OPT SERVICE MANUAL OPT Service Manual Version 1.0.0 Model: OPT Mark 2 SCR200 Date: 14 July 2017 Conditions of Use CONDITIONS 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 C4000 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 C4000 processor, or damages resulting from the inability to use the Compac C4000 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 C4000 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 C4000 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 nonapproved 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 C4000 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 C4000 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. Specifications Manual Title OPT Service Manual Original Publication Date July 2017 This manual pertains to the OPT Mark 2 SCR200. Models Covered 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 OPT 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 2. SAFETY Product Identification INFORMATION Document Control Information Document Information Document Details OPT Service Manual File Name and Location G:\Masters\Installation Sheets\OPT Current Revision Author(s) H Kleyer Authorised By Wendy Zheng Release Date: 14/07/2017 Revision History Version 1.0.0 Date Author(s) Revision Notes H Kleyer New manual 3. Contents Product Identification .......................................................................................... 2 Document Control Information ............................................................................ 3 Contents ............................................................................................................... 4 Safety ................................................................................................................... 6 Electrical Safety ........................................................................................ 7 240 Volt............................................................................................ 7 12 Volt.............................................................................................. 8 Power Supply ................................................................................... 8 Security ................................................................................................................ 9 Introduction........................................................................................................ 10 Operation ............................................................................................................ 11 Downloading OPT transaction data ........................................................ 11 Components ............................................................................................ 12 OPT Housing Layout ................................................................................ 13 Electronic Module Layout ....................................................................... 14 Servicing ............................................................................................................ 15 Tools ........................................................................................................ 16 Biannual Service ..................................................................................... 16 Annual Service ........................................................................................ 16 Printer ...................................................................................................... 17 Changing Paper .............................................................................. 17 Clearing Jam .................................................................................. 18 Replacement .................................................................................. 19 Electronic Module ................................................................................... 20 Removal ......................................................................................... 20 Power Supply .......................................................................................... 22 Replacement .................................................................................. 22 UPS Board................................................................................................ 23 Replacement .................................................................................. 23 Connections ................................................................................... 25 Power Loss .............................................................................................. 26 Battery ..................................................................................................... 27 Replacement .................................................................................. 27 MX Box .................................................................................................... 29 Replacement .................................................................................. 29 FMS Board ............................................................................................... 30 Replacement .................................................................................. 30 Connections ................................................................................... 32 Lantronix Board....................................................................................... 