Compac COM5 PT1 User manual

COM5 PT1 Service Manual
Version No 1.0.1
Model: COM5 PT1
Date: 20th September 2021

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 C5000 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.

Product Identification
Product Identification
Specifications
Models Covered
This manual applies to the COM5 PT1.
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 COM5 PT1 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
Manual Title
COM5 PT1 Service Manual
Current Revision Author(s)
Venuka Amarakoon
Original Publication Date
20 September 2021
Authorised By
Emily Sione
File Name
COM5 PT1 Service Manual v.1.0.1
Revision History
Version
Date
Author(s)
Revision Notes
1.0.0
20 August 2021
Venuka Amarakoon
New Manual
1.01
20 Sep 2021
Venuka Amarakoon
Updated Din rail connections

Contents
Contents
Safety ................................................................................................................... 1
Electrical Safety ....................................................................................................2
Security ................................................................................................................ 4
Introduction.......................................................................................................... 5
Operation ...............................................................................................................6
Downloading COM5 PT1 Transaction Data ..........................................................6
Components ..........................................................................................................7
COM5 PT1 Housing Layout....................................................................................8
Electronic Module Layout .....................................................................................9
Servicing ............................................................................................................ 10
Tools ....................................................................................................................11
Biannual Service .................................................................................................11
Annual Service ....................................................................................................11
Printer..................................................................................................................12
Electronic Module Removal ................................................................................15
Power Supply Replacement................................................................................16
Troubleshooting................................................................................................. 17
UPS Motherboard Connections...........................................................................17
COMMS board connections.................................................................................18
Din Rail connections ...........................................................................................18
Power Loss ..........................................................................................................19
Battery .................................................................................................................20
COMMS Board Replacement...............................................................................22
C5K Processor Board Replacement....................................................................23
UPS Motherboard replacement...........................................................................24
Comms Wiring .....................................................................................................26
PIN Pad Replacement..........................................................................................28
Card Reader Replacement ..................................................................................29
Fan & Filter ..........................................................................................................30
Modem LEDs ...................................................................................................... 31
Comset.................................................................................................................31
Machinelink.........................................................................................................32
Etic.......................................................................................................................33
Troubleshooting................................................................................................. 35
Spare Parts......................................................................................................... 38

1.
SAFETY
Safety
You must adhere to the following safety precautions at all times when working on the Compac
COM5 PT1. Failure to observe these safety precautions could result in damage to the COM5
PT1, injury, or death. Make sure that you read and understand all safety precautions before
installing, servicing, or operating the Compac COM5 PT1.
PRECAUTIONS
Always follow safe operating procedures, any national or local regulations and site-
specific instructions.
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.
Some components have sharp edges and corners. Wear gloves whenever practicable while
working inside the cabinet.
Site Safety
Comply with all safe site regulations for the site you are working on and any additional
instructions from the site manager.
Wear and use appropriate safety equipment such as safety boots, high visibility clothing, hard
hat, gloves, and barrier cream.
Cordon off the area you are working in using cones, barriers, caution tape etc.
CAUTION
When working near any flammable goods area, take all precautions to avoid all potential
sources of ignition. This includes but is not limited to: Open flames, hot exhausts, welding
flames or sparks, static electricity, non-intrinsically safe electrical equipment, use of mobile
phones.
These instructions are to be used as a guide only and may not cover all situations. It is the
responsibility of yourself and the site manager to take appropriate health and safety
precautions.

2.
SAFETY
Electrical Safety
CAUTION
Always turn off the power to the COM5 PT1 before removing the high voltage area Perspex
guard. Never touch wiring or components inside the high voltage area with the power on.
Always turn off the power to the COM5 PT1 using the mains switch and the battery isolation
switch before removing or replacing any PCB’s.
Always take basic anti-static precautions when working on the electronics, i.e., wearing a
wristband with an earth strap.
240 Volt
The COM5 PT1 is powered by 240-volt AC mains power. The mains power enters the cabinet via
a gland in the base and is connected into the main circuit breaker on the DIN rail. From the
circuit breaker, power goes to a connector block where it is split with wires running to the
thermostat/heater and to the power supply mounted on the back of the electronic module. The
power supply steps down the 230 Volts AC to 16-volt DC to power the main electronic
components.
Technicians should be able to safely operate and diagnose an COM5 PT1 with the cabinet door
open if they do not touch any of the 230 volt powered components behind the Perspex cover or
the 230 Volt terminals on the power supply.
Turning off the mains power at the mains circuit breaker should be sufficient to allow
maintenance of the COM5 PT1 providing isolation is tested.
The 2 DIN rails hold 230 Volt components. The 230 Volt components (230 Volt connector block,
circuit breaker, thermostat, and heater) should not be touched unless isolated. The 5 Volt wires
on the left-hand side can be safely touched to help diagnose connection problems.
CAUTION
The cabinet heater operates when the temperature inside the cabinet drops below a pre-set
level. In cold weather the heater can start without warning and may get hot enough to cause
skin burns if touched (105°C).

