Gasboy FuelOmat system 8 Popt Commverter User Manual

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MDE-4820H

88PPOORRTTCCOOMMMMVVEERRTTEER

OPERATION AND INSTALLATION MANUAL

This document P/N 817423401 is based on Orpak’s 8 port CommVerter operation and installation manual P/N 817423400

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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.

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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.

This document is the property of:

ORPAK SYSTEMS Ltd.

ISRAEL

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TABLE OF CONTENTS

Paragraph Page

GENERAL DESCRIPTION

1.1. SCOPE................................................................................................................................ 10

1.2. MANUAL ORGANIZATION............................................................................................ 10

1.3. GENERAL DESCRIPTION............................................................................................... 11

1.4. MODULES......................................................................................................................... 14

1.4.1. Modules .............................................................................................................................. 14

1.5. SPECIFICATIONS............................................................................................................. 15

1.5.1. Communication Rates......................................................................................................... 15

1.5.2. Electrical............................................................................................................................. 15

1.5.3. Mechanical Pump Rates ..................................................................................................... 15

1.5.4. Mechanical.......................................................................................................................... 16

1.5.5. Environmental..................................................................................................................... 16

1.6. PROTECTION ................................................................................................................... 16

2 APPLICA TIONS

2.1. SCOPE................................................................................................................................ 17

2.2. COMMVERTER SYSTEM ARCHITECTURE ................................................................ 17

2.2.1. General................................................................................................................................ 17

2.2.2. System Architecture 1: Centralized at the Station Office................................................... 18

2.2.3. System Architecture 2: Moved to the Isle Side .................................................................. 19

2.2.4. System Architecture 1: Using an OrPT and/or µVIT on the Isles...................................... 20

2.3. TYPES OF FUEL PUMP AND THEIR COMMUNICATION METHOD........................ 21

2.4. CONNECTORS.................................................................................................................. 24

2.4.1. General................................................................................................................................ 24

2.4.2. Mating a Connector ............................................................................................................ 25

2.5. LAN to RS-485 APPLICATION........................................................................................ 26

2.5.1. RS-485 Connector Pinout................................................................................................... 28

2.5.2. RS-485 Module Jumpers .................................................................................................... 28

2.6. LAN to RS-232 APPLICATION........................................................................................ 32

2.6.1. RS-232 Connector Pinout................................................................................................... 33

2.7. LAN to CURRENT LOOP................................................................................................. 34

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2.7.1. LAN to Current Loop Application...................................................................................... 34

2.7.2. Current Loop Connector Pinout.......................................................................................... 35

2.7.3. Current Loop Module Jumpers........................................................................................... 35

2.7.4. Current Loop Electronic Devices (Pump or any Current Loop Devices)........................... 36

2.7.5. Wayne Pump Configuration Example................................................................................. 39

2.7.6. Gilbarco Legacy & Gasboy 8800 Current Loop Electronic Pumps Configuration............40

2.7.6.1. SiteOmat Configuration for Gilbarco Legacy & Gasboy 8800 Current Loop Electronic

Pumps…………. ............................................................................................................................ 43

2.8. LAN to TOKHEIM APPLICATION ..................................................................................48

2.8.1. Tokheim Connector Pinout ................................................................................................. 49

2.8.2. Tokheim Module Jumpers................................................................................................... 49

2.8.3. Tokheim Electronic Devices (Pump or any Tokheim Devices)..........................................49

2.8.4. Addressing Dual-Sided Tokheim Pumps ............................................................................ 51

2.9. 4xCONTACTOR APPLICATION...................................................................................... 52

2.9.1. 4x Contactor Connector Pinout........................................................................................... 52

2.9.2. 4xContactor Module Jumpers.............................................................................................53

2.9.3. Station Setup ....................................................................................................................... 54

2.9.4. Pump Server Setup.............................................................................................................. 55

2.9.5. 8 Port CommVerter Setup................................................................................................... 56

2.10. LAN to RS422 APPLICATION.......................................................................................... 57

2.10.1. RS422 Module Application................................................................................................. 57

2.10.2. RS-422 Connector Pinout...................................................................................................58

2.10.3. Sub-RS422 Module Application......................................................................................... 58

2.11. LAN TO NUOVO PIGNONE APPLICATION.................................................................. 60

2.11.1. Nuovo Pignone Connector Pinout ......................................................................................61

2.11.2. COPTRON Communication to Nuovo Pignone Card........................................................ 61

2.12. LAN TO RS232/485 APPLICATION................................................................................. 61

2.12.1. RS-232/485 Connector Pinout............................................................................................ 62

.13 MECHANICAL PUMP INTERFACE (MPI-C)

2.13.. MECHANICAL PUMP INTERFACE (MPI-C)

2.13.1. MPI-C Connector Pinout and Signals................................................................................. 63

2.13.2. Mechanical Pump - Pulser Connections.............................................................................64

2.13.2.1. Pulse Rate....................................................................................................................... 64

2.13.2.2. Interface Connections..................................................................................................... 64

2.13.3. Pulse Divider....................................................................................................................... 66

2.13.4. Description for LED's on the MPI-C board........................................................................ 69

.................................................................62 2

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2.14. 5-PORT LAN SWITCH...................................................................................................... 70

2.15. CETIL ER3 MODULE....................................................................................................... 72

2.15.1. Sub module (Suspend Resume Relay Card)....................................................................... 73

2.15.2. Sub Module Pumalan.......................................................................................................... 74

2.16. DOOR OPEN DETECTION.............................................................................................. 75

2.16.1. Door Open Detector Installation......................................................................................... 75

3 COMMVERTER DESCRIPTION

3.1. SCOPE................................................................................................................................ 77

3.2. PHYSICAL......................................................................................................................... 77

3.2.1. Housing............................................................................................................................... 77

3.2.2. Front and Rear Panel .......................................................................................................... 78

3.3. LED INDICATORS............................................................................................................ 79

3.3.1. General................................................................................................................................ 79

3.3.2. Configuration...................................................................................................................... 79

3.4. MAIN BOARD CONNECTORS....................................................................................... 81

3.5. MAIN BOARD JUMPERS................................................................................................ 82

3.6. CHANGING THE IP ADDRESS....................................................................................... 83

4 INSTALLATION AND GROUNDING

4.1. GENERAL.......................................................................................................................... 89

4.2. PRELIMINARY PROCEDURES ...................................................................................... 89

4.2.1. Unpacking and Inspection .................................................................................................. 89

4.2.2. Installation Equipment........................................................................................................ 89

4.2.3. Protective Procedures ......................................................................................................... 90

4.3. INSTALLING THE COMMVERTER............................................................................... 90

4.3.1. General................................................................................................................................ 90

4.3.2. Desktop Installation............................................................................................................ 90

4.3.3. Cables’ Connections ........................................................................................................... 91

4.4. GROUNDING THE COMMVERTER .............................................................................. 92

4.4.1. General................................................................................................................................ 92

4.4.2. Grounding – General Concept............................................................................................ 92

4.4.3. Grounding the 8-port Commverter (without RS485 card) ................................................. 92

4.4.4. Grounding the 8-port Commverter (without RS485 card) ................................................. 93

4.4.5. Verifying the Grounding..................................................................................................... 94

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4.5. SUB-MODULE INSTALLATION AND GROUNDING ..................................................94

4.5.1. Installation of Protective Isolator Sheet.............................................................................. 94

4.5.2. Connector Mechanical Outline – Check Procedure............................................................94

4.5.3. Sub-Module - Grounding.................................................................................................... 94

4.5.4. Sub-Module Installation – Wiring Label Placing ...............................................................94

4.6. SUB-MODULE REPLACEMENT - REMOVAL INSTRUCTIONS................................95

4.6.1. General................................................................................................................................ 95

4.6.2. Removal Tool – Spring ARC.............................................................................................. 96

4.6.3. Removal Tool – Procedures ................................................................................................97

5 SETUP AND CONFIGURATION

5.1. GENERAL.......................................................................................................................... 98

5.2. DISPLAYING THE MAIN PAGE ..................................................................................... 99

5.3. ETHERNET SETUP PROCEDURES................................................................................ 101

5.4. TCP PORTS SETUP PROCEDURES................................................................................ 102

5.5. SERIAL PORTS SETUP PROCEDURES ......................................................................... 103

5.6. PIPES SETUP PROCEDURES (NOT TO BE USED) ......................................................104

5.7. DIGITAL I/O PORTS SETUP PROCEDURES (NOT TO BE USED).............................. 105

5.7.1. Door Open Detection Digital I/O Port Setup...................................................................... 105

5.8. ADMINISTRATION TASKS PROCEDURES..................................................................107

5.8.1. EEPROM Save Procedures................................................................................................. 107

