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Compac DCA Installation & Service Manual

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DCA Installation & Service Manual
Version 1.1.4

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Summary of Contents for Compac DCA

  • Page 1 DCA Installation & Service Manual Version 1.1.4...

  • Page 2: Conditions Of Use

    Subject to your right to use the unit, Compac does generally applicable to equipment of this type. The not convey any right, title, or interest in its...

  • Page 3: Table Of Contents

    Contents Conditions of Use ................................2 Product Identification ............................... 6 Document Control Information ............................7 Symbols and Units of Measure ............................8 Safety ....................................9 Introduction ..................................10 Options................................... 11 Components ................................12 Litres Total ................................14 Installation Guidelines ..............................15 Electrical Connections..............................
  • Page 4 Dynalink (Hayes type) ............................82 GSM Modem (Wavecom)............................82 Lantronix ..................................83 Diagnostic LEDs ................................87 Diagnostic LEDs in a system with Compac comms only ..................88 Reports ..................................... 89 Deleting Transactions ............................90 Troubleshooting ................................91 Error Messages ................................91 Service and Upgrade Procedures ..........................
  • Page 5 Part Locations ................................130 Spare Parts List ................................132 DCA Cabinet ................................ 132 Electronic Components ............................133 Modem / Router Options (DCA) ........................... 134 Printer .................................. 135 Card Reader ................................ 135 CWID HID & USB ..............................136 Exchange Parts ..............................136 Glossary of Terms .................................

  • Page 6: Product Identification

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

  • Page 7: Document Control Information

    11/07/2011 R Lacey Updated grade map table 1.1.3 01/11/2011 R Lacey Added generator precautions, tank gauging cable restrictions and DCA installation checklist 1.1.4 29/08/2012 R Lacey Updated Conditions of Use. Added Colibri TG info. New Custom printer. Updated ATG Box to Compac Box.Added Roseman spec Compac Box to spare parts.

  • Page 8: 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 9: Safety

    Obtain a Hot Work Permit if required. These instructions are intended as a guide only. It is the responsibility of the technician and the site manager to manage safety in accordance with local regulations and best safe site practice. Compac Industries Ltd. Page 9 www.compac.co.nz...

  • Page 10: Introduction

    Introduction Introduction The Compac DCA is designed as an authorisation station for controlling the operation of fuel pumping systems. It is compatible with most common fuel pumps and can be easily customised to accept a variety of authorisation methods and provide detailed transaction reporting. The main features include: ...

  • Page 11: Options

    Introduction Options The DCA is a very versatile unit and can be equipped for many different functions depending on the customer's requirements. Driveway Card Acceptor The Compac Driveway Card Acceptor [DCA] is a standalone unit designed for unattended refuelling. The DCA can accept multiple card bases simultaneously including all major Oil Company, Gas Company and third party cards.

  • Page 12: Components

    Post to support the DCA. This post is manufactured from stainless steel and is powder coated white. It has a removable back plate to allow the DCA housing to be easily bolted on and allow access to the electrical wiring to and from the cabinet.
  • Page 13 Introduction Figure 1: CC DCA Front View Compac Industries Ltd. Page 13 www.compac.co.nz...

  • Page 14: Litres Total

    Introduction Litres Total From July 2012, Compac dispensers that are connected to Compac fuel management systems (FMS) that do not have a customer receipt printer, are fitted with an additional display line labelled "Litres Total". This display shows the total amount of fuel dispensed from the site to the authorisation card or ID tag.

  • Page 15: Installation Guidelines

     If the DCA post is within 4 metres of a dispenser or within 1 metre of the end of any fuel dispenser hose, then the entire interior of the post may be considered a hazardous area.
  • Page 16 DCA on a Wall If the DCA is to be mounted on a wall, it needs to be attached to a bracket that bolts to and supports the unit from underneath. No holes are to be made in the back of the cabinet unless specifically approved by Compac.

  • Page 17: Electrical Connections

    Connect the lines to the terminals marked T, R and G Comms Lightning Protection If lightning protection is fitted on the Compac comms, connect the comms cable directly into terminals marked LINE. Match up cables to the colours at the other end of the lightning protection unit.

  • Page 18: Tank Gauging Setup

    Veeder Root 9600 8 Bit The Compac settings for each model of tank gauge are usually either set at the factory or sent via CompacOnline. Precautions when using Generator Power The power output from onsite generators can cause power spikes that may damage electrical components within the cabinet.

  • Page 19: Wiring Diagram

    Wiring Diagram Wiring Diagram Compac Industries Ltd. Page 19 www.compac.co.nz...

