Installation Manual
Contents
1. 17 Figure 18 PCU Application Config 18 Figure 19 HyperTerminal Baud Chang e cccsscsscecssssseeesseeeseeeseenseeeseeenseeesenesseeeseeesseeseenseeesens 19 Figure 20 ProFuel Configuration 20 Page Version 2 0 C6000 Installation Instructions computrol Version 2 01 UEL SYSTEMS INC computrol C6000 Installation Instructions UEL SYSTEMS INC Version 2 0 Introduction The C6000 PCU from Computrol is a new generation Pump Control Unit designed with the latest in microprocessor technology featuring multiple communication ports fully programmable messaging structure Flash Memory for data and program storage Complete field programmability The installation requirements of the C6000 are similar to other Computrol Pump Control Units and well documented in this manual The scope of the C6000 s capabilities and flexibility makes it most convenient to use the fuel control computer in conjunction with the ProFuel 2 Fuel Management Program for interactive configuration downloads and to take advantage of the full set of features System Architecture While many different configurations are possible all C6000 systems are based on the same primary components 6000 Main Board provides LAN or serial communications with2. UE 8 Pump RE 9 PUISE CIrCUIt WITING aiai 10 Pulser Configuration Wiring and Switches 10 COMMURICAHONS aM Ta oo NN EE E E EO 10 PCU ED gd c 12 Changing the Communication Port to a Network Connection eeeee sess 15 Computrol C6000 Pump Control Unit Firmware Upgrade 16 What vou need before you start 16 In preparation for performing the upgrade 16 Procedure for upgrade the firmware in a 000 16 Connecting to a Network een nnn nnn nnns nana anna nnn nana nnns 20 Connecting to Lantronix UDS10 from Computrol Pump Control Units 21 Table of Illustrations Figure 1 Basic C6000 ve cunc CHE SEES 1 Figure 2 Distrib
3. A 15 45 pue 1 00092 32 P N 90 041 Removable Front Door AT in 119 38 1 in 427 94cm 34 Bottom Mounting Plate 4 holes 14 2875mm 11 in 9 25 in 27 84cm 23 485cm LL 11 25in 28 57cm 34 13in 33 02emj 33 Bottom and Top Mounting Plates are 3 16 in Steel Al other Steel is 16 gauge min Front Plate Mounting Screws are 10 32 PCU to Top Plate Mounting Bolts are provided also available in stainless steel Front View Side View no door with door AB in 121 92 k in 20 32cm 5 Top Mounting Plate 4 holes 9 525mm tap UN coarse 5 25 in 9 251 23 495 3 in 27 84cm 3 Filaname PEDESTAL 48 V SD Dated October 17 2006 computrol UEL SYSTEMS INC Welded Steel Mounting Pedestal Page 33 C6000 Installation Instructions computrol Version 2 01 UEL SYSTEMS INC Diagrams and Screen Shots C6000 Main Control 7 Front Panel User Interface 8 PUMO CONTO oor o NER TEE 9 Housing Bottom View Mounting Holes 10 FO ero erre B E T 12 Pulser Configuration Wiring and 5 5 13 R5485 Port Wiring 14 Ethernet LAN VV I
4. Cable change 1 end so the connections include 1 3 2 6 3 1 and 6 2 Crossover Cables may be required to communicate directly to the PCU from a PC in situations where there is no HUB or existing network Page 11 UEL SYSTEMS INC Version 2 01 computrol C6000 Installation Instructions PCU Start Up On power up with its factory configuration the PCU will initialize and show Computrol on the display This message will remain until a configuration file is sent to the unit via the communication link using the ProFuel 2 program Detailed instructions on the ProFuel program are provided in the ProFuel 2 User Manual which accompanies the program on delivery The logical order of database record setup is Products Product Groups Locations Location Groups Tanks The entries into the database for the above are very straight forward and require little explanation This is especially true when setting up a database for testing PCUS are the next Database records to be setup and these much more complex The operation of the C6000 PCU is totally dependant and determined by the data entered into the PCU Database and while there are default values for many fields the proper operation of a specific PCU requires careful attention be given this section of the ProFuel setup oeparately the Accounts and Users must be set up as well For finalizing the commissioning of the PCU itself a single Account and User Card or Number need be
