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Compac C5000 Manual

Controlled pumps and dispensers
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C5000 MANUAL
C5000 Manual
Version 1.0.9
Model: C5000 Controlled Pumps and Dispensers
Date: 16
th
September 2020

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Summary of Contents for Compac C5000

  • Page 1 C5000 MANUAL C5000 Manual Version 1.0.9 Model: C5000 Controlled Pumps and Dispensers Date: 16 September 2020...
  • Page 2 Identification section. care. ▪ Only parts supplied by or approved by Compac may ▪ Compac Industries Limited accepts no liability for be used and no unauthorised modifications to the direct, indirect, incidental, special, or hardware of software may be made.
  • Page 3 Compac for archived manuals if required. Validity Compac Industries Limited reserves the right to revise or change product specifications at any time. This publication describes the state of the product at the time of publication and may not reflect the product at all times in the past or in the future.
  • Page 4 Document Control Document Information File Name and Location C5000 Manual v.1.0.9 Current Revision Author(s) V Amarakoon Authorised By W Zheng Revision History Version Date Author(s) Revision Notes 1.0.0 20/11/2018 S Laycock New manual 1.0.1 07/12/2018 R Liu Updated Contact Information 1.0.2...

  • Page 5: Table Of Contents

    Contents Safety ........................1 C5000 Power Supply .................... 2 Cable Requirements ....................3 Incoming Mains ....................4 Comms Connections ..................... 5 Power Supply ....................... 6 K-Factor Board ...................... 7 Typical Wiring ...................... 8 Pumps ........................8 Dispensers ......................10 K-Factor Settings ....................11 Using the Dispenser Menus ................

  • Page 6: Safety

    Electrical Safety Observe the following electrical precautions: Always turn off the power to the Compac C5000 processor before opening the flame proof box. Never touch wiring or components inside the high voltage area with the power on. Always turn off the power to the Compac C5000 processor at the mains switch before removing or replacing software or memory ICs.

  • Page 7: C5000 Power Supply

    C5000 Power Supply The C5000 may be supplied unmounted for use in applications such as controlling mechanical registers in a bulk dispensing area or mounted on a truck for mobile dispensing. When installing the C5000 power supply, please observe the following instructions.

  • Page 8: Cable Requirements

    ▪ Replace the lid making sure the gasket is in place and clean and that no wires have been pinched. External Earthing Where required, earth the C5000 Power Supply using an earth wire with a cross sectional area at least equal to the largest conductor. The earth wire is attached to the integrated point. Cable Requirements...

  • Page 9: Incoming Mains

    Incoming Mains Incoming mains connections should be brought in to the terminal board. An emergency stop connection, if desired, can also be wired into the terminal board, shown below. This will be in place of the normal loop between the triac and main phases. Wires have standard colours which are shown.

  • Page 10: Comms Connections

    Comms Connections The comms I/O is controlled by the connections to the Comms board. Refer to the following diagram for connecting RS485, RS232, Compac or Gilbarco pumps. The shown switch should be set to the desired setting. Switches 300, 302, and 303 are for RS485/RS232 Terminator application. Use the following table to configure these switches.

  • Page 11: Power Supply

    Power Supply The C5000 power supply is found within the flameproof box, located on the unit. The power supply contains the processor board and the terminal board. Processor Board Terminal Board Power Supply PCBs Flameproof box...

  • Page 12: K-Factor Board

    K-Factor Board Both the Parameter switch and K-Factor switch are found on the K-Factor board. Meters and air switches are also connected to this board. See below for the location of these. Parameter Switch K-Factor Switch Connect optional Bus out system Side A Connections mechanical totes cables...

  • Page 13: Typical Wiring

    Typical Wiring Pumps The following diagrams show the typical wiring required for C5000 pumps. The motor can be connected to the terminal board for both side A and side B. Only wire in the required side(s). The location of the fuses on the terminal board are also shown. These can be used for diagnosing problems with the unit.
  • Page 14 Triac Wiring The triac wiring is pre-installed and, in most cases, will not need to be changed. However, the wiring is shown here to aid triac replacement or other service procedures. These are colour coded with standard colours. In case these are not clear, the colours are as follows: ▪...

  • Page 15: Dispensers

    Dispensers When using the C5000 electronics for dispenser application, as well as connecting the incoming mains, the external pump contactors will have to be connected to the terminal board. Solenoids for side A and B are optional and can be wired in if preset and prepay options are desired.

  • Page 16: K-Factor Settings

    K-Factor Settings A summary of the K-Factor settings can be seen below. Information on these settings and how to change them can be found on the following pages. Setting Price display Litres display Dispenser settings C-A or C-B ******* Meter ID ID-A or id-b ****** Temperature calibration...

