This document P/N 817423401 is based on Orpak’s 8 port CommVerter
operation and installation manual P/N 817423400
SAFETY CONSIDERATIONS
Read all warning notes and instructions carefully. They are included to help you installing the Product safely
in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions
could result in serious injury or property damage. It is the installer responsibility to install, operate and
maintain the equipment according to the instructions given in this manual, and to conform to all applicable
codes, regulations and safety measures. Failure to do so could void all warranties associated with this
equipment.
Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure
that actual installation is performed by experienced personnel, licensed to perform work in fuel station and at
a flammable environment, according to the local regulations and relevant standards.
WARNING - EXPLOSION HAZARD
Use separate conduit for the intrinsically safe. Do not run any other wires or cables through this conduit,
because this could create an explosion hazard.
Use standard test equipment only in the non- hazardous area of the fuel station, and approved test equipment
for the hazardo us areas.
In the installation and maintenance of the Product, comply with all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for
Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70 “National Electric Code”, federal, state and
local codes and any other applicable safety codes and regulations.
Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work
operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury,
property loss and damage to you and other persons.
CAUTION - SHOCK HAZARD
Dangerous AC voltages that could cause death or serious personal injury are used to power the Product.
Always disconnect power before starting any work. The Product has more than one power supply connection
points. Disconnect all power before servicing.
WARNING – PASSING VEHICLES
When working in any open area of fuel station, beware of passing vehicles that could hit you. Block off the
work area to protect yourself and other persons. Use safety cones or other signaling devices.
WARNING
Components substitutions could impair intrinsic safety.
Attaching unauthorized components or equipment will void your warranties.
CAUTION
Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all
warranties related to this equipment.
PROPRIETY NOTICE
This document contains propriety and confidential information. It is the property of ORPAK SYSTEMS
Ltd. It may not be disclosed or reproduced in whole or in part without written consent of ORPAK
SYSTEMS. The information in this document is current as of the date of its publication, but is subject to
change without notice.
DISCLAIMER
This document is provided for reference only. Although every effort has been made to ensure correctness,
ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.
TABLE 3-1. COMMVERTER LED INDICATION ...................................................................... 81
TABLE 3-2. MAIN BOARD CONNECTOR FUNCTIONALITY............................................... 81
TABLE 3-3. MAIN BOARD JUMPERS FUNCTIONALITY...................................................... 82
TABLE 4-1. COMMVERTER UNIT KIT.................................................................................... 89
8 Port CommVerter Operation and Installation Manual
ix
0
SECTION
1
GENERAL DESCRIPTION
1.1. SCOPE
The 8 port CommVerter unit, referred to as "CommVerter" throughout this document, is a
component within the FuelOmat system. It serves as a universal and modular hardware interface
between the Ethernet communication from the Station Controller (FCC) and the other devices
communication interfaces such as RS485/422, Current Loop, etc.
As a communication interface unit, the CommVerter converts the Ethernet communication protocol
of any station devices into RS-485/422, Current Loop or Tokheim communication interfaces and
vice versa.
The CommVerter includes several modules designed to support each communication interface.
Some of these modules can be configured for different protocols by means of built-in Web pages.
The CommVerter unit is designed to survive the harsh forecourt environment. The RS-485 module
uses Spark Gaps protection for the links, and 1.5 KV isolation between the office controller and the
forecourt devices.
1.2. MANUAL ORGANIZATION
This manual provides information on the technical characteristics, installation and operation of the
CommVerter unit. This document deals with the physical level of the communication that is,
connecting the CommVerter unit to a network. It does not cover any software required to configure
the system. The manual is organized as follows:
Section 1. General Description: Includes general information regarding the CommVerter unit, its
components and functionality.
Section 2. Applications: Describes the types of communication where the CommVerter unit
provides interface applications.
Section 3. Description: Includes detailed information regarding the CommVerter unit and its
specifications.
Section 4. Installation and Removal: Provides instructions regarding the installation (and
removal) of the CommVerter unit at the station office.
Section 5. Setup and Configuration: Provides instructions concerning the instructions for the
setup and configuration of the CommVerter unit.
Section 6. Checks and Troubleshooting: Provides several recommended steps for checking the
system operability and for basic troubleshooting.
10
8 Port CommVerter operation and installation manual
1.3. GENERAL DESCRIPTION
The CommVerter is a Communication Converter, interfacing serial Forecourt devices such as
pumps and tank level gauges to the station automation system through a standard TCP/IP Ethernet
port.
Unlike off-the-shelf Ethernet to Serial interfaces, the CommVerter is designed to function in the
harsh environment of the petrol stations; eliminating ground loops, power surges and other
RFI/EMI noise to maximize the performance and reliability of the station automation solution. Each
link is ‘floating’ and is DC isolated from all other links and has surge protection and enhanced
filtering.
