3002 PET TFZ SA 070303 e

Petrodat 3002
For tank vehicles
Service instructions
SA 070303
Contents
I-1
Table of contents Page Date of last change

1 General instructions _______________________________ 1
2 Safety instructions ________________________________ 3
2.1 General safety instructions ___________________________ 3
2.2 Mounting instructions ________________________________ 4
2.3 Wiring instructions __________________________________ 6
2.4 Additional instructions on ground routing and cable shielding 7
2.5 Maintenance and repair ______________________________ 8
2.6 Tables ___________________________________________ 9
3 Block diagrams of measuring system tank trucks _____ 16
3.1 Examples for retrofitting of A3 and A1 ___________________ 16
3.2 Examples for reequipment of A3 and A1 _________________ 22
3.3 Examples with filling level monitor ______________________ 29
4 Installation and wiring ______________________________ 30
4.1 P-NET fieldbus cable ________________________________ 30
4.2 Other control cables ________________________________ 31
4.3 Controller _________________________________________ 32
4.4 Pulse counter A3 refitted type 6715-10 (11,12,13,14,15,16) _ 39
4.5 Pulse counter A3, reequipped _________________________ 43
4.6 Pulse counter A1, refitted Ex type 6716-10 (11,12,13,15,16) _ 45
4.7 Pulse counter A1, reequipped _________________________ 49
4.8 Pulse counter interface, type 6716-90 Ex ________________ 50
4.9 Temperature sensor A3, type 6701-20/-21 _______________ 50
4.10 Temperature sensor A1 Ex, type 6702-20/-21 ____________ 56
4.11 P-NET distributor box Ex, type 6789-10 _________________ 60
4.12 Output interface Ex, type 6752-10 ______________________ 62
4.13 Measurement system interface ________________________ 64
4.14 Temperature sensor Ex G1/2“, type 6702-31 _____________ 72
4.15 Pulse transmitter Ex, type 671x-5x _____________________ 75
4.16 I/O box VARIO 1, type 6753-10 ________________________ 76
4.17 Output relay modules _______________________________ 79
4.18 Voucher printer, type 6881-1 __________________________ 80
4.19 Voucher printer, type 6881-3x _________________________ 84
4.20 Form printer, type 6863-5 ____________________________ 87
4.23 Form printer, 24 V, type 6863-20 ______________________ 94
4.24 SSM cartridge station, type 6766-12 ____________________ 97
4.25 Ballast, type 6781-12/24-V module _____________________ 100
4.26 Cable combination for semi-trailer Ex, type 6789-50 _______ 102
4.27 Filling level monitor Ex, type 6728-65/-66 ________________ 106
4.28 Alert button _______________________________________ 108
Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Contents
I-2
4.29 V-24-(RS 232)/P-NET converter, type 4386-4/-6 __________ 110

4.30 P-NET/V.24 converter, type 4386 P041 _________________ 114
4.31 Connection of modem type “FALCOM A 2-1” _____________ 116
4.32 Connection of modem type „FALCOM A 1“ _______________ 116
GSM modem TC 35 / MC 35 including aerial _____________________ 117
4.33 Connection Onboard Computer ________________________ 123
4.34 GPS receiver (RS 232), type 6722-16 ___________________ 126
4.35 GPS receiver (RS 232), type 6722-18 ___________________ 128
4.36 Connection of card reader Ingenico Elite 790 _____________ 130
5 Startup __________________________________________ 131
5.1 Sequence and instructions ___________________________ 131
5.2 Calculate and enter the password ______________________ 131
5.3 Parameter printout __________________________________ 135
6 Calibration _______________________________________ 137
6.1 Calibration of PETRODAT 3002 _______________________ 137
6.2 Calibration-related instructions for servicing works at _____ 138
PETRODAT 3002
6.3 Model supplement for measuring system document ________ 140
7 Troubleshooting___________________________________ 141
7.1 If everything else fails _______________________________ 141
7.2 Software reset _____________________________________ 143
8 Replacement of devices ____________________________ 145
9 Software _________________________________________ 147
9.1 Program uploads ___________________________________ 147
9.2 BIOS setup________________________________________ 148
All rights reserved. Subject to change without prior notice. Copyright © 2014by
No part of this document may be reproduced, processed or distributed BARTEC BENKE GmbH
in any form or by any means without the prior written permission of Schulstraße 30
BARTEC BENKE. D-94239 Gotteszell
Document: SA 070303 Valid from: 10.07
Author: Michael Vogl
Translator: Eva Bauernfeind Revision: 24.05.2016

General instructions
1 General instructions
The operating instructions PETCO (BA 990602) and the configuration instructions (SAK
990601) are integral parts of the service instructions (SA 951019)! It is imperative to ob-
serve all points described in the instructions.
1. Observe the national regulations for start-up.
2. This service instruction only includes the data essential for the installation and connection
of the devices/components
3. For the complete technical data of the individual devices see the type-related data sheets.
Available from BARTEC BENKE on request!

General instructions

Safety instructions
2 Safety instructions
2.1 General safety instructions
 The operator of the system is responsible for the observance of all regulations applying to
storage, transport and handling of combustible liquids.
 All regulations and provisions remain valid as long as the system is operated with BARTEC
BENKE devices.
 The BARTEC BENKE devices have been built by adhering to the regulations in force and
have left the factory in perfect condition. Installation and maintenance of the devices to be
carried out by qualified staff.
 Make sure that the data and operating conditions specified by the manufacturer are complied
with.
 Observe the instructions for operating and servicing the devices.
 If you discover any damage or breakage on any parts of the system, or if the safe operation
cannot be guaranteed for any other reason, do not start the system or turn it off immediately.
 Contact your service representative.
 Get in touch with our service specialists if you discover any faults or defects during operation
or if you have cause to doubt that the devices are working properly.
 BARTEC BENKE devices are no replacement for the safety equipment of the tank vehicle or
of the customer (e.g. filling level monitor).
 To guarantee your own safety, always disconnect the complete PETRODAT system from the
power supply for maintenance and repair works.
Disclaimer
BARTEC BENKE GmbH and its vicarious agents only assume liability in the case of deliberate
acts or gross negligence. The extent of liability in such a case is limited to the value of the order
placed with BARTEC BENKE GmbH.
BARTEC BENKE accepts no liability for any damage resulting from non-observance of the safe-
ty regulations or from non-compliance with the operating instructions or operating conditions.
Secondary damage is excluded from the liability.
CAUTION!
Do not open casing cover when exposed to voltage!

Only work with the EEx-e terminals when they are voltage-free.
Observe national regulations for startup. For function controls observe the directives in accord-
ance with EN 60 079-17.

Safety instructions
2.2 Mounting instructions

 Install the devices in such a way that the specified climatic and temperature values are not
exceeded. If necessary, provide protection in the form of covers, heating or cooling (see ta-
ble “Climatic classifications”).
 Choose an installation site for the devices that is appropriate for their protection type (IPxx).
For instance, printers, SSM cartridge station etc. have to be permanently protected against
soiling and humidity by means of appropriate installation (e.g. driver´s cab) (see 2.5.1 table
”Protection types and climatic classifications“).
 Choose a shock-proof and vibration-free installation site. All components have to be protect-
ed against vibrations by means of stable holders.
 During mounting the devices (above all the printer or any opened devices) have to be pro-
tected against soiling (e.g. metal filings etc.)
 Close tightly with blind plugs all cable screwings that are not assigned.
 Remove the transport brace of the printer before putting it into operation. All built-in relays
and magnetic valves have to be interference-suppressed (free-wheeling diode).
 At first only slightly screw in all fastening screws of the casing covers, check if the casing
sealing fits correctly, then tighten screws diagonally.
 Very important: If welding works are carried out at the vehicle, the positive and nega-
tive poles of the power supply line to the device have to be disconnected (disconnect
on-board power supply or turn off with 2-pole switch)
2.2.1 Installation explosionprotected cable glands
Explosion-proof plastic cable glands in type of protection increased

safety "Ex e" are suitable for low degree of mechanical hazard.
Plastic-cable glands
When installing the equipment, make sure that the cable glands are
at no exposed areas and can not be damaged by moving objects.
Therefore, the following installation situations are recommended.

Safety instructions
recommended mounting
impermissible installation
If a higher degree of mechanical hazard, an additional protection by

a cover can be necessary.

Safety instructions
2.3 Wiring instructions

 Carry out installation in accordance with EN 60079-14 and GGVS/ADR and with the regula-
tions of the country concerned!
 Wiring of the devices only to be carried out in accordance with this service instructions and
by experienced staff.
 When laying the connection cables, make sure that no parts are sagging. It is recommended
to observe a fastening distance of about 15 to 20 cm by means of clamping pieces or cable
ties.
 Particular caution is required for laying the cables in the surroundings of the cooler, in the
motor space, in the frame parts of the truck and in the discharge cabin.
 Avoid by all means any weak spots where cables might be buckled, abraded, or exposed to
inadmissible heat impact or any other mechanical strain.
 Observe the specified minimum line cross-sections, and for clamping equip the lead ends
with suitable/prescribed wire end sleeves (clamping area l = 8mm). (see table 2.5.3 “Line
cross-section depending on terminal type”). Colour and size of wire end sleeves depend on
line cross-section.
 Tighten screw terminals that are not assigned.
 Select cable diameter in accordance with the cable screwings in order to guarantee a relia-
ble and tight clamping (see table 2.5.2 “Recommended cable diameters per PG size”).

Safety instructions
Make sure that the cables are In a humid atmosphere make

safely connected and the ca- sure that no water can pene-
ble screwings are firmly trate the device.
closed.
2.4 Additional instructions on ground routing

and cable shielding
To comply with the CE and electromagnetic compatibility requirements and with the galvanic
separation of the on-board power supply system of the collecting truck which is consistently car-
ried out in the system PETRODAT 3002, observe the following wiring instructions.
Ground routing:
The ground wire (0 V/GND) of the PETRODAT system may be connected to the vehicle chassis
at only one spot (star-shaped switching).
This is already guaranteed by the appropriate switching in the current supply units (e.g. power
supply plug-in unit, type 6757-101/-110). No additional measures are required.
To meet these requirements, system components whose signal GND has an electro conductive
connection to the metallic casing have to be mounted electrically insulated against the metallic
vehicle chassis.
This applies for instance to:

 GSM modem TC/MC 35
 GPS receiver type 6722-16
 Thermal printer type 6761-11
Please observe the appropriate instructions under chapter 4 referring to the individual compo-
nents.
Cable shielding:
The following schematic diagrams show the different variants of the shield connection appropri-
ate for each individual component.
Chapter 4 lists for each component the appropriate variant according to which the shield con-
nection has to be carried out.

Safety instructions
Schematic diagrams:
2.5 Maintenance and repair

 Maintenance and repair only to be carried out by qualified staff!
 Before carrying out any maintenance or repair works, disconnect the device.

Safety instructions
2.6 Tables
2.6.1 Protection types and climatic classifications
Protection types
Definition of protection types in accordance with DIN 40050

The protection types are named by a short sign consisting of two permanent code letters IP and two code numbers for the protec-
tion degree: e.g. IP 54.
Protection degrees for protection against contact and protection Protection degrees for water protection against foreign matters
Sec-
First Protection scope Protection scope
Designation ond Designation
code Explanation Explanation
code
0 No protection No particular protection of per- 0 No protection No particular protection
sons against direct contact with
active or moved parts. No pro-
tection of equipment against 1 Protection against Water drops falling vertically
penetration by solid foreign vertically falling drip- must not have a harmful effect
matters ping water
1 Protection against Protection against accidental 2 Protection against Water drops falling perpendicu-
big foreign matters contact with active and internal dripping water falling larly at any angle up to 15
mobile parts, e.g. with the hand, perpendicularly degrees must not have a harm-
but no protection against delib- ful effect
erate access to these parts.
Protection against penetration 3 Protection against Water drops falling at any angle
by solid foreign matters with a spray water up to 60 degrees must not
diameter  50 mm. have a harmful effect
2 Protection against Protection against contact with 4 Protection against Water splashing from all direc-
foreign matters of active or internal mobile parts. splash water tions against the equipment
medium size Protection against penetration must not have a harmful effect.
by foreign matters with a diame-
ter  12 mm. 5 Protection against A water jet from a nozzle
water jets splashing from all directions
against the equipment must not
have a harmful effect.
3 Protection against Protetcion against contact with
small foreign mat- active or internal mobile parts 6 Protection against In case of temporary flooding,
ters with tools, wires or similar ob- flooding e.g. caused by rough seas
jects having a thickness  water must not penetrate the
2.5mm. Protection against equipment in a harmful way
penetration by solid foreign
matters with a diameter  2.5 7 Protection in case of Water must not penetrate the
mm. immersion equipment in a harmful way if
the equipment is immersed into
4 Protection against Protection against contact of water under defined pressure
grain-shaped foreign active or internal mobile parts and time conditions.
matters with tools, wires or similar ob-
jects having a thickness  1 mm. 8 Protection in case of Water must not penetrate the
submersion equipment in a harmful way if
5 Protection against Complete protection against the equipment is submersed in
dust deposit contact with live parts or internal water
mobile parts. Protection against
harmful dust deposits. Dust Example First index : Protection against
penetration cannot be complete- Code letters IP 65 contact with and penetration by
ly prevented, but the dust must foreign matters
not penetrate to an extent that
the operating mode is impaired. Second index: Protection
against liquids
Complete protection against
6 Protection against conact with live parts or internal
dust penetration mobile parts. Protection against
dust penetration.