33 Replacement .................................................................................. 33 PIN Pad .................................................................................................... 34 Replacement .................................................................................. 34 Card Reader ............................................................................................. 35 Replacement .................................................................................. 35 4. SAFETY Conditions of Use ................................................................................................. 1 INFORMATION VoIP (Voice Over Internet Protocol) ........................................................ 36 VoIP Board Replacement................................................................. 37 Fan & Filter .............................................................................................. 38 Filter Replacement ......................................................................... 38 Fan Replacement............................................................................ 38 Software Upgrade Procedure ................................................................. 39 Troubleshooting ................................................................................................. 40 5. You must adhere to the following safety precautions at all times when working on the Compac OPT. Failure to observe these safety precautions could result in damage to the OPT, injury, or death. Make sure that you read and understand all safety precautions before installing, servicing or operating the Compac OPT. 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. 6. SAFETY Safety Electrical Safety CAUTION SAFETY Always turn off the power to the OPT 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 OPT using the UPS switch and 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. 240 Volt The OPT 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 12 volt DC to power the main electronic components. Technicians should be able to safely operate and diagnose an OPT with the cabinet door open as long as 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 OPT providing isolation is tested. The DIN rail holds both 240 volt components and 5 Volt communications connectors. 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 cabined 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). 7. The OPT runs on 12 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 switch on the UPS board or turn off the mains power and unplug the battery lead CON3 before working on any electronic components. CAUTION When removing the battery, take care not to short the positive terminal on the chassis of the OPT. Make sure the positive terminal is insulated before installing the battery. Power Supply The power supply converts the 230 Volt AC power to 12 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. 8. SAFETY 12 Volt Security SECURITY All users, technicians and help desk staff must be aware of the security implications involved with their operation of an OPT. The following is a list of guidelines that should be considered as a minimum for secure operation of an OPT 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 OPT or the card reader appears to have been tampered with do not use the OPT 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 OPT for signs of tampering and report if anything noticed. Keep the keys to the OPT 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 OPT 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. 9. The Online Payment Terminal (OPT) 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 OPT can accept multiple card bases simultaneously through Compac's EFTPOS partner, Direct Payment Solutions (DPS). The OPT 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, E-mail, Avery-Hardoll and FQ protocol pumps. Tank levels can be monitored with Veeder-root, Fafnir and Franklin tank gauges. The OPT is designed to AS/NZS 3100 wiring standards. Store and Forward (Offline) card control can be used to enable local account cards and network fuel cards that do not have an online interface. 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 OPT 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 Mains Power Loss 10. INTRODUCTION Introduction Operation OPERATION Following the instructions displayed on the OPT, the user inserts and removes their card. The OPT 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 OPT 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 OPT 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. 11. 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 OPT housing to be easily bolted on and electrically wired. OPT 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 OPT 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 using internet phone (VoIP) to a Help Desk assistant. 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 either an integrated guillotine or tear-off 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. 12. OPERATION Components OPT Housing Layout OPERATION 13. OPERATION Electronic Module Layout 14. Servicing SERVICING The OPT is designed for trouble free operation as long as 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 OPT 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 OPT 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. 15. 