Compac Master Manual

Compac Industries Ltd.
52 Walls Road. Penrose. Auckland 1061. New Zealand.
PO Box 12 417. Penrose. Auckland 1642. New Zealand.
Tel: [phone] Fax: [phone] [email protected]
www.compac.co.nz
Installation and Setup
Instructions
Model: Master
Version: MR160P
Date of issue: 27 January 2015

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Contents
Contents ........................................................................................................................................2
1. Conditions of use ....................................................................................................................3
2. Footprint ...............................................................................................................................4
2.1 Optional Flexi Coupling ....................................................................................................5
3. Static Electricity Precautions .....................................................................................................5
4. Pre-installation Check .............................................................................................................5
5. Installation ..........................................................................................................................5
6. Comms Dip-switch settings ......................................................................................................7
6.1 Standard Pump Comms Setting.........................................................................................7
6.2 Gilbarco Pump comms Setting ..........................................................................................7
7. Triac Dip-switches ..................................................................................................................7
8. Electrical Connections..............................................................................................................8
9. Dispensing Hoses and Nozzles...................................................................................................9
9.1 Breakaways ..................................................................................................................9
10. Setting up the C4000 ..........................................................................................................9
10.1 Configuration Codes........................................................................................................9
10.2 Parameter Switch Settings ...............................................................................................9
10.3 K-Factor Switch Settings .............................................................................................. 11
11. Calibration (K-Factor)........................................................................................................ 12
11.1 Setting the K-Factor..................................................................................................... 12
11.2 Sealing the K-Factor switch........................................................................................... 12
11.3 Standalone Operation................................................................................................... 13
12. Pump Controller .............................................................................................................. 13
13. Spare Fuses ................................................................................................................... 13
14. Precautions if Using Generator Power .................................................................................. 13
15. Error Messages ............................................................................................................... 14
16. MR160P Spare Parts ........................................................................................................ 15
17. Product Details................................................................................................................ 16
18. Contact Details................................................................................................................ 16
19. Notes ............................................................................................................................ 16
20. Revision History............................................................................................................... 17

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1. 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.

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2. Footprint
Outlet size: 1 ¼” BSP female socket.
Outlet is approximately 680mm above the base.

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2.1 Optional Flexi Coupling
3. Static Electricity Precautions
Electronic components used are sensitive to static. Please take anti-static precautions.
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.
Note: Compac Industries Limited reserves the right to refuse to accept any circuit boards
returned, if proper anti-static precautions have not been taken.
4. Pre-installation Check
Once the pump is received on site, check that no damage has occurred while in transit –in
particular, damage to electronics due to vibration or jarring. All terminals and plugs should be
checked, including IC chips, to ensure they are securely in place.
5. Installation
Installation should be in accordance with local regulations.
To obtain maximum flow on a self contained pump, observe the following guidelines:
1. Pumps must not be subject to any head pressure. Design your installation to eliminate any
possibility of this occurring.
2. Total length of horizontal piping between tank and pump should be no longer than 18
metres. Use galvanised steel or approved non-metallic pipe and fittings.
3. The unit contains two pumps each with an 1 ½” flanged inlet. It is recommended that each
inlet is supplied from the tank by a separate 2” pipe. If using a single supply pipe and a tee
joint, ensure that the size of the pipe and tee joint will be sufficient to provide adequate flow
otherwise pump performance will suffer. If a tee joint is used, check valves must be
installed before each pump inlet.
Note: Ensure you remove the bung from the pump inlet before connecting the pipe.
4. Pipe must slope up from the tank to the pump (approximately 15 mm per metre). Pipe
should be straight and supported along its length.
5. All horizontal piping must be buried at least 450mm below ground level.
6. The area under the pumping unit(s) must be filled with sand or dirt as far up the suction line
as possible. Use water to pack the sand or dirt when put in place.

