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- Page 1 C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL C4000 MASTER MANUAL Last Update: Friday, 03 May 2004 Compac Industries Ltd. P O Box 12-417 Penrose Auckland New Zealand Ph 64 9 5792 094 Fax 64 9 5790 635 www.compac.co.nz 31 May, 2004...
- Page 2 C4000 S ONTENTS ERVICE ANUAL OMPAC NDUSTRIES IMITED Page ii 31 May, 2004...
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Page 3: Table Of Contents
C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL Description1 1.1. General.............................. 1 1.2. Safety Precautions..........................2 1.3. Static Electricity Precautions ......................3 MAIN FEATURES ..................... 4 2.1. Components ............................4 2.2. Configurations..........................4 2.2.1. Single Commercial Fuel Dispenser ....................4 2.2.2. - Page 4 C4000 S ONTENTS ERVICE ANUAL OMPAC NDUSTRIES IMITED PRINTER SETUP.....................24 4.1. Comcard, Compin, and CWIDKey Basic Systems..............24 4.2. Printer Self Test ..........................24 DISPLAYING AND PRINTING TOTALS ............25 5.1. General ............................25 5.2. Scrolling Tote Option ........................25 5.3. Using a Totals Only - Report Printer....................25 5.4.
- Page 5 10.1. 230 Volt Wiring ..........................39 10.2. Communications (Comms) Wiring....................39 10.2.1. Comms DIP Switch settings......................39 10.2.2. C4000 Gilbarco Protocol Converter.................... 40 10.3. Intrinsically Safe Wiring ....................... 40 10.3.1. Air Detector Cut-out Switch......................40 10.3.2. Nozzle switch(es) ........................41 10.3.3.
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Page 7: General
1.1. General 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 8: Safety Precautions
1.2. Safety Precautions The C4000 head, and its associated circuits and wiring, is a certified piece of electrical equipment approved for use in a hazardous area (Class 1 Zone 1, Group IIA T3). Only parts identical to those covered by the certification may be used where the integrity of the intrinsic safety may be affected. -
Page 9: Static Electricity 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 10: Main Features
° • Last Sale, kilograms, litres and price Nozzle Switch (CNG only) 2.2. Configurations The C4000 'head' can be used with the equipment listed below in the following standard configurations: 2.2.1. Single Commercial Fuel Dispenser Standard Options: Extras: • •... -
Page 11: Single Retail
• Four Encoders • Four Nozzle Switches • Two Motor Outputs • One C4000 Head • Multi-price Displays, four – one per product per side 2.2.8. Multi Product (4 hose) Retail, Type 'A' all hoses in use Standard Options: Extras: •... -
Page 12: Multi Product (6 Hose) Retail
• Presets, two - one per side Receipt Printer • Six Encoders • Six Nozzle Switches • Three Motor Outputs - shared by C4000 Heads • Two C4000 Heads • Multi-price Displays, six - one per product per side 2.2.10. -
Page 13: Set-Up Modes
With CNG dispensers, the sequencing rate between 'banks' is also set using the parameter switch (reference section 3.3.6). The positions of the above switches are shown on Figure 1, page 1. Set up of the C4000 must be done in the following sequence: ‘K’... -
Page 14: K' Factor Switch
The power supply does not have to be interrupted. NOTE: The C4000 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 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 15: 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. 3.1.3. 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. -
Page 16: 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 C4000 will reset itself if the ‘K’ factor switch is left for more than 10 seconds. correct, release the ‘K’ Factor switch. -
Page 17: Pre-Set Cut-Off
C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ODES Setting the Solenoid Delay Refer to section 3.1.1 page 8. While setting this value, the price display will indicate ‘Sd’ and the volume display will indicate ‘dXXXX’ 3.1.6. Pre-Set Cut-Off Prior to the dispenser reaching its preset amount, the solenoids are switched to give a low flowrate. - Page 18 • 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: (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. NOTE: On a commercial pump/dispenser with litres-only display, only the total litres can be read.
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Page 20: Configuration Code
IMITED 3.1.8. Configuration Code The C4000 pump/dispenser software, the configuration code (used to set the pump/dispenser to single, dual or multi mode) has been extended to 5 digits. When configuring the pumps/dispensers, the litre display will display each digit, as shown in Figure 3 on page 15. - Page 21 B = LPG (Solenoids pulsed at end of delivery) C = Max. to 60,000 Ltrs or $. Decimal point moves @ 10,000 Ltrs or $. Requires Variable length records & Compac Controller. D = MPD preset values 20, 10, 5, 2 instead of 10, 5, 2, 1...