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 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 OPT door are not damaged or worn and that the OPT base is secure. 16. SERVICING Tools Printer SERVICING 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. Open the bottom OPT door. Tear the paper and remove from printer. Lift up the paper roll and pull it off the brass spindle. Mount a new roll on spindle. 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. 17. Clearing Jam 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. 18. SERVICING If the receipt paper is jammed, try to clear it using the following technique: Replacement Removal SERVICING Isolate the OPT 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 OPT and do a test print Perform a test transaction. 19. Removal To replace the power supply or for easier access to components, you can remove the electronic module from the cabinet. 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. 20. SERVICING Electronic Module Disconnecting CAUTION SERVICING Before any connections are removed be sure to write down, label, photograph or otherwise record all the connections. Due to the variety of customer requirements and variations in manufacturing the connection instructions given here can only be used as a guide. ComFMS Board. Unplug connector labelled current loop from the CommFMS board. UPS Board. Unscrew the fan, printer, router, PIN pad and card reader terminal block connectors on the UPS board and pull the wires back through the grommets. Power Supply. Unscrew terminals marked L, N, FG (Live, Neutral and Frame Ground respectively) Cut any cable ties that may be securing the wires to the chassis or wires that are part of the module. NOTE: The module is heavy. Make sure it is well supported and no wires are pulled as you remove it. Removal Turn off the mains switch and the UPS switch before commencing this procedure. Unscrew the two Electronic Module retaining nuts at the bottom of the unit. Unscrew the upper two of the four upper Electronic Module retaining nuts while supporting the Module. Using both hands pull the Module forward off the studs. Replacement Reconnect all the cables that were removed. Lift the module up, place on the studs and fasten with nuts and washers. Reconnect and replace the battery. Replace the Compac box and check all connections are secure. Re-power and test. 21. Replacement The power supply is a modular unit and repair is not recommended except by an experienced power supply repair technician. Turn off the mains switch and the UPS switch before commencing this procedure. Note the connections to the screw down terminals and remove the connections. Remove the power supply. 22. SERVICING Power Supply UPS Board SERVICING Replacement CAUTION Always take anti-static precautions when working with electronic components. i.e., wearing a wristband with an earth strap. CAUTION Always take precautions to avoid arcs and short circuits that may damage sensitive components. The high current from the battery leads and terminals may cause fire or explosion if shorted out. Replacement Ensure the replacement UPS switch is off and clip in the replacement UPS board. Connect all the screw down terminal block wires in the order noted during removal. Plug in the battery connector. Switch on UPS and check that the LEDs D5 and D6 are lit. 23. SERVICING Layout 24. Connections SERVICING Connector Use Wire Colours Comment CON 1 Input Power Red=12V Black=GND Connects to the 12 Volt output of the power supply. CON 1 Fan Red=12V Blue or Black=GND Supplies 12 volt power to the fan. It is not battery backed and will stop in the event of power failure. CON 3 Battery Red=12V Black=GND The 2 pin plug connects the UPS to the battery. While there is mains power, the UPS will keep the battery fully charged. CON 4 5 Volt Not used Supplies 12 volt UPS power to the printer. Note: Supplies 5 V and 12 V so use the 12V side of the connector. Second earth wire (if fitted) goes to the 5 V earth. CON 5 Printer Red=12V Black=GND CON 6 Router & Switch Black with white dashes=12V Black=GND Supplies 12 volt UPS power to the router and switch. Note: The wiring may be grey with black stripes to indicate +ve. If in doubt see router wiring instructions. CON 7 VoIP Board White=12V Blue=GND Supplies 12 Volt UPS power to the VoIP board. CON 8 PIN Pad & Card Rdr White=12V Black=GND Supplies 12 Volt UPS power to the PIN pad and card reader. CON 9 Compac Box Red=12V White=GND Supplies 12 Volt UPS power to the Compac box. Shares connector with door switch power. Note: White = GND CON 9 Door Switch White=12V Blue=GND Supplies 12 Volt UPS power to the door switch. Shares connector with Compac box power CON 10 FMS Board Thick Red=12V Thick Black=GND Thin Black=POK Thin Green=BOK Thin White=CLK Thin Red=DATA This connector supplies 12 volt UPS power to the FMS board and provides information about the status of mains and battery. UPS Switch This switch switches the power off to the printer, PIN pad / cardreader, router, switch. Compac box and FMS board. LEDs There are two LEDs on the UPS board. LED D5 indicates that Mains is OK LED D6 is for battery OK. Both mains and battery LEDs must be lit before the OPT will allow a transaction to take place. CAUTION Use the above table as a guide only as wire colours can change during production and after servicing. CAUTION Take care to observe correct polarity as there are components that can be permanently damaged if connected incorrectly. 