PCC Installation and Commissioning Guide - EMS Australia

POSTEC COMMUNICATIONS PCC4
CONTROLLER INSTALLATION AND COMMISSIONING MANUAL

For PCC MODEL 4

INSTALLATION AND
COMMISSIONING MANUAL

Revision 6.06
2nd July 2010

Postec Data Systems

Address: Unit A 45 – 47 Paul Matthews Rd
Albany
Auckland
New Zealand

Website: www.postec.co.nz
Email: [email protected]
Phone: +64 9 415 8803
Fax: +64 9 415 9042

PCC4 INSTALLATION AND COMMISSIONING MANUAL

TABLE OF CONTENTS

1 INTRODUCTION .....................................................................................................................................6

1.1 PCC4 ................................................................................................................................................6
1.2 PCC4E............................................................................................................................................11
1.3 PCC4R............................................................................................................................................13
1.4 PCC4RE .........................................................................................................................................16
1.5 PCC4EX .........................................................................................................................................18

2 PCC LOCATION ...................................................................................................................................19

3 POWER SUPPLY..................................................................................................................................20

3.1 Standard Linear Power Supply (with PCC Transformer) ................................................................20
3.2 Extended Power Supply .................................................................................................................22

3.2.1 Mains Front-end ...........................................................................................................................................................22
3.2.2
3.2.3 Vehicle Front-end.........................................................................................................................................................22
3.2.4
3.2.5 Extended Power Supply Specifications ........................................................................................................................24

Connectors...................................................................................................................................................................25
Switching off procedure – VERY IMPORTANT.............................................................................................................27

4 PUMP COMMUNICATIONS WIRING ...................................................................................................28

4.1 Active Pump Communications .......................................................................................................28

4.1.1 Active PEC UPI ............................................................................................................................................................29
4.1.2 Active Gilbarco UPI ......................................................................................................................................................30
4.1.3 Active Dresser Wayne Current Loop UPI .....................................................................................................................31
4.1.4 Active Email UPI ..........................................................................................................................................................33
4.1.5 Active RS485 UPI Half Duplex (New Version) ..............................................................................................................34
4.1.6 Active RS485 UPI Half Duplex (Original Version) .........................................................................................................35
4.1.7 Active RS422/RS485 UPI Full Duplex Tokheim (US Termination Boxes) / Dong Hwa..................................................36
4.1.8 Active RS232 UPI for Tokheim South Africa Termination Box / PEC FIC Box ..............................................................36
4.1.9 Active Tokheim UPI (Direct Pump Interface) ................................................................................................................37
4.1.10
Active Schlumberger UPI.........................................................................................................................................38

4.2 Passive Pump Communications.....................................................................................................39

4.2.1 Passive PEC UPI (Dual Loop)......................................................................................................................................39
4.2.2 Passive Gilbarco Current Loop UPI..............................................................................................................................40
4.2.3 Passive Dresser Wayne Current Loop .........................................................................................................................40
4.2.4 Passive Email UPI .......................................................................................................................................................41
4.2.5 Passive RS422/485 UPI...............................................................................................................................................42

5 POINT OF SALE TERMINAL COMMUNICATIONS.............................................................................43

5.1 PCC Bridge Ethernet LAN Interface ...............................................................................................43
5.2 PCC Asynchronous Serial Communication ....................................................................................44

5.2.1 RS232 Interface (single node)......................................................................................................................................44
5.2.2 Multi-Drop RS232 Interface ..........................................................................................................................................45
5.2.3 RS422 (Full Duplex) Interface ......................................................................................................................................46
5.2.4 RS485 (Half Duplex) Interface......................................................................................................................................47

6 SERIAL CONNECTION TO OTHER FORECOURT DEVICES ............................................................48

6.1 PCC Synchronous Serial Communication (PCC4E/EX & PCC4RE only) ......................................50

6.1.1 Dual-sync interface ......................................................................................................................................................50

6.2 PCC 45mA Current loop Interface Board .......................................................................................52

7 INTERNAL MODEM..............................................................................................................................53

7.1 Simple and GSM Data Modems .....................................................................................................53
7.2 Postec P336 Modem ......................................................................................................................53

7.2.1 PCC4 AUX Port setup ..................................................................................................................................................53
7.2.2 Postec P336 modem functionality checks ....................................................................................................................53
7.2.3 Redialling Warnings for Australia .................................................................................................................................54
7.2.4 Redialling Warnings for New Zealand ..........................................................................................................................54

7.3 GSM Data Modems ........................................................................................................................55

7.3.1 The GSM SIM card ......................................................................................................................................................55
7.3.2 AUX Port setup ............................................................................................................................................................55
7.3.3 GSM Data Modem functionality checks:.......................................................................................................................55

8 PERFORMING A MASTER RESET......................................................................................................56

9 FITTING AN ADDITIONAL UPI TO THE PCC......................................................................................57

9.1 UPI Internal Connections................................................................................................................57
9.2 UPI DIP Switch Settings .................................................................................................................57

PCC4 INSTALLATION AND COMMISSIONING MANUAL

9.3 PCC UPI CONFIGURATION..........................................................................................................58
10 PCC AUX CHANNEL CONFIGURATION .........................................................................................60
11 POSTEC INTELLIGENT PURCHASES INDICATOR (PIPI) CONNECTION....................................61

