Fleet Solutions

Site PRIME Installation

Manual

P/N: MDE-5623

Revision E
 SAFETY CONSIDERATIONS
Carefully read all warnings and instructions, provided to help you install and
maintain the equipment safely in the highly flammable environment of a
gas station.
Disregarding these warnings and instructions could result in serious injury
and property loss or damage.
It is your responsibility to install, operate and maintain the equipment
according to the instructions 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.
Ensure that the installation is performed by experienced personnel,
licensed to perform work in gas stations and in flammable environments,
according to the local regulations and all relevant standards.

WARNING - EXPLOSION HAZARD

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

CAUTION - SHOCK HAZARD

Dangerous AC voltages that could cause death or serious personal injury
are used to power the equipment. Always disconnect power before working
on the equipment. The equipment may have more than one power supply
connection point. Disconnect all power, including MCC circuit breaker,
before servicing.

Site PRIME Installation Manual i

 WARNING - PASSING VEHICLES
When working in an open area, block off the work area to protect yourself
and other persons. Use safety cones or other signaling devices.

WARNING
Substitutions of components could impair intrinsic safety. Use of
unauthorized components or equipment will void all warranties associated
with this equipment.

CAUTION
Do not attempt to make any repair on the printed circuit boards that reside
in the equipment, as this will void all warranties associated with this
equipment.

WARNING
The unit is not intended for installation in marine type environments.

PROPRIETARY NOTICE
The information contained in this guide is confidential and proprietary to
Orpak Systems Ltd. No part of this guide may be disclosed or reproduced in
any form without written permission of Orpak Systems Ltd. The information
provided in this document is current as of the date of its publication, and it
may be changed at any time without notice.

DISCLAIMER
This document is provided for reference only and while every effort has
been made to ensure correctness at the time of publication, Orpak Systems
Ltd. assumes no responsibility for errors or omissions.

ii Site PRIME Installation Manual

 FCC COMPLIANCE STATEMENT
This equipment has been tested and found to comply with the limits for a
Class B & C 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:

Reorient or relocate the receiving antenna

Increase the separation between the equipment and receiver
Connect the equipment to an outlet on a circuit different from that to
which the receive is connected
Consult an authorized dealer or service representative for help

FCC WARNING
Modifications not expressly approved by the manufacturer could void the
user authority to operate the equipment under FCC Rules.

PROPRIETARY NOTICE
The information contained in this guide is confidential and proprietary to
Orpak Systems Ltd. No part of this guide may be disclosed or reproduced in
any form without written permission of Orpak Systems Ltd. The information
provided in this document is current as of the date of its publication, and it
may be changed at any time without notice.

DISCLAIMER
This document is provided for reference only and while every effort has
been made to ensure correctness at the time of publication, Orpak Systems
Ltd. assumes no responsibility for errors or omissions.

This document is the property of:

Orpak Systems Ltd., Israel

Site PRIME Installation Manual iii

 Table of Contents

Section 1 Introduction
1.1. General 1
1.2. Solution Description 1
1.3. System Architecture 2
1.4. Documentation Conventions 2
1.5. Manual Structure 3
1.6. References 3

Section 2 System Overview

2.1. General 5
2.2. System Description 5
2.2.1. Automatic Vehicle Identification 6
2.2.2. Remote Web Access 6
2.2.3. Fleet Head Office 6
2.2.4. Restrictions and Limits 6
2.2.5. Site PRIME Capabilities for Forecourt Management 7
2.2.6. System Workflows 7
2.2.7. Main Components 8
2.2.8. Internal Configuration 11
2.3. Available Configurations 12
2.3.1. Site PRIME 12
2.3.2. Site PRIME UX 13
2.3.3. Site PRIME / Extension Box 14
2.4. Security and Protection 14
2.4.1. Network Security 14
2.4.2. Maintenance Security 15
2.5. Housing 15
2.6. Technical Specifications and Standards 15
2.6.1. Site PRIME Technical Specifications 15
2.6.2. AC/DC MPI Module Specifications 16
2.6.3. Communication Standards 18

iv Site PRIME Installation Manual

 Section 3 Preliminary Installation Procedures
3.1. General 19
3.2. Precautions and Safety Notes 19
3.3. Conduits 20
3.3.1. Requirements 21
3.3.2. Conduits in Site PRIME 21
3.3.3. Required Conduits in the Station 22
3.3.4. Wiring Conduits in Site PRIME 23
3.3.5. Installation 26
3.3.6. Sealing 26
3.4. Cable Insertion 26
3.4.1. Cable Types 27
3.5. Power Setup 27
3.5.1. Connection Diagram 28
3.5.2. Connecting the Power Equipment 28
3.5.3. Grounding 29

Section 4 Site PRIME Installation Procedures

4.1. General 30
4.2. Installation Guidelines 30
4.2.1. Precautions and Safety Notes 30
4.2.2. Safety Distances 31
4.3. Homebase Station 31
4.3.1. Station Architecture 32
4.4. Mapping the Site 33
4.4.1. Locating and Mapping all Objects of the Site 34
4.4.2. Assigning Logical Identifications (IDs) to the Devices 34
4.5. Installing the Site PRIME 34
4.5.1. Site Preliminary Setup Procedures 35
4.5.2. Support Rails Installation Procedure 35
4.5.3. Cable Gland Insertion 37
4.5.4. Installation Procedure on Wall 40
4.5.5. Installation Procedure on the Pole 42

Site PRIME Installation Manual v

 4.5.6. Sealing Conduits 45
4.6. Connections to Site PRIME 46
4.7. Pump Interface Modules 48
4.7.1. Site PRIME 1M Module 50
4.7.2. Electronic Pump Modules 51
4.7.3. Electronic Pump Modules Connections 52
4.8. Post-Installation Checklist 53
4.9. PRIME Add-Ons 54
4.9.1. Cellular Modem Module 55
4.9.2. Wi-Fi + BT Modem Module 68
4.9.3. nWGT 77
4.9.4. TR500 82

Section 5 PRIME Converter Setup

5.1. General 91
5.2. Home Page 92
5.3. Setup 93
5.3.1. Minimal Setup 93
5.3.2. General Setup 95
5.3.3. Channels Config 96
5.3.4. Log Level 99
5.3.5. Save Setup 101
5.4. Software Upload 105
5.5. Status 107
5.6. Change Password 108
5.7. Reset Password 109

Section 6 Troubleshooting
6.1. General 111
6.2. Site PRIME 111
6.2.1. System Down 111
6.2.2. Mechanical Pump Does Not Fuel 113
6.2.3. Pump is Authorized and Refueling but Volume Remains Zero 117
6.2.4. No Control Over Fueling 118

vi Site PRIME Installation Manual

 6.3. Communication 118

Appendix A
6.4. General 122

Site PRIME Installation Manual vii

 List of Figures

Figure 1-1 - Site PRIME 1

Figure 1-2 - System Architecture 2
Figure 2-1 - nOrCU 9
Figure 2-2 - OrPAY1000 9
Figure 2-3 - TR500 10
Figure 2-4 - Communication Configuration 11
Figure 2-5 - Internal Configuration 12
Figure 2-6 - Site PRIME 13
Figure 2-7 - Site PRIME UX 13
Figure 3-1 - Installation Control 20
Figure 3-2 - Conduit Layout for Mechanical Pump 24
Figure 3-3 - Conduit Layout for Electronic Pump 25
Figure 3-4 - Conduit Fitting 26
Figure 3-5 - Power Equipment Connections 28
Figure 4-1 - Installation Control Drawing 31
Figure 4-2 - Homebase Station System Diagram 32
Figure 4-3 - Support Rails Assembly Parts 36
Figure 4-4 - Top Rail 36
Figure 4-5 - Both Rails 37
Figure 4-6 - Knocking Out Using Hammer 38
Figure 4-7 - Knocked Out Opening 38
Figure 4-8 - Cable Gland Outside View 39
Figure 4-9 - Cable Gland Inside View 39
Figure 4-10 - Cable Gland Fastening 40
Figure 4-11 - Dimensions on the Wall 41
Figure 4-12 - Site PRIME Installed on Wall 42
Figure 4-13 - Dimensions on the Pole 42
Figure 4-14 - Base Secured to Column 43
Figure 4-15 - Rosette Cover 44

viii Site PRIME Installation Manual

 Figure 4-16 - Cable Trough 44
Figure 4-17 - Site PRIME Secured to Cable Trough 45
Figure 4-18 - Conduit Fitting 46
Figure 4-19 - High Voltage Area and Low Voltage & Communication Area 47
Figure 4-20 - AC Power Supply Connected to GND/Neutral/Line 47
Figure 4-21 - Fastening Point of the Mechanical Pump Module on the Right 49
Figure 4-22 - Fastening Point of the Electronic Pump Module on the Left 49
Figure 4-23 - 1M Module 50
Figure 4-24 - 1M Module Wiring Connections 50
Figure 4-25 - Electronic Pump Module 52
Figure 4-26 - RS232 Device Connected to RS422/232 Module 53
Figure 4-27 - FCC/IC label on Product Label 55
Figure 4-28 - Cellular Modem Module Assembly Parts 56
Figure 4-29 - Cellular Modem Module Assembly Parts 57
Figure 4-30 - Cellular Modem Module Assembly Parts 57
Figure 4-31 - Cellular Modem Module Assembly Parts 57
Figure 4-32 - Cellular Modem Module FCC/IC Label (10) 57
Figure 4-33 - Main Power Switch - OFF 58
Figure 4-34 - nOrCU Connection 59
Figure 4-35 - USB Cable Connected to the USB Connector 59
Figure 4-36 - USB Cover Placed 60
Figure 4-37 - USB Cover Fastened 60
Figure 4-38 - CommBoard SIM Socket 61
Figure 4-39 - SIM Socket Cover Raised 61
Figure 4-40 - SIM Card in SIM Socket 62
Figure 4-41 - SIM Socket Cover Replaced 62
Figure 4-42 - Antenna Anchor 63
Figure 4-43 - Antennas Connected to Module 64
Figure 4-44 - Modem on the CommBoard mPCIe Connector 65
Figure 4-45 - USB Installed on CommBoard 65

