Compac Industries C3000 Service Manual

Hide thumbs

Table of Contents

Quick Links

Download this manual

OMPAC

NDUSTRIES

IMITED

DESCRIPTION .................................................................................................. 4

1.1.

General.............................................................................................................................................. 4

1.2.

Safety Precautions............................................................................................................................ 5

1.3.

Static Electricity Precautions .......................................................................................................... 5

MAIN FEATURES ............................................................................................. 6

2.1.

Components ...................................................................................................................................... 6

2.2.

Configurations.................................................................................................................................. 6

2.2.1.

Single Commercial ........................................................................................................................ 6

2.2.2.

Single Suction Dual Commercial (Duo)........................................................................................ 6

2.2.3.

Dual Commercial (Dual or Double) .............................................................................................. 6

2.2.4.

Single Retail .................................................................................................................................. 7

2.2.5.

Single Suction Dual Retail (Duo).................................................................................................. 7

2.2.6.

Dual Retail (Dual or Double) ........................................................................................................ 7

2.2.7.

Multi Product (4 hose) Retail ........................................................................................................ 7

2.2.8.

Multi Product (4 hose) Retail, Type 'A' all hoses in use................................................................ 7

2.2.9.

Multi Product (6 hose) Retail ........................................................................................................ 8

2.2.10.

Multi Product (6 hose) Retail, Type 'A' all hoses in use................................................................ 8

2.2.11.

Futra (Uses 'Futra' Software)......................................................................................................... 8

SET-UP MODES ............................................................................................... 9

3.1.

Operating DipSwitch Settings ....................................................................................................... 10

3.1.1.

Switch 1....................................................................................................................................... 10

3.1.2.

Switch 2....................................................................................................................................... 10

3.1.3.

Switch 3....................................................................................................................................... 11

3.1.4.

Switch 4....................................................................................................................................... 11

3.1.5.

Typical Switch Settings............................................................................................................... 12

3.2.

'K' Factor Switch ........................................................................................................................... 13

3.2.1.

Using the 'K' Factor Switch........................................................................................................ 13

3.2.2.

Calibration ('K') Factor................................................................................................................ 13

3.2.3.

No Flow Cut-Off Timer .............................................................................................................. 14

3.2.4.

Display (Litres) Resolution ......................................................................................................... 15

3.2.5.

Solenoid Delay ............................................................................................................................ 15

3.2.6.

Pre-Set Cut-Off ........................................................................................................................... 16

3.2.7.

'b' Settings. Air Detection, End of Delivery Flag, and Price Per Litre Display ................................... 16

3.2.8.

Configuration Code ..................................................................................................................... 17

3.3.

Further Settings Available on the 'K' factor Switch................................................................... 19

3.3.1.

Product Density Factor................................................................................................................ 19

3.3.2.

Specific Density .......................................................................................................................... 19

3.3.3.

Temperature Calibration.............................................................................................................. 20

3.3.4.

ACV Valve Flowrate................................................................................................................... 20

3.3.5.

L-Cut ........................................................................................................................................... 20

3.3.6.

H-Cut........................................................................................................................................... 20

3.3.7.

F-Cut ........................................................................................................................................... 21

3.4.

Parameter Switch ........................................................................................................................... 22

3.4.1.

Program Version Number ........................................................................................................... 22

23/03/04

C3000 S

ERVICE

ANUAL

ONTENTS

Page 1

Table of Contents

Need help?

Do you have a question about the C3000 and is the answer not in the manual?

