Manual Gasboy

MDE-4814D
Fuel Truck Controller
INSTALLATION MANUAL
This document is based on Orpak’s Truck Controller Unit (OrTC)

installation manual P/N 817438028.
SAFETY CONSIDERATIONS
Read all warning notes and instructions carefully. They are included to help you in installing the Product
safely in the highly flammable environment of the fuel station. Disregarding these warning notes and
instructions could result in serious injury or property damage. It is the installer’s responsibility to install,
operate and maintain the equipment according to the instructions given in this manual, and to conform to all
applicable codes, regulations and safety measures. Failure to do so could void all warranties associated with
this equipment.
Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure
that actual installation is performed by experienced personnel, licensed to perform work in fuel station and
at a flammable environment, according to the local regulations and relevant standards.
For UL listing’s, all peripherals equipment connected to the device must be UL listed and suitable for
the applications.
WARNING - EXPLOSION HAZARD
Install the Product only in the non-hazardous area of the fuel station.
Use standard test equipment only in the non- hazardous area of the fuel station and approved test equipment
for the hazardous areas.
In the installation and maintenance of the Product, comply with all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for
Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70 “National Electric Code”, federal, state and
local codes and any other applicable safety codes and regulations.
Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping, and other metal work
operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury,
property loss and damage to you and other persons.
CAUTION - SHOCK HAZARD
Dangerous AC voltages that could cause death or serious personal injury are used to power the Product.
Always disconnect power before starting any work. The Product has more than one power supply connection
port. Disconnect all power before servicing.
CAUTION – EXTERNAL WIRING
For supply connections, use wires suitable for at least 90°C.
Signal wiring connected in this box must be rated at least 300 V.

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

Attaching unauthorized components or equipment will void your warranties.
CAUTION
Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all
warranties related to this equipment.
PROPRIETY NOTICE
This document contains propriety and confidential information. It is the property of ORPAK SYSTEMS
Ltd. It may not be disclosed or reproduced in whole or in part without written consent of ORPAK
SYSTEMS. The information in this document is current as of the date of its publication, but is subject to
change without notice.
DISCLAIMER
This document is provided for reference only. Although every effort has been made to ensure correctness,
ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.
FCC Compliance Statement
The FCC Wants You to Know:

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to
Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful
interference in a residential installation. This equipment generates uses and can radiate radio frequency
energy and, if not installed and used in accordance with the instructions, may cause harmful interference to
radio communications. However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is encouraged to try to correct the interference by
one or more of the following measures:
a) Reorient or relocate the receiving antenna.
b) Increase the separation between the equipment and receiver.
c) Connect the equipment to an outlet on a circuit different from that to which the receiver is connected.
d) Consult the dealer or an experienced radio/TV technician.
FCC Warning
Modifications not expressly approved by the manufacturer could void the user authority to operate the
equipment under FCC Rules.
This document is the property of:

ORPAK SYSTEMS Ltd.
ISRAEL
TABLE OF CONTENTS
Paragraph Page
SECTION 1 GENERAL DESCRIPTION

1-1. SCOPE ................................................................................................................................ 7
1-2. DESCRIPTION .................................................................................................................. 7
1-3. SYSTEM OVERVIEW ...................................................................................................... 8
1-3.1. Fuel Truck Controller System ........................................................................................ 8
1-3.2. Vehicle Identification ..................................................................................................... 8
1-3.3. Remote Web Access ...................................................................................................... 8
1-3.4. Fleet Head Office ........................................................................................................... 8
1-3.5. Restrictions and Limits .................................................................................................. 8
1-3.6. Fuel Truck Controller Capabilities for Mobile Station Management ............................ 9
1-3.7. System Workflow - Example ......................................................................................... 10
1-4. FUEL TRUCK CONTROLLER STRUCTURE ................................................................ 10
1-4.1. Main Components .......................................................................................................... 10
1-4.2. Fuel Truck Controller General Configuration................................................................ 12
1-4.3. Fuel Truck Controller Main Components Location ....................................................... 13
1-5. AVAILABLE CONFIGURATIONS ................................................................................. 14
1-5.1. General ........................................................................................................................... 14
1-5.2. Vehicle Identification System – FuelPoint PLUS .......................................................... 14
1-5.3. WGT External Box – Optional ...................................................................................... 14
1-5.4. Modem/Router ............................................................................................................... 15
1-5.5. External TAG Reader (OrTR)........................................................................................ 15
1-5.6. Fuel Truck Controller with OrTR and WGT ................................................................. 17
1-5.7. Fuel Truck Controller - Standard Models ...................................................................... 17
1-6. SECURITY AND PROTECTION ..................................................................................... 18
1-6.1. General ........................................................................................................................... 18
1-6.2. Authorization Security ................................................................................................... 18
1-6.3. Network Security ........................................................................................................... 18
1-6.4. RF Network Security ..................................................................................................... 18
1-6.5. Maintenance Security..................................................................................................... 18
1-6.6. RTC Backup ................................................................................................................... 18
1-7. HOUSING .......................................................................................................................... 18
1-8. SPECIFICATIONS ............................................................................................................. 20
1-9. STANDARDS .................................................................................................................... 20
MDE-4814D Fuel Truck Controller Installation Manual · February 2018 i

TABLE OF CONTENTS
Paragraph Page
1-9.1. Communication Standards ............................................................................................. 20

1-9.2. Security Standards .......................................................................................................... 20
1-10. MANUAL STRUCTURE ................................................................................................... 21
1-11. USING THIS MANUAL .................................................................................................... 22
1-12. REFERENCES ................................................................................................................... 23
SECTION 2 PRELIMINARY INSTALLATION INSTRUCTIONS

2-1. GENERAL .......................................................................................................................... 24
2-2. PRELIMINARY INSTALLATION INSTRUCTIONS ..................................................... 24
2-2.1. General ........................................................................................................................... 24
2-2.2. Precautions and Safety Notes ......................................................................................... 25
2-3. CONDUITS INSTALLATION .......................................................................................... 25
2-3.1. General ........................................................................................................................... 25
2-3.2. Conduit Requirements .................................................................................................... 25
2-3.3. Type of Conduits in the Truck ....................................................................................... 26
2-3.4. Wiring Openings in Fuel Truck Controller .................................................................... 27
2-3.5. Conduits Installation Procedures .................................................................................... 27
2-4. CABLES ............................................................................................................................. 27
2-4.1. General ........................................................................................................................... 27
2-4.2. Cable Types .................................................................................................................... 28
2-4.3. Cables Routing ............................................................................................................... 28
2-5. Electrical System................................................................................................................. 29
2-5.1. External Fuse .................................................................................................................. 29
2-5.2. Fuel Truck Controller Power System ............................................................................. 29
2-6. GROUNDING AND SHIELDING .................................................................................... 30
2-7. CONNECTIONS TO FUEL TRUCK CONTROLLER ..................................................... 31
SECTION 3 INSTALLATION PROCEDURES

3-1. GENERAL .......................................................................................................................... 32
3-2. INSTALLATION SPECIFICATIONS ............................................................................... 32
3-2.1. General ........................................................................................................................... 32
3-2.2. Precautions and Safety Notes ......................................................................................... 32
3-3. FUEL TRUCK - OVERVIEW ........................................................................................... 33
3-3.1. General ........................................................................................................................... 33
3-4. MAPPING THE TRUCK ................................................................................................... 34
ii MDE-4814D Fuel Truck Controller Installation Manual · February 2018

TABLE OF CONTENTS
Paragraph Page
3-4.1. General ........................................................................................................................... 34

3-4.2. Locating all objects of the fuel truck ............................................................................. 34
3-4.3. Assigning Logical IDs ................................................................................................... 34
3-5. INSTALLING THE FUEL TRUCK CONTROLLER ....................................................... 35
3-5.1. Installation Assembly Parts ............................................................................................ 35
3-5.2. Preliminary Procedures .................................................................................................. 36
3-5.3. Fuel Truck Controller Installation in Driver's Cabin ..................................................... 36
3-5.4. Determining the Spot Installation Fuel Truck Controller with Shock Absorber
Assembly……………………………………………………………………………….36
3-5.5. Shock Absorbers Assembly - Installation Procedures ................................................... 37
3-5.6. Fuel Truck Controller Installation Assembly................................................................. 38
3-6. INSTALLATION OF FUEL TRUCK CONTROLLER WITH WALL MOUNT KIT ..... 39
3-6.1. Installation Procedures ................................................................................................... 39
3-7. WIRING ............................................................................................................................. 39
3-7.1. General ........................................................................................................................... 39
3-7.2. Wiring Requirement ....................................................................................................... 40
3-7.3. Wiring Procedures.......................................................................................................... 40
3-7.4. General ........................................................................................................................... 40
3-7.5. Mechanical Pump – Terminal Block - Pin-Out Connections......................................... 40
3-8. PUMP - REQUIRED CONNECTIONS ............................................................................. 44
3-9. WIRING THE PERIPHERALS ......................................................................................... 45
3-9.1. Valve Wiring .................................................................................................................. 45
3-9.2. Pulser Wiring ................................................................................................................. 46
3-9.2.1. Electronic Pulser ....................................................................................................... 46
3-9.2.2. Mechanical Pulser ..................................................................................................... 47
3-9.3. In-Use Switch ................................................................................................................. 47
3-9.4. Nozzle Installation ......................................................................................................... 48
3-10. ONGOING TRANSACTION INDICATION .................................................................... 48
3-11. POST-INSTALLATION CHECKLIST ............................................................................. 48
3-12. FUEL TRUCK CONTROLLER SETUP ........................................................................... 48
MDE-4814D Fuel Truck Controller Installation Manual · February 2018 iii