Site PRIME Installation Manual ix

 Figure 4-46 - Antenna Tray Installation 67
Figure 4-47 - Wi-Fi + BT Modem Module Assembly Parts 69
Figure 4-48 - Wi-Fi + BT Modem Module Assembly Parts 69
Figure 4-49 - Wi-Fi + BT Modem Module Assembly Parts 70
Figure 4-50 - Wi-Fi + BT Modem Module FCC/IC Label (8) 70
Figure 4-51 - Main Power Switch - OFF 70
Figure 4-52 - nOrCU Connection 71
Figure 4-53 - M.2 Modem in the M.2 to mPCIe Adapter 71
Figure 4-54 - Antenna Anchor 72
Figure 4-55 - Antennas Fastened With Cable Tie 73
Figure 4-56 - Modem Assembly on the mPCIe Connector 74
Figure 4-57 - Antenna Tray Installation 76
Figure 4-58 - nWGT Assembly Parts 78
Figure 4-59 - nWGT Assembly Parts 79
Figure 4-60 - nWGT FCC/IC Label (9) 79
Figure 4-61 - Main Power Switch - OFF 80
Figure 4-62 - nWGT Installed 80
Figure 4-63 - Cables Connected 81
Figure 4-64 - Connected to CommBoard 82
Figure 4-65 - TR500 Assembly Parts 83
Figure 4-66 - TR500 Assembly Parts 83
Figure 4-67 - Main Power Switch - OFF 84
Figure 4-68 - Drill Locations 85
Figure 4-69 - Front Panel with Holes Drilled 86
Figure 4-70 - Threading Cables 86
Figure 4-71 - Attaching TR500 87
Figure 4-72 - Harness Anchored 87
Figure 4-73 - Connecting to Harness 88
Figure 4-74 - Cutting the Wires 89
Figure 4-75 - Connected to CommBoard 89

x Site PRIME Installation Manual

 Figure 4-76 - Site PRIME With TR500 Turned On 90
Figure 5-1 - PRIME Converter Setup Login 91
Figure 5-2 - PRIME Converter Setup Homepage 92
Figure 5-3 - Minimal Setup Tab 94
Figure 5-4 - General Setup Tab 95
Figure 5-5 - Channels Config Tab 97
Figure 5-6 - Log Level Tab 100
Figure 5-7 - Save Setup Tab 102
Figure 5-8 - Save Confirmation 103
Figure 5-9 - Sign In Prompt 103
Figure 5-10 - Update Configuration 104
Figure 5-11 - Download Setup File 105
Figure 5-12 - PRIME Converter Software Upload Page 106
Figure 5-13 - Confirm Upload Dialog 107
Figure 5-14 - PRIME Converter Status Page 108
Figure 5-15 - PRIME Converter Change Password Page 109
Figure 5-16 - PRIME Converter Reset Password Page 110
Figure 6-1 - Site PRIME with Orpay1000 123
Figure 6-2 - Site PRIME with TR500 123

Site PRIME Installation Manual xi

 List of Tables

Table 2-1 - Site PRIME Technical Specifications 16

Table 2-2 - AC/DC MPI Module Specifications 17
Table 3-1 - Conduits into Site PRIME 23
Table 3-2 - Site PRIME Cable Types 27
Table 4-1 - Site PRIME Assembly Parts 35
Table 4-2 - 1M Module - LED Indicators 48
Table 4-3 - 1M Module - LED Indicators 51
Table 4-4 - Electronic Pump Modules - Connections 52
Table 4-5 - Cellular Modem Module Assembly PartsAssembly Kit
Number: 819258125 Gasboy Kit Number: M15778B504 55
Table 4-6 - Wi-Fi + BT Modem Module Assembly PartsAssembly Kit
Number: 819258120Gasboy Kit Number: M15778B503 68
Table 4-7 - nWGT Assembly PartsAssembly Kit Number: 819227450 (Gasboy
P/N: M15778B505) 77
Table 4-8 - TR500 Assembly PartsAssembly Kit Number: 819258200 82
Table 5-1 - Device Information 93
Table 5-2 - General Setup Fields 96
Table 5-3 - Channels Config Channels Fields 98
Table 5-4 - Communication Interface Details by Pump Type 99
Table 5-5 - Log Level Fields 101
Table 6-1 - System is Down 112
Table 6-2 - Mechanical Pump Does Not Fuel 114
Table 6-3 - Pump is Authorized and Refueling but Volume Remains Zero 117
Table 6-4 - No Control Over Fueling 118
Table 6-5 - Communication Troubleshooting 119

Site PRIME Installation Manual xiii

Section 1 Introduction
1.1. General
This manual describes the Site PRIME, which is part of Gasboy’s Fleet Solution.
It provides a general description of the product, as well as installation
guidelines.
This manual is intended for qualified authorized installers of the Site PRIME
and its components.

1.2. Solution Description

The Site PRIME is a fuel control and data acquisition system (see Figure 1-1).
The Site PRIME is enclosed in a self-contained, weather-resistant cabinet
designed to be compatible with the forecourt environment. The cabinet is
designed to be installed on a wall or any flat surface.

Figure 1-1 - Site PRIME

Site PRIME is a major component in Gasboy’s Fleet Solution for homebase fuel
stations. Site PRIME provides the central function of the site controller, and
fulfills other essential services in the station such as Vehicle/Driver
Identification System, transaction data storage, device control and more. Its
user-friendly operating program enables fast and accurate service for the
driver in the refueling site.
Site PRIME can control up to four mechanical nozzles or up to 32 electronic
nozzles. The nozzles may be linked together or standalone.

Site PRIME Installation Manual 1

Site PRIME supports personal refueling identification devices such as
Vehicle/Driver Identification Unit (VIU) and FuelOPass.

1.3. System Architecture

Figure 1-2 shows a basic diagram of Site PRIME system architecture:

Figure 1-2 - System Architecture

1.4. Documentation Conventions

This manual uses the following conventions:

Warning notes contain information that, unless strictly observed,

could result in injury or loss of life.

Caution notes contain information that, unless strictly observed,

could result in damage or destruction of the equipment or long-

2 Site PRIME Installation Manual

 term health hazards to personnel.

Notes contain helpful comments or references to material not

covered in the manual.

Best practice notes contain helpful suggestions.

Example notes contain additional information to illustrate a

concept/procedure.

1.5. Manual Structure

Section 1: Introduction
This section provides a general description of the system.
Section 2: System Overview
This section provides a general description of the Site PRIME system.
Section 3: Installation Procedures
This section provides a detailed description of the Site PRIME installation
requirements and procedures.

1.6. References
This manual provides installation instructions for the Site PRIME system,
please refer to the following manuals:
For specific installation and setup instructions not included in this manual,
please refer to the following manual:

SiteOmat360 Setup and Maintenance Manual, P/N 817423748, MDE-

5414A
Fleet Solutions Site PRIME Installation Guide, P/N 817438032, MDE-5623
Wireless Gateway Installation Manual, MDE-4815
SiteOmat360 Station Controller User Manual, MDE-5415
Wireless Gateway Installation Manual, MDE-4815

Site PRIME Installation Manual 3

 FHO Installation and User Manual, MDE-4821
Fuel Point PLUS Installation and Configuration Manual, MDE-4851
Fuel & Drive Mobile Application User Manual P/N: 817400190

4 Site PRIME Installation Manual

Section 2 System Overview
2.1. General
This section provides a detailed description of the Site PRIME system, as well as
the available configurations, system specifications, and communication
standards.

2.2. System Description

Site PRIME is an innovative product that enables refueling in homebase gas

stations for a fleets’ authorized vehicles or drivers. Site PRIME electronically
locks all dispensers and pumps, ensuring that only appropriately authorized
vehicles and plants receive the required fuel. The system also ensures accurate
recording of each transaction.
The heart of the homebase station solution is the SiteOmat automation
software. SiteOmat runs on an embedded operating system on the controller
unit (nOrCU). The controller is an embedded hardware platform designed to
survive the harsh gas station environment. It uses a solid-state flash disk and

Site PRIME Installation Manual 5

RTC (Real Time Clock) with backup, along with surge suppressors for transient
and noise immunity. The system also includes power fail recovery
mechanisms.

2.2.1. Automatic Vehicle Identification

Vehicle Identification is an important option 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
combination of vehicle and driver identification is also possible for tight
tracking.

2.2.2. Remote Web Access

Remote Web-based capabilities for monitoring, management, and
maintenance are available. A standard PC with an internet browser (Google
Chrome / Microsoft Edge) is used for management of the site either locally or
remotely (secured). There is no need for special management software thanks
to the built-in Web server technology integrated into the station controller and
the large variety of communication links supported – both wired and wireless.

2.2.3. 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 have full control over the forecourt.

2.2.4. Restrictions and Limits

Control of a fleet’s fuel expenses can be controlled by defining limits (day,
week, month), maximum number of refueling (per day, week, month), and
setting restrictions (days of the week, fuel type, stations, time intervals). In case
of system configuration for multiple sites, the centralized Fleet Head Office
needs to synchronize the data between all sites so that the limits can be
applied to a whole system rather than to an individual site. In case of
communication failure, the specific site will be able to refuel for a predefined
grace period using the most recent limits stored in its database.

6 Site PRIME Installation Manual

2.2.5. Site PRIME Capabilities for Forecourt Management
Site PRIME provides the following operational features for a comprehensive
forecourt management:

Supports over 50 different types of dispensers used around the world.

This product has only been evaluated for use with UL Listed Dispensers.
Advanced electronic support of mechanical dispensers, enabling pumps
with totalizer, preset, and price update
Tank Level Gauging System (TLG) available for several brands. This
product has only been evaluated for use with UL Listed TLGs
Support of a wide variety of communication links: cellular, VPN, satellite,
ADSL and more.

2.2.6. System Workflows

The following are examples of operational workflows for self-service at the
homebase station.

Site PRIME Installation Manual 7

2.2.6.1. Refueling Scenario with VIU
A driver stops for fuel at the station. Their authorization device for the fueling
transaction is a Vehicle Identification Unit (VIU) mounted in the vehicle. The
driver lifts the nozzle and inserts it in the car fuel inlet.
The VIU information is automatically read and sent to the site controller (Site
PRIME) for authentication and approval. Upon approval, the fueling transaction
starts. Once the refueling is completed, the driver replaces the nozzle back to
the pump. At the end of the transaction, the data is kept internally and
transferred to the Fleet Head Office (FHO) for future billing.

2.2.6.2. Refueling Scenario with Magnetic Cards

A driver stops for fuel at the station. His authorization device for the fueling
transaction is a magnetic card. The client swipes the card through the
magnetic card reader on the payment panel.
The magnetic card information is read and sent to the site controller (Site
PRIME) for authentication and approval. The client lifts the nozzle and inserts it
in the car inlet. On approval, the fueling transaction starts, at the end of which
the transaction data is kept internally. The data is transferred to the Fleet Head
Office (FHO) for future billing.
The client may add more data to the transaction, by manually entering the
information using the payment panel keyboard. After the refueling is
completed, the driver replaces the nozzle to pump.

2.2.7. Main Components

The following provides a description of Site PRIME main sub units.

2.2.7.1. Orpak Controller Unit (nOrCU)

Orpak Controller Unit (nOrCU) is a complete forecourt controller with its own
embedded operating system. The unit consists of an embedded hardware
platform with a solid state flash storage, Real Time Clock (RTC) with a back up.
nOrCU features two separate and isolated networks (TCP/IP over Ethernet).
One network links the OrIC Prime system components. The second network is
intended for external remote communication (Head Office, 3rd party systems).
This network is protected by SSL security. nOrCU includes a built in server for
Web access through an internet browser. (see Figure 2-1).

8 Site PRIME Installation Manual

 Figure 2-1 - nOrCU

2.2.7.2. OrPAY1000 (Optional)

The OrPAY1000 terminal is an efficient and advanced user interface with its
4.3” multimedia color LCD display, 4 addressable screen keys, and a full
alphanumeric vandal proof 40-key keyboard (see Figure 2-2).