  • Page 20: Modem Connections

    ADSL communication requires an ADSL enabled phone line and a Lantronix board. The Lantronix board is installed and pre-wired at the factory if an ADSL capable DCA is ordered. The phone line is connected to the DCA in the same manner as the 56K modem. 3G (NZ) or NextG (Aus) Modem The 3G modem (if fitted) is prewired and only requires a SIM card to be fitted.
  • Page 21 Modem Connections Direct Host If the DCA is to be connected directly to the PC without a modem, a cable with a 9 pin female d-connector each end is available as an option. This may be cut and additional cable spliced into it to make up the required length up to a maximum of 9 metres.

  • Page 22: Operating Instructions

    CWID Key & CWID Block Readers Overview Compac authorisation units can be equipped with a Compac Wireless Identifier (CWID) sensor. Drivers with CWID keys can place their key close to the sensor to enable the pumps. The CWID keys have unique numbers so that each transaction can be assigned to a particular CWID.
  • Page 23 Operating Instructions CWID Key & CWID Block Readers Figure 3: CWID Key Figure 2: DCA with CWID Key Reader Compac Industries Ltd. Page 23 www.compac.co.nz...

  • Page 24: Hid Readers

    HID Readers Overview Compac authorisation units can be equipped with an HID reader. Drivers with HID keys can place their key close to the sensor to enable the pumps. The HID keys have unique numbers so that each transaction can be assigned to a particular key.

  • Page 25: Itrack Reader

    Operating Instructions iTrack Reader iTrack Reader Overview The Compac unit can be supplied with an iTrack reader that detects vehicles fitted with an authorised transponder and authorises the pump to dispense fuel. Standard iTrack Operation When the driver drives up to the pump the iTrack reader will sense the presence of an authorised vehicle.

  • Page 26: Usb Module

    While not recommended, if the USB key is removed while in use, no transaction data will be lost. If the USB key is removed, the operation will need to be repeated to ensure all the data stored on the unit is retrieved. Figure 6: USB Module Compac Industries Ltd. Page 26 www.compac.co.nz...

  • Page 27: Usb Memory Stick

    Each module must have its own key. You cannot have one USB key that covers multiple units. You should always keep a secure copy of this file as if you lose your Compac USB stick the USB Module will not recognise any other USB stick unless it contains the unique “USB.key”...

  • Page 28: Uploading And Downloading Files

    To use the USB Module lift the plastic cover of the module. The screen should display: “COMPAC USB module press any key”. Plug your USB stick into the USB slot and push any of the keys. It will then display “Searching USB...”.

  • Page 29: Do All

    Getting the buffer itself could take up to 5 minutes depend on how many transactions are in the unit. It is very important that you DO NOT unplug the USB stick before the USB module says “Complete Remove USB”. Compac Industries Ltd. Page 29 www.compac.co.nz...

  • Page 30: Set Price

    The unit will read “Please wait...” Wait for the USB Module to say “Complete Remove USB”. You can now either unplug the USB stick or wait a few seconds for the screen to return to the menu to continue uploading or downloading more files. Compac Industries Ltd. Page 30 www.compac.co.nz...

  • Page 31: Get Buffer

    It also marks them as re-writable so as the transactions fill up the memory, it will overwrite the old transactions. Depending on functions, the equipment can store up to 5,000 transactions. Compac Industries Ltd. Page 31 www.compac.co.nz...

  • Page 32: Working With Usb Module Files

    Working with USB Module Files You can access the files on your USB key by plugging it into the USB port of your computer and clicking on the Compac file. You will see the following folders: Figure 7: USB key folders Click on the Cards, Price or Transactions files to view, change or retrieve information.

  • Page 33: Cards

    When a PIN number is added in this column, the user will be prompted to enter their PIN number. If a cell in this column is left blank, a PIN will not be asked for. PIN numbers are 4 digits as standard. Compac Industries Ltd. Page 33 www.compac.co.nz...
  • Page 34 If the any of the above files are lost then a new file can be recreated by duplicating the headers in row 1 (case sensitive). Enter the card fields and save as a .csv file. Compac Industries Ltd. Page 34 www.compac.co.nz...

  • Page 35: Price

    File Format If the price file is lost then a new file can be recreated by duplicating the headers in row 1 (case sensitive). Enter the pricing information and save as a .csv file. Compac Industries Ltd. Page 35 www.compac.co.nz...

  • Page 36: Transactions

     Tag - Information is shown here if the unit uses mapped cards  User ID - The ID number of the user if the unit is set up to prompt for a number Compac Industries Ltd. Page 36 www.compac.co.nz...

  • Page 37: Customising Your Transaction Reports

    Software installation and setup instructions Copy the USBTransJoin.exe file onto the Compac USB key and put it in the “Compac” Folder In the “Cards” folder you will have a file called cards.csv . The two standard columns in this file are “CARD_NUM” and “VALID”...
  • Page 38 In this example below card number 51 had the name “Test 39” and Unit number “188” assigned against it. Compac Industries Ltd. Page 38 www.compac.co.nz...

