Compac Master MMR400S Aviation 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: MMR400S Aviation
Date of issue: 13 November 2014

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Contents
1. Conditions of use ....................................................................................................................3
2. Footprint ...............................................................................................................................4
3. Static Electricity Precautions .....................................................................................................5
4. Pre-installation Check .............................................................................................................5
5. Installation ..........................................................................................................................5
6. Comms Dip-switch settings ......................................................................................................5
6.1 Standard Pump Comms Setting.........................................................................................5
6.2 Gilbarco Pump comms Setting ..........................................................................................5
7. Triac Dip-switches ..................................................................................................................6
8. Electrical Connections..............................................................................................................7
8.1 Submersible Pump connections ........................................................................................7
9. Dispensing Hoses and Nozzles...................................................................................................8
9.1 Breakaways ..................................................................................................................8
10. Electrical Commissioning C4000............................................................................................8
11.Mechanical Commissioning and Air Purge ...............................................................................9
12. Setting up the C4000 ..........................................................................................................9
12.1 Configuration Codes........................................................................................................9
12.2 Submersible Delay (Sd) ................................................................................................ 10
12.3 Preset Cutoff (Pcut)...................................................................................................... 10
12.4 Parameter Switch settings ............................................................................................ 10
13. K-Factor Switch Settings................................................................................................... 12
14. Calibration (K-Factor)........................................................................................................ 13
14.1 Setting the K-Factor..................................................................................................... 13
14.2 Sealing the K-Factor switch........................................................................................... 13
14.3 Standalone Operation................................................................................................... 14
15. Pump Controller .............................................................................................................. 14
16. Spare Fuses ................................................................................................................... 14
17. Precautions if Using Generator Power .................................................................................. 14
18. Error Messages ............................................................................................................... 15
19. MMR400S Aviation Spare Parts .......................................................................................... 16
20. Product Details................................................................................................................ 17
21. Contact Details................................................................................................................ 17
22. Notes ............................................................................................................................ 17
23. Revision History............................................................................................................... 18

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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

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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.
The dispensing equipment shall be installed to prevent the delivery hose from contacting the
ground when not in use.
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.
Important Note: Compac M400 series high flow dispensers do not have an internal filtering
system fitted at the factory. It is the customer and/or installers responsibility to ensure the fuel
supplied to the dispenser is clean and free from any dirt, debris or metal particles that could
damage the meter or hydraulic components. A 10 micron filter is recommended. Compac does
not warranty the meter or hydraulic components for damage caused by contaminated fuel
supply.
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

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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 solenoid.
These switches are set in the factory and should not be changed.
If they are accidentally changed these are the correct settings for Master Dispenser
applications.Note: They are 3 position switches
Dispenser (low current output)
SW1
2
SW2
2
SW4
2

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8. Electrical Connections
Prior to pump installation ensure that there is at least a two-metre tail on the incoming
underground mains supply / pump contactor 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.
Refer to AS/NZS 60079.14 for appropriate cabling.
When replacing the lid of the flameproof enclosure, ensure the sealing O ring is in place.
Note: All cables entering the power supply must be glanded with approved 20mm flameproof
glands.
Note: Output to submersible pump(s) is 230 V ac, 300 mA max. It is wired to the pump
contactor/relay at the switchboard and not directly to the pump.
Note: Pump comm’s connect to pump controller such as DCA, CommunicatorController etc.
(option). Comms cable is not intrinsically safe.
8.1 Submersible Pump connections
Connect the feeds to the submersible pump relays / contactors to the C4000 Power Supply as
follows:
Pump supplying side A to terminal marked T1
Pump supplying side B to terminal marked T4 (not used on single hose dispensers)
If both sides are required to switch the same submersible pump then T1 and T4 should be linked
together.
Note: Dispensers do not use the terminals marked LOAD 1 & 2.

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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 222.
9.1 Breakaways
Any breakaway couplings 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. Electrical Commissioning C4000
Before beginning this test, check that fuel has not been applied to the dispenser. The factory
set-up information should have been programmed into the dispenser but all K-factor and
Parameter switch settings should be checked and confirmed before commissioning tests are
carried out.
Make sure that the inlet shut-off valves are closed (these are the valves in the inlet lines at the
base of the dispenser, but they are not part of the dispenser).
1. Turn on the power supply to the dispenser.
2. With the dispenser in a ready state, check that the C4000 Microprocessor Power LED (D1) is
turned on.
If the dispenser is receiving information, Comms RXD LED (D6) will poll. If the
dispenser responds to polls for its respective pump number/s, Comms TXD LED (D7) will also
poll.
Diagnostic LED (D18) slowly flashing. (If the dispenser is connected to an operational
Controller, it flashes slowly but erratically. If the dispenser is not connected to a
Controller, it flashes slowly and consistently.)
Watchdog LED (D5) is turned off
3. Turn side A switch to ON.
The display will show 888888 and the solenoids will energise, starting the pump motor.
Check that Diodes D8, D10 and D11 turn on, indicating a signal is being sent to the triacs to
open the solenoid valves.
The diagnostic LED (D18) flashes quickly when the start button is pushed or the nozzle
removed from the holster to initiate a fill. When the button is released or nozzle returned to
the holster it will return to the normal state and flash slowly.
4. Verify solenoid operation by listening for a click, or by using a screwdriver tip or some other
metallic tool to check for a magnetic field present on the solenoid coils.
5. The solenoids will switch off after four minutes. This is a default time-out setting in the
software for situations when there is no fuel flow registered. If there is air in the system, the
display may show an error code.
6. Turn switch to OFF
7. Repeat the operation for both hoses.
8. To clear the error code, re-power the dispenser and then move on to the Mechanical
Commissioning and Air Purge of the dispenser.

