Compac C5000 User manual

C5000 MANUAL
C5000 Manual
Version 1.0.9
Model: C5000 Controlled Pumps and Dispensers
Date: 16th September 2020

Conditions of Use
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 the equipment
incorrectly or without authorization.
▪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 operating the
Compac C5000 processor 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 Compac C5000 processor, or
damages resulting from the inability to use the
Compac C5000 processor, 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 Compac C4000 processor'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 Compac C5000 processor
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.
▪Only parts supplied by or approved by Compac may
be used and no unauthorised modifications to the
hardware of software may be made. The use of non-
approved parts or modifications will void all
warranties and approvals. The use of non-approved
parts or modifications may also constitute a safety
hazard.
▪Information in this manual shall not be deemed a
warranty, representation, or guarantee. For warranty
provisions applicable to the Compac C5000
processor, 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 Compac C5000 processor,
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.

CONDITIONS
Product Identification
Specifications
Manual Title
C5000 Manual v.1.0.9
Original Publication Date
20/11/2018
Models Covered
This manual applies to C5000 controlled pumps and
dispensers.
NOTE: Do not use this manual for earlier models. Contact
Compac for archived manuals if required.
Validity
Compac Industries Limited reserves the right to revise or change product specifications at any
time. This publication describes the state of the product at the time of publication and may not
reflect the product at all times in the past or in the future.
Manufactured By:
The Compac C5000 head 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
Email: [email protected]
www.compac.biz
Copyright ©2015 Compac Industries Limited, All Rights Reserved

Document Control
Document Control
Document Information
File Name and Location
C5000 Manual v.1.0.9
Current Revision Author(s)
V Amarakoon
Authorised By
W Zheng
Revision History
Version
Date
Author(s)
Revision Notes
1.0.0
20/11/2018
S Laycock
New manual
1.0.1
07/12/2018
R Liu
Updated Contact Information
1.0.2
28/05/2019
S Laycock
Updated title
1.0.3
16/07/2019
S Laycock
Updated incoming mains diagram
1.0.4
05/11/2019
S Laycock
Added software options
1.0.5
30/06/2020
V Amarakoon
Updated slave display configuration
1.0.6
10/07/2020
V Amarakoon
Updated ABD error
1.0.7
30/07/2020
V Amarakoon
Updated the COMMS board
1.0.8
07/08/2020
V Amarakoon
Updated slave display configuration, Updated
End of Sale indicators
1.0.9
16/09/2020
V Amarakoon
Added CC setting

Contents
Contents
Safety ................................................................................................................... 1
C5000 Power Supply............................................................................................ 2
Cable Requirements..............................................................................................3
Incoming Mains ................................................................................................... 4
Comms Connections .............................................................................................5
Power Supply ....................................................................................................... 6
K-Factor Board ......................................................................................................7
Typical Wiring ...................................................................................................... 8
Pumps....................................................................................................................8
Dispensers...........................................................................................................10
K-Factor Settings............................................................................................... 11
Using the Dispenser Menus ................................................................................11
Dispenser Settings ..............................................................................................12
Changing the V50 Meter ID.................................................................................14
Changing the Temperature Calibration ..............................................................15
Changing the Density Calibration.......................................................................15
Changing the Maximum Flow .............................................................................16
Changing the K-Factor........................................................................................16
Changing Configuration Settings .......................................................................17
Changing the Solenoid Delay..............................................................................20
Changing the Preset Cutoff.................................................................................20
Changing the Preset Rounding...........................................................................21
Changing the Flow Time Out...............................................................................22
Parameter Settings............................................................................................ 23
Using the Dispenser Menus ................................................................................23
How to View the Software Version .....................................................................24
Changing the Pump Number...............................................................................24
Changing the Price..............................................................................................25
Changing the Pump Settings ..............................................................................25
Changing the Low-flow Cutoff............................................................................27
Changing the High-flow Cutoff...........................................................................27
Changing the b Setting .......................................................................................28
Changing the Slave Display Configuration.........................................................28
Changing the Custom Display Configuration .....................................................29
How to View Last Sale ........................................................................................30
How to View Electronic Totes .............................................................................31
Commissioning .................................................................................................. 32
Electrical..............................................................................................................32
Mechanical ..........................................................................................................33
LED Diagnostics................................................................................................. 34
Processor Board..................................................................................................34
K-Factor Board ....................................................................................................35
Troubleshooting................................................................................................. 37
Electrical..............................................................................................................37
Mechanical ..........................................................................................................39
Generator Power ................................................................................................ 40
End of Sale Indicators........................................................................................ 41
Error Codes......................................................................................................... 42