Questions and answers

Summary of Contents for Compac Industries C3000

Page 1: Table Of Contents
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ONTENTS DESCRIPTION ....................4 1.1. General.............................. 4 1.2. Safety Precautions..........................5 1.3. Static Electricity Precautions ......................5 MAIN FEATURES ..................... 6 2.1. Components ............................6 2.2. Configurations..........................6 2.2.1. Single Commercial ........................6 2.2.2.
Page 2 C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ONTENTS 3.4.2. Setting the Price per Litre ......................22 3.4.3. Setting the Product Density ......................25 3.4.4. Setting the Dispenser/Pump Number...................25 3.4.5. Displaying the End of Sale Indications..................25 3.4.6. Setting the Sequencing Rate ......................25 3.4.7.
Page 3 10. ELECTRICAL WIRING..................39 10.1. 230 Volt Wiring ..........................39 10.2. Communications (Comms) Wiring....................40 10.2.1. C3000 Gilbarco Protocol Converter.................... 41 10.3. Intrinsically Safe Wiring ....................... 42 10.3.1. Diesel Air Cut-out Switch ......................42 10.3.2. Sump Switch (Issue "M" only)....................43 10.3.3.
Page 4: Description
TOTES Figure 1. Layout of C3000 Printed Circuit Board The C3000 microprocessor, commonly referred to as the 'head', is powered by an intrinsically safe power supply, and is designed to operate in both a class 1 zone 1 area and in the vapour-proof box 1.2m above the ground level.
Page 5: Safety Precautions
This is not a recommended alternative to wearing an anti-static wrist strap. Note: Compac Industries Limited reserves the right to refuse to accept any circuit boards returned, if proper anti-static precautions have not been taken.
Page 6: Main Features
Preset • ° Nozzle Switch Last Sale, kilograms, litres and price (CNG only) 2.2. Configurations The C3000 'head' can be used with the equipment listed below in the following standard configurations: 2.2.1. Single Commercial Standard Options: Extras: • • Litres only display, two - one per side Card-reader •...
Page 7: Single Retail
Presets, two - one per side Receipt Printer • Four Encoders • Four Nozzle Switches • Four Motor Outputs - two per C3000 Head • Two C3000 Heads (for Issue "L") • One C3000 Head (for Issue "M") and Version 25 software •...
Page 8: Multi Product (6 Hose) Retail
Presets, two - one per side Receipt Printer • Six Encoders • Six Nozzle Switches • Six Motor Outputs - three per C3000 Head • Two C3000 Heads • Multi-price Displays, six - one per product per side 2.2.10. Multi Product (6 hose) Retail, Type 'A' all hoses in use...
Page 9: Set-Up Modes
The positions of the above switches are shown on Figure 1, page 4. Also, note that a second, more readily accessible parameter switch is mounted in all pumps/dispensers. This gives quick access for service station staff to make changing price easier. Set up of the C3000 must be done in the following sequence: Operating Dipswitch Settings (power OFF the C3000 before changing) •...
Page 10: Operating Dipswitch Settings
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES SP: Set decimal place. Appears only when the unit is set-up for CNG. NOTE: 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 11: Switch 3
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES 3.1.3. Switch 3 If Switch 3 is ON, then dispenser/pump software will run in AUTO AUTHORISE mode of operation (used for wharf & aviation sites, or any other sites where the hose reel is remote from the pump unit): •...
Page 12: Typical Switch Settings
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES 'stand-alone' mode. When Switch 4 is ON, the unit must be connected to a Compac Central Controller. 3.1.5. Typical Switch Settings OPERATING DIPSWITCHES Typical models C40P or C80S Retail pump/dispenser to EFTPEC...
Page 13: K' Factor Switch
The power supply does not have to be interrupted. NOTE: The C3000 will reset at any stage during the 'K' Factor switch operation if the switch is not pressed for a period exceeding ten (10) seconds. If the C3000 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 14: No Flow Cut-Off Timer
Caution: Be careful when calibrating dual or multi-hose pumps & dispensers to ensure that the correct 'K' factor is being changed. 3.2.3. No Flow Cut-Off Timer Under normal conditions to end a transaction on a C3000 controlled pump/dispenser, there are three possibilities: • Returning the nozzle to its holder. • Reaching the preset amount entered.
