C4000 Master Manual Version 1.0.
Conditions of Use Read this manual completely before working on or making adjustments to the Compac equipment. Compac Industries Limited accepts no liability for personal injury or property damage resulting from working on or adjusting this unit incorrectly or without authorisation. Along with any warnings, instructions, and procedures in this manual, you should also observe any other common sense procedures that are generally applicable to equipment of this type.
Contents Product Identification C4000 Processor ......................................................................................................................... v Document Control Information ........................................................................................................................................ 6 Symbols and Units of Measure ........................................................................................................................................
Appendix A ...................................................................................................................................................................... 71 C4000 with RS232 Wiring ...................................................................................................................................... 71 RS485 Forecourt Wiring ........................................................................................................................................
Product Identification C4000 Processor Manual Title C4000 Processor Master Manual Models Covered All C4000 Series Application Power Supply 220 - 240 VAC; 50 Hz; 2 Amp +/- 10% Related Manuals Title Publication Date C4000 Futra Manual February 2009 ComFutra Installation & Service Manual September 2010 CNG Dispenser Service Manual February 2011 C4000 LPG Manual February 2009 Validity Compac Industries Limited reserves the right to revise or change product specifications at any time.
Document Control Information Document Control Information Document Information and Revision History Document Details: C4000 Master Manual File Name and Location: G:\Masters\Manuals\Authorised Manuals\C4000 Current Revision Author(s): R Lacey Authorised By: A Kingstone Release Date: 13/01/2011 Version Date Author(s) Revision Notes 1.0.0 06/09/2010 R Lacey Added RS485 and RS232 wiring info 1.0.1 13/01/2011 R Lacey Amended RS485 wiring 1.0.
Symbols and Units of Measure Symbols and Units of Measure Symbols 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. A reminder of safety practices or unsafe practices that could result in personal injury or damage to associated equipment.
Safety - C4000 Controller Mechanical Safety Safety - C4000 Controller You must adhere to the following safety precautions at all times when working on the Compac C4000 processor. Failure to observe these safety precautions could result in damage to the Compac C4000 processor, injury, or death. Make sure that you read and understand all safety precautions before operating the Compac Compac C4000 processor.
Electrical Commissioning Cable Requirements Electrical Commissioning Cable Requirements Cable requirements are as follows: Cable Type Requirements Power 3 Core Steel Wire Armour Cable 2.5mm2, 220 - 240 Volts. 50 Hz, +/-10% Core 1: 230 Volt Supply (Active). Core 2: Neutral. Core 3: Earth. Dispenser: 25w Idle, 200W with all solenoids active.
Electrical Commissioning Connecting Mains Power and Communication Connecting Mains Power and Communication In sites where the electrical supply is unstable, it is recommended that a power conditioner or UPS is installed. To connect the dispenser: 1. Wire the power and comms to the C4000 Termination Board, as shown in the diagram below. 2. Connect the earth lead of the supply cable to the earth stud in the flameproof junction box. All cables must be terminated with approved flameproof glands.
Electrical Commissioning Electrical Commissioning C4000 Electrical Commissioning C4000 This procedure outlines how to perform an electrical operational test before carrying out full mechanical commissioning and making sure that the dispenser is functioning correctly. Check for any damage that may have occurred in transit. Check all terminals, plugs, and chips to make sure that they are securely in place. Damage to electronics occurs most commonly from vibration and jarring.
Main Features C4000 Components Main Features The Compac C4000 is a microprocessor-based circuit board designed for use in liquid and gaseous fuel metering systems. It is suitable for commercial, retail, and bulk-metering applications and can be used for tank gauging, card reader access, and many other control functions. Connectors: J1: Comms Test J2: To I.S. Power J3: Encoder 1 J4: Encoder 2 J5: Encoder 3 J6: Encoder 4 J7: Displays J8: Temperature Comp.
Main Features Configurations Configurations The C4000 'head' can be used with the equipment listed below in the following standard configurations: Single Commercial Fuel Dispenser Standard Options: Extras: Litres only display, two - one per side Card-reader High/Low Flow Operation Motor circuit, one only PIN-Pad One Encoder One Nozzle Switch C4000 Head Also see 'FUTRA' configuration.