5.8.2. Service W eb Ports – TCP/IP Timeout Definition Procedures............................................. 109

5.8.3. Login Information Definition Procedures (Not to be used)................................................110

5.9. SYSTEM MONITOR INFORMATION SCREENS.......................................................... 111

5.9.1. General................................................................................................................................ 111

5.9.2. Counters Description .......................................................................................................... 113

5.10. TERMINAL SCREEN (Not to be used)............................................................................. 114

6 CHECKS AND TROUBLESHOOTING

6.1. GENERAL.......................................................................................................................... 115

6.2. POST-INSTALLATION CHECKS..................................................................................... 115

APPENDIX A UPGRADING THE COMMVERT ER TO A NEW VERSION

GENERAL......................................................................................................................................116

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APPLICABILITY .......................................................................................................................... 116

UPGRADING PROCEDURES...................................................................................................... 116

PRELIMINARY SETUP PROCEDURES ..................................................................................... 116

SETTING THE APPLICATION PARAMETERS IN THE DHCP SER VER................................ 118

SETTING THE APPLICATION PARAMETERS ......................................................................... 119

FINAL PROCEDURES.................................................................................................................. 120

MPI-C - DYNAMIC PULSER SAMPLING PERIOD.................................................................. 121

1. GENERAL.......................................................................................................................... 121

2. CALCULATION ................................................................................................................ 121

3. SETTING THE MPI-C....................................................................................................... 122

APPENDIX B PLANNING AND CONNECTION OF PI’S

GENERAL ..................................................................................................................................... 123

CONNECTORS.............................................................................................................................. 123

WORKING WITH COMMVERTER ............................................................................................ 123

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LIST OF ILLUSTRATIONS

Figure Page

FIGURE 1-1. COMMVERTER – GENERAL VIEW...................................................................11

FIGURE 1-2. COMMVERTER PCB - GENERAL VIEW........................................................... 12

FIGURE 2-1. COMMVERTER SYSTEM ARCHITECTURE – CENTRALIZED..................... 18

FIGURE 2-2. COMMVERTER SYSTEM ARCHITECTURE – MOVED TO ISLE SIDE ........19

FIGURE 2-3. COMMVERTER SYSTEM ARCHITECTURE – USING AN ORPT AND/OR µVIT2

FIGURE 2-4. COMMVERTER – CONNECTORS......................................................................24

FIGURE 2-5. COMMVERTER PCB - CONNECTORS.............................................................. 24

FIGURE 2-6. COMMVERTER – CONNECTOR........................................................................ 25

FIGURE 2-7. COMMVERTER – LAN TO RS-485 APPLICATION ..........................................26

FIGURE 2-8. RS-485 TWO PORT MODULE ............................................................................. 27

FIGURE 2-9. RS-485 MODULE JUMPERS................................................................................29

FIGURE 2-10 RS-485 ELECTRONIC PUMP - WIRING DIAGRAM ....................................... 30

FIGURE 2-11 RS-485 ELECTRONIC PUMP - WIRING DIAGRAM........................................31

FIGURE 2-12. LAN TO RS-232 CONFIGURATION..................................................................32

FIGURE 2-13. RS-232 TWO-PORT MODULE........................................................................... 32

FIGURE 2-14. CURRENT LOOP TWO-PORT MODULE......................................................... 34

FIGURE 2-15. CURRENT LOOP MODULE JUMPERS............................................................ 36

FIGURE 2-16. CURRENT LOOP WIRING DIAGRAM – SINGLE CLUSTER........................37

FIGURE 2-17. CURRENT LOOP WIRING DIAGRAM – MULTI CLUSTER.......................... 37

FIGURE 2-18. CURRENT LOOP ELECTRONIC PUMP-WIRING DIAGRAM....................... 38

FIGURE 2-19. COMMVERTER UNIT SETUP SITE – MAIN SCREEN..................................40

FIGURE 2-20. COMMVERTER UNIT SETUP SITE – ADMIN SCREEN................................41

FIGURE 2-21. COMMVERTER UNIT SETUP SITE – SERIAL PORTS SCREEN .................. 42

FIGURE 2-22. BUSES DIALOG BOX ........................................................................................ 43

FIGURE 2-23. SETUP PUMP SERVER DIALOG BOX............................................................. 44

FIGURE 2-24. PUMP SERVER SETTINGS DIALOG BOX...................................................... 45

FIGURE 2-25. SETUP PUMP SETTINGS DIALOG BOX .........................................................46

FIGURE 2-26. SETUP PUMP SETTINGS (MORE) DIALOG BOX.......................................... 47

FIGURE 2-27. LAN TO TOKHEIM CONFIGURATION ........................................................... 48

FIGURE 2-28. LAN TO TOKHEIM MODULE, TWO PUMPS CONFIGURATION................ 48

FIGURE 2-29 TOKHEIM ELECTRONIC PUMP - WIRING DIAGRAM .................................50

FIGURE 2-30 TOKHEIM ELECTRONIC PUMP - WIRING DIAGRAM .................................50

FIGURE 2-31 ADDRESSING TOKHEIM DUAL-SIDED PUMPS............................................51

FIGURE 2-31. 4XCONTACTOR MODULE................................................................................ 52

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LIST OF ILLUSTRATIONS

Figure Page

FIGURE 2-32. 4XCONTACTOR MODULE JUMPERS............................................................. 53

FIGURE 2-33. STATION SETUP.................................................................................................. 54

FIGURE 2-35. LAN TO RS422 CONFIGURATION................................................................... 57

FIGURE 2-36. RS422 MODULE ................................................................................................. 57

FIGURE 2-37. RS422 MODULE JUMPER J6 ............................................................................ 57

FIGURE 2-38. SUB-RS422 MODULE ........................................................................................ 59

FIGURE 2-39. NUOVO PIGNONE MODULE CONFIGURATION.......................................... 60

FIGURE 2-40. NUOVO PIGNONE MODULE ........................................................................... 60

FIGURE 2-41. MPI-C MODULE................................................................................................. 62

FIGURE 2-42. MPI-C WITH SUB-MODULE............................................................................. 62

FIGURE 2-43. MPI-C J2 AND J3 JUMPERS.............................................................................. 64

FIGURE 2-44 TERMINAL BLOCK WIRING CONNECTIONS ............................................... 65

FIGURE 2-45: LOW VOLTAGE ELECTRONIC PULSER ......................................................... 65

FIGURE 2-46 TERMINAL BLOCK AND 3-WIRE PULSER – WIRING CONNECTIONS .... 66

FIGURE 2-47. PULSE DIVIDER.................................................................................................. 66

FIGURE 2-48 LEDS ON THE MPI-C.......................................................................................... 69

FIGURE 2-49 5-PORT LAN SWITCH......................................................................................... 70

FIGURE 2-50 5-PORT LAN SWITCH ON 8-PORT PCB........................................................... 71

FIGURE 2-51. CETIL ER3 MODULE + SUB............................................................................ 72

FIGURE 2-52. COMVERTER EXTERNAL CONNECTOR...................................................... 72

FIGURE 2-53. CETIL SUB RELAY MODULE – CONNECTIONS........................................... 73

FIGURE 2-54. SUB MODULE PUMALAN – CONNECTIONS ............................................... 74

FIGURE 2-55. PUMALAN PORT MODULE – GENERAL VIEW CAT. NO. 819223445......... 74

FIGURE 2-56. DOOR OPEN DETECTOR CONNECTION........................................................ 76

FIGURE 3-1. COMMVERTER – FRONT PANEL...................................................................... 77

FIGURE 3-2. COMMVERTER – REAR PANEL (CURRENT LOOP / TOKHEIM

CONFIGURATION) ...................................................................................................................... 78

FIGURE 3-3. FRONT PANEL LEDS CONFIGURATION.......................................................... 79

FIGURE 3-4. COMMVERTER LEDS CONFIGURATION ON PCB........................................ 80

FIGURE 3-5. MAIN BOARD JUMPERS AND CONNECTORS............................................... 83

FIGURE 3-6. COMMVERTER UNIT SETUP SITE – MAIN SCREEN ................................... 84

FIGURE 3-7. COMMVERTER UNIT SETUP SITE – ADMIN SCREEN.................................. 85

FIGURE 3-8. COMMVERTER UNIT SETUP SITE – ETHERNET SCREEN .......................... 86

FIGURE 3-9. COMMVERTER UNIT SETUP SITE – TERMINAL SCREEN........................... 86

FIGURE 4-1. COMMVERTER UNIT – GROUNDING CABLE IN RS-485 CONNECTOR.... 92

FIGURE 4-2. COMMVERTER UNIT – GROUNDING THE UNIT (WITHOUT RS-485 CARD)93

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LIST OF ILLUSTRATIONS

Figure Page

FIGURE 4-3. COMMVERTER UNIT – DAMAGED SUB-MODULE.......................................95

FIGURE 4-4. SPRING ARC TOOL..............................................................................................96