Figure 2-2 - OrPAY1000

Site PRIME Installation Manual 9

2.2.7.3. TR500 (Optional)
The TR500 is a compact standalone reader unit for tags intended for vehicle or
driver tag identification in gas stations and other applications. The TR500
includes a Security Application Module (SAM) used to handle encrypted tags.
The TR500 is installed within easy reach for customers wishing to refuel, and it
transmits information to the station automation system over an Ethernet or
RS-485 cable. (see Figure 2-3)

Figure 2-3 - TR500

2.2.7.4. Communication Interfaces

Site PRIME contains seven slots for the various optional communication
interfaces. Three slots are intended for electronic pumps only (located on the
left side), and four slots are intended for mechanical pumps, 1M modules. The
maximum configuration is either three electronic pumps only, or two
electronic pumps and four mechanical pumps (see Figure 2-4).

10 Site PRIME Installation Manual

 Figure 2-4 - Communication Configuration

2.2.8. Internal Configuration

The following is an example of the Site PRIME internal configuration (see Figure
2-5):

Site PRIME Installation Manual 11

 Figure 2-5 - Internal Configuration

2.3. Available Configurations

Site PRIME is available in several configurations, in accordance with its
intended use and the components installed.
The following paragraphs describe the several configurations, and their device
composition.

2.3.1. Site PRIME

Site PRIME is supplied with the controller unit embedded in the cabinet. In this
configuration, Site PRIME acts as a full station controller, providing the
functions of authorization unit, central forecourt devices controller, link to the
Head Office, etc. (see Figure 2-6):

12 Site PRIME Installation Manual

 Figure 2-6 - Site PRIME

2.3.2. Site PRIME UX

Site PRIME is supplied with the controller unit embedded in the cabinet. In this
configuration, Site PRIME acts as a full station controller, providing the
functions of authorization unit, central forecourt devices controller, link to the
Head Office, etc.
Additionally the Site PRIME UX has an OrPAY1000 terminal and provides
optional AVI support. (see Figure 2-7:)

Figure 2-7 - Site PRIME UX

Site PRIME Installation Manual 13

2.3.3. Site PRIME / Extension Box
Site PRIME is supplied with the controller unit embedded in the cabinet. In this
configuration, Site PRIME acts as a full station controller, providing the
functions of authorization unit, central forecourt devices controller, link to the
Head Office, etc.
Site PRIME supports up to 4 mechanical pumps. If more pumps are needed, an
additional extension box is required. Each extension box can support up to 4
mechanical pumps.
In the Extension Box Configuration, the controller unit is removed from the
basic Site PRIME. This cabinet operates as an authorization terminal and is
intended to ease the system operation in large homebase stations. In this
configuration, the station includes a main Site PRIME and a second unit in
Extension Box Configuration.
The extension box unit is linked to the main Site PRIME via a CAT5E cable
(Ethernet), and communicates with the controller unit and the Head Office. In
this configuration, the controller unit in the Site PRIME is shared by both
cabinets.
The extension box is available in the three configurations of the Site PRIME:
Site PRIME (EXTN), Site PRIME UX (EXTN), and Site PRIME UX (EXTN, BC).

Note: The maximum number of devices/pumps on each bus is as

follows:
• For RS485 - 6 devices/pumps
• For Current Loop - 4 devices/pumps
For best communication balance, it is recommended to connect one
device/pump on each bus and then loop to the other buses, so that
all pumps/devices are divided across the buses. Of course, it is NOT
allowed to connect different device types on the same bus
(channel).

2.4. Security and Protection

The transaction activities of the Site PRIME are secured and protected for
transmission and authorization activities.

2.4.1. Network Security

The Ethernet LAN is isolated from the external WAN by the site controller. In
case of remote maintenance, a firewall should be applied either at the router

14 Site PRIME Installation Manual

level or preferably at the homebase station level.

2.4.2. Maintenance Security

The Site PRIME maintenance and setup procedures require inserting a user
name and password for access. For further information, please refer to the
SiteOmat Setup Instructions Manual, MDE-5414.
Site PRIME is locked by key to prevent unauthorized access to the bypass
switches and controller electronics.

2.5. Housing
The Site PRIME system enclosure is made of a sturdy cabinet. The enclosure is
weather-resistant in order to prevent humidity and dust penetration, and to
sustain the harsh environment of a homebase station.
The Site PRIME cabinet is locked by key for safety and security. The key should
be stored in a well-kept, secure, and safe place.

2.6. Technical Specifications and Standards

The following details the technical specifications, as well as the communication
and security standards for the Site PRIME.

2.6.1. Site PRIME Technical Specifications

The following details the physical, electrical, and environmental specifications
of the Site PRIME (see Table 2-1):

Site PRIME Installation Manual 15

 Table 2-1 - Site PRIME Technical Specifications
Parameter Value

Dimensions (W x H x 317mm x 294mm x 177mm (12.4803” x 11.5748” x 6.9685”)

D)

Supply Voltage 100 – 240VAC, 50/60 Hz, 65W

Power Consumption 1.65 (max)

Operating No OrPAY1000: -40°F to +158°F (-40°C to +70°C)

Temperature OrPAY1000: -40°F to +149°F (-40°C to +65°C)

Storage Temperature -22°F to +158°F (-30°C to +70°C) -40°F to +158°F (-40°C to

+70°C)

Humidity 80% Non-condensing

Communication Default:
Interface
1x Ethernet RJ-45 – GBE for WAN (nOrCU)
3x Ethernet RJ-45 100Base-T for internal or external
optional devices

Optional Modules:

4G LTE Cellular modem with 2G/3G backward

compatibility
Wi-Fi AP 2.4/5GHz
Wireless communication via nWGT (for units without
OrPAY1000)
Tag Reader via TR500 (for units without OrPAY1000)

Pump Interface Modules:

4-channel RS485 Module

4x Current Loop (2 wires) Module
1x Mechanical Pump Interface Module

2.6.2. AC/DC MPI Module Specifications

The following details the specifications of the AC/DC MPI Module:

16 Site PRIME Installation Manual

 Table 2-2 - AC/DC MPI Module Specifications
Parameter Value

For MPI Module Pump Control Open state voltage ratings:

Maximum Current AC: 100-240V
Single SSR DC: 10-32V

Open state leakage current: maximum 5mA

Close state maximum current: 1.8A

Power supply output voltage to Pulser 12 VDC 100mA max

unit

Pulser Input voltage levels Positive “Hi-Logic” voltage: 4V – 32VDC

Negative “Hi-Logic” voltage (-4V) – (-32V)DC

“Low-Logic” voltage (-0.6V) – (+0.6)VDC

In-use Low voltage DC in-use:

Active:

0 - 2 VDC

Inactive state:

6V - 32VDC

Open contact

High voltage AC in-use:

Active: 100VAC - 240VAC

Inactive: 0 - 10VAC

! Do not connect both Low and Hi In-use line simultaneously

Site PRIME Installation Manual 17

 Parameter Value

Bypass Mechanical bypass switch operates in parallel to SSR

Smart Bypass reporting:

When SSR is at an open state, voltage on SSR

contacts is monitored:

Standard:

AC: 100 - 240V

DC: 10-32V

Bypass:

AC or DC: 0 - 4V

When SSR goes to close state, the last value

before going to close state is reported

Note: When using digital pulsers, the voltage wave peak must
tangent to 0V, otherwise it will not intercept in the decoder or will
be counted twice.

2.6.3. Communication Standards

Site PRIME communicates over the following standards:

TCP/IP over Ethernet

RS-232 link (with the relevant Pump Interface module installed)
RS-485 link (with the relevant Pump Interface module installed)
RS-422 link (with the relevant Pump Interface module installed)
IEEE 802.15.4

Note: RS-232/485/422 communications unrelated to the Pump

Interface (PI) still require the relevant PI module to be installed.

18 Site PRIME Installation Manual

Section 3 Preliminary
Installation Procedures
3.1. General
This section provides preliminary guidelines for Site PRIME. These include:

Preliminary instructions
Wiring and wire conduits requirements

3.2. Precautions and Safety Notes

Prior to any 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.

The homebase environment is highly flammable and combustible. Therefore,

make sure that the installation is performed by experienced personnel,
licensed to perform work in a homebase station 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-70A “National Electric Code”,
federal, state, local codes, and any other applicable safety codes and
regulations.
System power may come from more than one source. Disconnect all power
sources, including pumps, before attempting to work on the system.
Install Site PRIME in an area in accordance with the safety restrictions (see
Figure 3-1).

Site PRIME Installation Manual 19

 Figure 3-1 - Installation Control
The Site PRIME site preparation is the customer’s responsibility.
Do not connect power to Site PRIME and other peripherals, including pumps,
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. This may result in death, serious personal injury, property
loss, and damage to you and other persons.
When working in any open area of the homebase station, beware of passing
vehicles. Block off the work area to protect yourself and other persons using
safety cones or other signaling devices.

3.3. Conduits
To install Site PRIME, the cable layout in the homebase station must be
prepared beforehand. This procedure consists of installing conduits within the
station, inserting the proper cables, and setting the proper power equipment
and sensors.
This section provides the procedures for infrastructure groundwork. These
procedures consist of:

Wire conduits installation

Cables routing within the conduits
Power equipment setup
Forecourt equipment wiring

20 Site PRIME Installation Manual

3.3.1. Requirements
The installation of Site PRIME in the station requires digging and setting several
conduits in the station ground. The conduits are required for the routing and
protection of the different types of cables used in a homebase station with Site
PRIME.
In sites where the infrastructure is already set up, you can only use the existing
conduits if they meet the requirements defined below.
Conduits must comply with the following:

All conduits must be made and installed according to local regulations

High-voltage AC and low-voltage DC must NOT be combined in a
common conduit, junction box, or wire trough
RS-485 or LAN communication must not exceed 330 feet (100 m). Cables
must be inserted in a separate low voltage conduit, away from AC wires.
Communication range can be extended using 3rd party devices
RS-232 communication must not exceed 50 feet (15 m). RS-232
communication shielded cable must be inserted in a separate low
voltage conduit, away from AC wires. Communication range can be
extended using 3rd party devices
Antenna wires must not exceed 330 feet (100 m) in case the VIU is in use,
and 50 feet (15 m) in case the Fuel Ring is used. Antenna wires must be
inserted in a separate low voltage conduit, away from AC wires
All conduits must be inserted in the Site PRIME enclosure through the
openings provided in the bottom panel.
Do not make any holes in the unit other than the ones available as
knockout plates. If you must make holes at locations other than those
provided, contact Gasboy Technical Support for approval, by calling 1-
800-444-5529
After completing the installation, all open holes should be resealed

3.3.2. Conduits in Site PRIME

The bottom panel in the Site PRIME includes four openings of 3/4" diameter for
the insertion of cables into the unit . Connect the wiring through cable glands.
The cables and wires are inserted through the conduits according to their
types and routed to their sources.
The conduits are used for:

Site PRIME Installation Manual 21

 One conduit is intended for high voltage cables
One conduit is intended for low voltage cables

Note: The high voltage conduit is only required if there is a 100-

240V power supply.