  • Page 17: Dispenser Settings

    Dispenser Settings The following diagram displays how to change the dispenser settings, such as the meter type, variant and minimum delivery. To get to the following menu, depress the K-Factor switch once when not in a transaction. The menu shown is for side A – if side B is required, continue depressing the K-Factor switch until the same menu for side B is reached and follow the same set up instructions.
  • Page 18 Meter Settings This setting corresponds to the type of meter plugged in to the dispenser. Options 1-3 are for an encoder meter and depend on the channel setting of this meter. Encoder meters are used for petrol and diesel, while V50 meters (option 4) are used for LPG and AdBlue. Some settings (such as temperature and density calibration) are only available for V50 and therefore will not appear if the meter type is not set to V50.

  • Page 19: Changing The V50 Meter Id

    Note that the MMQ still must be one of the valid values listed above. If the MMQ is calculated from the maximum flow, and is NOT one of the valid values listed above, it will be rounded up to the next valid value. For example, if the maximum flow was 600: ������...

  • Page 20: Changing The Temperature Calibration

    Changing the Temperature Calibration The temperature calibration can be used to adjust the temperature being retrieved from the meter, if this is not the actual temperature of the product being dispensed. The actual temperature of product being dispensed should be entered in this menu. This will be used to adjust new temperatures returned from the meter.

  • Page 21: Changing The Maximum Flow

    Changing the Maximum Flow If this setting is left at 0000 the maximum flow, or Qmax, is 40 litres/minute by default. When changing the maximum flow, note that the high flow cutoff, low flow cutoff (LPG only), MMQ, and preset rounding are calculated from the maximum flow. See Using the Dispenser Menus to edit these settings.

  • Page 22: Changing Configuration Settings

    Changing Configuration Settings The dispenser has settings for each side (as previously shown) as well as configuration settings for the entire unit. Use the following diagram to set the unit up as desired. 0000002 Hardware Variant Card Totals Pump Mode Pump Settings 0 –...
  • Page 23 Pump Settings Main display (K- Factor display) Each setting is a different configuration with different hardware. See below for descriptions of these configurations. 21. 5 3 For all pump settings, the main display shows information on 25. 8 4 side A. Slave displays will need to be configured to show side 1.
  • Page 24 Mode 1 = 5 digit Pump Protocol 0 = 6 digit 0 = Disabled 1 = Compac Channel 2 = PEC 0,1 (default) and 2 3 = Gilbarco Change the Protocol and the mode to match the controller’s settings. Channel 1 is the default channel for dispensers (channel number should always match the with the comms board terminal block used).

  • Page 25: Changing The Solenoid Delay

    Changing the Solenoid Delay Pumps have two solenoids for product flow. If the solenoids are unavailable, the pump preset should also be unavailable. The solenoid delay is the time between when the motor starts, and when the solenoids start at the beginning of a transaction. The value entered is in seconds. See Using the Dispenser Menus to edit these settings.

  • Page 26: Changing The Preset Rounding

    Changing the Preset Rounding The dispensed amount of fuel can be rounded to the preset if within the preset rounding parameters. If the preset rounding is left as zero, the preset rounding will be calculated from the MMQ. In LPG mode, 2% of the MMQ will be used for preset rounding. In non-LPG mode, 1% of the MMQ will be used for preset rounding.

  • Page 27: Changing The Flow Time Out

    Changing the Flow Time Out The flow time out is the amount of time it takes for the transaction to time out after flow stops, if the nozzle is not hung up. The default depends on the dispenser mode. If the dispenser is in LPG mode, the default time out will be 10 seconds.

  • Page 28: Parameter Settings

    Parameter Settings The following table summarises the parameter switch settings. Information on these settings and how to change them can be found on the following pages. NOTE: The configuration settings must be set before parameter settings can be accessed. Setting Price Display Litres Display Software Version...

  • Page 29: How To View The Software Version

    How to View the Software Version Pressing the parameter switch once will show the software version. P01. 0 0. 0 0 p01. 0 0. 0 0 The dispenser will then run through a segment test. Changing the Pump Number If the parameter switch is continually depressed, the following menu to change the pump number will appear.

  • Page 30: Changing The Price

    Changing the Price The price must be set before the dispenser can be used, otherwise an error will be returned. Set the price in dollars per litre. See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B. pa01.
  • Page 31 Standard Mode In standard mode, the main display will show: • Top row: Transaction total in dollars • Second row: Compensated litres for LPG, or uncompensated litres for non-LPG, dispensed by default, but can be changed in Dispenser Settings And the unit price window will display the price per litre. Purge Mode Test mode can be used for all calibrated runs with the exception of vapour tests.

  • Page 32: Changing The Low-Flow Cutoff

    Changing the Low-flow Cutoff A flow range is needed for each pump to dispense an accurate amount of product. If too much or too little fuel is dispensed, the meter can not accurately measure the dispensed fuel and therefore should cut off and display an end of sale message. The low-flow cutoff will end the transaction (without an error code) if flow drops below this value.

