Compac ComTank Assembly instructions

ComTank Unit Installation Sheet
Version 1.0.0

Product Identification
Manual Title
ComTank Unit Installation Sheet
Publication Date
Wednesday, 4 December 2013
Application
Compac ComTank
Power supply
230 - 240 VAC; 50 Hz; 1 Amp +/- 10%
Related Manuals
ComTank Pump Installation Sheet
C4000 Master Manual
CompacOnline User Guide (CompacOnline capable ComTank)
USB Key User Guide (USB equipped ComTank)
Master Installation Sheets
Validity
Compac Industries Limited reserves the right to revise or change
product specifications at any time. This publication describes the state
of the ComTank and related products 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 ComTank 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 ©2013 Compac Industries Limited, All Rights Reserved

Page 3
Contents
Product Identification ....................................................................................................................................................... ii
Document Control Information ........................................................................................................................................ 4
Introduction ....................................................................................................................................................................... 5
Safety ................................................................................................................................................................................. 6
Installation ......................................................................................................................................................................... 7
Tools Required .................................................................................................................................................................. 7
Pre-installation Checks..................................................................................................................................................... 8
Site Preparation................................................................................................................................................................. 8
Mounting Preparation ....................................................................................................................................................... 9
Electrical Preparation............................................................................................................................................. 10
Precautions if Using Generator Power.......................................................................................................................... 10
Electrical Connection...................................................................................................................................................... 11
Wiring Diagram –Control Unit ....................................................................................................................................... 12
Modem Connections ....................................................................................................................................................... 13
Powering up ........................................................................................................................................................... 14
Checking Pump Prices........................................................................................................................................... 14
Power on Tests................................................................................................................................................................ 15
Checking Authorisation Methods ........................................................................................................................... 15
Checking Card Reader .......................................................................................................................................... 15
Checking USB Module........................................................................................................................................... 15
Checking Transactions are Uploaded .................................................................................................................... 16
Finishing Up .................................................................................................................................................................... 16
Spare Parts ...................................................................................................................................................................... 16
Installation Checklist ...................................................................................................................................................... 17

Document Control Information
Compac Industries Ltd.
Page 4
www.compac.co.nz
Document Control Information
Document Information and Revision History
Document Details:
ComTank Installation Sheet
File Name and Location:
G:\Masters\Installation Sheets\ComTank Installation Sheet
Current Revision Author(s):
R Lacey
Authorised By:
Tim Mayson
Release Date: 04/11/2013
Version
Date
Author(s)
Revision Notes
Distribution
Name
Indicator
Location

Introduction
Compac Industries Ltd.
Page 5
www.compac.co.nz
Introduction
The Compac ComTank is a diesel fuel dispenser authorisation and reporting
device designed to be flush-fitted to a wall, fuel tank or in the side of a shipping
container. It is designed to be connected to Compac Master series pumps.
ComTank specific Master series pumps with remote displays and nozzle
holders are available to allow users to fully customise the location of
authorisation panel, pump display, hose outlet and nozzle holder to suit their
site requirements. Features include:
Effective solution for tanks and pumps that need to be securely locked
Ideal for portable installations
Control interface for Master mechanical components
Remote mountable nozzle holders
Commercial or Retail display, with the option of remote mountable
additional display
Single or Dual Hose
Choice of stainless steel panels (for corrosive situations) or gold
passivated mild steel
Authorisation Options
PIN pad
Electronic Tag (HID, iTrack or CWID - Compac Wireless Identifier- key
tag or nozzle tag)
Swipe card
Transaction Downloading Options
USB stick
CompacOnline
Tank Gauging Options
Veeder-Root
Fafnir
Vega
Franklin
Options may vary depending on application.
These installation instructions refer specifically to the ComTank
authorisation unit and related hardware. For detailed instructions on the
installation, setup and calibration of pumps and for the operation of the
authorisation and reporting systems, refer to their specific manual.

Safety
Compac Industries Ltd.
Page 6
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 on or near flammable goods areas take all
precautions to avoid sources of ignition.
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.

