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C4000 Master Manual v1.0.2a

1. COMMS Neutral ve Phase ve Earth Lo O 6D f H Ja J8 H T FFF ww fw w w 314 CET X alIE FE HH NINO TIT TIT TTT TTI O LD D D L LL L 4a E sw3fsw4 sw2 J swi mea TEST 0 ngos gL eo ER lzee lzee ze A jz F ZE YQ gt YM0000rR ad l l F1 F2 0 5A 0 25A O T T EY T T T T T T 1 en SLf l l l 1A L y a y re mates i Tee Ty ay ae J15 A 2 2 2 2 2 2 zi aj ee us C REO REOR se ses Fs E ss O Compac Industries Ltd Refer Electrical Wiring C4000 see page 45 for all other connections Page 10 www compac co nz Electrical Commissioning Electrical Commissioning C4000 Electrical Commissioning C4000 This procedure outlines how to perform an electrical operational test before carrying out full mechanical commissioning and making sure that the dispenser is functioning correctly Check for any damage that may have occurred in transit Che
2. On Pump On PIN Pad Dot LCD Matrix Display if Explanation Display Connected Card not read properly try re swiping In addition C4000 may be configured for REPAS pass Again the wrong card reader track or the card or card reader could be faulty HOLD System not ready Pump no longer communicating with Central Controller 0 0 The full colon on the display indicates that the processor supply has been OFF ne and back ON since the last transaction ee aes Restricted Fuel Card not validated for the pump dispenser fuel grade set Incorrect card used or the controller has the incorrect access code or ISO number z tS Wrong System x set Or requires setting for a particular Card Type UA Expired Card Card expiry date is earlier than controller date tes ene Bad Card Algorithm check sum on cards is invalid AA Wrong Pin An incorrect or invalid pin has been entered AE Wrong Network The network encoded on the card is invalidated in the controller RANGE Temperature probe out of range Only displayed when temperature setting selected on K Factor Switch Probe either faulty or not connected Low Battery Fault on Secure PIN pad Processor PCB replace complete PIN pad Memory Error Fault on Secure PIN pad processor PCB replace complete PIN pad Alr The air cut out switch has operated Flashing P GAS LPG ONLY Flow rate fell to between 0 and 6 litres min for more than 6 seconds flashing Indicates creepage
3. Normal wire position without C1210 or Wire Pm e with E 1210 or MT n Local wire not part of cable GEES O Cahlino e a 0 Cabling Option Cil4 u www compac co nz Page 75 Compac Industries Ltd Appendix A Gilbarco Interface Wiring iring Gilbarco Interface W IS Power Supply RXD TXD VIS POK mum TIO m TI srs TI2 prsi TI3 srs2 T14 prs2 TIS srs3 TIG prs3 TI7 mum TIS SPARE TI9 GND GND MICRO MICRO GND GND PERIPH PERIPH GND GND GND GND J E 8 Red Black E 4 MESETAS Gren Black 24 Hobeki el Ea 7 3 1 Blue Red E 2k Red Green 6 7 s e 7 0 23 WiseBlackiRed WhkelBlack Red Ei 11 12 Gilbarco I F TXD RXD E GND GND GND VIS ae 7 This is a 25 way cable of 24 AWG 0 5mm wire overall screen carth at the IS Power supply Cable rated to 80 C The colour coding of the wiring may vary Wire insulation gt 0 25 mm Jacket insulation 0 8 mm Microprocessor PCB dE i Bead 20 Red Green l connections on J2B are optional This plug may be used to connect to the IS Power Supply CLAN PCB or the Gilbarco Pump Comms Te GND GND VP VP GND GND TOO mrr1 TOI sri TO2 pri TO3 mrr2 TOA srs2 TOS prs2 TOG mTR3 TO7 srs3 TOS prs3 TO9 spare POK GND GND GND VL VL GND GND DCD DTR SEL CTS RXD TXD VEC GND D 2u nF n E u a 1 1 i
4. The following configurations K Factor switch settings are only available for CNG dispensers LPG dispensers or bulk meter registers As they are reasonably uncommon they have not been included in sequence with the four more common settings These uncommon settings are Density Factor dSF CNG needs appropriate software Temperature E LPG with compensation Bulkmeter ACV Valve Flow rate FLO Bulkmeter LCut L Bulkmeter H Cut H Bulkmeter F Cut F Bulkmeter Specific Density Calibration LP6 LPG with compensation and with densometer Page 28 www compac co nz Set up Modes Product Density Factor Setting the Product Density Factor Compac Industries Ltd Further Settings Available on the K Factor Switch Refer to C4000 Set Up K Factor Switch Settings see page 21 While setting the Product density factor the price display shows dSF dFb for side B and the volume display shows X XXXX Specific Density With a densometer This setting is only available for LPG dispensers with a densometer and set up for LPG with temperature compensation configuration code 7xx5x This is not available in other modes ANOTE ___ For Bulkmeter modes Sr 0 and LPG dispensers with temperature compensation but without a densometer configuration code 5xx5x the density must be set at the dispenser The specific density of the LPG is measured to allow the C4000 to accurat
5. ASNOTE ___ On a commercial pump dispenser with litres only display only the total litres can be read If the head is set up as a Comcard Compin or CWIDKey Basic system then after displaying the grand totals as above the head will also printout the totals for each card pin key irrespective of the digit 1 setting By setting digit 1 to one the Scrolling Totes option is selected Refer Displaying and Printing Totals see page 41 In this mode of operation after printing the totals as above the head will flash card totals on the pump s main display All non zero card totals are displayed consecutively for 10 seconds each ANOTE ___ The totals can only be zeroed by replacing the memory chip Conventional Pump Dispenser digit 3 set to zero or one If digit 1 is zero the pump dispenser can be operated in stand alone mode irrespective of the pump dispenser number loaded If digit 1 set to one the pump dispenser will not work in stand alone mode i e it requires initialisation from a controller ANOTE __ The pump dispenser ceases to work in stand alone mode if digit 1 is set to zero and it is connected to a controller Generally on retail forecourts this switch should be left off Hence if the forecourt controller breaks down the dispensers pumps can be set to work in the stand alone Page 19 www compac co nz b Settings Compac Industries Ltd Set up Modes mode simply by turning them OFF for
6. Cable Requirements Cable requirements are as follows Cable Type Requirements Power 3 Core Steel Wire Armour Cable 2 5mm 220 240 Volts 50 Hz 10 Core 1 230 Volt Supply Active Core 2 Neutral Core 3 Earth Dispenser 25w Idle 200W with all solenoids active Pumps with one motor 40 and 80 Ipm Single hose Motor start current 30 amps run current 6 amps Pumps with two motors 40 and 80 Ipm Dual pumps and 160 Ipm Single hose pumps Motor start current 30 amps run current 6 amps software prevents both motors starting simultaneously Comms 2 Core Steel Wire Armour Cable 1 5 mm Maximum cable length 100 m 12 V current loop A NOTE Make sure that there is at least a two metre cable tail on both the incoming underground 230 V and comms cables to reach the C4000 flameproof box Compac Industries Ltd Page 9 www compac co nz Connecting Mains Power and Communication Electrical Commissioning Connecting Mains Power and Communication A CAUTION jn sites where the electrical supply is unstable it is recommended that a power conditioner or UPS is installed To connect the dispenser 1 Wire the power and comms to the C4000 Termination Board as shown in the diagram below 2 Connect the earth lead of the supply cable to the earth stud in the flameproof junction box A NOTE All cables must be terminated with approved flameproof glands The thread is 20 mm
7. Orange Red White Red Blue Red Green Green White Black White Blue Black Red White Orange Black Green Black Blue Red Black White Black Orange Black White Red Orange Green Black Red Blue White A MIMI A E nm w Red Black White Compac Industries Ltd Page 74 www compac co nz C4000 with RS485 Forecourt Wiring Appendix A iring C4000 with RS485 Forecourt W IS Power Supply CI1 RXD TXD VIS POK maz TIO a TI1 s TI2 Fs TI3 se TI4 ma TIS ss TIG xs TI7 mm TIS sazz TIO GND GND MICRO MICRO GND GND PERIPH PERIPH GND GND GND GND GNDIS a VIS x VIS RXD A A TXD ze SEL GNDIS E 2 a p p _ o tim O E T Sareea oo DEE ERE 1 RS485 FORECOURT This is a25 way cable of 24 AWG 0 3mm wire overall screen earthat the IS Power supply Cable ratad to 80 C The colour coding of the wiring may vary Wire insulation 0 23 mm Jacket insulation 0 8 mm Cable length lt 3 m 23 Green Black White Microprocessor PCB C1140 lt 2 GI 23 Tite Dieser Dee Vare Slack Kad raue wnei GND GND VP VP GND GND TOO mtu TOI sa TO2 5731 TO3 mte TO4 sa TOS su TO6 mT TO ss TOS srs TOO sam POK GND GND GND VL VL GND GND SEL cr RXD TXD VEC GND ia Vee cc Gad RXO CTX Gas Gas
8. Set up Modes Comcard Compin amp CWIDKey Basic Systems The printer used is the Star printer with modifications Recessed in the left side of the printer are two 2 banks of dipswitches The switches are UP when set to ON see diagram below Figure 4 Star Printer Dipswitch Settings The cable used to connect the printer to the pump dispenser is supplied by Compac One end has a 25 way D connector with an interface PCB within the D connector housing The other end is a four pin AMP connector where Pin 1 Red Pin 4 Black Printer Self Test To carry out the self test press and hold down the FEED and ON LINE buttons while switching the power on Page 40 www compac co nz Set up Modes Displaying and Printing Totals Displaying and Printing Totals General Scrolling Tote Option Using a Totals Only Report Printer Receipt Printer Compac Industries Ltd To display litre and dollar totals for any single hose on a pump dispenser make sure all nozzles are hung up Then for pumps dispensers a With Preset Press either the Cancel or the Fill button on the hoses respective Preset five or more times and the totals will appear on the displays Without Preset Remove the nozzle from its holster and hold the nozzle switch in for five seconds Then press the nozzle switch rapidly five or more times ensuring that the switch clicks each time The five digit whole dollar and litre totals wi
9. Control Side A Control N C Solenoid T3 Primary Coil Solenoid Control Med 1A High Flow New Compac OCV Low 300 mA max Side A Control N C Solenoid T4 Electric Motor Control SW2 High A SW2 2 _ Tank Valve Signal SW2 2 Low 300 mA max mid Side B looped to T1 T5 Secondary Coil Solenoid Spare Spare Low 300 mA max Control Side B T6 Primary Coil Solenoid Control Low B Caltex Low 300 mA max Side B T7 Spare Med 1B SW4 2 Mobil SW4 2 Low 300 mA max T8 Spare Spare Shell Low 300 mA max T9 Spare High B BP Low 300 mA max T10 Excess flow output Turned on Auxiliary Output for Additive Pulse Low 300 mA max if flow rate exceeds 100litres min Stays on until dispenser turned off CNG Compressor Control Compac Industries Ltd Page 63 www compac co nz High Current Triac Option Solid State Relays Triacs High Current Triac Option Where high current 40A outputs are required i e driving the pump motor directly high current triacs are fitted to the power supply PCB If a high current triac is installed for T1 and or T4 then its respective snubber switch SW1 8 SW2 respectively needs to be switched to position 1 Refer Figure 8 SW1 SW2 SW4 SWITCH POSITION 1 High Current Mid Looped 2 Low Current T4 Mtr2 Mtrl Mtr Figure 8 High Current Triac Option Compac Industries Ltd Page 64 www compac co nz Indicator LEDs Indicator
10. J4 Encoder 2 J10 Totes J15 Cardreader 1 J5 Encoder 3 J11 ParSw amp Buzzer J16 Cardreader 2 J6 Encoder 4 J12 Nozzle Switches J17 Backlighting Figure 1 Layout of C4000 Microprocessor Board C4000 Components The main components associated with the C4000 head are Encoder Displays Litres Dollars litres and price Litres rate of flow and preset Preset Last Sale kilograms litres and price CNG only Page 12 Temperature compensation Card reader PIN Odometer Pad Printer Modem Mechanical Totaliser Tote Nozzle Switch www compac co nz Main Features Configurations Configurations The C4000 head can be used with the equipment listed below in the following standard configurations Single Commercial Fuel Dispenser Standard Options Extras Litres only display Card reader two one per side High Low Flow Operation Motor circuit one only PIN Pad One Encoder One Nozzle Switch C4000 Head Also see FUTRA configuration Single Suction Dual Commercial Duo Standard Options Extras Litres only display four two Preset per side Two motor circuit Two Encoders Two Nozzle Switches C4000 Head Dual Commercial Dual or Double Standard Options Extras Litres only display four two Preset per side Two Motor circuits Two Encoders Two Nozzle Switches C4000 Head Single Retail Standard Options Extras
