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.

Electrical Commissioning
Electrical Commissioning C4000
Compac Industries Ltd.
Page 11
www.compac.co.nz
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.
Before beginning this test, check that fuel has not been applied to the
dispenser. The factory set-up information should be programmed into
the dispenser but all K-factor and Parameter switch settings should be
checked and confirmed before commissioning tests are carried out.
Check that pump number is set. See Setting the Dispenser/Pump
Number (see page 37)
Check the pump price is set. See Setting the Price per Litre (see page
34)
To perform an electrical operational test:
1. Make sure that the inlet shut-off valves are closed (these are the
valves in the inlet lines at the base of the dispenser, but they are not
part of the dispenser).
2. Turn on the power supply to the dispenser.
3. With the dispenser in a ready state, check that the C4000
Microprocessor Power LED (D1) is turned on
If the dispenser is receiving information, Comms RXD
LED (D6) will poll. If the dispenser responds to polls for its
respective pump number/s, Comms TXD LED (D7) will also poll.
Diagnostic LED (D18) slowly flashing. (If the dispenser is
connected to an operational Controller, it flashes slowly but
erratically. If the dispenser is not connected to a Controller, it
flashes slowly and consistently.)
Watchdog LED (D5) is turned off
4. Lift the nozzle
The display will show 888888 and the solenoids energise,
starting the pump motor. Check that Diodes D8, D10 and D11 turn
on, indicating a signal is being sent to the triacs to open the solenoid
valves.
The diagnostic LED (D18) flashes quickly when the start button is
pushed or the nozzle removed from the holster to initiate a fill. When
the button is released or nozzle returned to the holster it will return
to the normal state and flash slowly.
5. Verify solenoid operation by listening for a click, or by using a
screwdriver tip or some other metallic tool to check for a magnetic
field present on the solenoid coils.
The solenoids will switch off after four minutes. This is a default
time-out setting in the software for situations when there is no fuel
flow registered.
Topic Number: 2 321

C4000 Components
Main Features
Compac Industries Ltd.
Page 12
www.compac.co.nz
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 J7: Displays J13: CWIT/Secure
J2: To I.S. Power J8: Temperature Comp. PINPad
J3: Encoder 1 J9: PINPads J14: Printers
J4: Encoder 2 J10: Totes J15: Cardreader 1
J5: Encoder 3 J11: ParSw & Buzzer J16: Cardreader 2
J6: Encoder 4 J12: Nozzle Switches J17: Backlighting
Figure 1. Layout of C4000 Microprocessor Board
C4000 Components
The main components associated with the C4000 head are:
Encoder
Displays
Litres
Dollars, litres and price
Litres, rate of flow and
preset
Preset
Last Sale, kilograms,
litres and price (CNG
only)
Temperature
compensation
Card-reader
PIN/Odometer Pad
Printer
Modem
Mechanical Totaliser
(Tote)
Nozzle Switch

Main Features
Configurations
Compac Industries Ltd.
Page 13
www.compac.co.nz
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
Motor circuit, one only
One Encoder
One Nozzle Switch
C4000 Head
Also see 'FUTRA'
configuration.
Card-reader
High/Low Flow Operation
PIN-Pad
Single Suction Dual Commercial (Duo)
Standard Options:
Extras:
Litres only display, four - two
per side
Two motor circuit.
Two Encoders
Two Nozzle Switches
C4000 Head
Preset
Dual Commercial (Dual or Double)
Standard Options:
Extras:
Litres only display, four - two
per side
Two Motor circuits
Two Encoders
Two Nozzle Switches
C4000 Head
Preset
Single Retail
Standard Options:
Extras:
Dollars, litres and price
display, two - one per side
Presets, two - one per side
One Encoder
One Nozzle Switch
One Motor Output
C4000 Head
* Also see 'FUTRA' configuration
Card-reader
PIN-Pad
Receipt Printer

Configurations
Main Features
Compac Industries Ltd.
Page 14
www.compac.co.nz
Single Suction Dual Retail (Duo)
Standard Options:
Extras:
Dollars, litres and price
display, two - one per side
Presets, two - one per side
Two Encoders
Two Nozzle Switches
Two Motor Outputs
C4000 Head
Dual Retail (Dual or Double)
Standard Options:
Extras:
Dollars, litres and price
display, four - two per
side
Presets, four - two per
side
Two Encoders
Two Nozzle Switches
Two Motor Outputs
C4000 Head
Multi Product (4 hose) Retail
Standard Options:
Extras:
Dollars, litres and price
display, two - one per side
Presets, two - one per
side
Four Encoders
Four Nozzle Switches
Two Motor Outputs
One C4000 Head
Multi-price Displays, four
–one per product per
side
Card-reader
PIN Pad
Receipt Printer
Multi Product (4 hose) Retail, Type 'A'
Standard Options:
Extras:
Dollars, litres and price
display, four - one per
product per side
Presets, four - one per
product per side
Four Encoders
Four Nozzle Switches
Two Motor Outputs
One C4000 Head