Main Features Configurations Single Suction Dual Retail (Duo) Standard Options: Dollars, litres and price display, two - one per side Presets, two - one per side Two Encoders Two Nozzle Switches Two Motor Outputs C4000 Head Extras: Dual Retail (Dual or Double) Standard Options: Dollars, litres and price display, four - two per side Presets, four - two per side Two Encoders Two Nozzle Switches Two Motor Outputs C4000 Head Extras: Multi Product (4 hose) Reta
Main Features Configurations Multi Product (6 hose) Retail Standard Options: Extras: Dollars, litres and price display, two - one per side Card-reader PIN Pad 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 Multi Product (6 hose) Retail, Type 'A' Standard Options: Dollars, litres and price display, six - three per side Pr
Set-up Modes Configuration Code Set-up Modes To enable the C4000 to operate as desired two things must be set: 1. Configuration (K Factor) Switch Settings Refer C4000 Set-Up K Factor Switch Settings (see page 21) This switch accesses different options that must be set appropriately for the particular type of dispenser. 2.
Set-up Modes Configuration Code Figure 3 Configuration Code Options Compac Industries Ltd. Page 17 www.compac.co.
Set-up Modes 'b' Settings 'b' Settings While setting the „b‟ settings, the price display shows 'b' and the volume display shows 'bXXXX'. Figure 2 'b'Settings Auto Authorise (Digit 4) 0: If digit 4 is set to zero, then the pump/dispenser software defaults to conventional operation, (i.e. the nozzle switch controls the pump start after initial authorisation).
Set-up Modes 'b' Settings 2: With digit 3 set to two, the head is set up for Comcard Basic, Compin Basic, or CWIDKey Basic, which are self-contained systems operating independently of any controller. To operate, a card-reader/CWIDKey reader must be plugged into the 'head' and the correct access code and card/key number validations must be set by the Parameter switch. For the Bulk Meter Register, digit 3 must be set to zero or one. Comcard, Compin, and CWIDKey Basic systems are not available in this mode.
Set-up Modes 'b' Settings mode simply by turning them OFF for 1 minute minimum, then back ON. However, for unattended situations (e.g. truck stops), the pumps must not be left able to work in the 'stand-alone' mode in case of a controller failure. Therefore, digit 1 should always be set to one for unattended operation. For the Bulk Meter Register configuration, when digit 1 is zero, the unit will work in the 'stand-alone' mode.
Set-up Modes C4000 Set-up C4000 Set-up The 'K' Factor switch is located on the C4000 PCB as shown in Figure 1. The 'K' Factor switch is used to access and change various set-up options of the C4000 head. The following charts detail the operation of setting up the C4000 head: Any change of set-up made by the 'K' Factor switch takes effect as soon as the C4000 resets. The power supply does not have to be interrupted.
Set-up Modes C4000 Set-up 'K'Factor Switch Using the ‘K’ Factor Switch Using the ‘K’ Factor Switch to Change a Setting Step ACTION RESULT 1 Ensure that the nozzles are hung up Dispenser in idle state 2 Press and release the „K‟ Factor switch, in quick succession, until the desired setting is displayed. The price display and volume display indicates the desired setting. See following paragraphs. 3 Press and hold the „K‟ factor switch. A digit, of the displayed setting, will begin to increment.
Set-up Modes Calibration ('K') Factor Calibration ('K') Factor The 'K' Factor is a ratio of litres dispensed per revolution of the meter. Below is the method of calibration, including how to calculate the new 'K' Factor and how to enter it in the C4000 memory. (See also Encoder (see page 54) for more information on the encoder/pulser) Calibration To calibrate the dispenser/pump, dispense fuel into a certified measuring container, and compare the display value with the amount dispensed.
Set-up Modes Calibration ('K') Factor Setting the Calibration 'K'Factor Refer to C4000 Set-Up K Factor Switch Settings (see page 21) The displays will indicate as below Type Price Display indication Volume Display Indication Single Hose „F‟ „X.XXXX‟ Side “A” „F‟ Side “B” „Fb‟ Hose 1 „F1‟ Hose 2 „F2‟ Hose 3 „F3‟ Hose 4 „F4‟ Dual Hose Quad or Multiproduct „X.XXXX‟ „X.
