Gasboy FuelOmat system 8 Popt Commverter User Manual

MDE-4820H

88PPOORRTTCCOOMMMMVVEERRTTEER

R

OPERATION AND INSTALLATION MANUAL

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

SAFETY CONSIDERATIONS

Read all warning notes and instructions carefully. They are included to help you installing the Product safely
in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions
could result in serious injury or property damage. It is the installer responsibility to install, operate and
maintain the equipment according to the instructions given in this manual, and to conform to all applicable
codes, regulations and safety measures. Failure to do so could void all warranties associated with this
equipment.

Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure
that actual installation is performed by experienced personnel, licensed to perform work in fuel station and at
a flammable environment, according to the local regulations and relevant standards.

WARNING - EXPLOSION HAZARD

Use separate conduit for the intrinsically safe. Do not run any other wires or cables through this conduit,
because this could create an explosion hazard.
Use standard test equipment only in the non- hazardous area of the fuel station, and approved test equipment
for the hazardo us areas.
In the installation and maintenance of the Product, comply with all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Code for
Motor Fuel Dispensing Facilities and Repair Garages”, NFPA-70 “National Electric Code”, federal, state and
local codes and any other applicable safety codes and regulations.
Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work
operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury,
property loss and damage to you and other persons.

CAUTION - SHOCK HAZARD

Dangerous AC voltages that could cause death or serious personal injury are used to power the Product.
Always disconnect power before starting any work. The Product has more than one power supply connection
points. Disconnect all power before servicing.

WARNING – PASSING VEHICLES

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

WARNING

Components substitutions could impair intrinsic safety.

Attaching unauthorized components or equipment will void your warranties.

CAUTION

Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all
warranties related to this equipment.

PROPRIETY NOTICE

This document contains propriety and confidential information. It is the property of ORPAK SYSTEMS
Ltd. It may not be disclosed or reproduced in whole or in part without written consent of ORPAK
SYSTEMS. The information in this document is current as of the date of its publication, but is subject to
change without notice.

DISCLAIMER

This document is provided for reference only. Although every effort has been made to ensure correctness,
ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.

This document is the property of:

ORPAK SYSTEMS Ltd.

ISRAEL

TABLE OF CONTENTS

Paragraph Page

GENERAL DESCRIPTION

1

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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0

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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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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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

1

GENERAL DESCRIPTION

1.1. SCOPE

The 8 port CommVerter unit, referred to as "CommVerter" throughout this document, is a
component within the FuelOmat system. It serves as a universal and modular hardware interface
between the Ethernet communication from the Station Controller (FCC) and the other devices
communication interfaces such as RS485/422, Current Loop, etc.

As a communication interface unit, the CommVerter converts the Ethernet communication protocol
of any station devices into RS-485/422, Current Loop or Tokheim communication interfaces and
vice versa.

The CommVerter includes several modules designed to support each communication interface.
Some of these modules can be configured for different protocols by means of built-in Web pages.

The CommVerter unit is designed to survive the harsh forecourt environment. The RS-485 module
uses Spark Gaps protection for the links, and 1.5 KV isolation between the office controller and the
forecourt devices.

1.2. MANUAL ORGANIZATION

This manual provides information on the technical characteristics, installation and operation of the
CommVerter unit. This document deals with the physical level of the communication that is,
connecting the CommVerter unit to a network. It does not cover any software required to configure
the system. The manual is organized as follows:

Section 1. General Description: Includes general information regarding the CommVerter unit, its
components and functionality.

Section 2. Applications: Describes the types of communication where the CommVerter unit
provides interface applications.

Section 3. Description: Includes detailed information regarding the CommVerter unit and its
specifications.

Section 4. Installation and Removal: Provides instructions regarding the installation (and
removal) of the CommVerter unit at the station office.

Section 5. Setup and Configuration: Provides instructions concerning the instructions for the
setup and configuration of the CommVerter unit.

Section 6. Checks and Troubleshooting: Provides several recommended steps for checking the
system operability and for basic troubleshooting.

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8 Port CommVerter operation and installation manual

1.3. GENERAL DESCRIPTION

The CommVerter is a Communication Converter, interfacing serial Forecourt devices such as
pumps and tank level gauges to the station automation system through a standard TCP/IP Ethernet
port.

Unlike off-the-shelf Ethernet to Serial interfaces, the CommVerter is designed to function in the
harsh environment of the petrol stations; eliminating ground loops, power surges and other
RFI/EMI noise to maximize the performance and reliability of the station automation solution. Each
link is ‘floating’ and is DC isolated from all other links and has surge protection and enhanced
filtering.

There are two CommVerters configurations: one which is supplied as an enclosed unit which
includes an internal power supply (as shown in Figure 1-1) and the other as a PCB, which is
installed in Gilbarco's products (see Figure 1-2).

Figure 1-1. CommVerter – General View

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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

2

APPLICATIONS

2.1. SCOPE

This section provides the interfaces available between the CommVerter and several types of fuel
pumps. This section also includes several applications for the CommVerter in different se ttings
within the station. The CommVerter ensures proper communication between the FCC and the
station devices in accordance with their communication protocols.

2.2. COMMVERTER SYSTEM ARCHITECTURE

2.2.1. General

The CommVerter system architecture consideration depends on the topology of the specific petrol
station.

There are three main architectures:

 Centralized at the station office
 Moved to the isle side
 When using an OrPT and/or µVIT on the isles

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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

J1

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
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

RS485 819223460 2 8 On 9600 8 None 1

RS485 819223460 2 8 On 9600 8 None 1

Board P/N

1

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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