Main Features
Configurations
Compac Industries Ltd.
Page 15
www.compac.co.nz
Multi Product (6 hose) Retail
Standard Options:
Extras:
Dollars, litres and price
display, two - one per side
Presets, two - one per
side
Six Encoders
Six Nozzle Switches
Three Motor Outputs -
shared by C4000 Heads
Two C4000 Heads
Multi-price Displays, six -
one per product per side
Card-reader
PIN Pad
Receipt Printer
Multi Product (6 hose) Retail, Type 'A'
Standard Options:
Extras:
Dollars, litres and price
display, six - three per
side
Presets, six - three per
side
Six Encoders
Six Nozzle Switches
Three Motor Outputs -
shared by C4000 Heads
Two C4000 Heads
Futra (Uses 'Futra' Software)
(This type is a stand-alone system that cannot be set up to communicate to any type of controller.)
Standard Options:
Extras:
Litres Only Display
Motor Circuit (One only)
One Encoder
One Nozzle Switch
C4000 Head
PIN-Pad
Card Reader
Retail Displays
Preset
Modem
High/Low Flow Operation
Tank Gauging, for one tank only
Receipt Printer

Configuration Code
Set-up Modes
Compac Industries Ltd.
Page 16
www.compac.co.nz
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. Parameter Switch Settings
Refer Parameter Switch (see page 33)
This switch is used to conduct the Display Segment Test, set price (product
density - if a bulkmeter or LPG), and set pump number. Also, when the
C4000 is configured for 'Comcard', 'Compin', or 'CWIDKey' the parameter
switch is used for card/pin/key validation and for setting the card/key
system number
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.
For FUTRA software configuration options, see the FUTRA
service supplement.
Multi-hosed Pump/Dispenser with LPG
An MPD with LPG is configured by setting digits 5=3 and 4=5.
With COM125 magnetic or Bennett meters, to set LPG compensation and
motor spirit without correction, set digit 1=4.
For COM125 optical meters when motor spirit correction is required as well,
set digit 1=6.
Refer Setting the Configuration Code (see page 16)
Setting the Configuration Code
Refer to Figure 3. While setting the configuration code, the price display
shows 'C' and the volume display shows 'XXXXX'.

Set-up Modes
Configuration Code
Compac Industries Ltd.
Page 17
www.compac.co.nz
Figure 3 Configuration Code Options

'b' Settings
Set-up Modes
Compac Industries Ltd.
Page 18
www.compac.co.nz
'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).
1: If digit 4 is set to one, then the dispenser/pump software will run in
the AUTO AUTHORISE mode of operation (used for wharf & aviation or
any other sites where the hose reel is remote from the pump unit):
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.
The pump/dispenser will switch off XXX * seconds after flow rate stops.
Can be adjusted to clients' requirements, between 1 and 256 seconds
The nozzle switch becomes a shut-off switch (i.e., the nozzle switch
can be replaced with a stop pushbutton or normally closed toggle
switch).
In AUTO AUTHORISE mode the nozzle input must be
shorted out.
Transaction Data (Digit 3)
0: If digit 3 is set to zero, the system will function as a conventional
dispenser/pump and the sale data goes through to Point of Sale as soon as
the preset is reached. This is the default setting.
1: If digit 3 is set to one, the system will function as a convention
dispenser/pump but the sale data will go through to the Point of Sale only
after the nozzle has been hung up.

Set-up Modes
'b' Settings
Compac Industries Ltd.
Page 19
www.compac.co.nz
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.
Price per Litre (Digit 2)
0: If digit 2 is set to zero, the price per litre is displayed as dollars per
litre ($0.000)
1: If digit 2 is set to one, the price per litre is displayed as cents per
litre (000.0 cents).
For CNG Only: If digit 2 is set to one then the display that normally shows
the dollar value of the transaction, will display the CNG pressure during the
fill. At the end of the fill the display will revert to displaying the value.
Controller Option (Digit 1)
The function of this digit (1) depends on whether the head has been set up
as one of the Basic Systems (Comcard, Compin, or CWIDKey) or a
conventional pump/dispenser, using digit 3.
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.
On a commercial pump/dispenser with litres-only display, only
the total litres can be read.
If the 'head' is set-up as a Comcard, Compin, or CWIDKey Basic system
then, after displaying the grand totals as above, the head will also printout
the totals for each card/pin/key, irrespective of the digit 1 setting.
By setting digit 1 to one, the 'Scrolling Totes' option is selected. Refer
Displaying and Printing Totals (see page 41). In this mode of operation,
after printing the totals as above, the 'head' will flash card totals on the
pump's main display. All non zero card totals are displayed consecutively,
for 10 seconds each.
The totals can only be zeroed by replacing the memory chip.
Conventional Pump/Dispenser (digit 3 set to zero or one)
If digit 1 is zero, the pump/dispenser can be operated in 'stand-alone' mode
irrespective of the pump/dispenser number loaded.
If digit 1 set to one, the pump/dispenser will not work in 'stand-alone' mode,
(i.e., it requires initialisation from a controller).
The pump/dispenser ceases to work in 'stand-alone' mode if
digit 1 is set to zero and it is connected to a controller. Generally on retail
forecourts, this switch should be left off. Hence, if the forecourt controller
breaks down, the dispensers/pumps can be set to work in the 'stand-alone'

'b' Settings
Set-up Modes
Compac Industries Ltd.
Page 20
www.compac.co.nz
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. When digit 1 is one, the unit must be
connected to a Compac Central Controller.