Compac DCA Supplement

DCA Installation & Service Manual
Version 1.1.4

Compac Industries Ltd.
Page 2
www.compac.co.nz
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
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 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
Conditions of Use ............................................................................................................................................................. 2
Product Identification ....................................................................................................................................................... 6
Document Control Information ........................................................................................................................................ 7
Symbols and Units of Measure ........................................................................................................................................ 8
Safety ................................................................................................................................................................................. 9
Introduction ..................................................................................................................................................................... 10
Options................................................................................................................................................................... 11
Components........................................................................................................................................................... 12
Litres Total ............................................................................................................................................................. 14
Installation Guidelines .................................................................................................................................................... 15
Electrical Connections.................................................................................................................................................... 17
Tank Gauging Setup .............................................................................................................................................. 18
Precautions when using Generator Power ................................................................................................................... 18
Wiring Diagram................................................................................................................................................................ 19
Modem Connections ....................................................................................................................................................... 20
Operating Instructions.................................................................................................................................................... 22
CWID Key & CWID Block Readers ........................................................................................................................ 22
HID Readers .......................................................................................................................................................... 24
iTrack Reader ........................................................................................................................................................ 25
USB Module ..................................................................................................................................................................... 26
USB Memory Stick................................................................................................................................................. 27
Uploading and Downloading Files................................................................................................................................. 28
1) Do All ................................................................................................................................................................. 29
2) Set Price ............................................................................................................................................................ 30
3) Send Cards........................................................................................................................................................ 30
4) Get Buffer .......................................................................................................................................................... 31
5) Get Transactions ............................................................................................................................................... 31
Working with USB Module Files .................................................................................................................................... 32
1) Cards ................................................................................................................................................................. 33
2) Price................................................................................................................................................................... 35
3) Transactions ...................................................................................................................................................... 36
Customising Your Transaction Reports ................................................................................................................. 37
Powering Up .................................................................................................................................................................... 39
Set Up............................................................................................................................................................................... 40
System Setup......................................................................................................................................................... 40

Compac Industries Ltd.
Page iv
www.compac.co.nz
Main Menu Options ......................................................................................................................................................... 41
Option #1 REPORTS ............................................................................................................................................. 41
Option #2 CARDS.................................................................................................................................................. 42
Option #3 FUELS................................................................................................................................................... 43
Option #4 SYSTEM................................................................................................................................................ 45
Option #5 PUMPS.................................................................................................................................................. 54
Comms Options ..................................................................................................................................................... 57
Option #6 TANKS .................................................................................................................................................. 63
Option #7 PRODUCT GROUPS and GRADES ..................................................................................................... 67
Tanks/Pumps/Groups ............................................................................................................................................ 68
Setting Product Groups.......................................................................................................................................... 70
Assigning Pump Numbers to Hoses ............................................................................................................................. 71
Pump numbers for each model .............................................................................................................................. 71
Order of pump numbers......................................................................................................................................... 71
Assigning Hoses to Product Groups............................................................................................................................. 71
Legend 4 Hose, 6 Hose and Laser 4 Hose Quad .................................................................................................. 72
Master, Premier and Laser (Single and Dual) ........................................................................................................ 73
Cards................................................................................................................................................................................ 74
Expiry Date ............................................................................................................................................................ 74
Setting ISO and Access codes............................................................................................................................... 74
Oil company ISO and Access codes...................................................................................................................... 75
ATG / CE Box................................................................................................................................................................... 76
Mechanical Registers............................................................................................................................................. 77
Cardreaders ..................................................................................................................................................................... 81
Modems............................................................................................................................................................................ 82
Dynalink (Hayes type)............................................................................................................................................ 82
GSM Modem (Wavecom)....................................................................................................................................... 82
Lantronix.......................................................................................................................................................................... 83
Diagnostic LEDs.............................................................................................................................................................. 87
Diagnostic LEDs in a system with Compac comms only....................................................................................... 88
Reports............................................................................................................................................................................. 89
Deleting Transactions ............................................................................................................................................ 90
Troubleshooting.............................................................................................................................................................. 91
Error Messages ............................................................................................................................................................... 91
Service and Upgrade Procedures.................................................................................................................................. 92
Com FMS Board Replacement (DCA) ................................................................................................................... 92
C4000 Board Replacement.................................................................................................................................... 95
Compac Box Replacement .................................................................................................................................... 96
Fit PC Replacement............................................................................................................................................... 97
Wiring a USB Module............................................................................................................................................. 98
CWID Interface Board Replacement.................................................................................................................... 101
CWID Aerial Replacement ................................................................................................................................... 103
CWID Nozzle Aerial Replacement ....................................................................................................................... 104
HID Reader Replacement.................................................................................................................................... 106
iTrack Reader Installation and Replacement ....................................................................................................... 108
Card Reader Replacement .................................................................................................................................. 111
Multiplex Board Replacement .............................................................................................................................. 114
Keypad and Display Screen Replacement........................................................................................................... 115
Router / Switch Replacement............................................................................................................................... 116
Replacing the Receipt Printer .............................................................................................................................. 117

v
Software Upgrading ............................................................................................................................................. 118
Maintenance .................................................................................................................................................................. 120
Receipt Printer ..................................................................................................................................................... 120
Replacing Paper - Seiko Printer........................................................................................................................... 121
Changing Paper on a Custom Printer .................................................................................................................. 122
Appendix........................................................................................................................................................................ 123
Comm FMS Board Connections .......................................................................................................................... 123
Plugs and Connectors.......................................................................................................................................... 126
Part Locations ............................................................................................................................................................... 130
Spare Parts List............................................................................................................................................................. 132
DCA Cabinet ........................................................................................................................................................ 132
Electronic Components........................................................................................................................................ 133
Modem / Router Options (DCA) ........................................................................................................................... 134
Printer .................................................................................................................................................................. 135
Card Reader ........................................................................................................................................................ 135
CWID HID & USB ................................................................................................................................................ 136
Exchange Parts.................................................................................................................................................... 136
Glossary of Terms......................................................................................................................................................... 137
Installation Checklist .................................................................................................................................................... 138

