Mde 3882B

MDE-3882B
Conversion of the Universal Distribution Box

[D-Box (PA0261XXXXXXX)]: RS-422 to
Two-wire and Two-wire to RS-422
November 2015
Introduction
Purpose
This manual provides instructions to convert the Universal Distribution Box (D-Box):
• From RS-422 to two-wire input for Passport® Point of Sale (POS) systems
• From two-wire to RS-422 for PAM™ 1000 systems
Intended Users
This manual is intended for Gilbarco-trained and certified Authorized Service Contractors
(ASCs).
IMPORTANT INFORMATION
Do not install this equipment unless you have proper training for installing equipment in a
hazardous location.
Table of Contents
Topic Page
Introduction 1
Important Safety Information 4
Before You Begin 6
Converting D-Box from RS-422 to Two-wire 7
Converting D-Box from Two-wire to RS-422 14
Required Tools and Materials

Following are the tools and materials required for the conversion of the Universal D-Box:
• Multimeter
• Needle Nose Pliers
• Phillips® Screwdriver #2
MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015 Page 1
Introduction
Parts List
Following tables list the parts included in the Conversion Kits:
Conversion Kit Q13241-107

Item Description Part Number Quantity
1 Assembly, Cable Two-wire J905/J102 D-Box R18810-G1 2
2 Cable, Work Area Q13850-100 2
3 Gender Mender Assembly, Modular Jack to D-Subminiature (D-Sub) Q13180-11B 2
4 Assembly, Screw Lock (Connector D-Sub) Q10437-07 4
Conversion Kit Q13241-118

Item Description Part Number Quantity
1 Assembly, Cable Two-wire J905/J102 D-Box R18810-G1 2
2 Cable, Work Area Q13850-100 2
3 Gender Mender Assembly, Modular Jack to D-Sub Q13180-11B 2
4 Assembly, Screw Lock (Connector D-Sub) Q10437-07 4
5 Cables, PC Q13240-09 1
Required Reading
WARNING
Where fuels are involved, you are working in a dangerous environment of gasoline,
gasoline vapor, and electricity. Failure to install this equipment in accordance with
National Fire Protection Association (NFPA) 30A and NFPA 70® could result in severe
injury or death.
Before installing the kits, read, understand, and follow:

•This manual.
•The National Electrical Code [NEC® (NFPA 70)].
•The automotive and marine service code (NFPA 30A).
•Any national, state, and local codes that may apply.
Failure to install the equipment in accordance with NFPA 30A and NFPA 70 may 
adversely affect the safe use and operation of the system.
Page 2 MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and Two-wire to RS-422 · November 2015
Introduction
Related Documents
Document
Number Title GOLDSM Library
MDE-2713 Universal Distribution Box (D-Box) Installation Manual • Advantage® and Legacy®
• POS Peripheral Devices
MDE-3804 Encore® and Eclipse® Start-up/Service Manual • Encore and Eclipse

• Service Manual
MDE-3816 Passport Hardware Start-up and Service Manual • Passport

• Service Manual
MDE-3839 Passport System Installation Addendum Passport

Note: Ensure to read and understand the installation documentation for the dispensers being connected to the D-Box.
Abbreviations and Acronyms

Term Description
CAT-5 Category 5
CRIND® Card Reader in Dispenser
D-Box Distribution Box

D-Sub D-Subminiature
ESD Electrostatic Discharge
GOLD Gilbarco Online Distribution
NEC The National Electrical Code
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Administration
PAM Pump Access Module
PCB Printed Circuit Board
POS Point of Sale
TAC Technical Assistance Center
TWI Two-wire Current Loop Interface
Important Safety Information

Notes: 1) Save this Important Safety Information section Read the Manual
in a readily accessible location. Read, understand, and follow this manual and any other labels
or related materials supplied with this equipment. If you do not
2) Although DEF is non-flammable, Diesel is
understand a procedure, call a Gilbarco Authorized Service
flammable. Therefore, for DEF cabinets that are
Contractor or call the Technical Assistance Center (TAC) at 
attached to Diesel dispensers, follow all the
1-800-743-7501. It is imperative to your safety and the safety of
notes in this section that pertain to flammable others to understand the procedures before beginning work.
fuels.