Installation
Compac Industries Ltd.
Page 7
www.compac.co.nz
Installation
You must be properly qualified, trained and authorised to install this
unit. Ensure you are qualified to perform each of the operations described.
Security
To help prevent unauthorised tampering, it is recommended that tamper resistant
fasteners be used and that all wiring outside the cabinet is enclosed.
Tools Required
Tools
It is expected that installers will carry a comprehensive tool kit including:
Metric and imperial spanners
Metric and imperial socket set
Metric and imperial allen keys
Torx and security torx keys
Phillips, pozidriv and flat blade screwdrivers
Power Tools
Electric drill (observe site safety protocols when using power tools)
Electrical Tools
Wire cutters
Wire stripper
Crimping tool
EPROM extractor
Multimeter
Earthing wrist strap
Diagnostic Equipment
Remote pump display to enable easier pump setup.
Laptop with fully charged battery and wireless modem
LAN cable
Fully charged cell phone
Test cards and/or authorisation keys
Safety Equipment
High visibility vest or jacket
Personal protective equipment (PPE) Boots, gloves, goggles, hearing
protection, hard hat etc.
Cones, barriers, tape to secure your working area
Other Equipment
Step ladder
Torch
Cable ties
Cleaning spray and clean cloths
The above list is a suggested minimum. It is recommended that you read the manual
thoroughly and include any other equipment that may assist you in completing the
job safely and quickly.

Pre-installation Checks
Compac Industries Ltd.
Page 8
www.compac.co.nz
Pre-installation Checks
Transit Damage
Once the unit is received on site, inspect the unit for the following:
Shipping damage to housing, display or any other equipment.
Water damage to components
Report any damage to the transport company and to the help desk.
Take photographs if required.
Tampering
Inspect for:
Evidence of tampering with the unit especially card reader or unauthorised
wiring.
Report any concerns to the help desk.
Take photographs if required.
Vibration
Inspect terminals, plugs and IC chips to check they are securely in place and have
not loosened due to vibration.
Site Issues
Check that all wiring and pipework has been installed correctly and is undamaged.
Report issues to site manager.
Inappropriate installation may void the warranty. If uncertain, contact
your Compac agent for advice.
Site Preparation
Refer to the Site Audit document if supplied.
To ensure maximum operating life, care should be taken when installing the
ComTank components. Considerations should include:
The card reader and PIN pad should face away from the prevailing wind
especially in dusty or wet areas.
In areas experiencing extremes of weather (heat, cold, wind, rain, salt spray
etc.) consideration should be given to installing additional shelter.
The rear of the displays and the electrical components must be protected from
dust, water or high humidity. Any protective surrounds that are constructed must
also allow for adequate cooling.
Inappropriate installation may void the warranty. If uncertain, contact
your Compac agent for advice.

Mounting Preparation
Compac Industries Ltd.
Page 9
www.compac.co.nz
Mounting Preparation
The ComTank unit needs to be mounted to a flat, steel plate prepared with a cut-out
and fastener holes as per drawing below. A steel template marked with the
appropriate dimensions is available as an option from Compac. Holes are drilled to
clear M6 (6 mm diameter) studs.
Ensure your mounting plate is thin enough to allow you to put the washers and nuts
on the end of the 20mm long studs.
The plate the ComTank is mounted on should be rust protected if it is not made from
stainless steel.
Ensure there is sufficient access to allow the installer and service people to
comfortably remove the cover from the rear of the unit and perform service work. A
minimum clearance of 850 mm is recommended.
Figure 1 ComTank Panel Cutout. Note: Do not cut to outer lines.
If installing ComTank pumps as part of the installation, refer to the ComTank Pump
Installation Sheet for pump, display and nozzle holder mounting instructions.

Precautions if Using Generator Power
Compac Industries Ltd.
Page 10
www.compac.co.nz
Electrical Preparation
The ComTank control unit requires its own wiring from the power supply. Power and
communication cables must meet or exceed local regulation requirements.
If no local regulations exist, we recommend as a minimum:
Power: 3 core 2.5 mm2Steel Wire Armour (SWA) cable
Comms (standard current loop): 2 core 1.5 mm2Steel Wire Armour (SWA) cable
The length of the communications cable must not exceed 100 metres.
Precautions if Using Generator Power
The power output from onsite generators can cause power spikes that may damage
electrical components within the cabinet. When connecting to sites powered by
generators, please take the following precautions:
Install a power conditioner. Although generators are fitted with power
regulators, most are not filtered sufficiently for powering sensitive electrical
components. We recommend installing a commercial power conditioner
and/or UPS between the generator and the unit.
Starting up. Before starting a generator, make sure the power to the unit is
turned off.
Start the generator, let the generator reach stable operating speed and wait
30 seconds before reconnecting the power to the unit.
For units where the generator starts and stops on demand, install a delay
timer or PLC to automatically isolate the unit until the operating speed and
consistent power output is achieved.
Isolate the unit before shutting down the generator.

