100% on the SFC Installer. Fuel and DCR communication lines no longer go through the Wayne Distribution box. Fuel COMMs are directly connected to the Wayne SFC current loop board and DCR COMMs are directly connected to either a Verifone RS485 Board or to an RS232/RS485 Converter (BnB). Determing Type for the Dresser Wayne Dispenser Entering the Option Programming Mode to find the Macro: To enter the option programming mode to view or make changes, as allowed in this mode, perform the following procedure: Note: The dispenser will time out and return back to GAL/PRICES if the selections are not made in few seconds. 1. Press the POSITION SELECT push-button. 2. Press and hold the TOTALS push-button until the ones digit in the unit price display is 0. Press and hold the TOTALS push-button again until the tens digit is 0. The fueling point number is now set to 00. The money display on both sides will show dashes and both sides of the dispenser will be inoperative. 40 December 19, 2011

3. Press the PRICE JOG push-button. The unit price display will show OP01 to indicate that you have entered the option programming mode and Option 01 has been selected. 4. Press the PRICE JOG push-button to go to the desired programming option. As you press the PRICE JOG push-button, the unit price displayd will show the selected option in the range of OP01 to OP99 Note: The MACRO setting is located in OP02. In the example below, the MACRO is 10 5. Write down the MACRO from the dispenser. The dispenser will go back to GAL/PRICES after a few seconds. Warning: Do not make any changes on the dispenser. If changes are made by mistake, then let the dispenser time out and go back to GAL/PRICES screen. Macro Table and Dispenser Model/Type: Macro Dispenser Model Dispenser Type 02 V387D1 02 03 MGD1, 2, or 3 product with SC-82 Data Link Emulation 01 04 V389D1 02 05 V390D1 02 06 V490D1 02 07 V590D1 30 08 V390D1/U, X/V490D1/U 02 09 V390D3/U 02 December 19, 2011 41

10 V580D1, V590D1/U 40 11 V580D3, V590D3/U 40 12 V585D1, V395D1/U 40 13 V395D1 40 Currently Supported Wayne Dispenser Types: Description Dispenser Type SC82 01 None 02 Fix 30 Variable 40 Verify Configuration on POS for Wayne SFC Verify that Gilbarco fuel was loaded on the POS with Gemstall. Even though this is Wayne site, the fuel has to be GILBARCO. Note: Gilbarco fuel is the only change to be made on the POS. Do not make any other changes in Gemstall. Verify Hose Assignments. Do not put NONE between grades. Example: UNLD MID1 PREM NONE NONE NONE Verify Pump Attributes. BLEND type must be entered if the pump is a blending pump. 42 December 19, 2011

Verify the Wayne FP Configurations for the Site Note: The examples below show different Wayne FP configurations by pump type. The following Product ID setups from the POS Fuel Manager are used in the examples. Product ID Number Notes: Fuel Grade Names 1 UNLD 2 MID1 3 PREM 4 MID2 5 MID3 6 MID4 7 DIESL 8 KERSN 9 REG Wayne SFC: SFC Installer FP Config uses Product ID Numbers POS: Fuel Manager Hose Assignment uses Fuel Grade Names December 19, 2011 43

Example 1: Wayne Dispenser Type: 01 Number of Types of Fuel: 03 POS Hose Assignment: UNLD MID1 PREM NONE NONE NONE 44 December 19, 2011

Example 2: Wayne Dispenser Type: 02 Number of Types of Fuel: 01 POS Hose Assignment: UNLD NONE NONE NONE NONE NONE December 19, 2011 45

Example 3: Wayne Dispenser Type: 30 Number of Types of Fuel: 03 POS Hose Assignment: UNLD MID1 PREM NONE NONE NONE 46 December 19, 2011

Example 4: Wayne Dispenser Type: 40 Number of Types of Fuel: 04 (3+1) POS Hose Assignment: DEISL UNLD MID1 PREM NONE NONE December 19, 2011 47

Example 5: Wayne Dispenser Type: 40 Number of Types of Fuel: 03 POS Hose Assignment: UNLD MID1 PREM NONE NONE NONE 48 December 19, 2011