Set-up Modes No Flow Cut-Off Timer No Flow Cut-Off Timer Under normal conditions to end a transaction on a C4000 controlled pump/dispenser, there are three possibilities: Returning the nozzle to its holder. Reaching the preset amount entered. Cut out on the 'No flow cut-off timer'. The No Flow Cut-off Timer sets the amount of time the dispenser/pump will allow a sale to continue when no flow is detected.
Set-up Modes Display (Litres) Resolution Display (Litres) Resolution For standard dispenser/pumps, high flow dispenser/pumps & bulk metering, different resolutions are often required: Display Resolution Sr setting on k factor switch Litres Display resolution Max presetable or fill amount Standard (default) 0.000 0.00 970 L Hi-Flow 0.00 0.00 9700 L Bulk-metering 0.0 00000.
Set-up Modes Solenoid Delay Solenoid Delay The Solenoid Delay was installed in the program to enable the "delay" between the submersible pump operating and the dispenser solenoids operating to be controlled on initial start-up. This setting should only be set on dispensers. This setting should never be set more than 4-6 seconds. Its main purpose is to allow the leak detector on the submersible pump to carry out its leak test. The default setting is 'd0000‟ (i.e., no delay).
Set-up Modes Pre-Set Cut-Off Pre-Set Cut-Off Prior to the dispenser reaching its preset amount, the solenoids are switched to give a low flow rate. 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 flow rate. With the value set to 0.00, the default values are used. These are: LPG 0.75 Oil 0.05 Other products 0.
Set-up Modes Further Settings Available on the 'K' Factor Switch Product Density Factor Setting the Product Density Factor Refer to C4000 Set-Up K Factor Switch Settings (see page 21) While setting the Product density factor, the price display shows 'dSF' („dFb‟ for side “B”) and the volume display shows 'X.XXXX'. Specific Density (With a densometer) This setting is only available for LPG dispensers with a densometer and set-up for LPG with temperature compensation (configuration code = 7xx5x).
Set-up Modes Further Settings Available on the 'K' Factor Switch Calibrating Specific Density (Densometer) To accurately calibrate the densometer the temperature reading must be correct. Always calibrate the temperature before calibrating the density. Using the ‘K’ Factor switch to calibrate the densometer: Step ACTION RESULT 1 Ensure that the nozzles are hung up Dispenser in idle state 2 Press and release the „K‟ Factor switch, in quick succession, until „LP6‟ is displayed in the price display.
Set-up Modes Further Settings Available on the 'K' Factor Switch 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 0 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 'XXX.X' to the known temperature value.
Set-up Modes Further Settings Available on the 'K' Factor Switch This value is the desired cut-off point to half flow (in litres) for the system. The “H-Cut” sets the amount (in litres), prior to the preset amount being attained, at which the flow rate of the system will be halved. Setting H-Cut Refer to K Factor Switch Settings (see page 21) While setting the “H-Cut”, the price display shows 'HCUt' and the volume display shows 'HXXXX'. F-Cut This is only available in Bulk Meter mode.
Set-up Modes Parameter Switch Parameter Switch Refer to Figure 1 Main Features C4000 (see page 12) to find the location of the parameter switch.
Set-up Modes Parameter Switch Setting the Price per Litre The C4000 processor board can be set for five hose configurations: 1. Single (e.g. one C4000 controls one hose) 2. Dual (e.g. one C4000 controls two hoses) 3. Quad (e.g. one C4000 controls four hoses but only two (one per side) can operate at any time) 4. True Quad (e.g. one C4000 controls four hoses which can all operate at once) 5. Six (e.g.
Set-up Modes Parameter Switch Setting the Price for Quad (four) Hose Configuration Step ACTION RESULT 1 Ensure that the nozzles are hung up Dispenser in idle state 2 Press and Hold the Parameter switch operated until the “Price per litre” is displayed. The Price for hose 1 is displayed as „PX.XXX‟ and „Pr1‟ is displayed on the price display. 3 Press and hold the Parameter switch. A digit, of the displayed „Price per litre‟, will begin to increment.