3.3.3. Required Conduits in the Station

Different types of conduits are necessary for different types of equipment.
Therefore, the locations of the conduits should be planned based on the
location of the equipment that connects to it.
There are two functional conduits:

High voltage conduits

Low voltage conduits

The following conduits are required in the station:

High voltage conduits

AC power for Site PRIME
Pump control from pumps to Site PRIME
Pump In-use signal from pumps to Site PRIME
Low voltage conduits
Internet line from LAN in office to Site PRIME
RS-232 communication line from TLG in office to Site PRIME
RS-485/422/C.L.
Pulser from pumps to Site PRIME
24V power
Grounding
At least 10 mm2 Grounding cable to pump chassis
At least 10 mm2 Grounding cable to Site PRIME
Grounding cable to TLG – in accordance with TLG manufacturer
instructions
Tank conduit
TLG Probe

22 Site PRIME Installation Manual

3.3.4. Wiring Conduits in Site PRIME
Site PRIME includes four wiring openings, each suited to specific wires, as listed
in the Table 3-1.
Table 3-1 - Conduits into Site PRIME
No. Conduit Type Type

1 Low voltage LAN cables, pump/TLS communication cables, 24V power

2 High voltage Pump power cable, all 100-240V cables

3 High voltage In-use, control

Site PRIME Installation Manual 23

 Figure 3-2 - Conduit Layout for Mechanical Pump

24 Site PRIME Installation Manual

 Figure 3-3 - Conduit Layout for Electronic Pump

Site PRIME Installation Manual 25

3.3.5. Installation
To install conduits in the island, proceed as follows:

1. Determine the location of the Site PRIME in the station

2. Dig and prepare passageways for the necessary conduits
3. Route the following conduits to the junction boxes:
Low voltage cables junction boxes:
One conduit to the office (control room)
One conduit to each pump
Two conduits to Site PRIME
High voltage cables junction box:
One conduit to the office (control room)
One conduit to each pump
Two conduits to Site PRIME

3.3.6. Sealing
The conduits must be sealed in accordance with NFPA requirements and local
regulations, to prevent the passage of gases through conduits, cables, and
conductors. Fittings are required wherever volatile liquids or gases are present
in the surroundings (see Figure 3-4).

Figure 3-4 - Conduit Fitting

3.4. Cable Insertion

The following describes the requirements and procedures for the insertion of
cables in the conduits.

26 Site PRIME Installation Manual

 Note: All devices in the system must be connected to the same
electric power phase.

Note: The type of cable needed varies in accordance with the

device it connects to. The wire used must be stranded and not a
solid core. Select a cable specification in accordance with local
environment conditions.

Warning: For supply connections, use wires suitable for at least

90°C / 194°F. Signal wiring connected in this box must be rated at
least 300V.

3.4.1. Cable Types

The following are the types of cables used for the wiring of the Site PRIME
system (see Table 3-2):
Table 3-2 - Site PRIME Cable Types
No. Function Type

1 AC Power Power cable, 3x1.5 mm2 NYY (14 AWG), in accordance with local standards

Control to
pumps
(valves)

In-use signal

2 Pulser Data communication cable, 300 V RMS, 90°C / 194°F, shielded twisted pair, oil
resistant, 24 AWG, low capacitance below 60 PF/meter (3.3') similar to Belden
TLG (RS-232) 9729 cable

3 LAN CAT5E, Shielded, 300 V RMS, 90°C / 194°F similar to Belden 121700A

4 GND Ground cable 0.4" (10.8 mm2)

3.5. Power Setup

The power equipment must be installed in the main power cabinet. It should
include the following:

Site PRIME Installation Manual 27

 Mains Circuit Control Box (MCC)
Uninterruptible Power Supply (UPS) – Online ("True") UPS
Power Distribution Box (PDB)

3.5.1. Connection Diagram

The following diagram shows the requested connections of the power
equipment (see Figure 3-5):

Figure 3-5 - Power Equipment Connections

Apart from the power equipment, other components should be connected to
the power supply such as the TLG and dispensers.

3.5.2. Connecting the Power Equipment

Before the Site PRIME can be installed on a surface, all cables and conduits
must be prepped on the unit's back wall.
To connect the power equipment, proceed as follows:

External Mains
Connect Mains power to the Mains Circuit Control Box (MCC)
Uninterruptible Power Supply (UPS)
Connect the MCC to the UPS

28 Site PRIME Installation Manual

 Power Distribution Box (PDB)
Connect the UPS to the Power Distribution Box (PDB)
Check the PDB wiring and ensure a separate Mains Circuit Breaker
(MCB) for each socket/device that requires power.
Wire one 0.4" (10mm) ground cable from the mains ground
connection to the PDB.

Note: If there is any doubt concerning grounding, ask for a ground

test, which must be performed by a qualified electrician.

3.5.3. Grounding
Proper system grounding is an extremely important part of the system
installation.
As with the AC power, the grounds for all system components should return to
the same circuit breaker panel. This assures a common ground throughout the
system, necessary for protection of the RS-485 data loop circuitry.
Ground for all system devices should be wired to the breaker panel ground
bus bar, which in turn should be grounded to a ground rod. A conduit ground
does not provide sufficient grounding. It is recommended that the neutral and
ground bus bars be bonded together when it is not prohibited by local codes.

Note: If the Site PRIME is being installed on a pole, all cables and
conduits must be run to the bottom of the pole (entering the pole
from the base). The cables have to be long enough to run through
the pole to the Site PRIME.

Site PRIME Installation Manual 29

Section 4 Site PRIME
Installation Procedures
4.1. General
This section provides the installation procedures for Site PRIME. These
procedures include:

Installation Guidelines
Homebase Station
Mapping the Site
Installing the Site PRIME
Connections to Site PRIME
Pump Interface Modules

4.2. Installation Guidelines

Best Practice: Perform a site survey of the station prior to

installation.

Installation procedures and requirements depend, to some extent, on the

specific fuel dispenser models and the site 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 ensure that it adheres to all local standards. This plan design
should reflect the existing electric infrastructure of the site.

4.2.1. Precautions and Safety Notes

Prior to actual installation activities, carefully observe the precautions and
safety notes detailed in Precautions and Safety Notes and Requirements.

Site PRIME Installation Manual 30

4.2.2. Safety Distances
The following shows the safety distances required for the installation of Site
PRIME adjacent to the dispensers. Site PRIME must be installed in a non-
hazardous location (see Figure 4-1).

Figure 4-1 - Installation Control Drawing

When mounting Site PRIME, a minimum clearance of 18 inches (0.5 m)
between the unit and any of the pumps or the dispensers must be maintained.
This clearance ensures that a safe amount of room is available for the wiring
and maintenance of the system.
Site PRIME is designed and approved for installation and use in a convenient
location on or near fuel island in the appropriate hazardous (classified)
location:

Where hazardous location is classified as Class 1, Division 2 and does not

extend higher than 18 inches (0.5 m) from the surface
A minimum safety separation of 18 inches (0.5 m) from any nearest
pump / dispenser

4.3. Homebase Station

Prior to installation, you are required to obtain an overview of the homebase
station functional architecture. This overview is required in order to draw an
architecture diagram with all components and their communication links.
The following shows a functional diagram of the links within the homebase
station (see Figure 4-2):

31 Site PRIME Installation Manual

 Figure 4-2 - Homebase Station System Diagram

4.3.1. Station Architecture

The homebase station functional architecture consists of the following levels:

Main Power Cabinet and homebase station forecourt

Head Office Center

4.3.1.1. Main Power Cabinet

The Main Power Cabinet includes the following components:

Site PRIME Installation Manual 32

 Mains Circuit Control Box (MCC)
Uninterruptible Power Supply (UPS)
Power Distribution Box (PDB)
TLG Controller

4.3.1.2. Homebase Forecourt

The homebase Forecourt includes the following components:

Site PRIME
Dispenser(s), up to four nozzles for each Site PRIME. This product has
only been evaluated for use with UL Listed Dispensers
One or more underground gas tanks
TLG probe for each gas tank. This product has only been evaluated for
use with UL Listed TLGs

4.3.1.3. Head Office System (Optional)

The Head Office system consists of a fully integrated management hardware
and software tool that supports the homebase stations and small gas stations
with their sale management of products including inventory management and
reporting.
The Head Office Center is a remote-control center that stores, processes and
analyzes all the transactions at the homebase station. The Head Office station
provides an integrated retail solution.

4.4. Mapping the Site

The following describes an example of site mapping.
This procedure consists of the following steps:

Locating and Mapping all Objects of the Site

Assigning Logical Identifications (IDs) to the Devices
Assigning the ethernet and serial addresses of devices linked to the
network
Obtaining a functional and physical map of the devices in the site

33 Site PRIME Installation Manual

4.4.1. Locating and Mapping all Objects of the Site
Locate the fuel tanks
Locate the intended position of the Site PRIME
Draw a basic map of the site with all the objects

4.4.2. Assigning Logical Identifications (IDs) to the Devices

To each fuel tank:
Assign the tank sequential number (coordinated with the station
manager)
Assign its fuel code and name
Assign its TLG Probe (AP) ID
To each dispenser unit:
Assign an ID to every dispenser name and pump server
Assign an ID to every dispenser pump (P)
Assign an ID to every pump CPU address, if any
Assign an ID to its nozzles (N)
Assign to each nozzle the tank (T) ID it is linked to
Assign the Site PRIME its ID after installation on a flat surface

Note: The map methodology and IDs will be used for setup
configuration.

4.5. Installing the Site PRIME

The Site PRIME is mounted in the safe area of the homebase gas station on a
wall or any flat surface up from the ground (panel, billboard) or on a pole
(purchased separately), and installed with wall mounting brackets that provide
a wall distance of 10 mm. The brackets are attached to four holding padded
holes in the inner rear wall of the Site PRIME.
The installation procedure consists of the following general steps:

Installing Site PRIME on a wall or pole

Running cables through the conduits to Site PRIME
Wiring Site PRIME

Site PRIME Installation Manual 34

4.5.1. Site Preliminary Setup Procedures
To perform the preliminary setup procedures:

1. Determine where the Site PRIME will be installed

2. Insert the cable glands into the Site PRIME
3. Run cable conduits for each type of cable to the determined location:
One High Voltage conduit from the dispenser
One Low Voltage conduit from the dispenser
One Low Voltage conduit from the office
One High Voltage conduit from the Mains Distribution Box
4. Run the cable conduits to the hole

The following sections describe in detail how to install Site PRIME in different
scenarios.

