Fuel Retail POS Integration: Technical Field Guide

Category: Equipment / POS Systems / Integration Equipment: Gilbarco Passport, Wayne Nucleus, Verifone Commander Last Updated: 12/25/2024 Difficulty: Intermediate to Advanced Cross-Reference: Error Codes Reference, Wayne Dispenser Troubleshooting

Quick Reference

Gilbarco Passport Support: 800-800-7498 Wayne/Dover Support: Contact authorized service center Verifone Commander Support: 800-837-4366

1. Major POS Platform Architectures

1.1 Gilbarco Passport

Windows-based architecture on the PX60 platform (Intel Core i3-2120, 4GB DDR3, SSD).

Key Component: Enhanced Dispenser Hub (EDH/EDH2)

• Separate controller handling all dispenser communications and modem interfaces
• Segregated architecture isolates payment from POS application
• Keeps POS free from PCI scope

Specifications:

• 120+ certified back-office partners
• Communicates with dispensers via current loop through EDH
• Competitive pump control requires D-Box converters:
  • PA0338X000 for Wayne
  • PA0338X001 for Tokheim
• Different protocols must run on separate loops

1.2 Wayne Nucleus

Separates forecourt control from POS through the Fusion automation platform.

Fusion Controller Variants: | Model | Capabilities | |-------|-------------| | Fusion 1000 | Basic forecourt control | | Fusion 3000 | Mid-range with expanded protocol support | | Fusion 6000 | Electronic payment processing separate from POS |

Key Facts:

• Supports 40+ different dispenser types out-of-box (including Gilbarco)
• ~25% of Nucleus installations interface with non-Wayne dispensers
• Default IP: 192.168.150.1
• File access: WinSCP with PPK key authentication

1.3 Verifone Commander

Runs on Secure Real-Time Linux with virtualized architecture.

Four Virtual Cores:

1. Store Controller - POS application (up to 32 terminals)
2. Forecourt Controller - Dispenser interface
3. Payment Controller - VIPER EPS with dedicated NIC for network segmentation
4. V950 Services - Remote diagnostics

Specifications:

• Supports up to 64 fueling positions
• Forecourt Control Interface (FCI) box with up to 4 interface boards
• Any combination of current loop and RS-485
• Web-based Commander Console for remote configuration

Platform Comparison

| Platform | OS | Payment Isolation | Multi-Vendor Approach | |----------|-----|------------------|----------------------| | Gilbarco Passport | Windows (PX60) | Segregated via EDH | Separate D-Box per protocol | | Wayne Nucleus | IBM retail-hardened | Fusion 6000 optional | Fusion controller 40+ protocols | | Verifone Commander | Secure Linux | Dedicated VIPER core | FCI box with mixed boards |

2. Communication Protocols

2.1 Industry Standards

IFSF (International Forecourt Standards Forum)

• Developed 1992 by major oil companies and pump manufacturers
• Two-layer architecture: device application + transport layer
• Transport: LON (LonWorks) or TCP/IP
• Messages use Type-Length-Value (TLV) format

IFSF Dispenser State Machine:

Inoperative → Closed → Idle → Calling → Authorized →
Started → Suspended Started → Fuelling → Suspended Fuelling

Conexxus FDC (North America)

• Forecourt Device Controller Specification V2.1.2
• XML-based messaging adapted from IFSF

2.2 Gilbarco Two-Wire Protocol

| Parameter | Value | |-----------|-------| | Architecture | Master-slave | | Baud Rate | 9600 bps | | Physical Layer | 2-wire current loop | | Data Format | 8 data bits, 1 start/stop, NO parity | | Max Distance | 1200 meters | | Current Levels | 20mA, 40mA, or 60mA (jumper selectable) |

Message Structure: Header-Body-Checksum with DLE character delimiting

2.3 Wayne DART Protocol

| Parameter | Value | |-----------|-------| | Physical Layer | RS-485 (2-wire half-duplex) | | Baud Rate | 9600 bps | | Parity | ODD (critical difference from Gilbarco) | | Data Format | 8 data bits, 1 stop bit |

DART Frame Structure: START → PUMP_ID → TRANS_CODE → LENGTH → DATA → CHECKSUM

2.4 Physical Layer Specifications

| Protocol | Physical Layer | Max Distance | Topology | |----------|---------------|--------------|----------| | RS-232 | 3-wire (TxD, RxD, GND) | 15 meters | Point-to-point | | RS-422 | 4-wire differential | 1200 meters | Multi-drop | | RS-485 | 2-wire half-duplex | 1200 meters | Multi-drop (daisy chain only) | | Gilbarco 2-Wire | Active current loop | 1200 meters | Multi-drop | | Wayne DART | RS-485 based | Site-wide | Multi-drop |