3.
SAFETY
12 Volt
The COM5 PT1 runs on 16 Volts DC and has an internal 12 Volt battery to supply power in the
case of mains failure. When the mains power is turned off, the unit will still be powered by the
battery. Turn off the battery isolation switch or turn off the mains power before working on any
electronic components.
CAUTION
When removing the battery, take care not to short the positive terminal on the chassis of the
COM5 PT1. Make sure the positive terminal is insulated before installing the battery.
Power Supply
The power supply converts the 230 Volt AC power to 16 Volt DC power. It is located behind the
electronics module and has exposed terminals. Do not place your hand in the gap between the
left-hand side of the electronics module and the cabinet side unless you have isolated the mains
power.

4.
SECURITY
Security
All users, technicians and help desk staff must be aware of the security implications involved
with their operation of an COM5 PT1.
The following is a list of guidelines that should be considered as a minimum for secure operation
of an COM5 PT1
User Security
▪Keep your fuel card in a safe place.
▪If your card requires a PIN number, memorise it or store the number in a safe place not
in the vicinity of your card.
▪Do not let others use your card or tell them your PIN number.
▪If your card is lost or stolen, notify the issuer immediately.
▪Be aware that skimming devices can be fitted to card readers. If the COM5 PT1 or the
card reader appears to have been tampered with do not use the COM5 PT1 and contact
the help desk immediately.
▪When refuelling at unmanned sites, be aware of suspicious activity.
▪Report all security concerns to Help Desk
Technician Security
▪Inspect the COM5 PT1 for signs of tampering and report if anything noticed.
▪Keep the keys to the COM5 PT1 cabinet in a secure place.
▪Keep laptop, keys, and all passwords in a secure place. Notify help desk immediately if
lost or stolen.
▪Keep all service PIN pads in a secure place. Notify help desk immediately if lost or stolen.
▪Do not replace the security cap screws with hex head or similar screws. Inspect the
COM5 PT1 for any signs of tampering.
▪When servicing remote sites, be aware of suspicious activity around the site and if
concerned, return to your vehicle and contact authorities.
▪Report all security concerns to Help Desk.

5.
INTRODUCTION
Introduction
The Online Payment Terminal (COM5 PT1) enables unattended refuelling at unmanned sites such
as truck stops, marinas, aviation sites and supermarkets where the driver, skipper or pilot can
pay for fuel by credit card, distributor card or on enabled sites, by EFTPOS. The COM5 PT1 can
accept multiple card bases simultaneously through Compac's EFTPOS partner, WindCave.
The COM5 PT1 is a National Measurement Institute (NMI) approved control system for fuel
dispensers. It incorporates a forecourt controller that is capable of controlling Compac, PEC,
Gilbarco, and E-mail protocol pumps. Tank levels can be monitored with Veeder-root, Fafnir, and
Franklin tank gauges. The COM5 PT1 is designed to AS/NZS 3100 wiring standards.
Card bases are setup as online and the offline mode can be enabled. Card bases can be set up
as "Limited Validation" meaning a list of valid cards is stored or as "Extended Validation"
meaning the card base is unlimited and the hot (lost/stolen) card lists are stored.
The COM5 PT1 has a backup power supply to allow communications and receipts to be printed
in the event of a power failure. For an overview of the backup battery operation refer to Power
Loss (see page 19.)