Safety instructions
10
Protection against penetration by liquids
Protection No pro- Dripping water Spray Splash Immer- Sub-

Water jet Flooding
against tection vertical transversal water water sion mersion
IEC 529
IP ... 0 IP ... 1 IP ... 2 IP … 3 IP … 4 IP … 5 IP … 6 IP … 7 IP … 8
DIN 40050
IP 0…
IP 00
IP 1…
IP 10 IP 11 IP 12
IP 2…
IP 20 IP 21 IP 22 IP 23
IP 3…
IP 30 IP 31 IP 32 IP 33 IP 34
IP 4…
IP 40 IP 41 IP 42 IP 43 IP 44
IP 5…
IP 50 IP 53 IP 54 IP 55 IP 56
IP 6…
IP 60 IP 65 IP 66 IP 67

Safety instructions
11
Climatic classifications:
1. Code letter Lower temperature 2. Code letter Upper temperature

limit limit
Reserved
See individual
regulation
Limits of relative air humidity 1)

Maximum values
Occasionally during
Permanently during
Permanently during
30 days of the year
60 days of the year
the remaining days

Average annual
Remarks
3. Code letter
value
See individual
regulation
Permanent
humidity
free
Condensation
Rare and
slight con-
densation
No
condensation
See individual regulation
1) For reference temperatures – see diagrams in annex I/II

2) These days should be distributed in a natural way
3) By complying with the average annual value
4) May occur, e.g. if devices installed outside are temporarily
opened
*) These code letters refer to annex II

Safety instructions
12
2.6.2 Table “Recommended cable diameters per PG

size“
Cable diameter
Screwing type
Clamping area mm
M 16 x 1.5 5 ... 10
M 16 x 1.5 EMV 6 ... 10
M 20 x 1.5 10 ... 14
M 32 x 1.5 11 ... 21
PG 7 KS 3 ... 6.5
PG 7 Ms 2 ... 6.5
PG 9 KS 4 ... 8
PG 9 Ms 3 ... 8
PG 11 KS 5 ... 10
PG 11 Ms 4 ... 10
PG 13.5 KS 6 ... 12
PG 13.5 Ms 5 ... 12
PG 16 KS 10 ... 14
PG 16 Ms 8 ... 14
PG 21 KS 13 ... 18
PG 21 Ms 11 ... 18
KS = plastic (Kunststoff)
Ms = brass (Messing)
2.6.3 Table “Line cross-section depending on termi-

nal type“
Terminal type Line cross-section mm²
TOP 1.5 max. 1.5
LPATOP max. 1.5
LPA max. 1.5
BLA max. 2.5
2.6.4 Lead colours and abbreviations

Black bk
Brown bn
Red rd
Orange or
Yellow yl
Green gn
Blue bu
Violet vi
Grey gy
White wt
Pink pk
Turquoise tq
Gold gd
Silver sr
Two-coloured leads are always designated accordingly:

Safety instructions
13
 Example: yellow-green = ylgn
If two or more leads have to be connected to one pin, this is designated as follows:
 Example: pink/grey/white = pk/gy/wt

Safety instructions
14
2.6.5 P-NET identification numbers of the system

components
P-NET slave addresses for system 3002 PETRO
Addr.
P-NET ID Quantity Device name PETRO function
range
GSM-modem, cable transmission 5
E7-ComIF 1c
Tally-Genicom printer 1d
5930 3 Router 1-way
Ingenico-Terminal 1e
Navigation system 1f
GPS 20
GSM-modem, cable transmission 5
E7-ComIF
5942 1 Router 3-way Tally-Genicom printer
Ingenico-Terminal 1/5
Navigation system
GPS
5939-6 6-fold T 8 Temperature sensor Temperature of medium 21..28
5925 Measuring system inter- Temperature sensor 21..28

4
5926 face OIF, pulse counter 29..30
5404 8 Pulse counter Volume 29..30
5906 Output Interface

8 I/O boxes Inputs/outputs, control functions 31..38
5922 Vario 1
5917 2 SSM cartridge box Data backup / data transmission 39/3a
5913 2 Power supply unit Km registration etc. 3b/3c
3221 4 Upi Pump control/density measurement 3d..40
5812 8 Slip printer Printer 41..48
5929 cannot be calibrated

2 Additivation Colouring, additivation 49/4a
5912 calibratable
Residual quantities, product identifica-
5909 2 Sensor interface 51..52
tion, tank identification
5935 2 SAFE scanner Hose supervision 53..54
5907 8 Wiegand reader Vehicle number at the bearing 59..60
5928 optical AS
2 Filling level monitors thermal, optical 69/6a
5934 thermal
5904 1 P-NET/V24 converter Radio access of airfield 77
5946 1 SPD interface Valve supervision 6b
Customer identification with TAG read-

5916 1 Reading station 59
er
5931 1 Dipstick-interface Level measurement 4b
1 1 A4-Printer Printer 42

Safety instructions
15

Block diagrams of measuring system tank trucks
16
3 Block diagrams of measuring sys-

tem tank trucks
3.1 Examples for retrofitting of A3 and A1
A3 compact measuring system vehicle, one fold TMU, retrofitted

17
A3 compact double measuring system vehicle, 2-fold TMU, retrofitted

18
A3 semitrailer measuring system vehicle, 1- or 2-fold TMU, retrofitted

19
A1 compact measuring system vehicle, 1- or 2-fold TMU, retrofitted

20
A1 semitrailer measuring system vehicle, 1- or 2-fold TMU, retrofitted

21
A1 semitrailer measuring system vehicle, 1- or 2-fold TMU, retrofitted with measuring

system interface

22
3.2 Examples for reequipment of A3 and A1

A3 compact measuring system vehicle, 1- or 2-fold TMU, reequipped

23
A3 semitrailer, measuring system vehicle, 1- or 2-fold TMU, reequipped

24
A3 measuring system vehicle, 1- or 2-fold TMU, reequipment stage 1 with measuring

system interface, additivation (see separate service instructions)

25
A1compact measuring system vehicle, 1- or 2-fold TMU, reequipment stage 1

26
A1 semitrailer measuring system vehicle, 1- or 2-fold TMU, reequipment stage 1

27
A1 semitrailer measuring system vehicle, 1- or 2-fold TMU, reequipment stage 1 with

measuring system interface, additivation (see separate service instructions)

28
A1 semitrailer measuring system vehicle, 1- or 2-fold TMU, reequipped with measuring

system interface

29
3.3 Examples with filling level monitor

Installation and wiring
30
4 Installation and wiring

4.1 P-NET fieldbus cable
4.1.1 General description
Most system components (e.g. controller, ballast etc.) are equipped with a P-NET fieldbus inter-
face and are interconnected by means of a 7-wire P-NET cable. 5 of these wires are reserved
for the P-NET connection, and 2 are available as reserve wires. These 2 wires can for instance
be used for the 24 V on-board voltage supply of the magnetic valves (see output interface).
Wires have to be equipped with wire end sleeves!
CAUTION!
When the system components are wired with the P-NET fieldbus cable, please note that a P-
NET ring is not required. The components are only connected with a branch line. That means
that a connection from the last device to the first device is not necessary.
4.1.2 Technical data

Electrical data
Operating voltage 300 V
Test voltage 1500 V
Conductor resistance (20° C) 33 /km
Insulation resistance (20° C) 153 M x km
Operating capacity One wire against remaining wires, shield grounded approx. 200
pF/m
Wire construction VDE 0881, copper litz wire 6 x 0,32 mm,  tinned = 0,56 mm²,
 of the insulated wire 1,5 mm, PVC insulated with bare shield
wire
Ambient conditions
Temperature range - heat -resistant 105° C in accordance with VDE 0209
(outer jacket)
- cold-resistant -20 °C, unrolling and laying
- -35° C storage and operation
Mechanical data
Outer jacket Mat black, made of special PVC, oil-resistant, petrol-resistant,
flame-retardant, weather-proof and UV-resistant,
external diameter approx. 8,2 mm
Winding and shielding The twisted leads are wrapped with overlapping transparent plas-
tic foil and shielded with a braid of tin-plated copper wires.

31
4.1.3 Cable assignment (order no. 660 102)

Wire colour Signal
yellow (yl) A
green (gn) B
Shield wire S
red (rd) + 24 V
blue (bu) GND (0 V)
white (wt) Reserve/ + 24 V for MV
black (bk) Reserve/GND for MV
4.2 Other control cables

In addition, the following multi-wired control cables are available:
Order no. 209 702 209 703 U 660 021 U 660 022
Technical data 10 x 0,5 mm 18 x 0,5 mm 24 x 0,5 mm 36 x 0,5 mm

shielded, shielded, shielded, shielded,
petrol-resistant petrol-resistant petrol-resistant petrol-resistant

32
4.3 Controller
4.3.1 General description
The controller is a central operating and information unit of the complete system.
The communication between the controller and other components within a system takes place
via a serial fieldbus (P-NET). The controller can be delivered in the following versions:
Controller, type 6732-10 (version with numerical keybord)
Controller Ex, type 6733-10 (like 6732-10, but approved for mounting in Ex zone 1)
Controller AN, type 6742-10 (version with alphanumerical keyboard)
Controller AN Ex, type 6743-10 (like 6742-10, but approved for mounting in Ex zone 1)
Controller type 6732-10 / 6733-10 Controller type 6742-10 / 6743-10

33

Controller Controller AN
Type 6732-10 Type 6733-10 Type 6742-10 Type 6743-10
Data processing 32-bit processor, 1MB flash-EPROM,
768 kB RAM battery-buffered (upgradable to 1MB), 2kB EEPROM on
CPU, 2x2 kB EEPROM on power-supply board, real-time clock, watch-
dog
Ambient conditions Climatic class. JSF, protection type: IP65
Operating temperature -20...+60 °C -20...+50 °C -20...+60 °C -20...+50 °C
Storage temperature -30...+85 °C
Display Graphic-capable LC display, 160 x 128 Pixel; illuminable, heatable,
field of view 96 x 77 mm, temperature-controlled contrast adjustment
Keyboard numerical alphanumerical
Interfaces P-NET (serial fieldbus interface, asynchronous, baudrate 76800 bit/s,
max. line length 1200m).
2x 1x 2x 1x
1x RS 232 1x RS 232
Electrical connection Screw terminals in controller bottom section, cable feed via PG 9
Screw terminals of the ”in-  
creased safety“ type
Ex approval,  
Ex-protection EEx em [ib] IIB T4
Nominal voltage DC 24V ± 20%
Nominal current 0,3 A 0,5 A 0,3 A 0,5 A
Fuse M 0,5 A M 0,5 A
General characteristics
Casing Robust aluminium die-cast casing, blue powder-coating; controller
holder made of bare aluminium die-cast
Dimensions 210 x 227,5 x 129,5 mm 210 x 287 x 129,5 mm
Weight 47 N (4,7 kg) 62 N (6,2 kg)
Mounting Controller holder is locked with 4 mounting screws M 8
4.3.3 Dimensions and mounting bores

Type 6732-10 and type 6733-10

34
Type 6742-10 and type 6743-10
4.3.4 Mounting instructions for controller

The controller is mounted on a controller holder with 4 screws (2).
Mount the controller holder on a mounting angle in

a way that a vertical view on the display is guaran-
teed and it can be easily read.
Mounting
1. Loosen the 4 screws (a) at the control and display element, remove them and disconnect
both flat ribbon cables.
2. Loosen the screw in the calibration switch and remove the calibration bolt (1). The calibra-
tion switch is at the lower left side of the controller casing (black turn switch next to cable
screwing).
3. Turn calibration switch by 90°, so that the screw below (in the controller) becomes visible.
4. Loosen the 4 screws (2) and then take the bottom section of the controller off the control-
ler holder.
5. Mount the controller holder in the vehicle.
6. After the controller holder has been mounted, reinsert the 4 O-rings (3) and put on the bot-
tom section of the controller.
7. Fasten the bottom section of the controller at the controller holder with the 4 screws (2).
Do not forget the Cu sealings!
8. Turn calibration switch and reinsert calibration bolt (after startup and setting of the config-
uration data have been competed).

35

36
4.3.5 Wiring
Controller type 6732-10 and type 6742-10

37
Controller type 6733-10 and type 6743-10 (A1)

38
4.3.6 Stamp position plan

39
4.4 Pulse counter A3 refitted type 6715-10

(11,12,13,14,15,16)
4.4.1 General
Calibration
Measurement chamber and pulse counter as measurement system can be calibrated in the
complete system. Data in the pulse counter relevant for calibration are protected by an electron-
ic seal.
Construction
The pulse counter type 6715 consists of a 3-phase pulse transmitter, the evaluation electronics
and the fieldbus connection unit. All components are mounted in an aluminium die-cast casing.
Device types 6715-10...16 only differ in their mechanical measurement chamber connections.
Mounting
Screw connection between pulse counter type 6715 and measurement chamber (four or eight
M6 screws within scope of delivery, depending on version).

Interface data
Fieldbus interface serial, asynchronous, baudrate 76.800 bit/s,
(P-NET) line length max. 1200 m. P-NET identification no.: 5404
Electrical data
Nominal voltage DC 24 V 20 %
Nominal performance 1,5 W
Connection internal screw terminals, cable feed via PG9
Ambient conditions
Operating temperature -20...+60 °C
Storage temperature -40 ...+85 °C
Climatic classification JWF in accordance with DIN 40040
Maximal rotation speed 5 rev./sec
Weight approx. 3,6 kg
Casing / mounting aluminium cast casing, protection type: IP65
Screw connection with measurement chamber

40
Types and dimensions
6715-11 6715-13
6715-12 6715-15
4.4.3 Wiring

41
4.4.4 Reference list

Flow rate Smallest Pulse
Measuring Cykl.
NW minimal maximal Scale value measured transmit-
unit volume
DN [l/min] [l/min] [l] quantity ter
type [l]
[l] UE type
Manufactured by Bopp & Reuter
OT 40 40 0,60 50 500 0,5 / 1 200 6715-12
OT 60.1 40 0,60 50 500 0,5 / 1 100 6715-12
OT 65 65 1,15 70 700 0,5 / 1 200 6715-12
OT 115.1 65 1,15 70 700 0,5 / 1 100 6715-12
OT 80 80 2,00 100 1000 1 200 6715-12
OT 200 80 2,00 100 1000 1 200 6715-12
Manufactured by Sening
GMVT 400 80 1,48 40 400 1 200 6715-10
GMVT 700 80 2,25 70 700 1 200 6715-10
GMVZ 400 80 0,60 40 400 1 200 6715-12
GMVZ 700 80 1,15 70 700 1 200 6715-12
GMVZ 1000 80 3,437 100 1000 1 200 6715-10
Z 1000 80 2,71 100 1000 1 200 6715-11
Manufactured by VAF / IM flow technology
J x 025 25 0,166 12 120 0,1 20
J x 040 40 0,166 25 250 0,1 20
J x 050 50 0,40 50 500 0,5 100
J x 080 80 2,94 190 1900 1 200
J x 100 100 5,28 270 2700 1 200
J x 150 150 11,89 460 4600 1 200
J x 200 200 29,19 800 8000 1 200
Manufactured by SATAM
ZC17-20 50 0,40 40 400 0,1 20 6715-13
ZC17-40 65 0,80 80 800 0,2 50 6715-13
ZC17-80 80 2,27 80 1400 0,2 50 6715-13
ZC17-80 80 2,27 80 1400 0,5 100 6715-13
ZC17-80 80 2,27 80 1400 1 200 6715-13
ZC17-110 80 3,35 60 1000 0,2 50 6715-13
ZC17-120 100 3,35 60 1000 0,5 100 6715-13
ZC17-120 100 3,35 60 1000 1 200 6715-13
ZC17-150 100 4,54 150 3000 1 200
ZC17-250 150 6,82 300 4000 1 200
Manufactured by Smith
T11 50 40 400
T20 80 2,25 83 830 1 200 6715-15
T40 100 3,437 116 1166 1 200
ST-40 50 40 400
ST-75 65 83 830
ST-42 80 166 1666
SF-60 100 250 2500
ASD-30 80 160 1600
ASF-60 100 300 3000
ASG-100 150 460 4600
G-6 150 375 3750

42

Cycl.
Measuring NW minimal minimal Flow measured transmit-
volume
unit type DN [l/min] [l/min] rate quantity ter
[l]
[l] UE type
Manufactured by Liquid Controls
M-5 40 27 270
M-7 50 45 450
M-15 80 90 900
M-25 80 110 1100
M-30 100 165 1650
M-60 100 280 2800
MS-5 40 27 270
MS-7 50 45 450
MS-15 80 90 900
MS-30 80 165 1650
Ms-75 100 330 3300
MA-4 40 20 115
MA-5 40 45 227
MA-7 50 75 380
MA-15 80 115 607
Manufactured by AVERY HARDOLL
BM-250
BM-450
BM-750

For all pulse transmitters, a seal has to be attached on the casing cover and on one of the fas-
tening screws.