11. conpac INTEGRATED REFUELLING SOLUTIONS C4000 Master Manual Version 1 0 2a 52 Walls Road Penrose Auckland 1061 New Zealand 3 eas peros Atare 101 os oo Aconpac BOX 117 Penrose Auckland 164 dew Zealand A Tel 64 9 579 2094 X 64 9 0639 info compac co nz www compac co nz INTEGRATED REFUELLING SOLUTIONS Conditions of Use Read this manual completely before working on or making adjustments to the Compac equipment Compac Industries Limited accepts no liability for personal injury or property damage resulting from working on or adjusting this unit incorrectly or without authorisation Along with any warnings instructions and procedures in this manual you should also observe any other common sense procedures that are generally applicable to equipment of this type Failure to comply with any warnings instructions procedures or any other common sense procedures may result in injury equipment damage property damage or poor performance of the Compac equipment The major hazard involved with installing and operating the unit is electrical shock This hazard can be avoided if you adhere to the procedures in this manual and exercise all due care Compac Industries Limited accepts no liability for direct indirect incidental special or consequential damages resulting from failure to follow any warnings instructions and procedures in this manual or any other common sense procedures generally a
12. 1 4 7 5 0 33 2 2 3 6 0 1 1 33 0 1 0 66 0 1 Compac Industries Ltd Page 50 www compac co nz Electrical Wiring C4000 Displays Litres only Retail Multi price amp Preset Displays Litres only Retail Multi price amp Preset The C4000 has a 32 pin connector on the microprocessor PCB refer General C4000 Figure 1 J7 which can be used to connect up to four display preset pairs see Figure 16 below Microprocessor PCB i PDINO _PDIN Ga MA me ore Cow TL Green fra Screen Screen 35 T DDLO DDLI GND The cables used here are all 8 way 24 AWG 0 5mm wire overall screen earthed at the microprocessor PCB Cables are rated to 80 C The colour coding of the wiring may vary Wire insulation gt 0 25mm Jacket insulation gt 0 8 mm The actual connections depends on the actual dispenser model used Figure 16 Microprocessor Display Connector J7 Figure 16 and Figure 17 show the two ends of the display preset multi price display cables The heavy line on one side of the plug indicates the side with the locking pins Commercial Retail Preset or Multi price Displays I VCC gt C DERR 3 Lecce 3 PCLK 3 el E E 5 DATA ss Blue ue 6 LO AD a 7 GND 8 sl Figure 17 Display Connector Figure 18 shows how the displays conne
13. 300 mA max Solenoid 1 Solenoid 1 T4 MTR2 Motor 2 relay control SW2 2 Motor 2 relay control SW2 Mid Low 300mA max or Internal pump motor 2 SW2 or or Mid orl LOAD2 Internal pump motor 2 SW2 1 High 40 A max T5 SFS2 Secondary Flow Coil Secondary Flow Coil Low 300 mA max Solenoid 2 Solenoid 2 T6 PFS2 Primary Flow Coil Primary Flow Coil Low 300 mA max Solenoid 2 Solenoid 2 T7 MTR3 Motor 3 relay control SW4 2 Motor 1 relay control SW4 Mid Low 300mA max MTR1 or Internal pump motor 1 SW4 or Mid orl Internal pump motor 3 SW Mid High 40 A max T8 SFS3 Secondary Flow Coil Secondary Flow Coil Low 300 mA max Solenoid 3 Solenoid 3 T9 PFS3 Primary Flow Coil Primary Flow Coil Low 300 mA max Solenoid 3 Solenoid 3 T10 Spare Spare Low 300 mA max ANOTE For a six hose MPD MPP T1 of side A loops to T7 of side B T4 of side A loops to T4 of side B and T7 of side A loops to T1 of side B Compac Industries Ltd Page 62 www compac co nz Solid State Relays Triacs Triacs C4000 LPG Single Dual CNG amp Bulk Meter Triacs C4000 LPG Single Dual CNG amp Bulk Meter Power Function High Low Terminal LPG Single Dual CNG Bulk Meter Current output T1 Electric Motor Control SW1 Low A SW1 2 Electric Motor Control SW1 2 Low 300 mA max 2 side A T2 Secondary Coil Solenoid Spare Low Flow New Compac OCV Low 300 mA max
14. until the first new transaction begins The display resolution does not affect the price display which will always display to a resolution of 0 01 dollars Setting the Display Resolution Refer to C4000 Set Up K Factor Switch Settings see page 21 Step ACTION RESULT 1 Ensure that the nozzles are hung up Dispenser in idle state Press and release the K Factor switch continuously until the Litres resolution is displayed The price display indicates Sr and the Litres Resolution is displayed as 0 00 standard resolution on 5 digit display Press and hold the K factor switch The decimal point will begin to move When the resolution decimal point is correct release the K Factor switch ANOTE The C4000 will reset itself if the K factor switch is left for more than 10 seconds Compac Industries Ltd Page 26 www compac co nz Set up Modes Solenoid Delay Compac Industries Ltd Solenoid Delay The Solenoid Delay was installed in the program to enable the delay between the submersible pump operating and the dispenser solenoids operating to be controlled on initial start up This setting should only be set on dispensers This setting should never be set more than 4 6 seconds Its main purpose is to allow the leak detector on the submersible pump to carry out its leak test The default setting is d0000 i e no delay All di
15. 1 minute minimum then back ON However for unattended situations e g truck stops the pumps must not be left able to work in the stand alone mode in case of a controller failure Therefore digit 1 should always be set to one for unattended operation For the Bulk Meter Register configuration when digit 1 is zero the unit will work in the stand alone mode When digit 1 is one the unit must be connected to a Compac Central Controller Page 20 www compac co nz Set up Modes C4000 Set up C4000 Set up The K Factor switch is located on the C4000 PCB as shown in Figure 1 The K Factor switch is used to access and change various set up options of the C4000 head The following charts detail the operation of setting up the C4000 head Any change of set up made by the K Factor switch takes effect as soon as the C4000 resets The power supply does not have to be interrupted Set up of the C4000 must be done in the following sequence K Factor Switch Settings starting with configuration setting and moving back through the options to the K Factor setting K Factor Switch Settings Setting Price Display Litres Display Reference Configuration Code C XXXXX Refer Configurations C4000 see page 13 Display Resolution Sr Sr X XX Refer Display Litres Resolution see page 26 Temperature E EXXON ena a see page 31 LPG ACV Flow rate FLO r XXXX Refer ACV Val
16. A NOTE Important information essential to the installation and operation of the Compac equipment Units of Measure The following units of measure are used in this manual Unit Measure Pressure Bar bar Temperature Degrees Celsius C Volume Litres L Cubic Metres m Mass Kilograms kg Length Metres m Millimetres mm Microns Micrometres um Inches Torque Newton Metres Nm Voltage Volts V Current Amps A Frequency Frequency Hz Compac Industries Ltd Page 7 www compac co nz Mechanical Safety Safety C4000 Controller Safety C4000 Controller Mechanical Safety Electrical Safety Safety Precautions Static Electricity Precautions Compac Industries Ltd You must adhere to the following safety precautions at all times when working on the Compac C4000 processor Failure to observe these safety precautions could result in damage to the Compac C4000 processor injury or death Make sure that you read and understand all safety precautions before operating the Compac Compac C4000 processor Observe the following mechanical precautions A CAUTION Make sure that the service area is thoroughly clean when servicing Dust and dirt entering the components reduce the life span of the components and can affect operation Observe the following electrical precautions A CAUTION Always turn off the power to the Compac C4000 processor before opening the flame proof box Never touch wiring or componen
17. ANOTE ___ The temperature is not updated while it is being displayed Setting the Temperature Refer to K Factor Switch Settings see page 21 While setting the temperature the price display shows E and the volume display shows XX X The temperature is displayed in degrees Celsius This is only available in Bulk Meter mode where the ACV Valve has Compac Designed controls The Configuration code must be set up for Compac flow modulation 4th digit set to 2 Refer to Configuration Code see page 16 Setting ACV Valve Flowrate Refer to K Factor Switch Settings see page 21 While setting the ACV Valve flowrate the price display shows FLO and the volume display shows rXXXX The desired flowrate for the system must be entered in litres per minute This is only available in Bulk meter mode This value is similar to the preset cut off used in a standard dispenser Prior to the delivery reaching its preset amount the solenoids are switched to give a low flowrate The L Cut sets the amount in litres prior to the preset amount being attained at which the solenoids will switch to a low flow rate Setting L Cut Refer to K Factor Switch Settings see page 21 While setting the L Cut the price display shows LCUT and the volume display shows LXXXX This is only available in Bulk Meter mode Page 31 www compac co nz Further Settings Available on the K Factor Switch Set up Modes F Cut Compac Ind
18. C4000 Head operates as a totally self contained system operating independently of the central controller The C4000 Comms circuitry which is usually used for communicating with a controller is now used to run an audit trail and or receipt printer Refer Printer Set up See page 40 These systems can have a maximum of 99 cards pins keys Comcard Basic The Comcard Basic system uses magstrip cards to initiate a transaction These cards are encoded with an access number and a card number There can be only one access number per pump and the card numbers must be in the range of 01 to 99 ANOTE In older Comcard basic systems card number 99 was reserved for servicing All Comcard Basic systems will have a card reader attached to the front or side of the pump dispenser Usually the card number is printed or embossed on the card If this is not the case the card can be identified in the same manner as the CWIDKey identification procedure Compin Basic The Compin Basic system simply uses a two digit PIN number to initiate a transaction This operates in the same manner as the Comcard Basic system except that digit 4 of the configuration code refer Setting the Configuration Code see page 16 must be set to two 2 Also there is no access number required The PIN number acts as the card number and all of the same totals are available CWIDKey Basic The CWIDKey Basic system uses a CWID Compac wireless Identifier key to initi
19. Fault Finding Symptom Watchdog LED is on refer to Figure 5 for the location of the Watchdog LED Diagnostic LED not flashing refer to Figure 6 for the location of the Diagnostic LED Power LED off refer to Figure 5 for the location of the Power LED Motor won t start Compac Industries Ltd High Current Triac Option Action Is the processor LED DL1 flashing Yes Turn power off Check for any foreign bodies i e wire off cuts etc on processor PCB Check all IC s are firmly in their sockets Re power the C4000 If watchdog resets i e stays off then everything is okay Replace C4000 PCB if watchdog still comes on after re power No Replace C4000 PCB Are IC s plugged in correctly Are IC chips the same Is LK1 made Are intrinsic plugs plugged in correctly Is Power LED on Yes Replace C4000 PCB No Refer below Is the power to the C4000 on Yes Check Fuse F1 Check for a short on intrinsic devices Unplug and re plug each device checking the power LED status each time If the LED still off turn power supply off for a few minutes then back on amp try again Replace C4000 PCB if fault not found No Turn on power supply amp try again Is Solid State Relay LED on Yes Check Triac Fuse F2 Check all Motor connections Check Motor Check wiring Select a spare High Current Solid State Relay if the above checks are ok No Check Nozzle Switch wiring amp operation P
20. is Er 8 Plug Single Single Suction Quad MHD s amp Name Dual 8 true MHP s Dual ENC 0 Encoder from Encoder from Encoder Encoder J3 meter side A meter from side A from product product 1 1 ENC 1 Not used Encoder from Encoder Encoder J4 side B meter from side A from product product 2 2 ENC 2 Not used Not used Encoder Encoder J5 from side B from product product 1 3 ENC 3 Not used Not used Encoder Not used J6 from side B product 2 Compac Industries Ltd Page 54 www compac co nz Electrical Wiring C4000 Displays Litres only Retail Multi price amp Preset High Low Flow Switch A High Flow Low Flow option is available on high flow dispensers pumps The two position switch is located on the side of the dispenser pump by the nozzle holster In the high flow position the full flow rate of the pump dispenser will be available at the nozzle In the low flow position approximately 40 to 70 Ipm will be available depending upon the application High Low Flow Operation Methods Method 1 When the pump is fitted with a hi lo flow switch it enables the user to be able to select two different flow rates The switch has two positions UP for high flow and DOWN for low flow 80litres m The two termination screws are located at the top When the hi lo switch is used in the HI position it energises outputs on the C4000 to operate motors 1 and 2 with a o