1.
Safety
Safety
PRECAUTIONS
Always follow safe operating procedures, any national or local regulations and site
specific instructions.
Always turn the power off to the unit and properly isolate so power cannot be turned on by
mistake.
Turn off isolating valves to the dispenser and drain the fuel before any mechanical servicing.
Electrical Safety
Observe the following electrical precautions:
Always turn off the power to the Compac C5000 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 C5000 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.
Site Safety
Obey all company regulations and site specific instructions relating to the installation. Before
working on any hydraulic equipment, drain the dispenser in an approved manner.
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.

2.
C5000 Power Supply
C5000 Power Supply
The C5000 may be supplied unmounted for use in applications such as controlling mechanical
registers in a bulk dispensing area or mounted on a truck for mobile dispensing.
When installing the C5000 power supply, please observe the following instructions.
Cable Entries
There are fourteen cable entries, five along the top of each of the long sides, three along one
short side of the box and one at the bottom. All cable entries have an M20 thread.
The bottom cable entry is used for the power supply output cable while the thirteen top cable
entries are for power cable and communication connections.
Use only certified Ex 'd' glands and thread adaptors if required. Blank all unused entries with
certified M20 Ex 'd' blanking plugs. Do not use thread adaptors with blanking plugs.
All cables must carry appropriate certification for the required application.
Area of Use
Correctly installed, the power supply is suitable for use in Zone 1 areas as defined in IEC 60079-
14, group classification IIA, temperature classification T4, ambient temperature range -25 to 55
degrees Celsius.
With the o-ring fitted in the base and the use of appropriate glands, the enclosure provides
protection to IP66.
Location
Mount the power supply in a horizontal position, isolated from vibration and sheltered from
excess water spray. Failure to do this may void the warranty.
Installation
Fasten the power supply using the four M6 tapped holes in the base. Hole centres are 185 mm x
105 mm. There should be a minimum of 9 mm and a maximum of 14 mm thread engagement.
Wiring
▪Wiring must be carried out in accordance with the relevant code of practice.
▪All terminal wiring must have a cross section area of 0.5 mm2to 4 mm2.
▪Wiring used should be suitable for 80 degrees Celsius.
▪Insulation must extend to within 1mm of the metal face of the terminal.
▪Not more than one single or multi-stranded wire should be connected to the terminals.
unless they have been pre-joined in an appropriate manner.
Procedure
▪Ensure the unit is isolated from the power source.
▪Remove the sixteen M10 x 20 stainless steel cap screws and remove the lid.

3.
C5000 Power Supply
▪Feed all wires into the box via an appropriate gland and connect. The Earth wire from
the power lead must be earthed to the casing using a proper terminal.
▪Replace the lid making sure the gasket is in place and clean and that no wires have
been pinched.
External Earthing
Where required, earth the C5000 Power Supply using an earth wire with a cross sectional area
at least equal to the largest conductor. The earth wire is attached to the integrated point.
Cable Requirements
Cable requirements are as follows:
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.
Submersible pump(s): Suitable cable for 230V solenoid switching current. 300mA maximum
load.
Do not wire submersible pumps directly to C5000 power supply.
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 C5000 flameproof box.
If using generator power refer to: Generator Power (see page 40.)

4.
Incoming Mains
Incoming Mains
Incoming mains connections should be brought in to the terminal board.
An emergency stop connection, if desired, can also be wired into the terminal board, shown
below. This will be in place of the normal loop between the triac and main phases. Wires have
standard colours which are shown. In case these are unclear, the colours are as follows:
▪Incoming mains phase: Brown
▪Incoming mains neutral: Blue
▪Incoming mains earth: Green/Yellow
Earth
Neutral
Phase
Incoming Mains
Emergency
Connection
Main Earth Terminal
(in the corner of the
flameproof box)

