PCC Installation and Commissioning Guide - EMS Australia

PCC4 INSTALLATION AND COMMISSIONING MANUAL

The dual-sync board performs the TTL to RS232 voltage level conversions required to communicate with
synchronous serial payment servers and synchronous serial site controllers. In such a configuration, the payment
server would connect via the RJ45 connector marked JP4. The site controller would connect through the RJ45
connector marked JP3.

The dual-sync board has four LEDs, two red and two green. The red LEDs indicate the status of data transmitted
from the PCC4 and the green LEDs indicate reception. The top two LEDs are associated with JP1 and JP4
(typically EPS), whilst the bottom two LEDs are associated with JP2 and JP5.

The following tables define the pin-out for the RJ45 connectors.

JP4 JP3

Pin number Function Pin number Function
1 RX Clock 1 Not used
2 RX Clock 2 TX Clock
3 RXD 3 TXD
4 GND 4 GND
5 RTS 5 CTS
6 TXD 6 RXD
7 RX Clock 7 Not used
8 Not used 8 Not used

Postec Data Systems Revision 6.06 Page 51 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

6.2 PCC 45mA Current loop Interface Board

The PCC4 45mA Current Loop Interface board is a full duplex system with the receive and transmit on separate
current loops (e.g. Used for Prowalco attendant tagging device)

The board is mounted in any of the slots that normally occupy RS232 or RS485 interface boards and converts TTL
level signals from the AUX port to 45mA current loop levels and vice versa.

On the PCC side, the board connects via JP1 (a 10 way ribbon connector) to an AUX port on the PCC4 main board.

The connections to the Prowalco device are though connectors P1 and P3. Connector P1 is the transmitter to the
Prowalco device and P3 is the receiver. The polarities are indicated on the legend. Refer to Figure 40 - Current
Loop Interface – Part Number 81-0555.

Isolated communications power is through the connector marked P2. Refer to Figure 40 - Current Loop Interface –
Part Number 81-0555.This connector should be connected to the isolated purple wires from the PCC4 power
supply.

Four LEDs appear on the board but only the top two are active. Red LEDs indicate transmission from the PCC and
Green indicates reception by the PCC.

Figure 40 - Current Loop Interface – Part Number 81-0555

Postec Data Systems Revision 6.06 Page 52 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

7 INTERNAL MODEM

All Postec modems plug into AUX4 of the PCC main board using a 10-way ribbon cable. For PSTN modems, a cord
set is provided with an RJ12 plug for the modem and a Telecom plug to suit each country‟s local requirements. The
Postec GSM data modem is provided with an external antenna.

Please note that in order to comply with the UL standard, the telecommunications cable connected to the modem has
to have a minimum wire thickness of 26 AWG.

If the modem does not have a dedicated telecom line, an Auto-Answer switch can be provided on the PCC‟s external
case. The PCC is programmed as to what time it can answer calls and after how many rings. The Auto Answer
switch provides an override to the configuration so that the PCC will answer at any time after 3 rings. An LED is
provided to indicate the position of the Auto-Answer switch.

The PCC4 communicates internally with the P336 modem at 38,400 BAUD and the modem performs speed
buffering to accommodate the line speed it can establish.

The PCC4 communicates internally with the GSM modem at 9600 BAUD.

7.1 Simple and GSM Data Modems

These modems require 12V supplied through a power cable connected to the earth stud in the PCC external
bulkhead space (black wire) and unregulated power from battery charger board. For retrofitting Simple modems
reference Technical Bulletin 028. For retrofitting GSM Modems reference Technical Bulletin 052.

7.2 Postec P336 Modem

7.2.1 PCC4 AUX Port setup
Using Forman4 or 4COM the PCC Aux device setup must be:

Aux 4 Device - Modem Specific Device - Postec P144-P336

7.2.2 Postec P336 modem functionality checks

Modem Status CTS RTS DCD RI RXD TXD

Modem idle ON ON OFF OFF OFF OFF
Modem ring ON ON ON Flashing OFF OFF
Connection ON ON ON OFF Flashes once after
Established OFF connection then OFF
File transfer / ON ON Flashing while
communication OFF Flashing while communicating
communicating

Postec Data Systems Revision 6.06 Page 53 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

7.2.3 Redialling Warnings for Australia
Modems connected to the Australian telecommunications network must be marked in accordance with the Labelling
Notice. This modem has been specifically configured to ensure compliance with the ACA Standards.