6.
INTRODUCTION
Operation
▪Following the instructions displayed on the COM5 PT1, the user inserts and removes
their card.
▪The COM5 PT1 requests the user to select which pump they wish to refuel from.
▪The user follows on-screen prompts to authorise the transaction. The prompts will vary
according to the type of card, the network in use and the country of use.
▪The COM5 PT1 display advises the user to take fuel.
▪After fuel has been taken and the pump nozzle hung up a receipt can be obtained by
the customer by re-inserting and removing their card. This can be done up to 20
minutes after the transaction
Downloading COM5 PT1 Transaction Data
EFTPOS and credit card transactions are handled by banks and transaction processing entities.
Distributor card transactions are stored in the unit and can be downloaded via the Internet using
the CompacOnline website www.compaconline.com. Instructions for using the CompacOnline
website are contained in the CompacOnline User Guide.

7.
INTRODUCTION
Components
The unit has the following main components:
▪Galvanised post base: Strong base bolted to concrete ground
▪Post:This post is manufactured from stainless steel and has a removable panel to allow
the COM5 PT1 housing to be easily bolted on and electrically wired.
▪COM5 PT1 housing: The housing is manufactured from stainless steel and is powder
coated. The card-reader, printer and PIN pad keypad/display are fitted into the COM5
PT1 housing doors.
▪Electronics module:Communicates to the pumps authorising them and recording and
storing details of the distributor card transactions. It also sets up price, fuel, groups,
hose, and tank information. Communicates to banks via a secure internet connection for
credit card and EFTPOS authorisation. Communicates to EFTPOS PIN pad and card
reader. Provides power in normal operation and in the event of a power outage enables
the unit to finish any current transaction and print a receipt.
▪PIN pad and card reader module: The Card Reader can accept 1 or 2 track Magstrip
with EMV chip card meeting EMV level 2 standards.
▪Receipt Printer: Thermal type printer with an integrated cut-off style receipt dispenser.
It uses special waterproof thermal paper. A thermostat-controlled heater element is
mounted in the cabinet to help eliminate paper jams.
NOTE: Do not use standard thermal paper as this may absorb moisture and jam in the printer.
Always order replacement paper from Compac.

8.
INTRODUCTION
COM5 PT1 Housing Layout
COM5 Processor
Board
COMMS Board
UPS Motherboard
COMSET Modem
12V-24V DC-DC
converter
12VDC-DC
Converter is at the
back
Custom VKP80III Receipt Printer
SCR200 Secure Card
Reader
Lock
Payment Express
SKP200 PIN pad
Pay wave BRF
Magtek Card Reader
Camlock
385W15VDC
power supply
module
Earth Bar
230V terminal
230V main ISO
Switch
Thermostat
12V Battery ISO
Switch
Heater

9.
INTRODUCTION
Electronic Module Layout
NOTE: An industrial grade ADSL router may be in place instead of the COMSET 4G router.
USB
BUS1
BUS2
POSTEC
Controller
ATG (optional)
(Veeder root/
Colibri /Fafnir)
Price Boards
(Biever/Novyc)
Secondary reader port
SCR reader
Printer out
12V/2A OUT for
SCR reader
12V Fan1
12V Fan 2
12V Heater
Control Relay output
12V IN
16V IN
12V/20A OUT to 12-
12VDC converter
12V/20A OUT to
12-24VDC converter
24V OUT to
the printer
24V/10A IN from
12-24VDC converter
12V/2A IN from
12-12VDC converter
12V/2A OUT
Modem
JTAG
COM5 Processor Board
COMMS Board
UPS Motherboard
Battery On-Off
Switch

10.
SERVICING
Servicing
The COM5 PT1 is designed for trouble free operation if the following regular maintenance is
performed. Depending on the environmental conditions and usage of the site, maintenance may
be required more frequently than stated.
Regular Testing
For trouble free operation, the COM5 PT1 should be regularly tested by performing zero value
transactions with a known working card.
Swipe card and enter PIN number etc.
Lift pump nozzle and wait until the pump indicates that it is ready to dispense then return pump
nozzle without dispensing fuel.
Swipe card and check that a receipt prints out.
Perform this task weekly or more frequently if customers have trouble with the COM5 PT1
operation.
Card Reader
Card reader should be swiped through with a cleaner card wet with cleaner fluid. The card
reader may need to be cleaned daily on dirty, dusty, or wet sites.
PIN Pad
The PIN pad keys should be inspected and cleaned to keep the printing legible. A soft cloth
should be used. Do not use a cloth moistened with solvent or petrol as the keys may be
damaged.
Receipt Printer
Check for foreign matter in the receipt box. Any dust or dirt should be cleaned away with a clean
dry fine bristled brush. Perform this task weekly or more frequently in dusty or harsh
environments.
Ensure printer has sufficient paper. Remote sites should have a new roll installed at every visit.
If there is a local site contact, leave part rolls with them.