43
4.5 Pulse counter A3, reequipped

4.5.1 Pulse transmitter for installation in measure-
ment chamber
The pulse transmitter of the Eltomatik type is installed directly in the measurement chamber.
The 3-channel pulse transmitter is Ex approved (PTB no. Ex-86.B.1023) and is connected to the
impulse counter interface type 6715-90.
Technical data
Auxiliary energy 5 V DC 10 % / max. 40 mA
Quantity of channels / pulses 3 x 25 pulses
Ex protection type EEx d IIB T6
Cable assignment for pulse counter interface
Signal +5 V K1 K2 K3 GND Shield

gree whit yel- grey brown shield
Colour n e low (gy) (bn)
(gn) (wt) (yl)
Terminals for pulse
11 12 14 16 17 18
transmitter I
Terminals for pulse
19 20 22 24 25 26
transmitter II
Dimensions

44
4.5.2 Pulse counter interface, type 6715-90
4.5.2.1 General description

Calibration
Measurement chamber, pulse transmitter and pulse counter interface as a measurement sys-
tem can be calibrated as a complete system. Data in the pulse counter interface relevant for cal-
ibration is protected by an electronic seal.
Construction
The pulse counter interface type 6716-90 consists of an evaluation electronics and the fieldbus
connection unit. All components are mounted in an aluminium die-cast casing.
4.5.2.2 Technical data

Interface data
Fieldbus interface serial, asynchronus, baudrate 76.800 bit/s,
(P-NET) line length max. 1200 m. P-NET identification no.: 5404
Electrical data
Connection Internal screw terminals, cable feed via PG9
Ambient conditions
Climatic classification JWF in accordance with DIN 40040
Pulses/sec. 500
Casing Aluminium cast casing, protection type: IP65
4.5.2.3 Wiring/dimensions/stamp position plan

45
4.6 Pulse counter A1, refitted Ex type 6716-10

(11,12,13,15,16)
4.6.1 General
Calibration
Measurement chamber, pulse transmitter and pulse counter interface as measurement system
can be calibrated in the complete system. Data in the pulse counter interface relevant for cali-
bration is protected by an electronic seal.
Construction
The pulse counter type 6716 consists of a 3-phase pulse transmitter, the evaluation electronics
and the fieldbus connection unit. All components are mounted in an aluminium diecast casing.
Device types 6716-10...16 only differ in their mechanical measurement chamber connections.
The casing has an explicit and inerasable laser identification marking.
Mounting
Screw connection between pulse counter type 6716 and measurement chamber (four or eight M
6 screws within scope of delivery, depending on version).

Interface data
TTL interface Signals TxD, RxD, PNET-ON
(P-NET protocol) P-NET identification no. 5404
Electrical data
Connection 2m connection cable, internal screw terminals, shielded, five-wire,
cable feed via PG7; with open ends for connection to distributor box
6789-10
Ambient conditions
Climatic classification JWF in accordance with DIN 40040,
Ex protection type EEx ib IIB T4
Maximal rotation speed 5 U/sec
Casing/mounting Aluminium cast casing, protection type: IP65
Screwing with measurement chamber

46
Types and dimensions
6716-11 6716-13
6716-12 6716-15

47
4.6.3 Reference list

Cycl. Scale
Measuring NW minimal maximal measured transmit-
volume value
unit type DN [l/min] [l/min] quantity ter
[l] [l]
[l] UE type
Manufactured by Bopp & Reuter
OT 40 40 0,60 50 500 0,5 / 1 200 6716-12
OT 60.1 40 0,60 50 500 0,5 / 1 100 6716-12
OT 65 65 1,15 70 700 0,5 / 1 200 6716-12
OT 115.1 65 1,15 70 700 0,5 / 1 100 6716-12
OT 80 80 2,00 100 1000 1 200 6716-12
OT 200 80 2,00 100 1000 1 200 6716-12
Manufactured by Sening
GMVT 400 80 1,48 40 400 1 200 6716-10
GMVT 700 80 2,25 70 700 1 200 6716-10
GMVZ 400 80 0,60 40 400 1 200 6716-12
GMVZ 700 80 1,15 70 700 1 200 6716-12
GMVZ 1000 80 3,437 100 1000 1 200 6716-10
Z 1000 80 2,71 100 1000 1 200 6716-11
Manufactured by VAF/IM flow technology
J x 025 25 0,166 12 120 0,1 20
J x 040 40 0,166 25 250 0,1 20
J x 050 50 0,40 50 500 0,5 100
J x 080 80 2,94 190 1900 1 200
J x 100 100 5,28 270 2700 1 200
J x 150 150 11,89 460 4600 1 200
J x 200 200 29,19 800 8000 1 200
Manufactured by SATAM
ZC17-20 50 0,40 40 400 0,1 20 6716-13
ZC17-40 65 0,80 80 800 0,2 50 6716-13
ZC17-80 80 2,27 80 1400 0,2 50 6716-13
ZC17-80 80 2,27 80 1400 0,5 100 6716-13
ZC17-80 80 2,27 80 1400 1 200 6716-13
ZC17-110 80 3,35 60 1000 0,2 50 6716-13
ZC17-120 100 3,35 60 1000 0,5 100 6716-13
ZC17-120 100 3,35 60 1000 1 200 6716-13
ZC17-150 100 4,54 150 3000 1 200
ZC17-250 150 6,82 300 4000 1 200
Manufactured by Smith
T11 50 40 400
T20 80 2,25 83 830 1 200 6716-15
T40 100 3,437 116 1166 1 200
ST-40 50 40 400
ST-75 65 83 830
ST-42 80 166 1666
SF-60 100 250 2500
ASD-30 80 160 1600
ASF-60 100 300 3000
ASG-100 150 460 4600
G-6 150 375 3750

48

Cycl.
Measuring NW minimal minimal Flow measured transmit-
volume
unit type DN [l/min] [l/min] rate quantity ter
[l]
[l] UE type
Fabrikat Liquid Controls
M-5 40 27 270
M-7 50 45 450
M-15 80 90 900
M-25 80 110 1100
M-30 100 165 1650
M-60 100 280 2800
MS-5 40 27 270
MS-7 50 45 450
MS-15 80 90 900
MS-30 80 165 1650
Ms-75 100 330 3300
MA-4 40 20 115
MA-5 40 45 227
MA-7 50 75 380
MA-15 80 115 607
Manufactured by AVERY HARDOLL
BM-250
BM-450
BM-750

For all pulse transmitters, a seal has to be attached on the casing cover and on one of the fas-
tening screws.

49
4.7 Pulse counter A1, reequipped

4.7.1 Pulse transmitter for installation in measure-
ment chamber
The pulse transmitter of the Eltomatik type is mounted directly into the measurement chamber.
The 3-channel pulse transmitter is Ex-approved (PTB no. Ex-86.B.1023) and is Ex-connected to
the pulse counter interface type 6716-90.
Technical data
Auxiliary energy 5 V DC 10 % / max. 40 mA
Electrical connection 5 m connection cable, shielded, five-wire, with open ends for
connection to the pulse counter interface type 6716-90 Ex
Quantity of channels x 3 x 25 or 3 x 100 pulses
pulses
Ex protection type EEx d IIB T6
Cable assignment for pulse counter interface

Colour green white yellow grey brown shield
(gn) (wt) (yl) (gy) (bn)
Dimensions

50
4.8 Pulse counter interface, type 6716-90 Ex

4.8.1 General
Calibration
Measurement chamber, pulse transmitter and pulse counter interface can be calibrated as a
complete system. Data in the pulse counter interface relevant for calibration is protected by an
electronic seal.
Construction
The pulse counter interface type 6716-90 Ex consists of an evaluation electronics and the
fieldbus connection unit. All components are mounted in an aluminium die-cast casing.
Mounting
Screw connection between pulse counter type 6716 and measurement chamber (four or eight
M6 screws within scope of delivery, depending on version).

Interface data
TTL interface Signals TxD, RxD, PNET-ON
(P-NET protocol) P-NET identification no.: 5404
Electrical data
Ambient conditions
Climatic classification JWF in accordance with DIN 40040,
Protection type IP65
Tem- 4.9
per ra-
ture sensor A3,

51
type 6701-20/-21
4.9.1 General
Mounting
For installation, the temperature sensor type 6701-20 is equipped with a screw-in thread where-
as type 6701-21 is equipped with a union nut. The version equipped with a union nut makes
possible a disassembly without cable twisting, even if the cable is connected.
Electrical connection
The port for P-NET input/output and for operating voltage is in the cover of the casing. To open
the sensor, you have to loosen the three hexagon socket head screws at the cover of the cas-
ing.

Measure- Measuring element Pt100 in accordance with DIN IEC 751 class
ment system B
Measurement range -100 ... +100 °C
Resolution nominal 0,1 °C for 10 measurement cycles
per sec.
Measurement error < 0,2 °C within measurement range
Response time t90 < 5 sec
Temperature influence on sys- < 0,1 °C within complete measurement
tem range
Influence of auxiliary energy < 10 ppm/V
Interface Fieldbus interface P-NET, serial, asynchronous
Baudrate 76800 bit/s
Line length max. 1200 m
P-NET identification no. 5402
Ambient Working temperature -20...+60 °C
conditions Storage temperature -40...+85 °C
Climatic classification JSF in accordance with DIN 40040
Electrical Auxiliary energy DC 24 V  20 % / 0,75 W
data Connection Cable feed via PG9, internal screw termi-
nals.
General Casing robust aluminium casing, blue powder-
characteris- coating
tics Protection type IP65
Measuring tip Stainless steel
Mounting 6701-20 Mounting with screw-in thread G1/2"
or G3/4"
Dimensions:  83 mm, l = 196 mm
Any mounting position

52
6701-21 Mounting with union nut G1/2" oder G3/4"

Dimensions:  83 mm, l = 190,5 mm
Type 6701-21
Temperature sensor with union nut G3/4“

Installation length L = 100

53
4.9.3 Installation instructions
4.9.3.1 Temperature sensor with union nut
Insert test sensor here and embed it in

heat-conducting paste. After the test
measurement close immersion shell P
again,
Seal
Caution!
Use only zone 1 devices for check measurements at A1 systems!

Do not use Hg thermometers (high inertia)!

54
4.9.4 Temperature sensor with screw-in thread

Recommended installation depth:
Sensor: T =d/3, d/2 (mm)
D is the clear width of the pipe
Test hole: t = T-10 to T-15 (mm), but at least

25 … 30 mm
Distance between sensor and test hole: approx.

50 … 80 mm
Attention: Install immersion shell vertically (heat-

conducting oil)!
Insert test sensor here and embed it in heat-

conducting paste. After the test measurement
close immersion shell P again.
Seal
Caution!
Use only zone 1 devices for check measurements at A1 systems!
Do not use Hg thermometers (high inertia)!

55
4.9.5 Wiring

56
4.10 Temperature sensor A1 Ex, type 6702-20/-21
4.10.1 General
Mounting
For installation, the temperature sensor type 6702-20 is equipped with a screw-in thread where-
as type 6702-21 is equipped with a union nut. The version equipped with a union nut makes
possible disassembly without cable twisting, even after the cable has been connected. The as-
sociated adapter included in the delivery scope generates the required flame-arresting gap and
must not be removed.
The port for P-NET input / output and for the operating voltage is in the cover of the casing. To
open the sensor, you have to loosen the three hexagon socket head screws at the cover of the
casing.
(Observe installation instructions under 4.9.3)

57

Measurement system Measuring element Pt100 in accordance with DIN IEC 751 class B
Measurement range -20 ... +60 °C
Resolution nominal 0,1 °C for 10 measurement cycles
per sec.
Measurement error < 0,2 °C within measurement range
Response time t90 < 5 sec
Temperature influence on system < 0,1 °C within complete measurement range
Influence of auxiliary energy < 10 ppm/V
Interface TTL interface (P-NET protocol) Signals: TxD, RxD, PNET-ON
Ambient conditions Working temperature -20...+60 °C
Climatic classification JSF nach DIN 40040
Electrical data Auxiliary energy: DC 7 V  120 % / 0,75 W
Connection Internally clamped 2-m-cable, five-wire, shield-
ed, with open ends for connection to distributor
box 6789-10
General characteristics Casing Robust aluminium casing, blue powder-coating
Mounting 6701-20 Mounting with screw-in thread G1/2" or G3/4"
6701-21 Mounting with screw-in thread G1/2" or G3/4"

58
4.10.3 Wiring
Type 6702-20
Temperature sensor Ex with screw-in thread G1/2" and G3/4,
installation length L = 100 mm
Temperature sensor Ex with screw-in thread G3/4",
Type 6702-21
Temperature sensor with union nut and adapter G1/2",
Temperature sensor with union nut and adapter G3/4",

59
Connection example

60
4.11 P-NET distributor box Ex, type 6789-10

Connections of the ”in- Auxiliary energy DC 24 V / 0,2 A
creased safety“ type P-NET port Serial, RS485, asynchronous
Baudrate: 76800 bit/s.
Line length: 1200 m
Intrinsically safe sensor Connections 1 - 4
connections Signals TxD, RxD, PNET-ON
(P-NET protocol),
Auxiliary energy DC 7 V / 60 mA, protected indi-
vidually with fuse block
Ambient conditions Working temperature -20...+60 C
Storage temperature -40...+85 C
Climatic classification JUF in accordance with DIN
40040
Casing Material Aluminium die-cast
Dimensions 260 x 160 x 90 (mm)
Weight 2,85 kg
Ex protection type EEx e m [ib] IIB T4
Electrical connection Sensor connections to internal connector, screw terminal connec-
tion, feed via 4 x intrinsically safe PG9, connection of P-NET and
DC 24 V to screw terminals of the ”increased safety“ type,
feed via 2 x PG9
Mounting Four mounting bores in the casing
for mounting with M6 cylinder screws