4.5.2. Support Rails Installation Procedure

The table below lists the assembly parts required for the installation of the Site
PRIME support rails (see Table 4-1, Figure 4-3):
Table 4-1 - Site PRIME Assembly Parts
Item No. Description Qty

1. SCREW, M6x12 SST + 2 WASHERS 4

2. MID RANGE WALL MOUNTING RAIL 2

3. CABLE GLAND, NYLON, EG-16, KSS 2

4. Unit Keys 2

35 Site PRIME Installation Manual

 Figure 4-3 - Support Rails Assembly Parts
To install the unit, proceed as follows:

1. Place one rail on the top pair of holes and fasten into place with 2x
M6x12 screws using a 5mm Hex (Allen) Key (see Figure 4-4):

Figure 4-4 - Top Rail

2. Place the second rail on the bottom pair of holes and fasten into place
with 2x M6x12 screws using a 5mm Hex (Allen) Key (see Figure 4-5):

Site PRIME Installation Manual 36

 Figure 4-5 - Both Rails

4.5.3. Cable Gland Insertion

To insert the cable glands to the Site PRIME, proceed as follows:

Note:

It is recommended to connect the cable glands before

installing the Site PRIME on the wall
Place the Site PRIME on a stable and level surface before
proceeding

37 Site PRIME Installation Manual

 1. Select the knockout openings for the installation and open them using a
hammer and large screwdriver (see Figure 4-6, Figure 4-7):

Figure 4-6 - Knocking Out Using Hammer

Figure 4-7 - Knocked Out Opening

Site PRIME Installation Manual 38

 2. Insert a cable gland into each opened knockout opening (see Figure 4-8,
Figure 4-9):

Figure 4-8 - Cable Gland Outside View

Figure 4-9 - Cable Gland Inside View

3. Fasten the cable gland securely with the appropriate tools to ensure a
proper seal (see Figure 4-10):

39 Site PRIME Installation Manual

 Figure 4-10 - Cable Gland Fastening

4.5.4. Installation Procedure on Wall

Note: If the OrPAY1000 will be used as an Wireless Gateway

(Master) for AVI support, the Site PRIME should be installed in a
location where the signal will not be blocked. It is recommended to
add a repeater to strengthen the RF network.

The following diagram details the dimensions of the Site PRIME when installed
on the wall (see Figure 4-11):

Site PRIME Installation Manual 40

 Figure 4-11 - Dimensions on the Wall
To perform the installation, proceed as follows:

1. Use the drill template provided with the product to mark the location of
the four holes for drilling
2. Drill four holes in the installation locations and insert four wall anchors
(or equivalent) in the holes
3. Set the Site PRIME on the location so that the installation holes on the
rails fit with the anchors
4. Secure the Site PRIME. Verify that the Site PRIME enclosure is firmly held
(see Figure 4-12):

41 Site PRIME Installation Manual

 Figure 4-12 - Site PRIME Installed on Wall

4.5.5. Installation Procedure on the Pole

The following diagram details the dimensions of the Site PRIME and the pole
(see Figure 4-13):

Figure 4-13 - Dimensions on the Pole

Site PRIME Installation Manual 42

To perform the installation, proceed as follows:

1. Secure the base of the pole to the column with the 5 Allen M6 screws
provided (see Figure 4-14):

Figure 4-14 - Base Secured to Column

2. On the installation surface, mark the location of the holes for drilling
3. Drill the holes in the installation locations and insert the screw anchors
(or equivalent) in the holes. Ensure the screw anchors are appropriate
for the diameter of the holes in the base of the pole. Line the base of the
pole up with the holes and secure it to the surface

43 Site PRIME Installation Manual

 4. Apply the rosette cover (see Figure 4-15):

Figure 4-15 - Rosette Cover

5. Place the cable trough provided onto the pole and secure it with the
provided allen M6 screws (see Figure 4-16):

Figure 4-16 - Cable Trough

6. After cables have been inserted through the cable glands, place the
controller on the cable trough and securely install it with the provided
screws, as shown in the image below (see Figure 4-17):

Site PRIME Installation Manual 44

 Figure 4-17 - Site PRIME Secured to Cable Trough
7. Close the pole cover with the 6 flat screws provided (3 on each side)

4.5.6. Sealing Conduits

The conduits must be sealed in accordance with NFPA requirements and local
regulations, to prevent the passage of gases through conduits, cables, and
conductors. Fittings are required wherever volatile liquids or gases are present
in the surroundings (see Figure 4-18).

45 Site PRIME Installation Manual

 Figure 4-18 - Conduit Fitting

4.6. Connections to Site PRIME

Do not perform any electrical work, maintenance, or repairs to the

product when it is connected to power. Before performing any work
on the product, disconnect it from the main power supply

Ensure the cable glands are securely tightened to the cables

running through them in order to ensure they are properly sealed

In order to perform the wiring, the protective cover over the high
voltage area needs to be removed and replaced once the work is
complete

The electrical and communication connections should be made as follows:

1. Designate an opening for the power supply, and other openings for the
high voltage, the pumps, the low voltage, and the communication cables
(see Figure 4-19):

Site PRIME Installation Manual 46

 Figure 4-19 - High Voltage Area and Low Voltage & Communication Area
2. High voltage cables and electrical wires should be placed to the right
3. Low voltage cables, wires, and communication cables should placed to
the left (see Figure 4-20):

Figure 4-20 - AC Power Supply Connected to GND/Neutral/Line

4. The connections are as follows:

47 Site PRIME Installation Manual

 Table 4-2 - 1M Module - LED Indicators
Input Power T.B Yellow/Green T.B Black T.B Red
Version
Range (1) (2) (3)

Site PRIME (including

100-240VAC GND/Earth Neutral (0) Line (~)
UX)

PumpTop PRIME 100-240VAC GND/Earth Neutral (0) Line (~)

4.7. Pump Interface Modules

To install the pump interface modules, proceed as follows:

1. Wire the connections to and from the modules before attaching the
module to the Site PRIME
2. The connections to the modules are made with the designated
connectors for each modules
3. To attach the modules, slide the module against the anchor in the
designated area, perpendicular to the main plate, and secure the
opposite side of the module with a screw, through the fastening point.
The orientation of the fastening point depends on the type of pump
module being installed (see Figure 4-21, Figure 4-22):

Site PRIME Installation Manual 48

 Figure 4-21 - Fastening Point of the Mechanical Pump Module on the Right

Figure 4-22 - Fastening Point of the Electronic Pump Module on the Left

49 Site PRIME Installation Manual

The following describes the various pump modules available and how to wire
them:

4.7.1. Site PRIME 1M Module

The 1M Module is a pump module designed for mechanical pumps (see Figure
4-23, Figure 4-24):

Figure 4-23 - 1M Module

Figure 4-24 - 1M Module Wiring Connections

4.7.1.1. 1M Module - LED Indicators

The following table describes the various LED indicators on the 1M Module and
their meaning (see 1M Module - LED Indicators). A legend below the tables
explains the symbols and their meanings:

Site PRIME Installation Manual 50

 Table 4-3 - 1M Module - LED Indicators
LED
Indicator Meaning
BYPASS INUSE PULSER IND RELAY ON

A bypass state is detected

In-use input is active

Pulses are counted

Power is on and working properly

SSR Relay is switched to close

state

LED on, LED flashing

A load must be applied to the SSR in & out in order for the unit to work.
Without load, the unit assumes it is in Bypass mode (bypass LED is on) and the
controller will consider the pump in offline.

Warning: For single SSR output of an MPI module, do not exceed

1.8 amps! This is the maximum current allowed when connecting
load.
For more information, see table 2-2 - AC/DC MPI Module
Specifications.

4.7.2. Electronic Pump Modules

The Site PRIME has various pump modules required for the different electronic
pumps it is compatible with (see Figure 4-25):

51 Site PRIME Installation Manual

 Figure 4-25 - Electronic Pump Module

4.7.3. Electronic Pump Modules Connections

The following table describes the various electronic pump modules compatible
with Site PRIME and their connections:
Table 4-4 - Electronic Pump Modules - Connections
Module
1 2 3 4 5 6 7 8 9
Description

4x Left CH1 CH1 CH1 N.C CH2 CH2 CH2 N.C Chassis
RS485 Connector (+) (-) (G) (+) (-) (G)
Module
Right CH3 CH3 CH3 N.C CH4 CH4 CH4 N.C Chassis
Connector (+) (-) (G) (+) (-) (G)

4 x C. Left CH1(-) CH1 CH1 N.C CH2 CH2 CH2 N.C Chassis
LOOP Connector (+) (G) (-) (+) (G)
Module
Right CH3 CH3 CH3 N.C CH4 CH4 CH4 N.C Chassis
Connector (-) (+) (G) (-) (+) (G)

2x Left CH1- CH1- CH1- CH1- CH1 CH2- CH2- CH2 Chassis
RS422 + Connector 422 422 422 422 (G) 232 232 (G)
2x (TX+) (TX-) (RX+) (RX-) (TX) (RX)
RS232
Module
Right CH3- CH3- CH3- CH3- CH3 CH4- CH4- CH4 Chassis
(see
Connector 422 422 422 422 (G) 232 232 (G)
note
(TX+) (TX-) (RX+) (RX-) (TX) (RX)
below)

Site PRIME Installation Manual 52

 Note: In case an RS232 device is connected to the RS422/232
module, the “chassis” pin must be connected to the GND pin on the
green connector (see Figure 4-26).

Figure 4-26 - RS232 Device Connected to RS422/232 Module

4.8. Post-Installation Checklist

After completing the installation procedure, carefully inspect the connection
between the Site PRIME and the external power mains and the data sources.
In particular, pay attention to the following:

53 Site PRIME Installation Manual

 Correct wiring
Is all of the wiring inserted within metal conduits?
Is the AC and DC wiring inserted in separate conduits, troughs,
etc.?
Are the systems and peripheral equipment powered on a separate
dedicated breaker?
Is the AC power for the systems and pumps on the same phase in
the breaker panel?
Is the system grounded properly?
Is the correct wire gauge installed?
Are the cables correctly routed in the station?
Are the communication lines under the maximum allowable
distance?
LAN: 330 feet (100 m)
RS-232: 50 feet (15 m)
RS-485: 330 feet (100 m)
Antenna wire:
330 feet (100 m) for VIU
50 feet (15 m) for Fuel Ring
Clean dirt and wire remnants
Make sure that power supply setup jumpers are properly set BEFORE
applying power to the Site PRIME

In case problems are detected after installation or during operation, repeat the
post-installation checks listed above.

4.9. PRIME Add-Ons

The following sections describe the assembly procedures for all the available
PRIME Add-Ons.
These add-ons need to be defined properly in the relevant software.
Each transmitting add-on has a different FCC/IC approval. A PRIME unit with a
transmitting unit installed from the production line will have the
FCC/IC number printed on it

Site PRIME Installation Manual 54

All add-ons require adding an FCC/IC label to the PRIME main label. After each
installation, add the Add-On FCC/IC label in one of the available spaces on the
product label (see Figure 4-27).