21. pressure bank occurs at 25 of the full flow rate To set the Sequencing rate Press and release the Parameter switch seventeen 17 or more times without holding it depressed for long enough to change any digits until SE9 XXX appears Hold the switch depressed until the correct sequencing rate is displayed then release The displayed sequencing rate is now selected and operation of the dispenser will be affected immediately The displays will reset after a ten 10 second timeout Validating Invalidating Cards Pins or Keys Setting the Access Code Compac Industries Ltd This is only available on Comcard Basic Compin Basic or CWIDKey Basic systems i e b setting digit 3 2 1 Ensure that the nozzle is hung up Press the Parameter switch 16 or more times without holding the switch depressed long enough for any digits to change or for the system to enter the pump number setting mode The switch must be depressed for two seconds or longer for the latter to occur Card status information will then appear on the litre display panel The left of the display panel shows a Y or n where Y is Valid amp n is Invalid the right of the panel shows the two digit card pin or key number 2 The desired card pin key number can be selected by changing each digit using the usual press hold release method with the Parameter switch When the figure on the left side of the display panel is selected it can be changed from n to
22. terminal and GND Closing the contacts on the flow selector switch of Side A FLOWO causes the T7 output terminal to energise For Side B the T9 output terminal is energised In Method 1 the 38mmNB Solenoid is wired to the T7 output and the flow selector switch is closed in the high flow position In Method 2 the 18mmNB Solenoid is wired to the T7 output and the flow selector switch is closed in the low flow position Compac Industries Ltd Page 55 www compac co nz Displays Litres only Retail Multi price amp Preset Electrical Wiring C4000 Totalisers Compac Industries Ltd Electromechanical Totalisers Only approved Compac totalisers are to be used Some totalisers have a ve and a ve terminal Electronic Totals As well as having electromechanical totalisers for litres dispensed from the pump each C4000 stores in its memory a five digit litres total of fuel dispensed from each hose Both these totals are non resettable These totals can be displayed by pressing the CANCEL or FILL buttons on the preset keypad of the meter hose in question five times in quick succession The totals will then appear on the pump displays on the LITRES and DOLLARS display for ten seconds before the display resets In the absence of a preset keypad remove the nozzle from the nozzle holder Hold the nozzle switch down for at least three seconds and then tap it down five times in quick succession The totals will appear a
23. the Display Segment Test set price product density if a bulkmeter or LPG and set pump number Also when the C4000 is configured for Comcard Compin or CWIDKey the parameter switch is used for card pin key validation and for setting the card key system number Configuration Code The C4000 pump dispenser software the configuration code used to set the pump dispenser to single dual or multi mode has been extended to 5 digits When configuring the pumps dispensers the litre display will display each digit ANOTE ___ For FUTRA software configuration options see the FUTRA service supplement ANOTE Multi hosed Pump Dispenser with LPG An MPD with LPG is configured by setting digits 5 3 and 4 5 With COM125 magnetic or Bennett meters to set LPG compensation and motor spirit without correction set digit 1 4 For COM125 optical meters when motor spirit correction is required as well set digit 1 6 Refer Setting the Configuration Code see page 16 Setting the Configuration Code Refer to Figure 3 While setting the configuration code the price display shows C and the volume display shows XXXXX Compac Industries Ltd Page 16 www compac co nz Set up Modes 0 2 B 6 Configuration Code Configuration code as displayed AOA AA IF Norm al Res lution Standard or Hiflow Bulkm et enn Resolution Bulkmetering om Card Ba b settings digt 3 setto two On Der Ss i b settings digit 3
24. 00 Basic Systems Comcard Compin amp CWIDKey Electrical Wiring C4000 230 Volt wiring Power for the C4000 head connects to the terminals marked Phase Neutral amp the Earth Stud Refer Connecting Mains Power and Communications see page 10 On the C4000 Power supply PCB the incoming phase feeds the microprocessor power supply through the fuse F2 250mA and feeds all low current solid state relay circuits through the fuse F3 1A Solenoids and motors are connected to the appropriate terminals Communications Comms Wiring Communication cables connect to the comms terminals marked Red and Black Refer Connecting Mains Power and Communications see page 10 CAUTION The Communications wiring is a 12 volt circuit and any contact with mains will cause permanent damage The C4000 can communicate with the following Forecourt Controllers Micro M Eftpec Compac Central Controller Task Postec Compac Commander Comms DIP Switch settings The Comms dipswitches are on the C4000 power supply PCB Refer Figure 7 Solid State Relays Triacs see page 60 Figure 9 Comms DIP Switch Settings Standard Compac Comms or PEC Comms Switch 1 3 ON Switch 2 4 OFF With Gilbarco consul interface Switch 1 3 OFF Compac Industries Ltd Page 45 www compac co nz Basic Systems Comcard Compin 8 CWIDKey Electrical Wiring C4000 Switch 2 4 ON C4000 Gilbarco Protocol Converter A Gilbarco interface boar
25. 2 Connector to C4000 Microprocessor PCB J8 Page 47 www compac co nz Basic Systems Comcard Compin amp CWIDKey Electrical Wiring C4000 Display Backlighting Card readers Compac Industries Ltd CONOaARWHND l O 2 ES l Dp 8 9 Figure 13 Connector to Temperature Compensation PCB CON5 The pressure sensors and temperature sensors supplied by Compac have the appropriate plug to be able to plug them into the Temperature Compensation PCB The backlighting PCB s consist of several red backlighting LED s and the PCB s are mounted on stand offs behind the displays The backlighting PCB s are supplied from the C4000 Backlight plug J17 This is an intrinsically safe supply The C4000 can drive two Card readers They plug into the C4000 Microprocessor PCB Connectors J15 amp J16 The Card readers can be a Track 1 or Track 2 type card reader The track number indicates the track on the magnetic strip of the card which will be read ANOTE ___ Compac Systems will be either a TK1 or a TK2 type and will never be used both together This is because information is coded and therefore gathered from either the first track or the second track of the coded magnetic strip Page 48 www compac co nz Electrical Wiring C4000 Compac Wireless Transceiver Compac Wireless Transceiver The CWID PCB is mounted in a separate enclosure Connector CON5 on the CWID PCB see below connects to J1
26. 3 on the C4000 Microprocessor PCB Refer Description C4000 with an eight wire cable see below 5 Broma PN ry VCC 1 Ll eae ls los GND 2 rl 3 Rx GND 3 5 _ 4 RXO 5 re GND 6 END GND 7 Pp GND 8 CTK 9 GND 10 Figure 1 CWID CONS to microprocessor J13 cable CONS AERIAL CON4 POLL Rx Tx Figure 2 CWID CI 101 issue D PCB Compac Industries Ltd Page 49 www compac co nz Compac Wireless Transceiver Tuning the Aerial Electrical Wiring C4000 Whenever the CWID PCB is changed the aerial will need to be tuned For locations of the connectors refer to the picture in CWID Interface Board Replacement 1 2 10 1 12 13 1 Connect a Multimeter set to Volts to CON8 Place a shorting link across pins 2 amp 3 of CON4 The poll LED will flash slower indicating Tuning Mode Using the dipswitches SW adjust the capacitance to obtain the maximum voltage at CON8 Each dipswitch adds a capacitor to the tuned circuit The DIP switches 1 to 5 are primary capacitors while 6 to 8 are fine tuning capacitors Use the following technique Turn on Switch 1 and measure voltage turn on switch 8 and see if voltage rises or falls If it rises turn off 8 and turn on switch 2 Continue this procedure for switches 3 4 and 5 until you get a voltage drop If the voltage drop occurs at switch 2 3 4 or 5 then return to the previous switch and add switches 6 7 and 8 until the voltage drops
27. 36 www compac co nz Set up Modes Setting the Product Density Parameter Switch Only available in Bulkmeter mode when Sr 0 or LPG with compensation but without a densometer configuration code of 5xx5x The product density kg m3 must be set In bulkmeter mode this can be done either at the register for stand alone C4000 Heads or at the central controller For controller sites the density entered at the register must be zero to allow the controller set density to override On LPG dispensers the product density kg m3 is set at the dispenser If the C4000 is in Bulkmeter mode or set up for LPG with temperature compensation but without a densometer Configuration code 5xx5x then the density can be set using the parameter switch ANOTE This is not available in other modes While setting the Specific Density the price display shows dEn and the volume display shows XXX X the density Kg m3 15 C Setting Specific Density Settable density ACTION RESULT Press and release the The price display top shows Parameter switch in quick dEn and the volume display succession until the density is shows the density XXX in displayed kg m3 15 C to increment When the digit is correct release the Parameter switch Repeat steps 3 and 4 for each NOTE ___ The C4000 will A digit of the density will begin digit of the density reset itself if the Parameter switch is left for mor
28. Dispenser in idle state hung up 2 Press and Hold the The Price for hose 1 is displayed Parameter switch operated as PX XXX and Pr1 is until the Price per litre is displayed on the price display displayed 3 Press and hold the A digit of the displayed Price per Parameter switch litre will begin to increment 4 When the digit is correct release the Parameter switch 5 Repeat steps 3 and 4 for ANOTE The C4000 will each digit of the Price per litre reset itself if the Parameter switch is left for more than 60 seconds Continue for other hoses 6 Press and release the The Price per litre for the next Parameter switch 8 or more hose is displayed as PX XXX times in quick succession Pr2 Pr3 or Prd is displayed on the price display 7 Repeat steps 3 to 5 above ANOTE Ifa Compac Central Controller EFTPEC Task forecourt controller or Compac Commander is used the price must be set to zero 0 at the pump dispenser The price can then be set at the Controller This applies to all configuration display options ANOTE The dispenser pump will stop when the dollar amount reaches 999 99 high flow 9999 9 or the litre amount reaches 999 991 high flow 9999 91 whichever occurs first Page 35 www compac co nz Parameter Switch Setting the Price for True Multi Product Configuration Compac Industries Ltd Step ACTION Set up Mod
29. Dollars litres and price Card reader display two one per side PIN Pad Presets two one per side Receipt Printer One Encoder One Nozzle Switch One Motor Output C4000 Head Also see FUTRA configuration Compac Industries Ltd Page 13 www compac co nz Configurations Single Suction Dual Retail Duo Standard Options Extras Dollars litres and price display two one per side Presets two one per side Two Encoders Two Nozzle Switches Two Motor Outputs C4000 Head Dual Retail Dual or Double Standard Options Extras Dollars litres and price display four two per side Presets four two per side Two Encoders Two Nozzle Switches Two Motor Outputs C4000 Head Multi Product 4 hose Retail Standard Options Extras Dollars litres and price a Card reader display two one per side PIN Pad Presets two one per n Receipt Printer side Pisan Four Encoders Four Nozzle Switches Two Motor Outputs One C4000 Head Multi price Displays four one per product per side Multi Product 4 hose Retail Type A Standard Options Extras Compac Industries Ltd Dollars litres and price display four one per product per side Presets four one per product per side Four Encoders Four Nozzle Switches Two Motor Outputs One C4000 Head Page 14 Main Features www compac co nz Main Features Multi Product 6 hose Retail Standard Op
30. LEDs Compac Industries Ltd High Current Triac Option POWER LED WATCHDOG LED COMMS RXD LED D6 COMMS TXD LED q EPROM MEMORY UPROCESSOR 5 uu oe O O microProcessor PCB m TT En no m IT TA PTA PTATTTTTTTA TTTTT mT TE ta nr Li TEER SHAR n H nen SS Wet TO Nae IS agepage55a8B fal me H u alli TTL uu Loy Lim Luin aaa J2A_J2B u 7 73 312 JJ Co Je J13 ii J10 Jg J15 J14 J J5 J4 J3 Figure 5 Location of Power Watchdog RXD amp TXD LEDs Power LED The Power LED refer Figure 5 lights when the processor board has power If this LED flashes this indicates that the processor has a fault on the processor power supply WatchDog LED The Watchdog LED refer Figure 5 lights only if the watchdog circuit has been triggered thereby indicating that a processor fault has occurred TXD amp RXD LEDs The TXD and RXD LEDs refer Figure 5 indicate polling of communications to from a controller The RXD LED flashes whenever any communi