25. SERVICING Power Loss The diagram below shows what happens when power is lost and then restored. A Battery fully charged and mains power is powering the unit B Mains power failure, unit running on battery. C 20 minutes after mains failure, power is shut off. D If mains power failed for a significant amount of time, the voltage of the battery may dip below the set 11.5 volts threshold. E Mains power restored, battery charging begins. F Battery reached set threshold level. G 30 minutes after battery reaching the threshold level, transactions can now take place. After mains power to the unit is lost it will no longer allow transactions but the user will still be able to obtain a receipt that was generated before the power outage. A receipt can be obtained for up to 20 minutes after mains power failure. The unit will completely power down after 20 minutes. After restoring mains power the unit will power up. If the voltage of the battery dipped below the threshold level at any time, transactions will be disabled until the battery has been charged for at least 30 minutes above the threshold voltage. This is to ensure there is enough power to print receipts should power fail again. If the battery voltage does not dip below the threshold level while the mains power is disconnected, normal operation can resume as soon as mains power has been restored. 26. Battery SERVICING Replacement The backup battery has an expected life of 5 years in ideal conditions. If the OPT stays on for less than 20 minutes during a power failure then the battery may need replacing. The backup battery for the UPS is mounted inside the electronics chassis. CAUTION Always take precautions with the exposed battery terminals to avoid arcs and short circuits. This can damage sensitive components or cause fire or explosion. 27. Remove the electronic module. Turn off the UPS switch and unplug the battery connector CON3. Unscrew the battery, and remove from electronic module, clear and remove the positive and negative leads from the battery. Replace. CAUTION Take care not to touch the exposed battery cables with the steel bracket. CAUTION Ensure the Red lead connects to the red battery terminal marked Severe internal damage can be caused if the battery is connected the wrong way round. CAUTION Please ensure the used battery is disposed of in accordance with local environmental regulations 28. SERVICING Removal MX Box SERVICING Replacement CAUTION Always take anti-static precautions when working with electronic components. i.e., wearing a wristband with an earth strap. CAUTION Always take precautions to avoid arcs and short circuits that may damage sensitive components. Removal Turn off the mains switch and the UPS switch. Take note of their location and unplug the connections. Remove MX box bracket from electronic module. Undo the four screws holding the MX box to the bracket. Snip any cable ties if required and remove the box. Replacement Fasten the new MX box to the bracket. Connect all plugs and connectors in the order noted during removal. Replace the cable tie clip on the screw adjacent to the power switch and cable tie the microphone and VoIP board cables. Check the MX box power switch is "on" and fasten the MX box and bracket back into the cabinet. Contact Compac to reconfigure software if required. Test for correct operation. 29. Replacement CAUTION Always take anti-static precautions when working with electronic components such as wearing a wristband with an earth strap. CAUTION Always take precautions to avoid arcs and short circuits that may damage sensitive components. NOTE: Before replacing the board, contact the Help Desk to ensure all data has been uploaded. Do not unplug the board until this has been done. Removal Turn off the mains switch and the UPS switch. Take careful note of the polarity/colour of all the existing connections on the FMS board. Label and photograph if required. Unplug the connections. Unclip the four standoffs using pliers and remove board. Remove the memory and software chips from the FMS board if they are to be reused and install them onto the replacement COM FMS board. NOTE: The software chips MUST be installed the right way round. Installing chips the wrong way will destroy them and will void any warranty. Replacement Install the software chips if required. Reconnect the FMS board making sure that all connections you removed are replaced in the same positions. Check that the standoffs are aligned so that the plastic clip is easily accessible to aid subsequent removal. Push the board onto the standoffs until they click into place. Make sure that all connections are secure. If you removed the electronics module, re-install it. Refer Electronics Module Replacement. Repower the unit. Contact the Help Desk and follow their instructions to re-install site parameters. 