2.5 Protocol Converters

PTS Controller (Technotrade):

• Supports 120+ dispenser brands
• Four independent ports, each programmable for different protocol/baud

Gilbarco Epsilon Controller:

• Handles ATCL, WCL, Gilbarco TwoWire, Wayne DART
• Up to 64 pumps using IFSF FDC POS protocol

Allied Controller (Wayne-to-Gilbarco):

• Channels 5-7: Wayne dispensers
• Channel 8: Wayne CATs

3. Communication Parameter Reference

3.1 Standard Configurations

| Controller/POS | Protocol | Baud Rate | Parity | Data/Stop Bits | |----------------|----------|-----------|--------|----------------| | Passport/EDH | Gilbarco EDIM | 1200 | Even | 7/1 | | Commander, Allied, NCR | VR Protocol DIM | 9600 | Odd | 7/1 | | Gilbarco Two-Wire | Native | 9600 | None | 8/1 | | Wayne DART | Native | 9600 | Odd | 8/1 |

CRITICAL: Gilbarco uses NO parity; Wayne uses ODD parity. Mixing these guarantees failure.

4. Common Failure Patterns

4.1 RS-485 Wiring Errors (Most Common)

Despite being called "2-wire," RS-485 requires three conductors:

1. Two data lines (differential pair A/B)
2. Signal ground for zero-volt reference

Cable shield does NOT provide signal ground - this misconception causes more failures than any other.

Common RS-485 Mistakes: | Issue | Symptom | Fix | |-------|---------|-----| | Missing signal ground | Intermittent comm | Add dedicated ground wire | | A/B polarity reversed | No communication | Swap A/B (causes no damage) | | Star topology | Intermittent comm | Rewire to strict daisy chain | | Missing termination | Reflections, errors | Add 120Ω at both line ends | | Inadequate line bias | False start bits | Add bias resistors |

Correct RS-485 Installation:

• Shielded twisted pair (10-12 twists/foot minimum)
• #18 AWG minimum (#14 AWG for long runs)
• Shield drain wire bonded to ground at ONE end only
• Keep stubs extremely short

4.2 Current Loop Errors

Gilbarco's 2-wire current loop permits only one "active" device supplying current—all others must be "passive."

Failure Mode: Connecting two active controllers to same loop causes communication collision.

Diagnosis:

1. Verify active/passive configuration
2. Check current flow with ammeter

4.3 Address Conflicts

Symptom: "Offline" or "No Communication" errors

Each fueling position requires a unique address.

Gilbarco-Specific Issue:

• Network ID stores on Passport server
• Grade ID stores on pump
• If POS-dispenser connection drops, pump retains Grade ID instead of Network ID
• Complicates recovery—may need to reprogram pump

4.4 Tank Gauge Integration (Veeder-Root TLS)

| Alarm | Meaning | Action | |-------|---------|--------| | Probe Out | Hardware failure | Inspect probe and wiring | | E1 Comm Alarm | No EDIM-POS communication | Verify port, cable, programming | | PLLD Shutdown | Failed line leak test | Investigate leak source |

EDIM Diagnostics: Menu → Diagnostics → Module → Comm

• Monitor Rx/Tx byte counts
• Both should show similar, increasing numbers
• No errors should display

4.5 Environmental Factors

| Factor | Risk | Prevention | |--------|------|------------| | Lightning/surges | Destroyed boards | UPS/surge protection on all controllers | | Underground cable damage | Intermittent/complete loss | Proper burial depth, conduit | | Connector corrosion | Signal degradation | Weather-sealed connections | | Vibration | Loose connections | Locking connectors, strain relief | | Temperature cycling | Component stress | Rated equipment for environment | | Power quality | Communication errors | Proper grounding per NEC 514 |

Power Quality: Voltage drop to pumps must be under 5% from panel.