31. M C4000 o aa 10 SECURE PINPAD J13 EI OY Ms N g gol o il MH O ol 5 Figure 19 Secure PIN Pad Modem This device is not covered in this part of the manual Refer to the FUTRA Service Supplement Compac Industries Ltd Page 53 www compac co nz Displays Litres only Retail Multi price amp Preset Encoder Electrical Wiring C4000 The rotary encoder translates meter turns into electrical pulses Each turn of the Bennett meter equals approximately 0 5 litre eight turns one US gallon The encoder converts this to 150 pulses so that each pulse corresponds to approximately to 3ml Exact values are One rotation 0 47 litre 150 pulses 0 47 litre One pulse 3 1 ml When the C4000 head is used for other meters this ratio can vary e g from 0 5 litres turn to as high as 10 litres turn The encoder will rotate up to 600 rpm before tripping an Er 7 message If the encoder is disconnected the C4000 will not start the pump and an Er 9 message will be displayed The encoder connects to the C4000 via a six core only five cores used data cable The five cores used are Orange or White 5V terminal Yellow or Black OV terminal Brown BO terminal Blue B1 terminal Red B2 terminal Where BO B1 8 B2 are the three opto senser connections To reverse the rotation of the encoder sensing the BO 8 B2 wires should be reversed The error message for reverse rotation
32. Printer to the Central Controller Comms Port 3 to obtain printouts Two operational options can be configured at the pump dispenser C4000 when the Receipt Printer is connected like this 1 Ifa Receipt Printer is connected to the Controller and left ON LINE then by setting the third digit of the Configuration Code to 0 or 2 for standard or Secure PIN pad operation respectively a receipt will be printed after each transaction This should be the set up chosen when a receipt is always required or when the pump dispenser does not have Page 42 www compac co nz Set up Modes Basic Systems Comcard Compin amp CWIDKey a PIN pad installed 2 Ifthe pump dispenser has a PIN pad connected then it can be configured to display a receipt prompt as part of the transaction authorisation process This prompt would be the same as for a pump dispenser with a Receipt Printer connected to the C4000 detailed on the previous page To select this option the third digit of the Configuration Code for the C4000 should be set to 4 or 5 depending upon whether a standard or Secure PIN pad is installed on the pump dispenser Electrical connection of the Receipt Printer in this mode is covered in the Central Controller Service Manual Basic Systems Comcard Compin amp CWIDKey Compac Industries Ltd For these systems to operate the b setting digit 3 must be set to two Refer b Settings see page 18 In this mode of operation the
33. Set up see page 40 No Check cable and plug If no fault found contact Compac Help Desk Page 68 www compac co nz Fault Finding Error Codes Error Codes Error Code Fault Action Err 3 No price set Set a price at the pump or at the controller Check connections Err 4 CWID offline Change CWID PCB Err 7 Excess flow Check for air Err 8 Excess reverse rotation of encoder NESK product e nor flowing pac me the tank once the delivery has finished Err 9 Faulty encoder or disconnected encoder Check encoder circuit Err 10 Configuration Lost Reconfigure C4000 Invalid access code Err 11 Enter valid access code Comcard or CWIDKey Basic systems only Err 12 C4000 memory failure Change memory E2prom chip Err 13 Temperature Pressure Interface unplugged Reconnect interface board or replace Err 14 Temperature Probe disconnected Reconnect temperature probe or replace Err 15 Pressure Probe disconnected LPG only Reconnect pressure probe or replace Compac Industries Ltd ANOTE __ For Error 7 LPG also occurs if flow rate exceeds 100 litres min For Error 8 excess reverse rotation means the encoder has turned backwards more than 3 4 of one turn during a delivery or within two seconds of the end of a delivery This only occurs if the non return valves installed on site are faulty Page 69 www compac co nz Error Messages Error Messages Fault Finding
34. When the drop occurs revert to the previous switch If there is no voltage drop as switches 6 7 and 8 are added compare this voltage to the voltage achieved at the next primary switch with 6 7 and 8 turned off If you can t get a voltage drop when the fine tuning switches are used use the chart below to calculate a capacitance figure between the switch combination achieved above For example lf 1 2 6 7 8 7 3 nF obtains a higher voltage than 1 2 3 8 33nF then try 1 2 5 7 33 nF if the voltage reading is higher than the two previous combinations switch on 8 then 7 then 6 until you get a drop If no drop is measured then try 1 2 4 7 66 nF Keep working with combinations until you get the voltage drop when one of the fine tuning switches is added or you have run out of combinations Always use the setting that achieves the highest voltage If the voltage drop occurs at step 5 turn off switch 1 and turn on switches 2 3 4 and 5 then test for voltage drop with switch 8 If voltage drops then turn off switch 5 measure voltage and test again with switch 8 Continue with combinations until a voltage drop occurs when one of the fine tuning capacitors is switched on Though the CWID aerial can work at lower voltages the voltage reading should be above 28 Volts Remove the shorting link fitted at 2 above Test the operation with a valid CWID key Dipswitch SW1 Capacitance nF Dipswitch SW1 Capacitance nF
35. Y to n etc by holding the Parameter switch depressed Therefore the respective card status can be selected by releasing the switch when the desired card status symbol is displayed To change multiple cards repeat the above process for the appropriate card numbers The display will return to normal operation after the Parameter switch is not operated for ten 10 seconds ANOTE ___ On older systems Card 99 is the Service card and was universally accepted by all Comcard card readers This is only available on Comcard or CWIDKey Basic systems i e b setting digit 3 2 ANOTE __ Compin does not require any Access Code Depress the Parameter switch 24 or more times without holding it depressed long enough to change any digits until AXXXX appears on the Page 38 www compac co nz Set up Modes Compac Industries Ltd Parameter Switch display This number is different for each Compac Card Key System which ensures that the cards keys for any one system cannot be used on any other systems The access code can be changed by the usual press hold release method using the Parameter switch ANOTE ___ Access Code will only need to be changed to prevent an existing Card Key System being used or to allow a new card system to be issued in the case of several lost or stolen cards Refer also to Displaying and Printing Totals see page 41 Page 39 www compac co nz Printer Set up Printer Set up Compac Industries Ltd
36. ac supplier using the contact details in the Product Identification section Information in this manual shall not be deemed a warranty representation or guarantee For warranty provisions applicable to this unit please refer to the warranty provided by the supplier Unless otherwise noted references to brand names product names or trademarks constitute the intellectual property of the owner thereof Subject to your right to use the unit Compac does not convey any right title or interest in its intellectual property including and without limitation its patents copyrights and know how Every effort has been made to ensure the accuracy of this document However it may contain technical inaccuracies or typographical errors Compac Industries Limited assumes no responsibility for and disclaims all liability of such inaccuracies errors or omissions in this publication Contents Product Identification C4000 Processor cccceseeeeeeeeeeeeeeee eee eeee eee eaaeae eases ea aseaeeeeese se aasaaeeesesesesseeaeaeseseseeeeeeneeees v Doctiment Control Information A a dasani aa aadi aiai Nada 6 Symbols and Units of Measure oonmmiccnnnncccnninnincrrnnr 7 Safety C4000 Controlle aa a aaae ar eea aaa raa a aan Aane raa rr 8 Mechanical Sel iii a a a a a e a a A S 8 Electrial Satety ciao pad 8 Safety PreCaUtlOMs sx irc pt dio capota cia eee tna 8 Electrical COMMISSIONINO id aliada 9 Cable Regue MENS ias 9 Connect
37. age 67 www compac co nz High Current Triac Option Fault Finding MN Replace C4000 PCB if fault not found Motor running all the time Solenoid not energising Preset Display Digit flashing Secure PIN Pad Display Off Secure PIN Pad not accepting numbers Star Printer not working Compac Industries Ltd Is Solid State Relay LED on Yes Check Nozzle Switch is releasing No Select a spare High Current Solid State Relay Replace C4000 PCB if fault not found Is Solid State Relay LED on Yes Check Triac Fuse F2 Check all Solenoid connections Check Solenoid Select a spare Low Current Solid State Relay if the above checks are okay No Check Nozzle Switch operation Replace C4000 PCB if fault not found Is the respective Preset Button stuck in Yes Remove grit if any and check spacing of keypad to fascia gives good key operation Check wiring amp condition of display plugs No Replace keypad If problem still exists replace preset PCB Is PIN pad backlighting on Yes Check 5V and TX wires for continuity NO Check the OV wire for continuity and that the plug is secure Replace Secure PIN pad if fault is not found Is PIN pad display on Yes Check RX wire for continuity No Check cable and plug If no fault found replace the Secure PIN pad Is power on Yes Check connection of comms cable Check dip switch settings refer Printer Set up see page 40 Carry out self test refer Printer
38. anical totals should also be recorded In the case of Comcard Basic Compin Mining or CWIDKey Basic systems a printout of card pin key totals must be obtained before changing software This printout will also give card pin key validation status If no printer is available use Scrolling Tote option refer Totalisers see page 56 The above steps are taken to safeguard against software incompatibility causing loss of information Turn off power Remove software EPROM removable chip labelled C4000 PXX or XX X XX XX X using an EPROM extractor See Figure 1 for the location of the EPROM Plug in new software EPROM being careful that the dimple is at the correct end of the socket i e software chip dimple to base dimple Also that all the legs are correctly located in the socket see diagram below Turn on power Check that the data recorded in Steps 2 and 4 is still present if not re enter Check the electronic totals if not as before then give before and after totals to relevant people on site Ensure that the status of cards pins keys on Comcard Compin or CWIDKey systems are as before If they are different in any way ensure that the relevant people on site receive before and after Page 58 www compac co nz Software Upgrade Procedure EEprom Socket Figure 3 Memory chip installation Figure 20 Software IC Insertion Compac Industries Ltd Displays Litres only Retail Mult
39. ate a transaction These systems have a CWID aerial placed at the nozzle or on the pump dispenser Where the aerial is placed at the nozzle the CWID tags must be mounted in close proximity to the filling spout If the aerial is on the dispenser the customer must hold the CWID tag close to the reader panel on the dispenser The CWID tags are a small approx 32mm x 5mm diameter sealed tag They do not require batteries The CWIDKey Basic system operates in the same manner as the Comcard Basic system except that digit 3 of the configuration code refer Setting the Configuration Code see page 16 must be set to six 6 The CWID tags Page 43 www compac co nz Basic Systems Comcard Compin amp CWIDKey Set up Modes Compac Industries Ltd are encoded with an access code and a key number in the same way that a comcard is encoded CWIDKey Number Identification When a valid key is presented to the dispenser the display will alternately flash the key totals then the key number until the nozzle is lifted The key number is displayed as c xx where xx is the keynumber The access number is never displayed If an invalid key with the correct access code is presented to the dispenser the display will show for one second then the key number for one second If a key with an incorrect access code is presented to the dispenser then the display will only show for two seconds Page 44 www compac co nz Electrical Wiring C40
40. be cleared is by replacing the C4000 memory IC chip The displays are only capable of displaying five digit whole litre totals maximum of 99999 but the C4000 memory stores seven digit whole litre totals maximum of 9999999 99 for printing With Central Controller and Futra systems it is possible to install a receipt printer either at the pump dispenser or at the Central Controller The receipt printout includes the following information Site Number Pump Number Card Number Reference Number Date Time Product Litres Dollars Dollars per litre Odometer Reading if prompted Page 41 www compac co nz Displaying and Printing Totals Electrical Connection Compac Industries Ltd Set up Modes Printer Housed at the Pump Dispenser Card King This is only permissible in Type B fuel pumps dispensers as defined by AS2229 1 or in pumps dispensers used in applications where less stringent requirements are set This is because the printer is not an intrinsically safe device and must have access to the pump dispenser exterior for the printer paper slot The printer receives the data for printing and cutter operation from the C4000 microprocessor PCB via an interface PCB C1125 which also provides the printer with a 12V power supply The interface PCB provides opto isolation between the C4000 intrinsically safe circuitry and the unsafe printer circuitry for the printer driver signal This Receipt Printer op