Figure 4-27 - FCC/IC label on Product Label

4.9.1. Cellular Modem Module

The Cellular Modem Module is a 4G LTE Cellular modem (with 2G/3G backward
compatibility), that allows communication between the controller and the HO
.It is provided with the following assembly kit components (see Figure 4-28,
Figure 4-29, Figure 4-30, Figure 4-31, Figure 4-32, Table 4-5):

Table 4-5 - Cellular Modem Module

Assembly Parts
Assembly Kit Number: 819258125
Gasboy Kit Number: M15778B504
Item No. Description Qty

1 Cellular Antennas 1

2 Cellular Modem Module 1

55 Site PRIME Installation Manual

 Item No. Description Qty

3 SCREW. M2x6, PAN HD PH 2

WASHER, SPRING, M2 2

WASHER, FLAT, M2 2

4 Screw, M4x8 SST+2 Washers 2

5 Antenna shelf 1

6 Cable tie 2

7 Harness 2x USB 1

8 Harness USB cover 1

9 Screw M3x20 PAN HD 1

10 FCC/IC Label 1

Figure 4-28 - Cellular Modem Module Assembly Parts

Site PRIME Installation Manual 56

 Figure 4-29 - Cellular Modem Module Assembly Parts

Figure 4-30 - Cellular Modem Module Assembly Parts

Figure 4-31 - Cellular Modem Module Assembly Parts

Figure 4-32 - Cellular Modem Module FCC/IC Label (10)

57 Site PRIME Installation Manual

To install the Cellular Modem Module, proceed as follows:

1. Turn the main power switch to OFF position (see Figure 4-33):

Figure 4-33 - Main Power Switch - OFF

2. Disconnect and extract the nOrCU and the CommBoard bracket (see
Figure 4-34). Disassemble the 3 captive screws (marked with yellow
arrows) and disassemble the power harness connector (marked by the
green arrow). Cut the cable ties (marked by the orange arrows):

Site PRIME Installation Manual 58

 Figure 4-34 - nOrCU Connection
3. Connect the USB cable to the USB connector on the nOrCU (for an
illustration of the connector port to connect to, see USB Installed on
CommBoard). Cover and fasten the cable with the cable cover, with the
M3x20 screw (see Figure 4-35, Figure 4-36, Figure 4-37):

Figure 4-35 - USB Cable Connected to the USB Connector

59 Site PRIME Installation Manual

 Figure 4-36 - USB Cover Placed

Figure 4-37 - USB Cover Fastened

4. Install the SIM card in the CommBoard SIM socket (see Figure 4-38):

Site PRIME Installation Manual 60

 Figure 4-38 - CommBoard SIM Socket
1. Gently pull up the SIM socket cover to enable insertion (see Figure
4-39):

Figure 4-39 - SIM Socket Cover Raised

2. Insert the SIM card into the SIM socket (see Figure 4-40):

61 Site PRIME Installation Manual

 Figure 4-40 - SIM Card in SIM Socket
3. Gently push the SIM socket cover back down to its place (see Figure
4-41):

Figure 4-41 - SIM Socket Cover Replaced

Site PRIME Installation Manual 62

 5. Install the antennas on the antenna tray:
1. Clean the antenna tray with alcohol to remove oil residue and dirt
2. Peel the adhesive guard tape and place the antennas
3. Secure the antenna wires with cable tie, and place the antenna
wires as follows (see Figure 4-42):

Figure 4-42 - Antenna Anchor

63 Site PRIME Installation Manual

 6. Connect the antennas to the module and fasten the antenna wires with a
cable tie as follows (see Figure 4-43):

Figure 4-43 - Antennas Connected to Module

7. Install the module to the CommBoard mPCIe connector. Slide the mPCIe
Modem into the mPCIe connector on the CommBoard (marked with an
orange arrow), and fasten with the screw and washers from the kit
(marked with purple arrow) (see Figure 4-44):

Site PRIME Installation Manual 64

 Figure 4-44 - Modem on the CommBoard mPCIe Connector
8. Install the USB cable to the relevant connector on the CommBoard (see
Figure 4-45):

Figure 4-45 - USB Installed on CommBoard

65 Site PRIME Installation Manual

 9. Install the Antenna tray and the nOrCU with the CommBoard bracket:
fasten the nOrCU block captive screw (marked with the red arrows), and
fasten the Antenna tray screws from the kit (marked with the orange
arrows). Close the bracket captive screws and fasten the tray using the
M4x8 screws (see Figure 4-46):

Site PRIME Installation Manual 66

 Figure 4-46 - Antenna Tray Installation

67 Site PRIME Installation Manual

 10. Reconnect all the disassembled harnesses and turn the main power
switch to the ON position.

4.9.2. Wi-Fi + BT Modem Module

The Wi-Fi + BT Modem Module is a Wi-Fi Access Point 2.4/5GHz that is used for
the Fuel & Drive app to connect with the controller. It is provided with the
following assembly kit components (see Figure 4-47, 4.9, Figure 4-48, Figure 4-
49, Figure 4-50, Table 4-6):

Table 4-6 - Wi-Fi + BT Modem Module

Assembly Parts
Assembly Kit Number: 819258120
Gasboy Kit Number: M15778B503
Item No. Description Qty

1 Wi-Fi Antenna set 1

2 Wi-Fi + BT M.2 Module 1

3 mPCIe to M.2 adapter+screws 1

4 SCREW. M2x6, PAN HD PH 2

WASHER, SPRING, M2 2

WASHER, FLAT, M2 2

5 Screw, M4x8 SST+2 Washers 2

6 Antenna shelf 1

7 Cable tie 2

8 FCC/IC Label 1

Site PRIME Installation Manual 68

 Figure 4-47 - Wi-Fi + BT Modem Module Assembly Parts

Figure 4-48 - Wi-Fi + BT Modem Module Assembly Parts

69 Site PRIME Installation Manual

 Figure 4-49 - Wi-Fi + BT Modem Module Assembly Parts

Figure 4-50 - Wi-Fi + BT Modem Module FCC/IC Label (8)

To install the Wi-Fi + BT Modem Module, proceed as follows:

1. Turn the main power switch to OFF position (see Figure 4-51):

Figure 4-51 - Main Power Switch - OFF

2. Disconnect and extract the nOrCU and the CommBoard bracket (see
Figure 4-52). Disassemble the 3 captive screws (marked with yellow

Site PRIME Installation Manual 70

 arrows) and disassemble the power harness connector (marked by the
green arrow). Cut the cable ties (marked by the orange arrows):

Figure 4-52 - nOrCU Connection

3. To assemble the M.2 modem in the M.2 to mPCIe adapter, insert the M.2
Module into the M.2 socket of the adapter and fasten with the supplied
adapter screws (see Figure 4-53):

Figure 4-53 - M.2 Modem in the M.2 to mPCIe Adapter

4. Install the antennas on the antenna tray
1. Clean the antenna tray with alcohol to remove oil residue and dirt
2. Peel the adhesive guard tape and place the antennas

71 Site PRIME Installation Manual

 3. Secure the antenna wires with the antenna anchor and fasten with
a cable tie (see Figure 4-54):

Figure 4-54 - Antenna Anchor

5. Connect the antennas to the modem assembly and fasten using a cable
tie (see Figure 4-55):

Site PRIME Installation Manual 72

 Figure 4-55 - Antennas Fastened With Cable Tie

73 Site PRIME Installation Manual

 6. Install the modem assembly to the mPCIe connector on the nOrCU. Slide
the mPCIe Wi-Fi set into the mPCIe connector on the nOrCU (marked
with a purple arrow), and assemble the screw and washers from the kit
(marked with an orange arrow) (see Figure 4-56):

Figure 4-56 - Modem Assembly on the mPCIe Connector

Site PRIME Installation Manual 74

 7. Install the Antenna tray and the nOrCU with the CommBoard bracket:
fasten the nOrCU block captive screw (marked with the red arrows), and
fasten the Antenna tray screws from the kit (marked with the orange
arrows) using the M4x8 screws (see Figure 4-57):

75 Site PRIME Installation Manual

 Figure 4-57 - Antenna Tray Installation

Site PRIME Installation Manual 76

 8. Reconnect all the disassembled harnesses and turn the main power
switch to the ON position

4.9.3. nWGT
The nWGT is provided with the following assembly kit components (see Figure
4-58, Figure 4-59, Figure 4-60, Table 4-7):

Table 4-7 - nWGT Assembly Parts

Assembly Kit Number: 819227450 (Gasboy
P/N: M15778B505)
Item No. Description Qty

1 PCB ASSY.nWGT-Wide 1

2 HARNESS MID RANGE NWGT W POWER 1

3 3 CABLE LAN UL, 60cm, 90 ° C 1

4 SCREW # 3x12 PAN HD, TO PLASTIC 4

5 Cable tie 4

6 WASHER M5, EXT. TOOTH LOCK 1

7 NUT, M5 1

8 WASHER FLAT M5 SST DIN-125 1

9 FCC/IC label 1

77 Site PRIME Installation Manual

 Figure 4-58 - nWGT Assembly Parts

Site PRIME Installation Manual 78

 Figure 4-59 - nWGT Assembly Parts

Figure 4-60 - nWGT FCC/IC Label (9)

To install the nWGT, proceed as follows:

79 Site PRIME Installation Manual

 1. Turn the main power switch to OFF position (see Figure 4-61):

Figure 4-61 - Main Power Switch - OFF

2. Install the nWGT on the Inside door panel, using four # 3x12 screws to
fasten the unit into place (see Figure 4-62):

Figure 4-62 - nWGT Installed

3. Connect the 60cm LAN cable to the nWGT power harness, anchoring the
cables to the door with the cable ties. Fasten the GND cable to the GND
stud using the M5 set (tooth lock washer, standard washer, and nut) (see
Figure 4-63):

Site PRIME Installation Manual 80

 Figure 4-63 - Cables Connected
4. Connect the power harness and the LAN cable to the CommBoard and
fasten the cables to the partition wall (see Figure 4-64):

81 Site PRIME Installation Manual

 Figure 4-64 - Connected to CommBoard
5. Turn the main power switch to ON position

4.9.4. TR500
The TR500 is provided with the following assembly kit components (see Figure
4-65, Figure 4-66, Table 4-8):

Table 4-8 - TR500 Assembly Parts

Assembly Kit Number: 819258200
Item No. Description Qty

1 HARNESS MID RANGE TR500 POWER 1

2 ANCHOR MOUNT, TA1S8-C 2

3 SCREW # 3x12 PAN HD, TO PLASTIC 2

4 FCC/IC Label 1

Site PRIME Installation Manual 82

 Item No. Description Qty

5 Cable tie 6

Figure 4-65 - TR500 Assembly Parts

Figure 4-66 - TR500 Assembly Parts

83 Site PRIME Installation Manual

To install the TR500, proceed as follows:

1. Turn the main power switch to OFF position (see Figure 4-67):

Figure 4-67 - Main Power Switch - OFF

2. Using a drill, cut four 3.5mm holes and a 20mm hole in the front panel
(see Figure 4-68, Figure 4-69):

Site PRIME Installation Manual 84

 Figure 4-68 - Drill Locations

85 Site PRIME Installation Manual

 Figure 4-69 - Front Panel with Holes Drilled
3. Pull the TR500 power supply and LAN harness through the 20mm holes
(see Figure 4-70):

Figure 4-70 - Threading Cables

4. Attach the TR500 to the panel and fasten with the four M3 screws
supplied with the TR500 (see Figure 4-71):

Site PRIME Installation Manual 86

 Figure 4-71 - Attaching TR500
5. Anchor the harness to the front panel with the anchors and screws
provided with the kit (see Figure 4-72):

Figure 4-72 - Harness Anchored

6. Connect the TR500 power harness to the kit power harness, Red to
Green, and Black to White+Clear. Cut the remaining wires in the TR500
power harness, Red, Black and Grey (see Figure 4-73):