Verify Application and Configuration on the Wayne SFC Note: Disconnect the Wayne SFC from the POS when downloading the application and the configurations on the Wayne SFC. Once the Wayne SFC has been configured, connect the RS232 cable into the red null modem and initialize FUEL and all DCR from the POS. Telnet into the SFC 1. Using a crossover cable connect laptop to the SFC. 2. Ping the SFC using the SFC Installer. 3. On the laptop, open a DOS CMD window and enter the following: CMD Prompt telnet 169.254.169.207 Login As usr1 Password 166831 This will bring you to the CMD prompt. December 19, 2011 49

Verifying that the SFC Application Is Running At the CMD $ prompt: CMD ps This will list all the files that are running 165 root 420 S /usr/sbin/dropbear 170 usr1 452 S -sh -c /home/usr1/sfc/scripts/start_sfc_app 289 usr1 376 S sleep 30 290 usr1 520 S -sh 291 usr1 400 R ps If you do not see any of the processes, but notice: o Sleep ## This means that the processes have not completely started. Enter the ps cmd again in few minutes and check again. 299 usr1 468 S /home/usr1/sfc/bin/pamctrl 305 usr1 468 S /home/usr1/sfc/bin/pamctrl 306 usr1 468 S /home/usr1/sfc/bin/pamctrl 307 usr1 468 S /home/usr1/sfc/bin/pamctrl 365 usr1 376 S sleep 30 366 root 880 S [svcsec] 367 usr1 400 R ps In the example above: The SFC is still not completely up yet. There is still sleep ##. Enter the ps cmd again in few minutes and check again. 298 usr1 604 S /home/usr1/sfc/bin/pamctrl 304 usr1 604 S /home/usr1/sfc/bin/pamctrl 305 usr1 604 S /home/usr1/sfc/bin/pamctrl 306 usr1 604 R /home/usr1/sfc/bin/pamctrl 360 usr1 516 S /home/usr1/sfc/bin/drwctrl 362 usr1 516 S /home/usr1/sfc/bin/drwctrl 363 usr1 604 R /home/usr1/sfc/bin/pamctrl 365 usr1 516 S /home/usr1/sfc/bin/drwctrl 366 usr1 516 S /home/usr1/sfc/bin/drwctrl 381 usr1 516 S /home/usr1/sfc/bin/drwctrl If the application was loaded correctly and running, then there will be several of the following processes running: o PamCtrl o DrwCtrl Note: If you do not see the sleep ## and still no process have been started, verify that the App and the Configs have been downloaded to the SFC. If you notice that there is DcrCtrl also with the other process listed above meant that the DCR Config was downloaded onto the SFC. The DCR connections on the SFC are either made with an RS485 board or an RS232/rs485 Converter. THE SFC DOES NOT CONTROL THE DCR ON A WAYNE SFC. 50 December 19, 2011

Verifying the Software Version on the SFC At the CMD $ prompt: CMD cd This cmd will take you to the root drive. CMD cd /tmp This will change the directory to /var/tmp$ CMD ls This will list all the files that are in the tmp folder. CMD cat version.txt This will display the software version on the SFC /var/tmp $ ls blend.dat grade.dat hose.dat version.txt /var/tmp $ /var/tmp $ /var/tmp $ cat version.txt 11/30/1999 0:18:37 SMART FUEL CONTROLLER PamCtrl.c:1654 11/30/1999 0:18:37 PamCtrl.c:1654 11/30/1999 0:18:37 Version 2.03.07R4 07/14/2011 PamCtrl.c:1654 When the files are listed look for version.txt, if the file is not there make sure that APP is running and configs where downloaded. In the example, the SFC version is 2.03.07R4 Verifying the Configuration Downloaded to the SFC At the CMD $ prompt: CMD cd This cmd will take you to the root drive. CMD cd SFC/config This cmd will get you to folder where the CONFIGS are located CMD ls This will list all the files that are in the config folder. ~ $ ls SFC ipkg ~ $ cd SFC/config ~/SFC/config $ ls fp.config sfc.config There should be only two for listed in the Wayne SFC: o fp.config o sfc.config December 19, 2011 51