Set-up Modes Parameter Switch Setting the Price for True Multi-Product Configuration Step ACTION RESULT 1 Ensure that the nozzles are hung up Dispenser in idle state 2 Press and Hold the „Side A‟ Parameter switch until the “Price per litre” is displayed. The Price for hose 1 side „A‟ is displayed as „PX.XXX‟ and „Pr1‟ is displayed on the price display. 3 Press and hold the Parameter switch. A digit, of the displayed „Price per litre‟, will begin to increment.
Set-up Modes Parameter Switch Setting the Product Density Only available in Bulkmeter mode (when Sr = 0) or LPG with compensation but without a densometer (configuration code of 5xx5x). The product density (kg/m3) must be set. In bulkmeter mode this can be done either at the register (for 'stand-alone' C4000 Heads), or at the central controller. For controller sites the density entered at the register must be zero to allow the 'controller set' density to override.
Set-up Modes Parameter Switch Setting the Sequencing Rate This is only available for CNG Dispensers. Needs appropriate software. The rate of sequencing between pressure banks for the CNG dispensers is done on a percentage basis. There are three percentage settings to choose from: Fast, 'FAS' switching to the next higher-pressure bank occurs at 45% of the full flow rate. Normal, 'nOr' switching to the next higher-pressure bank occurs at 35% of the full flow rate.
Set-up Modes Parameter Switch 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. Access Code will only need to be changed to prevent an existing Card/Key System being used, or to allow a new card system to be issued in the case of several lost or stolen cards.
Set-up Modes Printer Set-up Printer Set-up Comcard Compin & 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). 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.
Set-up Modes Displaying and Printing Totals Displaying and Printing Totals General To display litre and dollar totals for any single hose on a pump/dispenser, make sure all nozzles are hung up. Then, for pumps/dispensers: With Preset: Press either the Cancel or the Fill button, on the hoses' respective Preset, five or more times and the totals will appear on the displays. Without Preset: Remove the nozzle from its holster and hold the nozzle switch in for five seconds.
Set-up Modes Displaying and Printing Totals Printer Housed at the Pump/Dispenser (Card King) This is only permissible in 'Type B' fuel pumps/dispensers (as defined by AS2229-1) or in pumps/dispensers used in applications where less stringent requirements are set. This is because the printer is not an intrinsically safe device and must have access to the pump/dispenser exterior for the 'printer paper slot'.
Set-up Modes Basic Systems (Comcard Compin & CWIDKey) a PIN-pad installed. 2. If the pump/dispenser has a PIN pad connected, then it can be configured to display a receipt prompt as part of the transaction authorisation process. This prompt would be the same as for a pump/dispenser with a Receipt Printer connected to the C4000 (detailed on the previous page).
Set-up Modes Basic Systems (Comcard Compin & CWIDKey) are encoded with an access code and a key number in the same way that a comcard is encoded. CWIDKey Number Identification. When a valid key is presented to the dispenser the display will alternately flash the key totals then the key number, until the nozzle is lifted. The key number is displayed as "c xx" where xx is the keynumber. The access number is never displayed.
Electrical Wiring C4000 Basic Systems (Comcard Compin & CWIDKey) Electrical Wiring C4000 230 Volt wiring Power for the C4000 'head' connects to the terminals marked Phase, Neutral, & the Earth Stud. Refer Connecting Mains Power and Communications (see page 10) On the C4000 Power supply PCB, the incoming phase feeds the microprocessor power supply through the fuse F2 (250mA) and feeds all low current solid state relay circuits through the fuse F3 (1A).
Electrical Wiring C4000 Basic Systems (Comcard Compin & CWIDKey) Switch 2,4 ON 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& 3 OFF and switches 2 & 4 ON. The Gilbarco interface board plugs onto the IS Power supply PCB in the Flameproof box.