FIGURE 4-5. SPRING ARC TOOL – DIMENSIONS ................................................................. 96

FIGURE 5-1. COMMVERTER UNIT – SETUP MAIN SCREEN.............................................. 99

FIGURE 5-2. SETUP MAIN SCREEN – FIELDS....................................................................... 100

FIGURE 5-3. ETHERNET SETUP SCREEN............................................................................... 101

FIGURE 5-4. TCP PORTS SETUP SCREEN...............................................................................102

FIGURE 5-5. SERIAL PORTS SETUP SCREEN........................................................................ 103

FIGURE 5-6. PIPES SETUP SCREEN......................................................................................... 104

FIGURE 5-7. DIGITAL I/O PORTS SETUP SCREEN................................................................105

FIGURE 5-8. DIGITAL I/O PORTS SETUP SCREEN – DOOR OPEN DETECTION

ACTIVATION................................................................................................................................. 106

FIGURE 5-9. ADMINISTRATION TASKS SCREEN................................................................. 107

FIGURE 5-10. SERVICE WEB PORTS – TCP/IP TIMEOUT SCREEN ....................................109

FIGURE 5-11. SERVICE WEB PORTS – TCP/IP TIMEOUT SCREEN ....................................110

FIGURE 5-12. SYSTEM MONITOR SCREEN – THREADS RUNNING.................................111

FIGURE 5-13. SYSTEM MONITOR SCREEN – SOCKETS, MEMORY, FILE STATUS........112

FIGURE 5-14. SYSTEM MONITOR SCREEN – RESET COUNTERS, CONFIGURATION

STATUS ..........................................................................................................................................112

FIGURE 5-15. TERMINAL SCREEN.......................................................................................... 114

FIGURE A-1. DHCP SERVER – COMMUNICATION PARAMETERS.................................... 118

FIGURE A-2 APPLICATION SETTING PARAMETERS............................................................ 119

FIGURE A-3 APPLICATION SETTING PARAMETERS............................................................ 120

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LIST OF TABLES

TABLE PAGE

TABLE 1-1. COMMVERTER MODULES................................................................................... 14

TABLE 2-1. RS-485 MODULE JUMPERS STATUS (ACCORDING TO PUMPS) ................... 28

TABLE 2-7. PULSE DIVIDER PINOUT...................................................................................... 68

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

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SECTION

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.

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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

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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.

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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.

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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

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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.

No. Module Value

1 RS-232 Module 57600 bps max. 2 RS-485 Module 57600 bps max. 3 TCP/IP Module 100 Mbps (optional) 4 Current Loop 24V 45mA 9600 bps max. 5 Tokheim 9600 bps max.

1.5.2. Electrical

No. Parameter Value

1 Supply Voltage:

- Enclosed Commverter unit

- PCB unit

110 – 230 VAC, 50-60Hz

15 to 24 VDC

2 Power Consumption Typical 5W

Maximum 25W

3 Protection 1.5A Fuse, internal on board.

1.5.3. Mechanical Pump Rates

No. Parameter Value

1 Power supply output voltage

12 VDC +/-20%

to Pulsar Unit

2 Power supply maximum

80 mA max

output current

3 Pulsar Input High level

10 to 16 VDC (standard)

voltage

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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

-30C to +55C

-20C to +50C

supply)

3 Storage Temperature

-30C to +70C

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.

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SECTION

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

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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

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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

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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

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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

(Gilbarco) Bennet

Mexico Bennet

USA Cetill

EAS1 Cetill

ER3 Dong HWA

(prime)

Communication Type

RS485 819223460 5787 8 Even 1

RS232 819223451 2 1 N/A 4800 7 Odd 1

Current Loop 819223431 2 4 N/A 4800 8 Even 1

RS485 819223460 2 8 ? 2400 -

Cetil 819523425 1 1 ? 9600 8 None 1

RS485 819223460 2 remove

Board P/N No. of

channels / board (include sub board)

Max Number of pump heads per channel

Baud Rate Jumper

Baud Rate

Data Bits

Parity Stop

7 Even 1

9600

9600 8 Even 1

Bits

ENE (=Prime protocol)

EPCO (=Prime protocol)

FuelStar RS485 819223460 2 8 Remove 4800 8 Even 1 Gilbarco

USA Gasboy

USA Hong Yang RS232 2 4 N/A 4800 8 Even 1

Current Loop 819223431 2 8 Remove 5787 8 Even 1

RS422 819523471/2 2 8

RS485 819223460 2 8 Remove 9600 8 None 1

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No. of Pump/Dispenser Manufacturer Model (Protocol)

IFSF L&T

MPD/QPD L&T

Sprint RS485 819223460 2 8 On 9600 8 None 1 L&T

Z-Line, Pacemaker

L&T Tulip ( Mono & Dual) RS485 819223460 2 8 On 9600 8 None 1

L&T VMP ( Mono & Dual)

Communication Type

USB - >LON or PCI->LON

RS485 819223460 2 8 On 9600 8 None 1

Board P/N

channels

/ board

(include

sub

board)

Max Number of pump heads per channel

Max Allowed In LON

Baud Rate Jumper

Baud Rate

Data Bits

Parity

Stop Bits

Maser RS485 819223460 2 8 9600 8 None 1 MPD/QPD RS485 819223460 2 8 Remove 19200 8 None 1 Midco

Single RS485 819223460 2 8 Remove 19200 8 None 1 Midco

MMS Midco

Surefil RS485 819223460 2 8 Remove 19200 8 None 1 MPI-C

Rev D MPI

Orpak RS485 819223460 2 8 On 9600 8 None 1 Mepsan RS-485 819223460 2 8 On 9600 8 Odd 1 LPG 2A

Dart/Mepsan RS-485 819223460 2 8 ? ? ? ? Novotec RS485 819223460 2 8 9600 7 None 1 Nuovo Pignone

Blend Nuovo Pignone N/P 819223485 2 1 2400 8 Odd 1

RS485 819223460 2 8 Remove 19200 8 None 1

81922349 0 2 1 On 9600 8 None 1

RS485 819223460 2 8 Remove 2400 8 Odd 1

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No. of Pump/Dispenser Manufacturer Model (Protocol)

Petrotec CEM

Prime RS485 819223460 2 8 Remove 9600 8 Even 1 Pumalan

HT-Retrofit Pumalan 819223445 2 8 N/A 4800 7 Odd 1 Pumptronics

Gilbarco Real Tech China RS485 2 4 N/A 4800 8 Even 1 S&B T10 RS485 819223460 2 1 Remove 2400 7 Even 1 Schlumberger RS-422 819523471/2 2 1 N/A 1200 7 Even 1 Tatsuno

MPD/QPD RS485 819223460 2 8 Remove 19200 8 Even 1 Tatsuno

Pooly (Nonspace)

Communication Type

RS422 819523471/2 2 1 N/A 1200 7 Even 2

Current Loop 819223431 2 4800

RS485 819223460 Remove 19200 8 Even 1

Board P/N

channels

/ board

(include

sub

board)

Max Number of pump heads per channel

Baud Rate Jumper

Baud Rate

Data Bits

Parity

Stop Bits

Tatsuno Benc RS485 819223460 2 8 On 9600 7 EVEN 2 Tokheim Tokheim 819223420 2 1 N/A 9600 8 None 1 Tokheim Kaisen

L1+ RS485 819223460 2 1 On 9600 8 None 1 Tokheim 8800

(American Dispenser)

Wayne Dart RS485 819223460 2 8 On 9600 8 Odd 1

Wayne Vista

Tokheim 819223420 2 1 N/A 9600 8 None 1

Current Loop 819223431 2 4 N/A 9600 8 Odd 1

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2.4. CONNECTORS

2.4.1. General

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

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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

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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

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Figure 2-8. RS-485 Two Port Module

LEDs Indication

NOTE

This module does not require opening the Commverter to view the LEDs status and indications. The LEDs are displayed through the holes of the Commverter cover. The LEDs indication can be seen in the appropriate column above the module installation position. The column holes should be seen at the right-hand side from the vents of the Power Supply, from top down.

Connector Side

Channel 1 Rx D4 Channel 2 Tx D6 Channel 1 Tx D1 Channel 2 Rx D11 Blank Blank

LED Blinking – Communication on LED Off – No communication

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2.5.1. RS-485 Connector Pinout

The following pinout is required for the LAN to RS-485 application, for all devices that supports RS-485 and RS-485 board.

[ Revision D and above ]

8 7 6 5 4 3 2 1 E G - + E G - +

Channel 2 Channel 1

2.5.2. RS-485 Module Jumpers

The jumpers in the RS-485 m

odule can be set in two different configurations, as shown in Figure 3-7. The configuration is determined by four consecutive jumpers on the board: J1, J2, J5 and J6.