TABLE OF CONTENTS
Paragraph Page
SECTION 4 MAINTENANCE
4-1. GENERAL .......................................................................................................................... 49
4-2. TROUBLESHOOTING ...................................................................................................... 49
4-2.1. Fuel Truck Controller Troubleshooting ......................................................................... 49
4-2.2. Communication Troubleshooting................................................................................... 54
4-3. CLEANING ........................................................................................................................ 56
SECTION 5 GLOSSARY
5-1. FUELOMAT GLOSSARY ................................................................................................. 57
5-2. COMMUNICATION GLOSSARY.................................................................................... 58
APPENDIX A WIRING DIAGRAM…………………………………………………....59
APPENDIX B SITE SURVEY FORM – EXAMPLE………………………………….60
iv MDE-4814D Fuel Truck Controller Installation Manual · February 2018

LIST OF ILLUSTRATIONS
Figure Page
Figure 1-1. Fuel Truck Controller - General View with Shock Absorber Assembly.......................... 7
Figure 1-2. Fuel Truck Controller on a Fuel Truck - General Configuration Diagram ...................... 9
Figure 1-3. Internal Configuration Diagram – Mechanical Pump..................................................... 12
Figure 1-4. Fuel Truck Controller Internal Components Location ................................................... 13
Figure 1-5. Wireless Gateway Terminal (WGT) ............................................................................... 14
Figure 1-6. Tag Reader (OrTR) ......................................................................................................... 16
Figure 1-7. Fuel Truck Controller with OrTR ................................................................................... 16
Figure 1-8. Fuel Truck Controller with OrTR and WGT ................................................................. 17
Figure 1-9. Fuel Truck Controller - General View with Shock Absorber Assembly........................ 19
Figure 1-10. Shock Absorber - Detail ............................................................................................... 19
Figure 2-1. Fuel Truck Controller Wiring Openings ......................................................................... 26
Figure 2-2. Power Supply – Block Diagram ..................................................................................... 29
Figure 2-3. Cables Shielding ............................................................................................................ 30
Figure 2-4. Fuel Truck Controller Terminal Block, Power and LAN Connections .......................... 31
Figure 3-1. Fuel Truck Controller with Mechanical Pumps – System Diagram ............................... 33
Figure 3-2. Shock Absorber Assembly – Installation Holes ............................................................. 37
Figure 3-3. Fuel Truck Controller with Shock Absorber Assembly – Installation Holes ................. 38
Figure 3-4. Installing Fuel Truck Controller on Shock Absorber Brackets – Installation Holes ...... 38
Figure 3-5. Terminal Lug ................................................................................................................. 40
Figure 3-6. Terminal Block .............................................................................................................. 42
Figure 3-7. Terminal Block – Mechanical Pump - Wiring List Label .............................................. 42
Figure 3-8. Terminal Block – Mechanical Pump - Wiring List Label Installed ............................... 43
Figure 3-9. Fuel Truck Controller Mechanical Pump - Terminal Block Detailed Connections ....... 45
Figure 3-10. Terminal Block and 3-Wire Pulser – Wiring Connections ........................................... 46
Figure 3-11. Terminal Block and 2-Wire Pulser – Wiring Connections ........................................... 47
Figure 3-12. In-Use Switch ............................................................................................................... 47
Figure 3-13. Terminal Block – Barrier Inside Pump Wiring Link (Axial Barrier) ........................... 48
MDE-4814D Fuel Truck Controller Installation Manual · February 2018 v

LIST OF TABLES
Table Page
Table 1-1. Fuel Truck Controller- Standard Models ........................................................................ 17

Table 2-1. Conduits into Fuel Truck Controller ............................................................................... 27
Table 2-2. Fuel Truck Controller, Cables Type................................................................................ 28
Table 2-3. Fuel Truck Controller, Cables Routing ........................................................................... 28
Table 2-4. Nozzles to Fuel Truck Controller, Cables Routing ......................................................... 28
Table 3-1. Fuel Truck Controller, Installation Assembly Parts ........................................................ 35
Table 4-1. Fuel Truck Controller Troubleshooting ........................................................................... 50

Table 4-2. Communication Troubleshooting..................................................................................... 55
vi MDE-4814D Fuel Truck Controller Installation Manual · February 2018

i
SECTION 1
GENERAL DESCRIPTION
1-1. SCOPE
This manual provides assistance for installing Gasboy’s Fuel Truck Controller. The system must be
installed as described in this manual to ensure the system reliability and proper operation. This
manual includes a general and functional description of the Fuel Truck Controller and its main
components. It also provides the installation procedures for the Fuel Truck Controller.
This manual is intended for qualified authorized installers of the Fuel Truck Controller and its
components.
1-2. DESCRIPTION
Fuel Truck Controller is a fuel control and data acquisition system. Fuel Truck Controller system is
a self-contained weather-resistant cabinet installed on fuel trucks used as mobile refueling stations.
Fuel Truck Controller (see Figure 1-1) is a core component in Gasboy’s solution for mobile
refueling stations. Fuel Truck Controller provides the central function of the mobile site controller.
It also fulfills other essential services on site such as Vehicle/Driver Identification System,
Transaction data storage, devices control and more.
Figure 1-1. Fuel Truck Controller - General View with Shock Absorber Assembly
MDE-4814D Fuel Truck Controller Installation Manual · February 2018 7

1-3. SYSTEM OVERVIEW
1-3.1. Fuel Truck Controller System

Fuel Truck Controller system is a mobile Fleet Management System. The system controls,
monitors, and stores on-the-spot refueling data by tanker truck for customers with large land
moving equipment. The system is suitable for a large range of home base customers.
The system consists of a Controller mounted on the truck and Vehicle Identification Units (VIU)
installed on the fleet vehicles.
Fuel Truck Controller enables refueling of vehicles equipped with VIUs only. The vehicles fuel
inlet must be positioned in the proximity of the fuel pump nozzle, ensuring end-to-end
authentication of the vehicle, meaning that only authorized vehicles get fuel. After providing fuel,
the system registers the transaction data (see Figure 1-2).
The heart of the mobile solution is the Orpak Controller Unit (OrCU) operating with the SiteOmat
automation software. SiteOmat runs on an embedded operating system. OrCU is a hardware
platform designed to survive the harsh gas station environment. It uses a solid-state flash disk and
Real Time Clock (RTC) with backup, along with surge suppressors for transients and noise
immunity. The system also includes power fail recovery mechanisms.
1-3.2. Vehicle Identification

Vehicle Identification is an essential feature for maximal control and savings on fuel expenditure.
The dispenser is authorized to refuel after a positive identification of the vehicle and only while the
nozzle is inside the fuel inlet of the identified vehicle. All transaction information is automatically
recorded. A combined vehicle and driver identification is also possible for tight tracking.
1-3.3. Remote Web Access

Remote Web-based capabilities for monitoring, management, and maintenance are available. A
standard PC with Internet Browser (Explorer) is used for remote management of Fuel Truck
Controller. There is no need for special purpose management software thanks to the built-in Web
server technology integrated into Fuel Truck Controller.
1-3.4. Fleet Head Office

Centralized management is provided by the optional Fleet Head Office server. The Fleet Head
Office consolidates the data from multiple sites and generates reports, including exception reports.
It also enables control of the limits and restrictions placed on the various fleet vehicles.
Furthermore, authorized fleet personnel are able to log in remotely and are always in control.
1-3.5. Restrictions and Limits

Control of a fleet’s fuel consumption can be maximized by defining limits. Optional limits include:
volume per day/week/month, and fuel type. In case of communication failure, the specific site will
be able to refuel for a predefined grace period (parameter) using the most recent limits stored in its
database.
8 MDE-4814D Fuel Truck Controller Installation Manual · February 2018

1-3.6. Fuel Truck Controller Capabilities for Mobile Station Management
The Fuel Truck Controller provides features for a comprehensive mobile refueling station
management by enabling a large variety of communication links: Cellular, dial-in modem,
Wi-Fi, radio modem, and satellite.
Figure 1-2. Fuel Truck Controller on a Fuel Truck - General Configuration Diagram

1-3.7. System Workflow - Example
An example of an operational workflow for self-service at the Fuel Truck Controller site is provided
below:
The Fuel Truck Controller equipped fuel truck arrives at the construction site to refuel its fleet
vehicles. All fleet vehicles equipped with FuelPoint PLUS devices. The operator inserts the nozzle
into a vehicle fuel inlet and waits for authorization. Truck data is automatically read and stored in
the Controller for authentication and authorization. Upon approval, the fueling transaction starts, at
the end of which the transaction data is kept internally until transferred to the Head Office (HO) for
future billing.
1-4. FUEL TRUCK CONTROLLER STRUCTURE
1-4.1. Main Components

The following is a short description of the Fuel Truck Controller main sub units:
OrCU
OrCU is a complete controller with its own embedded
operating system. The unit consists of an embedded hardware
platform with a solid-state flash hard disk, RTC with backup,
along with surge suppressors for transient and noise
immunity.
It features two separate and isolated networks (TCP/IP over
Ethernet). One network links the Fuel Truck Controller system
components. The second network is intended for external
remote communication (Head Office, third party systems).
This network is protected by SSL security.
OrCU includes a built-in server for Web access through an internet browser (Windows® Explorer).
8-Port CommVerter
The 8-Port CommVerter is the communication interface
to the peripheral pumps. It consists of communication
modules for the mechanical pump elements. The
CommVerter includes one MPI-C card and sub card for
interface to two mechanical pumps, an Ethernet®
Switch.
The CommVerter communicates with the Site
Controller (OrCU) via a LAN (Ethernet) link.