30. SERVICING FMS Board Layout SERVICING 31. Connector Use Port 4 Port 5 Port 1 TTL Port 2 TTL Port 3 TTL Port 4 TTL Wire Colours Comment RS232 Tank gauging Not used Red/White/Green/ Red&Green/ Red&White/Black/ Red&Blue/Red&Black Blue/Orange IC (5pin) UPS Power Red/Black PIN Pad Keyboard Dot Matrix Display Green/Brown/ Orange/Red IBM Keyboard Batt Backup DIP Switches Port 1 and 2 connect to Con 10 on UPS board and to Lantronics using the supplied wiring loom Uses above loom Printer & low paper sensor Gilbarco Comm's Power for capacitance keypad. (service part) Uses 2 pin plug to bring power from UPS Board CON 10 For programming via internal key pad Power for dot matrix display backlighting (used with optional internal keypad for service) Red, Black 3.6V lithium battery Use DIP switches to allocate port functions. If replacing a board, make sure DIP switches match up with the original one. CAUTION Use the above table as a guide only as wire colours can change during production and after servicing. LEDs LED Colours Pump Com's (NZ) Yellow Green Red Pump Com's (Aus) ATG (NZ) ATC (Aus) Green Red Green Red Green Red Comment Toggles Yellow / Green = Normal Red = Comm's short Toggles Red Green = Normal Toggles Red Green = Normal Toggles Red Green = Normal 32. SERVICING Connections Lantronix Board SERVICING Replacement CAUTION Always take anti-static precautions when working with electronic components. i.e., wearing a wristband with an earth strap. Removal & Replacement Turn off the mains switch and the UPS switch. Unplug the network cable. Unclip the three standoffs using pliers and remove board. Replace 33. Replacement CAUTION Removal of the PIN pad or any of its covers will permanently disable it. Do not remove the PIN pad unless you have a new replacement on hand. Removal & Replacement Turn off the mains switch and the UPS switch. Unplug the PWR, COM2 and SCR connections from the back of the PIN pad. Undo the 6 nylok nuts holding the Pin pad to the door. Gently remove the PIN pad. Return the PIN pad to Compac. Replace. Anti-tamper Protection A unit that has been disabled will display the message: "Secure Link Fail - Terminal Locked". NOTE: The PIN pad is equipped with an anti-removal and anti-tamper protection. Once the unit has been powered up the protection devices are armed. After this, removal of the unit or any of its covers or subjecting it to mechanical force, extremes of temperature or voltage will disable it requiring return to the factory for testing and resetting. 34. SERVICING PIN Pad Card Reader Replacement SERVICING CAUTION Removal of the Card Reader or any of its covers will permanently disable it. Do not remove the Card Reader unless you have a new replacement on hand. Removal & Replacement Turn off the mains switch and the UPS switch. Unplug the PIN pad to card reader cable. Undo the 4 nuts holding the card reader to the door. Gently remove the card reader Replace Anti-tamper Protection A unit that has been disabled will display the message: "Secure Link Fail - Terminal Locked". NOTE: The card reader is equipped with an anti-removal and anti-tamper protection. Once the unit has been powered up the protection devices are armed. After this, removal of the unit or any of its covers or subjecting it to mechanical force, extremes of temperature or voltage will disable it requiring return to the factory for testing and resetting. 35. The VoIP (Voice Over Internet Protocol) allows the user to communicate to the Help Desk by pressing the "Need Assistance?" button. The button will ring the help desk and establish a two way phone connection using the microphone just above the button and a speaker at the top left side of the cabinet. VoIP is controlled by the MX box. An amplifier mounted on top of the card reader boosts the headphone output for the speaker. The UPS will run the VoIP in the case of power failure to the unit. When the VoIP function is not being used, the speaker will emit a constant, lowvolume crackle. VoIP Troubleshooting Check that the power is on and the back-up battery is charged. Check the audio plugs in the Compac box are in the correct sockets and pushed in properly. Check the VoIP button is working. Check the VIOP board is receiving power, that the wires in and out of the board are securely attached and that the MX box cable is the right way round and secure. If you can hear the help desk but they can't hear you, plug in another microphone into the MX box and try again. If the help desk can hear you but you can't hear the help desk. Plug headphones into the headphone jack and/or replace the speaker. Replace the VoIP board. 36. SERVICING VoIP (Voice Over Internet Protocol) VoIP Board Replacement Removal & Replacement SERVICING Turn off the mains switch and the UPS switch. Undo the 12 Volt and speaker wires Unplug the cable from CON2 Snip the cable ties holding the VoIP board to the card reader. Remove the VoIP board. Replace Speaker The speaker is held on with four nuts and washers and is connected to CON 5 of the VoIP board. Replacement is straight forward. Remember to replace the steel anti tamper-plate when refitting the speaker. Microphone The microphone is stuck to the door using double sided tape and a corflute holder. It is hard-wired to the cable and audio plug that connects to the Compac box. If doing an emergency repair, cable tie the new cable to the existing loom. Incorporate the new cable into the loom and remove the old microphone at the next scheduled service. VoIP Button The VoIP button should give no problems but can easily be replaced by lifting the yellow tag on the back and rotating it anti-clockwise. This will release the switch and allow the button collar to be unscrewed. When replacing the switch make sure the collar locks in place. 