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Compac C4000 Manual

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C4000 Master Manual
Version 1.0.0

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  • Page 1 C4000 Master Manual Version 1.0.0...
  • Page 2 This hazard Subject to your right to use the unit, Compac does can be avoided if you adhere to the procedures in not convey any right, title, or interest in its this manual and exercise all due care.

  • Page 3: Table Of Contents

    Solid State Relays (Triacs) ............................. 61 Triacs C4000 Single, Dual & Quad ........................62 Triacs C4000 MPD6 & MPP6 side A ........................63 Triacs C4000 LPG Single/Dual, CNG & Bulk Meter ....................64 High Current Triac Option ............................65 Indicator LEDs ................................. 66 Fault Finding ..................................
  • Page 4 Appendix A ..................................72 C4000 with RS232 Wiring ............................72 RS485 Wiring ................................. 73 C4000 with RS485 Wiring ............................75 Gilbarco Interface Wiring............................76 Glossary of Terms ................................77...

  • Page 5: Product Identification C4000 Processor

    Compac Industries Limited reserves the right to revise or change product specifications at any time. This publication describes the state of the C4000 processor at the time of publication and may not reflect the product at all times in the past or in the future.

  • Page 6: Document Control Information

    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: 06/09/2010 Version Date Author(s) Revision Notes 1.0.0...

  • Page 7: Symbols And Units Of Measure

    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 An extreme hazard that may result in death or injury if proper precautions are not taken.

  • Page 8: Safety - C4000 Controller

    Safety - C4000 Controller 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.

  • Page 9: Electrical Commissioning

    . Maximum cable length 100 m. 12 V current loop. 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...

  • Page 10: Connecting Mains Power And Communication

    UPS is installed. To connect the dispenser: Wire the power and comms to the C4000 Termination Board, as shown in the diagram below. Connect the earth lead of the supply cable to the earth stud in the flameproof junction box.

  • Page 11: Electrical Commissioning C4000

    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 If the dispenser is receiving information, Comms RXD LED (D6) will poll.

  • Page 12: Main Features

    Main Features C4000 Components 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.

  • Page 13: Configurations

    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 ...
  • Page 14 Receipt Printer side  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:  Dollars, litres and price...
  • Page 15  Six Encoders  Six Nozzle Switches  Three Motor Outputs - shared by C4000 Heads  Two C4000 Heads  Multi-price Displays, six - one per product per side Multi Product (6 hose) Retail, Type 'A' Standard Options: Extras: ...

  • Page 16: Set-Up Modes

    Set-up Modes Configuration Code 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.
  • Page 17 Set-up Modes Configuration Code Figure 3 Configuration Code Options Compac Industries Ltd. Page 17 www.compac.co.nz...

  • Page 18: B' Settings

     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.
  • Page 19 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.
  • Page 20 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. Compac Industries Ltd. Page 20...

  • Page 21: C4000 Set-Up

    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...
  • Page 22 Repeat steps 3 to 5 above. 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.

  • Page 23: 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 55) for more information on the...
  • Page 24 Set-up Modes Calibration ('K') Factor 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 „F‟ „X.XXXX‟ Single Hose Side “A” „F‟...

  • Page 25: No Flow Cut-Off Timer

    Set-up Modes No Flow Cut-Off Timer No Flow Cut-Off Timer Under normal conditions to end a transaction on a C4000 controlled pump/dispenser, there are three possibilities:  Returning the nozzle to its holder.  Reaching the preset amount entered. ...

  • Page 26: Display (Litres) Resolution

    „:0.0‟ 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...

  • Page 27: Solenoid Delay

    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 28: Pre-Set Cut-Off

    New preset cut-off to be entered is 0.33. Setting the Pre-Set Cut-Off 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.
  • Page 29 (configuration code = 5xx5x), the density must be set at the dispenser. The specific density of the LPG is measured to allow the C4000 to accurately convert the amount of LPG dispensed to the LPG dispensed @ 15ºC.
  • Page 30 15ºC. 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.
  • Page 31 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...
  • Page 32 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'. Compac Industries Ltd. Page 32 www.compac.co.nz...