Optional Mobile Printer
Fuel Truck Controller includes an optional Mobile Printer. Installed in
the driver's cabin and directly connected to the Controller Unit viva
RS-232 link, this compact device prints out all fueling transactions.
The Mobile Printer includes two LED indicators on the front panel:
• Green: Power ON
• Red: Out of paper

1-4.2. Fuel Truck Controller General Configuration
Figure 1-3 shows a general configuration diagram of Fuel Truck Controller.
Figure 1-3. Internal Configuration Diagram – Mechanical Pump

1-4.3. Fuel Truck Controller Main Components Location
Figure 1-4 shows the location of the main components of Fuel Truck Controller.
Figure 1-4. Fuel Truck Controller Internal Components Location

1-5. AVAILABLE CONFIGURATIONS
1-5.1. General
The Fuel Truck Controller is available in several configurations in accordance with its intended use
and with the components installed. All configurations are manufactured in accordance with specific
customer request.
The following paragraphs describe the several configurations and their components.
1-5.2. Vehicle Identification System – FuelPoint PLUS

The following options are available for vehicle identification:
• Wireless Gateway Terminal: (WGT) – with this terminal, the vehicle identification process
is performed in a wireless mode.
• No vehicle identification unit: The vehicle identification process will be done manually by
the truck driver with any accepted authorization devices such as cards, or tags. This option
will require an external tag reader connected to Fuel Truck Controller (refer to paragraph
1-5.6).
1-5.3. WGT External Box – Optional

The WGT receives and decrypts DataPass, FuelOpass, and VIU signals and transmits their
information to the station automation system (OrCU) in a secure manner over an RF signal. This
setup enables the RF signal to travel through various routes and bypass possible interferences (such
as a big truck/bus). The transmission signal range is 10 meters.
The WGT is designed to be installed in a designated external box on the truck on the side facing the
fueling elements. The WGT will be connected to the Fuel Truck Controller box using CAT-5E
cable. More than one WGT external boxes can be mounted on one truck for better RF area coverage.
In this case one WGT box will be Master and the other(s) will be routers. For more information,
refer to, MDE-4815 WGT External Installation Guide.
Figure 1-5. Wireless Gateway Terminal (WGT)

The units that provide data to the WGT are:
• DataPass - DataPass is a miniature unit that connects to the vehicle bus and captures data
from the vehicle CPU/BUS. It then transmits this data to the nearest WGT in the forecourt.
• FuelOpass - FuelOpass is a passive vehicle identification tag for refueling. Its encrypted data
includes the account to be charged and is read by the Nozzle Reader device using RFID
contactless technology.
• VIU - VIU is an active Vehicle Identification Unit for refueling. The data includes odometer
and engine hour meter.
• Nozzle Reader (NR) - Nozzle Reader is a self-contained unit installed on the nozzle which
reads the FuelOpass data using contactless technology.
To obtain maximal grid availability, several WGT units can be installed to create a robust ‘mesh’
network.
1-5.4. Modem/Router
Consult your local cellular service provider for the type of router supported in your area. The router
will be provided from your service provider with proper installation instructions. The router will be
connected to the LAN input in OrCU box.
1-5.5. External TAG Reader (OrTR)

OrTR (PA04020201) - OrTR (Orpak Tag Reader) receives Orpak tag signals for refuel authorization
purpose. OrTR transmits the information to the Station automation system (OrCU) over a CAT-5E
or RS-485 cable. OrTR contains LCD with 2 lines display. OrTR is designed to be installed in a
non-hazardous, convenient, and secured area in accordance with local state regulations.
In the vehicle, two installation alternatives are available:
• External box in any non-hazardous area. This installation mode requires a dedicated
mounting bracket. Such an installation shall be performed within safety distances required
for any installation adjacent to dispensers.
• Installation beneath Fuel Truck Controller box with mounting bracket (M09680B119).

• For more information, refer to MDE - 4816 OrTR Installation Guide.
Figure 1-6. Tag Reader (OrTR)
Figure 1-7. Fuel Truck Controller with OrTR

1-5.6. Fuel Truck Controller with OrTR and WGT
In this configuration (see Figure 1-8), the Fuel Truck Controller encompasses most types of
authorization devices. The WGT provides vehicle identification process in wireless mode while
Orpak Tag Reader (OrTR) reads Orpak tag signals to complete any transaction.
WGT communicates with Fuel Truck Controller over the LAN (CAT-5E cable) and is powered
directly by Fuel Truck Controller. RF transmission of data from WGT enables sending data of all
transactions to the Station controller.
Figure 1-8. Fuel Truck Controller with OrTR and WGT
1-5.7. Fuel Truck Controller - Standard Models
Table 1-1 define all the available product numbers for the different configurations of Fuel Truck
Controller:
Table 1-1. Fuel Truck Controller - Standard Models

Name Gilbarco P/N Orpak P/N
Fuel Truck Control Unit for 2 hose PA039600200 800938901
Fuel Truck Control Unit for 4 hose PA039600400 800938902

1-6. SECURITY AND PROTECTION
1-6.1. General
The transaction activities of the Fuel Truck Controller are secured and protected for transmission
and authorization activities.
1-6.2. Authorization Security

The contactless tags include Triple Data Encryption Standard (DES) encrypted data for user
identification and billing. Consequently, the Fuel Truck Controller includes a special Security
Application Module (SAM) for decryption and matching identification. Upon tag reading, the Fuel
Truck Controller attempts to decrypt the string from the tag. The Fuel Truck Controller disregards
Tags whose security scheme does not match the Fuel Truck Controller internal SAM.
1-6.3. Network Security

The Ethernet LAN is isolated from the external WAN by the Site Controller (OrCU). In case of
remote maintenance, a firewall should be applied either at the router level or preferably at the Home
Base Station level.
1-6.4. RF Network Security

The Fuel Truck Controller EIA 802.15.4 RF network is encrypted, using the AES 128 security
standard.
1-6.5. Maintenance Security

The Fuel Truck Controller maintenance and setup procedures require inserting a user name and
password for access. For further information, refer to the MDE-4817 SiteOmat Station Controller
Setup Manual.
Fuel Truck Controller is locked by key to prevent unauthorized access to the bypass switches and
controller electronics.
1-6.6. RTC Backup

The Real Time Clock backup is based on a maintenance free 1 Farad supercapacitor. Backup time is
3 to 6 days before time and date loss.
1-7. HOUSING
Fuel Truck Controller enclosure is a weather-proof metal cabinet able to sustain the harsh
environment of the Island. The Fuel Truck Controller is installed with a rear shock absorber
assembly that dampens vibrations from truck and road (see Figure 1-9).
The overall structure is installed vertically on any flat surface and secured with eight screws
(see Figure 1-10).
Fuel Truck Controller is locked by key for safety and security. The key should be kept in a
well kept, secure, and safe place.

We recommend installing the Fuel Truck Controller box in the truck cabin or any other protected
compartment on the truck. Any installation should provide convenient access for service and
maintenance.
Figure 1-9. Fuel Truck Controller - General View with Shock Absorber Assembly
Figure 1-10. Shock Absorber - Detail

1-8. SPECIFICATIONS
The following physical, electrical, and environmental specifications are applicable to the
Fuel Truck Controller:
Supply Voltage: 12 – 24 VDC
Power Consumption: 2.5 A max.
Operating Temperature: -22 F to +104 F (-30 C to +40 C)
Storage Temperature: -22 F to +104 F (-30 C to +40 C)
Humidity: 80% Non-condensing
Dimensions:
- Box without Shock Absorber W x H x D: 15 x 11.80 x 6.10”
Assembly: (380 x 300 x 155 mm)
- Box with Shock Absorber W x H x D: 16.50 x 18.10 x 7.90”
Assembly: (420 x 460 x 200 mm)
Communication Interface: RS-485 – 9600 bps, Half-Duplex

RS-232
Ethernet RJ-45 - 10 Mbps
Valve Control Maximum Current 12 V/2 A, 24 V/1 A
(4 Solid State Relay Channels):
Pulser Power Supply Voltage 12 VDC/30 mA max
Pulser Input High level Voltage 9 to 15 VDC

Pulser Input High level sink 3 mA
current (@15 V)
In use “ON” level (Input) Dry contact only (5 V/1 mA maximum)
1-9. STANDARDS
1-9.1. Communication Standards

The Fuel Truck Controller communicates, in different models, over the following
standards:
• RS-485 link
• TCP/IP over Ethernet
• EIA 802.15.4
1-9.2. Security Standards

• Triple DES encryption for Payment Devices (Contactless tags, magnetic stripe cards, etc.)