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11. Mechanical Commissioning and Air Purge
This procedure outlines how to perform a mechanical operational test and making sure that the
dispenser is functioning correctly. Before testing the unit, check for any damage that may have
occurred in transit. Check all terminals, plugs, and chips to make sure that they are securely in
place.
To test the unit please carry out the following tests:
1. Make sure that the electrical commissioning tests have been carried out and the solenoid
operation has been verified before carrying out the following tests.
2. Slowly open the fuel supply valves to the dispenser, checking for any leaks.
3. Turn on the power supply to the dispenser.
4. Turn side A switch to ON.
5. The display will show 888888 and the solenoids will energise, starting the pump motor and
pressurising the system. Check that Diodes D8, D10 and D11 turn on, indicating a signal is
being sent to the triacs to open the solenoid valves
6. Check all the dispenser fittings, solenoids and pipework for leaks.
7. Turn side A switch off and connect the hose to a suitable tank or container. Turn side A
switch on again.
8. The display and tote should increment when fuel is flowing.
9. Tuen switch off and repeat operation for side B.
10. The dispenser can now be calibrated. Refer to the C4000 Master Manual for calibration
instructions.
12. 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
The Submersible delay and Pcut (Preset Cutoff) both may need to be adjusted on site as follows.
These are found on the K factor switch.
12.1 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
Note: A special configuration code (07071) is required so that the preset amount is in litres
instead of dollars

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12.2 Submersible Delay (Sd)
This is the time delay from when the Submersible pump starts to when the solenoids in the
dispenser open to allow time for the leak detector to reset.
This is factory set by Compac at 005 (five seconds).
If problems are experienced with the leak detector tripping, firstly check that 'Sd' is still set and
then, if necessary, make it longer as follows.
1. Press and release the K factor switch repeatedly until 'Sd' appears on the Dollar display
'dXXX' will appear in the litres display.
2. Continue to press the K factor switch until the number to be changed flashes. Hold the switch
down and this number will then increment.
3. Release the switch when the required number is displayed. The value of the displayed number
will then be stored in the C4000 memory as the Submersible delay.
12.3 Preset Cutoff (Pcut)
If a preset keypad is fitted, it may be necessary to adjust the Pcut setting on site if the preset
overruns. The Pcut setting turns the solenoid output (T3) off prior to the preset amount being
reached to allow for preset overruns.
1. Do a preset delivery and observe if the preset overruns, and if so, by how much.
2. Press and release the K factor switch repeatedly until 'Pcut' appears on the Dollar display
3. Increase the Pcut setting and do another delivery. Adjust the Pcut setting again if required.
(The maximum value that the Pcut can be set to is 9.99 litres).
Notes:
1. The factory default setting is 0.00. When the Pcut is set to 0.00, the solenoid output (T3)
turns off 0.5 litre before the preset amount, when changed from this, the solenoid turns off
at the actual Pcut setting (x.xx litres).
2. Due to the high flow rate, it may not be possible to make the Pcut amount large enough to
eliminate any preset overruns completely.
.
12.4 Parameter Switch settings
12.4.1 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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12.4.2 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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13. 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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14. Calibration (K-Factor)
14.1 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.
14.2 Sealing the K-Factor switch
After calibration the K-factor switch should be sealed as shown

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14.3 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’.
15. 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.
16. 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.
17. 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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18. 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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19. MMR400S Aviation Spare Parts
Commercial display
(includes
backlighting)
F-CP-DISPLAY-CMH
Tote
F-BA-TOTE-A-K
C4000 microprocessor board
F-CP-C4PROCES-A
COM250 meter
(complete)
F-METER-COM250AS
COM250 Flowmeter
(electronics)
F-METER-125/250E
ACV Valve
P-VALVE-ACV-2
Solenoid Coil
F-D-SCI08COIL10W
C4000 Power Supply
(does not include box)
F-CP-C4PWR-ASSEM
Track 2 cardreader (option)
F-BA-CARD-T2C4M
PINPad (option) (Fascia c/w
keypad only)
F-CU-PINPAD-FAS
Always quote model and serial number when ordering spare parts.

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20. 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)
21. Contact Details
Service Agent
Phone
E-mail
Address 1
Address 2
22. 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 ©2014 Compac Industries Limited, All Rights
Reserved
Contact your service agent in the first instance for any installation issues.

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23. Revision History
Previous revision date
Summary of changes
New document 26/06/14
Added sump info in accordance with EPA. File ref. COM 09 29
Added Electrical and Mechanical Commissioning procedures
27 August 2014
Updated cover page footer