Do not adjust your modem or software outside the values indicated below. To do so would result in your modem
being operated in a non-compliant manner.

Call Attempts/Retries

Applications software shall be configured so that no more than 3 attempts are made to establish a connection to a
given number.

Note:

1. If the modem can detect service tones, up to 10 attempts can be made.

2. If the call sequence is unsuccessful, there shall be a delay of at least 30 minutes before attempting to call the
number again.

Failure to set the modem and any application software used with the modem, to the values shown above will result in
the modem being operated in a non-compliant manner. Consequently, this would be in violation of the Labelling
Notice for this equipment, and the Telecommunications Act 1997 prescribes penalties for the connection of non-
compliant equipment.

7.2.4 Redialling Warnings for New Zealand
The grant of a Telepermit for any item of terminal equipment indicates only that Telecom has accepted that the item
complies with minimum conditions for connection to its network. It indicates no endorsement of the product by
assurance that any item will work correctly in all respects with another item of Telepermitted equipment of a
different make or model, nor does it imply that any product is compatible with all of Telecom‟s network services.

“This equipment shall not be set to make automatic calls to the Telecom „111‟ Emergency Service”.

Some parameters required for compliance with Telecom‟s Telepermit requirements are dependent on the
equipment (PC) associated with this device. The associated equipment shall be set to operate within the following
limits for compliance with Telecom‟s Specifications:

a. There shall be no more than 10 call attempts to the same number within any 30 minute period for any single
manual call initiation, and

b. The equipment shall go on-hook for a period of not less than 30 seconds between the end of one attempt and
the beginning of the next attempt.

Some parameters required for compliance with Telecom‟s Telepermit requirements are dependent on the equipment
(PC) associated with this device. In order to operate within the limits for compliance with Telecom‟s Specifications,
the associated equipment shall be set to ensure that calls are answered between 3 and 30 seconds of receipt of
ringing.

This equipment should not be used under any circumstances, which may constitute a nuisance to other Telecom
customers.

Postec Data Systems Revision 6.06 Page 54 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

7.3 GSM Data Modems

Requires V6.23 (or later) software

7.3.1 The GSM SIM card

Must have the PIN disabled and be activated for data. In most countries service providers will provide a different
phone number for each service available on the SIM card e.g. Voice, Fax, Data. From experience, most cellular
service providers are not aware of this requirement and may state that a single number is used for voice and data.
While a single number can be used for voice and data when dialling out of the modem e.g. connecting to the
internet, a separate number is required for calling in to tell the modem the type of call which it is receiving.

If this is the case, problems are experienced dialling in to the PCC; remove the PCC SIM card and install it in a
Cellular phone handset, and then call the data number assigned to the SIM. The handset display should display the
incoming call as data and not give a standard voice ringing display and tone. If it doesn‟t, the number assigned to
the SIM is not a data service.

From experience, some persistence is required to find the technical staff with experience in Cellular dialup who
understand these requirements and can provide a data number for the SIM.

7.3.2 AUX Port setup
Using Forman4 or 4COM the PCC Aux device setup must be:

Aux 4
Device - Modem
Specific device - Postec P24 & GSM

7.3.3 GSM Data Modem functionality checks:

Modem Status LED Status
OFF
Modem not
ready/switched off ON (continuously)
Modem switched on, in
process of connecting to Flashing slowly
network Flashing rapidly
Modem idle

Modem connected /
Transmission mode

Postec Data Systems Revision 6.06 Page 55 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

8 PERFORMING A MASTER RESET

After installation, a Master Reset should be performed to initialize the PCC. This can be performed at the POS
terminals by the POS commissioning company.