1-10. MANUAL STRUCTURE
This manual comprises of the following sections:
Section 1: General Description
This section provides a general description of the Fuel Truck Controller system.
Section 2: Preliminary Installation Procedures
This section provides the preliminary installation requirements and procedures to be performed
before installing Fuel Truck Controller.
Section 3: Installation Procedures
This section provides a detailed description of Fuel Truck Controller installation requirements and
procedures.
Section 4: Maintenance
This section provides basic maintenance instructions for the Fuel Truck Controller.
Section 5: Glossary
This section includes a glossary of terms used for the Fuel Truck Controller description.
Appendix A: Wiring Diagram
This appendix includes the Wiring Diagram of the Fuel Truck Controller.
Appendix B - Site Survey Form – Example
This appendix includes an example of a form to be filled during a Site Survey. You may add or
remove parts of the questionnaire in order to fit your customer working environment.

1-11. USING THIS MANUAL
This manual includes alerting comments inserted along the document in order to draw the reader’s
attention to important issues. The comments are accompanied by symbols for ease of reference.
The following comment types are used:
WARNING
An operating procedure, practice, etc., if not
correctly followed, could result in injury or loss of
life.
CAUTION
An operating procedure, practice, etc, if not strictly
observed, could result in damage to, or destruction
of equipment.
TIP
This note is aimed for using the system in a better,
more efficient way.
NOTE
This comment is of importance for emphasizing.
INSIGHT
More detailed technical/functional information
regarding a relevant issue.

1-12. REFERENCES
For additional and related information regarding the Fuel Truck Controller system, refer to the
following manuals:
• MDE-4812 8-Port CommVerter User’s Manual

• MDE-4815 Fuel Point PLUS Installation
• MDE-4816 OrTR Installation Guide
• MDE-4817 SiteOmat Station Controller Setup and Maintenance Manual
• MDE-4818 SiteOmat Station Controller Setup Manual

SECTION 2
PRELIMINARY INSTALLATION INSTRUCTIONS
2-1. GENERAL
This section provides the preliminary installation procedures for Fuel Truck Controller. These
instructions shall be performed in order to ready the fueling truck to the installation of Fuel Truck
Controller.
These procedures include:
• Preliminary installation instructions
• Wiring and Wire Conduits requirements
2-2. PRELIMINARY INSTALLATION INSTRUCTIONS
2-2.1. General
NOTE
Perform a truck survey prior to installation.
Refer to Appendix B “Site Survey Form.”
Installation procedures and requirements depend, to some extent, on the specific fuel dispenser
models and the fuel truck layout. Therefore, use the information in this section to develop
installation plans for each specific installation. Since installation requirements vary widely from
case to case, no installation hardware is supplied by the equipment manufacturer and installation
planners must develop their own requirements.
The customer should provide an installation plan designed by an authorized engineer and
applicable to all authorities. This plan design should reflect the existing electric infrastructure of
the site.

2-2.2. Precautions and Safety Notes
Prior to actual installation activities, carefully observe the precautions and safety notes below.
WARNING
Before installing or servicing equipment, carefully
observe the warnings and precautions provided at
the beginning of this manual.
 Remember that the fuel truck environment is highly flammable and combustible.
Therefore, make sure that actual installation is performed by experienced personnel
licensed to perform work in fuel trucks and capable of implementing all applicable
requirements of the National Fire Protection Association NFPA-30 “Flammable and
Combustible Liquids Code”, NFPA-30A “Code for Motor Fuel Dispensing Facilities and
Repair Garages”, NFPA-70®A “National Electric Code (NEC®)”, federal, state, and local
codes and any other applicable safety codes and regulations.
 System power may come from more than one source. Disconnect all power sources before
attempting to work on the system.
 Install the Fuel Truck Controller only in non-hazardous locations, in accordance with the
safety restrictions.
 Fuel Truck Controller site preparation is in the customer’s responsibility.
 Do not connect power to the Fuel Truck Controller until complete installation is inspected
and certified.
 Do not perform any metal work in the hazardous area. Sparks generated by drilling,
tapping, and metal work operations could ignite fuel vapors and flammable liquids,
resulting in death, serious personal injury, property loss, and damage to you and other
persons.
2-3. CONDUITS INSTALLATION
2-3.1. General
The installation of the Fuel Truck Controller requires setting several conduits in the fuel truck. The
conduits are required for the routing and protection of the different types of cables.
The installation of the Fuel Truck Controller requires preparing the conduits and cable layout in
the fuel truck beforehead. This procedure consists of:
• Installing conduits within the truck
• Inserting the proper cables
• Connecting to power
2-3.2. Conduit Requirements

Conduits must comply with the following requirements:
• Conduits should be installed in accordance with local regulations.
• It is recommended to use metal conduits (preferably Vx metal) to provide the necessary
shielding and protection.
• Conduits should be inserted in the Fuel Truck Controller through openings provided in the
bottom plate (see Figure 2-1). Connect the wiring through optional glands or appropriate metal
tubing. For UL/cUL listing, this product has only been evaluated for use without the optional
glands.
(*) All glands in picture are optional.

Figure 2-1. Fuel Truck Controller Wiring Openings
2-3.3. Type of Conduits in the Truck

The types of conduits in the truck are a function of the different equipment and their location in the
truck. The following conduits are required in the Fuel truck:
• Voltage conduits
o DC power for Fuel Truck Controller
o Pump control from pumps to Fuel Truck Controller
o Pump In-use signal from pumps to Fuel Truck Controller
• Communication conduits
o Pulser from pumps to Fuel Truck Controller
o Barriers/Coils from pumps to Fuel Truck Controller – Non-Intrinsically
Safe wiring (NIS). Barriers may be enclosed in a special, separate Barriers
Box.
• Power conduit
o Fuel Truck Controller is fed from the truck power system after the ignition
switch. Conduits of power cable should be done in accordance with local practice.
NOTE
Barriers Box is not provided with Fuel Truck
Controller.

2-3.4. Wiring Openings in Fuel Truck Controller
Fuel Truck Controller includes several wiring openings to carry specific wires, as listed in
Table 2-1 and shown in Figure 2-1.
Table 2-1. Conduits into Fuel Truck Controller
No. Conduit Type Type

1 Low voltage Pulser, Barrier
2 Voltage DC power
3 Voltage Control, In-use
2-3.5. Conduits Installation Procedures

Proceed as follows:
1. Determine the location of the Fuel Truck Controller in the fuel truck.
2. Install a Junction Box (J-box) close to the valve for valve control.
3. Install a J-box for the pulser and nozzle antenna.
4. Deploy two conduits from the J-boxes to the Fuel Truck Controller (pulser, valve and
nozzle antenna).
5. Deploy a conduit from truck power system to Fuel Truck Controller. Fuel Truck
Controller is fed from the truck power system, after the ignition switch.
2-4. CABLES
2-4.1. General
This paragraph describes the requirements and procedures for the insertion of cables in the conduits.
NOTE
The type of required cable varies in accordance with
the device it connects. The wire used must be
stranded and not a solid core. Select a cable
specification in accordance with local environment
conditions.
CAUTION
For supply connections, use wires suitable for at
least 90°C.
Signal wiring connected in this box must be rated at
least 300 V.

2-4.2. Cable Types
Table 2-2 lists the types of cables used for the wiring of the Fuel Truck Controller system.
Table 2-2. Fuel Truck Controller, Cables Type
No. Function Type

1 Power supply and valve control As used in vehicles 1.5 – 2.5 mm² (15 to 13 AWG)
2 Coil (Barrier) Data communication cable, 300 V RMS, 90 ºC,

shielded twisted pair, oil resistant, 24 AWG, low
3 Pulser and In-use signal
capacitance below 60 PF/meter similar to Belden
9729 cable
4 LAN CAT-5E, Shielded, 300 V RMS, 90 ºC
similar to Belden 121700A
5 GND Ground cable 0.4” (10.8 mm2)
Connections should be done through a J-box (4x4x4” (10x10x10 cm)) located near
peripherals.
2-4.3. Cables Routing

Route the cables from peripherals to Fuel Truck Controller as listed in Table 2-3 and Table 2-4.
Proceed as follows:
Table 2-3. Fuel Truck Controller, Cables Routing
No. Functional From To Cable Type
Description (*)
1 DC Power DC to DC voltage Fuel Truck Controller box 1
converter terminal block
2 LAN Low voltage J-box 4
3 Pulser Fuel Truck Meter register, Pulser 3
Controller box
4 Valve control Valve Fuel Truck Controller box 1
terminal block
Route cables from the nozzles to Fuel Truck Controller through a Barriers box. Proceed as follows:
Table 2-4. Nozzles to Fuel Truck Controller, Cables Routing
No. Functional From To Cable Type
Description (*)
1 Nozzle antenna J-box Barriers box 2
2 Barriers Barriers box Fuel Truck Controller terminal block 2
(*) Refer to Table 2-2.