  • Page 39: Powering Up

    Powering Up Powering Up When you power up the USB Module it will display “COMPAC USB module ...no host” as the software has not started running yet. It should change after 2 minutes or so and display the idle message saying ”press any key”.

  • Page 40: Set Up

    The area where installers have the most difficulty is in setting up pumps and cards. Where possible Compac will set up the Pumps and Cards in the unit during manufacture. However as these details are not always available, some setting up...

  • Page 41: Main Menu Options

    If setup is required, push <NO> and “ENTER PASS CODE” will be displayed. Enter the pass code to access the main menu. (Factory default 654321). If you lose your pass code, contact Compac to get it reset. The following options are displayed: Option #1 REPORTS The reports menu is not used on current models.

  • Page 42: Option #2 Cards

    Main Menu Options Option #2 CARDS Option #2 CARDS Selecting 2 Cards will bring up this screen Choose 1 Identifier Validation to set up cards or 3 Network Setup to enter Access and ISO settings Compac Industries Ltd. Page 42 www.compac.co.nz...

  • Page 43: Option #3 Fuels

    <ENTER> 1) GRADE XX 2) PRICE 0.000 (stops flashing) <N> or <Y> to Change another price change grade <CLEAR> Returns to Main Menu Escape Manual pricing is overidden by USB or internet pricing. Compac Industries Ltd. Page 43 www.compac.co.nz...
  • Page 44 An authorisation station (grade 22) has a cardreader that enables the holder of a validated card to select and use a pump. This is typically used when non-Compac pumps are installed. An optional receipt printer may be attached to the authorisation station.

  • Page 45: Option #4 System

    The password and site number have to be set on site as they cannot be changed remotely by Netbase The Compac factory Passcode on new equipment is 654321. The system screen looks like this: Passcode The factory set passcode 654321 can be changed using the "PASSCODE" option in the Systems menu.
  • Page 46 SITE = XXXXXX (still flashes) number (Factory set Site number is #1 which can be left if unit is not part of a Network. If part of a Network, consult the Network Supervisor.) <ENTER> Returns to System menu Compac Industries Ltd. Page 46 www.compac.co.nz...
  • Page 47 <ENTER> Returns to system menu The clock setting is not shown on the display. To check the clock setting is correct, do a zero dollar transaction and check the time/date data on the receipt. Compac Industries Ltd. Page 47 www.compac.co.nz...
  • Page 48 0- Default Unused 0- Default Receipt 0 - Default Option 5 - Does not display NO RECEIPT in DCA mode if no receipt printer fitted Unused 0- Default Card File 0 - Default 5 - Big Hot Card file User ID option 0 - No PIN. Note: Encoding on the card can activate a prompt for PIN...
  • Page 49 <4> System menu is displayed CFG A = XXXXXXXXXXXX Set Configuration A <4> (flashes) was XXXXXXXXXXXX Edit 12 digit CFG A = XXXXXXXXXXXX ( number still flashes) was XXXXXXXXXXXX <ENTER> Returns to System menu Compac Industries Ltd. Page 49 www.compac.co.nz...
  • Page 50 3 - T2460 printer without cutter Unused CIM-less DCA 0 – DCA with CIM (early version card reader) Default Setting 1 – DCA with PINPad and Magtek TTL card-reader (changes receipt cut length) Unused Shift Reports Audit Trial 0 - LX300 (7bit; Even parity; 1 stop bit; 9600baud) 1 - LX300+ (8bit;...
  • Page 51 System menu is displayed <5> CFG B = XXXXXXXXXXXX (flashes) Set Configuration B was XXXXXXXXXXXX Type in 12 digit number CFG B = XXXXXXXXXXXX ( still flashes) was XXXXXXXXXXXX <ENTER> Returns to System menu Compac Industries Ltd. Page 51 www.compac.co.nz...
  • Page 52 Option #4 SYSTEM Credit Card Units "B" Settings The Compac credit card capable units can be set up with a variety of credit card authorisation options using the "B" settings. The settings differ from the normal "B" options fitted to the standard unit.
  • Page 53 System menu is displayed <5> CFG B = XXXXXXXXXXXX (flashes) Set Configuration B was XXXXXXXXXXXX Type in 12 digit number CFG B = XXXXXXXXXXXX ( still flashes) was XXXXXXXXXXXX <ENTER> Returns to System menu Compac Industries Ltd. Page 53 www.compac.co.nz...