Product Identification
Compac Industries Ltd.
Page 6
www.compac.co.nz
Product Identification
Manual Title
DCA Installation and Service Manual
Publication Date
Wednesday, 29 August 2012
Application
Compac models RAS, DCA, CC DCA and variants
Power supply
220 - 240 V +/- 10%, 50 Hz, 1 Amp
Related Manuals
C4000 Master Manual (CWID and Mechanical Register DCAs)
CompacOnline User Guide (CompacOnline capable DCAs)
Validity
Compac Industries Limited reserves the right to revise or change
product specifications at any time. This publication describes the state
of the DCA 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 DCA 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 ©2012 Compac Industries Limited, All Rights Reserved

Document Control Information
Compac Industries Ltd.
Page 7
www.compac.co.nz
Document Control Information
Document Information and Revision History
Document Details:
DCA Installation and Service Manual
File Name and Location:
G:\Masters\Manuals\Authorised Manuals\DCA
Current Revision Author(s):
R Lacey
Authorised By:
Release Date:
Version
Date
Author(s)
Revision Notes
1.0.1
07/12/2009
R Lacey
Added USB Module instructions
1.0.2
06/09/2010
R Lacey
Republished with formatting changes from Comfutra manual
1.1.0
13/01/2011
R Lacey
Added Working with USB Module & Gilbarco comms update
1.1.1
28/02/2011
R Lacey
Added USB key USBTransJoin.exe instructions
1.1.2
11/07/2011
R Lacey
Updated grade map table
1.1.3
01/11/2011
R Lacey
Added generator precautions, tank gauging cable restrictions and DCA
installation checklist
1.1.4
29/08/2012
R Lacey
Updated Conditions of Use. Added Colibri TG info. New Custom printer.
Updated ATG Box to Compac Box.Added Roseman spec Compac Box
to spare parts. Added Litres Total info. Added Fit PC info.
Distribution
Name
Indicator
Location

Symbols and Units of Measure
Compac Industries Ltd.
Page 8
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)

Safety
Compac Industries Ltd.
Page 9
www.compac.co.nz
Safety
You must adhere to the following safety precautions at all times when working
on this unit. Failure to observe these safety precautions could result in electrical
or mechanical damage to the unit or injury or death to yourself or bystanders.
Make sure that you read and understand all safety precautions before installing,
servicing or operating this unit.
Failure to follow safety instructions may invalidate any warranty.
Mechanical Safety
Observe the following mechanical precautions:
During installation, take care that the unit is well supported and
cannot fall over.
Take care with handling sharp edges, wear gloves where
required.
Make sure that the service area is thoroughly clean when
servicing. Dust and dirt entering the components may 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 unit before commencing work on
any wiring. Never touch wiring or components inside the high voltage area with
the power on. Be aware that capacitors and back up batteries may power the
unit even after mains power is removed.
Always turn off the power to the unit 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.
Environmental Safety
Observe the following environmental precautions:
Take care that you clean up after working on the unit.
Remove and carefully dispose of any waste.
Any spills must be cleaned up and disposed of in an approved manner.
Any spillage of fuel must be handled to minimise the risk of fire or
explosion. Major spills must be reported to the local environmental authorities.
Site Safety
Observe the following precautions when on site:
Personal safety is the responsibility of the site manager and technician.
Personal protective equipment appropriate to the situation is to be worn and if
required, the working area appropriately cordoned off with cones, tape and/or
barriers.
When working in or near hazardous areas, take all precautions to
avoid sources of ignition. Obtain a Hot Work Permit if required.
These instructions are intended as a guide only. It is the
responsibility of the technician and the site manager to manage safety in
accordance with local regulations and best safe site practice.

Introduction
Compac Industries Ltd.
Page 10
www.compac.co.nz
Introduction
The Compac DCA is designed as an authorisation station for controlling the
operation of fuel pumping systems. It is compatible with most common fuel
pumps and can be easily customised to accept a variety of authorisation
methods and provide detailed transaction reporting. The main features
include:
Stand alone unit for unattended refuelling
Stainless steel construction
Tactile keypad
Robust, reliable receipt printer
Authorisation options include: Card, Pin, HID tag, iTrack, Roseman or
Compac Wireless ID (CWID) tag or nozzle loop
Most major oil, gas company and third party cards accepted
Data retrieval and client management by CompacOnline software or
USB key
Reporting of tank gauge readings via CompacOnline (option)
Communication via ADSL modem, 3G wireless, LAN cable or wireless
LAN.
Ability to authorise high volume pumping systems
There are two basic models of Driveway Card Acceptor.
Model 1 is known as a Driveway Card Acceptor [DCA]
A Driveway Card Acceptor is designed to be used on an unattended site
where the fuel pumps are authorised and controlled totally by the DCA.
A DCA has the site controller circuit board [Communicator Controller]
included inside the unit.
A DCA can be configured with the appropriate hardware to communicate to
and control Compac, PEC protocol and selected Gilbarco and Email
protocol pumps.
Model 2 is known as a Retail Authorisation Station [RAS]
A RAS is designed to be used on a retail site where cash and card sales
can take place during attended hours and card sales only can take place
after hours. A RAS is connected to a Compac Communicator Controller on
the pump communication loop. The Communicator Controller is normally
located in a nearby office. You can have multiple Retail Authorisation
Stations on one site connected to the controller.
For clarity, all units are referred to as DCA units unless it
contains a feature specific to a RAS unit.