2-5. Electrical System
2-5.1. External Fuse

The Fuel Truck Controller requires an external fuse. Additional vehicle type 6 Amp fuse should
be installed between the truck’s power supply system and the Fuel Truck Controller.
SAFETY CAUTION
The fuse should link the wire very close to the battery
and at the distribution point (via a distribution block).
2-5.2. Fuel Truck Controller Power System

The truck’s power supply system is connected to the terminal block in the Fuel Truck Controller.
The system uses a Line Filter between the terminal block and the main switch in order to attenuate
conducted interference. The Line Filter is coupled with Timer relay; this timer provides 30
seconds delay between power-feed and power output. This delay protects against short bursts of
power when the driver starts the truck. The delay is reset at each starting attempt. Consequently,
Fuel Truck Controller is turned on 30 seconds after the truck is powered, which is when the motor
should be operating steadily.
Fuel Truck Controller does not include a power switch.
Figure 2-2. Power Supply – Block Diagram

2-6. GROUNDING AND SHIELDING
Proper system grounding is an extremely important part of the system installation. As with the DC
power, the grounds for all system components should return to the same circuit breaker panel. This
helps you assure a common ground throughout the system and is necessary for protection of the
RS-485 data loop circuitry.
The Fuel Truck Controller box is shielded through its installation screws to the vehicle chassis.
Fuel Truck Controller includes several grounding studs in order to comply with requirements. The
DC power ground wire should be attached to the stud close to the Line Filter.
Each shielded cable connected to the Fuel Truck Controller is stripped of its shielding at the box
entry. Its shield wires are bundled together at the entrance of the box and attached to a shielding
stud within the Fuel Truck Controller box. Figure 2-3 shows a functional diagram of the shielding.
Figure 2-3. Cables Shielding

2-7. CONNECTIONS TO FUEL TRUCK CONTROLLER
Most connections to the Fuel Truck Controller are performed to the Terminal Block located at the
bottom of the box (see Figure 2-4). The required connections are:
1. Pump wiring connections:
• Pulser
• Valve
• In use (Optional, not existing in most cases)
2. Communications:
• RS-485 for peripheral device
3. Power:
• DC Power to Line Filter
4. Other connections, not to the Terminal Block:
• LAN connection
(*) All glands in picture are optional

Figure 2-4. Fuel Truck Controller Terminal Block, Power and LAN Connections

SECTION 3
INSTALLATION PROCEDURES
3-1. GENERAL
This section provides the installation procedures for the Fuel Truck Controller.
These procedures include:
• Fuel Truck Controller installation
• Wiring
• Post installation check
3-2. INSTALLATION SPECIFICATIONS
3-2.1. General
NOTE
Perform a site survey of the fuel truck prior to
installation.
Installation procedures and requirements depend, to some extent, on the specific fuel truck and its
mechanical and electrical layout. Therefore, use the information in this section to develop an
installation plan for each specific installation. Since installation requirements vary widely from
case to case, no installation hardware is supplied by the equipment manufacturer and installation
planners must develop their own requirements.
The customer should provide an installation plan, designed by an authorized engineer. This plan
design should reflect the existing electric infrastructure of the fuel truck.
3-2.2. Precautions and Safety Notes

Prior to actual installation activities, carefully observe the precautions and safety notes detailed in
paragraph 3-2.2 and at the opening pages.

3-3. FUEL TRUCK - OVERVIEW
3-3.1. General
Prior to installation, you are required to obtain an overview of the fuel truck functional architecture.
This overview is required in order to draw an architecture diagram with all components and their
communication links.
Figure 3-1 shows a functional diagram of the links within the fuel truck with mechanical pump.
Figure 3-1. Fuel Truck Controller with Mechanical Pumps – System Diagram

3-4. MAPPING THE TRUCK
3-4.1. General
The mapping of the fuel truck is required prior to installation. This procedure consists of the
following steps:
3-4.2. Locating all objects of the fuel truck

• Locate installation of related objects in the fuel truck
• Locate the intended position of the Fuel Truck Controller
• Draw a basic map of the site with all the objects
3-4.3. Assigning Logical IDs

Logical IDs should be assigned to the Pump and Nozzle:
• Assign an id. to the pump (P)
• Assign an id. to its nozzle (N)

3-5. INSTALLING THE FUEL TRUCK CONTROLLER
The Fuel Truck Controller can be installed in two configurations:
a. Installation of Fuel Truck Controller only
This type of configuration is designed for installing the Fuel Truck Controller in
locations, such as inside truck cabins, that are not exposed to the harsh environment
and thus do not require shock absorbers.
b. Installation of Fuel Truck Controller with Shock Absorber Assembly
This type of configuration is designed for the installation of the Fuel Truck
Controller in vehicles (not in driver’s cabins) in areas of the vehicle that are exposed
to the harsh environment which need shock absorbers.
For installation of the Fuel Truck Controller with Shock Absorber Assembly, the
client must order the Shock Absorber Assembly (M09680B039) in addition to
ordering the Fuel Truck Controller (PA039600200).
3-5.1. Installation Assembly Parts

Table 3-1 lists the assembly parts for the installation of the Fuel Truck Controller.
Table 3-1. Fuel Truck Controller, Installation Assembly Parts
Item No. Part Number Description Qty

1 800938901 Fuel Truck Controller 1
(PA039699200)
2 819040120 Shock Absorber Assembly 1
(M09680B039)
3 815216200 Pan head screw, M6 x16 8
4. 815322200 Flat Washer, M6 8
5 815303100 Spring Washer, M6 8
6 815222000 M8 x 20 mm Hex bolt (*) 4
7 815305500 Washer, Flat, M8 4
8 815122000 Nut, M8 4
9 814605600 Shock absorber 4
(M09680B035)
10 814979800 Plate, shock absorbers 4
(*) Optional, for installing the Fuel Truck Controller to the Shock Absorber assembly.

3-5.2. Preliminary Procedures
For installation of Fuel Truck Controller only, the following procedures should be performed in
this order:
• Installing the Fuel Truck Controller on the support rails in driver’s cabin
• Running cables through the conduits to Fuel Truck Controller
• Wiring Fuel Truck Controller
For installation of Fuel Truck Controller with the Shock Absorber Assembly, the following
procedures should be performed in this order:
• Installing Shock Absorbers Assembly on support flanges in the selected area on the
truck
• Installing the Fuel Truck Controller on Shock Absorbers Assembly
• Running cables through the conduits to Fuel Truck Controller
• Wiring Fuel Truck Controller
3-5.3. Fuel Truck Controller Installation in Driver' s Cabin

To install the Fuel Truck Controller in the driver's cabin, proceed as follows:
a. Look for the support rail at the back of the driver's cabin in the fuel truck. There are usually
two perpendicular rails.
b. Select the rail where installation is easier (less cluttered area).
c. Prepare beforehand two support flanges with two setting holes in each.
d. Connect the Fuel Truck Controller through the internal four holes or through the wall mount
bracket to the support flanges.
e. Use dedicated drill screws for the installation to the support rails.
After the Fuel Truck Controller installation is completed, proceed with unit wiring according to
the instructions provided in paragraph 3-7 on page 39.
3-5.4. Determining the Spot Installation Fuel Truck Controller with Shock Absorber
Assembly
Proceed as follows:
1. Look for a support rail at the selected installation location in the fuel truck.
2. Select the rail where installation is easier (less cluttered area).
3. Prepare beforehand two support flanges with two setting holes in each.
4. Drill eight M6 Hex threads in the support flanges of the Shock Absorbers plate. See
location and dimensions in Figure 3-2 and Figure 3-3 (10 in Table 3-1).
5. Drill four Hex threads in the rails for the support flanges.
6. Install the support flanges and secure with bolts, spring washers, and flat washers.

