Engineering Application Bulletin for an

Integrated Surge Management System Power Protection Solution

CONTENTS 1.0 INTRODUCTION 2.0 THE INTEGRATED SURGE MANAGEMENT SYSTEM POWER PROTECTION SOLUTION 2.1 Overview 2.2 The Petroleum Equipment Network 3.0 THE SURGE MANAGEMENT SYSTEM 3.1 Surge Management System Distribution Cabinet Application Overview 3.2 Features of the Surge Management System 3.3 Typical Installation of a Surge Management System 4.0 PROTECTION FOR MODEMS 4.1 Telephone Line Protection 5.0 UNINTERRUPTIBLE POWER SUPPLIES FOR POINT OF SALES EQUIPMENT 5.1 Uninterruptible Power Supplies 6.0 PROTECTION FOR THE PETROLEUM NETWORK DATA EQUIPMENT 6.1 Dispenser Network Data Protection 6.2 Point of Sales Network Data Protection 7.0 THE PRODUCTS FOR A SURGE MANAGEMENT SYSTEM INTEGRATED SOLUTION 7.1 Surge Management System Part Numbers 7.2 Uninterruptible Power Supplies 7.3 Telephone Line Surge Suppressors 7.4 Petroleum Network Data Protection 8.0 SELECTING THE PRODUCTS FOR A SURGE MANAGEMENT SYSTEM INTEGRATED SOLUTION 8.1 Selecting a Surge Management System 8.2 Selecting the Uninterruptible Power Supplies 8.3 Selecting the Telephone Line Surge Suppression 8.4 Selecting the Data Circuit Surge Protection

This application bulletin and the information herein is confidential and the property of Power Integrity Corporation. This confidential information is disclosed to you on the condition that it not be disclosed to anyone other than a Power Integrity employee or an employee of your company for internal company use.

POWER INTEGRITY CORPORATION

APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

1.0 INTRODUCTION Power Integrity Corporations main field of study is the convenience store industry. During the last 10 years Power Integrity has been focused on providing a level of education to the industry. Power Integrity has been involved in evaluating oil companies electrical plans, completing site evaluations, giving on-site training and education to installers and electricians, and providing solutions to many problem sites. The integrated Surge Management System protection solution addresses the concerns and needs of the convenience store industry. The following were considered in the development of this application document. Power Protection v How do electronic circuits respond to changes in the electrical supply? v What is the susceptibility of electronic equipment to damage caused by irregular power conditions? v What are the requirements and recommendations of the governing agencies, such as: The National Electrical Code (NEC) Institute of Electrical and Electronic Engineers (IEEE) Underwriters Laboratories (UL)

The following sections describe in more detail the features, application, and pricing of each protection solution.

Modem Protectors Telephone line protectors help to provide complete protection for modems and devices that connect to telephone lines.

AC Surge Suppression Power protection is provided by a centralized Surge Management SystemTM

Uninterruptible Power Supplies Provide battery backup protection for the point-of-sales terminals and computers.

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

2.0 THE INTEGRATED SURGE MANAGEMENT SYSTEMTM POWER PROTECTION SOLUTION 2.1 Overview After reviewing general specifications and based on our experience and knowledge, Power Integrity has generated this power solution package. It is a modular electrical power protection and distribution solution package for new and tear-down/rebuild installations. A total protection package includes a Surge Management System distribution center, telephone line surge suppression, and uninterruptible power supplies. The Integrated Surge Management System Power Protection Solution provides the following: Surge Suppression Uninterruptible Power Protection for Point-of-sales Terminals and Computers Telephone Line Protection

2.2 The Petroleum Equipment Network Petroleum network equipment consists of all electronic equipment required to dispense and process the related sales transactions of petroleum products. This equipment can be identified by tracing the data communication wiring that interconnects this equipment. Data communication quality and communication ports are extremely susceptible to disturbances related to electrical problems. To have a reliable environment for the petroleum network to operate, the electrical circuits must be properly protected, specified, grounded, and installed.

Figure 2.1

The Petroleum network consists of equipment required to dispense and sell petroleum products.

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B 3.0 SURGE MANAGEMENT SYSTEM

Surge Management System Power Protection Solutions January 16, 2004

3.1 Surge Management System Distribution Cabinet Application Overview The Surge Management SystemTM (SMS) is designed to provide the required power protection for retrofit, new and remodeled sites. The SMS is mounted adjacent to the sites electrical panel and power distribution system. The SMS is a protection panel that houses multiple fused surge suppression modules. These modules are series connected in a branch circuit to provide dedicated line protection. Figure 3.1 illustrates a typical application in an existing site.

Figure 3.1 The application of a Surge Management System in a retrofit installation is shown.