There are two CommVerters configurations: one which is supplied as an enclosed unit which
includes an internal power supply (as shown in Figure 1-1) and the other as a PCB, which is
installed in Gilbarco's products (see Figure 1-2).
Figure 1-1. CommVerter – General View
8 Port CommVerter operation and installation
manual
11
Figure 1-2. CommVerter PCB - General View
The unit supports a combination of up to 8 serial links of various standards as required at the
forecourt, including: RS-232, RS-485 and current loop.
All links are carried to the station automation controller over one Ethernet port.
The specific protocol for each of these forecourt devices is part of the station automation while the
CommVerter unit is the physical serial interface for the specific devices.
One of the prime tasks of the CommVerter at the forecourt is to interface to the dispensers. The
specific protocol for every dispenser type resides in the “pump server” software module of the
station automation and is standard for all Gilbarco’s home base controllers.
The CommVerter unit is part of Gilbarco’s complete station automation solution and is not an
off-the-shelf standard product, but has a modular structure to enable flexibility for various petrol
stations’ configurations and size.
The CommVerter is a platform with plug-in units to address each specific installation.
12
8 Port CommVerter operation and in
stallation manual
Petrol stations around the globe are dramatically different in many aspects and the CommVerter
addresses all:
Total number of dispensers –several CommVerter units can be installed at the same
site.
Number of different dispensers at a specific site – various plug-ins are used,
according to the specific links that are required (RS-485, CL, Tokheim, etc.)
Number of contactless tag readers (OrTR, UPI, MiTag) and outdoor printers that
are needed at the petrol station (no more then 6 modules over one RS-485 link).
Number of tank level gauges and other 3rd party serial devices such as payment
terminals.
8 Port CommVerter operation and installation
manual
13
1.4. MODULES
1.4.1. Modules
Several types of modules are available to support each communication type. The configuration of
the CommVerter for each application is determined by the type of the installed modules within.
Select the CommVerter module suitable to the conversion method required at your station network.
Table 1-1 lists the available CommVerter modules.
CommVerter Modules P/N
4xCONTACTOR 819223481
Current Loop 819223431
MPI-C+SUB 819223490
Nuevo Pignone (485) 819223485
RS232 819223451
RS232/485 819223441
RS422 819223471
RS422 + SUB 819223472
RS485 819223460
5V P.S. for 8-LAN switch 819523442
Table 1-1. CommVerter Modules
Cetil 819223425
Tokheim 819223420
Pumalan 819223445
14
8 Port CommVerter operation and in
stallation manual
1.5. SPECIFICATIONS
Important Notice
At a rate above 9600 bps, the communication protocol with the 8Port Commverter shall handle 250 bytes
packets. The 8Port Commverter does not support a bytes stream flow at a rate higher than 9600 bps.
1.5.1. Communication Rates
The communication rates depend on the type of module.
8 Port CommVerter operation and installation manual
15
4 to 10 VDC (require wiring changes)
4 Pulsar Input High level sink
3mA
current (@15V)
5 Maximum pulse rate of
Up to 5 KHz
MPI-C at 50% duty cycle
6 In use "On" level (Input) 4 to 7 VDC
7 In use "Off" level (Input) -1 to 1 VDC
8 In use Input impedance 10 KOhm
9 In use-max Input current
106 uA
using external dry contact
(5VDC)
10 In use-max Input current at 7
50 uA
VDC
11 12 VDC Output 25 mA max
1.5.4. Mechanical
No. Parameter Value
1 Dimensions (HxWxD) 140 x 180 x 50 (mm)
1.5.5. Environmental
No. Parameter Value
1 Operating Temperature
2 Operating Temperature (with power
-30C to +55C
-20C to +50C
supply)
3 Storage Temperature
-30C to +70C
1.6. PROTECTION
The CommVerter in its 485 communication port (refer to Table 1-1) is protected electrically against
lightening and surges using transorbers and gas discharge (Arrosto) devices.
Additionally, grounding is required. Proper grounding is essential for protection to take place.
Refer to paragraph 4.4 - Grounding the Commverter.
16
8 Port CommVerter operation and in
stallation manual
0
SECTION
2
APPLICATIONS
2.1. SCOPE
This section provides the interfaces available between the CommVerter and several types of fuel
pumps. This section also includes several applications for the CommVerter in different se ttings
within the station. The CommVerter ensures proper communication between the FCC and the
station devices in accordance with their communication protocols.
2.2. COMMVERTER SYSTEM ARCHITECTURE
2.2.1. General
The CommVerter system architecture consideration depends on the topology of the specific petrol
station.