  • Page 33: Parameter Switch

    Set-up Modes Parameter Switch 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' ...
  • Page 34 Single (e.g. one C4000 controls one hose) Dual (e.g. one C4000 controls two hoses) Quad (e.g. one C4000 controls four hoses but only two (one per side) can operate at any time) True Quad (e.g. one C4000 controls four hoses which can all operate at once) Six (e.g.
  • Page 35 Repeat steps 3 to 5 above. 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.
  • Page 36 “B” 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.
  • Page 37 (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.
  • Page 38 The display will return to normal operation after the Parameter switch is not operated for ten (10) seconds. On older systems Card 99 is the Service card and was universally accepted by all Comcard card-readers. Compac Industries Ltd. Page 38 www.compac.co.nz...
  • Page 39 Depress the Parameter switch 24 or more times, without holding it depressed long enough to change any digits, until 'AXXXX' appears on the 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.

  • Page 40: Printer Set-Up

    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: ...

  • Page 41: Displaying And Printing Totals

    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'.
  • Page 42 This Receipt Printer option 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' ...

  • Page 43: Basic Systems (Comcard Compin & Cwidkey)

    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.
  • Page 44 "----" 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. Compac Industries Ltd. Page 44 www.compac.co.nz...

  • Page 45: Electrical Wiring C4000

    Basic Systems (Comcard Compin & CWIDKey) Electrical Wiring C4000 230 Volt wiring Power for the C4000 'head' connects to the terminals marked Phase, Neutral, & 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).
  • Page 46 Converter A Gilbarco interface board (CI143) 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 & Figure 9) must be set with switches 1& 3 OFF and switches 2 &...
  • Page 47 Basic Systems (Comcard Compin & 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. Diagnostic LED will flash rapidly when any nozzle is lifted regardless of hose configuration.
  • Page 48 This is an intrinsically safe supply. Card-readers The C4000 can drive two Card readers. They plug into the C4000 Microprocessor PCB (Connectors J15 & 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.

  • Page 49: 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 J13 on the C4000 Microprocessor PCB (Refer Description C4000) with an eight wire cable (see below) Figure 1: CWID (CON5) to microprocessor (J13) cable Compac Industries Ltd.
  • Page 50 Electrical Wiring C4000 Compac Wireless Transceiver Figure 2: CWID (CI 101 issue D) PCB Compac Industries Ltd. Page 50 www.compac.co.nz...
  • Page 51 Electrical Wiring C4000 Compac Wireless Transceiver Tuning the Aerial 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. Connect a Multimeter (set to Volts) to CON8.

  • Page 52: Displays: Litres Only, Retail, Multi-Price & Preset

    Displays: Litres only, Retail, Multi-price & 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). Figure 16. Microprocessor Display Connector (J7) Figure 16 and Figure 17 show the two ends of the display/preset/multi-price display cables.
  • Page 53 Electrical Wiring C4000 Displays: Litres only, Retail, Multi-price & Preset S in g le, D u al, D u o , o r D ou b le con fig uratio n R etail o r C o m m ercial P reset D isplay D isplay s.
  • Page 54 Displays: Litres only, Retail, Multi-price & Preset Secure PIN Pad Unit When connecting a BP Secure PIN pad to a C4000 a Distribution board CI- 36 is required as an interface. The Secure PIN pad / C4000 combination only works with old type Central Controllers Special software is required for the C4000.
  • Page 55 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.
  • Page 56 (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 one-second interval before motor #2 starts), which in turn operates their associated pump.
  • Page 57 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.

  • Page 58: End Of Sale Indications

    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.

  • Page 59: Software Upgrade Procedure

    Displays: Litres only, Retail, Multi-price & Preset Software Upgrade Procedure 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. Ensure, before working on the pump, that anti-static precautions are taken (i.e.
  • Page 60 Failure to correctly insert the IC chips or adhere to the above guidelines specified herein will result in a loss of memory data. Figure 3: Memory chip installation Figure 20. Software IC Insertion Compac Industries Ltd. Page 60 www.compac.co.nz...

