PSS 5000

Application Note

Fuel Theft Protection

(for suction dispensers)

Date November 8, 2012

Document number PSS5000/APNO/804763/02

Doms ApS Formervangen 28 Tel. +45 4329 9400 info@doms.dk

DK-2600 Glostrup Fax +45 4343 1012 www.doms.com
 PSS 5000, Application Note
Fuel Theft Protection

Table of content

1 Introduction ................................................................................................... 3
1.1 Purpose.................................................................................................. 3
1.2 Functional Description .......................................................................... 3
1.3 System Description ............................................................................... 4
1.4 Limitations ............................................................................................ 5
2 Hardware ....................................................................................................... 6
2.1 DSB451................................................................................................. 6
2.2 Opto Isolator ......................................................................................... 7
2.3 Contactor............................................................................................... 7
2.3.1 Contactor with manual switch (optional) ..................................... 8
2.4 Transformer (optional) .......................................................................... 8
2.5 Part List ................................................................................................. 9
3 Electrical Connections ................................................................................... 9
3.1 Number of modules for each site .......................................................... 9
3.2 Connection of a single pump .............................................................. 10
3.3 Site Connection ................................................................................... 11
3.4 Doms Cable 116209............................................................................ 12
3.5 Environment........................................................................................ 12
3.6 Low Voltage Contactor Drive (optional) ............................................ 13
4 PSS 5000 Configuration .............................................................................. 14
4.1 Digital I/O to Fp Mapping .................................................................. 14
4.1.1 PSS Software Configuration ...................................................... 14
4.1.2 Configuration Using Doms POS Protocol ................................. 14
4.2 Service Mode Parameter ..................................................................... 16
5 History ......................................................................................................... 17

PSS5000/APNO/804763/02 Page 2 of 17
 PSS 5000, Application Note
Fuel Theft Protection

1 Introduction
1.1 Purpose

This Application Note is written for people who need to implement extra
protection on the forecourt to reduce the risk of fuel theft occurring from the
forecourt pumps.

It explains how service companies can install the necessary hardware and how
POS suppliers can configure the forecourt controller to activate the
implemented protection.

1.2 Functional Description

While pumps are not authorized, this system retains a power supply to the
pump head calculator and display illumination, but it disables the power
supply to the fuel-pump motor(s). This is achieved by inserting a switch,
which is controlled by the PSS 5000, in the power supply circuit for each
pump.

Shop Forecourt

Mains for
calculator

Existing
cable
Mains for SWITCH
motor

PUMP

PSS 5000

When a fuelling point is authorized, power to the fuel-pump motors is returned

and normal fuelling can occur. It is not important how the fuelling point is
authorized; this can come from an OPT, POS or the forecourt controller in the
case of Fall Back mode or Recirculation (Pump Test) mode.

On completion of the individual fuelling transactions, the pump is no longer

authorized and the power to the fuel-pump motor(s) is once again disabled.

Note: With this protection, it is not possible to disconnect a pump from the
PSS and set it in Manual Mode. However, see chapter 2.3.1 for a special
solution, if necessary.

PSS5000/APNO/804763/02 Page 3 of 17
 PSS 5000, Application Note
Fuel Theft Protection

1.3 System Description

To implement this protection system, it is necessary to install some new

hardware and new application software. The major changes are made in the
Mains power distribution panel, which is normally in a secure location.

Shop Mains distribution panel Forecourt

G
N
P1 Existing
power
P2 P2 cable

P3 P3

PSS 5000
Contactor
PUMP

DSB451 Opto isolator

A motor contactor is installed in the power supply circuit for each pump. In its
resting state, the motor contactor disconnects 2 of the phases in the power
supply to the pump. This disables the fuel-pump motor(s) without affecting the
operating state of the pump head electronics and illuminated displays.

Each motor contactor is connected to an opto isolator, which in turn is

connected to a DSB451 digital I/O module installed in the PSS 5000. The PSS
5000 has special application software installed, which enables it to control the
opto isolator and motor contactor.