Follow the Regulations
This section introduces the hazards and safety precautions
Applicable information is available in National Fire Protection
associated with installing, inspecting, maintaining, or servicing
Association (NFPA) 30A; Code for Motor Fuel Dispensing
this product. Before performing any task on this product, read
Facilities and Repair Garages, NFPA 70; National Electrical
this safety information and the applicable sections in this
Code (NEC), Occupational Safety and Health Administration
manual, where additional hazards and safety precautions for
(OSHA) regulations and federal, state, and local codes. All
your task will be found. Fire, explosion, electrical shock, or
these regulations must be followed. Failure to install, inspect,
pressure release could occur and cause death or serious injury,
maintain, or service this equipment in accordance with these
if these safe service procedures are not followed.
codes, regulations, and standards may lead to legal citations
with penalties or affect the safe use and operation of the
Preliminary Precautions equipment.
You are working in a potentially dangerous environment of
flammable fuels, vapors, and high voltage or pressures. Only
Replacement Parts
trained or authorized individuals knowledgeable in the related
Use only genuine Gilbarco replacement parts and retrofit kits on
procedures should install, inspect, maintain, or service this
your pump/dispenser. Using parts other than genuine Gilbarco
equipment.
replacement parts could create a safety hazard and violate
local regulations.
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 Safety Symbols and Warning Words
the switch or circuit breakers that shut off all power to all fueling This section provides important information about warning
equipment, dispensing devices, and Submerged Turbine symbols and boxes.
Pumps (STPs). Alert Symbol
! ! WARNING
The EMERGENCY STOP, ALL STOP, and This safety alert symbol is used in this manual and on
PUMP STOP buttons at the cashier’s station warning labels to alert you to a precaution which must be
WILL NOT shut off electrical power to the  followed to prevent potential personal safety hazards. Obey
pump/dispenser. This means that even if you safety directives that follow this symbol to avoid possible injury
activate these stops, fuel may continue to flow or death.
uncontrolled. Signal Words
These signal words used in this manual and on warning labels
You must use the TOTAL ELECTRICAL  tell you the seriousness of particular safety hazards. The
SHUT-OFF in the case of an emergency and not precautions below must be followed to prevent death, injury, or
the console’s ALL STOP and PUMP STOP or damage to the equipment:
similar keys. 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
Total Electrical Shut-Off Before Access ! that could result in death or serious injury.
Any procedure that requires access to electrical components or CAUTION with Alert symbol: Designates a hazard or
the electronics of the dispenser requires total electrical shut off ! unsafe practice which may result in minor injury.
of that unit. Understand the function and location of this switch CAUTION without Alert symbol: Designates a hazard or
or circuit breaker before inspecting, installing, maintaining, or unsafe practice which may result in property or
servicing Gilbarco equipment. equipment damage.
Evacuating, Barricading, and Shutting Off

Any procedure that requires access to the pump/dispenser or
Working With Fuels and Electrical Energy
STPs requires the following actions:
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
• An evacuation of all unauthorized persons and vehicles dispenser or island.
from the work area
• Use of safety tape, cones, or barricades at the affected DEF is non-flammable. Therefore, explosion and fire safety
unit(s) warnings do not apply to DEF lines.
• A total electrical shut-off of the affected unit(s)
No Open Fire In an Emergency

Inform Emergency Personnel
Compile the following information and inform emergency
Open flames from matches, lighters, welding torches, personnel:
or other sources can ignite fuels and their vapors. • Location of accident (for example, address, front/back of
No Sparks - No Smoking 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,
Sparks from starting vehicles, starting, or using power tools, elderly)
burning cigarettes, cigars, or pipes can also ignite fuels and • Whether or not victim has received first aid (for example,
their vapors. Static electricity, including an electrostatic charge stopped bleeding by pressure, and so on)
on your body, can cause a spark sufficient to ignite fuel vapors. • Whether or not a victim has vomited (for example, if
Every time you get out of a vehicle, touch the metal of your swallowed or inhaled something, and so on)
vehicle, to discharge any electrostatic charge before you
approach the dispenser island. ! WARNING
Gasoline/DEF ingested may cause
Working Alone unconsciousness and burns to internal organs.
It is highly recommended that someone who is capable of Do not induce vomiting. Keep airway open.
rendering first aid be present during servicing. Familiarize Oxygen may be needed at scene. Seek medical
yourself with Cardiopulmonary Resuscitation (CPR) methods, if advice immediately.
you work with or around high voltages. This information is
available from the American Red Cross. Always advise the ! WARNING
station personnel about where you will be working, and caution DEF generates ammonia gas at higher temperatures.
them not to activate power while you are working on the When opening enclosed panels, allow the unit to air out to
equipment. Use the OSHA Lockout/Tagout procedures. If you avoid breathing vapors.
are not familiar with this requirement, refer to this information in If respiratory difficulties develop, move victim away from
the service manual and OSHA documentation. source of exposure and into fresh air. If symptoms persist,
seek medical attention.
Working With Electricity Safely
Ensure that you use safe and established practices in working ! WARNING
with electrical devices. Poorly wired devices may cause a fire, Gasoline inhaled may cause unconsciousness
explosion, or electrical shock. Ensure that grounding and burns to lips, mouth, and lungs. Keep airway
connections are properly made. Take care that sealing devices open. Seek medical advice immediately.
and compounds are in place. Ensure that you do not pinch
wires when replacing covers. Follow OSHA Lockout/Tagout
! WARNING
requirements. Station employees and service contractors need
to understand and comply with this program completely to Gasoline/DEF spilled in eyes may cause burns to
ensure safety while the equipment is down. eye tissue. Irrigate eyes with water for
approximately 15 minutes. Seek medical advice
Hazardous Materials immediately.
Some materials present inside electronic enclosures may
! WARNING
present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any Gasoline/DEF spilled on skin may cause burns.
equipment in the mouth. Wash area thoroughly with clear water.
Seek medical advice immediately.
! WARNING
! WARNING
The pump/dispenser contains a chemical known to the
DEF is mildly corrosive. Avoid contact with eyes, skin, and
State of California to cause cancer.
clothing. Ensure that eyewash stations and safety
showers are close to the work location. Seek medical
advice/recommended treatment if DEF spills into eyes.
! WARNING IMPORTANT: Oxygen may be needed at scene if gasoline has
The pump/dispenser contains a chemical known to the been ingested or inhaled. Seek medical advice immediately.
State of California to cause birth defects or other Lockout/Tagout
reproductive harm. 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 applies to all mechanical, hydraulic, chemical,
or other energy, but does not cover electrical hazards. Subpart
S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part
1910.333 contains specific Lockout/Tagout provision for
electrical hazards.
Before You Begin
Before You Begin