Every pair of jumpers is allocated to a different channel: J1 and J2 for Channel 1 / J5 and J6 for Channel 2.

The jumpers determine the transmission rate. Two transmission rates can be selected:

 9600 bps  4800 bps

To determine the transmission rate, set the jumpers accordingly. Proceed as follows:

1. Set the baud rate jumpers in the RS-485 cards in accordance with the pumps that

shall be connected to each channel (refer to Table 2-1).

The jumpers are: J1 for Channel 1 and J5 for Channel 2 (see Figure 2-9).

Table 2-1. RS-485 Module Jumpers Status (according to pumps)

8 port Commverter

Baud rate Jumper

Aplab Avery Gasboy MIDCO L&T NP NP Blend Tatsuno Wayne

Do not remove

Remove Remove

Do not remove

Remove Remove Remove

Dart

Do not remove

The Echo jumpers are J9 and J10.

 If no jumpers exist echo is enabled.  If jumpers exist echo is disabled (factory default)

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LED

Echo

jumper

Baud rate

jumper

* Jumper state 1 is the factory default setting

Figure 2-9. RS-485 Module Jumpers

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RS-485 Electronic Device Pump (For any RS-485 Devices) The wiring for the RS-485 electronic pump is provided as follows:

 Figure 2-10 shows the specific wiring connections between the 8 Port RS-485 card

and the RS-485 pump nozzle, and the terminals that differ from the Mechanical Pump. The figure shows the parallel connection between two RS-485 devices and the Terminal Block.

Figure 2-10 RS-485 Electronic Pump - Wiring Diagram

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Figure 2-11 RS-485 Electronic Pump - Wiring Diagram

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2.6. LAN to RS-232 APPL ICATION

The LAN to RS-232 application is required when the connection to specific devices, such as TLGs, is via RS-232. In this application, RS-232 Two-Port module (P/N 819223451) is installed within the CommVerter.

Figure 2-12 shows a typical station configuration in which the CommVerter is used as an interface between the Station Controller and several station devices - TLG.

Figure 2-12. LAN to RS-232 Configuration

Figure 2-13. RS-232 Two-Port Module

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LEDs Indication

NOTE

Connector Side

Channel 2 Rx D8 Channel 2 Tx D7 Channel 1 Rx D3 Channel 1 Tx D2 Blank Blank

LED Blinking – Communication on LED Off – No communication

2.6.1. RS-232 Connector Pinout

The following pinout is required for the LAN to RS-232 application.

8 7 6 5 4 3 2 1

G D I/O Rx Tx G D I/O Rx Tx

Channel 2 Channel 1

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2.7. LAN to CURRENT LOOP

2.7.1. LAN to Current Loop Application

The LAN to Current Loop configuration is applicable whenever the CommVerter includes a Current Loop Interface module (P/N 819223431). This communication conversion is used in stations with pumps such as Wayne, Benett or Gilbarco that use current loop communication.

Figure 2-14. Current Loop Two-Port Module

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LEDs Indication

NOTE

Connector Side

Blank Blank Channel 1 Loop D1 Channel 2 Loop D7 Blank Blank

LED On – Loop between the module and the pump functional

LED Blinking – Communication on LED Off – No communication

2.7.2. Current Loop Connector Pinout

The following pinout is required for the LAN to Current Loop application, for all Wayne and Gilbarco pumps.

8 7 6 5 4 3 2 1

E G - + E G - +

Channel 2 Channel 1

2.7.3. Current Loop Module Jumpers

The jumpers in the Current Loop module can be set in two different configurations, as shown in Figure 2-15. The configuration is determined by the two jumpers at opposite sides of the board.

Each configuration provides different power supply voltage:

12 Vdc

o o 24 Vdc (default)

In addition, there are fur jumpers that determine the current level, as follows:

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 Jumpers J1, J4 installed; (for old PCBs J3, J6 also installed)

for 45 mA (default) consumption

 Jumpers J1, J4 not installed; (for old PCBs J3, J6 also not

installed) for 20 mA consumption

Figure 2-15. Current Loop Module Jumpers

2.7.4. Current Loop Electronic Devices (Pump or any Current Loop Devices)

The wiring for the Current Loop electronic pump is provided as follows: Figure 2-18 shows the specific wiring connections

and Current Loop pumps. Figure

2-16 and Figure 2-17 show the connection between two

between the 8 Port Current Loop card

Current Loop twin-pumps and the Terminal Block: In cases where connecting twin pumps on a single cluster (module channel), set each pump with a different head number. If connecting each twin pump on dedicated cluster, there is no need to reprogram the pump. Pumps with identical Head number cannot be connected to the same Cluster.

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Figure 2-16. Current Loop Wiring Diagram – Single Cluster

Figure 2-17. Current Loop Wiring Diagram – Multi Cluster

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Figure 2-18. Current Loop Electronic Pump-Wiring Diagram

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2.7.5. Wayne Pump Configuration Example

The following paragraph provides the pump configuration required for models

3/G7237D/GHJKM/ - P/N 887695-0154/053. Unit version: 54 IGEM Verify programming codes on the pump as follows:

1. Set F01.00 to “1” for Serial Communications

2. Set F05.00 for the A side address (1-98)

3. Set F06.00 for the B side address (1-98)

4. Set F20.00 to “4” for US Current Loop

5. Set F20.01 to “02” for 9600 baud rate

6. Set F27.00 to “8” for Serial Comm

7. Set F27.01 to “0” for Serial Comm

8. Set F28.00 to “8” for Serial Comm

9. Set F28.01 to “0” for Serial Comm

NNOOTTEE

The F27 and F28 settings are dependant on whether the unit was shipped with a Pulse Output board. If the dispenser does not have pulse output, the above settings should work. If it does have a pulse output option and a pulse output template loaded, they may need to be changed. For serial communication, they

should be set as noted above.

Make sure that the Current Jumper on Current Loop module (P/N MO9680B029) is set to 45 mA and Voltage Jumper is set to 24 VDC. Verify that the serial communication param paragraphs 2.3 TYPES OF FUEL PUMP AND THEIR COMMUNICATION METHOD and 5.5

eters are set to: Baud 9600, Parity Odd, 1 stop bit (refer to

SERIAL PORTS SETUP PROCEDURES).

The Current

Loop connec

or on the Wayne Pump – US/UK J25 is found on the top right hand side.

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2.7.6. Gilbarco Legacy & Gasboy 8800 Current Loop Electronic Pumps Configuration

To set up the Gasboy 8800 current loop electronic pumps install the current loop board in the correct slot of the 8 port CommVerter board.

In the following example Slot 3 of the 8 port CommVerter board is used. The port assigned to Channel 1 of this Slot is 3005.

NNOOTTEE

The Current Loop Interface module can be installed in any slot of the 8 port CommVerter board. The slot used may vary depending on system configuration. Adjust the instructions according the Slot used for the Current Loop Interface module board. The Slot used is mapped to the assigned Port number.

In order for the Current loop board to communicate with the Gasboy 8800 pumps the ports setting must be changed. Proceed as follows:

1. Connect the CommVerter to a PC (LAN Connection)

2. Open the Web browser, and enter the IP address of the Commverter. The Setup Main Screen

is displayed (see Figure 2-19)

Figure 2-19. CommVerter Unit Setup Site – Main Screen

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3. Click on Admin Tasks. The Admin screen is displayed. Scroll down the page to reach the

TCP/IP timeouts section (see Figure 2-20)

Figure 2-20. CommVerter Unit Setup Site – Admin Screen

4. Select the Temporary disable (up to 5 minutes) checkbox

5. Click on the Send button in this section of the page

6. Select the Write to eeprom radio button in the Set/Get eeprom section

7. Click on the Send button in this section of the page

8. Select the Reset radio button in the Set/Get eeprom section

9. Click on the Send button in this section of the page

NNOOTTEE

These steps need to be completed in a timely manner or the EEPROM will reset all changes made prior to the reset.

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10. Click on Serial Ports. The Serial Ports screen is displayed. Scroll down the page to reach

the Port that needs to be changed (see Figure 2-21)

11. This example refers to Port 205. Actual Port number2xx is determined by the Port assigned

to the Slot of the Current Loop Interface module board

12. Change the port setting as needed. See paragraph 2.3

13. Click on the Send button for the appropriate port

Figure 2-21. CommVerter Unit Setup Site – Serial Ports Screen

14. After changing and sending the Port settings, the eeprom must be updated and reset: a. Click on Admin Tasks. The Admin screen is displayed b. Select the Write to eeprom radio button in the Set/Get eeprom section c. Click on the Send button in this section of the page d. Select the Reset radio button in the Set/Get eeprom section e. Click on the Send button in this section of the page

15. Give the system a few minutes to reboot and then verify that the settings have been saved.

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2.7.6.1. SiteOmat Configuration for Gilbarco Legacy & Gasboy 8800 Current Loop Electronic Pumps

NNOOTTEE

For further information, please refer to SiteOmat Installation and Maintenance Manual, P/N MDE-

4817.