5. a Front Panel and Pump Control board can be installed to serve as a terminal controlled by the Main Control board C6000 PCU Figure 3 Multiple Terminal Architecture C6000 Terminal ProFuel Computer The terminal configuration implements the same RS485 communications strategy used in a single enclosure system but with an additional Front Panel Board and Pump Control Board They are given addresses on the multidrop 485 link and the Main Control Board programming allows the terminal to work as like a second PCU The standard distance for RS485 communications with remote boards or terminals is nominally 75 meters from a single voltage source Installation of additional local power sources will allow installers to communicate on much longer runs The use of wireless RS485 communications modems fibre optic cable modems and other connectivity solutions is also possible Page 2 computrol C6000 Installation Instructions UEL SYSTEMS INC Version 2 0 These devices may be used to connect the Main Control Board with the ProFuel 2 Computer or to eliminate the need to install hard wire runs between the main components of the C6000 and any remotely installed components Consult with Computrol representatives for more information about these options Features and Capabilities While the C6000 software code is designed to make any of the hardware field configurable Computrol s C6000 PCU is factory configured to different applications as requi
6. and then Properties Figure 19 HyperTerminal Baud Change PEU 9600 TOUT CUM Z Properties Ds amp 00 i Pert Settings POL CEK 9600 Properties Show Set time of _____ date YYYY HH DD Display RedBoot version per second version B 9 00 hex dump b 1 4 RedBoot et b 115288 curi regian LE e Enter the ana code wilhout the longdistanca ni Error Illegal comma RedBoot gt baudrate b 966 Baud rate will be change Phones rmumber ____ Blow Mn m Baud rate changed to 966 ET gt pdate RedBoot non volal RedBoot gt ddd Error Illegal RedBoot gt baudrate b 115 Baud rate will be change ddedBoot gt d Ambiguous command 4 Error Illegal commar RedBoot gt reset Resetting Correct ung Disconnected ANSIWI Click on Configure and change the Baud rate to 9600 Click OK and Click OK Return to step F to transfer the firmware at the new Baud Rate Hemember to test the system using the old baud rate Page 19 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 01 Connecting to a Network Database Click on the word ProFuel at the top Left and click on System Settings Figure 20 ProFuel Configur
7. ro VFD or LCD Display Serial J3 gt Reader gt gt Card Reader p N Serial Magnetic Stripe Reader Centronics Printer SCN Oak QN OFF ON ADDRESS 3 shown oooooooooooooQo ooococce Stainless C6000 Kevpad lo00000000 m VV VV M oYoYoYa Keypad F300 Gnd 12vdc Printer Power to previous board to next board RS485 Multidrop Communications The Front Panel Board is the user interface allowing system users to key in data use cards or keyfobs and follow the prompting provided by the display This C6000 component is key in gathering the user information which enables the C6000 to authorize the dispensing of the products being controlled The Front Panel Board is addressed using switches on the board so that it can communicate with the Main Control board on the RS485 bus The architecture allows the board to identify itself as a uniquely numbered component so that several different Front Panel Boards typically 1 5 can be connected to a single Main Control Board A small number of configuration options are set in the ProFuel software and these will include PCU Number determined by the existing data record and installation UI Number shown in red indicating
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11. C6000 evision C6000 Installation Instructions computrol Version 2 01 UEL SYSTEMS INC computrol C6000 Installation Instructions UEL SYSTEMS INC Table of Contents REVUE OCG acai MR T 1 System Archltectufe coude a 1 C6000 Front Panel Controller 1 C6000 Pump Control Board a a 1 Features and us uda cu 3 Board Mtt 3 Front Pate eC ON ESSO __ RERUM NA NES RO 4 a nemore Mo or 2 e PH 6 LOW lij 6 High VONAGE RERO DT D DE 6 neg e 7 Site PRED ALAMOS coii reve vex EUR UU PIS cR quc aaa I Du RO 7 Eo feris cm E R RA 7 VONAGE 5 e 8 Pulse MONOMO sissioni AEE 8
12. NG e 14 POU Set 15 FE TAN Shek auandaiatansnesasuarouee 16 RS 485 Communications Wiring Internal 30 C6000 PCU Card Cage and Chassis 31 Typical Mechanical Pump 31 Computrol Connection to Maxstream Wireless 33 Computrol Connection to Black Box Line Drivers 34 Computrol Audit Trail Printer Wiring 35 C6000 PCU Chassis and Card Cage Exploded View 36 Computrol Mounting 37 Foldout 11x17 diagrams are included with Factory Printed Manuals Site Wiring Typical Site Wiring for Gasboy 9800 Series Site wiring for Fillrite Page 34
13. OSA yg Anz SHINER H S oR SUDISUBWWIQ pep ipn jend y HEJL 0 2485 101284495 4 szga 91 sae 5280 puga pe juud poys sajung 01125 si sje preg Pap Acud Bursn 864 preg ajeuidoidde uug aunByuory 91 pues 5 aun amp ijuoa 01 1 wasis 124 Jan Jod aJnso ou3 00095 peog UIEN 00095 jenas suomnoeuuo joujndwoy 31 SWALSAS 1313 aj Ajddns J8Mod G ajejd smalag ununao enpo Ajdadng Jamo F 01 n J yuswuije abeg pasn pms pen 2 2 40 apisul 7 ieai ui aped doene ununa L gt g 5155245 jabe 9 peg J L Dununo