87 Site PRIME Installation Manual

 Figure 4-73 - Connecting to Harness

Site PRIME Installation Manual 88

 7. Cut the remaining wires in the TR500 power harness: red, black, gray
(see Figure 4-74):

Figure 4-74 - Cutting the Wires

8. Connect the power harness and the LAN cable to the CommBoard and
fasten the cables to the partition wall (see Figure 4-75):

Figure 4-75 - Connected to CommBoard

89 Site PRIME Installation Manual

 9. Turn the main power switch to ON position (see Figure 4-76):

Figure 4-76 - Site PRIME With TR500 Turned On

Site PRIME Installation Manual 90

Section 5 PRIME Converter
Setup
5.1. General
This section provides instructions for setting up the PRIME Converter.
To access the setup site for Site PRIME, proceed as follows:
Open an internet browser (currently only Chrome is supported) and enter the
default IP address provided (the default is https://192.168.1.111). The
Converter Setup homepage appears with a login dialog (see Figure 5-1):

Figure 5-1 - PRIME Converter Setup Login

To log in, proceed as follows:

1. Enter the initial credentials for first login:

Username: Admin
Password: Admin
2. Click on Sign In. The following screen is displayed (see Figure 5-2):

Site PRIME Installation Manual 91

 Figure 5-2 - PRIME Converter Setup Homepage

3. Immediately after the first login, you will be prompted to change your
username and password

The Converter settings page includes the following navigation buttons on the
left side of the screen:

Home Page: Basic device information

Setup: Main device settings
Software Upload: Uploads configuration files and software / firmware
updates
Status: Displays previous software and firmware updates that were
uploaded, if any
Change Password: Enables the user to change the credentials used to
log into the website
Reset Password: Resets the password for the device in order to re-
activate it
Logout: Logging out of the web site

5.2. Home Page

The Home page displays current device information (see Figure 1-2, Table 5-1):

92 Site PRIME Installation Manual

 Table 5-1 - Device Information
Field Description

Ethernet IP Ethernet IP address

Ethernet MAC Ethernet MAC address

SW Version Software version installed on the device

HW Family Hardware version installed on the device

Boot Loader Version Boot Loader Version installed on the device

Pump Interface 1 Version Pump software version for the PI in Slot 1

Pump Interface 2 Version Pump software version for the PI in Slot 2

Pump Interface 3 Version Pump software version for the PI in Slot 3

Location Location of the Site PRIME

Serial Number Serial number of the device

Device Key The current key used for activating the device

Note: If no module has been connected in the slot for a specific

pump (1, 2, or 3), the corresponding Pump Interface 1/2/3
Version field will be blank. Only the details of connected pump
modules will be displayed.

5.3. Setup
The Setup page is comprised of five tabs: Minimal Setup, General Setup,
Channels Config, Log Level, and Save Setup. Click on the Setup navigation
button to view and define the parameters in each tab.

5.3.1. Minimal Setup

The Setup page opens with the Minimal Setup tab selected (see Figure 5-3):

Site PRIME Installation Manual 93

 Figure 5-3 - Minimal Setup Tab
The following actions are available:

In the Location field, enter a description for the location of the device
(optional)
Click Restore Factory Setup to reset the device to the factory defaults
(optional)

Caution: The Restore Factory Setup option should be used

only when there is an issue that can't be solved any other
way. When clicking this button, all previously defined settings
will be overwritten.

Click the Submit button to save the changes locally

Note: Clicking on Submit only saves the configuration temporarily

on a local level. To commit the changes permanently, make sure to
save everything via the Save Setup tab.

94 Site PRIME Installation Manual

5.3.2. General Setup
Click on the General Setup tab. The following screen appears (see Figure 5-4):

Figure 5-4 - General Setup Tab

The following actions are available:

Define the General Setup fields detailed in Table 5-2 below

Click on the Submit button to save the changes locally

Note: Clicking on Submit only saves the configuration

temporarily on a local level. To commit the changes
permanently, make sure to save everything via the Save
Setup tab.

Site PRIME Installation Manual 95

 Table 5-2 - General Setup Fields
Field Description

Ethernet Configuration

IP Address Device IP Address

Subnet Mask Subnet Mask address

Gateway Gateway

DHCP Not currently available

MAC MAC address

RTC

Date (dd/mm/yyyy) Date

Time (hh:mm:ss) Time

Note: The RTC (Real Time Clock) setting is important when

activating converter logging. When activated, the logger will draw
the timestamp from this setting.

Note: Make sure that no pumps at the station are actively fueling
before changing the date or time.

5.3.3. Channels Config

The Channels Config tab is the main screen for configuring the converter.
Clicking the Scan Interfaces button at the bottom of the screen automatically
identifies and populates the details of all connected modules, and presents
them with channel numbers on the left (see Figure 5-5), up to a maximum of
12 channels:

96 Site PRIME Installation Manual

 Figure 5-5 - Channels Config Tab
All new cards manufactured today include a built-in classification that is
automatically identified during the scan.

Note: After clicking the Scan Interfaces button, a confirmation

dialog with the following message will appear: "You are about to
scan hardware interfaces. Continue?". Click OK to proceed with the
scanning.

Each channel includes the following fields (see Table 5-3):

Site PRIME Installation Manual 97

 Table 5-3 - Channels Config Channels Fields
Field Description

Host

TCP/IP Port Host TCP/IP Port. Port numbers can range from 1024 to 56000

Device Name Device Name (Ideally should reflect the corresponding destination,
i.e. "CL" for Current Loop destinations)

No Data The controller checks communication at regular intervals, if no

Timeout communication is detected within the timeout interval, the channel
will automatically reset. The setting can range from 50 to 100. If set to
0, the channel will not reset

Destination

Interface Channel number between 1-12 (up to 4 per PI)

Number

Comm. Type Communication protocol for the interface

None (if there is no protocol)

RS-232 (electronic PI)
RS-485 (electronic PI)
RS-422 (electronic PI)
Current Loop (electronic PI)
MPI-C Standalone (channel in a single card) (mechanical PI)

RS-232 and RS-422 channels are configured on the same PI -

channels 1 and 2 are RS-232 and channels 3 and 4 are RS-422

Baud Rate Communication Interface details. Please see table below for details
by pump type
Data Bits

Parity

Stop Bits

Current This setting is for Current Loop channels only, and specifies the type
Select of current used by the channel. For Wayne type pumps, select 20mA,
and for Gilbarco type pumps, select 40mA.

98 Site PRIME Installation Manual

 Field Description

Frame Longest pause in milliseconds between received bits before

Timeout destination interface interprets the pause as the end of one
message, and interprets further transmissions as a new message (0 =
4 bytes of silence). If there are problems with the frame timeout, it is
recommended to start raising the value gradually (to 1, 3, 5, etc.) and
checking each time for improvement. The maximum recommended
value is 10

Table 5-4 - Communication Interface Details by Pump Type

Pump Type Baud Data Bits Parity Stop Bits
Rate

Gasboy 9600 8 None 1

Gilbarco Current Loop: 20mA 5787 8 Even 1

Wayne Current Loop: 40mA 9600 8 Odd 1

After setting the required parameters for the channels, click the Submit
button to save the changes locally.

Note: Clicking on Submit only saves the configuration temporarily

on a local level. To commit the changes permanently, make sure to
save everything via the Save Setup tab.

5.3.4. Log Level

The Log Level tab is required only when logs are needed (see Figure 5-6):

Site PRIME Installation Manual 99

 Figure 5-6 - Log Level Tab
The Log Level section defines settings for logs that are sent to the provider.

Note: Please consult with the provider's Customer Services prior to

defining the Log Level settings.

The following actions are available:

Define the Log Level fields detailed in Table 5-5) below

In the Debug Port Interface drop-down, select the port that the log will
be transferred through
None: Logs are not transferred
Com: Transfers the logs via RS-232
TCP/IP: Transfers the logs via LAN connection
Click on the Submit button to save the changes locally

100 Site PRIME Installation Manual

 Note: Clicking on Submit only saves the configuration temporarily
on a local level. To commit the changes permanently, make sure to
save everything via the Save Setup tab.

Table 5-5 - Log Level Fields

Field Description

General

Debug Port None: Logs are not transferred

Interface Com: Transfers logs via RS-232 (requires connecting a
communication cable)
TCP/IP: Transfers logs via LAN
Auto: Transfers logs automatically

Ethernet Debug Port number. The default is 5000

Port

Secure Channel

Log Levels: Select Debug Information

Source Logs:

TcpS
TcpC
DIAG
ADMIN
Prime

Log Levels Data (the most common setting is selecting the TcpS >
Data checkbox)
Debug
Info

5.3.5. Save Setup

Once you have completed and submitted all configuration details, you must
save all changes in the Save Setup tab in order to write the changes to the
flash memory and save the configuration permanently. To save changes,
proceed as follows:

Site PRIME Installation Manual 101

 1. Click on the Save Setup tab. The following screen appears (see Figure 5-
7):

Figure 5-7 - Save Setup Tab

2. Click Save and Reset. A confirmation pop-up appears with the message
"Save changes and reset the device?"

3. Click OK to continue. The following dialog appears (see Figure 5-8):

102 Site PRIME Installation Manual

 Figure 5-8 - Save Confirmation

4. Click OK to complete the save process. After a few seconds, you will be
logged out and asked to sign in again (see Figure 5-9):

Figure 5-9 - Sign In Prompt

5. After signing in, the following promp will appear (see Figure 5-10)

Site PRIME Installation Manual 103

 Figure 5-10 - Update Configuration
6. Click OK. The Home screen will display the updated settings
7. To download an XML file containing all of the settings defined on the
Setup page to the local machine, click Download Setup to PC. The
following dialog appears (see Figure 5-11):

104 Site PRIME Installation Manual

 Figure 5-11 - Download Setup File

8. Click OK to confirm

Note: The dialog screenshots in this procedure are for

demonstration purposes only, including the IP address in the
headers. Use the IP address provided to you by Customer Support
when performing this procedure.

5.4. Software Upload

The Software Upload screen enables uploading the newest software and
firmware versions provided to the technicians by the provider (see Figure 5-
12):

Site PRIME Installation Manual 105

 Figure 5-12 - PRIME Converter Software Upload Page
The Software Upload screen includes the following fields:

Field Description

File Type Application

Boot Loader
Configuration File
Pump Mezzanine

Update Currently only Update Immediate is available

Options

Choose Opens a browser to select a file for upload

File

Force When enabled, forces a software update. Used only when reverting
Update to a previous version of the software

106 Site PRIME Installation Manual

To upload a file to the device, proceed as follows:

1. In the File Type drop-down, select the file type that you'd like to upload
2. Click on Choose File to launch a browser window, and browse to the file
path of the software version to upload
3. Select the file and click Open
4. Click Upload. The following dialog appears (see Figure 5-13):

Figure 5-13 - Confirm Upload Dialog

5. Click OK to confirm and upload the file

Note: The Pump Mezzanine option refers to the converter's

interface with the connected device, which is displayed in the Pump
Interface 1/2/3 Version in the Home screen.