61
4.11.2 Wiring

62
4.12 Output interface Ex, type 6752-10

Supply voltage for electronics DC 24 V / 0,15 A (tolerance range: 16 ... 36 V)
Supply voltage for loads Depends on load supply principle
Quantity of outputs/inputs 4 or 8, short-circuit-proof
Switching capacity per output DC 24 V / 0,35 A
Cable feed 2 x PG9, 9 x PG7
2
Max. line cross-section 1,5 mm
Admissible ambient temperature -20...+50 °C
Climatic classification JWD in accordance with DIN 40040
Ex protection type EEx e m [ib] IIB T4
Casing Aluminium die-cast
Protection type IP 65 in accordance with DIN 40050
Weight 3 kg
Switching principle ("high side")
Control wire
Burden Burden Burden

63
Dimensions and mounting bores
4.12.2 Wiring

64
4.13 Measurement system interface

4.13.1 Measurement system interface, type 6718-xx
(Ex) and type 6717-xx (A3)
For the technical data, see the respective type-related data sheets.
3-channel pulse transmitter, made by BARTEC BENKE

65
Wiring of types 6718-10/-20 (Ex) and 6717-10/-20 (A3) for series “none and A”
Wiring of types 6718-10/-20 (Ex) and 6717-10/-20 (A3) for series B and higher

66
2-channel pulse transmitter with status symbol, type Endress + Hauser, Promass 64
(Ex-e)
Wiring of type 6718-20, P017, series B and higher
Caution!
 Due to the Ex-e version of Promass-64, the measurement system interface can only be in-
stalled and used within the A3 range.
 As a temperature sensor, use type 6702-31.
 Basic configuration of Promass 64: PASSIVE – NEGATIVE.
 Promass requires a separate voltage of 24 V.
2-channel pulse transmitter, type Faure Herman turbine counter, transmitter type FH 71.N
(Namur)
Wiring of type 6718-22, P018, for series B and higher (series 0 and A not possible)
For a temperature sensor, use type 6702-31!

67

68
2-channel pulse transmitter, type Sening THS-J-SG2AL
Wiring of types 6718-12/-22 (Ex) and 6717-12/-22 (A3) Series: none or A

(A no. smaller than 9911xxxx)
Caution!
 Measurement system interface type 6718-x2 (Ex) may only be installed in zone 2.
 As a temperature sensor, use type 6702-31.
Wiring of types 6718-12 (Ex) and 6717-12/-22 (A3) for series B and higher (A no. 9911xxxx and
higher)

69

70
2-channel pulse transmitter, type Daniel turbine counter, transmitter type PC/N 13-74X
(Namur)
Wiring of type 6718-11, for series B and higher

71
2-channel pulse transmitter, type mass flowmeter Micro Motion RFT 9739 FM transmitter
(double pulse output)
Wiring of types 6718-10, P0 16, series B and higher

72
4.14 Temperature sensor Ex G1/2“, type 6702-31

Mechanical data
Mounting/casing Installation with screw-in thread G 1/2"
Operating temperature of connection line - 30 °C... + 60 °C
Installation length 75 mm
Installation position Any
Weight Approx. 6 N (= 0,6 kg)
Ambient conditions
Operating temperature of connecting head - 40 °C ... + 60 °C
Operating temperature of connecting line - 30 °C ... + 60 °C
Protection type IP 65 in accordance with EN 60529
Device group/category Ex protection type II 1/2 G Ex ib IIC T6 Ga/Gb
SEV 13 ATEX 0197
Certificates
IECEx SEV 13.0010
EN 60079-0, EN 60079-11, EN 60079-26
Norms
IEC 60079-0, IEC 60079-11, IEC 60079-26
Electrical data
Cable connection 5 m cable, four-wire, shielded, with open ends for
connection to evaluation electronics.
Device-specific data
Measuring element Pt 100 in accordance with DIN IEC 751, class B
Measurement range - 30 °C ... + 100 °C

73
Response time t90 < 15 s

Calibration points 0 °C and 50 °C

74
CAUTION!
 It is imperative to comply with the installation instructions described in 4.9.3!
 Use the calibration values on the rear side of the Ex plate for configuration!
4.14.2 Cable assignment for measurement system in-

terface
Colour orange black red brown yellow-
(or) (bk) (rd) (bn) green
(ylgn)
Signal I_OUT_ N+ N- GND shield
Terminals for temperature sen- 1 2 3 4 5
sor I
Terminals for temperature sen- 6 7 8 9 10
sor II
4.14.3 Accessories
Adapter type WT 892

Ordering no. 05005665

75
4.15 Pulse transmitter Ex, type 671x-5x
Pulse transmitter Ex, type 6716-59

The incremental position encoder supplies 100 or 25 pulses / revolution in the shape of 3
square wave signals displaced by 120°
Electrical characteristics Voltage supply 5 V  10 %
Power consumption max. 25 mA
Output: open collector,
max. load 30 V/15 mA per channel,
max. low output VL = 0,4 V
4.15.2 Cable assignment for measurement system in-

terface
Colour green white yellow grey brown shield
(gn) (wt) (yl) (gy) (bn)
Terminals for pulse transmitter 11 12 14 16 17 18
I
Terminals for pulse transmitter 19 20 22 24 25 26
II

76
4.16 I/O box VARIO 1, type 6753-10

Inputs 8 digital inputs
UEin 0...24 V
Signal = 0 < DC +5 V
Signal = 1 > DC +14 V (green LED on)
Input resistance 4 k
Outputs 8 wear-free semiconductor outputs, output type FET, positive-
switching
Potential separation of logic and outputs via optocoupler
max. current per output at sig- 2 A (-20...35 °C),
nal 1  1,5 A (up to +45 °C),
 1 A (up to +60 °C)
Total load capacity 8 A (-20...+60 °C
Limitation of inductive interrupting voltage with free-wheeling diode
Supply voltage US DC 24 V (18...36 V)
Switching frequency of ohmic 100 Hz
load
Switching frequency of induc- 2 Hz
tive load
max. output level for signal = 0 DC 2 V (without load)
Interface Fieldbus interface (P-NET), serial, asynchronous
Baudrate 76800 bit/s
Line length max. 1200 m
Auxiliary energy UL DC 24 V / 85 mA
Connection P-NET and UL Internal screw terminals 5-pole
IN/OUT for basic and extension 10-pole, plugged
modules
2
Connecting lines up to 1,5 mm
Cable feeds PG 9
Ambient conditions Admissible working tempera- -20...+60 °C
ture
Admissible storage temperature -25...+80 °C
Climatic class IUF in accordance with DIN
40040
Construction/ mounting Casing dimensions 160 x 260 x 90 mm
Weight 2,01 kg
Basic module dimensions 155 x 85 x 58 mm
Weight 0,4 kg
4 fixing lugs with oblong hole for screwing with M6 screws

77
4.16.2 Wiring and mounting
4.16.3 Terminal wiring

Input Output
0V US 0 V = GND
US = +24V
0V
0 1 2 3 4 5 6
US + 7
Consumer
+ (e.g. magnetic valve)
Terminal strip busbar +24 V Terminal strip busbar 0 V
LEDs
Input Inputs active green

UL 24 V
busy blinking
P-NET blinking during communication with controller
Output 0V red for short-circuit
US green 24V
Outputs active orange

78
4.16.4 Wiring example

79
4.16.5 Extension modules
4.16.5.1 Technical data
Input extension module Output extension module,

6753-103 2,0 A 6753-105
Dimensions 55 x 85 x 58 mm (W x H x D)
Power consumption (logic) 0,1 W 0,2 W
Weight 0,12 kg 0,15 kg
Max. load 2,0 A per output / total: 8 A
4.17 Output relay modules

80

Output relay module Output relay module
6753-106 6753-107
Electrical connection bu  0 V on-board power supply; bn, rd, gn  output
Connecting lines 30 cm
Max. switching voltage (relay) AC 50 V
Dimensions (W x H x D) 55 x 74 x 65 mm 35 x 74 x 65 mm
Weight 150 g 75 g
Version 1x 6,3 A / 3x 2,0 A 1x 6,3 A / 1x 2,0 A
4.18 Voucher printer, type 6881-1

Electrical data
Auxiliary energy DC 24 V  10 %
In standby mode approx. 100 mA, in printing mode approx. 800 mA,
max. 1,5 A
Connection type Terminal connection, cable feed via cable screwing PG9 in the printer
holder
Interface Fieldbus P-NET, P-NET identication no. = 5812
Ambient conditions
Operating temperature 5 ... 40°C
Storage temperature -10 ... + 50°C (without paper and ink ribbon)
Climatic classifica- KYF / IP40
tion/protection type
Mechanical data
Casing Voucher printer = plastic casing, grey
Printer holder = aluminium sheet, 3 mm
Weight Approx. 20 N  2,0 kg including printer holder
Mounting site Only in dry and clean surroundings by complying with the admissible
operating temperature and climatic classification. Preferably in the
driver´s cab.
Mounting position Preferably horizontal (vertical position with cable connection upwards is
also possible)
Software address
System 3001 Address $11
System 3002 Address $41
NOTE
For system 3002, the internal address of the printer is not identical with the address of the pre-
vious system 3001. If the printer was used in system 3002, it can only be used in system 3001
(old) after the internal address has been manually reprogrammed.

81
4.18.2 Mounting and dimensions
4.18.3 Wiring
P-NET
+ 24 V supply voltage
Signal Wire colour

A yl
B gn
S bn
+ red
- blue

82
4.18.4 Operating voltage limitation, type 6881-1-1-044

For operation of printer type 6881-1 at on-board power supply

83
4.18.5 Change the ink ribbon

Loosen the screw (6) and take off the cover (1). Hold the old ribbon cassette (3) at the handle
and pull it off. Insert the new ink ribbon cassette and press it in firmly until it snaps into place.
Finally, tension the ribbon by turning the button (3b) and put the cover (1) back on.

84
4.19 Voucher printer, type 6881-3x

With printer holder, type 6881-100/-101

Electrical data
Auxiliary energy DC 24 V  10 %, max. 1,0 A
Connection type Terminal connection, cable feed via cable screwing PG9 in the
printer holder
Interface Fieldbus P-NET, P-NET identification no. = 5812
Ambient conditions
Operating temperature 5° C ... 40°C
Storage temperature -10° C ... + 50°C (without paper and ink ribbon)
Climatic classification / protection KYF / IP40
type
Mechanical data
Casing Terminal connection, cable feed via cable screwing PG9 in the
printer holder
Weight approx. 20 N  2,0 kg including printer holder
Mounting site Only in dry and clean surroundings by complying with the ad-
missible operating temperature and climatic classification.
Preferably in the driver´s cab.
Mounting position Preferably horizontal (vertical position with cable connection
upwards is also possible)
Important NOTE:
To log on the printer in the system configuration, you need to use the serial number ( ”A“ no.) of
the printer holder. You find this number on the type plate of the printer holder, type 6881-100

85
4.19.3 Wiring of printer holder, type 6881-100/-101
After having mounted the printer, connect and lock the RS 232 interface cable and power sup-
ply cable of the printer holder.
4.19.4 Dip-switch setting

86
4.19.5 Change the ink ribbon

Loosen the screw (6) and take off the cover (1). Hold the old ink ribbon cassette (3) at the han-
dle and pull it off. Insert the new ink ribbon cassette and press it in firmly until it snaps into
place. Finally, tension the ink ribbon by turning the button (3b) and put the cover (1) back on.

87
4.20 Form printer, type 6863-5

Auxiliary energy DC 24 V 10 %, max. 1,8 A, ripple 150 mV eff.
Admissible working temperature + 5 ... + 35 C
Admissible storage temperature 30 ... + 60 C
Admissible air humidity max. 80 % (without condensation)
Climatic classification LYF in accordance with DIN 40040
Casing Desktop casing 434 x 151 x 368 mm (W x H x D)
Connection 9-pole Submin-D plug (P-NET), 2-pole plug
(DC 24 V DC), *) 1,5 m power cable (DC 230 / 115 V).
*) For order no. 530 17 68635, the connection cable (0,8 m) is included in the delivery scope
For further technical data, see printer manual.
Remove the transport braces of the printer before putting it into operation (see printer manual).
For information on inserting and removing the ink ribbon, see printer manual.
Remove the transport braces of the printer before putting it into operation (see printer manual).
For information on inserting and removing the ink ribbon, see printer manual.
SW 1 ON SW 2 ON
1 8 1 4
4.20.2 DIP switch settings

Default setting LQ-570 (up to 11.93):
Default setting LQ-570+ (11.93 and higher, serial number 002xxx - EDG):
SW 1 ON SW 2 ON
1 8 1 4
For further details on the DIP switch setting, see printer manual "LQ-570+".
Software address
The internal address of the printer in system 3002 is not identical to the address of the previous
system 3001. If the printer was applied in system 3002, it can only be used in system 3001 after
the internal address has been manually reprogrammed.
System 3001 3002

88
Address $ 12 $ 42
4.20.3 Installation and electrical connection for printer

6863-5 and 6863-6
Choose printer location protected against direct solar radiation, excessive heat, humidity and
dust.
Please also observe the safety precautions in the printer manual.

89

Mechanical data
Connection 9-pol. Submin-D plug (P-NET), 2-pole plug (DC 24 V)
1,5 m mains cable (for AC 220)
Weight approx. 67 N (= 6,7 kg)
Electrical data
Print method 24-needle dot-matrix printing
Print image Alphanumerical and graphic character set with 14 international character sets,
1 italic and 5 graphic character maps.
Fonts Draft, Courier, Roman, Sans Serif, Prestige, Script, Script C, Orator, Orator S.
Font widths 10 cpi (80 characters / line),
12 cpi (96 characters / line),
0 cpi narrow (137 characters / line),
12 cpi narrow (160 characters / line).
Font sizes 8/10/12/14/16 etc. up to 32 didot points for Roman and Sans Serif.
Line spacing 1/6" or programmable (in steps of 1/360")
Print direction Bidirectional print path optimisation for text and graphic (for graphic also unidi-
rectional).
Print speed Print quality Font width Characters/sec./line
Darft 10 cpi 225
12 cpi 269
Letter Quality 10 cpi 75
12 cpi 90
Print paper Single sheet paper: 148 ... 257 mm wide (feed from top) or
182 ... 257 mm (feed from front).
Print width max. 203 mm.
Endless paper 101 ... 254 mm breit, print width max. 203 mm.

