PCC4 Installation and Commissioning Manual

INSTALLATION AND COMMISSIONING MANUAL
POSTEC COMMUNICATIONS
CONTROLLER
For PCC MODEL 4
INSTALLATION AND
COMMISSIONING MANUAL
PCC4
Revision 6.06
nd
2 July 2010
Postec Data Systems
Address: Unit A 45 – 47 Paul Matthews Rd

Albany
Auckland
New Zealand
Website: www.postec.co.nz
Email: info@postec.co.nz
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 Vehicle Front-end .........................................................................................................................................................22
3.2.3 Extended Power Supply Specifications ........................................................................................................................24
3.2.4 Connectors ...................................................................................................................................................................25
3.2.5 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
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
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
Revision History
Date Version Sections Content

02/03/2010 V6.03 Sections 3.2, 3.2.1 & Revised Extended Power Supply for two frontends,
3.2.2 Mains and Vehicle.
09/03/2010 V6.04 Section 6 Revised Figure 38 – Serial Connection to other
Forecourt Devices – RS422
06/04/2010 V6.05 Section 6.2 Revised PCC 45mA Current loop Interface Board, text
and legend.
02/07/2010 V6.06 Section 3.2.2 Added section - Vehicle Power Front End
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.
Postec Data Systems Revision 6.06 Page 6 of 68

Copyright © 2009
Figure 1 - PCC4 Open Case
Figure 2 - PCC4 Main Board

Copyright © 2009
Figure 3 - PCC4 Main Board Legend (new version) – Part Number - 81-0481

Copyright © 2009
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

Copyright © 2009
Figure 6 - PCC4 Bridge Legend – Part Number - 81-0213

Copyright © 2009
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

Copyright © 2009
Figure 8 - PCC4E Main Board
Figure 9 - PCC4E Main Board Legend – Part Number - 81-0340

Copyright © 2009
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

Copyright © 2009
Figure 11 - PCC4R Main Board
Figure 12 - PCC4R Main Board Legend (new version) – Part Number - 81-0482

Copyright © 2009
Figure 13 - PCC4R Main Board Legend (original version) – Part Number - 81-0258

Copyright © 2009
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

Copyright © 2009
Figure 15 - PCC4RE Main Board Legend - Part Number - 81-0483

Copyright © 2009
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

Copyright © 2009
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.

Copyright © 2009
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
Unregulated Measurement PURPLE GREEN 9V
Connection (+) Connection (-)
Regulated RED GREEN 5V
Measurement Connection (+) Connection (-)

Copyright © 2009
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 P6 outer 15V AC
White P6 centre OV AC
Red P6 outer 15V AC
Active Gilbarco UPI Purple P4 pins 1 & 4 30V AC
Active Email UPI Yellow P3 pins 1 & 2 15V AC
Active Wayne ISM UPI Purple P4 pins 1 & 4 30V AC
Active RS485 UPI Yellow JP1 pins 1 & 2 15V AC
Active & Passive RS422 UPI Yellow JP1 pins 1 & 2 15V AC
Active RS232 UPI Yellow JP1 pins 1 & 2 15V AC
Active Tokheim UPI Red P6 outer 15V AC
Red P6 outer 15V AC
Active Schlumberger UPI Red P6 outer 15V AC
Red P6 outer 15V AC

Copyright © 2009
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.

Copyright © 2009
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.

Copyright © 2009
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)
5.0 5.0 Non floating PCC4, SBC, Ethernet Switch
7.5 2.6 Non floating Modem, Switching RS232
12.0 0.2 Floating Email, RS232, RS485 & RS422 UPI‟s
16-0-16 0.5 Floating PEC, Tokheim & Schlumberger UPIs
40.0 0.18 Floating Gilbarco & Dresser Wayne UPI
60.0 0.08 Floating Available for future use
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.

Copyright © 2009
3.2.4 Connectors
Figure 17 - Extended Power Supply Connectors Legend (new version) – Part Number - 81-0451

Copyright © 2009
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.

Copyright © 2009
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.

Copyright © 2009
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
pumps
Active RS422/RS485 UPI Full Duplex Gilbarco US D-Box, Tokheim US D67 Box
Active Tokheim UPI (Direct Pump Interface) Tokheim
Active RS232 UPI Tokheim
Active Schlumberger Schlumberger
The following is the list of UPI pump interfaces available to date, and their forecourt wiring connections.