  • Page 54: Option #5 Pumps

    If a Dual pump on Gilbarco comms the pump number on side B should be lower than the pump number on side A. e.g. A = 2, B = 1 For Compac comms the side A pump number is usually the larger number but will work either way round.
  • Page 55 Operation Channel 1 pump comms e.g. via 2 pin 'PUMP COMMS 1' on rear panel (for Compac pumps) Can also be setup for RS232 comms via Port #5 Channel 2 pump comms used for the following: (a) Gilbarco comms I/F via TTL Port #4...
  • Page 56 Type in Number 'H1-G03' still flashes (6 Hose Multi only) <ENTER> 'H1-G03' stops flashing (number saved) Refer to Tanks/Pumps/Groups (see page 68) first for a detailed explanation on how to set up groups. Compac Industries Ltd. Page 56 www.compac.co.nz...

  • Page 57: Comms Options

    Comms Channels The Communicator has two comms channels (Compac or Gilbarco and Email). Usually Compac pump comms are assigned to channel 1 and the other comms assigned to channel 2. Channel 1 can be either Current loop or RS232 (to either an Email or Gilbarco I/F...
  • Page 58 Dip switches 6 and 7. Second Current Loop Comms Channel There are two current loop comms channels (for Compac Pumps) on the Com FMS board. If a fault occurs on Current Loop Channel 1 and Current Loop Channel 2 is not being used then the channels can be switched over.
  • Page 59 Take great care line up the locking tabs on the green plugs correctly as reversal of these will damage the Email board. Compac Industries Ltd. Page 59 www.compac.co.nz...
  • Page 60 - Pump is set up as a Hi-line instead of an Electroline A DC voltage of approx 2 to 5V can be measured across the Gilbarco comms to establish whether a pump is connected. Compac Industries Ltd. Page 60 www.compac.co.nz...
  • Page 61 Wiring can either be from CON3 on the Gilbarco I/F board to TTL port 4 on the communicator board (channel 2 only) or from CON4 to RS232 port 4 on the communicator board. Examples are shown below: Compac Industries Ltd. Page 61 www.compac.co.nz...
  • Page 62 Main Menu Options Comms Options Figure 14: Gilbarco Interface Card with TTL connection Compac Industries Ltd. Page 62 www.compac.co.nz...

  • Page 63: Option #6 Tanks

    Refer to Tank Comms table Tank number is usually set as 1. If there are more tanks, use the YES and NO keys to select to the tank number you want to set up. Compac Industries Ltd. Page 63 www.compac.co.nz...
  • Page 64 (2) Status. The tank gauge readings should be displayed. Select (3) Status and the tank temperature should be displayed. Depending on tank gauging and software installed, other options may or may not be available. Compac Industries Ltd. Page 64 www.compac.co.nz...
  • Page 65 Depending on tank gauging and software installed, other options may or may not be available. Tank Gauging Troubleshooting To check that the tank gauging unit is communicating with the FMS board, look at the following LEDs: Compac Industries Ltd. Page 65 www.compac.co.nz...
  • Page 66 The wiring of the tank gauging cable may change for different models. If you are changing tank gauge units, you may need to swap the Tx and Rx wires to get it to work. Compac Industries Ltd. Page 66 www.compac.co.nz...

  • Page 67: Option #7 Product Groups And Grades

    The group is a controller protocol that aids product reconciliation and also enables fuel dispensing to be tailored to suit different local conditions. The group is like a junction box through which tanks, pumps, devices and products are assigned. Compac Industries Ltd. Page 67 www.compac.co.nz...

  • Page 68: Tanks/Pumps/Groups

    The group numbers don't have to be in sequence and may be any numbers between 1 and 20. For the grade/function map refer to Pump Grade maps (see page 44). Compac Industries Ltd. Page 68 www.compac.co.nz...
  • Page 69 2 - on board current loop 2 / internal protocol converter. Set Type C12 - Compac current loop pump comms, 1200 baud (NZ Standard). C24 - Compac current loop pump comms, 2400 baud (Compac pumps only. GC - Gilbarco Calcopac. GEL - Gilbarco Electroline.

  • Page 70: Setting Product Groups

    Refer to Grade Map for Product number <ENTER> 2) IS (Selected Product name) Use N and Y keys to scroll Same as for previous Group up or down to select another Group or <CLEAR> Returns to Main menu Compac Industries Ltd. Page 70 www.compac.co.nz...

  • Page 71: Assigning Pump Numbers To Hoses

    Remove the doors and a 'FRONT' sticker will be found on the hydraulic mounting rail. When looking at the front of the Pump/Dispenser, Hose 1-Side A is always on your right (as per the following diagrams) Compac Industries Ltd. Page 71 www.compac.co.nz...

  • Page 72: Legend 4 Hose, 6 Hose And Laser 4 Hose Quad

    Side A Side A FRONT Hose 2 Hose 3 Hose 1 Side B Side B Side B Legend 6 Hose Side A Hose 2 Hose 3 Hose 1 Side A Side A Side A FRONT Compac Industries Ltd. Page 72 www.compac.co.nz...