90
Paper weight 52 ... 82 g/m² (single sheet) or 40 ... 58 g/m² (multiple form)
Copies Max. 3 copies
6
Ink ribbon Ink ribbon cassette black, no. 7753, max. durability 2 x 10 characters
P-NET port Serial fieldbus interface, P-NET (RS 485), 76.800 bit/s,
line length max. 1200 m, galvanically separated.
Auxiliary energy DC 24 V ±10 %, max. 1,8 A, ripple 150 mV eff.
or AC 220/240 V ±10 %, 50 - 60 Hz, max. 43 VA
Ambient conditions
Operating temperature 0 ... 50 °C
Storage temperature - 20 ... 60 °C
Protection type IP 30
Climatic class KWF in accordance with DIN 40040

91

Electrical data
Print method 24-needle dot-matrix printing
Print image Alphanumerical and graphic character set with 14 international
character sets, 1 italic and 5 graphic character maps
Fonts Draft, Courier, Roman, Sans Serif, Prestige, Script, Script C, Ora-
tor, Orator S, OCR-B
Font widths 10 cpi (80 characters / line),
10 cpi narrow (137 characters / line),
12 cpi narrow (160 characters / line).
Font sizes 8/10/12/14/16 etc. up to 32-dot for Roman and Sans Serif.
Line spacing 1/6" or programmable (in steps of 1/360")
Print direction Bidirectional print path optimization for text and graphic (for graphic
also unidirectional).
Print speed Print quality Font width Characters/sec./line
Draft 10 cpi 330
12 cpi 396
Letter Quality 10 cpi 110
12 cpi 132
Print paper Single sheet paper: 100 ... 257 mm wide (paper feed from top)
or
100 ... 257 mm (paper feed from front).
Print width max. 203 mm.
Endless paper 100 ... 257 mm wide, print width max. 203 mm.
Paper weight 52 ... 90 g/m² (single sheet) or 40 ... 58 g/m² (multiple form)
Copies max. 3 copies
Ink ribbon Ink ribbon cassette black, no. C13S015337
6
Max. durability 4 x 10 characters
P-NET port Serial fieldbus interface, P-NET (RS 485), 76.800 bit/s,
line length max. 1200 m, galvanically separated.
Auxiliary energy DC 11 … 36 V, max. 7A (on-board power supply),
IStandby = 0,2 A, INominal = 3,0 A
Ambient conditions
Operating temperature 0 ... 50 °C
Storage temperature - 20 ... 60 °C

92
Protection type IP 30
Climatic classification KWF in accordance with DIN 40040
Mechanical data
Connection 9-pol. Submin-D plug (P-NET), 2-pole plug (DC 24 V)

93
4.22.2 Installation and electrical connection for printer

type 6763-7
Choose printer location protected against direct solar radiation, excessive heat, humidity and
dust.
Please also observe the safety instructions in the printer manual.
CAUTION!
Voltage supply for printer type 6863-7
Do not apply the wire jumpers between ”KL3“ (INT+/-) and ”KL2“ in the printer holder type 6863-
7-01, which are compulsory for printers of the type 6863-5 and of the type 6863-6 as described
under 4.21.3.
For printer type 6863-7, voltage has to be supplied directly via on-board power supply (on-board
power supply +/-24 V at terminal „KL2+/-“).
Carry on connecting the control voltage and P-NET of the ballast to the terminals “KL4“ and
„KL5“ of the printer holder type 6863-7-01.

94
4.23 Form printer, 24 V, type 6863-20

Device-specific data
Print image Alphanumerical and graphic font with 19
international fonts
Fonts Roman, Sans Serif, Courier, Bold, Prestige, Script, Orator,
Gothic, OCR-A, OCR-B; Barcodes: UPC/A, UPS/E, EAN8,
EAN13, Code 39, Code 128, Interleaved 2/5, Industrial 2/5
Resolution 180 x 120 dpi (Draft), 180 x 360 dpi (LQ)
Font width 10 cpi (80 characters/lines)
12 cpi (96 characters/lines)
17.1 cpi (136 characters/lines)
(depending on used emulation)
Line density 3, 4, 5, 6, 8 lines/inch
Print head 24 needle; durability: 250 mio. characters
Space 64 kB
Printer Language Standard IBM 2390+ (inclusive ProPrinter XL24E), Epson ESC/P2,
Intermec 6820
Printing procedure Serial dot matrix printer
Print speed At10 cpi: 400 character/second (Draft);
at 12 cpi: 480 character/second (Draft);
at 10 cpi: 133 character/second (Letter)
Printing paper Normal paper and form sets
Paper width: 102 - 267 mm
Paper length: > 102 mm (continuous paper);
76 - 364 mm (single sheet)
Print width: max. 216 mm
Number of copies: 1 original + 3 copies
Paper weight 47 … 81 g/m² (single sheet); 40 … 64 g/m² (multiple form)
Paper source standard Push tractor for continuous forms, friction for single sheet
feeder, automatic feeder for the trailing edge, park position
Ink ribbon Ink ribbon cassette, 4 millions characters
Interfaces Serial interface (RS 232), USB 2.0 (Full Mode)
Optional interface Bluetooth (version 1.2), W-LAN
(IEEE 802.11b/g)

95
Electrical data
Input voltage 10,5 - 28 V DC, max. 10 A; Connection for wiring;
or
AC adapter 100 - 240 V ± 10 %; 47-63 Hz; 3,2 A
Power consumption Power Off Mode: 0,3 W
Sleep Mode: 2,0 W
Standby: 7,0 W
Printing: max. 150 W
Printer Drivers Windows 2000, XP (ESC/P2)
Ambient conditions
Operating temperature -20° C … +60 °C
Storage temperature -30° C … +65 °C
Climatic class JUF according to DIN 40040
Mechanical data
Dimensions 140 x 365 x 320 mm
4.23.2 Printer mounting type 6962-100

96
4.23.3 Dimensions printer mounting type 6962-100
4.23.4 Connection printer mounting type 6962-100

97
4.24 SSM cartridge station, type 6766-12
Application
The SSM cartridge station type 6766-12 is designed as an external data storage unit in system
3002.
Due to its robust design, it can be operated in tank trucks.
Moreover, the application in the office in order to record target data and to read out data ac-
quired during the tour can easily be realised by means of a connection to the RS-232 interface
of a PC.
The PC software available for that purpose can be operated on all Windows platforms (Win-
dows 95 and higher).
Moreover, the SSM cartridge station can be applied anywhere where the above-mentioned
SSM cartridges are available as data carriers and P-NET is available as fieldbus.
Function
For storage, one SSM cartridge has to be inserted in the front-side cartridge shaft. It is also very
easy to remove and replace the cartridges.
Three light-emitting diodes at the front side next to the SSM cartridge shaft signalise operating
states and errors:
LED RED: Error of a general kind

- No SSM cartridge in the shaft
- SSM cartridge defective
- Battery voltage in SSM cartridges too low
LED YELLOW In the case of an access to the SSM cartridge
LED GREEN: LED blinks - normal operation

LED does not blink - SSM cartridge station does not work any more.
For troubleshooting, turn operating voltage of SSM cartridge station
off for a short time.

98
Version
Module can only be operated in combination with a connecting kit!
Connection of P-NET fieldbus and operating voltage via screw terminals at the interior of the
rear side. It is possible to replace the electronics after removing the cover.
SSM cartridges
SSM cartridges are replaceable, integrated, non-volatile mass storage media. They contain bat-
tery-buffered SRAMs as memory components and are available at different capacity grades of
up to 4 MByte.
SSM cartridge station - tank truck version, dimensions SSM cartridge station - office Ver-
sion
Tank truck version, mounting with console fixing device Tank truck version, mounting

99
4.24.1 Wiring

Interfaces Fieldbus interface (P-NET): serial, asynchronous
Baudrate: 76 800 bit/s
Max. line length: 1 200 m
P-NET identification no.: 5917
RS-232 interface
Baudrate: 115 200 bit/s
Max. line length: 3 m
No HW handshake
General characteristics Weight: approx. 13 N (= 1,3 kg)
Dimensions: 137 x 80 x 148 mm
Casing: robust sheet steel casing, black-grey powder
coating
Front cover: plastic, blue
Ambient conditions Operating temperature: - 25 ... + 60 °C
Storage temperature: - 30 ... + 75 °C
Climatic classification: HUF 2
Protection type: IP 30
Mounting Tank truck version: with mounting plate
Locking with 4 x M5 hexagon socket head screws or
with 4 x 4 blind rivets
Office version: rubber feet (drawing)
SSM cartridges Type: 6766-10
Dimensions: 24,5 x 74 x 106 mm
Weight: approx. 2 N (= 0,2 kg)
Memory capacity: 128, 256, 512, 768 Kbyte 1 Mbyte,
2 Mbyte, 4 Mbyte
Memory: Batteriy-buffered SRAMs, integrated

100
4.25 Ballast, type 6781-12/24-V module

Performance data Input Uin = 12 ... 24 V
Output Uin = 12 … 24 V -> Uout = 24 V ±5 %*
Output current: max: 1,25 A,
Uin = 25 … 35 V -> Uout = Uin - 1 V*
Output current: max. 8 A*
Separate output with voltage Uin = 16...26 V -> Uout = Uin –2 V
limitation Uin = 27...35 V -> Uout = 24 V ±5 %
Overvoltage switch-off at Uin > DC 34 V * (see diagram 2)
Output current max. 8 A * (for overheat protection
see diagram 1)
Pulse load max. 16 A/10ms
Fuses 2 output fuses: each with 4A common earth return cables: 8 A
Ambient conditions Admissible working temper- -20 ... +70 C
ature
Climatic class JSD in accordance with DIN 40040
Casing Material Aluminium die-cast
Mounting bores 4 bores  7 mm für M6, horizontal distance 140 mm,
vertical distance 180 mm
Connection Cable feed 6 x PG9
2
Line cross-section max. 1,5 mm
* under nominal conditions 22 ±2° C
4.25.2 Mounting

101
4.25.3 Wiring

102
4.26 Cable combination for semi-trailer Ex, type

6789-50
4.26.1 Task
This cable combination serves to interconnect the electronic components installed on the tractor
and on the semitrailer. Two times three lines for the P-NET ring, two lines for the 24 V supply
voltage and two free spare lines are available.

Voltage DC 24 V / 4 A
Ex protection type EEx e II T4
Admissible ambient tempera- + 20 ... + 50° C
ture
Climatic class JWD in accordance with DIN 40040
P-NET ring-shaped wiring
Plug-in connection 10-pole (2x3 lines for P-NET, 2 x 24 V supply volt-
age, 2 free spare lines
Line cross-section 1,5 mm²

103
4.26.3 Dimensions
Terminal box, type 6789-300
Spiral connection cable

104
4.26.4 Mounting and wiring

For the volume measurement (TMU), the devices are not connected via a P-NET ring but with a
branch line, i.e. a connection from the last device to the first device is not required (see chapter
3, block diagrams).
In the terminal box type 6789-300, only the P-NET branch line (KL 14) has to be connected (A,
B, S, +24 V, GND).
KL8 is intended for the voltage supply for the magnetic valves.
Cable assignment
Spiral cable Connecting cable Connection cable

(white wires with numbers) (coloured wires) Signal
Cable Plug Cable Socket Cable Socket
Adr 1 PIN 1 Adr 1 PIN 1 gy 1 A
Adr 2 PIN 2 Adr 2 PIN 2 wt/bk 2 B
Adr 3 PIN 3 Adr 3 PIN 3 bu 3 S
Adr 4 PIN 4 Adr 4 PIN 4 ye/rd 4 +
Adr 5 PIN 5 Adr 5 PIN 5 ye 5 -
Adr 6 PIN 6 Adr 6 PIN 6 gy/gn 6 A
Adr 7 PIN 7 Adr 7 PIN 7 bk/rd 7 B
Adr 8 PIN 8 Adr 8 PIN 8 gy/rd 8 S
Adr 9 PIN 9 Adr 9 PIN 9 ye/bu 9 +
Adr 10 PIN 10 Adr 10 PIN 10 bk/wt 10 -
Adr 11 PIN 11 Adr 11 PIN 11 bk/gn 11 free
Adr 12 PIN 12 Adr 12 PIN 12 gn/rd 12 free
Adr 13 GND Adr 13 PIN GND bk (adapt to 1,5 GND free
2
mm if required)

105
Terminal board of the terminal box

106
4.27 Filling level monitor Ex, type 6728-65/-66

Please also observe the separate service instructions “Filling level monitor Ex, type 6728-65/-
66”!
4.27.1 Dimensions
4.27.2 Wiring
Wiring demonstrated at the example of 6728-66 (dual)
The supply voltage „+24 V (GWG-modules)“ for the AS/GWG-modules has to be connected with
the supply voltage “P-NET (+,-)“. Therefore, a cable bridge has to be clamped between the ter-
minals +Uo and +Ui and between -Uo and -Ui respectively.

107
For this system equipped with 2 limit value transmitters (GWG), the supply line leading to these
limit value transmitters have to be laid separately so that they can be unambiguously assigned
to the appropriate measuring point they are configured for.
This can be realised by the separate arrangement of a cable drum for the supply line to the limit
value transmitter coupling socket type 903 (TRbF 512).

108
4.28 Alert button

4.28.1 Control element, type 6783-101
The control element of the alert button can be optionally connected to the filling level monitor. It
is equipped with an emergency OFF option for immediate interruption of the filling procedure,
and with a green button which has to be pressed in periodic intervals but at least every 40 sec-
onds.

Auxiliary energy DC 5...24 V
Cable length 12 m
Casing IP 65 125 x 50 x 25 mm
Dimensions  40 mm
Ambient temperature -20...+50 °C
Protection type IP 20 nach DIN 40050
Climatic classification HVD in accordance with
DIN 40040
PTB no. Ex-94.C.2144
Wiring
The control element of the alert button can be connected to the filling level monitor either via the
cable adapter control element or via the extension unit type 6783-103.