Copyright © 2009
4.1.1 Active PEC UPI
Figure 19 - Active PEC UPI Legend - Part Number - 81-0026

Copyright © 2009
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
Copyright © 2009
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 For connection to the main board i2c2 header, and the next UPI
P3 4MON monitoring port.
10 way header used for RS232 Communications monitoring
P4 Dispenser communications Isolated power termination header
P5 Pump communications termination header for connection to the Communications isolation
switch box
P6 Reserved for Postec use only
P7 Should only be populated with a shorting jumper when used with Gilbarco China dispensers
that have limited open-loop voltage capabilities
SW1 Sets the UPI address.
Note: the new UPI does not have the second set of switches used on the older UPI.
LED 1 Red Tx indication – UPI sending to the dispenser
LED 2 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.
Copyright © 2009
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

Copyright © 2009
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.

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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 2 3
2 4 5 6
3 7 8 9
4 10 11 12
5 14 15 16
6 17 18 19
7 20 21 22
8 23 24 25

Copyright © 2009
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

Copyright © 2009
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.

Copyright © 2009
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.

Copyright © 2009
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.

Copyright © 2009
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

Copyright © 2009
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.

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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:

Copyright © 2009
Figure 38 – Serial Connection to other Forecourt Devices

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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

Copyright © 2009
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 Flashing OFF OFF
Connection ON ON ON OFF OFF Flashes once after
Established connection then OFF
File transfer / ON ON ON OFF Flashing while Flashing while
communication communicating communicating

Copyright © 2009
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.

Copyright © 2009
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
Modem not OFF

ready/switched off
Modem switched on, in ON (continuously)
process of connecting to
network
Modem idle Flashing slowly
Modem connected / Flashing rapidly

Transmission mode

Copyright © 2009
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.

Copyright © 2009
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

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

Node 1 = 1 on 2 on 1 = on, 2 = on
2 = 1 off 2 on
3 = 1 on 2 off
4 = 1 off 2 off
3 UPI active select
Off = enable 3 = off
On = disable
4 UPI Monitor port
On = enable 4 = off
Off = disable

Copyright © 2009
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) 1 16 1
2 3 (Email) 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.

Copyright © 2009
Example 2: A site with 24 pumps

Pumps 1-12 are Gilbarco (Pumps number 1-12)
Pumps 13-24 are Gilbarco (Pumps number 1-12)
UPI # Pump Type Logical Logical Internal

Pump Start Pump Stop Pump Start
1 2 (Gilbarco) 1 12 1
2 2 (Gilbarco) 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.

Copyright © 2009
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

Copyright © 2009
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.

Copyright © 2009
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.

Copyright © 2009
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.

Copyright © 2009
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

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

Copyright © 2009
APPENDIX A: PCC DIP SWITCH SETTINGS

Switches 1 & 2
Control the Baud rate for the PCC-POS communications.
Switch 1 2 Baud Rate

Off Off 4800
On On 2400
Off On 9600 (factory setting)
Other setting baud rates yet to be defined
Switches 3 & 4
Control the PCC poll no response timeout (NRT) for communications with POS devices.
Switch 3 4 Delay
(Standard ~ 170 msecs)
Off Off *1 (factory setting)
On Off *2 ~ 332 msecs
Off On *4 ~ 664 msecs
On On max delay ~ 1.05 secs
Switch 5
Modem Selections
Switch 5 Description
Off Limit modem baud rate to 9600 if switch 5 = off and disable aux
ports except for AUX9.
On Default position
Switch 6
Off Default position
Switch 7
Console Emulation Securities
This is used to select whether the PCC will allow a Forman Console to “cash out” a pump sale if the CTS (in) to the
PCC is not asserted by the ECR.
Off If allowed to cash out sale anytime.
On If ECR able to stop Forman cashing out pump sales.
Note that the PCC will always read the CTS (in) line to control its data flow into the ECR.