  • Page 73: Master, Premier And Laser (Single And Dual)

    Assigning Hoses to Product Groups Master, Premier and Laser (Single and Dual) Hose 1 Hose 1 Master Premier & Side B Laser (Single & Dual) Side A FRONT Compac Industries Ltd. Page 73 www.compac.co.nz...

  • Page 74: Cards

    If two cards systems are being supported (i.e. an Oil company / Nationwide card and an in-house Compac Standard card ) then the Oil company card must be set up as ISO/Access code 1 and the Compac Standard in-house card set up as ISO and Access 2 If they are setup the other way around the system may return a 'BAD CARD’...

  • Page 75: Oil Company Iso And Access Codes

    Oil company ISO and Access codes If the unit is part of a Network, the appropriate ISO and Access codes will be downloaded via the modem by the System Administrator. Otherwise contact the Compac Helpdesk. Compac Industries Ltd. Page 75 www.compac.co.nz...

  • Page 76: Atg / Ce Box

    ATG / CE Box ATG / CE Box Overview The Compac Box is an option fitted to the unit to monitor tank gauging. The Compac Box also communicates with the FMS board and stores transaction information. The tank gauging and transaction information can be accessed from the Compac Box by using either a USB key or CompacOnline software.

  • Page 77: Mechanical Registers

    Mechanical Registers Overview The DCA can be set up to monitor the bulk dispensing of fuel by taking signals from a mechanical register (flow sensor) installed in the fuel line. The signals are converted to provide a litre reading using a C4000 board and calibrated using a conversion (K) factor.
  • Page 78 ATG / CE Box Calibration A single litres only display is provided in the DCA for the purpose of setting up the C4000 board and changing the k factors. It is not used in normal operation of the DCA. The 'K' Factor is a ratio of litres dispensed per revolution of the meter.
  • Page 79 The setting for side “B” (or hose 2, 3, or 4) is displayed. times in quick succession Repeat steps 3 to 5 above. The K-Factor switch must be sealed with a lead or paper seal after commissioning. Figure 15: C4000 Board Compac Industries Ltd. Page 79 www.compac.co.nz...
  • Page 80 ATG / CE Box Figure 16: Solid State Relay Compac Industries Ltd. Page 80 www.compac.co.nz...

  • Page 81: Cardreaders

    Wiring connections are: Cardreader end J3 Unused Blue RDP White CLS Brown RCP Unused Red Vcc Black Ground Unused Unused Note pin 1 is marked on the cardreader pcb next to “J3” Communicator Controller end Compac Industries Ltd. Page 81 www.compac.co.nz...

  • Page 82: Modems

    It will then flash slowly when in its idle state. During a comms session it flashes faster. The baud rate in Netbase must be set to 9600 The Boot ROM software version in the Communicator must be BFA01052 or later Compac Industries Ltd. Page 82 www.compac.co.nz...

  • Page 83: Lantronix

    Lantronix Lantronix If you have given Compac the IP address that you want to use, the unit will have been set up by the factory. If you haven’t told Compac the IP address it will be 10.0.0.122 by default. Lantronix Setup Step 1 Connect the Lantronix port on the communicator to your computer network.
  • Page 84 Warning when you are setting the IP address on the Lantronix unit it cannot conflict with any IP address on your network. If you have a DHCP server you will have to reserve an IP address for the Lantronix unit. Compac Industries Ltd. Page 84 www.compac.co.nz...
  • Page 85 Make sure that the settings in the Communicator are the same as the settings in the Netbase. In this case  Passcode – 000000  Site Number– 000001  Config A (Parameter 1) = 202  Config B (Parameter 2) = 0 Compac Industries Ltd. Page 85 www.compac.co.nz...
  • Page 86 The baud rate must be always set to 9600. At this stage the communicator should be setup correctly and ready to communicate with the Netbase. To test the connection try doing a "Get date time" procedure. Compac Industries Ltd. Page 86 www.compac.co.nz...

  • Page 87: Diagnostic Leds

    Used for Receipt Printer and Commander RX/3 " " " " TX/4 Adjacent Port #4 TTL plug Green Only used when Gilbarco or Email pumps RX/4 " " " " Running on comms channel 2 Compac Industries Ltd. Page 87 www.compac.co.nz...

  • Page 88: Diagnostic Leds In A System With Compac Comms Only

    Diagnostic LEDs Diagnostic LEDs in a system with Compac comms only Diagnostic LEDs in a system with Compac comms only In a typical system (with Compac pumps only) this is how the diagnostic LEDs will appear. Com FMS Board Comms...