Electrical Wiring C4000 Basic Systems (Comcard Compin & CWIDKey) The nozzle switch leads plug in between 'NSWx' and 'GND' (see Figure 10 above). When the nozzle is lifted, the nozzles switch closes and the C4000 initiates a transaction. Diagnostic LED will flash rapidly when any nozzle is lifted regardless of hose configuration. Sump Switch The Sump Switch is a float switch located in a sump at the bottom of the dispenser.
Electrical Wiring C4000 Basic Systems (Comcard Compin & CWIDKey) 7 8 5 6 3 4 1 2 1– Loop 2 – Loop 3 4 – Red 5 – White 6 – Black 7 – Green 8 Figure 13. Connector to Temperature Compensation PCB (CON5) The pressure sensors and temperature sensors supplied by Compac have the appropriate plug to be able to plug them into the Temperature Compensation PCB. Display Backlighting The backlighting PCB's consist of several red backlighting LED's and the PCB's are mounted on stand-offs behind the displays.
Electrical Wiring C4000 Compac Wireless Transceiver Compac Wireless Transceiver The CWID PCB is mounted in a separate enclosure. Connector 'CON5' on the CWID PCB (see below) connects to J13 on the C4000 Microprocessor PCB (Refer Description C4000) with an eight wire cable (see below) Figure 1: CWID (CON5) to microprocessor (J13) cable Figure 2: CWID (CI 101 issue D) PCB Compac Industries Ltd. Page 49 www.compac.co.
Electrical Wiring C4000 Compac Wireless Transceiver Tuning the Aerial Whenever the CWID PCB is changed, the aerial will need to be tuned. For locations of the connectors, refer to the picture in CWID Interface Board Replacement. 1. Connect a Multimeter (set to Volts) to CON8. 2. Place a shorting link across pins 2 & 3 of CON4. The poll LED will flash slower, indicating "Tuning Mode" 3. Using the dipswitches (SW1), adjust the capacitance to obtain the maximum voltage at CON8.
Electrical Wiring C4000 Displays: Litres only, Retail, Multi-price & Preset Displays: Litres only, Retail, Multi-price & Preset The C4000 has a 32 pin connector on the microprocessor PCB (refer General C4000 Figure 1 J7) which can be used to connect up to four display-preset pairs (see Figure 16 below). Figure 16. Microprocessor Display Connector (J7) Figure 16 and Figure 17 show the two ends of the display/preset/multi-price display cables.
Electrical Wiring C4000 From C4000 Microprocessor. Displays: Litres only, Retail, Multi-price & Preset 0 Single, Dual, Duo, or Double configuration 1 Retail or Commercial Displays. AP209, CI121, CI123, CI127, or C137 2 3 Side B Side A Preset Display CI120 & Keypad CI114 OR One side of a six hose true multi-product configuration MPD Display. CI147 & Keypad CI149 OR Four hose True Multi-product configuration MPD Display. CI147 & Keypad CI149 MPD Display.
Electrical Wiring C4000 Displays: Litres only, Retail, Multi-price & Preset Secure PIN Pad Unit When connecting a BP Secure PIN pad to a C4000 a Distribution board CI36 is required as an interface. The Secure PIN pad / C4000 combination only works with old type Central Controllers Special software is required for the C4000. Secure PIN pads are not supported in either Futra or Communicator Controller software. Figure 19. Secure PIN Pad Modem This device is not covered in this part of the manual.
Electrical Wiring C4000 Displays: Litres only, Retail, Multi-price & Preset Encoder The rotary encoder translates meter turns into electrical pulses. Each turn of the Bennett meter equals approximately 0.5 litre (eight turns = one US gallon). The encoder converts this to 150 pulses so that each pulse corresponds to approximately to 3ml. Exact values are: One rotation = 0.47 litre 150 pulses = 0.47 litre One pulse = 3.1 ml When the C4000 'head' is used for other meters this ratio can vary, e.g.
Electrical Wiring C4000 Displays: Litres only, Retail, Multi-price & Preset High/Low Flow Switch A High Flow/Low Flow option is available on high flow dispensers/pumps. The two-position switch is located on the side of the dispenser/pump by the nozzle holster. In the high flow position, the full flow rate of the pump/dispenser will be available at the nozzle. In the low flow position approximately 40 to 70 lpm will be available depending upon the application.