11.1 PIPI Connection ..........................................................................................................................61
11.2 PCC Configuration ......................................................................................................................61
11.3 PIPI Testing ................................................................................................................................62
12 BATTERY BACKUP MODULE .........................................................................................................63
13 PCC BRIDGE TFTP AND TELNET...................................................................................................64
13.1 TFTP ...........................................................................................................................................64
13.2 Telnet ..........................................................................................................................................64
APPENDIX A: PCC DIP SWITCH SETTINGS .............................................................................................65
APPENDIX B: PCC SOFTWARE UPDATES...............................................................................................67
GLOSSARY ..................................................................................................................................................68

PCC4 INSTALLATION AND COMMISSIONING MANUAL

Table of Figures

Figure 1 - PCC4 Open Case ...........................................................................................................................7
Figure 2 - PCC4 Main Board...........................................................................................................................7
Figure 3 - PCC4 Main Board Legend (new version) – Part Number - 81-0481 ..............................................8
Figure 4 - PCC4 Main Board (original version) fitted with Ethernet Bridge Daughter Board...........................9
Figure 5 - PCC4 Main Board Legend (original Version) – Part Number – 81-0014........................................9
Figure 6 - PCC4 Bridge Legend – Part Number - 81-0213...........................................................................10
Figure 7 - PCC4E Open Case.......................................................................................................................11
Figure 8 - PCC4E Main Board ......................................................................................................................12
Figure 9 - PCC4E Main Board Legend – Part Number - 81-0340 ................................................................12
Figure 10 - PCC4R Open Case ....................................................................................................................13
Figure 11 - PCC4R Main Board ....................................................................................................................14
Figure 12 - PCC4R Main Board Legend (new version) – Part Number - 81-0482........................................14
Figure 13 - PCC4R Main Board Legend (original version) – Part Number - 81-0258...................................15
Figure 14 - PCC4RE Main Board..................................................................................................................16
Figure 15 - PCC4RE Main Board Legend - Part Number - 81-0483.............................................................17
Figure 16 - PCC4EX with SBC - Open Case ................................................................................................18
Figure 17 - Extended Power Supply Connectors Legend (new version) – Part Number - 81-0451 .............25
Figure 18 - Extended Power Supply Connectors Legend (original version) – Part Number - 81-0451 ........26
Figure 19 - Active PEC UPI Legend - Part Number - 81-0026 .....................................................................29
Figure 20 - Active Gilbarco UPI Legend (new version) - Part Number - 81-0453.........................................30
Figure 21 - Active Gilbarco UPI Legend (original version) - Part Number - 81-0020....................................30
Figure 22 - Active Gilbarco UPI Key Components ........................................................................................31
Figure 23 - Active Email UPI Legend - Part Number - 81-0017....................................................................33
Figure 24 - Active RS485 UPI Half Duplex Legend (new version) – Part Number - 81-0531.......................34
Figure 25 - Active RS485 UPI Half Duplex Legend (original version) - Part Number - 81-0085...................35
Figure 26 - Active RS422/RS485 UPI Full Duplex Legend - Part Number - 81-0221...................................36
Figure 27 - Active RS232 UPI Legend - Part Number - 81-0252..................................................................36
Figure 28 - Active Tokheim UPI Legend - Part Number - 81-0310...............................................................37
Figure 29 - Active Schlumberger UPI Legend - Part Number - 81-0301 ......................................................38
Figure 30 - Passive PEC UPI Legend - Part Number - 81-0064...................................................................39
Figure 31 - Passive Gilbarco Current Loop Legend - Part No 81-0012 ........................................................40
Figure 32 - Passive Email UPI Legend - Part Number - 81-0021 .................................................................41
Figure 33 - Passive RS422/485 UPI Legend - Part Number – 81-0514 .......................................................42
Figure 34 - Serial Cable ................................................................................................................................44
Figure 35 - Multidrop RS232 .........................................................................................................................45
Figure 36 - RS422 Connections....................................................................................................................46
Figure 37 - RS485 Connections....................................................................................................................47
Figure 38 – Serial Connection to other Forecourt Devices ...........................................................................49
Figure 39 - Dual Sync Interface Board – Part Number 81-0406 ...................................................................50
Figure 40 - Current Loop Interface – Part Number 81-0555 .........................................................................52
Figure 41 - Focus Forecourt Configuration - Auxiliary Devices ....................................................................60
Figure 42 - PIPI Connections ........................................................................................................................61

PCC4 INSTALLATION AND COMMISSIONING MANUAL

Revision History

Date Version Sections Content
Sections 3.2, 3.2.1 & Revised Extended Power Supply for two frontends,
02/03/2010 V6.03 3.2.2 Mains and Vehicle.
Section 6 Revised Figure 38 – Serial Connection to other
09/03/2010 V6.04 Forecourt Devices – RS422
Section 6.2
06/04/2010 V6.05 Revised PCC 45mA Current loop Interface Board, text
Section 3.2.2 and legend.
02/07/2010 V6.06
Added section - Vehicle Power Front End

PCC4 INSTALLATION AND COMMISSIONING MANUAL

1 INTRODUCTION

The POSTEC COMMUNICATIONS CONTROLLER (PCC) is a multi-processor based unit. It has an array of input
and output ports to facilitate digital data acquisition and process control.