It can also be performed independently at the PCC as follows:

1 Switch off PCC at the Power Entry Module to ensure the optional battery is isolated

2 Record the DIP SWITCH settings of SW1 (8 way) on the PCC main board
3 Set the switches "SW1" as follows:

Switch Function
1 off
2 on
3 off
4 on
5 off
6 on
7 off
8 on

4 Switch on PCC and wait 20 seconds

5 Switch off PCC

6 Restore "SW1" to original settings

7 Switch on PCC
This completes the Master Reset. The PCC‟s calendar clock is now set to 00:00:00 1 January 1990.

Note:

1. The first release of PCC4 has the battery mounted in the main bin of the PCC instead of the Power supply
bulkhead. For these units unplug the spade terminal at the battery before performing the Master Reset.

2. The PCC Main board uses a “super capacitor” to keep the contents of the CMOS memory intact and the real
time calendar clock chip running for five days in the absence of mains power.

Postec Data Systems Revision 6.06 Page 56 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

9 FITTING AN ADDITIONAL UPI TO THE PCC

Installation of a UPI module to the PCC is a relatively simple process.

9.1 UPI Internal Connections

The CPU power supply and inter-processor communications cable, loops from the PCC connector I2C/2 through the
I2C in and out connector plugs of each UPI. All the UPI's must have a unique UPI Node Number programmed into
their DIP switches. Refer to section 9.2UPI DIP Switch Settings

Each UPI has its own pump interface power supply circuit. This is sourced directly from an isolated winding of the
PCC's mains transformer or the connectors on the extended power supply board. Refer section 3 Power Supply

If the UPI Isolated power outputs are required for more than one UPI, they should be looped from UPI to UPI.
Refer to section 4.1 Active Pump Communications

9.2 UPI DIP Switch Settings

PEC UPI SW-1

Switch Function Factory Setting

1.2 UPI node number select 2 on 1 = on, 2 = on
Node 1 = 1 on 2 on
2 = 1 off 2 off 3,4 = off
3 = 1 on 2 off 5 = off
4 = 1 off 6 = on
7 = off
3,4 Reversed – off 8 = off
5 UPI active select
Factory Setting
Off = enable
On = disable
6 Reserved – on
7 UPI Monitor port
On=enable
Off = disable
8 Reserved – off

All Other UPI Models SW-1

Switch Function

1.2 UPI node number select 1 = on, 2 = on
Node 1 = 1 on 2 on
2 = 1 off 2 on 3 = off
3 = 1 on 2 off 4 = off
4 = 1 off 2 off

3 UPI active select
Off = enable
On = disable

4 UPI Monitor port
On = enable
Off = disable

Postec Data Systems Revision 6.06 Page 57 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

Gilbarco / Dresser Wayne UPI (Legacy only) SW2

This set of dip switches controls the current loop path on the UPI.

Set them as follows:

Switch # Setting

1 On
2 Off
3 On
4 Off

9.3 PCC UPI CONFIGURATION

The PCC UPI configuration can be configured using either FOCUS Forecourt Configuration or Forman 3 Console
Ver. 1.46 or later.

The information is stored in EEPROM and is not lost on a flat battery or during the Master reset process. It is
programmed in production by Postec and should only be changed if the Pump/UPI hardware configuration is
changed.

For each UPI the following information needs to be entered.

Pump Type

Logical Pump Start Number

Logical Pump Stop Number
Pump‟s Internal Start Number

Two UPI‟s can be mapped to the same range of pumps.

Example 1: A site with 12 Pumps:-
Pumps 1, 3, 5 are Gilbarco
Pumps 2,4,6,7 - 12 are Email

Configuration Table

UPI # Pump Type Logical Logical Internal
Pump Start Pump Stop Pump Start
1 2 (Gilbarco)
2 3 (Email) 1 16 1
1 16 1

The pumps can be remapped so that its Logical pump number is different from its physical (Internal) pump number.

This allows the physical pump number programmed into a pump to be remapped to a logical pump number, which
the site uses to identify a pump. This is particularly useful for sites with more than one pump loop and less than 16
pumps on each loop.