  • Page 89: Reports

    If a PC running NETBASE is used the printer is normally used to keep an audit trail log only. Reports are selected from DCA PIN Pad menus, and are only printed if an appropriate report printer is connected to RS232 Port 2 on the Controller and is ON LINE.

  • Page 90: Deleting Transactions

    A percentage reading of how full the transaction buffer is included in the printout which occurs on 'power up'. Once deleted, transactions can be overwritten, with no guarantee of retrieval. Compac Industries Ltd. Page 90 www.compac.co.nz...

  • Page 91: Troubleshooting

    The memory is full. Old transactions need to be deleted before any more transactions can be made - Refer to Deleting Transactions (see page 90). Pump unavailable or Pump Comms problem between the unit and the pumps. OFF LINE Compac Industries Ltd. Page 91 www.compac.co.nz...

  • Page 92: Service And Upgrade Procedures

     Replacement FMS board. Check if the board has memory and software chips (consult with Compac Help Desk to see if you can use existing software or if you also need to install new chips). Removal Turn off the mains switch.
  • Page 93 Service and Upgrade Procedures Com FMS Board Replacement (DCA) Figure 17: Comm FMS Board connections Compac Industries Ltd. Page 93 www.compac.co.nz...
  • Page 94 Service and Upgrade Procedures Com FMS Board Replacement (DCA) Due to the varied configurations of the units, all combinations of wiring can not be listed here. Take careful note of all connections before removal and use the list below as a guide only. The RS232 ports are RS232 mirrors of the TTL ports.

  • Page 95: C4000 Board Replacement

    The C4000 board can be set up in different ways depending on whether it is being used for CWID authorisation or for reporting mechanical register outputs. Refer to Compac and the C4000 Master Manual for details. Figure 18: C4000 Board Compac Industries Ltd.

  • Page 96: Compac Box Replacement

    Contact Compac who will remotely configure the unit. You may be asked to plug a laptop or screen, keyboard and mouse in to the Compac Box to do initial configuration. Figure 19: Compac Box (may be labelled as ATG Monitor) Compac Industries Ltd.

  • Page 97: Fit Pc Replacement

    Fit PC Replacement Fit PC Replacement The Fit PC is installed instead of a Compac Box when a wireless LAN connection is required. The Fit PC is recognised by the large heat sink. To Replace the Fit PC you will need ...

  • Page 98: Wiring A Usb Module

    Wiring a USB Module The diagram below shows the wiring diagram for USB interface board to a Compac Box. The power for the USB Interface Board is off J17 on the C4000 Process Board. An RS232 cable come off Port1 on the Com-fms board to the Com1socket on the Compac Box.
  • Page 99 Service and Upgrade Procedures Wiring a USB Module Figure 21: USB Module to Compac Box (COM2) Wiring Figure 22: Location of Port 1 on Com FMS board Compac Industries Ltd. Page 99 www.compac.co.nz...
  • Page 100 12 volt power supply either from a power transformer or by connecting into the TTL port of the Com-FMS board as shown. Wire both RS232 cables to the Compac Box as shown and plug the 6-way connector into the USB Interface board. The USB cable off the USB Interface board should be plugged into the USB port on the Compac Box.

  • Page 101: Cwid Interface Board Replacement

     Replacement CWID board. Check if the board has memory and software chips (consult with Compac Help Desk to see if you can use existing software or if you also need to install new chips). Removal Turn off the mains switch.
  • Page 102 The screw connector block can also be used for the CWID aerial connection. If either the aerial or the interface board are replaced the aerial must be re-tuned. Refer to Tuning the Aerial (see page 105). Compac Industries Ltd. Page 102 www.compac.co.nz...

  • Page 103: Cwid Aerial Replacement

    CWID board will illuminate when a valid CWID key is swiped. If either the aerial or the interface board are replaced the aerial must be re-tuned. Refer to Tuning the Aerial (see page 105). Compac Industries Ltd. Page 103 www.compac.co.nz...

  • Page 104: Cwid Nozzle Aerial Replacement

    Install the new cable the same way as the original. If either the aerial or the interface board are replaced the aerial must be re-tuned. Refer to Tuning the Aerial (see page 105). Compac Industries Ltd. Page 104 www.compac.co.nz...
  • Page 105 28 Volts. 12. Remove the shorting link fitted at 2 above. 13. Test the operation with a valid CWID key. Dipswitch Capacitance Dipswitch Capacitance (SW1) (nF) (SW1) (nF) 0.33 1.33 0.66 Compac Industries Ltd. Page 105 www.compac.co.nz...

  • Page 106: Hid Reader Replacement

    Service and Upgrade Procedures HID Reader Replacement HID Reader Replacement The HID unit if ordered from Compac will come with approximately 1.5 metres of cable terminated with a 5 pin plug. To Perform This Operation You Will Need  New HID Reader ...
  • Page 107 Service and Upgrade Procedures HID Reader Replacement Figure 25: HID Reader Connections Compac Industries Ltd. Page 107 www.compac.co.nz...