The PCC is a technology platform from which a number of communications controller systems can be created.
Application modules (or building blocks) can be selected from a software library and linked together to provide
solutions for a variety of applications and complexities.

1.1 PCC4

The original PCC4 did not have Ethernet capability. To satisfy this requirement a retro fitted daughter board was
developed which was named „Bridge‟. This board fits on top of the original PCC4 main board as shown in
Figure 4 .The „Bridge‟ daughter board is still readily available for extending the original PCC4 main boards which are
in the field.

At a later stage, these two boards were combined into a single board which was named „Combo‟ as shown in
Figure 8.The manufacturing of the original board has since ceased and the following five variants of the combo
board replace the originals: PCC4, PCC4E, PCC4RE, PCC4R and PCC4EX.

PCC4 replaces the original PCC4 since it has similar characteristics, no Ethernet but with eight serial ports.
PCC4E replaces the original „Combo board‟ since it has Ethernet with eight serial ports.
PCC4R replaces an earlier board called „Restricted‟ since it has limited serial ports.
PCC4RE is new; it has Ethernet and limited serial ports.
PCC4EX is the same main board as the PCC4E with the addition of an extended power supply.

This manual describes the site installation of the PCC and its connection to external devices.

Further information can be obtained by contacting POSTEC DATA SYSTEMS.

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Figure 1 - PCC4 Open Case

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Figure 3 - PCC4 Main Board Legend (new version) – Part Number - 81-0481

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Figure 4 - PCC4 Main Board (original version) fitted with Ethernet Bridge Daughter Board

Figure 5 - PCC4 Main Board Legend (original Version) – Part Number – 81-0014

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Figure 6 - PCC4 Bridge Legend – Part Number - 81-0213

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1.2 PCC4E

This variant of the PCC combines the functions of the original PCC4 with those of the Ethernet Bridge on a single
board.
The Ethernet part of the PCC4E has a number of enhancements to that of the original Bridge including increased
FLASH and RAM and 2 x Synchronous com ports for EFT applications.

Figure 7 - PCC4E Open Case

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Figure 8 - PCC4E Main Board

Figure 9 - PCC4E Main Board Legend – Part Number - 81-0340

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1.3 PCC4R

In contrast to the PCC4 the PCC4R has a limited array of input and output ports to facilitate digital data acquisition
and process control, and serves as a less expensive controller to meet the lower end of the Service Station market.

The PCC4R is cased the same as the PCC4, but the mother board design restricts the configuration to:

1. A single RS232 board for interfacing to a PoS, Forman3, Forman4 or FOCUS
2. Two UPI boards allowing sites to have a maximum of two pump protocol types and/or 32 filling positions.

The PCC4R does not support an internal modem or additional RS232/RS485 boards.

Relevant sections for PCC4R installation are:

Section 4 PUMP COMMUNICATIONS WIRING
Section 5 POINT OF SALE TERMINAL COMMUNICATIONS
Section 8 PERFORMING A MASTER RESET
Section 9 FITTING AN ADDITIONAL UPI TO THE PCC
Section 9.3 PCC UPI CONFIGURATION

Figure 10 - PCC4R Open Case

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Figure 11 - PCC4R Main Board

Figure 12 - PCC4R Main Board Legend (new version) – Part Number - 81-0482

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Figure 13 - PCC4R Main Board Legend (original version) – Part Number - 81-0258

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1.4 PCC4RE

This variant of the PCC combines the functions of the PCC4R with those of the Ethernet Bridge on a single board.
The Ethernet part of the PCC4RE has a number of enhancements to that of the original Bridge including increased
FLASH and RAM and 2 x Synchronous com ports for EFT applications.

Figure 14 - PCC4RE Main Board

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Figure 15 - PCC4RE Main Board Legend - Part Number - 81-0483

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1.5 PCC4EX

This variant of the PCC combines the PCC4E with an SBC and an extended power supply. Refer to section 3.2
Extended Power Supply.

Figure 16 - PCC4EX with SBC - Open Case

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2 PCC LOCATION

The PCC is best installed in a location away from the busy Retail Kiosk area. The PCC case is designed to be
mounted on a wall by a pair of slotted screw mounts.

Some considerations when choosing the installation position are:

Power supply availability
Communications wiring to the forecourt
Communications wiring to POS Terminals
Communications wiring to other forecourt devices, i.e. car wash, EFT controller, Automatic Tank Gauge.
Visual access to monitoring LED's mounted on the top of the case

Note:

1. The PCC4EX ( extended cabinet with internal SBC fitted), must be mounted vertically on the slotted screw
holes provided with the orientation such that the text on the PCC lid is horizontal and the right way up. This
ensures that heat rising from the SBC CPU heatsink dissipates away from the printed circuit broad.

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3 POWER SUPPLY

The PCC, like any other piece of electronic equipment on the forecourt, needs a clean mains supply. Avoid using a
feed that sources equipment with compressors (e.g. refrigerators).

The power feed to the Point of Sale equipment may be a good choice. If a UPS is used on the site the PCC should
be powered from it as it requires very little power i.e. 30VA.

A connector block inside the earlier versions of the PCC is clearly labelled for the Phase and Neutral. An Earth stud
is provided on the case. Later PCC cases have a power entry module, which accommodates a standard IEC mains
plug. The PCC is supplied with an IEC plug inside the case.