3.2 Features of the Surge Management System The Surge Management System contains individual surge suppressor modules, (see Figure 3.2). Each module is connected to, and provides protection of a single branch electrical circuit. A module is to be installed in each electrical circuit that is connected to a piece of equipment that is part of the petroleum network. Figure 3.3 shows the typical connection of a single branch circuit that is connected through a surge suppression module to the electronic equipment.

Surge Suppression Modules

EXISTING ELECTRICAL PANEL

SURGE MANAGEMENT SYSTEM

Petroleum Network Electronic Equipment

Circuit Breaker

Ground Bar

Series Connected Fused Surge Suppression Module

Figure 3.2 In addition to multiple surge suppression modules the Surge Management System provides a surge suppression ground.

Figure 3.3 Series connected surge suppression modules are connected between the branch circuit breaker and the equipment being protected.

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

3.3 Typical Installation of a Surge Management System The Surge Management System is designed to be installed adjacent to the general-purpose electrical panels. Figure 3.5 shows a typical panel elevation detail as would be found in a set of electrical blueprints. In this example a Surge Management System Model PS-12-12-15 is shown.

Figure 3.5 System

A Typical Panel Elevation with a Surge Management

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B 4.0 PROTECTION FOR MODEMS

Surge Management System Power Protection Solutions January 16, 2004

4.1 Telephone Line Protection For complete protection of the petroleum network it is necessary to provide protection for all electrical paths in which surges can enter the network from the outside environment. To do so requires that all telephone circuits which are connected to any type of modems or credit card terminals be protected. Power Integrity offers two models of telephone line protectors. One model (TLP-2B) is designed for protection of a standard voice or dial-up telephone circuit. The other model (TLP-60) is designed to protect additional conductors and is used where a modem or credit card terminal may be connected to a leased high speed data line. High-speed lines can be identified by the size of the modular plug. For protection at the majority of sites (2) standard telephone line protectors and (1) high-speed data line protector will provide adequate telephone line protection.

Modem Protectors Telephone line protectors help to provide complete protection for modems and devices that connect to telephone lines. 5.0 UNINTERRUPTIBLE POWER SUPPLIES FOR POINT OF SALES EQUIPMENT 5.1 Uninterruptible Power Supplies An uninterruptible power supply (UPS) has been specified for each point of sales terminals. Each UPS is rated for 500va and provides the necessary backup time to allow an orderly shut down of the sales terminals. The UPS also prevents short power flickers such as those caused by brown outs and black outs, from resetting the sales equipment. This eliminates the waiting required for a system to reboot.

UNINTERRUPTIBLE POWER SUPPLIES Provides battery backup protection for the point of sales terminals.

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

6.0 Protection for the Petroleum Network Data Circuits and Equipment 6.1 Dispenser Data Circuit Protection Designed to protect the credit card and dispenser data that flows between the fuel dispensers and the dispenser data distribution box, the Dispenser Data Circuit Protectors provide protection against excessive voltages that can cause erroneous data and damage equipment. The system is installed in-line with the circuits running between the dispensers and the distribution box. Depending on the quantity of dispensers on site, the system includes an enclosure and up to four data protectors. The enclosure comes in two sizes for a single protector or up to four protectors. Each protector can protect up to eight circuits. Systems can be configured in either RS-485, Current Loop, or a combination dependent on the site.

Dispenser Network Data Protection

Protectors provide protection against excessive voltages that can damage equipment and cause erroneous data.

6.2 Point-of-Sales Data Circuit Protection Designed to protect the credit card and dispenser data that flows between the Point of Sales (POS) terminals and the dispenser data distribution box, the Point of Sales Data Circuit Protectors provide protection against excessive voltages that can cause erroneous data and damage equipment. The system installs in-line with the circuits running between the POS terminals and the distribution box. Depending on the quantity of POS terminals being protected, the system includes a bracket and up to four data protectors. The bracket comes in two sizes, for two protectors or up to four protectors. The system can be configured in either RS-232 or RS-422/485 depending on system requirements.

Point of Sales Network Data Protection

Protectors provide protection against excessive voltages that can damage equipment and cause erroneous data.