Electrical Connection
Compac Industries Ltd.
Page 11
www.compac.co.nz
Electrical Connection
Cable requirements
ComTank control unit power: 3 Core Steel Wire Armour Cable 2.5mm2. 230 Volts,
10A, 50 Hz
Pump comms (standard current loop): 2 core Steel Wire Armour (SWA).
Pump comms (RS485): 3 core Steel Wire Armour (SWA).
230V Mains
Refer to the wiring diagram on page 12. Connect the incoming mains as follows:
All terminals marked “N” are common.
All terminals marked “P” are common.
Connect the Earth to the busbar at the bottom of the cabinet.
Pump Comms
Connect the pump comms cable(s) to the terminals on the DIN rail.
If pumps do not communicate on start up, swap the wires over.
Nozzle switches
The nozzle switch cable is pre-wired to the pump. Plug into the socket(s) on the
nozzle switch(es) making sure the correct cable is connected to the nozzle.. Coil
and neatly cable tie any excess cable out of the way.
Tank Gauging (option)
Tank gauging if fitted should be wired to the Tx, Rx and G terminals. If tank level
does not appear on your administration program after initial setup swap the Tx and
Rx wires.
All wires entering the unit should be glanded and secured to prevent
stressing the terminals.

Wiring Diagram
Compac Industries Ltd.
Page 12
www.compac.co.nz
Wiring Diagram

Modem Connections
Compac Industries Ltd.
Page 13
www.compac.co.nz
Modem Connections
Cellular Modem
The cellular modem (if fitted) is prewired and only requires a SIM card to be fitted.
To fit the SIM card
1. Depress the small yellow button on the top of the cell modem.
2. Remove the black plastic SIM card-holder.
3. Insert the SIM card.
4. Refit the SIM card holder.
There is a red diagnostic LED on the end of the Cell modem which
will initially be permanently on but will start to flash when the Cell Modem is
connected to the Network.

Powering up
Modem Connections
Compac Industries Ltd.
Page 14
www.compac.co.nz
Powering up
When all connections have been made and checked. Install the protective perspex
cover over the terminals.
Where regulations require, a registered electrician must check and
approve connections.
Connect power to the unit and turn on the circuit breaker.
Check that the PIN pad screen (if fitted) is illuminated and boots up.
If the unit is controlled via the internet, contact your help desk and confirm that the
unit is on line. Confirm the on-line pump pricing.
Checking Pump Prices
The following is a brief overview for technicians who are experienced in the
installation and setup of similar equipment. Specific instructions for each option are
either supplied or available from Compac.
The ComTank unit controls the pricing at the pumps. In most circumstances the
pricing information is sent to the unit either via a USB key or via the internet using
Netbase or CompacOnline.
Pricing via USB Module
Start up your laptop, insert the Compac USB key and open the Price file. Check the
price is correct. If not, change it and save.
Insert the key into the USB module, select Set Price and confirm.
Turn off the unit and the pumps, connect the pump communications wires and
repower.
Check that the pricing on each hose is correct.
Pricing via Internet
Confirm that the unit is on line and that the help desk has installed all updates.
Write down the on-line price(s).
Turn off the unit and the pumps, connect the pump communications wires and
repower.
Check that the price on each hose matches the on-line price.