41. cations polling is received and the TXD LED flashes whenever the C4000 processor responds to polls for its respective pump number s Page 65 www compac co nz High Current Triac Option Compac Industries Ltd Indicator LEDs EJ ra E ot en as uno tees TI E E Q u ee C4000 microProcessor PCB 2 ps m mmm mmm a Mi HHTHH SA HHH r En IOMA Hot m m u In u E EPROM MEMORY UPROCESSOR u PEA O q ag uu r h 1 38 J12 sn no Js NS J4 Ie 5 J4 B Output LEDs Pppp pppd Diagnostic LED Figure 6 Location of Output amp Diagnostic LEDs Output LEDs The ten Output LEDs refer Figure 6 indicate which triac outputs are being switched on D8 D17 corresponds to the output triacs T1 T10 refer Figure 7 Diagnostic LED The Diagnostic LED Figure 6 flashes in three different states when the processor is working properly When the pump is idle and in stand alone mode the LED flashes slowly and consistently When the pump is idle and communicating with a controller the LED flashes slowly but erratically When the nozzle is lifted from its holster the LED flashes quickly Page 66 www compac co nz Fault Finding
42. ck all terminals plugs and chips to make sure that they are securely in place A NOTE Damage to electronics occurs most commonly from vibration and jarring Before beginning this test check that fuel has not been applied to the dispenser The factory set up information should be programmed into the dispenser but all K factor and Parameter switch settings should be checked and confirmed before commissioning tests are carried out Check that pump number is set See Setting the Dispenser Pump Number see page 37 Check the pump price is set See Setting the Price per Litre see page 34 To perform an electrical operational test 1 Make sure that the inlet shut off valves are closed these are the valves in the inlet lines at the base of the dispenser but they are not part of the dispenser 2 Turn on the power supply to the dispenser With the dispenser in a ready state check that the C4000 Microprocessor Power LED D1 is turned on A NOTE If the dispenser is receiving information Comms RXD LED D6 will poll If the dispenser responds to polls for its respective pump number s Comms TXD LED D7 will also poll Diagnostic LED D18 slowly flashing If the dispenser is connected to an operational Controller it flashes slowly but erratically If the dispenser is not connected to a Controller it flashes slowly and consistently Watchdog LED D5 is turned off 4 Lift the nozzle The display will show 888888 and th
43. ct to the C4000 for various dispenser models The four circuits 0 3 shown in Figure 18 are the same four circuits shown in Figure 16 Compac Industries Ltd Page 51 www compac co nz Displays Litres only Retail Multi price amp Preset Electrical Wiring C4000 AS a Aa a Y 232 Single Dual Duo or Double configuration l S 8 SS l E S Retail or Commercial Preset Display l 3 Displays AP209 C1120 CI121 C1123 C1127 amp Keypad i l or C137 CI114 One side of a six hose true multi product configuration MPD Display CI147 amp Keypad C1149 Four hose True Multi product configuration MPD Display MPD Display C1147 C1147 amp Keypad amp Keypad C1149 CI149 All hose Quad configuration Retail or Commercial Preset Display Displays AP209 C1120 C121 C1123 C1127 Keypad I or C1137 Side A 1 CI114 Figure 18 Display Connections for Various Dispenser Models Compac Industries Ltd Page 52 www compac co nz Electrical Wiring C4000 Displays Litres only Retail Multi price amp Preset Secure PIN Pad Unit When connecting a BP Secure PIN pad to a C4000 a Distribution board Cl 36 is required as an interface ANOTE ___ The Secure PIN pad C4000 combination only works with old type Central Controllers Special software is required for the C4000 Secure PIN pads are not supported in either Futra or Communicator Controller software F CP C1DISTRT sa FRO
44. d C1143 plus any software version HIA29107 onwards or HIU29107 for USA Gilbarco protocol is required if the C4000 is to connect to a Gilbarco Consul The Comms dipswitch settings See Figure 7 amp Figure 9 must be set with switches 1 amp 3 OFF and switches 2 amp 4 ON The Gilbarco interface board plugs onto the IS Power supply PCB in the Flameproof box The IS Cable must be setup to connect to the Gilbarco interface board The Comms still connects to the Red amp Black terminals as with the standard Comms Intrinsically Safe Wiring The location of the various connectors are shown in Figure 1 Refer Description C4000 Air Detector Cut out Switch The Air detector cut out switch is required on any Bennett pump pumping diesel or any Bennett pump pumping any product at more than 55 litres per minute This switch is a normally open pressure activated switch which closes when the pressure of the air venting from the pumping unit exceeds a preset level The closing of this switch disables the C4000 s outputs ending the transaction in progress The pump can be re authorised and another transaction can take place immediately after the pump stops without the need to de power and re power the electronics AIR AIRI Figure 10 Connector J12 Nozzle Air Sump and Flow switches Nozzle Switch es Compac Industries Ltd Page 46 www compac co nz Electrical Wiring C4000 Sump Switch Temperature Pressure Co
45. digit of the displayed Price per Parameter switch litre will begin to increment 4 When the digit is correct release the Parameter switch 5 Repeat steps 3 and 4 for NOTE The C4000 will each digit of the Price per reset itself if the Parameter switch litre is left for more than 60 seconds Continue for Dual hose units 6 Press and release the The Price per litre for side B is Parameter switch 8 or displayed as bX XXX and Pr is more times in quick displayed on the price display succession 7 Repeat steps 3 to 5 above ANOTE If a Compac Central Controller EFTPEC Task forecourt controller or Compac Commander is used the price must be set to zero 0 at the pump dispenser The price can then be set at the Controller This applies to all configuration display options The dispenser pump will stop when the dollar amount reaches 999 99 high flow 9999 9 or the litre amount reaches 999 991 high flow 9999 91 whichever occurs first The dispenser will not allow the price litre to be altered during a delivery When the price litre is altered the dispenser will display the new price litre for at least 5 seconds before allowing a new transaction to begin Compac Industries Ltd Page 34 www compac co nz Set up Modes Setting the Price for Quad four Hose Configuration Compac Industries Ltd Parameter Switch Step ACTION RESULT 1 Ensure that the nozzles are
46. due to presence of vapour Compac Industries Ltd Page 70 www compac co nz C4000 with RS232 Wiring Appendix A Appendix A iring C4000 with RS232 W IS Power Supply C1139 RXD TXD VIS POK mane TIO ne 111 srsi 112 resi 113 srs2 T14 prs2 T15 ss 116 Pesa TIF nera TIS spare 119 GND GND MICRO MICRO GND GND PERIPH PERIPH GND GND GND GND GNDIS Crs VIS DCD v o oa no _4Green 4 C Somme O 6e da 7 White Black 8 RedBlack 9 Green Black OO 11 Blue Black 12 BlackWhite 13 RediWhite A 14 GreeniWhite 15 Blue White 17 White Red 21 Orange Green 22 Black White Red Screen 00 00M wone a ES N 0 a u o ONDA A wN e 24 Red Black White 23 White Black Red Ped 18 OrangeRed 4 Black 13 Blue Red__ 20 Red Green 16 BlackRed o This is a 25 way cable of 24 AWG 0 5mm wire overall screen earth at the IS Power supply Cable rated to 80 C The colow coding of the wiring may vary Wire insulation 0 25 mm Jacket insulation 2 0 8 mm Cable length 3 m Microprocessor PCB C1140 15 Blue hite 16 Black Red 21 Orange Green 22 Black White Red 5 Orange 7 White Black A OBADARWN H Ll Bree fm 130 ee 4 10 Oranqe Black 12 rss 45 11 Blue Black 12 BlackiWWhite 14 GreeniWhite 16 A 1 49 17 W
47. e A Comcard or CWIDKey pumps dispensers only Conducting Display Segment Test ANOTE Parameter Switch Settings all must be set but the order of the set up is not critical To determine program version number hang up the nozzle then push the parameter switch once The system enters a diagnostic mode whereby it displays the program type data and performs a display segment test When showing program data the display panel shows PXX where XX is the program version number Page 33 www compac co nz Parameter Switch Set up Modes Setting the Price per Litre The C4000 processor board can be set for five hose configurations 1 Single e g one C4000 controls one hose 2 Dual e g one C4000 controls two hoses 3 Quad e g one C4000 controls four hoses but only two one per side can operate at any time 4 True Quad e g one C4000 controls four hoses which can all operate at once 5 Six e g one C4000 controls six hoses but only two can operate at once The following charts are to be used to set the price Setting Price for a Single or Dual Hose Configuration Step ACTION RESULT 1 Ensure that the nozzle is Dispenser in idle state hung up 2 Press and Hold the The Price for side A is displayed Parameter switch operated as PX XXX and Pr is displayed until the Price per litre is on the price display displayed 3 Press and hold the A
48. e solenoids energise starting the pump motor Check that Diodes D8 D10 and D11 turn on indicating a signal is being sent to the triacs to open the solenoid valves The diagnostic LED D18 flashes quickly when the start button is pushed or the nozzle removed from the holster to initiate a fill When the button is released or nozzle returned to the holster it will return to the normal state and flash slowly 5 Verify solenoid operation by listening for a click or by using a screwdriver tip or some other metallic tool to check for a magnetic field present on the solenoid coils The solenoids will switch off after four minutes This is a default time out setting in the software for situations when there is no fuel flow registered Compac Industries Ltd Page 11 www compac co nz Compac Industries Ltd C4000 Components Main Features Main Features The Compac C4000 is a microprocessor based circuit board designed for use in liquid and gaseous fuel metering systems It is suitable for commercial retail and bulk metering applications and can be used for tank gauging card reader access and many other control functions yossa90udn m u u AYOwaw 2 u H K FACTOR 3 SWITCH A S Ow 3 3 0p1 19 Aline co 0 yo EE COMPAC IND C4000MPU J1 Comms Test To l S Power J7 Displays J8 Temperature Comp J13 CWIT Secure PINPad J3 Encoder 1 J9 PINPads J14 Printers
49. e than 60 seconds ANOTE The same density is used for all hoses on a multi hose dispenser Setting the Dispenser Pump Number Press and release the Parameter switch nine 9 or more times and the message Pn will appear on the Price top display The number displayed in the volume middle display is the pump number Press and hold the parameter switch and the processor will roll the displayed number until the switch is released The value of the displayed number will then be stored as the pump dispenser number Displaying the End of Sale Indications Compac Industries Ltd Press and release the Parameter switch nine 9 or more times and the message Pn will appear on the Price top display The number displayed in the volume middle display is the pump number and the number displayed in the price per litre bottom display is the end of sale indicator Page 37 www compac co nz Parameter Switch Setting the Sequencing Rate Set up Modes This is only available for CNG Dispensers ANOTE ___ Needs appropriate software The rate of sequencing between pressure banks for the CNG dispensers is done on a percentage basis There are three percentage settings to choose from Fast FAS switching to the next higher pressure bank occurs at 45 of the full flow rate Normal nOr switching to the next higher pressure bank occurs at 35 of the full flow rate Slow SLO switching to the next higher
50. econdary Flow Coil Secondary Flow Coil Low 300 mA max Solenoid 1 Solenoid 1 T3 PFS1 Primary Flow Coil Primary Flow Coil Low 300 mA max Solenoid 1 Solenoid 1 T4 MTR2 Motor relay control SW2 2 Motor relay control SW2 2 Low 300mA max orl or Horo Hor LOAD2 Internal pump motor SW2 1 Internal pump motor SW2 1 High 40 A max T5 SFS2 Secondary Flow Coil Secondary Flow Coil Low 300 mA max Solenoid 2 Solenoid 2 T6 PFS2 Primary Flow Coil Primary Flow Coil Low 300 mA max Solenoid 2 Solenoid 2 T7 SFS4 Spare Secondary Flow Coil Low 300 mA max Solenoid 4 SW4 2 T8 SFS3 Spare Secondary Flow Coil Low 300 mA max Solenoid 3 T9 PFS3 Spare Primary Flow Coil Low 300 mA max Solenoid 3 T10 PSF4 Spare Primary Flow Coil Low 300 mA max Solenoid 4 Compac Industries Ltd Page 61 www compac co nz Triacs C4000 MPD6 amp MPP6 side A Triacs C4000 MPD6 amp MPP6 side A Solid State Relays Triacs Power Symbol Function High Low Terminal MPD6 MPP6 side A MPD6 MPP6 side B Current Output T1 MTR1 Motor 1 relay control SW1 2 Motor 3 relay control SW1 Low 300mA max MTR3 Mid or Internal pump motor 3 or or SW1 1 ort LOAD1 Internal pump motor 1 SW1 1 High 40 A max T2 SFS1 Secondary Flow Coil Secondary Flow Coil Low 300 mA max Solenoid 1 Solenoid 1 T3 PFS1 Primary Flow Coil Primary Flow Coil Low