11.
SERVICING
Tools
Having all the correct tools will make installation, upgrade, and repair procedures easy and
minimise the risk of damage to components.
Before you arrive on site, make sure you have a minimum of all the tools listed here.
▪5.5mm nut driver
▪7mm nut driver
▪8mm nut driver
▪T30 Torx drive bit or driver
▪T10 Torx drive bit or driver
▪Metric spanner set
▪Metric 3/8" or 1/4" drive socket set
▪1/4" screwdriver bit holder
▪1/4" A/F spanner
▪6" adjustable spanner
▪Flat blade screwdriver set (1.5 - 5mm blades)
▪#0, #1, #2 Phillips screwdrivers
▪#1, #2 Pozidriv screwdrivers
▪Set of metric Allen (hex) keys
▪Fine long nose pliers, side cutters & pliers
▪Hacksaw
▪Stanley knife or similar sharp blade
▪Felt tip pen or marker
▪Glue - Loctite 601 or similar
▪Insulating tape and masking tape
▪Spray bottle of water and detergent
▪Ruler
▪Multimeter
▪Isopropyl alcohol wipes, cleaning spray and cloths, baby wipes for cleaning
▪Flat Precision screwdriver 0.23 x 1.5 mm tip
Biannual Service
▪Clean or replace the ventilation filter.
▪Check the ventilation fan runs smoothly and without abnormal noise.
▪Check the UPS by powering down the unit at the mains switch and timing how long
before the unit switches off. If the unit turns off in less than 20 minutes the battery may
need replacing.
▪Ensure the printer has sufficient paper.
Annual Service
▪Check the seals on the COM5 PT1 door are not damaged or worn and that the COM5
PT1 base is secure.

12.
SERVICING
Printer
Changing Paper
CAUTION
Use only Compac supplied thermal paper. If you do not use this paper, you may void the
warranty, damage the printer, and have receipt printing problems.
To change the paper:
▪Open the COM5 PT1 door.
▪Tear the paper and remove from printer.
▪Lift the paper roll and pull it off the paper roll holder.
▪Put a new roll into the paper roll holder.
▪Check the paper is feeding the correct way off the roll (when facing the printer, the end
of the paper is closest to you). Push the end of the paper into the slot at the back of the
printer. The printer will take the paper and feed it through the machine. (Make sure the
paper end is cut square or you may have problems.)
▪The paper will automatically feed into the printer.

13.
SERVICING
Clearing Jam
If the receipt paper is jammed, try to clear it using the following technique:
▪Lift the plastic lid on the top of the printer.
▪Pick out any loose or jammed paper.
▪Check the receipt chute is clear and undamaged.
▪Lower the plastic lid.
▪Feed the paper back into the machine and perform a test print.
If the printer roll appears wet or damaged, replace it.

14.
SERVICING
Removal
▪Isolate the COM5 PT1
▪Remove paper roll
▪Unplug the power and communication connectors from the back of the printer
▪Unscrew the nylok nuts that fasten the printer to the door and remove the printer
▪Taking note of the position and orientation of the paper roll support arm, undo the
retaining screws and remove
▪Unplug the paper low sensor from the printer
Replacement
▪Fasten the old paper roll arm onto the new printer in the same position as it was on the
old printer
▪Plug the paper low sensor into the printer
▪Fasten the new printer to the door
▪Plug the power and communication cables back into the printer
▪Replace the printer roll, repower the COM5 PT1 and do a test print
▪Perform a test transaction.

15.
SERVICING
Electronic Module Removal
To replace the power supply or for easier access to components, the electronic module can be
removed from the cabinet.
•Push the bottom latch toward the PT1 to fold the electronic module forward or
backward.
•Pull down the top hinge to remove the electronic module from the OPT.
CAUTION
Always take anti-static precautions when working with electronic components for example,
wearing a wristband with an earth strap.
NOTE: If the module is still functioning, contact the Technical Help Desk to ensure all data has
been retrieved before disconnecting.