Note:

1. Whenever the lid on top of the PCC4 is removed, for whatever reason, it is very important that the mains cable
be completely detached from the Power Entry Module.

2. The PCC power supply has been designed with components to protect it against transient mains spikes and
interference. An Earth Connection is required for this to be effective.

3.1 Standard Linear Power Supply (with PCC Transformer)

The PCC requires a nominal 230/240volt AC mains supply (approx. 30 VA), for countries with that mains voltage. A
115volt AC mains version (approx. 30VA) is also available for countries with the lower mains voltage. The mains
voltage is clearly marked on a label, next to the Power Entry Module.

The PCC Mains transformer provides a pair of orange wires which provides a nominal 9VAC input into the PCC
battery charger power supply board. This board provides the following tabled DC output voltages.

ALL POWER TESTPOINT REFERENCE NOMINAL
SUPPLY BOARDS 9V
Unregulated Measurement PURPLE GREEN 5V
Connection (+) Connection (-)
Regulated RED GREEN
Measurement Connection (+) Connection (-)

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Each UPI has its own pump interface power supply circuit. This is sourced directly from an isolated winding of the
PCC's mains transformer windings according to the following table.

PUMP CARD TYPE Transformer Wires PCB Plug ID and Pinout
Active & Passive PEC UPI Red
White P6 outer 15V AC
Active Gilbarco UPI Red
Active Email UPI P6 centre OV AC
Active Wayne ISM UPI Purple
Active RS485 UPI Yellow P6 outer 15V AC
Active & Passive RS422 UPI Purple
Active RS232 UPI Yellow P4 pins 1 & 4 30V AC
Active Tokheim UPI Yellow
Yellow P3 pins 1 & 2 15V AC
Active Schlumberger UPI
Red P4 pins 1 & 4 30V AC
White
Red JP1 pins 1 & 2 15V AC
Red
White JP1 pins 1 & 2 15V AC
Red
JP1 pins 1 & 2 15V AC

P6 outer 15V AC

P6 centre OV AC

P6 outer 15V AC

P6 outer 15V AC

P6 centre OV AC

P6 outer 15V AC

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3.2 Extended Power Supply

There are two different variants of the Extended Power Supply, one is mains powered and the other is vehicle
powered. The only difference is the front end.

3.2.1 Mains Front-end
This frontend is powered by mains power. It makes use of an off-the-shelf front-end switching power supply which
accepts a wide range of input voltages ranging from 100V to 250V (rated). It has been tested over a wider range,
namely 60V to 280V. The power rating of the front-end is 75 Watts.

3.2.2 Vehicle Front-end
This frontend is available in two versions, namely a 12V or 24V nominal power source. It makes use of one of two
off-the-shelf front-end switching power supplies. The 12V accepts a range of input voltages from 11V to 16V. The
24V accepts a range of input voltages from 23V to 30V. The power rating of the front-end is 50 Watts.

The IEC connector that is providing mains power to the PCC4 is replaced with an assembly, housing a switch and a
cable gland. A short non-detachable power supply cable is installed and terminates into a Cannon-type circular
connector.

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The matching connector has four screw terminals and the installer has to wire these to a suitable vehicle power
source of the right voltage. Pin 1 on the connector goes to the positive of the supply and pin 2 is the return or earth
connections.

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3.2.3 Extended Power Supply Specifications

The front-end supplies direct current power at 12 V DC to a board that further conditions and distributes this energy.
The following voltages are derived:

DC Current Isolation Use
voltage rating
(Amps) Non floating PCC4, SBC, Ethernet Switch
5.0 5.0 Non floating Modem, Switching RS232
7.5 2.6 Floating Email, RS232, RS485 & RS422 UPI‟s
12.0 0.2 Floating PEC, Tokheim & Schlumberger UPIs
16-0-16 0.5 Floating Gilbarco & Dresser Wayne UPI
40.0 0.18 Floating Available for future use
60.0 0.08

Please note that these current ratings apply to individual outputs and that the total power provided by the front-end
may not be exceeded.

This board also maintains sealed lead acid batteries and should mains power fail, the batteries will supply complete
backup power. The batteries are rated 12 volt, 2.4 Ampere-hour. These batteries are charged through a three state
cycle, using a controller IC that measures and compensates for ambient temperature. The following table defines
the charging states:

Battery state D26 D25 D24

Bulk charging Off On Off

Overcharge Off On On

Floating On On Off

Switchover from mains power to battery power is done electronically without introducing any glitches in power.

While on battery power, another part of the circuit monitors battery voltage and will protect the batteries from being
drained completely.

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3.2.4 Connectors

Figure 17 - Extended Power Supply Connectors Legend (new version) – Part Number - 81-0451

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Figure 18 - Extended Power Supply Connectors Legend (original version) – Part Number - 81-0451

Connector Description
JP1 Connector that connects to the switch on the Power Entry Module.

JP2 Connector that connects to the batteries. Pin 1 is +12V and pin 2 is ground.

JP3 A ten-way connector. Refer to section 3.2.4.1 JP3 Pin Functions for the pin functions.

JP4 Connector that connects to the 12 volt front-end power supply. Pin 1 is +12 volt and pin 2 is ground.