14. ProFuel 6000 Front Panel Controller drives all input devices including card readers displays and keypads 6000 Pump Control Board interfaces to the pump circuits to provide ON OFF control and monitor delivery of the product The three boards are connected by a single 4 wire trunk line using 2 wires for RS485 communications and 2 wires to distribute 12 volt dc power to each The multi drop configuration of this communications bus allows each board to take an address so the Main Board can always determine which board is communicating The basic C6000 unit will be comprised of a Main board a Pump Control Board and Front Panel Controller Other system components such as the power supply and the thermostatically controlled heater plate will also be in any Computrol enclosure Figure 1 Basic C6000 Architecture C6000 PCU ProFuel Computer Page 1 computrol C6000 Installation Instructions UEL SYSTEMS INC Version 2 01 A basic design feature of the C6000 hardware provides the ability to separate the main components for installation Installations can be proposed where the individual boards can be located in a building while the Front Panel board is installed on the island C6000 PCU Figure 2 Distributed C6000 Architecture Main Board or 1 Pump Control installed remotely Many C6000 applications may call for separate reader and display controls on 2 or 3 fuel island on a site A separate enclosure with
15. Rite connect to Gnd and Pulse 010 Balcrank Oil Pulser connect to 12V and Pulse 00 1 10K Input for Active12V or 24V Pulser connect to Gnd and Pulse Do not select both 2 and 3 Use 2 or 3 only Switch 2 1 is ON Switch 0 is Off The chart shows most pulser types currently defined with the DIP switch settings and wiring connections required to which make them work properly Communications Wiring Four types of communications are available for use in the C6000 system All Communications from the Main Control Board to Front Panel boards and Pump Control boards in any combination uses by Multi Drop RS485 wired as shown below Figure 11 C Bus RS485 Wiring Tx 2 Gnd RS485 Ports Vin 7 to Main Board or J1 Next Board Tx e Gnd Vin Page 10 computrol C6000 Installation Instructions UEL SYSTEMS INC Version 2 0 Main Communication Channel Figure 12 Main Channel Communications RJ45 Communication to the ProFuel Management computer can implement Ethernet LAN RS232 in 3 wire format or 8 wire format to provide Hardware Handshaking Ethernet LAN Wiring Connection Cat 5 Wire Color Commem Orange White Transmit 1 amp 2 Orange Orange Green White Blue Receive 8 amp 6 Green Blue White Green Brown White Pins 4 5 7 and 8 are unused Brown For Standard Cable all pins go straight through ie 1 1 2 2 3 3 6 6 For Crossover
16. after the Pump Handle Switch has been moved to the ON position The C6000 control circuits will use the Current Sense circuit or the Voltage Sense circuit to determine that the pump is running If the wiring does not allow the board to Sense that the pump is ON and interrupt that Sense with the Handle Switch then the system will not be considered operable The C6000 uses the sense to know the pump is on and must be able to sense immediately that the Pump Handle has been turned OFF and the transaction can be terminated normally If assistance is required to specify the type of wiring required consult with Computrol representatives Page 9 UEL SYSTEMS INC Version 2 01 computrol C6000 Installation Instructions Pulse Circuit Wiring Accurate pulse counts are imperative and a wide range of pulse circuits are found in the field The C6000 Pump Control Board provides a 3 position DIP switch for each pulser circuit to provide compatibility with a large number of different pulser types Choose from the chart below Pulser Configuration Wiring and Switches Figure 10 Pulser Connects and DIP SW SW5 Pump 1 J5 3 FON 2 412V e 1 Pulse On Off Gnd SW6 Pump 2 J7 SW Pos 123 Compatible Pulsers Wire Positions 010 Veeder Root V R 100 1 connect 12vdc Pulse and Ground 010 Krause D amp H connect to 12vdc and Pulse 110 Gasboy 9800 series connect to Gnd and Pulse 10 1 Veeder Root 10 1 Fill
17. ation Connect i ProFuel Configurations 8 Use the Connect button Transactions Language English Spanish Product Water Unit US mile gallon etc Tank Monitoring System Available SSS x Make sure that you test the connection before closing dialog Click OK on the Screen that appears H Data Link Properties Provider Connection Advanced Use the button circled to browse the network and locate the locations specified as having the new database select it and click OK The system returns to this screen Use the Test Connection button to confirm that the location will work Specify the following ta connect ta Access data 1 Select or enter a database name 2 Enter information to log on to the database User name Password Blank password Allow saving password Test Connection Cancel Help Save and Close Page 20 comput C6000 Installation Instructions FUEL tro Version 2 0 Connecting to Lantronix UDS10 from Computrol Pump Control Units It is best to plug the UDS10 device in near your personal computer and configure the device using the following steps before installing in its final working place Install the Lantronix Configuration Software and the Redirector Module from the manufacturer s CD With the UDS10 Plugged into a power source and connected to the network use the START button and Al