Postec Data Systems Revision 6.06 Page 58 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

Example 2: A site with 24 pumps
Pumps 1-12 are Gilbarco (Pumps number 1-12)
UPI # Pumps 13-24 are Gilbarco (Pumps number 1-12)
1
2 Pump Type Logical Logical Internal
Pump Start Pump Stop Pump Start
2 (Gilbarco)
2 (Gilbarco) 1 12 1
13 24 1

Note: The pump range should only be limited when a second UPI serves a bank of pumps which are the same type,
as in example 2.

Postec Data Systems Revision 6.06 Page 59 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

10 PCC AUX CHANNEL CONFIGURATION

The PCC4 has 16 serial channels for communications to devices other than the dispensers, which are handled via
the intelligent UPI cards.

Devices are mapped to these serial channels by the “Aux Channel Device” assignment table, which is contained in
the PCC‟s site parameter file. The configuration and downloading of this table can be done by 4COM or FOCUS /
Forman4. The Aux Device Table is stored in the PCC‟s EEPROM, which makes it non-volatile even if the battery
goes flat. The table is also preserved during a PCC “Master Reset”.

To ensure that a PCC will always operate in a minimum configuration regardless of the integrity of the Aux Device
Table, two of the Aux Device channels are fixed regardless of what is configured in the table. That is the Modem Port
on Aux 4 and the Postec POS port on Aux 9.

The following screen shows the Aux Device Table editing facilities. Reference your FOCUS / Forman4 or 4COM
manuals for downloading information.

The PCC will be supplied pre-configured to support the interfaces requested on the order.

Figure 41 - Focus Forecourt Configuration - Auxiliary Devices

Postec Data Systems Revision 6.06 Page 60 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

11 POSTEC INTELLIGENT PURCHASES INDICATOR (PIPI) CONNECTION

The PIPI is a compulsory peripheral for use with the PCC in Australia as required by S398 approval.
Note: This is not required for older systems approval under S244 and S244A.

Under normal operation the PIPI acts as a customer display being driven by the FOCUS/Forman 4 PC Visual
Console or integrated POS application. However if the FOCUS/Forman 4 PC should fail, unprocessed dispenser
sales can be recalled to the PIPI display from the PCC by toggling the push button switch mounted on the PIPI
base.

11.1 PIPI Connection

The PIPI has two cables to connect to the FOCUS/Forman 4 PC and the PCC respectively.
The PIPI to PCC cable is documented below. This cable has to be made on site to suit the location of the PCC and
PIPI.

Figure 42 - PIPI Connections

The cable plugs into the PCC‟s nominated Aux port in the range Aux 5 – 8 via a Postec Switching RS232 Interface
board labelled PIPI.

11.2 PCC Configuration

The PCC nominated Aux port must be programmed to support the PIPI application. This is done using one of the
following programs:

FOCUS Forecourt Configuration
4COM

The Aux port should be assigned to:

Device 11:PIPI
Specific Device 2: PCU LCD Mk2
This configuration is stored in non-volatile EEPROM and is not erased by a Master reset or flat battery.

Postec Data Systems Revision 6.06 Page 61 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

The PIPI to FOCUS/Forman 4 PC cable is provided with the PIPI. This cable plugs into an unused serial port on the
PC and is configured by the FOCUS Forecourt Manager / Configuration tab / Settings tab / POS tab, or by the
integrated POS application if used. The PIPI backlight power supply is also sourced from this cable.

11.3 PIPI Testing

When the PIPI is connected to the PCC, the PCC switching RS232 green “IN” LED should be normally on and go
off when the PIPI switch is pressed. If the reverse is found, the PIPI is a very early MK1 model and should be
upgraded. If using a MK1 temporarily, the Aux port specific device must be configured to 1: PCU LCD Mk1

Holding the push button down for 5 seconds will power cycle the PIPI and display the PCC hardware and software
identification details when the switch is released. The PCC‟s PIPI RS232 driver board green in led is off while the
button is pushed, and the TX LED flashes once at the start and end of the sequence.

Postec Data Systems Revision 6.06 Page 62 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

12 BATTERY BACKUP MODULE

The PCC is fitted with a battery backup module. If mains power is removed, the battery will keep the PCC CPU
processor logic running for up to 20 minutes (depending on the configuration).