When a fuelling point is authorized, the PSS 5000 software triggers an output
on the DSB451 digital I/O module. The opto isolator switch then closes a
circuit and enables the high-voltage motor relay to reconnect the isolated
phases in the power supply to the fuel-pump motors.

Note: When this system is implemented, disconnecting the pump and putting
it in Manual Mode is no longer possible. Even during maintenance the pump
must be authorized. Typically, the PSS authorizes a fuelling point by using
Service Mode 41; but this can be implemented differently in different systems.

PSS5000/APNO/804763/02 Page 4 of 17
 PSS 5000, Application Note
Fuel Theft Protection

1.4 Limitations

The protection system described here is based on the fact that each pump is
equipped with its own motor(s). Consequently, submersible pumps are not
supported.

If lane oriented pumps are used, this protection does not provide protection if
the adjacent fuelling point is fuelling. If an adjacent fuelling point is
authorized the motors are energized and no theft protection is active.

PSS5000/APNO/804763/02 Page 5 of 17
 PSS 5000, Application Note
Fuel Theft Protection

2 Hardware
The theft protection is described as if it is added to an existing installation. The
additional hardware required for this protection is listed here:

DSB451, Digital input/output module for PSS 5000 mount,

Opto isolator for DIN rail mount
Contactor for DIN rail mount in the distribution panel

2.1 DSB451

The DSB451 is an interface module for use in the PSS 5000 forecourt
controller. The DSB451 is driven via a DSB-cable (Doms Serial Bus), a 10-
wire ribbon cable, connection to the central processor board.

The DSB451 provides 8 outputs. Each output can drive one opto isolator. The
output drive voltage is 4.2 volt DC at 20mA output current (max load).

The width of the DSB451 is 75mm, which means that 75mm of DIN-rail is
occupied by the module.

Each output is equipped with the following indicators:

A red light emitting diode (LED), which is on when the output is

energized.
A red (RX, data from CPB) and green (TX, data to CPB) for
communication with the central computer board (CPB).
A yellow for DSB451 power on (VDC).
A yellow for controller running (RUN).

PSS5000/APNO/804763/02 Page 6 of 17
 PSS 5000, Application Note
Fuel Theft Protection

2.2 Opto Isolator

The opto isolator makes a separation between the low voltage drive and 230
VAC. The module input is 5 volt and the output is 230 volt.

The input is driven from the DSB451 in the PSS 5000 and the output drives
the contactor (solenoid input).

The opto isolator must be placed in the mains power distribution panel
separated from the high voltage parts, such as fuses and contactors. The opto
isolator fits a 35mm DIN-rail mount and must be installed according to local
regulations.

The opto isolator used here is a Phoenix Contact type DEK-OV-

5DC/240AC/800, but equivalent units can be used.

2.3 Contactor

The contactor, which is driven by the opto isolator, makes the high power
switching. Two of the contactor switches are used for two of the phases
towards the pump.

The contactor is for a 35mm DIN-rail mount and must be placed in the mains
power distribution panel.

The contactor shown here is a Siemens type 5TT5730-0. It is rated for a 4 kW

load. The contactor (input) coil is driven by 230VAC.

PSS5000/APNO/804763/02 Page 7 of 17
 PSS 5000, Application Note
Fuel Theft Protection

2.3.1 Contactor with manual switch (optional)

The contactor can be delivered in a special version with a manual control

switch. This contactor can be used where it is absolutely necessary to put the
pump in manual operation without using the PSS 5000 Service Mode 41.

Doms does not recommend this way of operation.

During normal operation, the switch on the front must be placed in position
AUTO. In this position, the contactor operates as a standard contactor.

If the switch is moved into position 1, the contactor is switched on and this
enables the service personnel to put the pump into manual mode without PSS
5000 involvement. The first time the pump is authorized by the PSS 5000, the
switch will move back to AUTO, automatically.