3-5.5. Shock Absorbers Assembly - Installation Procedures
The Shock Absorbers Assembly should be mounted on any flat surface on the truck. The rear
wall of the shock absorber assembly includes eight holding holes for support screws.
Proceed as follows:
1. Locate the eight installation holes on the mounting flanges (see Figure 3-2 and Figure 3-3).
2. Check that eight M6 Hex threads in the installation flange have been drilled.
3. Set Shock Absorbers assembly (2 in Table 3-1) on the spot (see Figure 3-2) so that its installation
holes fit with the threads.
4. Secure Shock Absorbers assembly with eight M6 Pan head bolts, M6 flat washers, and M6
spring washers (3, 4, 5 in Table 3-1).
Figure 3-2. Shock Absorber Assembly – Installation Holes

Figure 3-3. Fuel Truck Controller with Shock Absorber Assembly – Installation Holes
3-5.6. Fuel Truck Controller Installation Assembly

Fuel Truck Controller box is secured to Shock Absorber Assembly from within Fuel Truck
Controller (see Figure 3-4).
Figure 3-4. Installing Fuel Truck Controller on Shock Absorber Brackets – Installation Holes

Proceed as follows:
1. Install Fuel Truck Controller box on assembly on Shock Absorbers Assembly so that the
shock absorbers fit into place.
2. Open Fuel Truck Controller box.
3. Secure Fuel Truck Controller box to Shock Absorbers Assembly with four M8 Hex bolts,
four M8 flat washers, and four Nuts (6, 7, 8 in Table 3-1).
4. Perform Fuel Truck Controller wiring (refer to paragraph 3-7).
5. Lock Fuel Truck Controller box door with key.
3-6. INSTALLATION OF FUEL TRUCK CONTROLLER WITH WALL MOUNT KIT
3-6.1. Installation Procedures

Proceed as follows:
Note: If the wall mount is already installed, go to step 4.
1. Open Fuel Truck Controller enclosure.
2. Turn Fuel Truck Controller enclosure; you face its rear panel.
3. Attach to each support hole in the rear panel a wall bracket, with nut, M8 x 20 screw, and
flat washer. Set the bracket so that they fit to the proper installation.
4. Set the Fuel Truck Controller enclosure (with wall brackets) in the spot and mark the four
holes location from brackets for drilling. Make sure you select place that will allow you to
open completely the Turn Fuel Truck Controller door.
3-7. WIRING
3-7.1. General
After completing the installation procedure, perform the wiring procedures. The wiring is
performed in the Fuel Truck Controller Terminal Block only.
The wires should be pulled from the conduits, or in the opposite direction, from the Terminal Block
to the devices in the fuel truck. Proceed as follows:
1. In accordance with the mapping, run cable conduits in accordance with the type of cables to
the spot:
• One conduit from the pump valve
• One conduit from the pulser
• One conduit from the nozzle
• One conduit from power
2. Run the cables along the conduits to the openings in the box. Connect the wiring through
optional glands or appropriate metal tubing. For UL/cUL listing, this product has only been
evaluated for use without the optional glands.
3. Insert all power and communication cables through the openings in the bottom panel.

3-7.2. Wiring Requirement
For any type of pump and wire, prior to inserting a wire, proceed as follows:
1. Insert all wires with a terminal lug only.
2. Use the proper Terminal Crimper to attach the lug to the wire.
3. For UL Listing, The Terminal Lug must be a UL recognized components.
Figure 3-5. Terminal Lug
TIP
Mark each cable at its both ends with a number or
sign that will identify its functionality in the future.
3-7.3. Wiring Procedures
3-7.4. General
The wiring for Fuel Truck Controller is provided in two modes:
• Table 3-3 lists the wiring in the sequential order of the terminals. This table provides the
signal name and a functional description of the signal.
• Figure 3-6 shows the wiring list for connection to the Terminal, as published in the Wiring
Label added to the inner door (see Figure 3-7). The Wiring Label follows the physical
location of the wires in the Terminal Block (see Figure 3-6).
3-7.5. Mechanical Pump – Terminal Block - Pin-Out Connections

The Fuel Truck Controller Terminal Block connections for a Mechanical Pump are listed in the
following table.
Table 3-2. Fuel Truck Controller Terminal Block - Mechanical Pump – Connections Definition
Terminal No. Signal Name Functional Description
1 BARRIER 1 (-) Connection to Safety Barrier for Nozzle 1 (1st wire)
5 BARRIER 1 (+) Connection to Safety Barrier for Nozzle 1 (2nd wire)

Terminal No. Signal Name Functional Description
9 TX-RS-232 Transmit (optional RS-232 connection)
10 GND-RS-232 RS-232 Ground (optional RS-232 connection)
11 RX-RS232 Receive (optional RS-232 connection)
12 RS-485 (+) (+) RS-485 (optional equipment interface)
13 RS-485 (-) (-) RS-485 (optional equipment interface)
14 RS-485 GND (Gnd) RS-485 (optional equipment interface)
15 PULSER 1 P Pulser Input – Nozzle 1
18 PULSER 4P Pulser Input – Nozzle 4
19 GND PULSER 1 Nozzle Grounding – Nozzle 1
23 +12 V 1 P +12 VDC Output to Pulser – Nozzle 1
27 IN USE 1 A Handle Up - In Use signal input - Nozzle 1
31 IN USE 1 B(-) Handle Up - In Use (dry contact) signal return - Nozzle 1
35 LOAD 1 Pump control output - Nozzle 1
39 LINE 1 Pump control 12/24 VDC Input - Nozzle 1
43 +12 VDC up to +24 VDC Input voltage
44 -12 VDC up to -24 VDC Input voltage
45 GROUND IN Main ground

Figure 3-6. Terminal Block
Figure 3-7. Terminal Block – Mechanical Pump - Wiring List Label

Figure 3-8. Terminal Block – Mechanical Pump - Wiring List Label Installed

3-8. PUMP - REQUIRED CONNECTIONS
This paragraph describes the required wiring connections between the mechanical pump and the
Fuel Truck Controller.
Pulse Wires: The pump outputs pulses to the system by means of the Pulser unit
installed inside the pump. The Pulse rate per volume (liter/gallon) is
determined by the Pulser unit. It is programmed as a “factor” by the
OrCU Controller.
In Use Wires: Some applications require a trigger signal to the OrCU controller. The
OrCU can operate with in-use signal to the MPI-C. This signal
indicates that a transaction is about to be made. Once the transaction
is initiated, the in-use switch must be turned off in order to end the
transaction.
Another option is not connecting the In Use wires. In that case, the
OrCU Controller will start a transaction as soon as the nozzle
antenna detects an authorization device.
Authorization Output The dispenser requires an authorization signal from the Fuel Truck
Wires: Controller to start a sale transaction. Without this authorization signal,
the electric valve (or pump) will not open and the sale transaction will
not begin. The Fuel Truck Controller sends the authorization signal in
the form of an DC power signal to the valve. When the dispenser
receives the authorization signal, fuel is flow.
NOTE
In cases where fuel truck meters are required, it is
highly recommended to use Liquid Controls (LC) or
Veeder-Root Meters.

3-9. WIRING THE PERIPHERALS
3-9.1. Valve Wiring

The MPI-C module in the Fuel Truck Controller activates the hose solenoid at the truck. Wire the
solenoid as follows (see Figure 3-12):
• Connect two wires to the solenoid and run them through the pump conduit to the J-box.
• From the J-box, run the cables through the low power entrance opening.
• Connect wires (LOAD, LINE) to the Fuel Truck Controller terminal block.
Figure 3-9. Fuel Truck Controller Mechanical Pump - Terminal Block Detailed Connections

3-9.2. Pulser Wiring
This paragraph describes the required wiring connections between the Pulser in the mechanical
pump and the Fuel Truck Controller. Two types of pulser can be found in trucks:
- Electronic pulser
- Mechanical pulser
Connect the Fuel Truck Controller to the Pulser in accordance to its characteristics.
NOTE
Pulser should be installed in accordance with the
pulser manufacturer’s instructions. Some pulsers do
not have a barrier. In that case, you must add a
pulser barrier. Barriers and nozzle rings are not
provided with Fuel Truck Controller
Barriers and nozzle rings must be installed on truck
as UL Listed by Report Retrofit kits prior to the
installation of the Fuel Truck Controller.
3-9.2.1. Electronic Pulser

• Three-Wire Pulser - requires an external power source in order to operate.
Figure 3-10 shows a schematic diagram of the connections between the Terminal Block and a
three-wire Pulser.
Figure 3-10. Terminal Block and 3-Wire Pulser – Wiring Connections

3-9.2.2. Mechanical Pulser
• Two-Wire Pulser, powered by the Fuel Truck Controller.
Figure 3-11 shows a schematic diagram of the connections between the Terminal Block and a
two-wire Pulser.
Figure 3-11. Terminal Block and 2-Wire Pulser – Wiring Connections
3-9.3. In-Use Switch

Some applications require a trigger signal to the controller. The OrCU can operate with in-use
signal to the MPI. This signal indicates that a transaction is about to be made. Once the transaction
is initiated, the in-use switch must be turned off in order to end the transaction.
Figure 3-12. In-Use Switch

3-9.4. Nozzle Installation
FuelPoint PLUS devices like FuelOpass or data pass are detected through nozzle readers.
Refer to the Nozzle Installation Manual.
3-10. ONGOING TRANSACTION INDICATION
We recommend connecting a warning lamp (e.g. flashing light) in parallel with the valve control to
indicate fueling in progress. This option enables the operator to see if the valve is authorized and
open for refueling.
3-11. POST-INSTALLATION CHECKLIST

After completing the installation procedure, inspect carefully the connection between the Fuel
Truck Controller and the external power mains and the data sources.
In particular, pay attention to the following issues:
• Correct wiring
o Is all the wiring inserted in metal conduits?
o Is the DC wiring inserted in a separate conduit?
o Is the system/peripheral equipment powered on a separate dedicated breaker?
o Is the wiring shielded properly?
o Are the cables correctly routed in the truck?
o Are the communication lines under the maximum allowable distance?
▪ RS-485: 330 feet (100m)
▪ Antenna wire:
• 330 feet (100m) for VIU
• 50 feet (15m) for FuelOpass
• Clean dirt and wire remnants
In case problems are detected after installation or during operation, repeat the post-installation
checks listed above.
3-12. FUEL TRUCK CONTROLLER SETUP

For more information, refer to MDE-4817 SiteOmat Setup Manual.