5.
Incoming Mains
Comms Connections
The comms I/O is controlled by the connections to the Comms board. Refer to the following
diagram for connecting RS485, RS232, Compac or Gilbarco pumps. The shown switch should be
set to the desired setting.
Switches 300, 302, and 303 are for RS485/RS232 Terminator application. Use the following
table to configure these switches. Switch 300 is for channel 1, and switches 302 and 303 are
for channel 2.
SW300
SW302
SW303
RS485 (Channel 1)
ON
-
-
RS485 (Channel 2)
-
ON
OFF
RS232 (Channel 2)
-
OFF
ON

6.
Power Supply
Power Supply
The C5000 power supply is found within the flameproof box, located on the unit. The power
supply contains the processor board and the terminal board.
Terminal Board
Processor Board
Power Supply PCBs
Flameproof box

7.
Power Supply
K-Factor Board
Both the Parameter switch and K-Factor switch are found on the K-Factor board. Meters and air
switches are also connected to this board. See below for the location of these.
Side A Connections
Connect Air
Switch to here
Connect Meter
to here
Connect Nozzle
Switch to here
Connect Sump
Switch to here
Connect optional
mechanical totes
to here
Bus out system
cables
Parameter Switch
K-Factor Switch

8.
Typical Wiring
Typical Wiring
Pumps
The following diagrams show the typical wiring required for C5000 pumps.
The motor can be connected to the terminal board for both side A and side B. Only wire in the
required side(s). The location of the fuses on the terminal board are also shown. These can be
used for diagnosing problems with the unit.
Solenoids for side A and B are optional and can be wired in if preset and prepay options are
desired.
Earth
Motor Side A
Earth
Neutral
Phase
Motor Side B
Phase
Neutral
Triac Fuse
C5000 Power
Supply Fuses
Secondary Solenoid
Primary Solenoid
Primary Solenoid
Secondary Solenoid
Side B
Side A

9.
Typical Wiring
Triac Wiring
The triac wiring is pre-installed and, in most cases, will not need to be changed. However, the
wiring is shown here to aid triac replacement or other service procedures. These are colour
coded with standard colours. In case these are not clear, the colours are as follows:
▪MTR Relay: Orange
▪Phase: Red
▪Motor: White
Phase
MTR Relay Low
Motor (1KW)

10.
Typical Wiring
Dispensers
When using the C5000 electronics for dispenser application, as well as connecting the incoming
mains, the external pump contactors will have to be connected to the terminal board.
Solenoids for side A and B are optional and can be wired in if preset and prepay options are
desired.
Secondary Solenoid
Primary Solenoid
Primary Solenoid
Secondary Solenoid
Side B
Side A
External Pump
External Pump

11.
K-Factor Settings
K-Factor Settings
A summary of the K-Factor settings can be seen below. Information on these settings and how
to change them can be found on the following pages.
Setting
Price display
Litres display
Dispenser settings
C-A or C-B
*******
Meter ID
ID-A or id-b
******
Temperature calibration
E-a or e-b
**.*
Density calibration
D15-a or d15-b
***.*
Maximum flow
QA **** or qb ****
K-Factor
FA or FB
***.****
Configuration code
C
*******
Comms
Cc
****
Solenoid delay
5da *** or 5db ***
Preset cutoff
Pca *.** or pcb *.**
Preset rounding
Prla*.** or prlb*.**
prxa*.** or prxb*.**
Flow time out
n-a *** or n-b ***
Using the Dispenser Menus
When changing settings on the dispenser, pressing the K-Factor switch in quick succession
cycles between the options available. The location of this switch can be found on page 7. Each
press of the button will cycle between the digits. When going through the menus, each menu
will cycle through the digits twice for ease of operation.
When a digit is flashing, hold down the relevant switch to increment this digit. Release the
switch on the desired value.
The system timeout is 10 seconds.