JP5 Connector that supplies 7.5 volt power to modems and switches. Pins 1, 3 and 5 are +7.5 volts and
pins 2, 4 and 6 are ground.

JP6 A floating 12 volt output. It is used to power Email, RS232, RS485 and RS422 UPIs. On a PCC with
a conventional power supply, the wires used for this function would be yellow. The output of this
connector is direct current but, due to the design of the UPI, the terminals can be connected in any
order. For reference, pin 1 is positive and pin 2 is ground.

JP7 A floating 16-0-16 volt output. It is used to power PEC, Tokheim and Schlumberger UPIs. On a PCC
with a conventional power supply, the wires used for this function would be red, white and red. On
this power supply pin 1 is positive with respect to pin 2 and pin 3 is negative with respect to pin 2.
However, due to the design of the UPIs, only the centre pin (centre tap) needs to be connected
correctly, the outer terminals can be connected in any order.

JP8 A floating 40 volt output. It is used to power Gilbarco and Dresser Wayne UPI‟s, or more commonly
called current loop UPIs. On a PCC with a conventional power supply, the wires used for this
function would be purple. The output of this connector is direct current but, due to the design of the
UPI, the terminals can be connected in any order. For reference, pin 1 is positive and pin 2 is
ground.

JP9 A floating 60 volt output is available for future use.

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3.2.4.1 JP3 Pin Functions

Pin Number Function
1 Five volt output
2 Ground for five volt
3 Five volt output
4 Ground for five volt
5 Analog output, indicating mains DC voltage
6 Ground
7 RS232 output indicating mains power present
8 Control signal input to switch off power supply
9 Negative RS232 supply to be provided by SBC
10 Ground

3.2.5 Switching off procedure – VERY IMPORTANT

The power supply gives an electronic indication to the SBC as to whether it is on mains power or battery power. In
addition to this, the power supply is under control of the SBC in that the SBC can switch off the power supply,
provided it is running on battery power.

As a result, the PCC should not be turned off at the switch, which is part of the Power Entry module. Doing that
would mean that power to the SBC would be shut off, without giving it time to perform an orderly shutdown.

The correct shutting down procedure is to first remove power from the PCC, without touching the switch at the
Power Entry Module. This could be done by unplugging the mains supply cable at the Power Entry Module, or
alternatively, by switching the power off at the wall socket. The new power supply will sense the loss of power and
switch to battery power. At the same time, the SBC will be notified, which in turn will result in an orderly shutdown of
the SBC software. The final action will be that of the SBC shutting down the power supply, which at that stage is still
running on battery power.

The shutdown time will depend on whether there were any EFT transactions in progress at the time of power failure.
If so, these will need to be finalised with the host first which may take a few minutes to complete before the SBC
operating system shutdown process commences.

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4 PUMP COMMUNICATIONS WIRING

The PCC can be fitted with Universal Pump Interface (UPI) cards. These cards have a customized
hardware/software interface designed specifically for each pump type the PCC supports.

The front of the PCC4 panel has four round holes. These holes are for pump communications wiring and they are
fitted with cable glands, the number of which will match the number of UPI pump interface cards. The remainder of
the holes are covered with knock-out covers. Cables should be fed through the cable glands. Should any unused
glands remain, the glands should be removed and the hole covered with a knock-out cover.

The number of pumps that can be controlled by a communications channel is dependent on the pump type.
Typically each UPI supports 16 pump filling positions.

A 4way Ribbon Cable connects the UPI to the PCC Main board header marked “I2C/2”. If multiple UPI cards are
installed, a second 4way header on each UPI provides a second connection to the I2C/2 port enabling the UPI‟s to
be “daisy chained” together.

DIP switches on each UPI are used to program the UPI node number. Refer to section 9.2 UPI DIP Switch Settings

4.1 Active Pump Communications

The following table details Active UPI‟s and supported pumps.

UPI Pump Supports

Active PEC UPI PEC, Compac, Fuelquip

Active Gilbarco Current Loop UPI (new version) Gilbarco US, Gilbarco Australia, Gilbarco China

Active Gilbarco Current Loop UPI (original version) Gilbarco US, Gilbarco Australia

Active Dresser Wayne Current Loop UPI (new version) Dresser Wayne

Active Dresser Wayne Current Loop UPI (original version) Dresser Wayne

Active Email UPI Email

Active RS485 UPI Half Duplex (new version) Tatsuno, Dresser Wayne Dartline, Orpak SC-20x0,

Nuovo Pignone, Midco, Larson and Toubro (LnT), Avery,

Aplab pumps, Tokheim Kaizen

Active RS485 UPI Half Duplex (original version ) Tatsuno, Dresser Wayne Dartline, Orpak SC-20x0, Nuovo
Pignone, Midco, Larson and Toubro (LnT), Avery, Aplab
Active RS422/RS485 UPI Full Duplex pumps
Active Tokheim UPI (Direct Pump Interface) Gilbarco US D-Box, Tokheim US D67 Box
Active RS232 UPI Tokheim
Active Schlumberger Tokheim
Schlumberger

The following is the list of UPI pump interfaces available to date, and their forecourt wiring connections.