18. d pictured above includes connection points for Low Voltage Wiring Pulsers up to 3 pulser wires 12vdc Pulse In and Ground DIP switch SW5 and SW6 configure the board to read different pulse signals including pulses Krause and Gasboy or Veeder Root Electronic pulsers as well as Fill Rite and Veeder Root Mechanical pulsers see Page 10 Pulse Ratios are set in the ProFuel Software and the configuration is downloaded to the C6000 Flow Switches additional security against theft or broken pulser wiring is provided when the pump is fitted with a Flow Switch These devices are not commonly used RS485 Ports In and Out provide communications from the last board and to the next board in the RS485 Communication link This allows the Main Control Board to communicate with each component of the PCU system network High Voltage Wiring 120 240 Volt AC Control Wiring from the Pump Typically includes Hot and Switch leg but may include Voltage Sense Wire as well Page 6 computr trol C6000 Installation Instructions FUEL SYSTEMS INC Version 2 0 Installation Instructions The C6000 installation must be performed according to the instructions provided by Computrol and in accordance with all national and local electrical codes All wiring should be in steel conduit to avoid damage from lightening and power surges which might impair proper operation of the unit Site Preparations The C6000 is designed for installation outside ar
19. d 1Amp Figure 8 Conduit Termination in Pedestal eee Junction Box e ze Junction Box contractor msi B4 E ener SS Pulse Monitoring 2wire or 3 wire pulse circuits as specified by pump supplier low conduit runs from each C6000 Pump Control Board to each pump or dispenser Communications Ethernet using TCP IP RS232 using 3 wire with software flow control or 8 wire to implement higher speeds using hardware handshaking for flow control Page 8 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 0 Pump Control Wiring The Pump Control board in the C6000 is designed to control up to 2 pumps or dispensers using 120VAC circuits at less than 1 Amp The basic configuration is shown in the following diagram Figure 9 Pump Wiring Basics Pump On Off Switch IN C6000 Pump Control Board OUT LOAD 1 f L 120VAC More detailed installation instructions are available The premise of the Pump Control board s operation is that once the pump is authorized a relay is powered to provide power to the pump Control Load The Load is in some cases the pump as a whole powering up only when authorized In most modern cases however the Load is a solenoid or motor relay interrupted by the pump handle switch Pumps of this type may have electronic heads or even older mechanical registers When the Pump Control board authorizes the Pump Load it will run
20. eas classified as Class Il Hazardous This means that the unit must be at least 18 inches above grade and at least 18 inches away from all pump cavities EYS seals must be used in accordance with all applicable electrical codes to prevent fire and explosions The wiring and conduit runs for a proper installation include High Voltage Conduits Low Voltage Conduits The bottom of the PCU housing facilitates 2 x 1 conduits The left conduit is typically for Low Voltage The conduit on the right is reserved for High Voltage wiring A junction box by others in the pedestal is used to collect individual conduits so only 2 connect to the C6000 enclosure Figure 7 PCU Enclosure Mounting Holes front of housing 1 inch holes for 1 conduit Low Voltage and High Voltage cch 528 9 25 j Low Voltage Circuits include Communication wiring to remote C6000 components and where required cabling to the ProFuel Management Computer or modem location Pulser wiring and Flow Switch wiring optional from the pump or dispenser Page 7 computrol C6000 Installation Instructions UEL SYSTEMS INC Version 2 01 High Voltage Circuits include Power for Electronic Computer a dedicated 120VAC supply for the C6000 PCU Pump Control Wiring Hot and Switch Leg for each pump where Load Current is less than 1 Amp Hot Switch Leg and Voltage Sense wire where Load Current excee