Page 15: Display (Litres) Resolution
Press and hold the ‘K’ factor switch. The decimal point will begin to move. When the resolution (decimal point) is NOTE: the C3000 will reset itself if the ‘K’ factor switch is left for more than 10 seconds. correct, release the ‘K’ Factor switch.
Page 16: Pre-Set Cut-Off
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES 3.2.6. Pre-Set Cut-Off Pre-set Cut-off is available from Software Version 26:01.0. Prior to the dispenser reaching its preset amount, the solenoids are switched to give a low flowrate. 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 flowrate.
Page 17: Configuration Code
3.2.8. Configuration Code Since version 17 of the C3000 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, as shown in Figure 3 on page 18.
Page 18 4 = Remote receipt printer (at controller) 5 = CWID + Seiko printer 6 = CWID Mode 7 = CWID + Local receipt printer (Driven by C3000) 8 = CWID + Remote receipt printer (at Controller) 9 = Micro-M consul/power modem...
Page 19: Further Settings Available On The 'K' Factor Switch
This setting is only available for LPG and Bulkmeter modes The specific density for LPG must be set to allow the C3000 to accurately meter the amount of LPG dispensed. The specific density of the product should be obtained from the LPG...
Page 20: Temperature Calibration
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES 3.3.3. Temperature Calibration 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 3.2.8 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 'EXXX.X' to the known temperature value.
Page 21: F-Cut
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES 3.3.7. F-Cut 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 section 3.2.1 page 13. While setting the “F-Cut”, the price display shows 'FCUT' and the volume display shows 'FXXXX'.
Page 22: Parameter Switch
The C3000 processor board can be set for five hose configurations: Single (e.g. one C3000 controls one hose) Dual (e.g. one C3000 controls two hoses) Multi (for Issue "L") - e.g. one C3000 controls two or three Controls 4 hoses (Issue "M" only) Quad (for Issue "M") - all hoses.
Page 23 When the digit is correct, release the Parameter switch. Repeat steps 3 and 4 for each digit of NOTE: the C3000 will reset itself if the Parameter switch is left for more than 60 the ‘Price per litre’. seconds.
Page 24 NOTE: The Compac “All Hose” multi-product pumps and dispenser are configured as either 3 dual hose C3000s, or 1 quad and 1 dual hose C3000. 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.
Page 25: Setting The Product Density
'controller set' density to override). To set Product Density at the C3000, press and hold the Parameter switch until the message 'den XXX.X' appears on the display. Then change this value using the usual press/hold/release method to obtain the desired density.
Page 26: Setting The Access Code
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES 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 'Y' to 'n' etc. by holding the Parameter switch depressed.
Page 27: Printer Setup
C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL RINTER PRINTER SETUP 4.1. Comcard, Compin, and 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).
Page 28: Displaying And Printing Totals
Card/pin/key status is also displayed on this printout. The printer may also be permanently wired to the C3000 comm's. 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.
Page 29: Printer Housed At The Pump/Dispenser (Card King)
This Receipt Printer option is only available for C3000 microprocessors controlling one hose pumps/dispensers, or for C3000s which are set-up in 'True Multi' configuration. A PINpad must also be connected to the C3000 and the third digit of the Configuration Code must be set to '1' or '3' (See Section 3.2.8) •...
Page 30 To select this option the third digit of the Configuration Code for the C3000 should be set to '4' or '5', depending upon whether a standard or Secure PINpad is installed on the pump/dispenser. (See Section 3.2.8).
Page 31: Basic Systems (Comcard , Compin , & Cwidk Ey )
For the COMPIN system, the Configuration Digit "4" must be set to 2 and the 'Operating dipswitch' two (2) must be OFF. In this mode of operation the 'C3000 Head' operates as a totally self-contained system operating independently of central controller. The C3000 'Comms' circuitry, which is usually used for communicating with a controller, is now used to run an audit trail and/or receipt printer (see section 4 for printer setup details and sections 5.2 and 5.3 for details on how to...