  • Page 61: Solid State Relays (Triacs)

    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.

  • Page 62: Triacs C4000 Single, Dual & Quad

    Solid State Relays (Triacs) Triacs C4000 Single, Dual & Quad Triacs C4000 Single, Dual & Quad Power Symbol Function High / Low Terminal Single / Dual Quad Current Output MTR1 Motor relay control (SW1 = 2) Motor relay control (SW1 = 2)

  • Page 63: Triacs C4000 Mpd6 & Mpp6 Side A

    Solid State Relays (Triacs) Triacs C4000 MPD6 & MPP6 side A Triacs C4000 MPD6 & MPP6 side A Power Symbol Function High / Low Terminal Current Output MPD6 / MPP6 side 'A' MPD6 / MPP6 side 'B' MTR1 / Motor 1 relay control (SW1 = 2)

  • Page 64: Triacs C4000 Lpg Single/Dual, Cng & Bulk Meter

    Solid State Relays (Triacs) Triacs C4000 LPG Single/Dual, CNG & Bulk Meter Triacs C4000 LPG Single/Dual, CNG & Bulk Meter Power Function High / Low Terminal LPG Single/Dual Bulk Meter Current output Electric Motor Control (SW1 = Low A (SW1 = 2)

  • Page 65: High Current Triac Option

    PCB. If a high current triac is installed for T1 and/or T4 then its respective snubber switch (SW1 & SW2 respectively) needs to be switched to position 1 (Refer Figure Figure 8 High Current Triac Option Compac Industries Ltd. Page 65 www.compac.co.nz...

  • Page 66: Indicator Leds

    The TXD and RXD LEDs (refer Figure 5) indicate polling of communications to/from a controller. The RXD LED flashes whenever any communications polling is received and the TXD LED flashes whenever the C4000 processor responds to polls for its respective pump number(s).
  • Page 67 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. Compac Industries Ltd. Page 67 www.compac.co.nz...

  • Page 68: Fault Finding

    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?
  • Page 69 Fault Finding High Current Triac Option Replace C4000 PCB if fault not found Motor running all the time Is Solid State Relay LED on? Yes - Check Nozzle Switch is releasing No - Select a spare High Current Solid State Relay.

  • Page 70: Error Codes

    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.

  • Page 71: Error Messages

    On PIN Pad Dot 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.

  • Page 72: C4000 With Rs232 Wiring

    Appendix A C4000 with RS232 Wiring Appendix A C4000 with RS232 Wiring Compac Industries Ltd. Page 72 www.compac.co.nz...

  • Page 73: Rs485 Wiring

    Appendix A RS485 Wiring RS485 Wiring The following changes are made to standard Compac dispensers to allow the use of RS485 communication with other devices. C4000 Power Supply 1) An RS485 Board is fitted inside the Power supply flame proof box.
  • Page 74 Appendix A RS485 Wiring Figure 6: J2B C4000 Processor 3) A new plug will need to be made for J13 and the following wires removed from J2A and inserted into pins 5 and 9. Compac Industries Ltd. Page 74 www.compac.co.nz...

  • Page 75: C4000 With Rs485 Wiring

    Appendix A C4000 with RS485 Wiring C4000 with RS485 Wiring Compac Industries Ltd. Page 75 www.compac.co.nz...

  • Page 76: Gilbarco Interface Wiring

    Appendix A Gilbarco Interface Wiring Gilbarco Interface Wiring Compac Industries Ltd. Page 76 www.compac.co.nz...

  • Page 77: Glossary Of Terms

    A model of pump mounted authorisation terminal made by Compac. Central Processing Unit. CWID Compac Wireless Identifier. Driveway Card Acceptor - A type of pump authorisation terminal made by Compac. Encoder A device that translates rotary motion into electronic pulses. Often referred to as a pulser. Head Dispenser calculator/Indicator.

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