21. eated Ensure an updated version of ProFuel 2 is ready to download a configuration to the PCU Not all firmware upgrades will require a new system ini but to be sure check with your technical support team Typically the C6000 is factory set to use 9600 Baud 8 Bits 1 Stop Bit Parity None and Xon Xoff Flow Control Confirm the connection information store in the ProFuel 2 PCU Communications Setup 6 screen The information includes is the Com Port last used and TCPIP address if required Procedure for upgrade the firmware in a C6000 a Connect to the PCU and ensure clean communications is possible b Logon with User ID and Password typically root and root Once logged on type reboot and the C6000 will restart showing messages such as the one shown below Figure 15 PCU Reboot Dialogue gt reboot AMD AM79C874 waiting for ucO neqotiallon ees Ethernet eth0 MAC address 00 50 02 50 d0 0e IP 192 169x 1 111 255 255 255 0 Gateway 1982168 141 perault server 192 169 2 79 RedBoot tm bootstrap and debug environment ROM Computrol release version Rev 2 1 0 2 built 11 34 46 Mar 6 2006 Copyright C 2000 2001 2002 Red Hat Inc RAM 0x80000000 0x82000000 0x8001bf60 0x81fdfa00 available FLASH Oxbe000000 0 0000000 256 blocks of 0x00020000 bytes each Executing boot script in 5 000 seconds enter C to abort d As shown above use CTRL C C when prompted This will s
22. fferent pump initiation sequences for individual users send messages to individuals who fuel vehicles and capture accurate transaction details in a secure memory for subsequent reporting The Main Control Board is the driver for the other system components which include the Front Panel Controller and the Pump Control Board Page 3 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 01 Figure 4 C6000 Main Control Board Power IN B 85485 Wiring to SH ML Pump Control Front Panel Boards M Channel RS232 Ethernet LAN USB USB DE9 Male RJ 45 Slave Connections to the C6000 Main Control board are clearly marked Front Panel Controller This board takes it commands from the Main Controller Board over an RS485 connection and performs functions including Display message tasks Card reader interface Keypad interface Receipt Print Control option The Front Panel Board is the user interface allowing system users to key in data use cards or keyfobs and follow the prompting provided by the display This C6000 component is key in gathering the user information which enables the C6000 to authorize the dispensing of the products being controlled Page 4 UEL SYSTEMS INC Version 2 0 computrol C6000 Installation Instructions Figure 5 Front Panel Board UI 1240404040 Serial Card
23. ile Config Systern ini Capture File Once the system has been downloaded and reset the new configuration will take effect and the pumps can be tested to ensure they are secure and counting accurately Test each of the pumps by 1 ensure the pump will not turn on without authorization from the PCU 2 perform 2 3 transactions with at least a small amount of fuel being delivered before turning the pump off 3 use the manual communications link to login typically user root and password root and use the L T A command to check the transactions that are displayed Page 13 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 01 If the value of fuel dispensed is correct and the termination code for the transaction is Normal then the system is wired correctly and the basic features of fuel control have been initialized properly Note If no product is counted check the pulser wiring and the pulser circuit configuration DIP switches on the Pump Control Board Note If product is not accurately counted then check that the pulse ratio on the PCU Pump Configuration screen matches the ration set in the pump or pulser Typically the error is a decimal location so 10 gallons is counted as 1 or 100 Larger transactions must be performed and checked to ensure volume limits are working on a per card basis where Transaction Limits or Polling Limits are implemented Page 14 computrol C6000 Installation Instruct
24. ions UEL SYSTEMS INC Version 2 0 Changing the Communication Port to a Network Connection If the unit is to communicate on the network a number of steps are required depending on the type of network and this information must be provided and supported by the IT professionals who determined the network parameters When a PCU is configured to communication using its Ethernet port the original serial communications setup is also configured This means that once downloaded with a system ini file which specifies the Ethernet connection is to be used the comm port will continue to function Take advantage of this fact at the time of set up by following the steps below This should be completed only after stable communications has been established 1 on the PCU s System 1 screen select DHCP as a server setting 2 Open the Communication setup 6 screen and select the radio button for TCP IP 3 Save the changes 4 Use the Export button to create the System ini file with the updated configuration 5 Change the Communications Setup 6 screen back to use COM Port as the means of communication This is required so the new information can be sent to the PCU which at this time has not been configured to use the Ethernet for communication Save the change 6 Follow the procedure for sending the system ini file to the PCU by opening the Communication screen selecting File Transfers and clicking the Config System ini button 7 Make sure the PCU is connec