51. ect release the K Factor switch 8 Repeat steps 6 amp 7 until the The volume display indicates volume display reads the the correct specific density correct density as measured by a hydrometer and corrected to 15 C ANOTE _ The C4000 will reset itself if the K factor switch is left for more than 10 seconds Pressure does have a small effect on density so you will notice that the LPG pump will run while the density is being calibrated This ensures that the density is always being measured and calibrated at approximately the same pressure Compac Industries Ltd Page 30 www compac co nz Set up Modes Temperature Calibration ACV Valve Flow Rate L Cut H Cut Compac Industries Ltd Further Settings Available on the K Factor Switch Only available for LPG and Bulk meter modes and only if the Temperature Compensation PCB is installed and temperature compensation configured as detailed in Section 0 To set the temperature place the probe in product of a known temperature Allow 10 minutes for the probe temperature to stabilise then adjust the temperature setting in the register XXX X to the known temperature value To check operation of the probe press the K factor switch to observe E in the Price display and XXX X in the volume display Allow the display to return to normal Warm the probe and recheck the K Factor switch temperature setting The new temperature should be displayed
52. eeeeeesasaaeeeeaneae e 58 Solid State Relays Triacs oi dde 60 Triacs C4000 Single D al amp QUag ici AI ra 61 Triacs C4000 MPD6 8 MPP6 side A ooooonccicoccccnonoccncnonancnnnonononononcnnnnnonnn ron n cnn ano nn rr nan nn r nen n nn naar nr nena n rn era nn narran naan Ennn 62 Triacs C4000 LPG Single Dual CNG Bulk Meter ccccccecceeeeceece cece ee eeceneaeceeeeeseseeaaeaeeeeesesecaeaeeeeeeeeeesneaeees 63 High Current Tria Optio inssin inoin e 64 Indicator LEDS ic tia 65 FaUltiFINdINO alcalina andinas A du data sacs teat ad duaesanctadece dadas 67 Error COS tica ss 69 Error MESSAGES cocina tada dia tato datada 70 Appendix A C4000 with RS232 Wiring RS485 Forecourt WIRING ici Ri C4000 with RS485 Forecourt Wiring Dick assed O RO 75 Gilbarco Interface Wide cae tiezeenetal obsecdedesaede ees sighted nenetes dbees adaat vated Siei iaia 76 Glossary of Terns a daa 77 Product Identification C4000 Processor Manual Title C4000 Processor Master Manual Models Covered All C4000 Series Application Power Supply 220 240 VAC 50 Hz 2 Amp 10 Related Manuals Publication Date C4000 Futra Manual February 2009 ComFutra Installation 8 September 2010 Service Manual CNG Dispenser Service February 2011 Manual C4000 LPG Manual February 2009 Validity Compac Industries Limited reserves the right to revise or change product specifications at any time This publication describes the state of the C4000 pr
53. ely convert the amount of LPG dispensed to the LPG dispensed 15 C The specific density of the product is measured using the Compac densometer and is corrected to specific density at 15 C It is always displayed in units of kg m3 Page 29 www compac co nz Further Settings Available on the K Factor Switch Calibrating Specific Density Densometer Set up Modes To accurately calibrate the densometer the temperature reading must be correct Always calibrate the temperature before calibrating the density Using the K Factor switch to calibrate the densometer Step ACTION RESULT 1 Ensure that the nozzles are Dispenser in idle state hung up 2 Press and release the K The volume display indicates Factor switch in quick 00000 succession until LP6 is displayed in the price display 3 Press and hold the kK factor A digit of the volume display switch will begin to increment 4 When the digit is correct release the K Factor switch 5 Repeat steps 3 amp 4 until the The volume display indicates volume display reads 1 00001 5 Press and release the K The LPG pump will start and Factor switch in quick the volume display indicates succession until den is the specific density 15 C displayed in the price display 6 Press and hold the K factor A digit of the displayed switch setting will begin to increment 7 When the digit is corr
54. es RESULT 1 Ensure that the nozzles are Dispenser in idle state hung up 2 Press and Hold the Side A The Price for hose 1 side A is Parameter switch until the Price per litre is displayed displayed as PX XXX and Pr1 is displayed on the price display 3 Press and hold the A digit of the displayed Price per Parameter switch litre will begin to increment 4 When the digit is correct release the Parameter switch 5 Repeat steps 3 and 4 for NOTE The C4000 will reset each digit of the Price per itself if the Parameter switch is left litre for more than 60 seconds Continue for each hose 6 Press and release the Parameter switch 8 or more times in quick succession The Price per litre for the next hose on side A is displayed as PX XXX Pr2 or Pr3 is displayed on the price display 7 Repeat steps 3 to 5 above Continue for side B 8 Repeat steps 1 to 7 for side BP ANOTE Ifa Compac Central Controller EFTPEC Task forecourt controller or Compac Commander is used the price must be set to zero 0 at the pump dispenser The price can then be set at the Controller This applies to all configuration display options ANOTE ___ The dispenser pump will stop when the dollar amount reaches 999 99 high flow 9999 9 or the litre amount reaches 999 991 high flow 9999 91 whichever occurs first Page
55. ge 1 21 00 TC2 CNG Temperature compensated fill stage 2 22 00 TC3 CNG Temperature compensated fill stage 3 Compac Industries Ltd Page 57 www compac co nz Displays Litres only Retail Multi price amp Preset Software Upgrade Procedure Software Upgrade Procedure Compac Industries Ltd This is the software upgrade procedure to be followed for all bulk meter registers and all pumps with a C4000 other than those with FUTRA software 1 O 91 75 0 10 11 12 13 14 15 16 Ensure before working on the pump that anti static precautions are taken i e wearing of wristband with earth strap Gain access to C4000 Processor Board and record all set up data by accessing the configuration K Factor switch and the parameter switch this includes recording the comms dipswitch settings Data set up to include K factor F No flow delay n Pre set cut off margin PCut Density Factor dSF CNG only Specific density SPG LPG only Flow rate FLO r some bulkmeters only Temperature E bulk meter or LPG only LCut L or LCUT bulkmeter only H Cut H or HCUT bulkmeter only F Cut F or FCUT bulkmeteronly Set resolution Sr Configuration C b Settings Price Pr or P Density d bulkmeters only Pump number Pn Sequencing Rate SE9 CNG only Access code A comcard or CWIDKey Basic dispensers only Electronic and mech
56. hiteRed 24 Red Black White 23 FF gt Il 18 OrangeRed 19 Blue Red 20 Red Green 2 maj 23 White Black Red Bleck Fares gt co oan w n f GND TOO mtr TO1 ses1 TO pst TO3 mrrz TO4 srs2 TOS prs2 TO6 mrra TO srs3 TOS prs3 TOS SPARE POK GND GND GND C1139 with R5232 Option to C1140 www compac co nz Page 71 Compac Industries Ltd RS485 Forecourt Wiring Appendix A RS485 Forecourt Wiring C4000 Power Supply C4000 IS Cable for RS485 Forecourt The following changes are made to standard Compac C4000 wiring to allow the use of RS485 communication with other devices 1 An RS485 Board is fitted inside the Power supply flame proof box 2 The IS cable pinouts will need to be changed to match the wiring detailed below E LA A al gt aa A zda Blue Red Red Black White Compac Industries Ltd ae iG A Blue Red Black Orange Black Black White Green White a E La Link Wire gt pee Le mo White v Page 72 www compac co nz Appendix A RS485 Forecourt Wiring J7 Black Red White Red gt Orange Red EA Black White Red White Black Red Green Black White Orange Green Screen MENA CNA A TA MICROPROCESSOR END Wiite Black Red Compac Industries Ltd Page 73 www compac co nz RS485 Forecourt Wiring Appendix A J2A Green Black white
57. i price amp Preset printouts of card pin key totals 17 Test pump operation CAUTION When replacing Integrated Circuit chips refer to Figure 19 below ensure that the notch is facing in the direction of the IC board socket the notch is the end that we refer to as the front When inserting the IC chip the rear pin of the IC chip must be plugged into the rear pin socket of the IC board socket Any spare pin sockets should be in front Failure to correctly insert the IC chips or adhere to the above guidelines specified herein will result in a loss of memory data Memory Chip SPARE 4 2 eoch side Insert with both notches at the same end Page 59 www compac co nz Displays Litres only Retail Multi price amp Preset Solid State Relays Triacs Solid State Relays Triacs General The solid state relay as the name implies is a solid state switch controlled by the C4000 These solid state switches control the C4000 220 240volt outputs COMMS NCOMING MAINS ve Motor Side B Neutral E Ve mums Phase Earth Excess Flow 3 4 LJ OD 998909009090999 Pf Figure 7 Location of Solid State Relays Triacs and Comms DIP Switches SW3 There are 10 separate solid state relays small triacs on the C4000 PCB The output terminals for these triacs is T1 to T10 Their function varies depending on what the C4000 head is controlling Below are tables showing the use of these
58. ing Mains Power and Communication cccccccceeeeeeeceeeceeeeeeeeeceaeaeeeeeeeseceaeaeeeeeeeseseesaeeeeeeeseteenieeeeeeeees 10 Electrical Commissioning C4000 cccececcecceceeeeeeeeee eset ee eeeeeaaeaeeeee cece eaaeaeeeeeeeeeceaeaeeeeeeesecqcaeeeseeeseceecaeeeeeeeseeeea 11 Main Features conidios 12 GAQOO COMPONEMIS arrire ianen a e aeaea ts eens aa aeaaaee a ea teeta eitebeanasataaveedteieeen is 12 Configurations a r e aer ee e a dit 13 Set Up MOdeS EEE ETET T E E E T 16 Configuration Code citrico aa 16 A O O E 18 C4000 UP in A A A tin 21 Calibration K Factor ae 23 No Flow Cut Of Timer ad alicia 25 Display Litres Resol clica a A a AE 26 MS O A NN 27 SA O 28 Further Settings Available on the K Factor SWitCh oooonccccononicinnnoccnnnoncncnonannnn nono nnn nn nn nc nano rn r anna rr rra 28 Param ter S Witch taa piano i n Printer Set Up O a tes A ielan dant Eae a EE ES Displaying and Printing Totals Basic Systems Comcard Compin amp CWIDKey ooooooccconoccccconoccnononononononcncnono nono nono nn nn non n rr narrar nn n nn 43 Electrical Wiring C4000 coonnnnnnnnncccnnnsnnncrnsccccn rr 45 Compac Wireless Tradseaiver cai ee 49 Displays Litres only Retail Multi price amp PreSet ooooooonnccccononccinococcnononcncnononcnn corn nn nono n nr rnnnn rr rn cnn rra rar 51 EN O Sale Ac eee cede seventeen aad ee che hoes Ge ae aai 57 Software Upgrade Procedure cccccsseeeeeeeneeeeeeeeneeeeeeeeeeeeee
59. lf CNG then this will display pressure in the Dollars display during delivery 0 If digit 4 is set to zero then the pump dispenser software defaults to conventional operation i e the nozzle switch controls the pump start after initial authorisation 1 If digit 4 is set to one then the dispenser pump software will run in the AUTO AUTHORISE mode of operation used for wharf amp aviation or any other sites where the hose reel is remote from the pump unit The pump dispenser will start automatically after it has been initialised by the card reader or remotely by a Compac controller The dispenser pump will switch off after four minutes if flow does not commence The pump dispenser will switch off XXX seconds after flow rate stops Can be adjusted to clients requirements between 1 and 256 seconds The nozzle switch becomes a shut off switch i e the nozzle switch can be replaced with a stop pushbutton or normally closed toggle switch ANOTE In AUTO AUTHORISE mode the nozzle input must be shorted out Transaction Data Digit 3 Compac Industries Ltd O If digit 3 is set to zero the system will function as a conventional dispenser pump and the sale data goes through to Point of Sale as soon as the preset is reached This is the default setting 1 If digit 3 is set to one the system will function as a convention dispenser pump but the sale data will go through to the Point of Sale only after the no
60. ll then be shown on the display for ten seconds This is only available on Comcard Compin and CWIDKey Basic systems i e b setting digit 3 2 To access this option the b setting digit 1 must be set to one Pump Dispenser totals are accessed as above then after displaying the pump dispenser total for ten seconds the card pin key number and card pin key total will appear The display will flash for 10 seconds and then go to the next card pin key All cards pins keys with non zero totals and all valid cards pins keys will be scrolled This is only available on Comcard Compin or CWIDKey Basic systems i e b setting digit 3 2 Plug the two core cable from the printer into the four pin plug Red Comms Pin 1 Black Comms Pin 4 on the side of the pump dispenser Power up the printer and make sure it is ON LINE Then depress the nozzle switch five or more times ensuring that the switch clicks each time The printout will contain all cards pins with non zero totals and all valid cards pins keys Card pin key status is also displayed on this printout The printer may also be permanently wired to the C4000 comms If the printer is left with the power on and on line it will then act as an audit trail printer It will then print out the card pin key number litres dispensed and the total in dollars at the end of each fill ANOTE ___ All totals mentioned above are non resettable totals the only way they can