Power on Tests
Checking Authorisation Methods
Compac Industries Ltd.
Page 15
www.compac.co.nz
Power on Tests
Depending on the setup of the unit, you will need to perform a number of tests.
Checking Authorisation Methods
Units can be authorised in a wide variety of ways:
No authorisation required. Unit just records transactions.
PIN pad authorisation. Customer enters a PIN number and/or odometer reading
to authorise pumps.
Fuel card authorisation. Customer swipes their issued fuel card. A PIN number
and/or odometer reading may or may not be requested.
Credit card authorisation. Customer swipes credit card to authorise pumps.
HID or CWID key authorisation. Customer passes a coded RFI key in front of a
reader.
CWID nozzle authorisation. A CWID key is attached to the vehicle filler and a
reader is attached to the pump nozzle. Inserting the nozzle into the filler
authorises the pump.
iTrack reader authorisation. A unit attached to the vehicle authorises the pumps
as it pulls into the forecourt.
All authorisation methods set up on the unit will need to be tested.
Checking Card Reader
Check the card reader to see if it reads approved cards.
Swipe a test card and check that a transaction can be made. The card is inserted
with the stripe to the top and on the right hand side.
Do this for all types of approved cards.
Checking USB Module
The USB module allows downloading of pricing updates and authorised card
numbers and uploading of transactions.
Perform a test transaction and print a receipt for each hose.
Insert the Compac Supplied USB key into the reader.
At the prompt, choose Get Transactions.
Wait while the transactions are uploaded then remove key.
Insert the Key into your laptop, open the Transactions folder and see if you can see
the recorded transactions.
Check that the receipt information matches the transaction information.

Checking Transactions are Uploaded
Finishing Up
Compac Industries Ltd.
Page 16
www.compac.co.nz
Checking Transactions are Uploaded
Contact the your Netbase or CompacOnline administrator and check that your test
transactions and any customer transactions that have taken place have been
recorded correctly on Netbase or CompacOnline.
For USB equipped units, download your test transactions and check that the
information recorded matches the information on the receipts.
Finishing Up
When you are confident the site is trading correctly, complete the installation
checklist.
If you do not have one, a copy is attached at the end of these instructions.
Fax the installation sheet to Compac as soon as you can.
Replace and fasten the cover on the back of the ComTank unit and any pump
covers that may have been removed.
Remove all tools, clean the unit, pick up all debris and tidy the surrounding area.
Remove any barriers or cones.
Contact help desk and tell them that you are about to leave the site.
Spare Parts
Order spare parts from your Compac agent. You must quote the model and serial
number of the unit.

Installation Checklist
Checking Transactions are Uploaded
Compac Industries Ltd.
Page 17
www.compac.co.nz
Installation Checklist
Version 1.0.0.
ComTank.
Site number and name:
Date:
Installer name and phone number:
Serial number:
When a new unit is being installed use the following checklist to make sure the unit is fully operational. Check each box
or write N/A where not applicable. Refer to the relevant installation manual for procedures.
Mechanical
Checks
Yes
No
Check unit is undamaged and has not been tampered with.
Is the unit in a sheltered position and facing away from the prevailing wind and rain?
Check all panels are securely fastened using tamper-proof fastenings where
supplied.
Check that all cable entries to unit are through glands and unused glands are
sealed.
Power on
Checks
Yes
No
Check that the CE board, FMS board, pinpad, printer, cardreader, router and
modem all power up.
Check pumps are re-priced to the current fuel price.
Check that different fuels are correctly priced on all hoses.
Transaction
Checks
Yes
No
Complete transaction using white card/CWID/HID/Pin authorisation methods
Check that all hoses can be selected and authorised by the unit.
USB Module
Checks (where
fitted)
Yes
No
Check the supplied USB key is recognised by the unit.
Select "Get Transactions" and check that transactions are uploaded to the USB key.

Checking Transactions are Uploaded
Installation Checklist
Compac Industries Ltd.
Page 18
www.compac.co.nz
CompacOnline
Checks (when
connected)
Yes
No
Check the site appears on CompacOnline.
Check that transactions have been recorded on CompacOnline.
Tank Gauging
Checks (where
fitted)
Yes
No
Check that tanks are set up in CompacOnline and that correct levels are being
reported.
Check that the correct products are assigned to the correct tanks.
Customer
Training
Yes
No
Check site attendants understand refuelling procedures.
Check that site administrators understand how to obtain transactions and administer
cards.
Final Checks
Yes
No
Ensure all cables are plugged back in after remote accessing.
Tidy up all rubbish and clean the exterior of the unit before leaving.
If one or more of these tests fail, contact the Compac help desk or your service centre so the
problem can be logged and parts issued if required.
Notes
To validate warranty and receive future help desk
assistance please fax both sides of this form to:+64 9
579 0635 or post to: Compac Industries Ltd, PO Box 12
417 Penrose, Auckland 1642, New Zealand.
Report any damage immediately to Compac Industries on:
[phone]. Any site safety issues should be reported
immediately to the site manager.