5.5. Status
The Status page displays all the previous software and firmware updates that
were uploaded and implemented in the device. These uploads will be listed in
the table under Firmware storage (see Figure 5-14):

Site PRIME Installation Manual 107

 Figure 5-14 - PRIME Converter Status Page
To clear all the uploads listed under Firmware storage, click the Clear
Storage button.

5.6. Change Password

In the Change Password page, the user can change the password used to log
into PRIME Converter web site (see Figure 5-15).

108 Site PRIME Installation Manual

 Figure 5-15 - PRIME Converter Change Password Page
To change password, proceed as follows:

1. In the Change Password Page, fill in the details for the following fields:
Username: enter the existing user name
Current Password: enter the existing password
New Password: enter the desired new password
Confirm Password: enter the new password again to confirm it
2. After filling in all the details, click Submit. The new password is now in
effect

5.7. Reset Password

The Reset Password page is used to change the password or Device Key used
to log into the device (see Figure 5-16):

Site PRIME Installation Manual 109

 Figure 5-16 - PRIME Converter Reset Password Page
The device key is replaced every few seconds. When a technician wants to
reset the device password (such as when they forgot the password), they need
to contact the provider and perform the reset with them, as follows:

1. The technician gives the provider the number that is displayed in the Key
box
2. The provider gives the technician a confirmation code
3. The technician then enters the code provided into the Confirmation
Code box
4. The technician clicks the Submit button. The user name and password
are reset to Admin / Admin

Note: To reset the password, the user needs to open the page in
the browser with the Converter's IP address, and immediately click
the Reset Password tab on the left of the screen BEFORE the login
screen appears (see Figure 5-1). This action should be performed
quickly.

110 Site PRIME Installation Manual

Section 6 Troubleshooting
6.1. General
This section provides a list of common pump / system problems which may be
encountered when using the Site PRIME system, as well as corrective actions
covering problems related to the system and its peripherals.

6.2. Site PRIME

The following describes Site PRIME troubleshooting procedures and
appropriate corrective actions.

6.2.1. System Down

The following table describes the Site PRIME troubleshooting procedure and
appropriate corrective actions when the system is down (see Table 6-2):

Site PRIME Installation Manual 111

 Table 6-1 - System is Down
Probable
Fault Checks Corrective Action
Cause

No Site PRIME main Turn main switch on

communication switch is off
After power on, wait a
nOrCU LEDs are few seconds for the
not lit timer relay to be
connected

No Verify all input power Correct wiring problems

12VDC/24VDC connections: if 12 VDC/24 VDC is not
supply to the measured
1. Check cabling from
unit
junction box to the
unit

2. Verify that power

cable is properly
connected to unit
terminal block

3. Verify the input &

output voltage of the
DC to DC 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
immediately after being in the power
turned on? line cable

2. Check
grounding

112 Site PRIME Installation Manual

 Probable
Fault Checks Corrective Action
Cause

Circuit breaker Is the breaker off or tripped? Turn the breaker on, if
is off off

Is 12VDC/24VDC being Replace breaker if

switched through breaker? 12VDC/24VDC is not
being switched

Is 12VDC/24VDC measured at Correct wiring problems

the power input terminal if 12VDC/24VDC is not
block? measured

Does the breaker turn off Check for loads or

immediately after being shorts in the power line
turned on?

Internal fuse Check the two pico fuses (red Replace the fuse if it is
blown wires) at the bottom of the blown
power supply using an ohm-
meter

Power supply Verify that green LED on 1. Replace mini

failure power supply is lit fuse

2. Replace power
supply

6.2.2. Mechanical Pump Does Not Fuel

The following table describes the Site PRIME troubleshooting procedure and
appropriate corrective actions when the mechanical pump does not fuel (see
Table 6-2):

Site PRIME Installation Manual 113

 Table 6-2 - Mechanical Pump Does Not Fuel
Probable
Fault Checks Corrective Action
Cause

Pump does not Device is not 1. Open the pump Enable the device to refuel
supply fuel allowed to refuel from SiteOmat
Status screen

2. Verify that the

vehicle/device
has no limitation
in FHO setup

Pump setup is Check pump setup: 1. Set pump parameters

incorrect 2. Save and reload
Pump server

Buses 3. Check again

Prices

Pulse Rate

Faulty connection Check control cables from Make a secure electrical

to pump Site PRIME to pump connection

Converter failure Verify that Power LED is lit If it is off, use a voltmeter to
check power supply to the unit:
If power supply is okay, then
replace the converter board. If
power supply is faulty, replace
the power supply

During Authorization, 1. Replace MPI-C board

verify that the control LED 2. Replace the converter
on the converter (near
the white connector)
board is lit

Pump malfunction Turn the Site PRIME If the problem persists:

bypass switch on, lift the
1. Check handle-on
nozzle and check that the
switch
pump supplies fuel
2. Repair pump

114 Site PRIME Installation Manual

 Probable
Fault Checks Corrective Action
Cause

Handle-on switch Is the red in-use LED on 1. Check in-use cable and
problem the MPI-C board lit when repair (if necessary)
the nozzle is lifted? 2. Check terminal wires
and repair (if
necessary)

3. Check in-use switch in

the pump and repair (if
necessary)

Pump is authorized Faulty in-use Power off the pump. Use Replace pump switch in cases
but call state is not switch in pump an ohm-meter to where no short was detected
detected (nozzle icon measure the switch in at
in SiteOmat Status on and off states
screen does not
Faulty connections Check in-use Make good electrical
display call state)
cable connection, if faulty

Check in-use
terminal block
connections

Faulty in-use Replace in-use terminal block

terminal block

Faulty MPI-C board Verify that the red call If the red LED is not lit,
LED is lit when nozzle is replace the MPI-C
lifted board

If the led is lit, the

problem is external to
the controller

Faulty converter Replace converter

Pump is authorized, Faulty Does the pump solenoid Replace valve

pump motor is solenoid valve produce a clicking Repair pump
running, but no fuel valve sound?
is supplied Faulty
pump

Site PRIME Installation Manual 115

 Probable
Fault Checks Corrective Action
Cause

Payment device Communication 1. Check 1. Replace

(card, key, tag, Fuel fault between communication communication cable,
Ring) is not accepted TR500 and cable if necessary
SiteOmat 2. Check TR500 2. Set TR500 parameters
setup properly

3. Check SiteOmat 3. Set SiteOmat

setup parameters properly

Communication 1. Check connection Repair communication

fault between FHO path with FHO between FHO and SiteOmat,
and SiteOmat 2. Verify that the providing a reliable

station is communication line

available and
synchronized
with FHO in FHO
Stations Status
screen

Device was not 1. Log into FHO as Define the device parameters
defined or is Fleet Manager in FHO properly
defined incorrectly 2. Check that the
in FHO device is defined

3. Check device
parameters

4. Check that the

device rules do
not limit refueling

Device limit was Verify that the device is For testing only, remove any
passed within the limits of its rule rule associated to this device

116 Site PRIME Installation Manual

 Probable
Fault Checks Corrective Action
Cause

Device was set as 1. Log into FHO and Change the device setting to
Driver go to Device Vehicle
Management

2. Select the specific

device and check
it was configured
as a Driver

Device is blocked 1. Log into FHO and Change device status to

go to Devices Unblocked
Management

2. Check the status

of the device in
the Status column
in the Devices
grid(blocked /
unblocked)

6.2.3. Pump is Authorized and Refueling but Volume Remains Zero

The following table describes the Site PRIME troubleshooting procedure and
appropriate corrective actions when the pump is authorized and refueling but
the volume remains at zero (see Table 6-3):
Table 6-3 - Pump is Authorized and Refueling but Volume Remains Zero
Probable
Fault Checks Corrective Action
Cause

Pump is refueling Pulse factor is Check SiteOmat pump Change Pump Settings to correct
but volume zero setup the factor for the relevant pump
remains zero
Faulty Disconnect the pulser and If pulses are received during
MPI-C short the pulse-in wires to refueling, replace pump pulser. If
board simulate pulses not, replace MPI-C board

Faulty
pulser

Site PRIME Installation Manual 117

6.2.4. No Control Over Fueling
The following table describes the Site PRIME troubleshooting procedure and
appropriate corrective actions when there is no control over fueling (see Table
6-4):
Table 6-4 - No Control Over Fueling
Fault Probable Cause Checks Corrective Action

Pump is Pump is in bypass Verify that the Turn bypass switch off,
refueling Site PRIME if it is on
without any bypass switch is
control off

Faulty SSR/relay Replace the relevant

SSR/relay unit
connected to Site PRIME

If an external relay is used to control the Add a snubber

pump / valve, it may be stuck due to a (capacitor + resistor) in
small current leak parallel to relay input

6.3. Communication
The following table describes problems related to communication to
peripherals and consequent corrective actions (see Table 6-5):

118 Site PRIME Installation Manual

 Table 6-5 - Communication Troubleshooting
Fault Probable Cause Checks Corrective Action

No Communication between FHO and SiteOmat Controller

No connection Cabling issue Inspect the network 1. Verify that the LAN2
to the station cable to LAN2 Port LED is blinking
from FHO 2. Unplug the cable and
Stations screen plug it back in

3. Replace the LAN cable

(if necessary)

4. If the cable is in a good

condition; contact the
IT department to
confirm that the switch
/ router connected to
the LAN cable is
installed properly

5. Check the controller

network settings (IP
addresses, mask,
gateway, etc.)

No Communication with the Pumps (converter)

Site PRIME Installation Manual 119

 Fault Probable Cause Checks Corrective Action

Warning signs Incorrect converter setup Check the 1. If there is no activity on

displayed for all physical the LAN port connected
pumps on the connection of to the converter,
SiteOmat the converter to replace the short
Status screen the local Ethernet cable and / or
network (5-port change the LAN port to
switch activity) confirm normal

Check network operation

connectivity by 2. Check the status of the

performing a LEDs on the converter
"ping" (upper right corner of
command the board): the first and
locally or the third LED should be
remotely, lit to confirm power
through PuTTY and network
application connection, while
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 with the Nozzles (Wireless Gateway)

120 Site PRIME Installation Manual

 Fault Probable Cause Checks Corrective Action

Can’t read the 1. No Check the 1. If no activity on the LAN

vehicles and / communication physical port, check the cable
or no with the Wireless connection of and/or change the port
authorization at Gateway the Wireless on the 5-port switch
the pumps 2. Incorrect nozzle Gateway to the 2. Remove the top cover
reader setup local network to access the Wireless
(5-port switch) Gateway and check the
Check the status of the LEDs
Wireless 3. Connect to the Wireless
Gateway Gateway through the 9-
network pin serial port and
settings open Hyperterminal
Check the HyperTerminal
programming (115200, 8, None, 1,
of the Wireless None), reset the
Nozzle Readers. Wireless Gateway and
follow the startup
messages to find the IP
address.

Site PRIME Installation Manual 121

Appendix A
6.4. General
This appendix provides the wiring diagrams of the Site PRIME, as follows:

122 Site PRIME Installation Manual

 Figure 6-1 - Site PRIME with Orpay1000

Figure 6-2 - Site PRIME with TR500

Site PRIME Installation Manual 123