61. mpensation PCB C1075 Compac Industries Ltd Basic Systems Comcard Compin amp CWIDKey The nozzle switch leads plug in between NSWx and GND see Figure 10 above When the nozzle is lifted the nozzles switch closes and the C4000 initiates a transaction ANOTE Diagnostic LED will flash rapidly when any nozzle is lifted regardless of hose configuration The Sump Switch is a float switch located in a sump at the bottom of the dispenser If the dispenser pipe work leaks then the tray fills with product thereby activating the switch If the switch closes then the dispenser stops and the litres display reads SunP The Sump Switch is wired into the SUMP and GNS terminals on the J12 connector see Figure 10 If there is more than one head in the dispenser e g MHD6 then the sump switch is to be connected to both heads Ensure that the SUMP terminals are joined and the GNS terminals are joined AXCAUTION DO NOT connect the GNS terminal on one head to the SUMP terminal on the other The Temperature Compensation PCB is mounted in a separate enclosure and is connected to the C4000 Microprocessor via a four wire cable The PCB Pin headers and cable connectors are shown below Temperature Compensation PCB C1075 gt 1 Red on aa 2 S Se a 2 Green al oe 3 Screen ig 3 2 4 gt i e a gt Whit OB 5 Biadk NN BL e oo A Pa ae gt 2 SNL 4 6 C4000 Microprocessor PCB C1140 Figure 1
62. ne second interval before motor 2 starts which in turn operates their associated pump When the hi lo switch is in the LOW position only motor 1 and its associated pump operates ANOTE ___ The changing of the Flow Selector switch position during a transaction has an immediate effect on Pump 2 s operation l e The motor for Pump 2 can be turned off and on during a transaction Method 2 This is used in dispensers supplied by submersible pumps and in pumping units with a preset operation Two solenoids valves 38mm NB amp 18mm NB are installed in parallel after the meter For high flow both solenoids valves are open For low flow only the 18mm NB solenoid valve is open Method 3 3 Phase Pump M200P This is used in pumping units without preset operation One 18mmNB solenoid valve is piped as a by pass across the pumping unit When open this allows some of the product being pumped to return to the inlet low pressure side of the pump and hence reduces the flow rate through the nozzle Electrical Connections To control the solenoids in high low flow operation the two core cable from the flow selector switch connects to FLOWx or FLOWx terminals on the C4000 Microprocessor PCB connector J12 see Figure 10 FLOWO is used for side A and in the case of a dual with high low flow on both sides then side B s flow selector switch connects to the FLOW1 terminal The switches are to be connected between the FLOWx
63. ocessor at the time of publication and may not reflect the product at all times in the past or in the future Manufacturer Contact The Compac C4000 processor is designed and manufactured by Details Compac Industries Limited 52 Walls Road Penrose Auckland 1061 New Zealand P O Box 12 417 Penrose Auckland 1641 New Zealand Phone 64 9 579 2094 Fax 64 9 579 0635 www compac co nz Copyright 2011 Compac Industries Limited All Rights Reserved Document Control Information Document Control Information Document Information and Revision History Document Details C4000 Master Manual File Name and Location G Masters Manuals Authorised Manuals C4000 Current Revision Author s R Lacey Authorised By A Kingstone Release Date 13 01 2011 pei Ji nio Compac Industries Ltd Page 6 www compac co nz Symbols and Units of Measure Symbols and Units of Measure Symbols Symbols are used in this manual to highlight information that is critical to the safety of people and equipment and for the safe and correct operation of the Compac equipment A DANGER _ An extreme hazard that may result in death or injury if proper precautions are not taken A DANGER _ A reminder of safety practices or unsafe practices that could result in personal injury or damage to associated equipment A CAUTION A reminder of safety practices or unsafe practices that could result in damage to associated equipment and or voids the warranty
64. outputs for various applications The T1 and the T4 outputs can be used to drive a high current triac whose output will be on the LOAD1 and LOAD2 terminals respectively Each of these outputs T1 and T4 has an associated switch SW1 and SW2 respectively which must be used to select the type of output required refer Figure 8 The T7 output cannot drive a high current triac directly but may be looped to T1 or T4 of another C4000 If it is looped then SW4 must be in the mid position Position 1 of SW4 should never need to be used The power for the triac outputs can be supplied from a separate mains supply Separate from the supply for the microprocessor There are two blocks of connectors for the phase connection refer Figure 7 The block of six connectors supplies the microprocessor and the block of four connectors supplies the triac outputs These two blocks of connectors are normally looped together in the factory Compac Industries Ltd Page 60 www compac co nz Solid State Relays Triacs Triacs C4000 Single Dual amp Quad Triacs C4000 Single Dual amp Quad Power Symbol Function High Low Terminal Single Dual Quad Current Output T1 MTR1 Motor relay control SW1 2 Motor relay control SW1 2 Low 300mA max lorD or Corl orl LOAD1 Internal pump motor SW1 1 Internal pump motor SW1 1 High 40 A max T2 SFS1 S
65. pplicable to equipment of this type The foregoing limitation extends to damages to person or property caused by the unit or damages resulting from the inability to use the unit including loss of profits loss of products loss of power supply the cost of arranging an alternative power supply and loss of time whether incurred by the user or their employees the installer the commissioner a service technician or any third party Compac Industries Limited reserves the right to change the specifications of its products or the information in this manual without necessarily notifying its users Variations in installation and operating conditions may affect the unit s performance Compac Industries Limited has no control over each installation s unique operating environment Hence Compac Industries Limited makes no representations or warranties concerning the performance of the unit under the actual operating conditions prevailing at the installation A technical expert of your choosing should validate all operating parameters for each application Compac Industries Limited has made every effort to explain all servicing procedures warnings and safety precautions as clearly and completely as possible However due to the range of operating environments it is not possible to anticipate every issue that may arise This manual is intended to provide general guidance For specific guidance and technical support contact your authorised Comp
66. s described above Page 56 www compac co nz End of Sale Indications Displays Litres only Retail Multi price amp Preset End of Sale Indications The C4000 can display the reasons the last sale ended This information is displayed as a number which appears in the price per litre panel when setting the pump number The following table gives the reasons corresponding to each number Numerical Readout Explanation Indicator 1 00 NOZ Nozzle hung up 2 00 PRESET rad eas a ve dispensers completed a 3 00 TIMEOUT No flow 4 00 REMSTOP Pump controller initiated stop 5 00 MAX Maximum litres and or dollars reached AIR Air cut out Diesel air cut out switch 6 00 GAS Creepage due to vapour LPG Dispenser 7 00 ERROR Encoder error excess flow etc 8 00 SEQUENCE CNG applications only 9 00 SUMP Switch activated by leaking product 10 00 BULK SAFETY 11 00 NEW CWID 12 00 DPE MAIN Parity error on main display 13 00 DPE MP Parity error on multi price display 14 00 DA MAIN Parity error on main display 15 00 DA MP1 Parity error on multi price display 1 16 00 DA MP2 Parity error on multi price display 2 17 00 DA MP3 Parity error on multi price display 3 18 00 DA MP4 Parity error on multi price display 4 19 00 LPG CREEP 20 00 TC1 CNG Temperature compensated fill sta
67. s displayed paragraphs 3 Press and hold the K factor A digit of the displayed setting switch will begin to increment 4 When the digit is correct release the K Factor switch 5 Repeat steps 3 and 4 for ANOTE The C4000 will each digit of the setting reset itself if the K factor switch is left for more than 10 seconds Continue for multiple hose units if appropriate 6 Press and release the K The setting for side B or factor switch 8 or more hose 2 3 or 4 is displayed times in quick succession 7 Repeat steps 3 to 5 above ANOTE ___ The C4000 will reset at any stage during the K Factor operation if the switch is not pressed for ten 10 seconds If the C4000 resets out of any field before the numbers have been set correctly then that field must be entered again to ensure the details are correct ANOTE ___ The K Factor switch must be sealed with a lead or paper seal after commissioning Page 22 www compac co nz Set up Modes Calibration K Factor Calibration Compac Industries Ltd Calibration K Factor The K Factor is a ratio of litres dispensed per revolution of the meter Below is the method of calibration including how to calculate the new K Factor and how to enter it in the C4000 memory See also Encoder see page 54 for more information on the encoder pulser To calibrate the dispenser pump dispense fuel into a certified mea
68. set to zero orone b settings digit 3 set to two ni muii Vv i b settings digt 3 setto zero orone Figure 3 Configuration Code Options Compac Industries Ltd Single Dual Mu iti pe duct M HP6 o r MHDG side A Mu iti pe duct MHP4or MHD 4 or Quad 2d ph ys Quad dhoses 2 prod ucts Ide phys Mu iti pe duct M HP6 o r MHDG side B No rmald penser pump oil Com pin Mining Korea n M nua tu with litre preset option Vanuatu LPG CNG Nee de ap pro pr ate softwa re Commercial Hi Flow ie 0 1 litres be fre meter reg iters Pa k ta n Ru pees Korean LPG mode LPG Solenoids pu keda te nd of delivery Max to 60 000 Lts or Decimal pint mows 10 000 ltrs or Requires Vara be k ap th reco rds Co mpac Co ntro le r MPD preset sa lues 20 10 5 Zimteadof105 2 1 DD p j x i do 23 Trach 2with Star printer Track 1 with Star primer Track 1 with Actro nic printer Track 2with Actro nic printer CWID Key Eb sic No rmalo pe ration Local Actron ic receiptprinter D riven by C300 Sec ure PIN Pad Local Se lo receipt prin ter Remote receipt printer f tcont m ller CWID Seiko prin t r CWID Mode CWID Loa I receipt pr nter Drive n by C3000 CWID Remote receipt printer at Co mt rolle Mic ro M consul power modem Sec we PIN Pad andSeko receipt prin ter Sets miscellaneous options O is O is 2 3 4 S5 Nor malServte Card BP Servie Card Pre setsenteredvi
69. spensers with a self contained pump should be left at the default setting Setting the Solenoid Delay Refer to C4000 Set Up K Factor Switch Settings see page 21 While setting this value the price display will indicate Sd and the volume display will indicate dXXXX where X equals one second Page 27 www compac co nz Pre Set Cut Off Pre Set Cut Off Setting the Pre Set Cut Off Set up Modes Prior to the dispenser reaching its preset amount the solenoids are switched to give a low flow rate The preset cut off sets the amount in litres prior to the preset amount being attained at which the solenoids will switch to a low flow rate With the value set to 0 00 the default values are used These are LPG 0 75 Oil 0 05 Other products 0 32 The Preset Cut off is calculated as follows Price per Litre X over run displayed as a dollar value default value as above Example Price per Litre 0 96 Dollar amount of fuel required 20 00 After delivery price display shows 20 01 0 01 is the over run dollar value New preset 0 96 x 0 01 0 32 Other Products 0 3296 0 3296 rounded up 0 33 New preset cut off to be entered is 0 33 Refer to C4000 Set Up K Factor Switch Settings see page 21 The Price display shows PCut and the volume display shows PCX XX The range is from 0 01 to 9 99 litres Further Settings Available on the K Factor Switch Compac Industries Ltd
70. suring container and compare the display value with the amount dispensed Example Display shows 10 00 True volume 20 00 To calculate the correct K Factor from the information above firstly record the existing K Factor Dispensed Amount New K Factor Existing K Factor x Displayed Amount 0 00 0 00 Existing K Factor x 2 Existing K Factor x Change the existing K factor to this value Page 23 www compac co nz Calibration K Factor Set up Modes Setting the Calibration K Factor Refer to C4000 Set Up K Factor Switch Settings see page 21 The displays will indicate as below Price Display Volume Display Type indication Indication Single Hose FP X XXXX Side A P Dual Hose X XXXX Side B Fb Hose 1 FT i Hose 2 F2 aes Multi XXXXX Hose 3 FS Hose 4 Fa ANOTE ___ Once the dispenser pump resets with the correct K factor entered the display will show the new volume unless the head is in Compensation Mode in which case the display volume will not change ANOTE Be careful when calibrating dual or multi hose pumps amp dispensers to ensure that the correct K factor is being changed Compac Industries Ltd Page 24 www compac co nz Set up Modes No Flow Cut Off Timer Compac Industries Ltd No Flow Cut Off Timer Under normal conditions to end a transaction on a C4000 controlled pump dispenser there are