The following boards are battery backed so their interfaces will continue to operate:

RS232 Interface
RS232 Buzzer Interface
RS485 Interface
Optically Isolated RS485 Interface
8 Channel Parallel Input Interface (Alarm board)
Internal Modems - Postec P12, Postec P24, Postec P336 and Simple Modem

The PCC main board uses a super capacitor to keep the contents of the CMOS memory intact and the real time
calendar clock chip running for about 3 days. The super capacitor device has a rapid recharge and requires no
maintenance, lasting the lifetime of the PCC.

From 2008 all PCCs are fitted with an additional Lithium battery block which works in tandem with the super capacitor
to maintain the contents of the CMOS memory. The Lithium battery is not rechargeable and will need replacing after
5 years.

Note:

1. On the standard PCC power supply, the battery does not maintain the special isolated voltages used on the
UPI cards. This means the dispenser communications will fail when mains power is removed. The PCC
extended power supply does provide battery backed power to the UPIs.

3. The PCC uses a sealed lead acid technology battery, which is trickle charged by the PCC‟s power supply when
connected to the mains. The life expectancy for a properly maintained battery is up to 5 years.

4. If stored for an extended period, it is recommended that the battery be charged for 24 hours once every two
months by applying mains power to the PCC. While in storage ensure that the power entry module switch on
the front of the PCC is in the OFF position.

Postec Data Systems Revision 6.06 Page 63 of 68
Copyright © 2009

PCC4 INSTALLATION AND COMMISSIONING MANUAL

13 PCC BRIDGE TFTP AND TELNET

In addition to providing Ethernet/TCP-IP LAN connectivity for LAN based PoS Consoles via the PCC‟s inbuilt
Forecourt Server, the PCC Bridge provides communications via TFTP to allow the extraction of PCC files, and via
Telnet to allow communications monitoring and debugging.

13.1 TFTP

The PCC uses the non-standard port number of 7022 for TFTP communications. Unfortunately, the standard
Windows TFTP client does not allow a custom port number to be chosen, so an alternative TFTP client must be
used.
All PCC files are named using the 6-digit site number and a 3-character extension. E.g. 000101.PAR is the parameter
file for site number 000101. It is important to note that the 3-character file extension must be specified in capital
letters.

Below is a summary of available files:

File Extension File Type File Description
Site parameter file
.PAR Site Parameters Tank inventory
Tank Parameters where x is tank number. 1-9 and then A-G for tank
.TNK Tank Data numbers 10-16.
Tank Parameters where x is tank number. 1-9 and then A-G for tank
.TPx Tank Parameters numbers 10-16.
Event file
.TCx Tank Calibration Dispenser totals
Dispenser electronic totals
.EVT Events
.TOT Totals Tank variances
.NRT Non-resettable Tank deliveries
totals Tank reconciliation
.VAR Variance Site statistics such as UPI Communications errors, Dispenser errors etc.
.FIL Fill Grade Prices
.REC Reconciliation Transactions
.STA Statistics 4DET parameters
.PRC Price Card file
.TRN Transaction Alarms
.DET 4DET parameters Extended transactions
.CRD Card
.ALM Alarm Tank and dispenser reconciliation records based on VR EDIM emulation
.ETF Extended interface
Transactions Scheduled grade price changes
.TDR Tank / Dispenser
reconciliation
.SGP Scheduled grade
prices

13.2 Telnet

The PCC also uses the non-standard port number of 7023 for Telnet communications. The standard Windows

Telnet client allows a custom port number to chosen and so can be used with the PCC Telnet implementation.
Communications monitoring, transparent communications, memory dumps and Postec Kermit „P‟ commands can be
performed through the PCC‟s Telnet interface. After connecting to the PCC, a list of available commands can be
seen by typing „?‟ or „help‟ and then Enter.
Before most commands can be executed, a login must be performed using the „Login‟ command. The user name
can be anything at all up to 11 characters in length, and is simply entered into the PCC‟s event file as part of a

Remote Access event. The password is the site password, which can be up to 10 characters.

Postec Data Systems Revision 6.06 Page 64 of 68
Copyright © 2009