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7. Avoid asphalt drive surfaces covering the piping. Asphalt increases heat absorption causing
vapour lock.
8. Static lift must not exceed 3 metres (vertical distance from the product level in the tank to
the centre of the pump unit).
9. To absorb ground movement from settling of the tank, frost heaving of the ground or pump
island settling, a swing joint must be used in the supply line at the tank and directly
underneath the dispenser. Three additional directional changes using elbows are permitted.
10. Piping must hold a 3.4 Bar (50PSI) pressure test for a minimum of 10 minutes.
11. It is recommended that a vertical, in-line check valve be installed underneath the pump.
12. The dispensing equipment shall be installed to prevent the delivery hose from contacting the
ground when not in use.
13. A Check Valve must be installed at the tank end of the suction pipe on the top of the tank in
a serviceable location. Many clients install an extra check valve at the inlet to the pump. It
is important neither of the check valves interfere with the flow of fuel. They must be
adequately sized
Refer to the footprint drawings for pump installation details.
Where local regulations require a sump to be fitted:
a. Sumps must be provided at all dispenser installations with secondary containment pipework
and at all new installations; and
b. at all sites with sumps, dispensers should be installed with a liquid level detection device
fitted in the sump that will raise an alarm if liquid is detected in the base of the sump.
The pump inlet must not be pressurised at any time. This will cause fuel to flow
from the air eliminator. Unregulated connection to an above ground tank will cause
pressurisation.
For above ground tanks a regulator valve such as a Tokheim valve or similar
device MUST be used so that the inlet of the pump cannot become pressurised at any time.
The air switch is not to be disconnected. Disconnection will void NSC and TMU
approvals.

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6. Comms Dip-switch settings
6.1 Standard Pump Comms Setting
(Dipswitch SW3)
1-ON
2-OFF
3-ON
4-OFF
These are factory set to the standard setting unless ordered otherwise.eg Gilbarco.
6.2 Gilbarco Pump comms Setting
(Special software and interface board required)
1-OFF
2-ON
3-OFF
4-ON
7. Triac Dip-switches
Important note:
Great care should be taken not to accidentally change the setting of these switches while
working in the Flame-proof box. Operating the unit with these incorrectly set can result in
damage to the C4000 Power Supply or incorrect operation of the triacs.
These switches are set in the factory and should not be changed.
If they are accidentally changed these are the correct settings for Master / Premier Pump
applications.Note: They are 3 position switches
Pump (Motor triac fitted)
SW1
1
SW2
1
SW4
Centre

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8. Electrical Connections
Prior to pump installation ensure that there is at least a two-metre tail on both the incoming
underground mains supply cable and comms cable (if comms enabled). These cables are
terminated at the C4000 power supply, which is housed in the flameproof enclosure located in
the bottom of the pump, behind the door.
Mains power wiring should be rated for a maximum current draw of 10 A rms at 220-240 V ac.
The incoming cables are terminated as shown in the following picture.
Refer to AS/NZS 60079.14 for appropriate cabling.
Note: All cables entering the power supply must be glanded with approved 20mm flameproof
glands.
Note: Comms cable is not intrinsically safe.
Note: Pump comm’s connect to pump controller such as DCA, Communicator Controller etc.
(option).
When replacing the lid of the flameproof enclosure, ensure the sealing O ring is in place.
Neutral
Phase
Earth
+ ve
- ve
COMMS
INCOMING MAINS