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4.1.1 Active PEC UPI

Figure 19 - Active PEC UPI Legend - Part Number - 81-0026

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4.1.2 Active Gilbarco UPI
There are two different versions of the Gilbarco UPI.
4.1.2.1 Active Gilbarco UPI (New Version)

Figure 20 - Active Gilbarco UPI Legend (new version) - Part Number - 81-0453
4.1.2.2 Active Gilbarco UPI (Original Version)

Figure 21 - Active Gilbarco UPI Legend (original version) - Part Number - 81-0020

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The Active Gilbarco UPI new version has the following changes:

Improvements in the constant current source circuit
Supports Software updates to Flash Memory
Uses surface mount technology
Automatically limits the open-loop voltage

The following table outlines the various key components of this UPI.

Component ID Functional Description
P1 and P2
P3 For connection to the main board i2c2 header, and the next UPI
4MON monitoring port.
P4 10 way header used for RS232 Communications monitoring
P5 Dispenser communications Isolated power termination header
Pump communications termination header for connection to the Communications isolation
P6 switch box
P7 Reserved for Postec use only
Should only be populated with a shorting jumper when used with Gilbarco China dispensers
SW1 that have limited open-loop voltage capabilities
Sets the UPI address.
LED 1 Note: the new UPI does not have the second set of switches used on the older UPI.
LED 2 Red Tx indication – UPI sending to the dispenser
Green Rx indication – UPI receiving from the dispenser

Figure 22 - Active Gilbarco UPI Key Components

4.1.3 Active Dresser Wayne Current Loop UPI

A slightly modified version of the Gilbarco UPI is also used for Dresser Wayne Dispensers. As is the case for
Gilbarco UPI, there are two versions of this UPI as well.

4.1.3.1 Active Dresser Wayne Current Loop UPI - Part Number - 81-0456 (New Version)
This version of the UPI has the changes as listed in the Gilbarco section.

Refer to section 4.1.2.1Active Gilbarco UPI (New Version)

+ to the Dresser Wayne positive Communications wire
- to the Dresser Wayne negative Communications wire

Note: When using the standard linear power supply, the Dresser Wayne US UPI power supply is only capable of

driving up to 12 physical pump loads.
i.e. SC-82 head – 1 physical pump load = 1 pump number or filling position

SC-86 Duplex head - 1 physical pump load = 2 pump numbers or filling positions

When using the PCC Extended power supply, the Dresser Wayne US UPI power supply is capable of driving up
to 10 pump loads.

4.1.3.2 Active Dresser Wayne Current Loop UPI - Part Number - 81-0318 (Original Version)

Refer to section 4.1.2.2 Active Gilbarco UPI (Original Version) and Figure 22 - Active Gilbarco UPI Key Components for
connection setting.

+ to the Dresser Wayne positive Communications wire
- to the Dresser Wayne negative Communications wire

Note: The Dresser Wayne UPI power supply is only capable of driving up to 12 physical pump loads.

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i.e. SC-82 head – 1 physical pump load = 1 pump number or filling position
SC-86 Duplex head - 1 physical pump load = 2 pump numbers or filling positions

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4.1.4 Active Email UPI

Figure 23 - Active Email UPI Legend - Part Number - 81-0017
Note:
Email pumps must be connected through the intrinsically safe Isolation box which is available from Email
Electronics Australia.

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4.1.5 Active RS485 UPI Half Duplex (New Version)
Used for Tatsuno / Dresser Wayne Dartline / Orpak SC-20x0 / Nuovo Pignone, Midco, Larson and Toubro (LnT),
Avery, Aplab pumps, Tokheim Kaizen
Overall the UPI has four times the current drive capability.

Figure 24 - Active RS485 UPI Half Duplex Legend (new version) – Part Number - 81-0531

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4.1.6 Active RS485 UPI Half Duplex (Original Version)
Used for Tatsuno / Dresser Wayne Dartline / Orpak SC-20x0 / Nuovo Pignone

Figure 25 - Active RS485 UPI Half Duplex Legend (original version) - Part Number - 81-0085

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4.1.7 Active RS422/RS485 UPI Full Duplex Tokheim (US Termination Boxes) / Dong Hwa
For direct connection to Tokheim pumps refer to section 4.1.9 Active Tokheim UPI (Direct Pump Interface)

Figure 26 - Active RS422/RS485 UPI Full Duplex Legend - Part Number - 81-0221
4.1.8 Active RS232 UPI for Tokheim South Africa Termination Box / PEC FIC Box

Figure 27 - Active RS232 UPI Legend - Part Number - 81-0252

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4.1.9 Active Tokheim UPI (Direct Pump Interface)

Figure 28 - Active Tokheim UPI Legend - Part Number - 81-0310

The Tokheim UPI provides a male D-25 connector for pump communications connection with each physical
dispenser. The D-25 connector should be cabled to a termination box that provides a screw terminal connector for
terminating the pump communications cables from the forecourt. Each pump has a 3-core data cable which connects
to the Tokheim UPI D-25 as documented in the table below. The pumps can be connected to any UPI Tokheim port
number, but only one physical pump per Tokheim UPI port. The Tokheim UPI supports up to 8 physical pump circuits
and 16 logical pump numbers (or filling positions)

TOKHEIM UPI D-25 TERMINATION

UPI Tokheim Communication Cable JP9

Pump Port Common RX TX

1 1 23

2 4 56

3 7 89

4 10 11 12

5 14 15 16

6 17 18 19

7 20 21 22

8 23 24 25

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4.1.10 Active Schlumberger UPI