109
4.28.3 Cable adapter control element, type 6728-107
Wiring
Cable length: 0,45 m
Function Cable no. Terminal in filling

level monitor
1 Female con- GND 1 GND
nector
2 Blind plug
3 Female con- A-button 2 AT
nector
4 Blind plug
5 Female con- Loudspeaker yl/gn LS
nector
6 Blind plug
Blind plug
4.28.4 Extension unit, type 6783-103
Connection plan

110
4.29 V-24-(RS 232)/P-NET converter, type 4386-4/-

6
The converters serve to operate any devices equipped with an RS 232 interface via the fieldbus
P-NET.
With type 4386-4, it is possible to connect one RS 232 device, with type 4386-6 up to three RS
232 devices.
4386-4 4386-6

4386-4 4386-6
Electrical data
DC 10 ... 36 V, DC 10 ... 36 V,
Auxiliary energy
40 mA for DC 24 V 0,15 A for DC 24 V
1 x P-NET 1 x P-NET
Interfaces
1 x RS 232-C 3 x RS 232-C
Fuses 300 mA (reversible) 300 mA (reversible)
Ambient conditions
Operating temperature -10 ... +50°C -10 ... +50°C
Storage temperature -20 ... +70°C -20 ... +70°C
Climatic classifica-
KWF / IP 40 KWF / IP 40
tion/protection type
Mechanical data
20 x terminals 1,5 mm² 31 x terminals 1,5mm²
Connections
4 x cable gland PG 9 6 x cable gland PG 9
350 mA max. / 60 V
Switching output
galvanically separated

111

Type 4386-4
250
218 43
60
70
4,5 2
Type 4386-6

112
4.29.3 Connection and block diagram

Type 4386-4
Switching output
Ub
P-NET
Interface RS 232
Auxiliary energy: DC 10...36 V
1
RS232
Auxiliary energy
+ +
DC 10 ... 36 V Ub
 
Power supply unit Interface 1

Interface 2
+
Switching output

DSR
A CPU DTR
RS 232
B GND
P-NET
TxD
S
RxD

113
Type 4386-6
Ub
Interface 2
RS 232
Ub
Interface 1
Interface 3 RS 232
P-NET
DC 10 ... 36 V Ub
Interface 4 Interface 0
P-NET RS 232
DC 10 ... 36 V
Equipment emergency current
Screen
Interface 2
Interface 3
Interface 1
Interface 4
Interface 0

114
4.30 P-NET/V.24 converter, type 4386 P041

The P-NET/V.24 converter is a µp-controlled interface which couples devices equipped with a
V.24 (RS232C) interface to the fieldbus P-NET.
P-NET / V.24 converter for connection with P-NET fieldbus:
 Two V.24 interfaces (RS 232 C)

 Data retrieval, control and setting of the transmission parameters via a galvanically sepa-
rated P-NET fieldbus interface (RS 485)
 Safe communication by means of integrated test protocols

V.24 connection 1 serial interface RS 232 C (RxD, TxD, 4 handshake lines)
1 serial interface RS 232 C, two-wire (RxD, TxD)
Baudrate (75 ... 19200 baud)
Word length, protocol and mode adjustable via P-NET
Voltage level  12 V, cable length max. 20 m
P-NET port Serial, asynchronous RS 485, galvanically separated 76800 baud,
P-NET protocol, cable length max. 1200 m
Connection 9-pole plug (P-NET), 25-pole plug (V.24), jack plug (power supply)
Power supply Auxiliary energy 10 ... 30 V DC  10 %, ripple 150 mV eff.
Power consumption max. 100 mA
Ambient conditions Admissible operating temperature: 0 ... + 50 °C
Admissible storage temperature: -10 ... + 70 °C
Climatic class: KWF in accordance with DIN 40040
Casing Desktop casing, black plastic, protection type IP 30
Dimensions: 144 x 68,5 x 36 mm
Weight Approx. 2,5 N (= 0,25 kg)
Dimensions

115
Mounting bores (in combination with mounting kit 4386-1-03)
Pin assignment of 9-pole D Sub plug
Signal Colour
PIN 5 = S shield
PIN 3 = A yellow
PIN 8 = B green
PIN 7 = + grey/pink
PIN 2 = - white/blue
Pin assignment of 25-pole D Sub plug
Signal Signification
PIN 2 = TxD (CH A) output
PIN 3 = RxD (CH A) input
PIN 4 = RTS (CH A) output
PIN 5 = CTS (CH A) input
PIN 6 = DSR (CH A) input
PIN 10 = DTR (CH A) output
PIN 7 = GND (CH A and CH B)
PIN 14 = TxD (CH B) output

PIN 16 = RxD (CH B) input
PIN 22 = + 5 V
PIN 23 = + 5 V Operating voltage for
PIN 24 = GND card reader
PIN 25 = GND

116
4.31 Connection of modem type “FALCOM A 2-1”

Connection of voltage supply to P-Net/V24 converter
4-pole plug
- UB Weiß
yellow free
green + UB
brown + UB
Connection of data cable to P-Net/V24 converter
Interface 1 RS 232/V24, 9 pin D-Sub DIN 41652

9-pole plug
green RXD
yellow TXD
brown GND
Connect pink and grey
Connect white and blue
4.32 Connection of modem type „FALCOM A 1“

Connection of voltage supply, connection cable from modem (Falcom A1)
Modem + 24 V GND
FALCOM A 1 white brown
yellow
Connection of data cable to P-Net/V24 converter
Interface 1 RS 232/V24, 9 pin D-Sub DIN 41652

9-pole plug
Green RXD
Yellow TXD
Brown GND
Connect pink and grey
Connect white and blue

117
GSM modem TC 35 / MC 35 including aerial

For radio-controlled data transmission between milk collecting truck and disposition.
The GSM modem can only be operated via an RS 232 / P-NET converter type 4386-4 or type
4386-6 (interface 2).

Operating voltage DC 8 ... 30 V
Weight approx. 130 g
Fastening with two lens head screws M3 x 50 mm
Connections
Fig.1 Front view Fig. 2 Rear view
Connection of power
adapter cable LED Display
RS 232 interface Telephone con- Card holder

(9-pin D-Sub) Aerial plug
nection
Insert SIM card
Fig. 3 Fig. 4

118
4.32.2 Mounting and wiring

Please proceed in the following order:
1. Mount the GSM modem at a place suitable for the open design, in a dry area of the vehi-
cle that is free of dust and dirt.
Please observe the respective cable lengths of the GSM aerial and of the RS 232 cable
when selecting the site.
In combination with RS 232/P-NET converter type 4386-7/-8, the GSM modem can also
be installed into these converters with an appropriate protection.
Caution:
For mounting, please note that the metallic fastening screws of the GSM modem can
have a connection to the GND potential. Consequently the modem has to be fastened
electrically insulated against the vehicle chassis ground.
BARTEC BENKE accessories: mounting kit for GSM modem type 6722-102, order no.:
234662
The GSM modem Siemens TC35i may only be attached at the truck chassis by means of
the insulating mounting kit (order no. 234662) (screws might jumper through ground).
Beyond that, only the BARTEC BENKE magnetic aerial (order no. 232484) and, for in-
stallation in the driver´s cab (windscreen), the adhesive aerial (order no. 216923) may be
used.
2. Fasten the GSM aerial (magnetic or adhesive holder depending on type) at a place
where the receiving conditions are good (e.g. window pane or top side of vehicle).
3. Connection of RS 232 cable to the respective RS 232 / P-NET converter in accordance

with connection diagram and to the 9-pole Sub-D female connector of the GSM modem.
4. Important:
Before inserting the SIM card into the GSM modem, the PIN number of the card has to
be entered correctly at the controller MAK 3002.

119
Then disconnect power supply, insert SIM card into GSM modem (see fig.3 + fig. 4) and
insert card holder completely again.
Connect power supply again.
If you proceed in another order, the SIM card will be blocked!

120
GSM connection to RS 232 converter (type 4386-4)
Power supply
ABS+-
Connection to P-NET
ye A
gn B
shield S
rd +
bu - 24 V
RS232 Aerial connection

Configuration of call parameters:
Phone no.: Entry of call string gn  RxD

ye  TxD
Modem: ON = operation with modem bn  GND
Shield  shield
Pin: PIN code of Sim card
Zero modem: Data transmission via cable Jumpers (with luster terminals)
2 GSM modem: ON if GSM modem is also installed wt  bu

in office. pk  gy
Version: Output of version number of trans-
mission module
auto. Init: ON = automatic initialization
After power failure  always ON V 24 P-NET converter
Port2-Mod 2=Modem
Port2-Baud 2=4800
Handshake AUS

121
GSM connection to RS 232 converter (type 4386-6)
Connection
Power supply
Interface 2
P-NET
Interface 3 Interface 1
P-NET P-NET
Interface 4
P-NET
Interface 0
P-NET
A  yellow
B  green
S shield
+  red Connection of GPS interface 1
-  blue
red  24 V
black  GND_1
blue  TXD_1
white  RXD_1
RS232
Aerial connection
The GSM modem is connected to interface 2
Green  RxD_2
Yellow  TxD_2
Blue  CTS_2
White  RTS_2
Brown  GND_2
Jumper between pink and grey
If a GSM modem is used at the truck, option can be set with

“handshake“ and ”19200“.
Without handshake, blue and white have also to be jumpered.

122
Connection diagram
GSM-Modem TC 35
RS 232/P-NET RS 232/P-NET
to converter converter
type 4386-4 type 4386-6
interface 2
RS 232 Signal Colou PIN
cable r
TxD gn 2 Terminal R x D Terminal R x D_2

RxD ye 3 Terminal T x D Terminal T x D_2
GND bn 5 Terminal GND Terminal GND_2
CTS wt 7 Connect with Terminal RTS_2
RTS bu 8 luster terminal Terminal CTS_2
DSR pk 4 Connect with luster Connect with luster
DTR gy 6 terminal terminal
Shield yegn Casing Note 1) Note 1)
Power + Ub wt Terminal + (Ub) Terminal + 24 V
adapter Ignition yl Terminal + (Ub) Terminal + 24 V
cable 0V pk Terminal - (Ub) Terminal 0 V
Power +Ub wt Terminal + (Ub) Terminal + 24 V
adapter Ignition gn Terminal + (Ub) Terminal + 24 V
cable 0V bu Terminal - (Ub) Terminal 0 V
(new)
Note 1): Cable shielding: Variant 3 in accordance with 2.4
If GSM modem TC 35i and connected handshake lines „RTS/CTS“ are used, the option can be
set in the controller with ”handshake“ and baud rate ”19200“ .

123
4.33 Connection Onboard Computer
V-24/P-NET converter, type

4386-4
Switching output
Schaltausgang
Ub
Schnittstelle 1
Interface
RS232
RS 232
Connection cable RS 232, with open ends
Order no.: U08001676 (l = 2 m)

238844 (l = 15 m)
Interface 1 9 pin Sub-D plug
Rear view

124
4.33.1 Connection diagram

RS 232/P-NET converter
to
type 4386-4
RS 232 cable Signal Colour PIN
TxD gn 2 Terminal RxD
RxD ye 3 Terminal TxD
GND bn 5 Terminal GND
CTS wt 7
RTS bu 8
DSR pk 4
DTR gy 6
Shield yegn Casing

Wires that are not used have to be insulated separately.

125
Connection cable with female connector, with open ends
Order no.: 215250 (l = 2 m)
Interface 1 9-pin Sub-D female connector
Front view

RS 232/P-NET converter
Connection cable with Signal Colour PIN to type 4386-4
female connector
TxD gn 2 Terminal TxD
RxD ye 3 Terminal RxD
GND bn 5 Terminal GND
CTS wt 7
RTS bu 8
DSR pk 4
DTR gy 6
Shield yegn Casing
Note1): Cable shielding: Variant 3 in accordance with 2.4


126
4.34 GPS receiver (RS 232), type 6722-16

In combination with system PETRODAT 3002, automatic vehicle localisation via satellite.

Electrical data
Auxiliary energy DC 6 ... 40 V
Power consumption, typical 50 mA bei DC 24 V
Receiving aerial built-in
Interfaces RS 232
Electrical connection 5m cable length, open lead ends
Ambient conditions
Operating temperature - 30 ... + 85° C
Storage temperature - 40 ... + 90° C
Climatic classification/protection type HQG/IP 65
Mechanical data
Dimensions/mounting bores
Weight 150 g (cable excluded)

Casing Upper shell made of polyester, ground plate made of
metal

127
4.34.2 Wiring
GPS receiver Converter Converter
6722-16 4386-4 4386-6
to
Interface
Signal Lead colour Interface 1
0+1
DC 24 V red (rd) Teminal “+” Terminal “+ 24 V”
(Ub) (Ub)
GND black (bk) Terminal Terminal
„GND“ „GND“
RxD blue (bu) Terminal Terminal
„T x D“ „T x D“
TxD white (wt) Terminal Terminal
„R x D“ „R x D“
Shield Bare lead Note 1) Note 1)
Mounting instructions:
As the aerial is integrated in the receiver, the receiver has to be mounted as horizontally as
possible on top of the vehicle (e.g. on top of the rear cabin). Avoid by all means that the device
is covered by metallic parts. Make sure there is at any time a free view to all sides.
Caution:
The metallic base plate has to be mounted electrically insulated against the vehicle ground.
The GPS receiver 6722-16 may only be mounted to the truck chassis in combination with the
insulating mounting kit (order no. 234661) (no ground for semi-trailer).

128
4.35 GPS receiver (RS 232), type 6722-18

In combination with system PETRODAT 3002 automatic vehicle localisation via satellite.

Electrical data
Auxiliary energy DC 6 ... 40 V
Power consumption, typical 50 mA for
DC 24 V
Receiver aerial built-in
Interfaces RS 232
Electrical connection 5m cable length, open lead ends
Ambient conditions
Operating temperature - 30 ... + 80°C
Protection type IP 67 (1 m immersion depth for 30 min)
Mechanical data
Dimensions / mounting bores
Mounting screws 3 x M4, do not exceed max. thread depth of 8.0 mm (risk of
breakage)
Weight 330 g incl. 5 m cable
Configuration of GPS receiver type 6722-18 at the controller
In the “peripheral“ menu, press softkey “select page“ and then select ”1 GPS receiver“.
Enter the serial number of the P-NET converter and port 1.
For „Type“ = 1
For „Nfix“ = 1
Baudrate = 4800

129
4.35.2 Wiring
GPS receiver Converter Converter
6722-18 4386-4 4386-6
to
Interface
Signal Lead colour Interface 1
0+1
DC 24 V red (rd) Terminal “+” Terminal “+ 24 V”
(Ub) (Ub)
GND black (bk) Terminal Terminal
Remote ON/OFF yellow (ye) „GND“ „GND“
RxD blue (bu) Terminal Terminal
„T x D“ „T x D“
TxD white (wt) Terminal Terminal
„R x D“ „R x D“
Shield Bare lead Note 1) Note 1)
Mounting instructions:
As the aerial is integrated in the receiver, the receiver has to be mounted as horizontally as
possible on top of the vehicle (e.g. on top of the rear cabin). Avoid by all means that the device
is covered by metallic parts. Make sure there is at any time a free view to all sides.
Caution:
For system installations with simultaneous application of a W-LAN adapter type 6722-17 for da-
ta transmission, the adapter has to be mounted at the vehicle at a minimum distance of 1m to
the GPS receiver in order to prevent interferences.
Ideal mounting: no visual contact between the devices, e.g. GPS receiver on top of the rear
cabin, W-LAN adapter at the side of the tank.
General recommendation:
Mount GPS receiver as far away as possible (> 1 m) from all other radio aerials and electrical
system components (e.g. ventilator motor, magnetic valves, radio remote controls).
If possible, do not guide the connecting cable past electrical system components and do not
guide it in parallel to other system supply cables.
Fastening recommendation:
We recommend to fasten the GPS receiver on a horizontal and plain mounting plate with silicon
or an equivalent elastic mounting glue.
Spread the glue evenly all over the glue surface in order to prevent water from penetrating un-
der the receiver and to exclude the risk of frost heave.