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

7.0 THE PRODUCTS FOR A SURGE MANAGEMENT SYSTEM INTEGRATED SOLUTION 7.1 Surge Management System Part Numbers Surge Management Systems are available for the following configurations
Standard Models Description

PS-06-06-15 PS-09-09-15 PS-12-12-15 PK-15-09-06 PK-18-09-09 PK-21-12-09

Surge Management System with 6 Surge Protection Modules Surge Management System with 9 Surge Protection Modules Surge Management System with 12 Surge Protection Modules Surge Management System PS-06-06-15 and PS-09-09-15 Two (2) Surge Management System PS-09-09-15 Surge Management System PS-09-09-15 and PS-12-12-15

7.2 Uninterruptible Power Supplies The following are the Uninterruptible Power Supplies that are recommended. All models are rated for 120VAC.
UPS Models Description Load Capacity

UPS-PICO500 UPS-PICO750

500VA, 120VAC 750VA, 120VAC

500 VA 750 VA

7.3 Telephone Line Surge Suppressors The following are the Telephone Line Surge Suppressors that are recommended.
Telephone Line Surge Suppressor Models Description

TLP-2B TLP-60

Standard Voice / Dial-up Telephone Line Surge Suppressor Leased Line Telephone Line Surge Suppressor

7.4 Data Circuit Protectors

The number and model of DCP protectors is dependent upon the configuration of dispensers and POS systems. Below are some of our DCP models. For more information contact Dave Waterman 800.237.6260 Data Circuit Protectors Description

DCP-8TCL DCP-8TRS4 DCP-AM8/232 DCPAM8/422/485 DCP-DBD9/232 DCPDBD9/422/485 DCP-DBD25/232

Data Circuit Protector 8 Pair, 50V Plug Term Current Loop Data Circuit Protector 8 Pair, Plug Term RS485/422 Data Circuit Protector, 8 Pin Modular for RS232 Data Circuits with Cable Data Circuit Protector, 8 Pin Modular 7 V for RS-422/485 Data Circuits Data Circuit Protector, DB9 M-M 15V for RS232 Data Circuits Data Circuit Protector, DB9 F-F 7V for RS422/485 Data Circuits Data Circuit Protector, DB25 M-F 15 V for RS232 Data Circuits

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

8.0 SELECTING THE PRODUCTS FOR A SURGE MANAGEMENT SYSTEMTM INTEGRATED SOLUTION 8.1 Selecting a Surge Management System To select the required Surge Management System power protection it is necessary to count the number of electrical circuits that are required to power the electronic equipment of the petroleum network. Table 7.1 is provided for assistance. Number of Circuits

Electronic Equipment Dispensers Site Control or Distribution Boxes (generally backroom equipment) Point-of-sale, POS Paypoints Managers Office PCs Automatic Teller Machines Lottery Machine Video / Security System Electronic Safes Standalone Card Readers Printers not associated with the POS Other Equipment TOTAL

Table 7.1

If the total number of circuits is less than or equal to 6 then order a PS-06-06-15. Or If the total number of circuits is less than or equal to 9 then order a PS-09-09-15. Or If the total number of circuits is less than or equal to 12 then order a PS-12-12-15.

8.2 Selecting the Uninterruptible Power Supplies To select the required Uninterruptible Power Supplies use the following guidelines. v For each Point-of-sales terminal order (1) UPS-PICO500 v If (2) Point-of-sales terminals are close enough together (1) UPS-PICO750 can be used in place of (2) UPS-PICO500 units. v For an office computer that requires a UPS order a UPS-PICO500 v Some older dispenser networks and third party point-of-sales systems may require a UPS for a control box. If so additional UPS may be necessary.

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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APPLICATION BULLETIN
AB-1044-B

Surge Management System Power Protection Solutions January 16, 2004

UPSPICO-500 UPSPICO-750

UPSPICO750 UPSPICO1000

8.3 Selecting the Telephone Line Surge Suppression To select the required number and type of telephone line surge suppressors use the following guidelines. v For each standard / dial-up telephone line order (1) TLP-2B v For each leased telephone line order (1) TLP-60 8.4 Selecting the Data Circuit Surge Suppression To select the required number and type of data circuit surge suppressors use the following guidelines.

Petroleum System Information

Dispenser
Manufacturer Qty w/ Credit Card Qty w/o Credit Card Qty w/ Speed Pass TM

Site Controller
Manufacturer Qty.

Gilbarco Wayne Tokheim Slumberger Other

Wayne EC Tokheim DHC Tokheim VXDHC Gilbarco PAM Schlumberger SAM

Point Of Sales
Manufacturer Qty.

Allied Box Other None (Integral to Point of Sales)

Wayne Plus
Gilbarco G-Site Site Controller) Autogas Regal Site Controller) (Integrated (Integrated

Dispenser Distribution Box

Manufacturer Qty.

Veriphone Ruby MSI Radiant

Glbarco UBD Tokheim 67A Tokheim 67B Tokheim 69

Other Third Party POS (RS-232) Other Third Party POS 422/485) (RS-

Schlumberger UDB Autogas UDB Other

Other Third Part POS

Power Integrity Corporation

P.O. Box 9682, Greensboro, NC 27429

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