Compac C4000 Futra User manual

C4000 Master Manual
Version 1.0.0

ii
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.
Failure to comply with any warnings, instructions,
procedures, or any other common sense procedures
may result in injury, equipment damage, property
damage, or poor performance of the Compac
equipment
The major hazard involved with installing and
operating the unit is electrical shock. This hazard
can be avoided if you adhere to the procedures in
this manual and exercise all due care.
Compac Industries Limited accepts no liability for
direct, indirect, incidental, special, or consequential
damages resulting from failure to follow any
warnings, instructions, and procedures in this
manual, or any other common sense procedures
generally applicable to equipment of this type. The
foregoing limitation extends to damages to person or
property caused by the unit or damages resulting
from the inability to use the unit including loss of
profits, loss of products, loss of power supply, the
cost of arranging an alternative power supply, and
loss of time, whether incurred by the user or their
employees, the installer, the commissioner, a
service technician, or any third party.
Compac Industries Limited reserves the right to
change the specifications of its products or the
information in this manual without necessarily
notifying its users.
Variations in installation and operating conditions
may affect the unit's performance. Compac
Industries Limited has no control over each
installation's unique operating environment. Hence,
Compac Industries Limited makes no
representations or warranties concerning the
performance of the unit under the actual operating
conditions prevailing at the installation. A technical
expert of your choosing should validate all operating
parameters for each application.
Compac Industries Limited has made every effort
to explain all servicing procedures, warnings, and
safety precautions as clearly and completely as
possible. However, due to the range of operating
environments, it is not possible to anticipate every
issue that may arise. This manual is intended to
provide general guidance. For specific guidance
and technical support, contact your authorised
Compac supplier, using the contact details in the
Product Identification section
Information in this manual shall not be deemed a
warranty, representation, or guarantee. For
warranty provisions applicable to this unit, please
refer to the warranty provided by the supplier.
Unless otherwise noted, references to brand
names, product names, or trademarks constitute
the intellectual property of the owner thereof.
Subject to your right to use the unit, Compac does
not convey any right, title, or interest in its
intellectual property, including and without
limitation, its patents, copyrights, and know-how.
Every effort has been made to ensure the accuracy
of this document. However, it may contain technical
inaccuracies or typographical errors. Compac
Industries Limited assumes no responsibility for
and disclaims all liability of such inaccuracies,
errors or omissions in this publication.

iii
Contents
Product Identification C4000 Processor ......................................................................................................................... v
Document Control Information ........................................................................................................................................ 6
Symbols and Units of Measure........................................................................................................................................ 7
Safety - C4000 Controller.................................................................................................................................................. 8
Mechanical Safety....................................................................................................................................................8
Electrical Safety.......................................................................................................................................................8
Safety Precautions...................................................................................................................................................8
Electrical Commissioning ................................................................................................................................................ 9
Cable Requirements................................................................................................................................................9
Connecting Mains Power and Communication ...................................................................................................... 10
Electrical Commissioning C4000 ........................................................................................................................... 11
Main Features.................................................................................................................................................................. 12
C4000 Components............................................................................................................................................... 12
Configurations........................................................................................................................................................ 13
Set-up Modes................................................................................................................................................................... 16
Configuration Code................................................................................................................................................ 16
'b' Settings.............................................................................................................................................................. 18
C4000 Set-up......................................................................................................................................................... 21
Calibration ('K') Factor............................................................................................................................................ 23
No Flow Cut-Off Timer........................................................................................................................................... 25
Display (Litres) Resolution..................................................................................................................................... 26
Solenoid Delay....................................................................................................................................................... 27
Pre-Set Cut-Off...................................................................................................................................................... 28
Further Settings Available on the 'K' Factor Switch................................................................................................ 28
Parameter Switch................................................................................................................................................... 33
Printer Set-up......................................................................................................................................................... 40
Displaying and Printing Totals................................................................................................................................ 41
Basic Systems (Comcard Compin & CWIDKey).................................................................................................... 43
Electrical Wiring C4000................................................................................................................................................... 45
Compac Wireless Transceiver............................................................................................................................... 49
Displays: Litres only, Retail, Multi-price & Preset................................................................................................... 52
End of Sale Indications................................................................................................................................................... 58
Software Upgrade Procedure......................................................................................................................................... 59
Solid State Relays (Triacs) ............................................................................................................................................. 61
Triacs C4000 Single, Dual & Quad........................................................................................................................ 62
Triacs C4000 MPD6 & MPP6 side A...................................................................................................................... 63
Triacs C4000 LPG Single/Dual, CNG & Bulk Meter............................................................................................... 64
High Current Triac Option...................................................................................................................................... 65
Indicator LEDs................................................................................................................................................................. 66
Fault Finding.................................................................................................................................................................... 68
Error Codes............................................................................................................................................................ 70
Error Messages...................................................................................................................................................... 71