Before you begin, read and understand “Important Safety Information” on page 4.
CAUTION
A properly grounded Electrostatic Discharge (ESD) wrist strap must be worn
while servicing any electronic devices or components. Failure to use
electrostatic precautions may damage electronic components and void
warranty.
1 Inform the manager.
2 Barricade the unit to be worked on.
3 Remove power to the unit at the breaker panel. Follow OSHA lockout/tagout procedures.
WARNING
Failure to turn off the unit during the installation of the kit may cause injury or bodily harm
from electrical shock. Ensure that all power to the unit is switched off before opening the
door to the unit and during kit installation.
4 Match the parts received in the kit with “Parts List” on page 2.
Converting D-Box from RS-422 to Two-wire

To convert a D-Box from RS-422 to two-wire, proceed as follows:
1 Loosen the two screws on the bottom front of the D-Box, and lift the lid.
2 Disconnect the cable(s) at ports P101 and P103 of T17651 Board and ports P101 and P103A/B
of M14301 Board.
CAUTION
Working on Printed Circuit Boards (PCBs) without connecting to a ground or discharging
static can damage electronic parts. Use a wrist strap and store parts in antistatic storage
bags.
3 Remove the two screws that secure the 9-pin D-Sub connectors to the D-Box case; then,
remove and discard the cable assembly.
4 Install the R18810-G1 Two-wire Cables at the D-Sub positions. Secure the cable with the
standoffs.
5 Connect the other end of the R18810-G1 Cable(s) to port P102 (for T17651) and 
port P102A/B (for M14301) on the PCBs. Note the orientation of the cable.
6 Change and verify the jump jack settings.
Following table lists the correct jump jack configurations:

Configuration 8 Loops/1 Input 16 Loops/1 Input 16 Loops/2 Inputs
Two-wire Current Loop Interface Figure 1 on page 8 and Figure 3 on page 10 and Figure 5 on page 12 and
(TWI): Dispensers or CRIND Figure 2 on page 9 Figure 4 on page 11 Figure 6 on page 13
devices
7 Reconnect the cable at the port P101.
8 Connect the Q13850-100 Data Cables and Q13180-11B Gender Menders from the Passport
CPU or Passport Dispenser Hub.
Note: In case of D-Box with M14301 Board, Q13850-100 Cable can be directly connected to
RJ-45 input connectors P1 and P2 of the board so steps 4 to 6 are not required. An
additional step is to open the knockouts of box for P1 and P2, if they are not opened
already.
9 Plug in the AC power cord.
10 Replace the D-Box cover, and secure with screws.
11 Verify the operation of card readers and/or dispensing units.
Converting the D-Box from RS-422 to two-wire is now complete.
Jumper Settings
Following are the diagrams for jumper settings for T17651 and M14301 Boards:
Figure 1: Jumper Settings - TWI, Single T17651 Board, Single Input, 8 Loops
Figure 2: Jumper Settings - TWI, M14301 Board, Single Input, 8 Loops
Figure 3: Jumper Settings -TWI, Dual T17651 Boards, Single Input, 16 Loops Total
Figure 4: Jumper settings - TWI, M14301 Board, Single Input, 16 Loops Total
Figure 5: Jumper Settings - TWI, Dual T17651 Boards, Two Inputs, 8 Loops Each
Figure 6: Jumper Settings - TWI, M14301 Board, Two Inputs, 8 Loops Each
Converting D-Box from Two-wire to RS-422