Copyright © 2009
Switch 8
Forman Model 2 Consoles

Terminal Manager Setup Access Password
Off Password by-passed (useful if password lost)
(factory setting)
On Password enabled

Copyright © 2009
APPENDIX B: PCC Software Updates

PCC software updates are performed using the Postec Flasher application. A Master Reset should always be
performed unless explicitly advised by Postec support personnel. Details can be found in the Postec Flasher
Manual. Where Data Loggers are fitted please refer to the Data Logger Installation and Commissioning Manual for
additional procedures required when performing PCC4 software upgrades.

Copyright © 2009
Glossary
Term Description
AUX Auxiliary port
CMOS Complementary metal oxide Semiconductor
CTS Clear to send
CRInD Card Reader in Dispenser
ECR Electronic Cash Register
EFT Electronic Funds Transfer
ICR Island Card Reader
NRT Non-resettable total
PCC4 Postec Communications Controller
PIPI Postec Intelligent purchases indicator
PoS Point of Sale
SBC Single Board Computer
TFTP Trivial File Transfer Protocol
UPS Uninterruptible power supply
UPI Universal Pump Interface

Copyright © 2009

PCC4 Installation and Commissioning Manual

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PCC4 Installation and Commissioning Manual

Uploaded by

Copyright:

Available Formats

INSTALLATION AND COMMISSIONING MANUAL

Postec Data Systems

Address: Unit A 45 – 47 Paul Matthews Rd

9.3 PCC UPI CONFIGURATION .......................................................................................................... 58

Date Version Sections Content

Further information can be obtained by contacting POSTEC DATA SYSTEMS.

Postec Data Systems Revision 6.06 Page 6 of 68

Figure 1 - PCC4 Open Case

Figure 2 - PCC4 Main Board

Postec Data Systems Revision 6.06 Page 7 of 68

Postec Data Systems Revision 6.06 Page 8 of 68

Postec Data Systems Revision 6.06 Page 9 of 68

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

Postec Data Systems Revision 6.06 Page 10 of 68

Figure 7 - PCC4E Open Case

Postec Data Systems Revision 6.06 Page 11 of 68

Figure 8 - PCC4E Main Board

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

Postec Data Systems Revision 6.06 Page 12 of 68

1. A single RS232 board for interfacing to a PoS, Forman3, Forman4 or FOCUS

Relevant sections for PCC4R installation are:

Section 4 PUMP COMMUNICATIONS WIRING

Figure 10 - PCC4R Open Case

Postec Data Systems Revision 6.06 Page 13 of 68

Figure 11 - PCC4R Main Board

Postec Data Systems Revision 6.06 Page 14 of 68

Postec Data Systems Revision 6.06 Page 15 of 68

Figure 14 - PCC4RE Main Board

Postec Data Systems Revision 6.06 Page 16 of 68

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

Postec Data Systems Revision 6.06 Page 17 of 68

Figure 16 - PCC4EX with SBC - Open Case

Postec Data Systems Revision 6.06 Page 18 of 68

Some considerations when choosing the installation position are:

Power supply availability

Postec Data Systems Revision 6.06 Page 19 of 68

3.1 Standard Linear Power Supply (with PCC Transformer)

ALL POWER TESTPOINT REFERENCE NOMINAL

Postec Data Systems Revision 6.06 Page 20 of 68

PUMP CARD TYPE Transformer Wires PCB Plug ID and Pinout

Postec Data Systems Revision 6.06 Page 21 of 68

3.2 Extended Power Supply

3.2.1 Mains Front-end

3.2.2 Vehicle Front-end

Postec Data Systems Revision 6.06 Page 22 of 68

Postec Data Systems Revision 6.06 Page 23 of 68

3.2.3 Extended Power Supply Specifications

DC Current Isolation Use

Battery state D26 D25 D24

Postec Data Systems Revision 6.06 Page 24 of 68

Postec Data Systems Revision 6.06 Page 25 of 68

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

Postec Data Systems Revision 6.06 Page 26 of 68

3.2.4.1 JP3 Pin Functions

Pin Number Function

3.2.5 Switching off procedure – VERY IMPORTANT

Postec Data Systems Revision 6.06 Page 27 of 68

4 PUMP COMMUNICATIONS WIRING

4.1 Active Pump Communications

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

UPI Pump Supports

Postec Data Systems Revision 6.06 Page 28 of 68

4.1.1 Active PEC UPI