12.
K-Factor Settings
Dispenser Settings
The following diagram displays how to change the dispenser settings, such as the meter type,
variant and minimum delivery. To get to the following menu, depress the K-Factor switch once
when not in a transaction. The menu shown is for side A –if side B is required, continue
depressing the K-Factor switch until the same menu for side B is reached and follow the same
set up instructions.
These settings will likely be set in the factory. Only change the following settings if required. See
following pages for information on these settings.
-A
0000000
Meter Settings
1-1 Channel Encoder
2-2 Channel Encoder
3-3 Channel Encoder
4-V50 Meter
Variant Settings
0-Non-LPG
4-AdBlue (Diesel
Emissions Fluid)
5-LPG
Quantity Settings (V50 Meter
Only)
0-Litres Compensated
1-Litres Uncompensated
2-Mass (CNG only)
NOT USED
Minimum Measured
Quantity Exponent –
Must be a valid digit-
see below
Minimum Measured
Quantity Coefficient –
MUST be 1,2 or 5
Air Settings
0-Normally open –turn
air switch ON for error
1-Normally closed –turn
air switch OFF for error

13.
K-Factor Settings
Meter Settings
This setting corresponds to the type of meter plugged in to the dispenser. Options 1-3 are for an
encoder meter and depend on the channel setting of this meter. Encoder meters are used for
petrol and diesel, while V50 meters (option 4) are used for LPG and AdBlue. Some settings (such
as temperature and density calibration) are only available for V50 and therefore will not appear if
the meter type is not set to V50.
Variant Settings
This setting should be changed depending on the product –set the variant to 0 for liquid fuels
such as petrol or diesel. Set the variant to 4 for diesel emissions fluid (AdBlue). Set the variant to
5 for LPG.
Quantity Settings
This setting is what quantity will be shown on the main display when fuel is being dispensed.
This is only valid for V50 meters and is ignored for encoder meters which always display Litres
uncompensated.
Air Settings
Air switches can be turned on or off to trigger this error, depending on this setting.
Minimum Measurable Quantity (MMQ)
Minimum measured quantity (MMQ) is the minimum amount of fuel that can be dispensed and
measured. The MMQ is calculated with the following equation:
  
With the value in litres. For example, if the coefficient was set to 2, and the exponent was set to
1:
  
So the minimum delivery would be 20 litres.
The exponent can only be certain values;
•If the coefficient is 1, the exponent can be 0, 1, 2, 3 (valid values are then 1, 10, 100,
1000)
•If the coefficient is 2, the exponent can be 0, 1, 2 (valid values are then 2, 20, 200)
•If the coefficient is 5, the exponent can be 0, 1, 2 (valid values are then 5, 50, 500)
If either of the values entered are not valid, or the value is left as 00, the MMQ will be
calculated from the maximum flow. The MMQ is the maximum flow x 0.05. For example, if the
maximum flow was 40 (the default):
   

14.
K-Factor Settings
Note that the MMQ still must be one of the valid values listed above. If the MMQ is calculated
from the maximum flow, and is NOT one of the valid values listed above, it will be rounded up to
the next valid value. For example, if the maximum flow was 600:
  
30L is not a valid value, and therefore the MMQ would be rounded up to 50L.
The MMQ sets the display suppression. When a transaction starts, the quantity dispensed will
not show until a percentage of the MMQ has been dispensed. For LPG, display suppression is
4% of the MMQ. For non-LPG operation, display suppression is 2% of the MMQ. For example, if
the dispenser is in LPG mode and the MMQ is 2L:
  
So the quantity dispensed will not show until more than 0.08L has been dispensed.
Changing the V50 Meter ID
All V50 meters have a specific ID which must match the ID recorded in the dispenser settings.
This is a 6-digit number which can be found on the meter.
If the IDs do not match, the dispenser will return an error.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
As meter IDs are only relevant for V50 operation, this option will not show if the meter is not set
to V50.
id-A
802060

15.
K-Factor Settings
Changing the Temperature Calibration
The temperature calibration can be used to adjust the temperature being retrieved from the
meter, if this is not the actual temperature of the product being dispensed. The actual
temperature of product being dispensed should be entered in this menu. This will be used to
adjust new temperatures returned from the meter.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
As only V50 meters return temperature readings, this option is only for V50 operation and will
not appear if the meter is not set to V50.
Changing the Density Calibration
The density calibration can be used to adjust the density being retrieved from the meter, if this is
not the actual density of the product being dispensed. The actual density of product at 15 °C
being dispensed should be entered in this menu. This will be used to adjust new densities
returned from the meter.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
As only V50 meters return density readings, this option is only for V50 operation and will not
appear if the meter is not set to V50.
E-A
15.0
D15-a
520.0