25. its importance in this configuration Address DIP switches set the board s unique address for this installation site Card Reader options include Magnetic Stripe Coil Cards 34 or 26 bit HID Cards Enabled check box allows the setting to be recorded prior to implementation Refer to the ProFuel Il Manual for PCU and UI setup for detailed information Page 5 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 01 Pump Control Board Each C6000 Pump Control Board is capable of controlling and monitoring 2 pumps or dispensers Where more than 2 control circuits are required additional boards are inserted on the 485 link either in an existing enclosure or they are installed remotely The new boards must have a unique address and the new configuration information is downloaded easily to the C6000 from the ProFuel II software The circuit board is compatible with all older style Computrol control and pulser wiring providing customers with a direct upgrade path to the C6000 The C6000 Pump Control board is not compatible with older PCU hardware Figure 6 Pump Control Board TF J4 V Sense TTE Pump 2 or Port 2 A Pump 2 Fuse This Board 14 Fast Blow Pump 1 or Port 1 This Board Reverse Side of Board SW2 ADDRESS 5 shown ON RS485 Ports 5E to Main Board or 12345 6 7 Next Board Pump 1 Fuse 1A Fast Blow J6 V Sense Pump 2 The C6000 Pump Control Boar
26. l Programs Programs to select the Lantronix Device Installer Use the search button and the program will display the units it can find Mi DeviceInstaller 3 6 ioj x File Edit wiew Device Tools Help 2 M S Search Assign IP IP Address Hardware Address r Ready 7 If more than one appears use the Hardware Address to confirm that it is the one you are trying to setup Use the Assign IP button to ensure the IP address is set properly and write it down for reference later Assign IP Address E A IF Settings Please fillin the IP address subnet and gateway bo assign the device The subnet will be Filled in automatically as you but please verify For accuracy Incorrect values in any of the below Fields can make it impossible For your device to communicate and can cause network disruption IP address 0 0 0 0 Subnet mask 0 0 0 0 Default gateway 0 0 0 0 Back Cancel Help You will return to the original screen and when you select the device you wish to configure the Configure button will appear Click Configure Page 21 comput C6000 Installation Instructions FUEL Version 2 01 DeviceInstaller 3 6 BE x File Edit View Device Tools Help AAA E Search Assign IP Configure Upgrade Telnet Web LIP Address Hardware Address _ Ready ZA The configuration screen appears at which time you should select a port and edit the settings some UDS10s c
27. meout 1000ms resolution 5 center Use BOOTP for network configuration false lt enter gt TP address 45 lt enter gt Local IP address mask lt enter gt Default server IP address 192 168 2 79 lt enter gt Console baud fate 9600 ici lt enter gt GDB connection port 9000 ses lt enter gt Force console for special debug messages false lt enter gt MAC 0 hardware address ESA 0x00 0x50 0xC2 0x56 0xD0 0x0E lt enter gt Network debug at boot time false lt enter gt Update RedBoot non volatile configuration continue Y enter Y or changes will not be stored Gateway IP address lt enter gt RedBoot reset m The reset command will be executed and in approximately 1 minute the unit will be ready to communicate and resume operations using the new firmware n After entering the login and password use the Print Version command to confirm the upgrade was done successfully Page 18 comput C6000 Installation Instructions FUEL tro Version 2 0 Baud Rate Changes use only if the PC is connected directly to the Serial port Modems line drivers and other communications devices may be configured for the lower speed O To change the baud rate type baudrate b 115200 p The unit will respond but the characters will be garbled because the properties for HyperTerminal are still at 9600 Baud To change the communications speed in HyperTerminal click on the Off Hook phone icon
28. not need the redirector program though is may be useful for initial tests Use the Add IP button and enter the IP address you assigned Also enter the TCP IP Port as 10001 IP Service Setup xi Host 32 158 2 35 T CPPart 0001 Click OK and continue Page 24 computrol C6000 Installation Instructions UEL SYSTEMS INC Version 2 0 Click on the Port Settings button and check the Raw Mode check box Port Settings X Timeout Reconnect Fore 2 Protocol Server Reconnect Net Close Inband Listen Raw E E Connection Timeout Cancel Help Click OK and return to the Redirector Main screen click save and exit Use HyperTerminal to test the communications by setting the HyperTerminal session to the Com port selected and the speed you set You can perform a loop back test using a staple to short Pin 2 and 3 together in the UDS10 25 PIN comm port DB25 Female 2 Pin 3 Looking at the socket side With the jumper in place the characters you type will echo on the screen When you remove the jumper the echo will cease This confirms that the UDS10 is ready for installation at the working location Connect the device to the Computrol PCU Serial Port and to the LAN Test it from a computer on the network If the PCU does not respond it may be because the RX and TX lines on the PCU have been reversed for communications with a modem or other device previou