Figure 29 - Active Schlumberger UPI Legend - Part Number - 81-0301

The Schlumberger UPI provides a male D-25 connector for pump communications connection with each physical
dispenser. The D-25 connector should be cabled to a termination box that provides a screw terminal connector for
terminating the pump communications cables from the forecourt. Each pump must be connected to the UPI pump
circuit number which matches the communications Address programmed into that pump as documented in the table
below. Each pump has a 2-core data cable which connects to the Schlumberger UPI D-25 as documented in the
table below. The Schlumberger UPI supports up to 8 physical pump circuits and 16 logical pump numbers (or filling
positions)

SCHLUMBERGER UPI D-25 TERMINATION

Schlumberger Communication Cable JP1

Pump Address + Terminal - Terminal

0 15 2

1 14 1

2 17 4

3 16 3

4 19 6

5 18 5

6 21 8

7 20 7

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4.2 Passive Pump Communications

The PCC can be fitted with Passive Universal Pump Interface (UPI) cards.

This means that it can monitor pump communications messages and record information from data received when
pumps are under the control of another pump controller.

Unlike the Active UPI‟s, the Passive UPI‟s connect to the PCC Main Board Aux ports via a 10 way DIL header
ribbon cable.

The following table details Passive UPI‟s and supported pumps.

UPI Pump Supports
Passive PEC UPI Dual Loop PEC, Compac, Fuelquip
Passive Gilbarco Current Loop Gilbarco US, Gilbarco Australia, Gilbarco China
Passive Dresser Wayne Current Loop Dresser Wayne
Passive Email Email
Passive RS422/485 UPI Gilbarco US D-Box, Tokheim US D67 Box

The following is the list of Passive UPI pump types available to date, and their forecourt wiring connections:

4.2.1 Passive PEC UPI (Dual Loop)

Figure 30 - Passive PEC UPI Legend - Part Number - 81-0064
The Passive PEC UPI is connected in parallel with the pumps and controller.

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4.2.2 Passive Gilbarco Current Loop UPI

Figure 31 - Passive Gilbarco Current Loop Legend - Part No 81-0012

The Passive Gilbarco UPI is connected in series with the pumps and controller. It can be terminated at the Gilbarco
Communications Termination switch box just like another dispenser, however care must be taken not to switch the
UPI out of the loop. Postec recommend the passive UPI be wired in series with the Gilbarco Communications
Termination switch box to prevent this occurring. The PCC does not require mains or battery power to maintain
current flow through the loop.

Note: If using the Gilbarco US Distribution box, a passive RS422 4 wire UPI must be used to monitor the
communications on the console RS422 interface, as the current loop circuits to each pump are separated.

4.2.3 Passive Dresser Wayne Current Loop

The legend for this UPI is the same as that of the Passive Gilbarco Current Loop UPI and therefore the installation
and termination details are the same as described above. However it differs in that it uses a lower loop current and
therefore is not interchangeable with the passive Gilbarco Current Loop UPI.

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4.2.4 Passive Email UPI

Figure 32 - Passive Email UPI Legend - Part Number - 81-0021
The Passive Email UPI is connected in parallel with the pumps and controller. If an Email Safety Isolation box is
installed, the Passive Email UPI should be connected on the controller side of the barrier, not the pump side.

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4.2.5 Passive RS422/485 UPI

The Passive RS422/485 4-wire UPI is used for monitoring pump termination boxes which provide a full duplex 4
wire RS422/485 connection to the console, e.g. Gilbarco US D-Box, Tokheim US D67 Box.

Two pairs of wires connect from the Console Tx and Console Rx termination point on the D-box wire to the 5 pin
header JP2 with the shield connection as shown in the diagram below. It does not matter which pair of wires on the
D-box goes to which pair of wires on the Passive UPI, as long as the polarity of each of the wires within the pair is
correct.

Figure 33 - Passive RS422/485 UPI Legend - Part Number – 81-0514

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5 POINT OF SALE TERMINAL COMMUNICATIONS

5.1 PCC Bridge Ethernet LAN Interface

The PCC Bridge provides Ethernet/TCP-IP LAN connectivity for LAN based PoS Consoles.

Communication between the Bridge and PoS console is through a RJ45 connector fitted to the 10BASE-T board. A
10-way coloured ribbon cable connects the Bridge board with JP1 on the 10BASE-T board. A standard UTP
network cable (unshielded, twisted pair), plugs into the RJ45 connector protruding from the front of the PCC4 case.
10BASE-T has a distance limit of approximately 100 meters. The two LED‟s protruding from the case are labelled
LINK and ACTIVITY.

LINK LED
Will be constantly ON if the network cable has been connected.
Indicates that the physical link to the network is functioning.

ACTIVITY LED
Will flash intermittently.
Indicates that data is present on the current network branch but does not necessarily indicate
communication between FOCUS, Forman4 or PoS and the PCC4.

Each PCC Bridge is assigned a default Internet Protocol (IP) address. PCCs are dispatched from the factory with a
default IP address of 192.168.0.100. To change the IP Address, refer to the PCC Connection Wizard in the
FOCUS or Forman 4 Installation and Commissioning Manual.