There are three main architectures:
Centralized at the station office
Moved to the isle side
When using an OrPT and/or µVIT on the isles
8 Port CommVerter Operation and Installation
Manual
17
2.2.2. System Architecture 1: Centralized at the Station Office
The CommVerter is usually installed centralized at the station office together with the station
controller. This topology requires serial links all the way from the office to each dispenser or other
forecourt serial devices.
Figure 2-1. CommVerter System Architecture – Centralized
18
8 Port CommVerter Operation and I
nstallation Manual
2.2.3. System Architecture 2: Moved to the Isle Side
In some applications, it is recommended to move the CommVerter to the isle side, carrying one
Ethernet link and power cable to the isle and then split to the serial links required at each isle.
Such an architecture usually requires only one or 2 plug-in units for each CommVerter on an isle.
Figure 2-2. CommVerter System Architecture – Moved to Isle Side
8 Port CommVerter Operation and Installation
Manual
19
2.2.4. System Architecture 1: Using an OrPT and/or µVIT on the Isles
Other system configuration could be implemented when using an OrPT and/or µVIT on the isles.
In this configuration, both the OrPT and µVIT use a built-in Ethernet to RS-485 CommVerter,
supporting serial forecourt devices on the isle such as printers and contactless tag readers.
These links provided by the µVIT /OrPT could be off-loaded from the centralized CommVerter unit
to minimize cabling and installation cost.
Figure 2-3. CommVerter System Architecture – Using an OrPT and/or µVIT
20
8 Port CommVerter Operation and I
nstallation Manual
2.3. TYPES OF FUEL PUMP AND THEIR COMMUNICATIO N METHOD
The CommVerter is used as an interface for several types of fuel pumps, as listed below:
Pump/Dispenser
Manufacturer
Model
(Protocol)
Aplab RS485 819223460 2 8 On 9600 8 None 1
Aplab
Swadesh II
Avery RS485 819223460 2 4 On 9600 8 Odd 1
Baransay
The CommVerter in its basic version includes four separate connectors. Each connector supports up
to two distinctive channels for every module. However, in RS-422 and Sub RS-422 modules,
MPI-C and MPI-C + Sub, only one channel is supported.
A rear panel view of the CommVerter unit connectors is shown in Figure 2-4.
Figure 2-4. CommVerter – Connectors
A general view of the CommVerter connectors in PCB configuration (without the casing) is shown
in Figure 2-5.
Figure 2-5. CommVerter PCB - Connectors
24
8 Port CommVerter Operation and I
nstallation Manual
2.4.2. Mating a Connector
The CommVerter kit includes one size mating connectors to be wired in accordance with the
selected fuel station configuration and consequently, the required conversion method.
To wire a mating connector (see Figure 2-6), proceed as follows:
1. For all modules, use standard 8-pin Phoenix-type male connector (P/N 813325001),
to be connected to the CommVerter.
2. For LAN connection, use RJ45 cat5 LAN cable (not included in the kit).
3. Wire the connector in accordance with its pinout definition as described in the
following paragraphs. The wiring shall be performed in accordance with the
CommVerter configuration.
NOTE
The connector pinout definition (pin number on top, signal
in second row) is provided when facing the connector,
from right to left.
4. The following paragraphs provide the wiring definition of the ports. These wiring
definitions are also shown on the connectors' labels (see Figure 2-4 and Figure 2-6).
Verify compatibility before connection!!!
Figure 2-6. CommVerter – Connector
8 Port CommVerter Operation and Installation
Manual
25
2.5. LAN to RS-485 APPL ICATION
The LAN to RS-485 application is required when connecting fuel pumps and other serial devices to
home base controller that uses TCP/IP communication. In this configuration, the RS-485 Two-Port
module (P/N 819223460) is installed within the CommVerter.
If several CommVerter units are to be connected to the FCC, a Hub must be added to the network in
order to support several connections.
Figure 2-7. CommVerter – LAN to RS-485 Application
The CommVerter diverts the LAN communication to the relevant RS-485/422 device. The relevant
module is addressed with its IP address, and a unique port is configured during the device setup.
Interfaces using this mode of communication and conversion include Wayne Dart, Midco, L&T,
Tatsuno, Aplab, and more.
The following table provides the configuration of the RS-485 piggy-back board (Commverter
module) per type of pump.
Commverter Module Configuration
Aplab (485) 9600,8,N,1
Avery (485) 5700,8,E,1
Gilbarco (485) 9600,8,N,1
L & T (485) 9600,8,N,1
Midco (485) 19200,8,N,1
Nuovo Pignone (485) 2400,8,O,1
Tatsuno (485) 19200,8.E,1
Wayne Dart (485) 9600,8,O,1
26
8 Port CommVerter Operation and I
nstallation Manual
Loading...
+ 99 hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.