If the switch is put into position 0, the pump is switched off. It will stay in this
position until it is pushed back to AUTO.

The contactor shown here is a Siemens type 5TT5 8306. Equivalent types can
be used.

2.4 Transformer (optional)

If you want a better separation between the control signals from the PSS and
the contactor, a transformer with a low output voltage can be used for the opto
isolator output switch current. Please see chapter 3.6 for connection details.

The transformer shown in chapter 3.6 is a 24VAC output type. The

manufacturer is Noratel and the type number is RDS12-2024-M2P.

The transformer is for a 35mm DIN-rail mount.

Note! The contactor with 24VAC coil must be used in this case. This could be
a Telemecanique type LC1D12B7 or equivalent.

PSS5000/APNO/804763/02 Page 8 of 17
 PSS 5000, Application Note
Fuel Theft Protection

2.5 Parts List

The parts described are listed below.

Ref Doms Stock no Description Manufacturer Manuf. part no

1 133765 Paralel I/O module, x8 Doms DSB451
2 142934 Opto Isolator, x1 Phoenix Contact DEK-OV-5DC/240AC/800
3 Contactor Siemens
4 119042 Data Cable: 2x2x0.5mm2 Doms
5 116209 Data Cable: 2x6x0.5mm2 Doms
6 Contactor with switch Siemens 5TT58306
7 Transformer 230/24VAC Noratel RDS12-2024-M2P
8 Contactor with 24 Volt Coil Telemecanique LC1D12B7

3 Electrical Connections
All new installations are implemented inside the shop building. The cables
connected to the pumps are unchanged.

A condition for this theft protection upgrade is that each pump is supplied by
its own 5 wire power supply cable for a 3 phase mains supply.

The DSB451 is placed inside the PSS 5000 cabinet. The opto isolator and
contactor are placed in the Mains power distribution panel. The connections
between these parts are described in the following text.

3.1 Number of modules for each site

A single DSB- port on the CPB in PSS 5000 can support up to 4 DSB451
modules, where each module has 8 connectors. So, each port on the CPB can
support up to 32 pumps.

Note! If lane oriented pumps are used, each DSB451 output will cover two
fuelling points. In this case, a single DSB451 will cover 16 fuelling points.

Each pump requires one opto isolator and one contactor.

Example: For 6 lane oriented pumps the following is needed:

1 x DSB451,
6 x opto isolators
6 x contactors

PSS5000/APNO/804763/02 Page 9 of 17
 PSS 5000, Application Note
Fuel Theft Protection

3.2 Connection of a single pump

A schematic concerning the connection of a pump is shown here.

The cable from the PSS 5000 to the opto isolator is a 0.5 mm2 data signal
cable, the cable between opto isolator and contactor is a 1.5 mm2 installation
wire and the cable towards the pump already exists (2.5 mm2).

Please be aware that the signal cable from the DSB451 to the opto isolator
must be placed separately from the mains cables. This is due to both noise and
safety considerations.

Separate section in mains Mains distribution Pump

distribution

From pump fuses

N P1 P2 P3
+1

-2

-
A1 2 4 6 8
+

230VAC
PSS 5000
A2 1 3 5 7

13 14

P3 - motors only
DSB451 P2 - motors only
-2

-2
+1

+1

P1 - calculator and motors

-2

-2
+1

+1

A2 - A1 +
N
-2

-2
+1

+1

5VDC
-2

-2
+1

+1

PSS5000/APNO/804763/02 Page 10 of 17
 PSS 5000, Application Note
Fuel Theft Protection

3.3 Site Connection

For a site with 8 pumps the connection is shown in principle. For precise wire
connections, please use the previous drawing.