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9. Dispensing Hoses and Nozzles
The unit may or may not be supplied with dispensing hose and nozzle assemblies.
If customer supplied hose assemblies, pylons, reels, safe breaks and nozzles are used they must
comply with the requirements outlined in AS/NZS 2229.
9.1 Breakaways
For all dispensers fitted with breakaways, ensure the breakaway is installed between the nozzle
and the high-mast or pylon (if fitted). Any breakaways that have been subject to a break-away
situation should be inspected and refitted or replaced in accordance with the original
manufacturer’s instructions.
10. Setting up the C4000
Once the pump is connected on site, the final setup check and calibration to complete the
installation must be carried out, using the Parameter Switch and Calibration (K-Factor) Switch.
These switches are found on the C4000 Microprocessor Board which is housed in a metal
enclosure located on the left front of the unit below the display panel
10.1 Configuration Codes
The configuration code has been set at Compac and should not be changed
In the event of it being lost and having to be re-entered the configuration is written on the yellow
label on the C4000 processor board cover
10.2 Parameter Switch Settings
10.2.1 Setting the Pump Number
This must be set at the pump, for each hose, so that communications with
a controller can take place. The location of this switch is shown in the
diagram below.
Depress the Parameter Switch nine (9) or more times until the message
'PnA XX' appears in the litres display window. When the switch is
pressed again 'Pnb XX ' will appear on the display. These two options
will toggle each time the switch is pressed. To alter either of the pump numbers, press and hold
the Parameter Switch when the pump number to be altered appears on the display. This number
will then increment. The switch should be released when the desired pump number is displayed.
The value of the displayed number will then be stored in the C4000 memory as the pump
number for that hose.
NOTE: For a single hose only ‘Pn” will appear

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10.2.2 Setting the Price
Using the Parameter Switch, follow the chart to set the price for the hose(s) in question.
Step
ACTION
RESULT
1
Ensure that the nozzle is hung up
Dispenser in idle state
2
Press and Hold the Parameter switch until the
“Price per litre” is displayed.
The price for side ‘A’ is shown as ‘PX.XXX’ on the
litres display and ‘PrA’ is displayed on the money
display.
3
Press and hold the Parameter switch.
A digit, of the displayed ‘Price per litre’, will begin to
increment.
4
When the digit is correct, release the Parameter
switch.
5
Repeat steps 3 and 4 for each digit of the ‘Price per
litre’.
NOTE: the C4000 will reset itself if the Parameter
switch is left for more than 60 seconds.
Continue for Dual hose units
6
Press and release the Parameter switch 8 or more
times in quick succession
The price for side ‘B’ is shown as ‘PX.XXX’ on the
litres display and ‘Prb’ is displayed on the money
display.
7
Repeat steps 3 to 5 above.

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10.3 K-Factor Switch Settings
K-Factor, and other various configuration settings, are set via this switch. The position of the K-
Factor switch is shown in the diagram below:
J1: Comms Test
J7: Displays
J13: Not used
J2: To Power Supply
J8: Temperature (for
Temperature
compensation only)
J14: Not used
J3 : Input from KG Meter
Side A
J 9 Power for KG Meters
J15: Not used
J4: Input from KG Meter
Side B
J10: Totes
J16: Not used
J5 : Not Used
J11: Buzzer
J17 Backlighting
J6 Not used
J12 Nozzle Switches
Parameter
Switch
K Factor
Switch
Parameter
Switch
K factor
Switch

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11. Calibration (K-Factor)
11.1 Setting the K-Factor
K-Factor is a proportional calibration factor of litres dispensed per revolution of the meter.
To calibrate the dispenser/pump, dispense fuel into a certified measuring container, and
compare the display value with the amount dispensed.
Example:
Display shows 10.00
True volume 20.00
To calculate the correct 'K' Factor from the information above; firstly record the existing
'K' Factor.
2FactorK''Existing
10.00
20.00
FactorK''Existing
AmountDisplayed
AmountDispensed
FactorK''ExistingFactorK''New



Change the existing 'K' Factor to this new value.
11.2 Sealing the K-Factor switch
After calibration the K-factor switch should be sealed as shown