  • Page 108: Itrack Reader Installation And Replacement

    If the iTrack reader has been set up at the factory, it will connect to the pre- wired sockets on the DIN rail as follows: Isolate the unit before attempting any work on the iTrack reader. Compac Industries Ltd. Page 108 www.compac.co.nz...
  • Page 109 To connect an iTrack reader where no DIN rail connection is supplied you can wire the reader to an RS232 plug as follows: The picture above shows the factory wiring. When wiring the iTrack direct to the RS232 plug use the colours in the table. Compac Industries Ltd. Page 109 www.compac.co.nz...
  • Page 110 Port 3 on the Com FMS board. Connect the Blue/White wire to the 12v supply side of socket J17 on the C4000 board and the blue wire to the earth (twinned with the wire to RS252 pin 5). Compac Industries Ltd. Page 110 www.compac.co.nz...

  • Page 111: Card Reader Replacement

    Replacing the card reader is the reversal of the removal procedure. Replace the gasket if it is perished or damaged. When reconnecting, pay attention that the connector orientation is the same as when it was removed. Figure 26: P Series card reader Compac Industries Ltd. Page 111 www.compac.co.nz...
  • Page 112 Service and Upgrade Procedures Card Reader Replacement Figure 27: P Series Card Reader - Inside Figure 28: IntelliStripe 65 Series Card Reader Compac Industries Ltd. Page 112 www.compac.co.nz...
  • Page 113 Service and Upgrade Procedures Card Reader Replacement Figure 29: IntelliStripe 65 Series - Inside Compac authorisation units are fitted with a variety of card readers. Quoting the serial number when ordering will ensure you get the correct part. Compac Industries Ltd.

  • Page 114: Multiplex Board Replacement

    Com FMS board. To Replace Multiplex Board Removal and replacement is straight forward with the board held in by machine screws and the connections replaced as removed. Figure 30: Multiplex Board Compac Industries Ltd. Page 114 www.compac.co.nz...

  • Page 115: Keypad And Display Screen Replacement

    Unscrew the four nylock nuts that retain the keypad to the door. Replacement Replacing the keypad is the reversal of the removal procedure. Test the keypad and display for correct operation. Replace the gasket if it is damaged or perished. Compac Industries Ltd. Page 115 www.compac.co.nz...

  • Page 116: Router / Switch Replacement

    7mm nut driver to unscrew the nuts, then pull off the mounting plate. Replacement Reverse the removal procedure above to replace the router / switch. Once the unit has been installed contact Compac to set up the router user name, password and port forwarding. Figure 31: ADSL Router Compac Industries Ltd.

  • Page 117: Replacing The Receipt Printer

    The receipt printer uses special waterproof thermal paper. Do not use standard thermal paper as this may absorb moisture and jam in the printer. Order paper from your Compac agent. 57mm wide paper: Part number F-BA-PRTER-CK-RL 60mm wide paper: Part number F-BA-PRT-TG60X80 (new model printer) Figure 32: Receipt Printer Compac Industries Ltd.

  • Page 118: Software Upgrading

    IC board socket. If the chip is shorter than the socket, any spare pin sockets should be at the front. Failure to correctly insert the IC chips or adhere to the above guidelines specified will result in a loss of memory data. Compac Industries Ltd. Page 118 www.compac.co.nz...
  • Page 119 Service and Upgrade Procedures Software Upgrading Figure 33: Memory Chip Orientation Compac Industries Ltd. Page 119 www.compac.co.nz...

  • Page 120: Maintenance

    No other service is required, as there are no moving parts. Door Seals If the seals appear perished or damaged or there is water leakage into the cabinet through the seals, they should be replaced. Order new seals through your Compac agent. Protection The unit should have been mounted facing away from prevailing winds and in a sheltered place.

  • Page 121: Replacing Paper - Seiko Printer

    Replacing Paper - Seiko Printer Changing Paper Use only Compac supplied waterproof thermal paper. If you do not use this paper you may damage the printer and have receipt printing problems. Unlock the two locks on the door or cover (depending on model) to access the printer.

  • Page 122: Changing Paper On A Custom Printer

    Changing Paper on a Custom Printer Changing Paper on a Custom Printer Use only Compac supplied 60mm wide waterproof thermal paper. If you do not use this paper you may void the warranty, damage the printer and have receipt printing problems.