29. ome with a second comm port FE Configure Device ml Documentation Ports Advanced 9600 8 None 1 Xanxaff Using the Edit Settings button will cause the following screen to appear Port Settings Advanced Baud Rate joo Data bits gf Parity Stop bits Flow control konor Page 22 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 0 Make the appropriate changes as required noting that Fleet 300 PCUs use 1200 Baud 8 1 Xon Xoff C600 PCUs use 1200 or 2400 Baud 8 None 1 Xon Xoff C6000 PCUs are shipped using 9600 Bd 8 None 1 Xon Xoff but can be configured on site using ProFuel 2 to use almost any set of serial communication parameters Click OK and when the previous screen comes forward click Apply Write down the IP address that was assigned and click Close Use the Redirector program to continue Page 23 C6000 Installation Instructions computrol Version 2 01 UEL SYSTEMS INC Open the Redirector program using the START button and Programs to find Lantronix rea 5 x Port Configuration Redirect COMS To Advanced il Com Setup Silent Made Port Settings Status Idle This program is used to send the serial communication port signals over the LAN to the UDS10 where the signals will be converted back to RS232 Serial communications signals ProFuel 2 does
30. ownload the C6000 will respond with the following technical jargon or similar followed by the prompt RedBoot gt indicating the next command can be issued CCCULEntry point 0x80040000 address range 0x80040000 0x8011d998 xyzModem CRC mode 1 SOH 891 STX O CAN packets 4 retries RedBoot gt Page 17 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 01 command fis create lt new version specified gt should be typed the prompt where FIS CREATE is a command and lt new version specified gt is the file that was just downloaded This step is to inform the C6000 that the file just downloaded is a file which can be run as a program The next command tells the C6000 that it should run the new file when it reboots The command is FCONFIG and a snapshot of the resulting conversation is shown below Note bold underlined text is typed using the keyboard while smaller text is sent from the PCU Hitting the enter key in response to a line displayed means the line will be unchanged Figure 18 PCU Application Config FIS wie Sate x fconfig Run script at boot true lt enter gt BOOL SCripl fis load SR VO7 M Script terminate with empty line fis load new version specified lt enter gt AJ qo c lt enter gt So Anes ee wee lt enter gt entering a blank line indicates no more lines are to be entered Boot script ti
31. red for individual customer specifications Some of the optional hardware modules include e Card Readers using Proximity from HID Sensor Wiegand Magnetic Stripe Barium Ferrite from Securakey and Computrol Coil Card technologies e Keypad only operation is also provided and keypad options include rubber or stainless steel buttons with different button configurations e Control or 2 4 6 or 8 hoses e Receipt Printer type The system features include Simultaneous control of up to 16 hoses Configurable hardware addresses High Speed Serial communication TCP IP Ethernet LAN communications DIP Switch configurable Pulse Counter Circuits Optional voltage sense for pump control Pump timeouts for total time no flow or fail to start User configurable user prompt sequences User configurable display prompt messages Outgoing messages for users 1 time or repeat Main Board The Main Board is the primary component in the C6000 and is comprised of a reliable high speed processor with flash memory and a number of communications ports used for RS232 RS485 Ethernet LAN and USB The Main board drives all of the functionality in the other boards and stores the main data files for uploading and updating with the ProFuel Il Management Computer The Main Board s flash memory is loaded with the C6000 software which allows Computrol customers to fully customize the operation of the unit Among other features the C6000 allows the user to configure di