  • Page 33: Changing The B Setting

    Changing the b Setting The b setting is currently only used for LCD dimming. Set the b configuration code as desired. 0000 LCD Dimming 0 – Disabled 1 – Enabled Changing the Slave Display Configuration Slave displays can be configured as, a clone of the main display, to show side A, or to show side B.

  • Page 34: Changing The Custom Display Configuration

    Assigning a number to slave display Slave display numbers can be set with dip switch 2 and 3 on the slave display board. Use the following table as a guide to configure the slave displays Slave Display Switch 1 Switch 2 Switch 3 CAUTION : Make sure the device is powered off before attempting to change the dip switches...

  • Page 35: How To View Last Sale

    How to View Last Sale To view the last sale details, continue pressing the parameter switch until the following display is shown. This will only show up if the dispenser is in V50 mode. 4. 7 0 529. 8 The top row will show uncompensated, unsuppressed quantity dispensed in litres, while the bottom row will show the density reading at 15°C.

  • Page 36: How To View Electronic Totes

    How to View Electronic Totes The dispenser records electronic totes for price and dollars. To view the electronic totes, continue pressing the parameter switch until the following display is shown: La 0031 l0556. 6 1 The bottom row is a continuation of the top row – for example, the above display should be read as 00310556.

  • Page 37: Commissioning

    2. Turn on the power supply to the dispenser. 3. With the dispenser in a ready state, check that the C5000 processor board Power LED is turned on.

  • Page 38: Mechanical

    Mechanical The following mechanical commissioning instructions are for liquid fuel pumps and dispensers. If LPG, CNG, or AdBlue is being dispensed, refer to the specific manuals for these. Make sure that the electrical commissioning tests have been carried out and the solenoid operation has been verified before carrying out the following tests.

  • Page 39: Led Diagnostics

    LED Diagnostics LEDs on the circuit boards can be used to diagnose faults in the unit. View the LEDs and their corresponding tables to see the state of the board. Processor Board DIAG: Diagnostics PWR: Power Processor Board LEDs Operation/Possible Cause Power This should be on when there is power to the unit.

  • Page 40: K-Factor Board

    K-Factor Board RD: Receiving Data TD: Transmitting Data PWR: Power DIAG: Diagnostics T1-7: Output LEDs – depend on application COM: Not currently in use K-Factor Board LEDs Operation/Possible Cause Power This should be on when there is power to the unit. In normal operation, this should flash slowly, and then flash quickly Diagnostics when the nozzle switch is lifted.
  • Page 41 K-Factor Board Output LEDs The following table describes what each output LED represents for each mode. The output LED will light up when the corresponding outlet is engaged. Outputs for both side A and B are shown. Mode Primary Secondary High Flow High Single...

  • Page 42: Troubleshooting

    ▪ Check Diagnostics LED on the processor board to see if there is a software issue. ▪ If Diagnostic LED is off, check that memory chips are firmly in their sockets. ▪ Replace C5000 if LED is on after repowering unit. Pump Not Starting ▪...
  • Page 43 Diagnostic LED flashes faster when switch is on. ▪ Select a spare Low Current Solid State Relay if the above checks are okay. ▪ Replace C5000 if fault not found. Solenoid Not De-energising ▪ If output LEDs on the K-Factor board are on, check nozzle switch is releasing, the nozzle switch is working if the Diagnostic LED flashes faster when switch is on.

  • Page 44: Mechanical

    Solenoid Valve Not Opening ▪ Check the output LEDs on the K-Factor board. ▪ Check the electrical supply to the coil. Check the C5000 output triac is switched on. There should be 220 – 240 volts across the solenoid coil.

  • Page 45: Generator Power

    Generator Power The power output from onsite generators can cause power spikes that may damage electrical components within the cabinet. Although generators are fitted with power regulators, most are not filtered sufficiently for powering sensitive electrical components. We recommend installing a commercial power conditioner and/or UPS between the generator and the unit.

  • Page 46: End Of Sale Indicators

    End of Sale Indicators The reason for the end of sale for each transaction is recorded by the unit. These are helpful for troubleshooting the unit. Keypad Display Dispenser Display Meaning Nozzle hung up PRESET Reached preset DISP Normal end of delivery OFFLINE Pump –...

  • Page 47: Error Codes

    Error Codes The unit will have error codes programmed in. The following is a list of error codes and how to rectify these errors. Error Code Fault Action/Information Excess flow Maximum flow rate exceeded Er FLO Calibrate meter density using the K-Factor Density out of range switch ER DEN...
  • Page 48 Meter error If the problem persists, repower the unit. Er 52 Replace the meter if necessary Meter stopped vibrating If the problem persists, repower the unit. Er 53 Replace the meter if necessary Temperature sensor failure If the problem persists, repower the unit. Er 54 Replace the meter if necessary Meter not ready...
  • Page 49 Overrun – flow above preset Increase the preset cutoff Orun Sump error – liquid detected in Empty the sump. Check the dispenser for 5ump the sump leaks For LPG, the density being Calibrate meter density using the K-Factor returned from the meter is to switch...

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