Electrical Wiring C4000 Displays: Litres only, Retail, Multi-price & Preset Totalisers Electromechanical Totalisers Only approved Compac totalisers are to be used. Some totalisers have a +ve and a -ve terminal. Electronic Totals As well as having electromechanical totalisers for litres dispensed from the pump, each C4000 stores in its memory a five-digit litres total of fuel dispensed from each hose. Both these totals are non-resettable.
End of Sale Indications Displays: Litres only, Retail, Multi-price & Preset 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. Numerical Indicator Readout Explanation 1.00 "NOZ" Nozzle hung up. 2.00 "PRESET" Stopped at the preset.
Software Upgrade Procedure Displays: Litres only, Retail, Multi-price & Preset Software Upgrade Procedure This is the software upgrade procedure to be followed for all bulk meter registers and all pumps with a C4000 other than those with FUTRA software. 1. Ensure, before working on the pump, that anti-static precautions are taken (i.e. wearing of wristband with earth strap). 2.
Software Upgrade Procedure Displays: Litres only, Retail, Multi-price & Preset printouts of card/pin/key totals. 17. Test pump operation. When replacing Integrated Circuit chips (refer to Figure 19 below), ensure that the notch is facing in the direction of the IC board socket (the notch is the end that we refer to as the "front"). When inserting the IC chip, the rear pin (of the IC chip) must be plugged into the rear pin socket of the IC board socket. Any spare pin sockets should be in front.
Solid State Relays (Triacs) Displays: Litres only, Retail, Multi-price & Preset Solid State Relays (Triacs) 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. COMMS INCOMING MAINS + ve - ve Excess Flow Output Solenoid Side B Motor Side B Solenoid Side A Neutral Phase Earth Motor Side A Figure 7.
Solid State Relays (Triacs) Triacs C4000 Single, Dual & Quad Triacs C4000 Single, Dual & Quad Power Symbol Function Terminal T1 MTR1 High / Low Single / Dual Quad Current Output Motor relay control (SW1 = 2) Motor relay control (SW1 = 2) Low 300mA max Internal pump motor (SW1 = 1) Internal pump motor (SW1 = 1) High (40 A max) Secondary Flow Coil Secondary Flow Coil Low (300 mA max) Solenoid 1 Solenoid 1 Primary Flow Coil Primary Flow Coil Solenoid 1 Solenoid 1 Motor relay control (S
Solid State Relays (Triacs) Triacs C4000 MPD6 & MPP6 side A Triacs C4000 MPD6 & MPP6 side A Power Symbol Function Terminal High / Low MPD6 / MPP6 side 'A' MPD6 / MPP6 side 'B' Current Output Motor 1 relay control (SW1 = 2) Motor 3 relay control (SW1 = Low 300mA max or or (SW1 = 1) LOAD1 Internal pump motor 1 (SW1 = 1) T1 T2 T3 T4 MTR1 / MTR3 SFS1 PFS1 MTR2 Secondary Flow Coil Secondary Flow Coil Solenoid 1 Solenoid 1 Primary Flow Coil Primary Flow Coil Solenoid 1 Solenoid 1
Solid State Relays (Triacs) Triacs C4000 LPG Single/Dual, CNG & Bulk Meter Triacs C4000 LPG Single/Dual, CNG & Bulk Meter Power Terminal Function High / Low LPG Single/Dual CNG Bulk Meter Current output T1 Electric Motor Control (SW1 = 2) side „A‟ Low A (SW1 = 2) Electric Motor Control (SW1 = 2) Low (300 mA max) T2 Secondary Coil Solenoid Control Side „A‟ Spare Low Flow. New Compac OCV Control N/C Solenoid Low (300 mA max) T3 Primary Coil Solenoid Control Side „A‟ Med 1A High Flow.
Solid State Relays (Triacs) High Current Triac Option High Current Triac Option Where high current (40A) outputs are required (i.e. driving the pump motor directly) high current triacs are fitted to the power supply PCB. If a high current triac is installed for T1 and/or T4 then its respective snubber switch (SW1 & SW2 respectively) needs to be switched to position 1 (Refer Figure 8). Figure 8 High Current Triac Option Compac Industries Ltd. Page 64 www.compac.co.