4.6 Quick Error Code Reference

| Code | Platform | Meaning | |------|----------|---------| | 11 | Gilbarco Encore | Communication problem | | 50 | Gilbarco Encore | Communication loss with POS | | E01 | Wayne iGEM | Sapphire/POS sync issue |

5. Troubleshooting Sequence

Universal Fault Isolation:

1. Verify power - Check voltage at controller and dispensers
2. Check wiring continuity - Test all conductors end-to-end
3. Verify polarity - Especially A/B on RS-485
4. Check termination - 120Ω at both ends of RS-485
5. Confirm addresses - Each position unique
6. Match parameters - Baud, parity, data bits must match exactly
7. Test with loopback - Isolate controller from network
8. Substitute known-good equipment - Final step

6. EMV Migration Status

6.1 Timeline & Compliance

Final Liability Shift Dates:

• April 17, 2021 (Visa)
• April 16, 2021 (Other networks)

Current Status (as of April 2021):

• Only 48% of major fuel merchants fully EMV compliant
• Non-compliant merchants: $13,000+/year estimated fraud exposure

6.2 Terminal Generations

| Generation | Features | Certification | |------------|----------|--------------| | Gen 1 (pre-2015) | Mag-stripe only, RS-485, dial-up | None | | Gen 2 (2015-2019) | Hybrid (mag+chip), transitioning to Ethernet | PCI PTS 3.x | | Gen 3 (2019+) | NFC contactless, TCP/IP required, touchscreen | PCI PTS 4.x-6.x |

6.3 Platform-Specific EMV Solutions

Gilbarco FlexPay: | Version | PCI Level | Notes | |---------|-----------|-------| | FlexPay II | PTS 3.x | Legacy EMV | | FlexPay IV | PTS 4.x | First U.S. fuel terminal (2017) | | FlexPay 6 | PTS 5.x/6.x | 9" all-in-one or 15.6" modular |

FlexPay Connect System:

• Backroom Communications Module (BRCM) supports 8 dispensers
• Dispenser Communications Module (DCM) at each unit
• Converts existing 2-wire to Ethernet

Wayne iX Pay: | Version | Display | Certification | |---------|---------|--------------| | iX Pay | Original | PCI PTS 2.x | | iX Pay 2 | First PTS 3.0 certified | | | iX Pay T5 | 5.7" | Current | | iX Pay T7 | 7" WVGA touchscreen | Media capable |

Wayne Connectivity Requirements:

| Connection Type | EPP Mode | EMV | Media | |----------------|----------|-----|-------| | Direct RS-485 | Yes | NO | NO | | Wayne Connect | Yes | Yes | Yes | | Ethernet | NO | Yes | Yes |

6.4 EMV Certification Levels

| Level | What It Certifies | Who Needs It | |-------|-------------------|--------------| | L1 | Physical hardware (electrical/mechanical) | Terminal manufacturer | | L2 | EMV payment kernel software | Software provider | | L3 | Complete terminal-to-host integration | MERCHANT |

CRITICAL: Installations without L3 certification leave merchants liable despite having EMV hardware. The POS must be L3 certified with the specific payment processor.

6.5 Network Infrastructure for EMV

Pre-EMV:

• RS-485 serial at 9.6-115 Kbps
• Two-wire twisted pair
• Dial-up connections

EMV Requirements:

• TCP/IP Ethernet (minimum 1 Mbps)
• CAT5e/CAT6 wiring (or Ethernet extenders)
• PCI-compliant network segmentation
• VLAN capability for payment isolation

Field Solutions: | Solution | Pros | Cons | |----------|------|------| | New CAT6 conduit | Best performance | Expensive, disruptive | | Ethernet extenders | Uses existing wire | Distance limits | | Secure wireless | No trenching | UL listing required |

7. Emerging Technologies

7.1 Contactless Payment Adoption

• 61% of consumers prefer contactless-enabled merchants
• 84% find smartphone payments more convenient
• Major brands deployed: ExxonMobil, Shell, Chevron mobile apps

7.2 Future Payment Technologies

| Technology | Status | Notes | |------------|--------|-------| | Vehicle-to-pump (Car IQ Pay) | Rolling out 2024 | ExxonMobil first | | Voice payments | Emerging | "Alexa, pay for gas" | | In-vehicle integration | Development | Built into infotainment |

Related Documentation

• Error Codes Diagnostic Reference
• Wayne Dispenser Troubleshooting
• Veeder-Root CSLD Failures
• Verifone Connectivity Troubleshooting

This guide synthesizes field technician reference materials for Gilbarco Passport, Wayne Nucleus, and Verifone Commander platforms. Always verify against current manufacturer documentation for your specific equipment revision.