Page 32: Cwidkey Number Identification
Err 10 Configuration Lost Reconfigure C3000 Err 11 Invalid access code Enter valid access code. (Comcard or CWIDKey Basic systems only). Err 12 C3000 memory failure. Change memory E prom 'chip'. Err 13 Temperature/Pressure Reconnect interface board Interface unplugged. or replace.
Page 33 (if Connected) REPAS Pass Again Card not read properly, try re-swiping. In addition, C3000 may be configured for the wrong cardreader track, or the card or cardreader could be faulty. HOLD System not ready Pump no longer communicating with Central Controller.
Page 34: Indicator Led's
The TXD and RXD LEDs 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 C3000 processor responds to polls for its respective pump number(s). 23/03/04...
Page 35: Solid State Relays (Triacs)
SOLID STATE RELAYS (TRIACS) 9.1. General The solid state relay, as the name implies, is a solid state switch, controlled by the C3000. These solid-state switches control the C3000 230-volt outputs. NOTE: A leakage current of 4 to 6 mA can sometimes cause problems when the outputs are used to control high impedance loads such as control relays, small contactors, and small solenoid coils.
Page 36: Changing Solid State Relays
9.2. Changing Solid State Relays As can be seen, there are more relays on the C3000 PCB than are normally required. This means that there are often spare relays available for use if a relay fault occurs. As there are two types of relays, it is important that the correct relay type is maintained when changing from one relay to another.
Page 37: Low Current To Low Current Relay
Before changing relays, check the faultfinding section in this manual. Step One There are 10 tracks on the C3000 PCB, one track for each solid state relay. These tracks are part of the circuitry connecting the CPU to the solid state relays.
Page 38 Remedy - Replace the triac with another SGS Thomson BTA40-600B triac. The triac is mounted on the heatsink using two machine screws and has three spade terminals for electrical connection. The triac terminal layout for Issue L C3000's is as below: Issue ‘L’ & issue ‘M’...
Page 39: Electrical Wiring
ELECTRICAL WIRING 10.1. 230 Volt Wiring Power for the C3000 'head' connects to the terminals marked Phase 2, Neutral, & the Earth Stud. On board the C3000 Microprocessor the incoming phase feeds the microprocessor power supply through the fuse F1 (250mA) and feeds all low current solid state relay circuits through the fuse F2 (1A) and resistor R50.
Page 40: Communications (Comms) Wiring
• Compac Commander DIP SWITCH Figure 9. Location of Comms Dipswitches On C3000 issue 'P' From C3000 Issue P a DIPswitch replaces the links that were on Issue M and all earlier boards. Comms DIP Switch settings: • With LX400 Printer : °...
Page 41: C3000 Gilbarco Protocol Converter
The interface board, shown in Figure 10, may be located at the dispenser or at the switchboard. A three core cable is required to connect the interface board to the C3000. The red and black terminals on the C3000 must be connected together and the cable should be connected to the terminals labelled Green, White, and Red/Black.
Page 42: Intrinsically Safe Wiring
The two (2) core cable from the air pressure switch terminates on pins 2 & 8 of the 'Auxiliary' plug on the C3000 PCB. For two hose pumps, use pins 2 & 8 for Side A and pins 1 & 8 for side B.
Page 43: Sump Switch (Issue "M" Only)
HE AD A 1KΩ KEYBOARD BLACK ORANGE 1KΩ BROWN 1KΩ 8 CORE CABLE INTO PLUG FROM C3000’s HE AD B 1KΩ FRONT VIEW 2 CORE CABLES FROM AIR CUT-OUT SWITCHES TO PLUG P UM P 1 P UM P 3 P UM P 2 Figure 12.
Page 44: Temperature Compensation Pcb
10.3.3. Temperature Compensation PCB The PCB is 'piggybacked' on the C3000 PCB above the memory and software I.C. chips. There are two (2) different types of temperature compensation PCB's: 1) Old type 2) New type. Both are depicted as follows in the diagrams below:...
Page 45: Display Backlighting
10.3.5. Card-readers The C3000 can have a 'Track 1' or 'Track 2' type card-reader connected to it. The 'track' number indicates the track on the magnetic strip of the card which will be read. 'Track 1' card-readers use an adapted Omron 3S4YR-HSR 3 (5V) card-reader and a light blue ribbon cable to connect to the C3000'Cardreader' plug.
Page 46 1 – Red 2 – Black 3 – Brown 4 – Blue 5 - Green Figure 18. The C3000 (cardreader connector) end The CWID RX line is connected to the TOTE 3 output on the C3000. CWIT RX Line CON8 Dipswitches CON3...