In order to configure Gilbarco Legacy & Gasboy 8800 Current Loop Electronic Pumps, proceed as follows:

1. Go to the SiteOmat Setup screen and click on the Advanced Mode button

2. Select the Buses tab. The Buses dialog box appears (see Figure 2-22)

Figure 2-22. Buses Dialog Box

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3. Set up a bus for use by Gilbarco Legacy & Gasboy 8800 pumps. Note: port number may

differ.

4. Save the newly added Bus by clicking on the New button

5. Select the P. Servers tab. The Setup Pump Server dialog box appears (see Figure 2-23)

6. Set up a Pump Server for use by Gilbarco Legacy & Gasboy 8800 pumps. Note: port

number may differ

7. Save the newly added Pump Server by clicking on the New button

Figure 2-23. Setup Pump Server Dialog Box

8. After adding the Pump server, highlight the Pump Server and Click on the Addtl. Features

button. The Pump Server Settings dialog box appears (see Figure 2-24)

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Figure 2-24. Pump Server Settings Dialog Box

9. Add a cluster for use by Gilbarco Legacy & Gasboy 8800 pumps. Be sure to select the

Enable Echo checkbox when adding the cluster

10. Save any changes that were made

11. On the Setup screen, click Save and then Reload. After the reload has been successfully

completed, the Gilbarco Legacy & Gasboy 8800 pumps may be added

12. Click on the Add Pump button on the Setup screen. The Setup Pump Settings dialog box

appears (see Figure 2-25)

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Figure 2-25. Setup Pump Settings Dialog Box

13. Fill in the Pump number, Pump Head, and Number of hoses. The Pump Head number

must match the Pump ID set in Gilbarco Legacy & Gasboy 8800 pump

14. Select the correct Pump server and Cluster from the drop-down lists

15. Set the Message Factors as shown in the screen above. These settings work in most cases

but may need to be adjusted to make the pump and transaction data match

16. Set the Specific section as shown in the screen above. These settings work in most cases but

may need to be adjusted to match the specific pump used

17. Save any changes that were made

18. Select the newly added Pump

19. Select the More Options button. The following screen appears (see Figure 2-26)

20. Set the additional pa

rameters as shown in the screen below. These settings work in most

cases but may need to be adjusted to match the specific pump used

21. Save any changes that were made

22. On the Setup screen, click Save and then Reload

23. After the reload has completed successfully, verify that all added pumps have been saved.

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Figure 2-26. Setup Pump Settings (More) Dialog Box

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2.8. LAN to TOKHEIM APPLICATION

The LAN to Tokheim module is installed in the CommVerter whenever the pumps in the station are of Tokheim brand. The CommVerter converts the LAN into Tokheim (and vice versa). Figure 2-27 shows a block diagram of a LAN to Tokheim communication application

Figure 2-27. LAN to Tokheim Configuration

o This module (two separate ports) interfaces with up to two pumps. In this configuration'

each pump is interfaced in a separate port.

o This module can be set to 5V or12V according to the Pump Interface requirement (Jumper

setting).

Figure 2-28. LAN to Tokheim Module, Two Pumps Configuration

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LEDs Indication

NOTE

There is no external indication of the LEDs status. Remove the Commverter cover to reveal the module LEDs.

Connector Side

Channel 1 Rx D1 Channel 1 Tx D2 Channel 2 Rx D3 Channel 2 Tx D4

LED Blinking – Communication on LED Off – No communication

2.8.1. Tokheim Connector Pinout

The following pinout is required for the LAN to Tokheim application, for all Tokheim brand pump

8 7 6 5 4 3 2 1

G COM TTC TTD G COM TTC TTD

Channel 2 Channel 1

2.8.2. Tokheim Module Jumpers

This module can be set to 5V or 12V according to the Pump Interface requirement. There are two jumpers that determine the voltage level, as follows:

o Jumpers J1, J2 installed: 5V o Jumpers J1, J2 removed: 12V

2.8.3. Tokheim Electronic Devices (Pump or any Tokheim Devices)

The wiring for the Tokheim electronic pump is provided as follows:

 Figure 2-29 shows the specific wiring connections between the 8 Port Tokheim card

and the Tokheim pump nozzle, and the terminals that differ from the Mechanical Pump.

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8 PORT

MODULE

P/N:

819223420

DISPENSER

TTD

TTC

DCC-GND

Figure 2-29 Tokheim Electronic Pump - Wiring Diagram

Figure 2-30 Tokheim Electronic Pump - Wiring Diagram

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2.8.4. Addressing Dual-Sided Tokheim Pumps

Figure 2-31 shows an example of the pump settings that should be defined in SiteOmat FCC to address dual-sided Tokheim pumps.

Figure 2-31 Addressing Tokheim Dual-Sided Pumps

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2.9. 4xCONTACTOR APPLICATION

The 4xContactor module includes four relays that toggle status from NC (normally close) to NO (normally open), and vice versa in accordance with the jumper position (refer to paragraph 2.9.2). This board is a relays module for four channels.

The relays contact rating is:

 1A 24 VDC  0.5A 120 VAC

Figure 2-32. 4xCONTACTOR Module

2.9.1. 4x Contactor Connector Pinout

The following pinout is required for the 4x Contactor application.

8 7 6 5 4 3

2 1

K4 K3 K2 K1

Switch 4 Switch 3 Switch 2 Switch 1

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2.9.2. 4xContactor Module Jumpers

The jumpers in the 4xContactor module can be set in two different configurations. The module includes four consecutive jumpers, J1 to J4.

The jumper configuration determines the status of its related relay.

Figure 2-33. 4xCONTACTOR Module Jumpers

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2.9.3. Station Setup

The relays control the pump's valve according to pump server's pump state which does not support the suspend resume commands by protocol. Each valve of such pump should be connected to the relay or through another power relay (according to the voltage or current needs of the valve). 2 pumps example connection is shown on Figure 2-34.

Figure 2-34. Station Setup

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2.9.4. Pump Server Setup

The ini file contains definitions used to communicate with the relays. Example for one pump is given below:

[cluster_01] commtype=tcp ip=192.168.1.108 port=3001 enable_echo=N log_cluster_port=10001

[pump_01] clusterid=1 addr=1 num_of_nozzles=1 specific=specific_01

[specific_01] taiwan_soft_ver=N use_relay=Y relay_port=6500 relay_ip=192.168.1.108 relay_con_timeout=200 channel=1

New definitions are

 relay_port – this is the Digital I/O port for relay's comm  relay_ip - The comverter IP where the relays are placed.  channel - The relay channel which will be activated ( it could be from 1 to 8 ) .

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2.9.5. 8 Port CommVerter Setup

The 8 port CommVerter should be activated via its digital control (see Figure 2-35) listening port. After setting the port number (should be the same as in the ini file of pump server) and enabling the checkbox save and reset the CommVerter.

Figure 2-35. Digital Control

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2.10. LAN to RS422 APPLICATION

2.10.1. RS422 Module Application

The RS422 module (and the RS422 sub-module) transforms incoming data transmission into RS-422 standard point to point. The RS422 module is installed on the main board and controls Channel 1. In this module, pins 1 to 5 (GND) only are active, to provide RS422 transmission.

Figure 2-36. LAN to RS422 Configuration

Figure 2-37. RS422 Module

In order to disable echo, short Jumper J6 as shown in

Figure 2-38.

Figure 2-38. RS422 Module Jumper J6

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NOTE

There is no external indication of the LEDs status. Remove the Commverter cover to reveal the module LEDs.

LEDs Indication

Connector Side

Channel 1 Rx D4 Channel 1 Tx D1

LED Blinking – Communication on LED Off – No communication

2.10.2. RS-422 Connector Pinout

The following pinout is required for the LAN to RS-422 application.

8 7 6 5 4 3 2 1

G T- T+ R- R+

2.10.3. Sub-RS422 Module Application

The RS422 Module has an additional sub-RS422 module on top of it (connector CN4). This sub-module provide data transmission conversion into RS422 for Channel 2.

The pinout of the connection is the same as for the RS422 module. Pins 1 to 5 (GND) only are active, to provide RS422 transmission).

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Figure 2-39. Sub-RS422 Module

LEDs Indication

NOTE

There is no external indication of the LEDs status. Remove the Commverter cover to reveal the module LEDs.

Connector Side

Channel 2 Rx D4 Channel 2 Tx D1

LED Blinking – Communication on LED Off – No communication

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2.11. LAN TO NUOVO PIGNONE APPLICATION

The LAN to Nuovo Pignone module transforms data transmission into Nuovo Pignone Pump Interface.