32. setup initially Figure 13 Export PCU System File Pump Controller Unit Edit NI NN Close Save Add T Dele PCU No Controller ID 1 PC Surrey Transaction Format 7 Receipt _ Automation 9 Error Messages 4 Pumps Printers U Communication Setup 6 System 1 Display Prompts 2 Once all changes have been made the Export button is used to create a C6000 configuration file Description Water Frant Out Going Message for All Vehicle GoodMoming Operator Ma 0 Network Settings Audit Trail On Server DHCP Remote Channel Yes El 5 Channel Console Yes 12 computr trol C6000 Installation Instructions FUEL SYSTEMS INC Version 2 0 Once completed the setup must be sent to the PCU for the changes to take effect This is accomplished by 1 Exporting the PCU system information to a file called system ini for each PCU 2 Entering the Communications screen and selecting File Transfers 39 Select the PCU which is to be configured 4 Use the Config System ini button to automatically transfer the information to the PCU Figure 14 Send System File to PCU E Communication Ba File Transfers Sent to the C6000 in seconds The C6000 immediately implements the system ini file to operate exactly as specified Send Receive File PCU Locattion Number File here to select F
33. sly or it may have been installed incorrectly Reversing the terminals in a Fleet 300 or C600 should be done before re visiting other settings or doing other tests A C6000 will be wired correctly if a standard AT MODEM communications cable is used This is a DB25 Male to 089 Female cable END Instructions Page 25 Version 2 01 C6000 Installation Instructions UEL SYSTEMS INC computrol RS485 Communications Wiring Between Boards peog Jo peog 0 dung Ssauadv ZMS peog JO epig asianay dwnd 00099 PIED asuag A Kejds ped ay jenes SP 8 ue uue gsn asn UIEW ZEZSM C 1uoJ4 pue jo 3uo2 dung 01 k 1 IPAZ uel u J9MOd 26 JNI SW4ALSAS 13fl 10 1 01103 epis esJeAeJ uo 398g Ajddng 180g gmB na3 ssgdAg dung Joo DR dung peog jouo mw T ES EX ES EX ENS mw mm um mm pex me ON S EN Em Um Emm mom ms E r S mu 1 i kA a B tit peog dung yoo 7 PRA 9 oy oj puc Ag E AZ uuo 20258 Y aBeyo
34. ted properly to the network and cycle the power on the PCU so it will initialize the Ethernet port and attempt to find a DHCP server 8 Use Manual Communications to log on to the PCU and use the Print Status command and make note of the IP address shown 9 Disconnect the serial communications cable 10 Open the Communications Setup 6 screen and after clicking the TCP IP radio button enter the IP address in the Host Address box provided Save the changes 11 Close the PCU setup screen and return to the Communication screen 12 Use the Manual Communications button click on Connect to PCU after selecting the proper PCU and the system will negotiate the connection 13 Type root as a UserlD and root as the password unless different information has been configured and use the PCU 6000 commands such as P S for Print Status and L T A for List Transaction All The PCU should respond to the commands and the PCU is properly configured for Ethernet communications Page 15 UEL SYSTEMS INC C6000 Installation Instructions computrol Version 2 01 Computrol C6000 Pump Control Unit Firmware Upgrade Using RS232 Serial Communications Port What you need before you start PC Computer with RS232 Com Port HyperTerminal Installed typically part of O S install Cabling required for connecting to C6000 PCU Firmware file to be installed In preparation for performing the upgrade Poll the transactions or otherwise ensure a backup is cr
35. top the C6000 from executing its boot script ie starting to run the firmware it has on board e The prompt RedBoot gt will appear Page 16 UEL SYSTEMS INC Version 2 0 computrol C6000 Installation Instructions The file transfer described in the next few steps will take approximately 20 minutes at 9600 Baud but only a minute or so at 115200K Baud You can not use a higher speed unless you are connected directly to the C6000 If you wish to use a higher communications speed skip to step o page 4 then return to step f when done To use the existing baud rate proceed now to step f f Type Load m ymodem lt enter gt g The C6000 is waiting to receive a file Use HyperTerminal to send the file containing the new firmware This done by Clicking On Transfer or using the keystroke ALT T then selecting the option to Send or typing S at which time the following screen will appear Figure 16 Send File Dialogue Send File Folder C Documents and Settings Chriss Start Filename new version specified Protocol h Enter the filename to be sent lt new version specified gt is used as an example only or browse to the location in which it has been stored Select Ymodem as the Protocol and press the Send button l A standard data transmission screen will be displayed showing progress when the complete file has been transmitted the screen will appear similar to the following On completion of the d
36. uted C6000 Architecture 2 Figure 3 Multiple Terminal Architecture 2 Figure 4 C6000 Main Control 4 Figure 5 Front Panel Board 5 Figure 6 Pump Control 6 Figure 7 PCU Enclosure Mounting Holes 7 Figure 8 Conduit Termination in 8 Figure 9 Pump Wiring BASICS 9 Figure 11 C Bus 15495 our no daana iaia 10 Figure 12 Main Channel Communications 45 11 Figure 13 Export PCU System File 12 Figure 14 Send System Pile to 13 Figure 15 PCU Reboot DIaloQle NN S ME 16 Figure 16 Send File Dialers 17 Figure 17 Send File
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