Verifying the Site Configuration on the SFC At the CMD $ prompt: CMD cat fp.config This cmd will display the info in the fp.config file. ~/SFC/config $ cat fp.config #FP: Slow flow: Delivery limit: Disp Type: Pos1 G1: Pos1 G1%: Pos1 G2: Pos 1G2%: Pos 1 G3: Pos 1 G3%: Pos 2 G1: Pos 2 G2%:... 01:090:00500:01:7:100:0:000:0:000:0:000:0:000:0:000:0:000:0:000:0:000:0:00 0:0:000:0:000:0:000:0:000:0:000:0:000:0:000:0:000:0:000:0:000:0:000 02:090:00500:02:0:000:0:000:0:000:0:000:0:000:0:000:1:100:0:000:0:000:0:00 0:0:000:0:000:2:100:0:000:0:000:0:000:0:000:0:000:3:100:0:000:0:000 03:090:00500:30:0:000:0:000:0:000:0:000:0:000:0:000:1:100:0:000:0:000:0:00 0:0:000:0:000:2:100:0:000:0:000:0:000:0:000:0:000:3:100:0:000:0:000 04:090:00500:40:0:000:0:000:0:000:0:000:0:000:0:000:1:100:0:000:0:000:0:00 0:0:000:0:000:2:100:0:000:0:000:0:000:0:000:0:000:3:100:0:000:0:000 The example above displays: o Number of Fueling Points: 4 o Slow flow:90 o Delivery limit: 500 o Dispenser type: FP1: 01 = SC82 FP2: 02 = None FP3: 03 = Fix FP4: 04 = Variable o Positions1-7: Site dispenser specific (refer to Wayne SFC Install guide for more info.) CMD cat sfc.config This cmd will display the info in the SFC.config file ~/SFC/config $ cat sfc.config ENABLE_syslog = done APPLICATION = SFC/Scripts/Start_SFC_app ENABLE_LOG_K00 = 0 MAXDRIVER = 1 POS_PORT_ID = 0 POS_AUX_PORT_ID = 0 2_WIRE = 0 #DRIVER_DATA=DRIVER_INDEX:MAXFPID:DRIVERTYPE:TTYID:DATA_BIT:PARITY:STOP_BI T:FLOW _CONTROL:BAUD_RATE:VTIME:DTDMIN:DTDMAX DRIVER_DATA= 1 : 4 : W : 3 : 8 : O : 1 : N : 9600 : 0 : 0 : 0 The example above displays: 1 : 4 : W : 3 : 8 : O : 1 : N : 9600 : 0 : 0 : 0 o 1 = Only Port 1 board is being used (refer to SFC manual for more info) o 4 = Number of Fueling points in the example o W = These are Wayne dispensers Note: If there is a G that means the fuel is configured as Gilbarco and not as Wayne. o All other settings are to be set as default. DO NOT CHANGE THE BAUD RATE UNLESS SPECIFIED BY ENGINEERING. 52 December 19, 2011

A VERIFYING VOLTAGE MEASUREMENTS AC Voltage on 2-Wire Sets For the following measurements, any reading or AC voltage is bad: Measure the AC voltage on the 2 wires by just unplugging the connector from the SFC Current Loop Distribution board and putting the multi-meter across the wires and setting it to read AC voltage. Measure AC voltage from either wire to earth ground. Open Circuit Voltage If the dispenser connector is removed from the SFC Current Loop Distribution board, the output pins on the SFC Current Loop Distribution board should read about 11.5 to 12 volts. You cannot measure the voltage from either of the pins/wires to ground because this voltage is entirely floating and not connected to ground; so, there is NO signal ground in this circuit. Closed Circuit Voltage When the dispenser connector is plugged into the SFC Current Loop Distribution board and there is no data transmission, you will measure about 2.5 to 3.5 volts DC across the 2 wires. This is the voltage required to activate the diode input of the optocoupler in the dispenser. This voltage will fluctuate with data transmissions. AC Voltage with RS232 Unplugged The output voltage at the connector on the SFC Current Loop Distribution board will be close to zero on the multimeter when you do the following. Unplug the RS232 cable on the back of the Ruby to get the SFC to stop polling the pumps. Unplug the cable between the SFC Current Loop Distribution board and the AUX board, which will probably leave the dispenser outputs turned OFF. December 19, 2011 53