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Page 22: Further Settings Available On The 'K' Factor Switch
5xx5x), the density must be set at the dispenser. Refer to 3.3.3. 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. The specific density of the product... -
Page 23: Temperature Calibration
15ºC. NOTE: 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 24: Acv Valve Flowrate
3.2.4. ACV Valve Flowrate 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 Figure 3 page 15) Setting ACV Valve Flowrate Refer to section 3.1.1 page 8. -
Page 25: Program Version Number
The C4000 processor board can be set for five hose configurations: Single (e.g. one C4000 controls one hose) Dual (e.g. one C4000 controls two hoses) Quad (e.g. one C4000 controls four hoses. If a true multi then only two hoses (one per side) can operate at any time) Multi (e.g. - Page 26 When the digit is correct, release the Parameter switch. Repeat steps 3 and 4 for each digit of NOTE: the C4000 will reset itself if the Parameter switch is left for more than 60 the ‘Price per litre’. seconds.
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Page 27: Setting The Product Density
Repeat steps 1 to 7 for side “B” NOTE: 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 28: Setting The Dispenser/Pump Number
NDUSTRIES IMITED If the C4000 is in Bulkmeter mode (See clause 3.1.4) or set-up for LPG with temperature compensation but without a densometer (Configuration code = 5xx5x) then the density can be set using the parameter switch. This is not available in other modes. -
Page 29: Validating/Invalidating Cards, Pins, Or Keys
'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. The access code can be changed by the usual press/hold/release method using the Parameter switch. -
Page 30: Printer Setup
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 31: Displaying And Printing Totals
Card/pin/key status is also displayed on this printout. The printer may also be permanently wired to the C4000 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 32: Printer Housed At The Pump/Dispenser (Card King)
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 PINpad must also be connected to the C4000 and the third digit of the Configuration Code must be set to '1' or '3' (See Section 3.1.8) •... - Page 33 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 PINpad is installed on the pump/dispenser. (See Section 3.1.8).
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Page 34: Basic Systems (Comcard , Compin , & Cwidk Ey )
'C4000 Head' operates as a totally self-contained system operating independently of the central controller. The C4000 'Comms' circuitry, which is usually used for communicating with a controller, is now used to run an audit trail and/or receipt printer (see section 4 for printer setup details and sections 5.2 and 5.3 for details on how to print or... - Page 35 C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL ASIC YSTEMS If an invalid key with the correct access code is presented to the dispenser the display will show "----" for one second then the key number for one second. If a key with an incorrect access code is presented to the dispenser then the display will only show "----"...
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Page 36: Error Codes
(if Connected) REPAS Pass Again Card not read properly, try re-swiping. In addition, C4000 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 37 C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL RROR ODES processor supply has been OFF and back ON since the last transaction. _ _ _ _ _ Restricted Fuel Card not validated for the pump/dispenser fuel grade set. Wrong System Incorrect card used or the controller has the incorrect _ _ _ _ _ access code or ISO number set.
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Page 38: Indicator Led's
POWER LED WATCHDOG LED COMMS RXD LED COMMS TXD LED C4000 microProcessor PCB Figure 5. Location of Power, Watchdog, RXD, & TXD LEDs 8.1. Power LED The Power LED (refer Figure 5) lights when the processor board has power. If this LED flashes, this indicates that the processor has a fault on the processor power supply. -
Page 39: Txd And Rxd 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 40: Diagnostic Led
LEDS C4000 S NDICATOR ERVICE ANUAL OMPAC NDUSTRIES IMITED 8.5. Diagnostic LED The Diagnostic LED Figure 6) flashes in three different states when the processor is working properly: ° When the pump is idle and in 'stand-alone' mode, the LED flashes slowly and consistently. -
Page 41: Solid State Relays (Triacs)
ANUAL OLID TATE ELAYS SOLID STATE RELAYS (TRIACS) 9.1. General The solid state relay, as the name implies, is a solid state switch, controlled by the C4000. These solid-state switches control the C4000 220-240volt outputs. 31 May, 2004 Page 35... - Page 42 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.
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Page 43: High Current Triac Option
Low A (SW1 = 2) Electric Motor Control (SW1 = 2) Low (300 mA max) side ‘A’ Secondary Coil Solenoid Control Spare Low Flow. New Compac OCV Low (300 mA max) Side ‘A’ Control N/C Solenoid Primary Coil Solenoid Control Med 1A High Flow. - Page 44 C4000 S OLID TATE ELAYS ERVICE ANUAL OMPAC NDUSTRIES IMITED SW1 / SW2 / SW4 SWITCH POSITION High Current Looped Low Current Gate Mtr2 Mtr1/Mtr Load 2 Load 1 Gate 1 - 2 3 - 4 5 - 6 1 - 2...