130
4.36 Connection of card reader Ingenico Elite 790

Connection cable of check-card reader with open ends
Order no.: 215250 (l = 2 m)
Interface 1 9 pin D-Sub female connector
Front view

Converter Converter
to 4386-4 4386-6
RS 232 cable Signal Colour PIN Interface 1 Interface 2
TxD gn 2 Terminal TxD Terminal TxD
RxD ye 3 Terminal RxD Terminal RxD
GND bn 5 Terminal GND Terminal GND
CTS wt 7
RTS bu 8
DSR pk 4
DTR gy 6
Shield yegn Casing

Startup
131
5 Startup
5.1 Sequence and instructions
The startup of the system should essentially take place in the following sequence:
1 Before switching on the on-board voltage, check the wiring of the complete system.
2 Setting of all parameters at the controller:

You can follow successively the items of the menu structure. It is not absolutely necessary
to comply with this sequence, but all menu items should be handled! For the individual
menus, their meaning and their setting options, see service instruction instructions “Config-
uration of PETRODAT 3002” . For operating the system, see the operating instructions.
After the startup has been successfully completed, it is recommended to print the parameters
(for your vehicle documents). The preset configuration data can be stored on an SSM cartridge
and reloaded if required (EEP menu).
Devices such as printers which were operated in system 3002 (new generation) can only be
applied in system 3001 (PETROCOMP) after the address has been reprogrammed. At present
this can only be carried out by BARTEC BENKE.
5.2 Calculate and enter the password

The configuration of the software is protected by several passwords. The different passwords
permit access to different configuration levels.
After the password has been entered, the configuration level to which access is permitted is
displayed.

Startup
132
Driver password
The driver password permits the access to configuration level 1.

The system time and the language within the controller parameters can be changed. After the
clocktime has been changed under the driver password, an appropriate message appears after
each program start until it is confirmed under the user password. The date cannot be changed
under the driver password.
The driver password is the sum from month, day and hour (as shown in the basic menu).
Driver password = day + month +hour
Example:
Date: 20. 05. 1999, 06:46
Driver password= 20 + 5 + 6 = 31
User password
The user password is the password of the truck fleet manager. It consists of a maximally 3-digit
code defined by the truck fleet manager. The user password permits the access to configuration
level 2. On this level, configuration data not subject to calibration can be changed, for instance
turning on and off several options and hardware modules.
User password = driver password x (code + 1) + code
Example:
Driver password = 31, code = 120
User password = 31 x 121 + 120 = 3871
When the device is delivered, the code = 0. The user password is identical to the driver pass-
word.
Service password
The service password permits the access to all configuration options which are not subject to
calibration (configuration level 3).
The service password is constituted according to a special mode and is changed periodically.
The service password is only revealed to authorised service staff.
Calibration switch
After the calibration switch has been turned on, all configuration options are accessible (configu-
ration level 4). Data subject to calibration can only be changed while the calibration switch is
turned on.
The following settings are possible without a password:

- Setting of contrast within the configured limits (Contr.-param./Contrast)
- Selection of language (Program param./Language)
Manual entry of additive price (Program param./Product data)
- Clocktime (Contr. Param./System time/ Time).

Startup
133
Text entries at a controller equipped with a numerical keyboard

Select the field where the text entry shall be made. Press any key then (except the softkeys
which are assigned a function at present). An input mask is displayed.
^ 6 7 8 9 0 - DEL F1 START
^ 6 7 8 9 0 - DEL F1 START
1 2 3 4 5 . F2 STOP
1 2 3 4 5 . F2 STOP
The two upper softkeys are assigned a double function: for normal operation, the cursor is
moved left or right (represented in the display by < and > left of both softkeys).
The second function is shown on the right side of the softkeys (ASCII or ABC). To use it, press
the softkey and at the same time the shift key ([^]).
Text can be entered in two different ways.
1. Enter text via ASCII code

- To enter a letter at a selected position, press softkey ASCII ([^] + [<|ASCII])
- Enter the ASCII code for the required character.
- Then set the cursor to the next position (softkey [>|ABC]).
- Enter the next character in the same way.
In the table below, the ASCII codes for the most important characters are listed. It is possible
that the printer does not print all characters in the same form as they are represented on the
display. The output on the printer depends on the font installed there.
ASCII code table Character Decimal code Character Decimal code Character Decimal code
Space 032 A 065 a 097
! 033 Ä 142 ä 132
" 034 B 066 b 098
# 035 C 067 c 099
$ 036 D 068 d 100
£ 156 E 069 e 101
% 037 F 070 f 102
& 038 G 071 g 103
* 042 H 072 h 104
+ 043 I 073 i 105
- 045 J 074 j 106
. 046 K 075 k 107
/ 047 L 076 l 108
0 048 M 077 m 109
1 049 N 078 n 110
2 050 O 079 o 111
3 051 Ö 153 ö 148
4 052 P 080 p 112
5 053 Q 081 q 113
6 054 R 082 r 114
7 055 S 083 s 115
8 056 T 084 t 116
9 057 U 085 u 117
Ü 154 ü 129
V 086 v 118
W 087 w 119
X 088 x 120

Startup
134
Y 089 y 121
Z 090 z 122
Enter customer name “Ast“:

Example
1. Press softkey [select field ] to select input field
2. Press any key (except active softkeys)
3. Press softkey „ASCII“ ( [^] + [<|ASCII] )
4. Enter ASCII code 065 for “A": [^]+[_] ;[_]; 6
1
0
5
Press softkey [OK]

5. Set cursor to next position: Press softkey [>|lower casel]
6. Press softkey „ASCII“ ([^] + [<|ASCII] )
7. Enter ASCII code 115 for ”s": [_]; [_]; [_]; 6
1
6
1
0
5
Press softkey [OK]

8. Set cursor to next position: Press softkey [>|upper case]
9. Press softkey „ASCII“ ([^] + [<|ASCII] )
10. Enter ASCII code 116 for “t" : [_]; [_];[^]+[_];
6
1
6
1
6
1
Press softkey [OK]

11. Press softkey [OK]
The entry of the name “Ast" is completed.
2. Enter text by selecting characters

As an alternative to entering the ASCII code you can use the [_] key to ”scroll“ through the —
.
characters:
[_] : forward
—
.
—
[^] + [_] : backward .
If the cursor is on a field where a character has already been entered, the [>lower case] softkey
and the [>|upper case] softkey are available to switch between upper case and lower case for
the displayed letter.
Enter customer name „“Ast“:

Example
1.Press softkey [select field] to select input field
2.Press any key (except active softkeys)
3.Press softkey „ABC“ ( [^] + [>|ABC] )  an „A“ appears at the cursor posi-
tion.
4.Set cursor to next position: Press softkey [>|lower case]
5.Press softkey „ABC“ ([^] + [>|ABC] )  An „A“ appears at the cursor posi-
tion.
—
6.Press [_] until “S“ appears at the cursor position
.
(if required, you can scroll back by pressing [^] + [_).

—
.
7.Switch to lower case: [^] + [>|KLEIN]  an “s“ appears at the cursor posi-
tion.
8.Set cursor to next position: Press softkey [>|upper case]
9.Press softkey „ABC“ ([^] + [>|ABC] )  an ”A“ appears at the cursor posi-
tion.
—
10.Press [_] until a “T“ appears at the cursor position.
.
11. Switch to lower case: [^] + [>|lower case]  ”t“ appears at the cursor
position.
12.Press softkey [OK]
The entry of the name “Ast" is completed.

Startup
135
The softkey [>|ABC] is only available if no letter has been entered at the cursor position. If a let-
ter has already been entered at the cursor position, the softkey is designated with [>|upper
case] or [>|lower case].
Starting from any character, you can “scroll” among the characters.
Figures as well as “." and “-" can be entered directly via the keys. If you enter the digits 6 to 0
and “-", you also have to press the shift key ( [^] ).
Figures are inserted at the place where the cursor is located; if you enter another character, the
character which was there before is overwritten.
Press [DEL] to delete the character left of the cursor.
5.3 Parameter printout

For a detailed description of all parameters, see service instructions ”Configuration“. The pa-
rameter printout depends on the version and the configuration.
P = Product no.
E = Calibration factor no.
BT = Base temperature (e.g. 15 C)
KMod = Conversion procedure: 0,00
K = Compensation ON/OFF
A = Delivery of product with additive
M = Allocation, measurement chamber for double discharge 0 both
Explanatory notes on the parameter printout concerning obligatory calibration

All parameters marked with * (asterisk) are locked with the external calibration switch. There are
5 groups of parameters:
1. Version numbers of software modules subject to calibration.

2. Conversion of quantity into kg, specific for Switzerland.
3. Conversion parameters and names of individual products.
4. Serial numbers (A no.) and preset factors of the pulse transmitters/measurement chambers.
5. Serial numbers (A no.) and calibration counters of the temperature sensors.
ref. to 1.
The version numbers of the internal calibration-relevant program parts provide information on
the update status of the device-internal software. The device-internal software is exclusively
written by BARTEC BENKE. For more details, see “Calibration-related description of system
3002, 3.2.11".
ref. to 2.
In Switzerland, the quantity is displayed in kg. This operation mode is not permitted in Germany.
This parameter must be OFF. The parameter is protected with a calibration switch.
ref. to 3.
Product data (conversion data, assigned calibration factors etc) and product names have a di-
rect influence on the precision and they prevent deliberate abuse. This data is protected with a
calibration switch.

Startup
136
ref. to 4.
The serial numbers of the pulse transmitters, the data of the pulse transmitter and the calibra-
tion factors of the maximally three product groups as well as the number of the measurement
chamber or of the measuring point (counter number) are protected with a calibration switch as
they have a direct impact on the precision. As the controller can serve two measuring points at
the same time, there are two pulse transmitter data or measuring unit data.
ref. to 5.
The serial numbers of the temperature sensors are protected with a calibration switch (check if
they have been replaced). The calibration counters indicate the calibration status of the temper-
ature sensors. The sensors are calibrated in a water bath by BARTEC BENKE. This is only
possible by means of a secret and particularly protected procedure. After each successful cali-
bration (and of course also in the case of an attempted manipulation) this calibration counter
reading stored in the temperature sensor is changed. The controller reads out this calibration
counter and compares it to the internal value stored under the calibration switch. If there is a di-
vergence, error messages are generated.
These parameters of the temperature sensor are protected with the calibration switch.
The marking of the important parameters that may be subject to obligatory calibration with *
(asterisk) in the parameter printout shall enable the weights and measures inspector to find
them more easily for control purposes. The important parameters are listed under
menu/configuration/calibration parameters and can be checked and changed there if required.

Calibration
137
6 Calibration
6.1 Calibration of PETRODAT 3002
For the calibration, observe the following issues:
1. Check parameter setting

You can do this under menu/configuration/calibration parameters. All parameters relevant for
calibration are listed there. It is better to print the parameter list (menu/configuration/parameter
print) and to check the parameters by means of this list. The parameters subject to calibration
are marked with an asterisk there.
2. Check calibration factor setting (also see 1.)

 For new measurement chambers already pretested with pulse transmitters, the pulse valen-
cy (pulse/liter) from the type plate of the measurement chamber can be adopted directly as
the calibration factor.
 For retrofittings, set calibration factor 1.0000 or 10.000 for the first measurement (conver-
sion will be easier).
The calibration factors are calculated from the indicated quantity, the nominal quantity and
the preset calibration factor.
Calibration factor = Indicated quantity (uncompensated) x preset calibration factor

Nominal quantity
Example:
1000 l are discharged for the measurement. The display shows an uncompensated quantity of
1153 l. Preset calibration factor = 1,25.
Calibration factor 1153 l x 1,25 =1,4412

= 1000
Before the calibration starts, define which of the 3 possible calibration factors shall apply to the
different products.
3. After the calibration, move the calibration switch on the bottom side of the controller to a hor-
izontal position and seal it. It is imperative for the system to be in the basic menu during this
process (ULTRAKUST at the upper edge of the display). In the unprotected state (calibration
switch is open) a capital E is blinking in the middle of the basic menu. When the calibration
switch is in horizontal position, this E disappears and the parameters subject to calibration are
locked. You can then check for instance whether it is impossible now to change the calibration
factors. After the calibration has been carried out, any measured discharge mustn´t be possible
without the prior release by PETRO-COMP.
The calibration switch is located at the bottom section of the device and is equipped with a cali-
bration bolt protected by a calibration seal. To turn the calibration switch on, undo the seal and
remove the calibration bolt.

Calibration
138
4. It is not necessary to complement the measuring system type plate attached to the system as
the type plate at the controller is permanently connected to the entire measurement system af-
ter the sealing process. This seal simultaneously protects the fastening screws for the bottom
section of the controller and the type plate. As there is only one general approval, it is not nec-
essary to replace the type plate of the measurement chamber. All details specified by the manu-
facturer there remain valid
5. Collect all preliminary test certificates delivered with the device and submit them to the
weights and measures inspector.
6. Enter device numbers into measuring system document.
7. Create final parameter printout and attach to measuring system document.
6.2 Calibration-related instructions for servicing

works at
PETRODAT 3002
Before starting the servicing works, print out the parameters if possible or record the pa-
rameter settings manually.
When the servicing works are completed, recheck all the parameters against the previ-
ously compiled parameter list and the parameter list enclosed to the measuring system
document.
1. Devices equipped with calibration marks may only be replaced by pre-tested parts. These
devices usually include the temperature sensor, the printer, the measuring system inter-
face and the controller (either complete or alternatively only top section or bottom sec-
tion).
2. The repair engineer´s mark may only be attached if the calibration term (indicated on the
main stamp) has not yet expired.
3. The repair engineer´s mark has to be attached on the replaced or repaired part. If any
security stamps have been damaged (lead seals), the main stamp (calibrated until…) has
also to be cancelled. The repair engineer´s stamp has to be attached. It is imperative to
enter the date with waterproof ink on the repair engineer´s mark.
4. Damaged lead seals have to be replaced by new ones and stamped with the repair engi-
neer´s mark. If for instance temperature sensors of PETRODAT are replaced, a seal wire
with a new seal has to be affixed and stamped with a counter bearing. Every authorised
repair engineer has a metal stamp for this purpose.
5. The responsible calibration authorities have to be notified immediately on the fact that the
repair engineer´s stamp has been attached.
6. In the measuring system document (to be kept in the vehicle), each repair has to be not-
ed. In the fields designed for this purpose, the repair engineer has to give a brief descrip-
tion of the repair, identify the respective device with letters, enter date and name. It may
be necessary to additionally enter the new serial number (A no.) of the device. The cus-
tomer has to contact the calibration authorities to have the measuring system document
countersigned. The repair engineer has to advise the customer to do this.