PCC4‟s with PCC Bridge boards are shipped ready to run with the appropriate software already loaded. Should the
need arise to upgrade the software, use Postec Flasher for any further updates. Refer to Postec Flasher User
Manual.

The PCC Bridge is part of the PCC Ethernet communications architecture, which includes a number of applications:

The Forecourt Server Application broadcasts forecourt status data via UDP on port 7020 to all forecourt clients.
It also supports up to 16 client connections via TCP port 7020. The TCP connection facilitates the serving of
Forecourt client requests providing forecourt control and management facilities.

The TFTP Application allows the direct transmission and reception of PCC native files and listens on TCP port
number 7022.

PCC filenames are of the following format:
XXXXXX.YYY

Where „X‟ is the 6 digit PCC site number which must be padded to 6 digits with leading zeros if necessary.
Refer to section 13.1TFTP

The Telnet Application provides a terminal interface to the PCC for performing monitoring of communications
channels within the PCC and between the PCC and external devices, along with enabling debugging sessions. It
listens on TCP port number 7023, which is different from the standard Telnet port number of 23. Any Telnet client
used with the PCC must allow the port number to be specified. The standard Microsoft Windows Telnet client does
support this feature.

e.g. TELNET 192.168.0.100 7023

The OPT Server Application provides connection to thin client OPTs which use the PCCs internal Forecourt PoS
application. The PCC supports 32 lanes and the OPTs can be configured in a Card Reader in Dispenser (CRInD)
or Island Card Reader (ICR) mode.

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5.2 PCC Asynchronous Serial Communication

The PCC main board is fitted with a number of ten way IDH sockets labelled AUX 1 - 10. A ribbon cable connects
AUX 9 to the interface board for communications with the integrated POS terminal, FOCUS or Forman Console
network. Refer to section 1.1PCC4

5.2.1 RS232 Interface (single node)
RS232 communication should only be used where the devices are a maximum distance of 15m from each other.
For distances further than 15m use RS422 Interface board. Refer to section 5.2.3
RS422 (Full Duplex) Interface
The Green “Rx” LED on the RS232 interface card flashes to indicate the POS/FOCUS/Forman terminals are
answering the PCC‟s polls. This will only happen when the application software is running on the POS terminals.

The POS/FOCUS/Forman terminals will not communicate (Green LED will not flash) unless they receive Polls from
the PCC (Red LED flashing).

Figure 34 - Serial Cable

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5.2.2 Multi-Drop RS232 Interface
Up to 8 POS terminals can be multi-dropped from the DB25 connector on the RS232 interface board. The
connection details for multi-dropped RS232 Communications between POS terminal and PCC are shown below.
The DB25 connector pin connections are provided for the PCC and the POS terminals.

The Red “Tx” LED on the RS232 interface card flashes to indicate the PCC is polling the POS/FOCUS/Forman
terminals.

RX and TX connections
between DB25 connectors are
crossed (2-3 and 3-2) while RX
and TX connection between
DB9 and DB25 connectors are
straight.

A small signal diode is used to
„sum‟ the
POS/FOCUS/FORMAN TX
signals in a “wire-or” con-
figuration, e.g. 1N4148, 1N914.

Figure 35 - Multidrop RS232

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5.2.3 RS422 (Full Duplex) Interface
The PCC can be configured for RS422 communications. RS422 provides a more robust interface than RS232, so
when the devices are further apart than 15m this interface is required. This interface is usable up to 1200m.
The connection details for RS422 are shown below.

Figure 36 - RS422 Connections

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5.2.4 RS485 (Half Duplex) Interface
The PCC can be configured for RS485 communications. RS485 provides a more robust interface specifically
designed for multi-drop connection to multiple devices. It is preferable to use this interface where the devices are
more than 15m from each other.

The half duplex RS485 interface is also an option that can be used with Forman3 consoles. The Forman3 console
must also be configured for RS485.

The connection details for RS485 are shown below.

Figure 37 - RS485 Connections

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6 SERIAL CONNECTION TO OTHER FORECOURT DEVICES

The PCC serial interface cards are used for connection to other devices on the forecourt e.g. Automatic Tank Gauge,
Car Wash etc.
The cable specifications for these devices will be covered by separate documents.
The following PCC serial interface cards are available:

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Figure 38 – Serial Connection to other Forecourt Devices

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6.1 PCC Synchronous Serial Communication (PCC4E/EX & PCC4RE only)

PCC4E/EX and PCC4RE boards are fitted with two ten way IDH sockets labelled JP7 and JP8. A ribbon cable
connects these to a double channel synchronous interface board, called “dual sync”, for communications with
synchronous servers and controllers.

6.1.1 Dual-sync interface
The dual-sync interface board connects via a ribbon cable to the synchronous ports marked JP7 and JP8. These
ports are only available on the PCC4E and PCC4RE variants. In a typical configuration, JP1 on the dual-sync board
will connect with JP7 on the main board and JP2 on the dual-sync board with JP8 on the main board.

Red LEDs indicate transmission from the PCC and Green indicates reception by the PCC.

Note: Due to the Synchronous communications, these links carry a clock which means the LED indicators should
always appear on with a slight flicker when data is transmitted.

To HDLC based EPS
To HDLC based EPS port on PoS
Figure 39 - Dual Sync Interface Board – Part Number 81-0406

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