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Page 45: Electrical Wiring
Postec ° Compac Commander 10.2.1. Comms DIP Switch settings The Comms dipswitches are on the C4000 power supply PCB (see Figure 7 on page 35) Comms Dipswitches Std Comms Figure 9. Comms Dipswitches On C4000 • Standard Compac Comms (or PEC Comms) °... -
Page 46: C4000 Gilbarco Protocol 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&... -
Page 47: Nozzle Switch(Es)
10.3.4. Temperature Pressure Compensation PCB (CI075) The Temperature Compensation PCB is mounted in a separate enclosure and is connected to the C4000 Microprocessor via a four wire cable. The PCB Pin headers and cable connectors are shown below. Temperature Compensation... -
Page 48: Display Backlighting
The 'track' number indicates the track on the magnetic strip of the card which will be read. NOTE: Compac Systems will be either a TK1 or a TK2 type, and will never be used both together. This is because information is coded, and therefore gathered, from either the first track or the second track of the coded magnetic strip. -
Page 49: Displays: Litres Only, Retail, Multi-Price & Preset
Displays: Litres only, Retail, Multi-price & Preset The C4000 has a 32 pin connector (J7 see Figure 16) which can be used to connect up to four display-preset pairs. Refer to Figure 1 for the location of connector 'J7' on the Microprocessor PCB. - Page 50 2: Brown 1: Black Figure 17. Display Connector Figure 18 shows how the displays connect to the C4000 for various dispenser models. The four circuits (0-3) shown in Figure 18 are the same four circuits shown in Figure 16. Page 44...
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Page 51: Modem
C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL LECTRICAL IRING Single, Dual, Duo, or Double configuration Retail or Commercial Preset Display Displays. AP209, CI120 CI121, CI123, CI127, & Keypad Side B or C137 CI114 Side A One side of a six hose true multi-product configuration MPD Display. -
Page 52: Secure Pin Pad Unit
IMITED 10.3.11. Secure PIN Pad Unit When connecting a BP Secure pinpad to a C4000 a Distribution board CI-36 is required as an interface. Note: The Secure Pinpad / C4000 combination only works with old type Central Controllers Special software is required for the C4000. Secure Pinpads are not supported in either Futra or Communicator Controller software. -
Page 53: Encoder
One pulse = 3.1 ml When the C4000 'head' is used for other meters this ratio can vary, e.g. from 0.5 litres / turn to as high as 10 litres / turn. The encoder will rotate up to 600 rpm before 'tripping' an ‘Er 7’ message. If the encoder is disconnected, the C4000 will not start the pump and an ‘Er 9’... -
Page 54: High/Low Flow Operation Methods
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 55: Electromechanical Totalisers
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-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 56 Turn off power. Remove software EPROM (removable chip labelled C4000 PXX or XX-X-XX:XX.X) using an EPROM extractor. (See Figure 1 for the location of the EPROM.) Plug in new software EPROM, being careful that the dimple is at the correct end of the socket.
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Page 57: 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 58: End Of Sale Indications
11.1. 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. See paragraph 3.3.5 for method of displaying numerical indicator. - Page 59 C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL AULT INDING Numerical Readout Explanation Indicator 1.00 "NOZ" Nozzle hung up. 2.00 "PRESET" Stopped at the preset. For CNG dispensers - completed a temperature compensated fill 3.00 "TIMEOUT" No flow. 4.00 "REMSTOP" Pump controller initiated stop.
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Page 60: Glossary Of Terms
A device that translates rotary motion into electronic pulses. Often Encoder refered to as a pulser. Head Dispenser calculator/Indicator. C4000 PCB, complete with power supply. Intrinsically safe A circuit in which any spark or any thermal effect produced in the... -
Page 61: Appendix A (Is Cable Microprocessor - Is Power Supply)
C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL PPENDIX APPENDIX A (IS CABLE MICROPROCESSOR - IS POWER SUPPLY 31 May, 2004 Page 55... - Page 62 C4000 S AULT INDING ERVICE ANUAL OMPAC NDUSTRIES IMITED Page 56 31 May, 2004...
- Page 63 C4000 S OMPAC NDUSTRIES IMITED ERVICE ANUAL PPENDIX Microprocessor PCB IS Power Supply 15: Blue/White 1: Black 16: Black/Red This is a 25 way cable of 24 2: White AWG (0.5mm) wire, overall 21: Orange/Green screen earth at the IS Power...
- Page 64 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 Printed in New Zealand 31 May, 2004...
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