Figure 2-40. Nuovo Pignone Module Configuration

LEDs Indication

Figure 2-41. Nuovo Pignone Module

NOTE

There is no external indication of the LEDs status. Remove the Commverter cover to reveal the module LEDs.

Connector Side

Channel 1 Rx D15 Channel 1 Tx D16 Channel 2 Rx D17 Channel 2 Tx D18

LED Blinking – Communication on LED Off – No communication

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2.11.1. Nuovo Pignone Connector Pinout

The following pinout is required for the LAN to RS-232 application.

8 7 6 5 4 3 2 1

TX2- TX2+ RX2- RX2+ TX1- TX1+ RX1- RX1+

Channel 2 Channel 1

2.11.2. COPTRON Communication to Nuovo Pignone Card

Connector TB4A in Coptron pump (Pump Head 1)

Table 2-2 . Pump Communication Connector for 8 Port NP Module

Coptron

Pin Out

pin1_TXB pin3_Tx1+

Nuovo Pignone Card Pin Out

pin2_ TXA pin4_Tx1pin3_ RXB pin1_Rx1+ pin4_ RXA pin2_Rx1-

When Coptron dispenser detects serial-communication, it starts working in automatic mode.

2.12. LAN TO RS232/485 APPLICATION

This module is dual-purpose and supports two different communication protocols: RS232 and RS485.

The LAN to RS-232 application is required when the connection to specific devices, such as TLGs, is via RS-232. The RS232 circuit is dedicated for Channel 1

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. The RS485 circuit is dedicated for Channel 2.

NOTE

There is no external indication of the LEDs status. Remove the Commverter cover to reveal the module LEDs.

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LEDs Indication

Connector Side

Channel 1 (RS232) Rx D3 Channel 1 (RS232) Tx D2 Channel 2 (RS485) Rx D9 Channel 2 (RS485) Tx D4

LED Blinking – Communication on LED Off – No communication

2.12.1. RS-232/485 Connector Pinout

The following pinout is required for the LAN to RS-232/485 application.

8 7 6 5 4 3 2 1

G - + G D I/O RX TX

Channel 2 – RS485 Channel 1 – RS232

2.13.

MECHANICAL PUMP INTERFACE (MPI-C)

This paragraph describes the required wiring connections between the mechanical pump and the MPI-C Card and the MPI-C sub-module (see Figure 2-42 and Figure 2-43).

Figure 2-42. MPI-C Module.

Figure 2-43. MPI-C with Sub-Module.

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2.13.1. MPI-C Connector Pinout and Signals

Table 2-3 details the MPI-C pinout, Table 2-4 describes MPI-C signals.

Table 2-3. MPI-C Pinout

8 7 6 5 4 3 2 1

GND ByPass Inuse Pulse B Pulse A SSR V GND V OUT

CHANNEL 1/2

Table 2-4. MPI-C Signals

Signal Description

Pulse Input (5) The dispenser outputs pulses to the system by means of the Pulser unit,

installed in accordance with the manufacturer instructions. The Pulse rate per volume (liter/gallon) is determined by the Pulser unit. It is programmed as a "factor" by the Head Office controller

Handle Status Input (6)

Authorization Output (3)

The handle signal is used to indicate the system that the pump is "In Use" mode. When the dispenser handle is lifted this contact will close. This should signal the system that the pump is "In Use" or that the transaction ended

The dispenser requires an authorization signal from the MPI-C card to start a sale transaction. Without this authorization signal, the electric valve (or pump) will not open and the sale transaction will not begin. The MPI-C card switches the AC power signal to the valve. When the dispenser receives the authorization signal, fuel is flowing

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2.13.2. Mechanical Pump - Pulser Connections

This paragraph describes the required wiring connections between the pulser in the mechanical pump and the MPI-C. The system can accept many types of pulsers, please contact Gilbarco for more information. Two types of pulsers can be found in pumps:

- Electronic pulser

- Mechanical pulser Connect the MPI-C card to the Pulser in accordance to its characteristics.

2.13.2.1. Pulse Rate

The MPI-C may be configured to work with normal and high rate pulses (see Table 2-5), as may be generated by Electronic Pulsers. The wiring is identical for both cases, yet the technician is required to change jumper settings as detailed below. It is highly recommended to use normal rate pulsers to prevent noise.

Table 2-5. Pulse Rate Specifications

Parameter Normal Rate High Rate Input Voltage

Minimum:7 VDC Minimum: 4VDC Maximum: 15 VDC Maximum: 12 VDC

Pulse Rate Cycle Width

Maximum: 0.5 KHz Maximum: 5 KHz Minimum: 2 ms Min imum: 0.2 ms

By default the MPI-C card is set to work with Normal Rate pulses: J2 and J3 jumpers' pins 1 and 2 are shorted (see Figure 2-44). In cases where the pump outputs high rate pulses, short pins 2 and 3.

Figure 2-44. MPI-C J2 and J3 Jumpers

2.13.2.2. Interface Connections

Figure 2-45 shows Mechanical Pump Interface Connections, including Mechanical and Electronic Pulsers.

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Figure 2-45 Terminal Block Wiring Connections

Figure 2-46 shows the MPI-C – Low Voltage Electronic Pulser Wiring Connection

Figure 2-46: Low Voltage Electronic Pulser

Figure 2-47 shows a schematic diagram of the connections between the Terminal Block and a 3-wire Pulser, which requires an external power source (12V) in order to operate

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Figure 2-47 Terminal Block and 3-Wire Pulser – Wiring Connections

2.13.3. Pulse Divider

The Pulse Divider P/N 800911300 (see Figure 2-48) is used in cases where the pulser output cannot be read by the MPI-C due to weak signal, too high frequency or differential signal.

The Pulse Divider receives the inappropriate pulser signal (Pickup signal), shapes it and/or divides its frequency to match the signal to the MPI-C requirements for reading.

The Pulse Divider can be connected in three ways: refer to Table 2-6 and Table 2-7 for optional connections and pinout.

Figure 2-48. Pulse Divider

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Table 2-6. Pulse Divider Connections

Signal Type Description Connection Diagram

Input pulses are

Option A

above/under zero level and/or weak

Option B

Input pulses are above zero level (positive)

Option C

Input pulses are differential

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Table 2-7. Pulse Divider Pinout

Description Name Wire Color Pin#

DC INPUT RED 1

Input voltage from CommVerter to Pulse Divider (10-28VDC)

Ground GROUND BLACK 2 Input pulses from pulser to Pulse Divider SIGNAL IN 1 BROWN 3

SIGNAL IN 2 GREEN 4

Input pulses from pulser to Pulse Divider (when input signal is differential). Threshold voltage applied to Pulse Divider when Input pulses are other than differential

N/A DC OUT ORANGE 5

REF/V OUT GRAY 6

1.4VDC reference voltage connected to the green wire only in cases where Option B is utilized (otherwise unused)

Output signal divided by 2 :2 OUT VIOLET 7 Output signal divided by 4 :4 OUT YELLOW 8 Output signal divided by 8 :8 OUT BLUE 9 Output signal divided by 16 :16 OUT 10 WHITE

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2.13.4. Description for LED's on the MPI-C board

Figure 2-49 LEDs on the MPI-C

MPI-C MPI-C sub Signal Description

D_21 D_20 In Use ON=NOZZLE Out D_16 D_17 Bypass/Authorization Bypass or Authorization ON=IN Bypass D_18 D_19 Pulse Flash D_10 D_11 N/A Software LED

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2.14. 5-PORT LAN SWITCH

The 5-Port LAN Switch enables internal communication to peripheral devices. It supports up to five LAN channels.

The 5-Port LAN Switch is shown in Figure 2-50. The user can connect the LAN cables to any one of the five ports on the 5-Port LAN Switch.

NOTE

Make sure the RJ-45 connector of a LAN cable is plugged and locked properly into the port.

LEDs Indication

The 5-Port LAN Switch has several indication LEDs. The power LED indicates supply voltage to the device.

Each channel has two indication LEDs: green and red. If the green LED illuminates, it indicates a communication rate of 100 Mbps. If it is not illuminated, the communication rate is 10 Mbps.

If the red LED blinks, it indicate communication traffic in the channel.

Figure 2-50 5-Port LAN Switch

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The location of the 5-Port LAN Switch is on the 8-port PCB, at CN14 connector (see Figure 2-51).

Figure 2-51 5-Port LAN Switch on 8-Port PCB

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2.15. CETIL ER3 MODULE

(see Figure 2-52) For ER3 use the following: Cetil ER3 comverter module P/N 819523425 Sub (relay card) P/N 819523427 Cetil ER3 module + Sub P/N 819223425

Figure 2-52. Cetil ER3 Module + Sub

Connect pump communication wires to the 8 port comverter see Figure 2-53.:

Figure 2-53. Comverter External Connector

The following pinout is required for the Cetil application.