SECTION 4
MAINTENANCE
4-1. GENERAL
This section provides general maintenance instructions for the Fuel Truck Controller as well as a
comprehensive troubleshooting guide.
4-2. TROUBLESHOOTING
The next paragraphs provide a list of common pump/system problems that may be encountered
when using the Fuel Truck Controller system as well as corrective action instructions, covering the
following problems related to the system and its peripherals:
• Fuel Truck Controller (see paragraph 4-2.1)
• Communication to peripherals (see paragraph 4-2.2)
4-2.1. Fuel Truck Controller Troubleshooting

The Fuel Truck Controller troubleshooting procedure and consequent corrective actions are
described in Table 4-1.
Table 4-1. Fuel Truck Controller Troubleshooting

Fault Probable Cause Checks Corrective Action
System is down
No Fuel Truck Turn main switch/ truck
communication Controller main ignition switch ON.
switch or truck
OrCU LEDs After power on, wait a few
ignition switch are
are not lit seconds for the Timer
OFF Relay to be connected.
Defective fuses Check the fuses Replace the fuses if blown.
1. External fuse (6 Amp)
2. Internal fuse harness
which is located
between the
Terminal block
(TB 43) and Line
Filter

No No 12 VDC/24 VDC Verify all input power Correct wiring problems if
communication feed to the unit connections: 12 VDC/24 VDC is not
1. Check cabling from measured.
OrCU LEDs J-box to the unit.
are not lit 2. Verify that power cable
is properly connected to
unit terminal block.
3. Verify the Input &
Output voltage of the
DC2DC Converter.
4. Is 12 VDC/24 VDC
measured at the power
input terminal block?
Power failure Does the unit shut down 1. Check for shorts in the
immediately after being power line cable.
turned on? 2. Check grounding.
Circuit breaker is Is breaker OFF or tripped? Turn breaker ON, if OFF.

off
Is 12 VDC/24 VDC being Replace breaker if
switched through breaker? 12 VDC/24 VDC is
not being switched.
Is 12 VDC/24 VDC Correct wiring problems if
measured at the power 12 VDC/24 VDC is not
input terminal block? measured.
Does the breaker turn Check for loads or shorts in
OFF immediately after the power line.
being turned ON?
Internal fuse blown Check the two pico fuses Replace the fuse if it is
(red wires) at the bottom blown.
of the power supply using
an ohmmeter.
Power supply Verify that green LED on 1. Replace mini fuse.
failure power supply is lit. 2. Replace power supply.

System is down (continued)
Mechanic pump does not refuel
Pump does Device is not 1. Open the pump from Enable the device to refuel.
not supply allowed to refuel SiteOmat Status
fuel screen.
2. Verify that the
vehicle/device has no
limitation in FHO
setup.
Pump does Pump setup is Check pump setup: 1. Set pump parameters.
not supply incorrect • Pump server 2. Save and reload.
fuel • Buses
• Prices 3. Check again.
• Pulse rate
Faulty connection to Check Control cables Make good electrical
pump from Fuel Truck connection.
Controller to pump.
8-port failure Verify that Power LED is If it is OFF, use a
lit. voltmeter to check power
supply to the unit:
If power supply is OK, then
replace the 8-port board. If
power supply is faulty,
replace the power supply.
During Authorization, 1. Replace MPI-C board.

verify that Control red 2. Replace 8-port.
LED on MPI-C board is
lit.
Pump malfunction Turn the Fuel Truck If the problem persists:
Controller bypass switch
on, lift the nozzle and 1. Check Handle-On
check that the pump Switch.
supplies fuel. 2. Repair pump.
Handle-on switch Is the In Use red LED 1. Check In Use cable and
problem in MPI-C board lit repair, if necessary.
when nozzle is lifted? 2. Check Terminal wires
and repair, if
necessary.
3. Check the In Use Switch
in the pump and repair,
if necessary.

Pump is Faulty in-use switch Power OFF the pump, Replace pump switch in
authorized but in pump using a ohmmeter cases where no short was
Call state is not measure the switch in ON detected.
detected (nozzle and OFF states.
icon in SiteOmat Faulty connections Check In Use cable Make good electrical
Status screen connection if faulty one
does not display Check In Use terminal
exists.
Call state) block connections.
Faulty In Use Replace In-use terminal
terminal block block.
Faulty MPI-C board Verify that the Call red If the red LED is not lit,
LED is lit when nozzle is replace MPI-C board.
lifted. If the LED is lit, the
problem is external to the
controller.
Faulty 8-Port Replace 8-Port.
Pump is Faulty solenoid Does the pump solenoid 1. Replace valve.
authorized, pump valve valve produce a clicking 2. Repair pump.
motor is running, sound?
Faulty pump
but no fuel is
supplied
Payment device Communication 1. Check communication 1. Replace com cable, if
(card, key, tag, fault between OrTR cable. necessary.
Fuel Ring) is not and SO 2. Check OrTR setup. 2. Set OrTR parameters
accepted properly.
3. Check SO setup.
3. Set SO parameters
properly.
Communication 1. Check connection path Repair communication

fault between FHO with FHO. between FHO and SO,
and SO 2. Verify that the station providing a reliable
is available and communication line.
synchronized with
FHO in FHO Stations
Status screen.

Payment device Device was not 1. Log in to FHO as Define the device
(card, key, tag, defined/incorrectly Fleet manager. parameters in FHO
Fuel Ring) is not defined in FHO properly.
2. Check that the device
accepted
is defined.
3. Check device
parameters.
4. Check that device
rules does not limit
refueling.
Device limit was Verify that the device is For testing only, remove
passed within the limits of its any rule associated to this
rule. device.
Device was set as 1. Log in to FHO and Change the device setting
Driver go to Devices to “Vehicle”.
Management.
2. Select the specific
device and check if it
was configured as
“Driver”.
Payment device Device is blocked 1. Log in to FHO and Change device status to
(card, key, tag, go to Devices “Unblocked”.
Fuel Ring) is Management.
not accepted 2. Check the status of the
device in the Status
column in the Devices
grid
(blocked/unblocked).
Pump is Authorized and refueling but volume remains zero
Pump is Pulse factor is zero Check SO pump setup. Change Pump Settings to
refueling but correct the factor for the
volume remains relevant pump.
zero
Faulty MPI-C board Disconnect the pulser and If pulses are received
short the pulse-in wires to during refueling, replace
Faulty pulser simulate pulses. pump pulser.
If not, replace MPI-C board.

No control on refueling
Pump is refueling Pump is in bypass Verify that Fuel Truck Turn bypass switch OFF,
without any Controller bypass switch if ON.
control is OFF.
Faulty SSR Replace the relevant SSR
unit inside the Fuel Truck
Controller.
If an external relay Add a snubber (capacitor +
is used to control resistor) in parallel to relay
the pump/valve, it input.
may be stuck due to
a small current
leak.
4-2.2. Communication Troubleshooting

The troubleshooting procedure for problems related to communication to peripherals and
consequent corrective actions are described in Table 4-2.
Table 4-2. Communication Troubleshooting

No communication between FHO and SO controller
No connection to Cabling issue Visually inspect the 1. Verify that LAN2.0 Port
the station from network cable to LED is blinking.
FHO Stations LAN2.0 2. Unplug the cable and plug it
screen back in.
3. Replace LAN cable, if
necessary.
4. If the cable is in good
condition, contact the IT
department to confirm that
the router connected to the
LAN cable is properly set.
5. Check the Controller
network settings (IP
addresses, mask, gateway,
etc.).