  • Page 123: Appendix

    Figure 35: ComFutra FMS Board Connections Connecter shown below is for the capacitive (hard) type key pad. Refer to membrane key pad wiring for soft type key pad wiring. Compac Industries Ltd. Page 123 www.compac.co.nz...
  • Page 124 Appendix Comm FMS Board Connections For a "White Card" and Fuelcard enabled unit the receipt printer plugs into Port 3 TTL of the Comm FMS board as shown below: Compac Industries Ltd. Page 124 www.compac.co.nz...
  • Page 125 Appendix Comm FMS Board Connections For a Credit Card enabled unit the plug for Port 3 TTL is wired like this and terminates at the Comm FMS RS232 Port Expansion Board. Compac Industries Ltd. Page 125 www.compac.co.nz...

  • Page 126: Plugs And Connectors

    Appendix Plugs and Connectors Plugs and Connectors Display The Display is connected as shown below: Compac Industries Ltd. Page 126 www.compac.co.nz...
  • Page 127 The membrane type (soft) key pad requires a different cable to the capacitance (hard) type key pad. Key pads can be interchanged but a software change is required if a different key pad is fitted. Compac Industries Ltd. Page 127 www.compac.co.nz...
  • Page 128 Printer power is supplied by the Printer Power Supply Board. Port 3 TTL on the Com FMS or Com FMS Expansion Board connects to CN 7. The paper feed switch connects to "Feed". Figure 36: Printer Board Compac Industries Ltd. Page 128 www.compac.co.nz...
  • Page 129 Port 3 TTL from the Comm FMS board plugs into Con 1 (8 pin) Con 2 plugs into connector CN 7 on the receipt printer. The EMV card reader plugs into either Con 3 or Con 4 Compac Industries Ltd. Page 129 www.compac.co.nz...

  • Page 130: Part Locations

    Part Locations Plugs and Connectors Part Locations Because there is a wide variety of RAS, DCA and CC DCA options this manual will not exactly cover every combination of setup. The pictures below indicate the most common parts and their location.
  • Page 131 Part Locations Plugs and Connectors Figure 39: DCA with Printer and ADSL Router Compac Industries Ltd. Page 131 www.compac.co.nz...

  • Page 132: Spare Parts List

    To ensure you get the correct parts, always quote serial number of the unit when ordering. DCA Cabinet Part Number Description FD-CF-BOX-DCA DCA Cabinet (with hinges / no door) FD-CF-BX-DCA-DPE DCA Cabinet Door (quote DCA serial number) FD-P-SEALANT-01 DCA Door Frame Sealing Tape F-KEYS-144...

  • Page 133: Electronic Components

    RS232 Comm Port Expansion PCB CI118 F-CP-COMM-DPIA Commander RS232 PORT I/F F-CP-PINPADT Complete Capacitance PIN Pad (DCA) Obsolete F-FAS-PPAD-CMFM Tactile PIN Pad assembly without LCD (DCA) F-FAS-PPAD-CMFC4 Tactile PIN Pad assembly without LCD (RAS) F-BL-20X4LCD-LCD PIN Pad LCD Display (DCA) F-CP-CF-IFDISP PIN Pad LCD Display with I/F Board &...

  • Page 134: Modem / Router Options (Dca)

    Spare Parts List Modem / Router Options (DCA) Modem / Router Options (DCA) F-BA-MDM-CELGSM GSM Modem 1306B GPRS Modem FD-BA-MDM-CELDCB Modem Data Cable FD-BA-MDM-CD1625 Aerial FD-P-GSKT-AERIAL Aerial Gasket FO-ADSL-001 Linksys AG 300 ADSL Router F-BA-MDM-CDR990 3G Vodafone Router ( NZ)

  • Page 135: Printer

    FD-BA-PRT-RCT-DR DCA Receipt Printer Door *From June 2012 the DCA printer was changed from a guillotine type with a receipt door to a tear-off style. The new style uses a 60mm wide paper with a different spindle bore size. The paper is not interchangeable between models. Make sure you order the correct paper for the printer.

  • Page 136: Cwid Hid & Usb

    Spare Parts List CWID HID & USB CWID HID & USB F-CIM-CWCRD CIM Cardswipe for CWID & C4000 equipped DCA F-CP-CWID-E CWID board for one or two aerials F-CU-CWIDD-TAG1 CWID Tag block type - programmed F-CU-CWIDD-TAG2 CWID Tag key ring type - programmed...

  • Page 137: 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.

  • Page 138: Installation Checklist

    Complete transaction using white card/CWID/HID/Pin authorisation methods Complete transaction using credit card (credit card DCA only). Check that all hoses can be selected and authorised by the unit. Check all hoses stop on or before the pre-authorised value (credit card DCA only). Receipt Checks (where fitted) Check that the correct $, L and fuel grade are printed on the receipt.
  • Page 139 Tidy up all rubbish and clean the exterior of the unit before leaving. If one or more of these tests fail, contact the Compac help desk or your service centre so the problem can be logged and parts issued if required.

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