Page 47: Displays: Litres Only, Retail, Multi-Price & Preset
• Diagnostic messages, e.g. 'Invalid Card' or 'Wrong System' This dot matrix now incorporates 12Vdc backlighting and requires a 12Vdc supply. CAUTION: Earlier versions of C3000's did not have a 12Vdc supply. Earlier pinpads used 5V backlighting. PINpad keypad This is the board containing the push buttons for entering numbers when prompted to authorise the pump.
Page 48: Secure Pin Pad Unit
One (1) pulse 3.1 ml When the C3000 '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 C3000 will not start the pump and it will display an ‘Er 9’...
Page 49: High/Low Flow Switch
OMPAC NDUSTRIES IMITED ERVICE ANUAL LECTRICAL IRING The encoder connects to the C3000 via a six-core (only five cores used) data cable. The five cores used are: Orange or White - 5V terminal Yellow or Black - 0V terminal Brown...
Page 50: Oil Air Bleed Switch
When emersed in oil, the float switch is up and its contacts are open. As air accumulates, the float drops, closing its switch contacts that input to the C3000. The C3000 then turns on an output that opens a solenoid to vent the air to atmosphere. This causes the oil level to rise again deactivating the float switch and so shutting the solenoid valve.
Page 51: Cng Dispenser Shut-Off Switch
Electronic Totals As well as having electromechanical totalisers for litres dispensed from the pump, each C3000 stores in its memory a five-digit litres total of fuel dispensed from each hose. Both these totals are non-resetable. 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 52: Mains (220/240Vac) Wiring
Pumps/Dispensers with Junction Box. (Non LPG or CNG dispensers) Where a flameproof junction box is provided the C3000 has been wired to a strip connector inside this box. The incoming mains and communications cables are to be glanded into this box using appropriate "Ex d"...
Page 53: Software Upgrade Procedure
Ensure, before working on the pump, that anti-static precautions are taken (i.e. wearing of wristband with earth strap). Gain access to C3000 Processor Board and record all set-up data by accessing the configuration (K-Factor) switch and the parameter switch, this includes recording the operating and comms dipswitch settings.
Page 54 The above steps are taken to safeguard against software incompatibility causing loss of information. Turn off power. Remove software EPROM (removable chip labelled C3000 PXX or XX-X-XX:XX.X) using an EPROM extractor. Plug in new software EPROM, being careful that the dimple is at the correct end of the socket.
Page 55 C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL LECTRICAL IRING NOTE: The 256K chips are to become obsolete. The 512K chips are being used in their place and CK1 is permanently linked. 23/03/04 Page 55...
Page 56: Fault Finding
Check all IC's are firmly in their sockets. Re-power the C3000 If watchdog resets (i.e. stays off), then everything is okay. Replace C3000 PCB if watchdog still comes on after re- power. No - Replace C3000 PCB. Are IC's plugged in correctly?
Page 57: End Of Sale Indications
Select a spare Low Current Solid State Relay if the above checks are okay. No - Check Nozzle Switch operation. Replace C3000 PCB if fault not found Solenoid not de-energising Is Solid State Relay LED on? Yes - Check Nozzle Switch is releasing No - Select spare Low Current Solid State Relay.
Page 58 C3000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL AULT INDING Numerical Readout Indicator Explanation 1.00 "NOZ" Nozzle hung up. 2.00 "PRESET" Stopped at the preset. 3.00 "TIMEOUT" No flow. 4.00 "REMSTOP" Pump controller initiated stop. 5.00 "MAX" Maximum litres and/or dollars reached.
Page 59: Glossary Of Terms
Compac Wireless Transceiver. A device that translates rotary motion into electronic pulses. Encoder Head C3000 PCB, complete in enclosure. Intrinsically safe A circuit in which any spark or any thermal effect produced in the circuit test conditions prescribed in this standard (which include normal operation and specified fault conditions) is incapable of causing ignition of a given explosive atmosphere.
Page 60: Appendix
Link #2 must be connected and Link #3 disconnected for interfacing to any controller or Comcard, Compin, or CWIDKey Basic printer. Link #3 must be connected and Link #2 disconnected only when a C3000 'Futra' type 'head' is interfaced to a PC or a printer.
Page 61 Compac Industries Ltd. 52 Walls Rd., Penrose, Auckland, P.O.Box 12-417 Penrose, Auckland, New Zealand. Phone: + 64 (09) 5792094 Fax: +64 (09) 5790635 or +64 (09) 5711878...