8 7 6 5 4 3 2 1

G (chassis ground)

-Z +Y G (chassis ground)

(chassis ground)

- Z + Y

Channel 2 Channel 1

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LEDs Indications

Connector Side

Channel 1 Tx D16 Channel 1 Rx D17 Channel 2 Tx D18 Channel 2 Rx D19

S/W

LED

NOTE

Each pump head is connected to a single port.

2.15.1. Sub module (Suspend Resume Relay Card)

Since ER3 protocol doesn’t support the Stop (suspend) command, there is a need to use an external relay in order to suspend VIU refueling.

The relay card can drive low voltage contactor, or a solenoid valve as follow:

Voltage 12-24volt Current 1A max

Each comverter can connect to eight pump heads (total).

Figure 2-54. Cetil Sub Relay Module – Connections

The following pinout is required for the Cetil sub-module application.

8 7 6 5 4 3 2 1

N/A COMMON NC NO N/A COMMON NC NO

Channel 2 Channel 1

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2.15.2. Sub Module Pumalan

Pumalan Module (Cat. No. 819223445) consists of two separate communication ports (clusters). Pin 1-4 = first communication port Pin 5-8 = second communication port The Pumalan pump protocol does not support Suspend/Resume commands, therefore, an external

relay connection is required. In cases where the relay should be used, refer to Paragraph 2.9, to conduct the appropriate

connections.

Figure 2-55. Sub Module Pumalan – Connections

Pumalan Connector Pin out

8 7 6 5 4 3 2 1 E G TX RX E G TX RX

Figure 2-56. Pumalan Port Module – General View Cat. No. 819223445

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2.16. DOOR OPEN DETECTION

The FFC includes a feature for preventing unauthorized third parties from forcing the sealed FCC box door.

The FCC generates an alarm in cases where the door was opened. The function setup procedure comprehends:

a. Physical connection of the detector, as described below b. Digital I/O jumper setup (described in paragraph 5.7.1) c. SiteOmat setup (described in SiteOmat Installation and Maintenance Manual, P/N

817423756, paragraph 6.3.1)

2.16.1. Door Open Detector Installation

The detector is composed of two parts:

 A connector including a m

agnet at the end of the cable

 An additional magnet

The detector should be connected to the 8-Port Commverter and affixed to the FCC cabinet. Proceed as follows:

1. Connect the detector connector to the I/O Cn6 Jumper (see

Figure 2-57)

2. Attach the additional magnet to the inner side of the FCC door, using the adhesive

tape

3. Attach the detector magnet to the box inner wall in front of the additional magnet,

using the adhesive tape

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Figure 2-57. Door Open Detector Connection

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SECTION

COMMVERTER DESCRIPTION

3.1. SCOPE

This section provides a detailed description of the CommVerter and its specifications.

3.2. PHYSICAL

3.2.1. Housing

The CommVerter can be installed in various places either on a desk or a shelf, or on a wall, or any location within the fuel station office. The CommVerter kit includes the required items for on-wall mounting as well as required mating connectors.

Figure 3-1. CommVerter – Front Panel

In some cases, the CommVerter is installed without its casing (see Figure 1-2).

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3.2.2. Front and Rear Panel

The CommVerter front panel includes eight red LED indicators behind a transparent protecting window (see Figure 3-1).

The rear panel of the case includes the communication connectors and the power connector. A 110VAC to 230VAC power cord is added. The rear panel connectors’ layout is determined by the CommVerter modules installed in it.

For example: The LAN to Current Loop, Tokheim modules, that convert LAN communication into Current Loop, Tokheim communication only, feature a rear panel with four connectors for four different modules.

Figure 3-2. CommVerter – Rear Panel (Current Loop / Tokheim Configuration)

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3.3. LED INDICATORS

3.3.1. General

The CommVerter unit includes eight LED indicators on its front panel, protected behind a transparent plastic window. The LED indicators provide visual display on data traffic, power on as well as system functionality.

The LED indicators enable performing a system check after installation in accordance with the status of LEDs 1 to 4.

3.3.2. Configuration

The LED indicators are configured as shown below, from left to right, when facing the CommVerter front panel:

Figure 3-3. Front Panel LEDs Configuration

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If the CommVerter PCB is used, the locations of the LEDs on the board are shown in Figure 3-4.

Figure 3-4. CommVerter LEDs Configuration on PCB

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Table 3-1. CommVerter LED Indication

LED No. Name Assigned to Indication

1 --- Blinking Application running

--Blinking

One of the channels send/receives

messages 3 SCAN Channel reconnect Digital I/O status has changed 4 --- For future use N/A 5 WD WD Watch dog - Hardware failure 6 POWER Power On ON - System is on. 7 LAN ACTIVITY LAN activity Communication activity in the line 8 LAN LAN connection LAN communication is active

3.4. MAIN BOARD CONNECTORS

The Main Board includes two special purpose connectors, as listed below (see Figure 3-5).

Table 3-2. Main Board Connector Functionality

Connector Function

J2 MONITOR /future use

Hardware Watchdog / Normally closed

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3.5. MAIN BOARD JUMPERS

The main board includes several jumpers for different conversion methods. Each conversion method can be set by a different jumper setting (see Figure 3-5).

NOTE

The RS-232 to RS-485 conversion configuration is factory-set only; no access to the jumper set is required.

Table 3-3. Main Board Jumpers Functionality

Jumper

Function

Number Cn3 RS-232 monitoring

Cn12 Keyboard option Cn2 Display connector Cn24 Mode select /future use

Cn6

Single wire com – Open Door

Detection Feature Cn8 SPI/pin 1-2 shorted Cn10 J –tag lattice Cn25 J-tag AVR

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Figure 3-5. Main Board Jumpers and Connectors

3.6. CHANGING THE IP ADDRESS

In order to change the CommVerter IP address, as it may be required in cases where more than one unit is in use in the station, proceed as follows:

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NNOOTTEE

In cases where unit's IP is unknown or there is no Ping to the unit, proceed as follows:

1. Turn OFF the unit

2. Short CN8 jumper pins 4 and 6 (see Figure 3-5)

3. Turn the unit back ON

4. Browse to the default IP address 192.168.1.108 to view the current settings

1. Power OFF the unit

2. Short jumper CN8 pins 2 and 3

3. Power ON the unit

4. Connect the CommVerter to a PC (LAN Connection)

5. Open the Web browser, and enter the IP address of the

Commverter. The Setup Main Screen is displayed (see Figure 3-6)

Figure 3-6. CommVerter Unit Setup Site – Main Screen

6. Click on Admin Tasks. The Admin screen is

displayed. Scroll down the page to reach the TCP/IP timeouts section (see Figure 3-7)

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Figure 3-7. CommVerter Unit Setup Site – Admin Screen

7. Select the Temporary disable (up to 5 minutes)

checkbox

8. Click on the Send button in this section of the page

9. Click on Ethernet. The Ethernet screen appears

(see Figure 3-8)

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Figure 3-8. CommVerter Unit Setup Site – Ethernet Screen

10. Enter the required IP Address

11. Click Send

12. Click Admin Tasks. The Admin screen is

displayed. (see Figure 3-7)

13. Select the Write to eeprom and reset radio button

14. Click on the Send button. Wait until the Term

inal screen is displayed (see Figure 3-9) to verify the command was sent

Figure 3-9. CommVerter Unit Setup Site – Terminal Screen

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15. Power OFF the unit

16. Power ON the unit

17. Check login with the modified IP.

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SECTION

INSTALLATION AND GROUNDING

4.1. GENERAL

This section provides the installation procedures for the CommVerter, and the removal instructions for sub-module replacement. Paragraphs 4.2 to 4.4 provide the installation procedures specifically for the enclosed type Commverter unit only.

4.2. PRELIMINARY PROCEDURES

4.2.1. Unpacking and Inspection

This section provides information for unpacking and inspection:

 Examine the shipping container for damage before unpacking the

unit. Perform a visual inspection to reveal any physical damage to the equipment.

 Verify that the equipment is complete, as listed in Table 4-1.

4.2.2. Installation Equipment

The CommVerter is supplied in a kit with the necessary items for its proper installation, as listed below.

Table 4-1

No. Description

1 CommVerter Unit 2 Connector for RS-485 / RS-232 / Current Loop / Tokheim and more 3 Mounting Bracket for wall installation

The kit includes the relevant connector only (Item 2), in accordance with the supported communication conversion method.

. CommVerter Unit Kit

NOTE

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4.2.3. Protective Procedures

Prior to installing the unit, verify the following safety and operating environment requirements:

o Make sure the local AC power voltage (110VAC to 230VAC) meets the model

requirements of the CommVerter unit you are installing. If not, add a proper voltage converter.

o Check all safety warnings (as included in the manual opening pages) are met before

proceeding with the installation.

o Connect the CommVerter unit (neutral, line and earth) lines to the local electricity

network only after all installation procedures are completed.