37. The Filter element can become blocked up in dusty environments and may be removed from the ducting and cleaned with a vacuum cleaner or compressed air. If the filter is excessively dirty or damaged it can be replaced with a new filter. The Fan has a Life expectancy of 100,000 hours in ideal conditions. If the fan fails or becomes excessively noisy it should be replaced. Filter Replacement Removal & Replacement Unclip the fan connector or turn off the OPT Unscrew the four screws that hold the air duct together and remove the filter housing. Remove the filter. Replace. NOTE: The filter element can be cleaned with a vacuum or compressed air. Fan Replacement Removal & Replacement Unclip the fan connector. Remove fan from OPT housing. Replace. 38. SERVICING Fan & Filter Software Upgrade Procedure This is the software upgrade procedure to be followed for all EPROMS. SERVICING Ensure, before working on the OPT, that anti-static precautions are taken (i.e. wearing of wristband with earth strap). Check that all current data has been uploaded from the unit. Record all existing parameters and settings. The above steps are taken to safeguard against software incompatibility causing loss of information. Turn off power. Remove software EPROM using an EPROM extractor. Plug in new software EPROM, being careful that the dimple is at the correct end of the socket. Also ensure that all the legs are correctly located in the socket. Turn on power. Check date/time and all other settings are correct. Test operation. CAUTION When replacing Integrated Circuit chips, ensure that the notch is facing in the direction of the IC board socket (the notch is the end referred to as the "front"). When inserting the IC chip, the rear pin (of the IC chip) must be plugged into the rear pin socket of the IC board socket. If the chip is shorter than the socket, any spare pin sockets should be at the front. Failure to correctly insert the IC chips or adhere to the above guidelines specified will result in a loss of memory data. 39. Problem No Power/No Lights Possible Cause Recommended Action No power entering unit Ensure that power is entering unit, check external fuses and switches Faulty power supply Replace the electronics module No power to printer Printer data cable unplugged Will not Print “Paper low” on internal PIN pad (EFTPOS PIN pad displays “Receipt unavailable OK?” after swiping card) Will not read cards Transaction not complete Trying to print on wrong side of paper Remove paper and re-insert Faulty Printer Replace Printer Faulty Electronics module Replace the electronics module No paper or low on paper Faulty low paper sensor Poor adjustment of low paper sensor Load a full roll of paper Disable Low Paper Sensor Disable Low Paper Sensor Door Open Close Door Debris on card or magnetic head Wrong system (with distributer / In-house cards) Clean card or card reader’s magnetic head using head cleaning kit. Wrong card base (ISO, Access number) Check card base is loaded onto the OPT Re-power OPT and jiggle network cables to see if fault re-occurs. If so try replacing cables and/or connectivity module Replace the electronics module Check LEDs To Pumps/5, From Pumps/5 or To Pumps/4, From Pumps/4 on the CommFMS board are flashing? If not check the Pump Comms cabling from pumps to the FMS board and also the Port 4, Port 5 fuses Check pumps and their protocols matches what is set in the OPT. Refer to the Installation Manual Intermittent or broken connection between CommFMS or Embedded PC and network switch. Will not communicate to pumps “Pump offline” on EFTPOS PIN pad after pump number has been selected Check voltages on printer and try performing test print Check cable is plugged in correctly at both ends and is free from corrosion Ensure all nozzles relating to the transaction are properly hung up Connection to the pumps has been cut No power on pumps Wrong pump protocol Faulty pump(s) 40. TROUBLESHOOTING Troubleshooting Problem TROUBLESHOOTING “Pump Error” on display “System not ready” on EFTPOS PIN pad Unable to Auth/Block cards from Compac online Pumps will not dispense fuel Possible Cause Recommended Action Pumps have gone into standalone mode Configure pumps for inhibit standalone mode. (On C4000 Compac pumps set the thousand position of the b configuration to 1. i.e. 1xxx) CommFMS board fault Replace the FMS Board One of the linked pumps or dispensers has encountered an error. Read the error message on the pump display to find out what is wrong. No fuel in tanks Verify tanks have sufficient product Pump fault Try another pump to verify. Contact pump service agent Re-power OPT. Check connection by Internet connection to card plugging laptop computer into one of processing company the connectivity module ports and unavailable trying to open a common web site. Check with internet service provider Internet connection quality for information on internet service low or intermittent quality. OPT not communicating See "Will not communicate to Pumps" with pumps above Ensure pump number set in pumps Wrong pump number matches pump number set in selected controller and also pump number written on the pump. Have service agent check pumps Unable to get data from OPT Wrong site number / passcode Internet connection down VoIP not working Unit will not boot up Microphone and speaker are connected to the wrong ports Main I/O cable is installed back to front HDD not seated properly 41. Enter correct site number / passcode into Compac Online software. Check with internet service provider for information on internet service quality Check connections. Refer to picture on PIN Pad Light Board Replacement Check connection and reverse if required Check HDD is correctly mounted with no bent pins
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