Indicator LEDs High Current Triac Option Indicator LEDs POWER LED D1 WATCHDOG LED D5 COMMS RXD LED D6 D7 COMMS TXD LED C4000 microProcessor PCB Figure 5. Location of Power, Watchdog, RXD & TXD LEDs 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.
Indicator LEDs High Current Triac Option C4000 microProcessor PCB Output LEDs Diagnostic LED D17 D16 D15 D14 D13 D12 D11 D10 D9 D8 D18 Figure 6. Location of Output & Diagnostic LEDs Output LEDs The ten Output LEDs (refer Figure 6) indicate which triac outputs are being switched on. D8-D17 corresponds to the output triacs T1-T10 (refer Figure 7). Diagnostic LED The Diagnostic LED Figure 6) flashes in three different states when the processor is working properly: Compac Industries Ltd.
Fault Finding High Current Triac Option Fault Finding Symptom Action Watchdog LED is on Is the processor LED (DL1) flashing? (refer to Figure 5 for the location of the Yes - Turn power off Watchdog LED) Check for any foreign bodies i.e. wire off-cuts etc, on processor PCB. 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.
Fault Finding High Current Triac Option Replace C4000 PCB if fault not found Motor running all the time Is Solid State Relay LED on? Yes - Check Nozzle Switch is releasing No - Select a spare High Current Solid State Relay. Replace C4000 PCB if fault not found Solenoid not energising Is Solid State Relay LED on? Yes - Check Triac Fuse F2 Check all Solenoid connections Check Solenoid Select a spare Low Current Solid State Relay if the above checks are okay. No - Check Nozzle Switch operation.
Fault Finding Error Codes Error Codes Error Code Fault Action Err 3 No price set. Set a price at the pump or at the controller. Err 4 CWID offline. Check connections. Change CWID PCB. Err 7 Excess flow. Check for air. Err 8 Excess reverse rotation of encoder. Check product is not flowing back into the tank once the delivery has finished. Err 9 Faulty encoder or disconnected encoder. Check encoder circuit.
Fault Finding Error Messages Error Messages On Pump LCD Display On PIN Pad Dot Matrix Display (if Connected) Explanation REPAS Pass Again Card not read properly, try re-swiping. In addition, C4000 may be configured for the wrong card reader track, or the card or card reader could be faulty. HOLD System not ready Pump no longer communicating with Central Controller. The full-colon on the display indicates that the processor supply has been OFF and back ON since the last transaction. :0.
Appendix A C4000 with RS232 Wiring Appendix A C4000 with RS232 Wiring Compac Industries Ltd. Page 71 www.compac.co.
Appendix A RS485 Forecourt Wiring RS485 Forecourt Wiring The following changes are made to standard Compac C4000 wiring to allow the use of RS485 communication with other devices. C4000 Power Supply 1. An RS485 Board is fitted inside the Power supply flame proof box. 2. The IS cable pinouts will need to be changed to match the wiring detailed below. C4000 IS Cable for RS485 Forecourt Compac Industries Ltd. Page 72 www.compac.co.
Appendix A Compac Industries Ltd. RS485 Forecourt Wiring Page 73 www.compac.co.
Appendix A RS485 Forecourt Wiring Compac Industries Ltd. Page 74 www.compac.co.
Appendix A C4000 with RS485 Forecourt Wiring C4000 with RS485 Forecourt Wiring Compac Industries Ltd. Page 75 www.compac.co.
Appendix A Gilbarco Interface Wiring Gilbarco Interface Wiring Compac Industries Ltd. Page 76 www.compac.co.
Glossary of Terms Gilbarco Interface Wiring Glossary of Terms TERM DESCRIPTION ATG Automatic Tank Gauging Class 1 Zone 0 An area in which an explosive-gas atmosphere is present continuously or is present for long periods. Class 1 Zone 1 An area in which an explosive-gas atmosphere is likely to occur in normal operation. Class 1 Zone 2 An area in which an explosive-gas atmosphere is not likely to occur in normal operation, and if it does occur it will exist for short periods only.