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11.3 Standalone Operation
In standalone operation, the dispenser will continue working when not connected to a controller.
'Stand-alone' mode being when no authorisation of fills is required and so fills are simply
initiated by removing the refuelling assembly from its holder. If standalone operation is inhibited,
the dispenser will not work in 'stand-alone' mode, regardless of whether the dispenser is ON
LINE to a controller or not.
The dispenser ceases to work in 'stand-alone' mode if connected to a controller, regardless of
the position of standalone setting.
Generally on retail forecourts the dispenser should be set-up for standalone operation. Hence, if
the forecourt controller breaks down the dispensers can be set to work in 'stand-alone' mode
simply by turning them off then on again.
For unattended refuelling sites, the dispensers should not be able to work in 'stand-alone' mode
in the event of a controller failure. Therefore the dispenser should be set-up to inhibit
standalone operation.
This is set in the 'b' code on the K factor switch.
The 'b' code to run Standalone without Dispenser Controller is ‘0000’.
The 'b' code to inhibit Standalone is ‘1000’.
12. Pump Controller
If the pump is connected to a controller, check that pump data and transaction information is
being correctly uploaded to it. Refer to the controller manual for specific instructions regarding
connection and setup.
13. Spare Fuses
In the event of a fuse blowing on the C4000 Power supply a bag of 3 is included in each
flameproof box. Any fuses used from this bag should be replaced
Note: There are three different ratings used. If replacing a fuse, ensure that the correct value is
used.
14. 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:
1) 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.
2) 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.
3) 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.
4) Isolate the unit before shutting down the generator.

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15. Error Messages
Error Code
Fault
Action
Err 3
No price or pump number set.
Set the pump number or:
Set a price at the pump or at
the controller.
Err 7
Excess flow.
Max Flowrate exceeded
Err 8
Excess reverse rotation of encoder.
Check product is not flowing
back into the tank once the
delivery has finished.
Err 9
Faulty or disconnected meter encoder.
1. Check that encoder is
plugged in.
2. Replace encoder PCB on
meter
Err 10
Configuration Lost
Reconfigure C4000 refer to
C4000 manual
Err 12
C4000 memory failure.
Change memory IC.
F-AD-DS1225 (not applicable
to Futra)
Ped
Abd
Display error
1. Check display cable for
loose wires/crimps
2. Replace display PCB

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16. MR160P Spare Parts
Commercial display as shown
(includes backlighting)
F-CP-DISPLAY-CMH
Retail display not shown (includes
backlighting)
F-CP-DISPLAY-GD1H
Tote
F-BA-TOTE-A-K
Nozzle holder
F-NOZL-HLDR-M5SR
C4000 microprocessor board
F-CP-C4PROCES-A
COM125 meter (complete)
F-METER-COM125-K
COM125 meter (electronics only)
F-METER-125/250E
Electric motor
F-MOTOR-230-550W
Pump unit
F-PUMP-ZYB-50
(incl inlet and outlet gaskets)
C4000 power supply
(does not include box)
F-CP-C4PWR-ASSEM
Motor triac
F-AT-BTA40-RD91
Also not shown
Track 2 cardreader
F-BA-CARD-T2C4M
Preset (Fascia c/w keypad
and interface PCB)
F-FAS-PSET-MEM

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17. Product Details
Fill in the product details and service agent contact details. Use this information when contacting
service agent or help desk.
Model number
Serial number
Date of manufacture
Date of installation
Software version
Equipment connected to the unit
Phone number (if dial in site)
Merchant ID number (Eftpos site)
18. Contact Details
Service Agent
Phone
E-mail
Address 1
Address 2
19. Notes
Manufacturer Contact
Details
The Compac Master Dispenser 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 ©2015 Compac Industries Limited, All Rights
Reserved
Contact your service agent in the first instance for any installation issues.

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20. Revision History
Previous revision date
Summary of changes
22 May 2009
25 May 2010
Added contact details and revision history, updated spare parts
11 Nov 2010
Added tank and pipe information
16 June 2011
Added text “The dispensing equipment shall be installed to prevent
the delivery hose from contacting the ground when not in use.”
06 June 2012
Added Conditions of Use and Installation info.
06 June 2012
Amended Installation Instructions. Generator power, breakaway info.
12 June 2013
Updated wiring information. Added controller information.
5 September 2013
Added sump info in accordance with EPA. File ref. COM 09 29
Added flange and flexi coupling detail.
27 August 2014
Added front page footer, added outlet size.
13 September 2014
Added outlet height dimension