No communication to the pumps (8-port CommVerter)
“Warning” signs Incorrect 8-port Check the physical 1. If no activity is detected on
displayed for all CommVerter setup connection of the the LAN port connected to
pumps on the 8- port CommVerter the 8-port CommVerter,
SiteOmat Status to the local network replace the short Ethernet
screen (5- port switch cable or/and change the
activity) LAN port to confirm
normal operation.
All pumps are Incorrect 8-port Check network 2. Check the status of the
showing CommVerter setup connectivity by LEDs on the 8-port (upper
“warning” signs performing a “ping” right corner of the board):
on the SiteOmat command locally or the first and the third LED
Status screen remotely, through should be lit to confirm
PuTTY application power and network
connection, and second LED
should blink to confirm
network activity. The last
two LEDs (from left to
right) should be blinking
constantly, to confirm
communication with
controller.
3. In cases where all LEDs are
lit periodically (every 30
seconds) the unit is resetting
due to connection loss to the
controller.
4. Reset the IP and reconfigure
the Pump Server (PS) in
controller setup.
No communication to nozzles (Wireless Gateway)
Can’t read the 1. No Check the physical 1. If no activity on the LAN
vehicles and/or communication connection of the port, check the cable and/or
no authorization to Wireless Wireless Gateway to change the port on the 5-port
at the pumps Gateway the local network switch.
2. Incorrect nozzle (5- port switch). 2. Remove the top cover to
readers setup Check the Wireless access the Wireless Gateway
Gateway network and check the status of the
settings. LEDs.

Can’t read the Check the 3. Connect to the Wireless
vehicles and/or programming of the Gateway through the 9-pin
no authorization WNRs. serial port and open
at the pumps Hyperterminal (115200, 8,
None, 1, None); then, reset
the Wireless Gateway and
follow the startup messages
to find the IP address.
4-3. CLEANING
The Fuel Truck Controller itself as a standalone unit should be cleaned periodically at short
intervals, due to the harsh environment where they operate.
CAUTION
DO NOT use any solvents such as thinner or

benzene.

SECTION 5
GLOSSARY
5-1. FUELOMAT GLOSSARY
ComVerter LAN/232/485/422/C.L./Tokheim Communication Converter

DataPass Vehicle Data Transceiver
FHO Fleet and Fuel Head Office
MPI Mechanical Pump Interface
MPI-C Mechanical Pumps Interface Card
NIS Non-Intrinsically Safe
NR Nozzle Reader (Wireless Nozzle Reader unit)
OrCU Orpak embedded Controller Unit
OrCU 3000 Orpak site Controller Unit
OrIC Orpak Island Controller
OrIT Orpak Island Terminal
OrPT Orpak/Outdoor Payment Terminal (display, Keyboard, key reader,
magnetic card reader, LEDs, buzzer; install in fueling area)
FTC Fuel Truck Controller
OrTR Orpak Tag Reader
POS Point of Sale
SAM Security Application Module (security card in the VIT/UPI)
TLS Tank Level System (measuring fuel tank level in station)
VBIS Vehicle Bus Information System
VIS Vehicle Information System
VIT Vehicle Information Transceiver
VIU Vehicle Identification Unit (VIU3/35/45)
WGT Wireless Gateway Terminal

5-2. COMMUNICATION GLOSSARY
Access Point An internetworking device that seamlessly connects wired and wireless
networks together.
Ad Hoc A peer-to-peer wireless network without Access Point. A group of wireless
clients consistent with an independent wireless LAN.
Backbone The core infrastructure of a network, it is the portion of the network that
transports information from one central location to another central location. The
information is then off-loaded onto a local system.
BSS Basic Service Set. An Access Point associated with several wireless stations.
DES Data Encryption Standard. LANs with high level of security. A method of data
encryption.
DHCP Dynamic Host Configuration Protocol.
ESS Extended Service Set. More than one BSS can be configured as an
Extended Service Set. An ESS is basically a roaming domain.
ESSID Extended Service Set Identifier. The length of the ESSID information is between
0 and 32 octets. A zero-length identifier indicates the broadcast SSID.
Ethernet A popular local area data communications network, originally developed by
Xerox Corp., which accepts transmission from computers and terminals. Ethernet
operates on 10/100 Mbps transmission rate over shielded coaxial cable or over
shielded twisted pair telephone wire.
Infrastructure An integrated wireless and wired LAN is called an infrastructure configuration.
LAN Local Area Network

Roaming A function that allows one to travel with a mobile end system (wireless LAN
mobile station, for example) through the territory of a domain (an ESS, for
example) while continuously connecting to the infrastructure.
TCP/IP Communication protocol used in Ethernet/Internet.
Triple DES A method of data encryption.
WAN Wide Area Network
WEP Wired Equivalent Privacy. The optional cryptographic confidentiality algorithm
specified by IEEE 802.11 used to provide data confidentiality that is subjectively
equivalent to the confidentiality of a wired LAN medium that does not employ
cryptographic techniques to enhance privacy.
WG Wireless Gateway
RAS Remote Access Services

APPENDIX A
WIRING DIAGRAM
This appendix provides the wiring diagram of the Fuel Truck Controller.
Figure A-1. Fuel Truck Controller – Wiring Diagram (Mechanical Pump)

APPENDIX B
SITE SURVEY FORM - EXAMPLE
Date: / /
Prepared by:
E-mail: @
Phone:
Gas Station Identification:

Company name:
Address:
Contact person:
Phone: Mobile phone:
Truck Data:
Station name:
Site Name:
Power Supply:  12 VDC  24 VDC  Other
Number of nozzles
(To be connected to Fuel Truck Controller):
Number of Authorizers required:
Hose on:  Reel  Long hose  Other (photo required)
Reel has continued connectivity (brushes)  Yes  No
Electronic Pulser installed:  Yes  No
If Pulser installed, model?
Air Slip needed:  Yes  No
ON/OFF switch available:  Yes  No
Mini Fuel Truck Controller Printer required:  Yes  No
Preferred mounting location
for Fuel Truck Controller box:

Data Download Method
Cellular modem installed:  Yes  No
Cellular modem model:
Cellular modem
SIM Data Number:
WiFi connectivity:  Yes  No
Nozzle Equipment
Hose Diameter:  3/4”  1”  Other
Hose Length:
Hose Thread:  Male  Female
Nozzle/Hose Thread:  Inch  Millimeter  BSP  NPT
Manufacturer:
Model: .
Diameter of nozzle spout:
Break Away: Location on the hose:
Vapor Recovery:
Vehicle Devices to Be Used

VIU:
FuelOpass:
Contactless TAG:

Site Inspection
Provide drawings and/or photos of the site - Pay attention to the following features:
Distances
Location of:
Pumps
Reel
Nozzles
Valves
Pulsers
Cabinet
Miscellaneous
Color schemes and Graphics that may affect the appearance of our equipment on the truck:
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MDE-4814D

Fuel Truck Controller

This document is based on Orpak’s Truck Controller Unit (OrTC)

WARNING - EXPLOSION HAZARD

CAUTION - SHOCK HAZARD

CAUTION – EXTERNAL WIRING

For supply connections, use wires suitable for at least 90°C.

Signal wiring connected in this box must be rated at least 300 V.

Components substitutions could impair intrinsic safety.

FCC Compliance Statement

The FCC Wants You to Know:

This document is the property of:

SECTION 1 GENERAL DESCRIPTION

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 i

1-9.1. Communication Standards ............................................................................................. 20

SECTION 2 PRELIMINARY INSTALLATION INSTRUCTIONS

SECTION 3 INSTALLATION PROCEDURES

ii MDE-4814D Fuel Truck Controller Installation Manual · February 2018

3-4.1. General ........................................................................................................................... 34

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 iii

APPENDIX A WIRING DIAGRAM…………………………………………………....59

APPENDIX B SITE SURVEY FORM – EXAMPLE………………………………….60

iv MDE-4814D Fuel Truck Controller Installation Manual · February 2018

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 v

Table 1-1. Fuel Truck Controller- Standard Models ........................................................................ 17

Table 4-1. Fuel Truck Controller Troubleshooting ........................................................................... 50

vi MDE-4814D Fuel Truck Controller Installation Manual · February 2018

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 7

1-3.1. Fuel Truck Controller System

1-3.2. Vehicle Identification

1-3.3. Remote Web Access

1-3.4. Fleet Head Office

1-3.5. Restrictions and Limits

8 MDE-4814D Fuel Truck Controller Installation Manual · February 2018

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 9

1-4.1. Main Components

10 MDE-4814D Fuel Truck Controller Installation Manual · February 2018

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 11

Figure 1-3 shows a general configuration diagram of Fuel Truck Controller.

Figure 1-3. Internal Configuration Diagram – Mechanical Pump

12 MDE-4814D Fuel Truck Controller Installation Manual · February 2018

Figure 1-4. Fuel Truck Controller Internal Components Location

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 13

1-5.2. Vehicle Identification System – FuelPoint PLUS

1-5.3. WGT External Box – Optional

Figure 1-5. Wireless Gateway Terminal (WGT)

14 MDE-4814D Fuel Truck Controller Installation Manual · February 2018

1-5.5. External TAG Reader (OrTR)

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 15

Figure 1-6. Tag Reader (OrTR)

Figure 1-7. Fuel Truck Controller with OrTR

16 MDE-4814D Fuel Truck Controller Installation Manual · February 2018

Figure 1-8. Fuel Truck Controller with OrTR and WGT

1-5.7. Fuel Truck Controller - Standard Models

Table 1-1. Fuel Truck Controller - Standard Models

MDE-4814D Fuel Truck Controller Installation Manual · February 2018 17

1-6.2. Authorization Security

1-6.3. Network Security

1-6.4. RF Network Security

1-6.5. Maintenance Security