Calibration
139
7. If the top section of the controller is replaced, there is usually no need to set any parame-
ters. For safety reasons it is imperative to check the parameters though. The issues de-
scribed above have to be observed. If the bottom section of the controller is replaced, all
parameters have to be entered again. The data of the parameter list attached to the
measuring system document or the previously made printout has to be entered with ab-
solute accuracy. If due to a defect the parameters relevant for calibration cannot be read,
the repair engineer´s mark must not be attached after the end of the works. The vehicle
has to be withdrawn from circulation and a recalibration has to be carried out immediate-
ly. The repair engineers have to advise the customer to do this, and the responsible cali-
bration authorities have to be notified immediately. If there is the slightest doubt in the
measurement accuracy of the system (for any other reasons), proceed accordingly.
8. To replace the measuring system interface, open the calibration switch at the bottom sec-
tion of the controller. Enter the serial number (A no.). Then the calibration switch has to
be locked and stamped in accordance with 3. and 4. above. Check the parameters.
9. Preliminary test certificates accompanying any replacement parts have to be handed over
to the customer´s contact person or to be attached to the measuring system document.

Calibration
140
6.3 Model supplement for measuring system

document
- Supplement -
Equipment of the measuring system with an electronic counter
Type _______________ Manufacturer ______________ PTB approval ________
Identification no. ____________ see parameter printout: calibration factors ___________________________
Printing unit
 Type ________________ No. _______ / /
Temperature sensor
 Type ________________ No. _______ / /
Temperature sensor
 Type ________________ No. _______ / /
 Pulse transmitter Type ________________ No. _______ / /
 Pulse transmitter Type ________________ No. _______ / /
 Measuring system interface, double A1 Type ________________ No. _______ / /
Measuring system document no. ____ Supplement no. ______________
Voucher printer
type 6881-1 Pulse counter
Temperature sensor type 6716-xx
type 673x-xx
Belegdrucker
Typ 6881-1 Impulszähler
Temperaturfühler
Typ 6716-xx
Controller Typ 6702-30
type 673x-xx
Measurement
system interface Seal location
Controller type 6718-xx
Typ 673x-xx
Meßanlagen-Interface
doppelt A1 Typ 6718-xx
Troubleshooting
141
7 Troubleshooting
7.1 If everything else fails
Apply the following instructions only in extreme emergencies and after consulting the BARTEC
BENKE service staff!
A P-NET error message (e.g. NO RESPONSE ...) can have one of the following causes:
1. The supply voltage is not correct (too low voltage or no voltage at all).
Please check:
– on-board voltage,
– input and output voltage of BARTEC BENKE voltage supply,
– all cables and connections of each device.
2. Defective cable or defective wire (short-circuit, cable break, ...)
Please check:
– cables and lines of the devices (supply lines and data lines),
– Interrupt connection to all devices and deactivate the devices in the controller software until
the message disappears.
3. The device mentioned in the message is defective.
4. If the device is okay, the voltage supply in the controller might be disordered.
7.1.1 Basic menu does not appear when system is

turned on
If (for instance after upload, exchange of top section, first startup etc.) the basic menu is not
displayed on the controller after the system has been turned on, proceed as follows.
 Display remains dark after the device has been tuned on:
Check complete system wiring or check if the ribbon cables are properly connected between
the top section and the bottom section.
 Display shows test menu and then stops:
1. Confirm all error messages with (Abort) or (OK) until the basic menu appears. If this is not
possible, press (DEL) during the booting procedure in order to get to BIOS. Then proceed
as described in 2**.

Troubleshooting
142
2. To delete the internal memories, proceed as follows:
Delete EEPROM : Menu

1:Configuration
8:Bios
** Config
System Config
Time/Date/RAM
EEPROM clear
Quit
Delete RAM: RAM clear

Quit
Wait for the basic menu to appear after booting.
3. Interrupt voltage for approx. 5 sec.

4. Confirm all error messages with (abort) or (OK) until the basic menu appears.
5. Set the language by means of the following key combinations:
menu
1: configuration
2: contr.config
3: language select
2: German
0: end
Confirm until basic menu appears.
6. Carry out further configuration steps in accordance with the operating instructions. The
configuration is not stored before you have returned to the basic menu
 If the basic menu does not appear, an additional program upload is necessary.
1. If it is necessary to reload the program, connect the SSM cartridge shaft
2. Apply voltage.
3. Turn off calibration switch (switch in vertical position).
4. Confirm all error messages with [Abort] or [OK] until the main menu appears. If this is
not possible, press [DEL] during the booting procedure to get to BIOS. Then proceed
as described under 5**.
Key sequence: Menu

1:configuration
8:Bios
** Prog.Load
From HLK
Quit
Wait until the basic menu appears or until the first error message is displayed.
5. Interrupt voltage for approx.5 sec.

6. Carry out further configuration steps in accordance with operating instruction. The
configuration is not stored before you have returned to the basic menu.

Troubleshooting
143
7.1.2 Problems during activation of a peripheral

To activate a device, actuate the appropriate “ON“ in the PERIPHERAL menu, then enter the
serial number (“A” no.). If any error messages appear during activation of a device, they have to
st
be ignored at first. Activate all other devices (1 run).
If there are still error messages after the activation of all devices (“No Response“ or “Wrong se-
nd
rial number“), repeat the procedure (2 run). Delete the respective “A” no. and enter it again.
nd
After this 2 run everything should work, and there should not be any error messages.
If there are still error messages, the device is defective or the wiring is not correct.
7.2 Software reset

7.2.1 Controller
If the controller – like a PC – stops or does not run any more, it can be booted by means of a
reset. After the reset the test routines run through, then the basic menu appears. Error messag-
es have to be confirmed.
A reset can only be carried out when the calibration switch is turned off (in vertical position).
For controller type 6732-10 and type 6733-10, press the following keys simultaneously:
Softkeys [1] and [4] as well as [SHIFT].
For controller type 6742-10 and type 6743-10, press the following keys simultaneously:
Softkeys [1] and [4] as well as [ALT].
7.2.2 Printer
By means of the software reset, the printer is initialised and reset into the initial position.
Form printer, type 6863-5:
1. Turn off the printer.
2. Press [Load/Eject] and [LF/FF] and [ALT] and [TEAR-OFF] simultaneously and turn on the
printer.
3. Press these keys for approx. 4 seconds.
4. Reset is completed!
Form printer type 6863-6:
Reset:
- Printer
- Hold down both reset keys
- Turn on the printer
- Hold down the reset keys until you hear the confirmation beep

Troubleshooting
144
Form printer type 6863-7:
Reset:
- Printer
- Hold down both reset keys
- Turn on the printer
- Hold down the reset keys until you hear the confirmation beep
Voucher printer type 6881-1:
1. Printer is on.
2. Press [Release] and [Reverse] and [Forward] simultaneously.
3. Printing unit starts.
4. When printing unit stops again, release the keys.
5. Reset is completed!
PLEASE NOTE:
Reset is only possible for series A + B. For series C, this function is not available any more.

Replacement of devices
145
8 Replacement of devices
All serial numbers (“A” no.) of the devices are registered in the controller (peripherals). If a de-
vice is defective and has to be replaced, the “A” no. of the new device has to be entered. Basi-
cally the procedure is the same as for startup. Delete the “A” no. of the defective device in the
menu “configuration/peripheral“ and enter the new “A” no.
The complete calibration and configuration data is stored in EEPROMs in the bottom section of
the controller. If the bottom section has to be replaced, a new startup and a recalibration is nec-
essary
Replacement of devices explained at the example of the printer, with controller type
6743-10:
1. Turn the system off!
2. Disconnect the defective printer and remove it from the holder (loosen the appropriate
screws).
3. Mount and connect the replacement printer.
4. Then enter the serial number (“A” no. on the type plate) of the replacement printer at the
controller, as otherwise it cannot be addressed.
Proceed as follows:
Turn on the system and confirm all error messages.

The basic menu appears, and you have two possibilities of entering:
“Tour start” or “Menu” (softkeys at the right side of the display)
Press: [Menu]
Select field: 1:Configuration
Confirm selection: [OK]
Select field: 1: Entry of password

Enter user password or service password
Select field: 5: Peripheral

Select field: 5: Printer

There are different messages indicating there is “no response". Consequently a dialog between
controller and device is not possible.
Confirm the messages with softkey [Abort] (right of the display).

Replacement of devices
146
The menu Printer appears Printer: ON

Serial no..: new A. no.
Version: ..........
Select the field Serial no. and press any numeric key, e.g. 1.
Additionally the following 2 softkeys appear:

[<|_ASCII] and [>|_ABC]
By means of these keys, you can move the cursor to the left or to the right side.
Move the cursor to the extreme right with: [>|_ABC].
Then delete the old serial number digit after digit by repeatedly pressing [DEL].
Enter the new A. no. from the type plate of the printer.
Please note the double assignment of the numeric keys! To change over, press the left key (ar-
row upwards).
After the entry press [OK].
The following message appears: Printer

Module activated
Printer : ON
This menu appears:
Serial no.: new A no.
Version: ..........
Press: [Ready]
Then repeatedly press [OK] until you are back in the basic menu.
Replacement is completed.

Software
147
9 Software
9.1 Program uploads
This chapter describes how to carry out a program update. The program is stored on an SSM
cartridge (1 MB) which can only be used for this purpose. Please note the instructions accom-
panying the SSM cartridge which contains the appropriate program!
Proceed as follows:
1. Put cartridge containing the program into the SSM cartridge box.
2. Turn on the system and confirm all error messages.
The basic menu appears.
Turn off calibration switch: a blinking E appears on the display.
Then press [menu] (softkey on the right side of the display)
Make a parameter printout first (in submenu “configuration“).

It is necessary only in few cases to delete the EEPROM areas.
Select the field: 1:Configuration

Confirm the selection: [OK]
Select the field: 7: BIOS-Setup

Menu BIOS SETUP appears.
Press softkey: [Progr.load]

nd
2 menu appears with 3 softkeys:
Press softkey: [from_SSM cartridge]
A message on the contents of the SSM cartridge appears (program name, version etc.)
Then press softkey: [Quit]
Now the program loading starts, the old program is erased first. The whole procedure takes
about 10 minutes. The percentage of loading is displayed. Then there is a check if everything
has been transmitted correctly. The display shows an hour-glass. After about 1 minute the basic
menu appears. The loading procedure has been successfully completed!

Software
148
Some error messages and warnings may appear on the basic menu after the upload. They can
be ignored and deleted by pressing [OK].
Please make sure that by no means the voltage supply is interrupted during the upload proce-
dure. Otherwise the upload procedure will be disturbed and the controller will have to be repro-
grammed!
Delete EEPROM areas (if required):
Select the field: 1:Configuration

Select the field: 2:Contr.parameters

Select the field: 4:Delete EEPROM

The menu Delete EEPROM appears.
All of the 3 EEPROM areas should be deleted : CPU EEPROM

Calibration EEPROM
Configuration EEPROM
st
To delete them, select the 1 field (CPU-EEPROM) and press [OK].
The program asks you again: „Warning: delete EEPROM?“
Confirm with: [YES].
Proceed in the same way to delete the 2 other EEPROM areas!
After having deleted the 3 EEPROMs, return to the basic menu!
Then press softkey [Menu]
After the upload has been completed, all configuration parameters have to be entered again in
accordance with the parameter printout (if the EEPROM areas are deleted!).
9.2 BIOS setup

See separate operating manual “Bios Setup, System 3002"
This manual describes the BIOS setup of the controller for system 3002. The settings required
in individual cases are dependent on the respective system configuration and can be found in
the documentation of the respective devices.
The BIOS setting parameters are preset at delivery. Modifications are only necessary in special
cases. Incorrect settings may result in serious malfunctions. Contact our service staff if neces-
sary!

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For tank vehicles

Table of contents Page Date of last change

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

4.29 V-24-(RS 232)/P-NET converter, type 4386-4/-6 __________ 110

Document: SA 070303 Valid from: 10.07

Author: Michael Vogl

Translator: Eva Bauernfeind Revision: 24.05.2016

1. Observe the national regulations for start-up.

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Do not open casing cover when exposed to voltage!

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

2.2 Mounting instructions

2.2.1 Installation explosionprotected cable glands

Explosion-proof plastic cable glands in type of protection increased

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

If a higher degree of mechanical hazard, an additional protection by

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

2.3 Wiring instructions

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Make sure that the cables are In a humid atmosphere make

2.4 Additional instructions on ground routing

This applies for instance to:

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

2.5 Maintenance and repair

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Definition of protection types in accordance with DIN 40050

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Protection against penetration by liquids

Protection No pro- Dripping water Spray Splash Immer- Sub-

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

1. Code letter Lower temperature 2. Code letter Upper temperature

Limits of relative air humidity 1)

60 days of the year

the remaining days

See individual regulation

1) For reference temperatures – see diagrams in annex I/II

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

2.6.2 Table “Recommended cable diameters per PG

2.6.3 Table “Line cross-section depending on termi-

2.6.4 Lead colours and abbreviations

Two-coloured leads are always designated accordingly:

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

 Example: yellow-green = ylgn

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

2.6.5 P-NET identification numbers of the system

5925 Measuring system inter- Temperature sensor 21..28

5404 8 Pulse counter Volume 29..30

5906 Output Interface

5917 2 SSM cartridge box Data backup / data transmission 39/3a

5913 2 Power supply unit Km registration etc. 3b/3c

3221 4 Upi Pump control/density measurement 3d..40

5812 8 Slip printer Printer 41..48

5929 cannot be calibrated

5935 2 SAFE scanner Hose supervision 53..54

5907 8 Wiegand reader Vehicle number at the bearing 59..60

5904 1 P-NET/V24 converter Radio access of airfield 77

5946 1 SPD interface Valve supervision 6b

Customer identification with TAG read-

5931 1 Dipstick-interface Level measurement 4b

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)

Service instruction PETRODAT 3002 SA 070303 16.16/ HaK (24.05.16)