null  User manual
OPT
SERVICE
MANUAL
OPT Service Manual
Version 1.0.0
Model: OPT Mark 2 SCR200
Date: 14 July 2017
Conditions of Use
CONDITIONS
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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.
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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
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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
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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
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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:
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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.
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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
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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
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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.
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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
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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.
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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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