To convert a D-Box from two-wire to RS-422, proceed as follows:
1 Loosen the two screws on the bottom front of D-Box, and lift the lid.
2 Disconnect the cables at ports P101 and P102 of T17651 Board and ports P102A/B of M14301
Board.
CAUTION
Working on PCBs without connecting to a ground or discharging static can damage
electronic parts. Use a wrist strap and store parts in antistatic storage bags.
3 Remove the two screws that secure the 9-pin D-Sub connector(s) to the D-Box case; then,
remove and discard the cable assembly.
4 For T17651 Board, install the R19249-G1 Two-wire Cables at the D-Sub position(s). For
M14301 Board, install shorter R19249-G1 Cable near the board at D-Sub position and longer
R19249-G2 Cable at D-Sub position away from board. Secure the cable with standoffs.
5 For T17651 Board, connect the other end of the R19249-G1 Cable(s) to port P103. For
M14301 Board, connect R19249-G1 Cable to port P103A and R19249-G2 Cable to port
P103B. Note the orientation of the cable.
6 Change and verify the jump jack settings.
Following table lists the correct jump jack configurations:

Configuration 8 Loops/1 input 16 Loops/1 Input 16 Loops/2 Inputs
RS-422: Dispensers or Figure 7 on page 15 and Figure 9 on page 17 and Figure 11 on page 19 and
CRIND Devices Figure 8 on page 16 Figure 10 on page 18 Figure 12 on page 20
7 Reconnect the cable at the port P101.
8 Connect the Q13850-100 Data Cables and Q13180-11B Gender Menders from the Passport
dispenser hub.
9 Plug in the AC power cord.
10 Replace the D-Box cover, and secure with screws.
11 Verify the operation of card readers and/or dispensing units.
Converting the D-Box from two-wire to RS-422 is now complete.
Jumper Settings
Following are the diagrams for jumper settings for T17651 and M14301 Boards:
Figure 7: Jumper Settings - RS-422 Interface, Single T17651 Board, Single Input, 
8 Loops
Figure 8: Jumper Settings - RS-422 Interface, M14301 Board, Single Input, 8 Loops
Figure 9: Jumper Settings - RS-422 Interface, Dual T17651 Board, Single Input, 
16 Loops Total
Figure 10: Jumper Settings - RS-422 Interface, M14301 Board, Single Input, 16 Loops
Total
Figure 11: Jumper Settings - RS-422 Interface, Dual T17651 Board, Two Inputs of 
8 Loops Each
Figure 12: Jumper Settings - RS-422 Interface, M14301 Board, Two Inputs of 8 Loops 
Each
The Advantage® Series, CRIND®, Encore®, Eclipse®, Legacy®, and Passport® are registered trademarks of Gilbarco Inc. GOLDSM is a
service mark of Gilbarco Inc. PAM™ is a trademark of Gilbarco Inc. Phillips® is a registered trademark of Phillips Screw Company.
© 2015 Gilbarco Inc.

7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone (336) 547-5000 · http://www.gilbarco.com · Printed in the U.S.A.
MDE-3882B Conversion of the Universal Distribution Box [D-Box (PA0261XXXXXXX)]: RS-422 to Two-wire and
Two-wire to RS-422 · November 2015

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MDE-3882B

Conversion of the Universal Distribution Box

Required Tools and Materials

Conversion Kit Q13241-107

Conversion Kit Q13241-118

Before installing the kits, read, understand, and follow:

MDE-3804 Encore® and Eclipse® Start-up/Service Manual • Encore and Eclipse

MDE-3816 Passport Hardware Start-up and Service Manual • Passport

MDE-3839 Passport System Installation Addendum Passport

Abbreviations and Acronyms

CRIND® Card Reader in Dispenser

D-Box Distribution Box

Important Safety Information

Evacuating, Barricading, and Shutting Off

No Open Fire In an Emergency

Before You Begin

1 Inform the manager.

2 Barricade the unit to be worked on.

Converting D-Box from RS-422 to Two-wire

6 Change and verify the jump jack settings.

Following table lists the correct jump jack configurations:

7 Reconnect the cable at the port P101.

9 Plug in the AC power cord.

10 Replace the D-Box cover, and secure with screws.

11 Verify the operation of card readers and/or dispensing units.

Converting the D-Box from RS-422 to two-wire is now complete.

Figure 2: Jumper Settings - TWI, M14301 Board, Single Input, 8 Loops

Converting D-Box from Two-wire to RS-422

6 Change and verify the jump jack settings.

Following table lists the correct jump jack configurations:

7 Reconnect the cable at the port P101.

9 Plug in the AC power cord.

10 Replace the D-Box cover, and secure with screws.

11 Verify the operation of card readers and/or dispensing units.

Converting the D-Box from two-wire to RS-422 is now complete.

© 2015 Gilbarco Inc.

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