iv
Appendix A...................................................................................................................................................................... 72
C4000 with RS232 Wiring...................................................................................................................................... 72
RS485 Wiring......................................................................................................................................................... 73
C4000 with RS485 Wiring...................................................................................................................................... 75
Gilbarco Interface Wiring........................................................................................................................................ 76
Glossary of Terms........................................................................................................................................................... 77

v
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
October 2008
ComFutra Installation &
Service Manual
September 2010
C4000 LPG Manual
Validity
Compac Industries Limited reserves the right to revise or change product
specifications at any time. This publication describes the state of the
C4000 processor at the time of publication and may not reflect the product
at all times in the past or in the future.
Manufacturer Contact
Details
The Compac C4000 processor is designed and manufactured by:
Compac Industries Limited
52 Walls Road, Penrose, Auckland 1061, New Zealand
P.O. Box 12-417, Penrose, Auckland 1641, New Zealand
Phone: + 64 9 579 2094
Fax: + 64 9 579 0635
www.compac.co.nz
Copyright ©2010 Compac Industries Limited, All Rights Reserved

Document Control Information
Compac Industries Ltd.
Page 6
www.compac.co.nz
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: 06/09/2010
Version
Date
Author(s)
Revision Notes
1.0.0
06/09/2010
R Lacey
Added RS485 info
Distribution
Name
Indicator
Location

Symbols and Units of Measure
Compac Industries Ltd.
Page 7
www.compac.co.nz
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.
A reminder of safety practices or unsafe practices that
could result in damage to associated equipment and/or voids the
warranty.
Important information essential to the installation and
operation of the Compac equipment
Units of Measure
The following units of measure are used in this manual:
Unit
Measure
Pressure
Bar (bar)
Temperature
Degrees Celsius (°C)
Volume
Litres (L)
Cubic Metres (m³)
Mass
Kilograms (kg)
Length
Metres (m)
Millimetres (mm)
Microns, Micrometres (m)
Inches (")
Torque
Newton Metres (Nm)
Voltage
Volts (V)
Current
Amps (A)
Frequency
Frequency (Hz)

Mechanical Safety
Safety - C4000 Controller
Compac Industries Ltd.
Page 8
www.compac.co.nz
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.
Mechanical Safety
Observe the following mechanical precautions:
Make sure that the service area is thoroughly clean when
servicing. Dust and dirt entering the components reduce the life span of the
components and can affect operation.
Electrical Safety
Observe the following electrical precautions:
Always turn off the power to the Compac C4000 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 C4000 processor at
the mains switch before removing or replacing software or memory ICs.
Always take basic anti-static precautions when working on the
electronics, i.e., wearing a wristband with an earth strap.
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. All circuit boards are to be repaired only by Compac Industries
Ltd.
Static Electricity Precautions
Electronic components used are sensitive to static. Please take anti-static
precautions.
All circuit boards must be carried and transported in static-shielded bags.
An anti-static wrist strap should be worn and connected correctly when
working on any electronic equipment. If an anti-static wrist strap is
unavailable, or in an emergency, hold onto an earthed part of the
pump/dispenser frame whilst working on the equipment. This is not a
recommended alternative to wearing an anti-static wrist strap.
Compac Industries Limited reserves the right to refuse to
accept any returned circuit boards if proper anti-static precautions have not
been taken.

Electrical Commissioning
Cable Requirements
Compac Industries Ltd.
Page 9
www.compac.co.nz
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.
Pumps with one motor (40 and 80 lpm Single hose)
Motor start current = 30 amps, run current = 6 amps
Pumps with two motors -40 and 80 lpm Dual pumps and 160 lpm
Single hose pumps
Motor start current = 30 amps, run current = 6 amps
(software prevents both motors starting simultaneously)
Comms
2 Core Steel Wire Armour Cable 1.5 mm2. Maximum cable length 100 m.
12 V current loop.
Make sure that there is at least a two metre cable tail on
both the incoming underground 230 V and comms cables to reach the
C4000 flameproof box.

Connecting Mains Power and Communication
Electrical Commissioning
Compac Industries Ltd.
Page 10
www.compac.co.nz
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. The thread is 20 mm.
COMMS Neutral
Phase
Earth
+ve
-ve
SW 3 SW 4 SW 2 SW 1
LOAD2
LOAD1
NEUTRAL
NEUTRAL NEUTRAL
PHASE PHASE
PHASE
F3
1A
F1
0.5A
VCC
RED BLK DTR DCD
CTS GND TXDP DTRP
GND
N
N
N N
N
N
PH
T10
T7
T9 T8 T6 T5
T3 T2
T4
T1
TEST
Refer Electrical Wiring C4000 (see page 45) for all other connections.