Technical room Equipment mounted in mains distribution Forecourt

Pump 1 fuse

Pump 2 fuse

Pump 3 fuse

Pump 4 fuse
Pump 5 fuse

Pump 6 fuse

Pump 7 fuse

Pump 8 fuse
PSS5000
Pump 8

Pump 7

DSB451
Pump 6
1 2 3 4
5 6 7 8

Pump 5

Pump 4

Pump 3

Pump 2

Pump 1

1 pcs DSB451 8 pcs opto isolators 8 pcs contactors

Doms Phoenix Contact Siemens
133765 2964623 5TT57300

See chapter 3.4 for connections between the DSB451 and opto isolators.

PSS5000/APNO/804763/02 Page 11 of 17
 PSS 5000, Application Note
Fuel Theft Protection

3.4 Doms Cable 116209

For the connection between the DSB451 and the opto isolator, it is convenient
to use one cable per DSB451. To make the installations look as equal as
possible, the following cable color reference can be used:

DSB451 OPTO ISOLATORS

PUMP 8 12 Red/blue DSB451 OUT 8+ A1 +

8
A2 -
4

PUMP 7 11 Grey/pink DSB451 OUT 7+ A1 +

COMM 7/8 10 Violet DSB451 OUT 7- A2 -

7
3

PUMP 6 9 Black DSB451 OUT 6+ A1 +

6
A2 -
2

PUMP 5 8 Red DSB451 OUT 5+ A1 +

COMM 5/6 7 Blue DSB451 OUT 5- A2 -

5
1

PUMP 4 6 Pink DSB451 OUT 4+ A1 +

4
A2 -

PUMP 3 5 Grey DSB451 OUT 3+ A1 +

COMM 3/4 4 Yellow DSB451 OUT 3- A2 -

3

PUMP 2 3 Green DSB451 OUT 2+ A1 +

2
A2 -

PUMP 1 2 Brown DSB451 OUT 1+ A1 +

COMM 1/2 1 White 1

DSB451 OUT 1- A2 -

The cable refers to a Doms 2x6x0.5mm cable, stock no. 116209, but an
equivalent cable can be used. The cable is shielded, but the shield is not
shown.

3.5 Environment

All electrical installations must comply with the local regulations. But, in order
to protect the PSS 5000, it is recommended that the PSS 5000 and the 3-phase
connections for the forecourt devices are installed in separate sections of the
electrical distribution panel.

If further separation between PSS 5000 and contactor is needed, please see
chapter 3.6.

PSS5000/APNO/804763/02 Page 12 of 17
 PSS 5000, Application Note
Fuel Theft Protection

3.6 Low Voltage Contactor Drive (optional)

If a contactor with a 24VAC coil is used together with a transformer, the drive
circuit can be implemented as 24VAC.

Separate section in mains Mains distribution/sikringstavle

distribution or separate cabinet

230VAC
Safety Transformer
Noratel
RDS12-2024-M2P
+1

-2

A1
Motor Contactor
Coil: 24VAC
- Contacts: 12A
24VAC Telemecanique
+ LC1D12B7
PSS 5000
A2

13 14
-2

-2
+1

+1
-2

-2
+1

+1

A2 - A1 +
-2

-2
+1

+1

5VDC
-2

-2
+1

+1

DSB451 Opto Isolator

Shielded Cable
2x6x0.5mm2 Phoenix Contact
Doms no. 116209 DEK-OV 2-5DC/240AC/800
(Io max = 0.8A)

Connection of a single pump is illustrated above.

PSS5000/APNO/804763/02 Page 13 of 17
 PSS 5000, Application Note
Fuel Theft Protection

4 PSS 5000 Configuration

4.1 Digital I/O to Fp Mapping

4.1.1 PSS Software Configuration

The software in the PSS 5000 must be configured so that each fuelling point
on the forecourt is mapped to a connector on the DSB451 module(s).

Note: Each output connector on the digital I/O module can have one or more
fuelling points connected.