4.3. INSTALLING THE COMMVERTER

4.3.1. General

The CommVerter can be mounted in two ways as follows:

o On-desk installation o Wall installation

4.3.2. Desktop Installation

This type of installation means that the CommVerter can simply be installed on any plane, clean surface in the station offices.

Proceed as follows:

o Locate a secure, well-shaded and ventilated, location place at the office o Install the CommVerter in the selected area o Perform the necessary connections.

Make sure that the unit is placed in a well-shaded and ventilated location.

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4.3.3. Cables’ Connections

The next step in the installation procedures requires connection of cables to the CommVerter.

NOTE

The connection to the Mains power plug should be done only after all the communications cables are inserted, and not previously.

Proceed as follows:

1. Make all necessary communication cables’ connections to the CommVerter , in

accordance with the fuel station configuration and with the special requirements of the installed cables

NOTE

The CommVerter kit includes only the relevant connectors as specified in the supported communication conversion method.

2. Connect the Power Supply cable to the CommVerter

3. Connect the power cable to the Mains (110VAC to 230 VAC).

NOTE

If an adapter to the Mains wall plug is required (in accordance with the local configuration), please obtain it beforehand – it is not included in the shipment.

NOTE

The CommVerter kit includes only the relevant connectors as specified in the supported communication conversion method.

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4.4. GROUNDING THE COMMVERTER

4.4.1. General

The CommVerter must be grounded for safety and protection, once installed. This requirement is achieved by grounding the RS-485 connector of the external communication cable.

4.4.2. Grounding – General Concept

The shields of the density probes, density displays, Tag Readers and pumps (RS-485) are looped to the Earth of the FCC enclosure.

In order to connect the 8-port Commverter with the Earth of the FCC enclosure, it is enough to loop only one of the shield pins of the enclosure with the Earth pins at the 8-port Commverter RS-485 connector.

4.4.3. Grounding the 8-port Commverter (without RS485 card)

Proceed as follows:

2. Make a wire loop between pin 3 and pin 4 (see Figure 4-1) in the RS-485 input

connector of channels 1 and 2

3. Use at least 1 mm of yellow-green wire

4. Use a separate lug for each wire-end inside the port.

Figure 4-1. CommVerter Unit – Grounding Cable in RS-485 Connector

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4.4.4. Grounding the 8-port Commverter (without RS485 card)

Proceed as follows:

Open the screw

Insert the lug between the cover and the chassis.

Figure 4-2. CommVerter Unit – Grounding the Unit (without RS-485 Card)

1. Connect a round lug to a grounding cable (color green or yellow).

2. Connect the other end of the grounding cable to the FCC enclosure main ground.

3. On the corner of the CommVerter at the power supply side, open the screw that

closes the cover of the 8 port CommVerter.

4. Insert the lug between the cover and the chassis of the CommVerter.

5. Close the screw and tight it well.

6. Verify proper grounding

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4.4.5. Verifying the Grounding

Proceed as follows:

5. After connecting the Earth cable between the 8-port Commverter and the FCC

enclosure earth bar, use a multi-meter to verify its is properly grounded

6. Verify impedance [up to 5 Ω] between the 8-port Commverter chassis and the FCC

earth.

4.5. SUB-MODULE INSTALLATION AND GROUNDING

NOTE

When installing piggy-backs on the CommVerter, power to the board should disconnected

4.5.1. Installation of Protective Isolator Sheet

Before installing a sub-module on the CommVerter main board, insert a Protective Isolator Sheet (P/N 815608200) between the board and the sub-module. This Isolator Sheet prevents damage during removal of the item from the board due to the use of a screwdriver or other unsuitable sharp device.

4.5.2. Connector Mechanical Outline – Check Procedure

When installing a sub-module on the CommVerter main board, carefully check that the sub-module connector mechanical outline is identical with the connector in the Main board. The current connectors have a rectangular form, where in previous versions of the main board, the connectors were circular. Do not use force, you may damage the boards!!!

4.5.3. Sub-Module - Grounding

Once you have installed any sub-module (piggy-back board) on the m

ain board, secure the sub-

module by locking it with the appropriate screw. This screw also serves as protective grounding.

4.5.4. Sub- Module Installation – Wiring Label Placing

In enclosed type CommVerter, after placing a piggy-back board on the PCB, stick the supplied wiring label associated with the specific installed piggy-back. The label should be placed on the rear panel, under the relevant piggy-back connector.

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4.6. SUB-MODULE REPLACEMENT - REMOVAL INSTRUCTIONS

4.6.1. General

The main sub-module in the CommVerter main board needs to be replaced during maintenance and replacement procedures. These units may be heavily damaged as a result of mishandling. Use of screwdrivers or other unsuitable sharp devices to detach the item can cause broken pins due to excessive force exerted on the sub-module.

You are required to use the proper tool and operate properly, as described next.

Figure 4-3. CommVerter Unit – Damaged Sub-Module

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4.6.2. Removal Tool – Spring ARC

In order to detach a sub-module from the CommVerter main board, use only the Spring-ARC tool, a unique device from Orpak (P/N 814423700).

Figure 4-4. Spring ARC Tool

Figure 4-5. Spring ARC Tool – Dimensions

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Gasboy FuelOmat system 8 Popt Commverter User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL DESCRIPTION

1.1. SCOPE

1.2. MANUAL ORGANIZATION

1.3. GENERAL DESCRIPTION

1.4. MODULES

1.4.1. Modules

1.5. SPECIFICATIONS

1.5.1. Communication Rates

1.5.2. Electrical

1.5.3. Mechanical Pump Rates

1.5.4. Mechanical

1.5.5. Environmental

1.6. PROTECTION

APPLICATIONS

2.1. SCOPE

2.2. COMMVERTER SYSTEM ARCHITECTURE

2.2.1. General

2.2.2. System Architecture 1: Centralized at the Station Office

2.2.3. System Architecture 2: Moved to the Isle Side

2.2.4. System Architecture 1: Using an OrPT and/or µVIT on the Isles

2.3. TYPES OF FUEL PUMP AND THEIR COMMUNICATIO N METHOD

2.4. CONNECTORS

2.4.1. General

2.4.2. Mating a Connector

2.5.2. RS-485 Module Jumpers

2.6. LAN to RS-232 APPL ICATION

2.6.1. RS-232 Connector Pinout

2.7. LAN to CURRENT LOOP

2.7.1. LAN to Current Loop Application

2.7.2. Current Loop Connector Pinout

2.7.3. Current Loop Module Jumpers

2.7.4. Current Loop Electronic Devices (Pump or any Current Loop Devices)

2.7.5. Wayne Pump Configuration Example

2.7.6. Gilbarco Legacy & Gasboy 8800 Current Loop Electronic Pumps Configuration

2.7.6.1. SiteOmat Configuration for Gilbarco Legacy & Gasboy 8800 Current Loop Electronic Pumps

2.8. LAN to TOKHEIM APPLICATION

2.8.1. Tokheim Connector Pinout

2.8.2. Tokheim Module Jumpers

2.8.3. Tokheim Electronic Devices (Pump or any Tokheim Devices)

2.8.4. Addressing Dual-Sided Tokheim Pumps

2.9. 4xCONTACTOR APPLICATION

2.9.1. 4x Contactor Connector Pinout

2.9.2. 4xContactor Module Jumpers

2.9.3. Station Setup

2.9.4. Pump Server Setup

2.9.5. 8 Port CommVerter Setup

2.10. LAN to RS422 APPLICATION

2.10.1. RS422 Module Application

2.10.2. RS-422 Connector Pinout

2.11. LAN TO NUOVO PIGNONE APPLICATION

2.11.1. Nuovo Pignone Connector Pinout

2.11.2. COPTRON Communication to Nuovo Pignone Card

2.12. LAN TO RS232/485 APPLICATION

2.12.1. RS-232/485 Connector Pinout

MECHANICAL PUMP INTERFACE (MPI-C)

2.13.1. MPI-C Connector Pinout and Signals

2.13.2. Mechanical Pump - Pulser Connections

2.13.2.1. Pulse Rate

2.13.2.2. Interface Connections

2.13.3. Pulse Divider

2.13.4. Description for LED's on the MPI-C board

2.14. 5-PORT LAN SWITCH

2.15. CETIL ER3 MODULE

2.15.1. Sub module (Suspend Resume Relay Card)

2.15.2. Sub Module Pumalan

2.16. DOOR OPEN DETECTION

2.16.1. Door Open Detector Installation

COMMVERTER DESCRIPTION

3.1. SCOPE

3.2. PHYSICAL

3.2.1. Housing

3.2.2. Front and Rear Panel

3.3. LED INDICATORS

3.3.1. General

3.3.2. Configuration

3.4. MAIN BOARD CONNECTORS