71. the preset pad Pre set ente red via PIN pad Retail Di ph yo nly Flow mo nitor mode D ph ys compe mated and uno mpensa ted litres CW D mode a llows 10sec bes ofco ntact with the CWID before turningout off Version 51509 CWID mode requiesonk asing ea uthonston le filproceeds event kssof co mact Verb n26 6 5 Push start mode Lire preset DO NOT use with MPD Diph y Sets compensation O No compensation Mic ro mo to n flow meter ifC NG 1 Compemation If Bu lk me tr Tempen ture Comp O therw is e flow Co mp fr Be nnett 2 Compac CNG flow meter ifCNG Otherwee Compe COM 2504 3 Com pac COM1 5 metero ptial CompcCOM1S meter with LPG te mp co mp 5 LPG temp compenation eth ble de ns ty 6 Motor spirit 7 LPG Temp Co mpena tio n wit hdenso meter Page 17 www compac co nz b Settings b Settings Set up Modes While setting the b settings the price display shows b and the volume display shows bXXXX Figure 2 b Settings Auto Authorise Digit 4 O Standard 1 Auto authorise mode df CNG then auto end O Stand alone operation 1 Inhibit stand alone operation Sale goes through to Point of Sale as soon as the preset is reached Default Nozzlehasto be hung up before the sale goes through to the Point of Sale Comcard Compin md CWIDKey Basic Systems O Priceflitre is displayed as Vlitre Default NZ 1 Priceflitre is displayed as c litre Default AUS
72. three possibilities Returning the nozzle to its holder Reaching the preset amount entered Cut out on the No flow cut off timer The No Flow Cut off Timer sets the amount of time the dispenser pump will allow a sale to continue when no flow is detected This timer applies at both the beginning fill before filling commences and at the end of the fill after flow has stopped The No Flow Cut off Timer is terminated if the nozzle is returned to its holster The range available is between 1 amp 256 seconds The default setting is n0000 256 seconds Setting the No Flow Cut Off Timer Refer to C4000 Set Up K Factor Switch Settings see page 21 While setting this value the price display will indicate n and the volume display will indicate nXXXX Page 25 www compac co nz Display Litres Resolution Display Litres Resolution Set up Modes For standard dispenser pumps high flow dispenser pumps amp bulk metering different resolutions are often required Di Sr setting Litres Display Max isplay r on k factor presetable or Resolution A 3 switch resolution fill amount Standard default 0 000 0 00 970 L Hi Flow 0 00 0 00 9700 L Bulk metering 0 0 00000 0 0 000000 000000 0 0 is not displayed ANOTE As well as displaying the decimal point a full colon will show on the display after power on until the first transaction is started i e the display shows 0 0
73. tion is only available for C4000 microprocessors controlling one hose pumps dispensers or for C4000s which are set up in True Multi configuration A PIN pad must also be connected to the C4000 and the third digit of the Configuration Code must be set to 1 or 3 Ona pump dispenser set up with a receipt printer a receipt is obtained as follows 1 Authorise the transaction as for a normal fill until the PIN pad display reads REQUIRE RECEIPT YES OR NO 2 Press YES 3 The display will read TAKE FUEL Continue the fill as per normal and at the completion of the fill a receipt will print automatically Ifthe nozzle is still in holster 1 Pin pad reads LOAD PRESET 2 Press ENTER Ifthe nozzle is lifted Pin pad reads TAKE FUEL ANOTE ___ f the Receipt Printer is not operational e g out of paper then when the PIN pad displays PASS CARD it will also display NO RECEIPT The data cabling for the printer connects to the C4000 intrinsically safe terminals at connector J14 The other end of these wires connects to connector CON5 on the Interface PCB C1125 The 220 240V supply connection on the Interface PCB is at connector CON1 Power and data connections to the printer and cutter are from CON2 amp CON3 on the Interface PCB Receipt Printer Connected to the Central Controller Where a Central Controller is installed on site it is possible to connect a Receipt
74. tions Multi Product 6 hose Retail Type A Dollars litres and price display two one per side Presets two one per side Six Encoders Six Nozzle Switches Three Motor Outputs shared by C4000 Heads Two C4000 Heads Multi price Displays six one per product per side Standard Options Dollars litres and price display six three per side Presets six three per side Six Encoders Six Nozzle Switches Three Motor Outputs shared by C4000 Heads Two C4000 Heads Futra Uses Futra Software Extras Card reader PIN Pad Receipt Printer Extras This type is a stand alone system that cannot be set up to communicate to any type of controller Standard Options Compac Industries Ltd Litres Only Display Motor Circuit One only One Encoder One Nozzle Switch C4000 Head PIN Pad Extras Page 15 Card Reader Retail Displays Preset Modem High Low Flow Operation Tank Gauging for one tank only Receipt Printer Configurations www compac co nz Configuration Code Set up Modes Set up Modes To enable the C4000 to operate as desired two things must be set 1 Configuration K Factor Switch Settings Refer C4000 Set Up K Factor Switch Settings see page 21 This switch accesses different options that must be set appropriately for the particular type of dispenser 2 Parameter Switch Settings Refer Parameter Switch see page 33 This switch is used to conduct
75. trical equipment in which all the circuits are intrinsically safe The equipment may be self contained or may form part of an intrinsically safe electrical system An assembly of interconnected items of electrical equipment in which the circuits or parts of circuits intended to be used in an explosive atmosphere are intrinsically safe circuits Light emitting diode EPROM chip that stores parameters and or transaction amp totals Outdoor Payment Terminal A type of authorisation terminal designed for credit card applications made by Compac Printed Circuit Board Retail Authorisation Station Authorisation terminal designed for manned sites Plated through hole in a PCB that enables tracks to swap sides on a PCB EPROM chip with label indicating program version Page 77 www compac co nz
76. ts inside the high voltage area with the power on A CAUTION Always turn off the power to the Compac C4000 processor at the mains switch before removing or replacing software or memory ICs A CAUTION Always take basic anti static precautions when working on the electronics i e wearing a wristband with an earth strap AXCAUTION The C4000 head and its associated circuits and wiring is a certified piece of electrical equipment approved for use in a hazardous area Class 1 Zone 1 Group IIA T3 Only parts identical to those covered by the certification may be used where the integrity of the intrinsic safety may be affected All circuit boards are to be repaired only by Compac Industries Ltd Electronic components used are sensitive to static Please take anti static precautions All circuit boards must be carried and transported in static shielded bags An anti static wrist strap should be worn and connected correctly when working on any electronic equipment If an anti static wrist strap is unavailable or in an emergency hold onto an earthed part of the pump dispenser frame whilst working on the equipment This is not a recommended alternative to wearing an anti static wrist strap ANOTE __ Compac Industries Limited reserves the right to refuse to accept any returned circuit boards if proper anti static precautions have not been taken Page 8 www compac co nz Electrical Commissioning Cable Requirements Electrical Commissioning
77. ustries Ltd This value is the desired cut off point to half flow in litres for the system The H Cut sets the amount in litres prior to the preset amount being attained at which the flow rate of the system will be halved Setting H Cut Refer to K Factor Switch Settings see page 21 While setting the H Cut the price display shows HCUt and the volume display shows HXXXX This is only available in Bulk Meter mode This is the final cut off point to pre set in litres FXXX X for the system Setting F Cut Refer to K Factor Switch Settings see page 21 While setting the F Cut the price display shows FCut and the volume display shows FXXXX Page 32 www compac co nz Set up Modes Parameter Switch Program Version Number Compac Industries Ltd Parameter Switch Refer to Figure 1 Main Features C4000 see page 12 to find the location of the parameter switch The Parameter switch has several functions including Identifying the software programme version number P XX Setting the dispenser pump price Pr or P Setting the product density dEn Bulkmeter Registers and LPG with compensation but without a densometer only Setting the pump dispenser number Pn Displaying End of Sale indications Setting the dispenser sequencing rate SE9 CNG only Validating and invalidating cards pins keys Y or n Comcard Compin or CWIDKey pumps dispensers only Setting the card access cod
78. ve Flow Rate see page 31 Density Calibration LP6 00000 ad Specific Density see page No flow cut off m n XXX Refer No Flow Cut Off Timer C4000 see page 25 Solenoid delay Sd d XXX Refer Solenoid Delay see page 27 Preset Cut Off PCut PC X XX Refer Pre Set Cut Off see page 28 b settings b b XXXX Refer b Settings see page 18 K Factor eee X XXXX Refer Setting the K Factor see page 24 or H Cut HCut HXXXX Refer H Cut see page 31 Bulk metering only L Cut LCut LXXXX Refer L Cut see page 31 Bulk metering only F Cut FCut FXXXX Refer F Cut see page 32 Bulk metering only Density Factor JSF X XXXX ie Product Density Factor see page 29 CNG Compac Industries Ltd ANOTE ___ The K Factor setting should be done last of all i e until parameter switch settings are made the pump dispenser may not be operational and so a calibration fill may not be possible Page 21 www compac co nz C4000 Set up K Factor Switch Using the K Factor Switch Compac Industries Ltd Set up Modes Using the K Factor Switch to Change a Setting Step ACTION RESULT 1 Ensure that the nozzles are Dispenser in idle state hung up 2 Press and release the K The price display and volume Factor switch in quick display indicates the desired succession until the setting See following desired setting i
79. www compac co nz Page 76 Compac Industries Ltd Glossary of Terms Gilbarco Interface Wiring Glossary of Terms TERM ATG Class 1 Zone 0 Class 1 Zone 1 Class 1 Zone 2 ComFutra CPU CWID DCA Encoder Head HID Intrinsically safe circuit Intrinsically safe electrical equipment Intrinsically safe electrical system LED Memory chip OPT PCB RAS Via Software chip Compac Industries Ltd DESCRIPTION Automatic Tank Gauging An area in which an explosive gas atmosphere is present continuously or is present for long periods An area in which an explosive gas atmosphere is likely to occur in normal operation An area in which an explosive gas atmosphere is not likely to occur in normal operation and if it does occur it will exist for short periods only A model of pump mounted authorisation terminal made by Compac Central Processing Unit Compac Wireless Identifier Driveway Card Acceptor A type of pump authorisation terminal made by Compac A device that translates rotary motion into electronic pulses Often referred to as a pulser Dispenser calculator Indicator C4000 PCB complete with power supply Transponder key authorisation system A circuit in which any spark or any thermal effect produced in the test conditions prescribed in the relevant standard which includes normal operation and specified fault conditions is incapable of causing ignition of a given explosive atmosphere Elec
80. zzle has been hung up Page 18 www compac co nz Set up Modes Price per Litre Digit 2 Controller Option Digit 1 Compac Industries Ltd b Settings 2 With digit 3 set to two the head is set up for Comcard Basic Compin Basic or CWIDKey Basic which are self contained systems operating independently of any controller To operate a card reader CWIDKey reader must be plugged into the head and the correct access code and card key number validations must be set by the Parameter switch ANOTE ___ For the Bulk Meter Register digit 3 must be set to zero or one Comcard Compin and CWIDKey Basic systems are not available in this mode 0 If digit 2 is set to zero the price per litre is displayed as dollars per litre 0 000 1 If digit 2 is set to one the price per litre is displayed as cents per litre 000 0 cents For CNG Only If digit 2 is set to one then the display that normally shows the dollar value of the transaction will display the CNG pressure during the fill At the end of the fill the display will revert to displaying the value The function of this digit 1 depends on whether the head has been set up as one of the Basic Systems Comcard Compin or CWIDKey or a conventional pump dispenser using digit 3 Basic Systems digit 3 set to two With all Compac pumps dispensers the head will display the dollars and litres grand totals when the nozzle switch is pressed quickly five or more times

C4000 Master Manual v1.0.2a

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