For example, if 3 pumps are present on the forecourt, then the fuelling points
on each pump can be assigned as shown below:

Pump 1
This is a double-sided pump with 2 fuelling points. The fuelling points use the
same fuel-pump motors. Therefore, it is possible to connect the fuelling points
to the same connector.
Fp1 assigned to Connector 1
Fp2 assigned to Connector 1

Pump 2
This is a double-sided pump with 2 fuelling points. Each fuelling point has its
own fuel-pump motor(s). Therefore, it is necessary to connect the fuelling
points to separate connectors.
Fp3 assigned to Connector 2
Fp4 assigned to Connector 3

Pump 3
This is a single-sided pump with 1 fuelling point. As this fuelling point has its
own motor, it is connected to its own connector.
Fp7 assigned to Connector 4

4.1.2 Configuration Using Doms POS Protocol

Using Doms POS Protocol, it is possible to configure which fuelling point(s) is

connected to the individual digital I/O module connectors (pin).

The Doms POS Protocol message used to install this configuration relationship
is: install_Diop (Diop is short for digital I/O pin).

PSS5000/APNO/804763/02 Page 14 of 17
 PSS 5000, Application Note
Fuel Theft Protection

Using the example in 4.1.1, the message contents for install_Diop will be as
follows:

Pump 1

NAME: install_Diop
EXTC: 0401H
SUBC: 00H
DATA: DiopId=1 + (digital I/O module connector)
DiopType=0000H +
PssChannelNo=11 +
PhysicalAddress=1 +
DiopNameLen=21 +
DiopName
{
"PumpLight Fp1 and Fp2"
}+
DiopFunctionCode=03H + (03: Pump Indication (OPT Light))
NoDiopInstallParameters=2
{

DiopInstallParId=02:DiopActiveLevel +
DiopInstallParLen=1 +
DiopInstallPar
{
DiopActiveLevel=01H
}+

DiopInstallParId=07:FcDeviceIdList + (indicates that a list is used)

DiopInstallParLen=3 +
DiopInstallPar
{
FcDeviceIdList
{
FcDeviceIdListLen=2
{
FcDeviceId=1 + (Fueling points are listed here)
FcDeviceId=2
}
}
}
}

Note! DiopInstallParId = 07 is used to indicate that a list of fuelling points is

used for that specific configuration.

PSS5000/APNO/804763/02 Page 15 of 17
 PSS 5000, Application Note
Fuel Theft Protection

Pump 2

NAME: install_Diop
EXTC: 0401H
SUBC: 00H
DATA: DiopId=2 + (digital I/O module connector)
DiopType=0000H +
PssChannelNo=11 +
PhysicalAddress=2 +
DiopNameLen=13 +
DiopName
{
"PumpLight Fp3"
}+
DiopFunctionCode=03H + (Pump Indication (OPT Light))
NoDiopInstallParameters=2
{

DiopInstallParId=02:DiopActiveLevel +
DiopInstallParLen=1 +
DiopInstallPar
{
DiopActiveLevel=01H
}+

DiopInstallParId=01:FcDeviceId + (only a single Fp is used)

DiopInstallParLen=1 +
DiopInstallPar
{
FcDeviceId=3 (Fueling point ID is here)
}
}

Fp4 and Fp7 are configured as shown above for Fp3 using DiopInstallParId =
01, and changing the FcDeviceId to 4 and 7 respectively and changing DiopId
/ PhysicalAddress to 3 and 4 respectively, according to the example in 4.1.

Further details about this message, and how it is used, can be found in Doms
POS Protocol, Application Level Specification, Chapter K – Digital I/O
Control (804452/--).

4.2 Service Mode Parameter

For all service modes, the following parameter must be set to the value shown:

SmParName SmParId Value Description

PumpLightMode 16 01H On at authorize

PSS5000/APNO/804763/02 Page 16 of 17
 PSS 5000, Application Note
Fuel Theft Protection

5 History

Date Rev. Init Comments

2009-06-11 00 IbJ First version
2009-08-03 01 kmb Added a new section, which provides information about
the Service Mode parameters
2012-11-08 02 kmb Updated stock numbers in 2.5 Parts List

PSS5000/APNO/804763/02 Page 17 of 17