ComTank Unit Installation Sheet Version 1.0.0
Product Identification Manual Title ComTank Unit Installation Sheet Publication Date Wednesday, 4 December 2013 Application Compac ComTank Power supply 230-240 VAC; 50 Hz; 1 Amp +/- 10% Related Manuals ComTank Pump Installation Sheet C4000 Master Manual CompacOnline User Guide (CompacOnline capable ComTank) USB Key User Guide (USB equipped ComTank) Master Installation Sheets Validity Compac Industries Limited reserves the right to revise or change product specifications at any time. This publication describes the state of the ComTank and related products at the time of publication and may not reflect the product at all times in the past or in the future. Manufacturer Contact Details The Compac ComTank is designed and manufactured by: Compac Industries Limited 52 Walls Road, Penrose, Auckland 1061, New Zealand P.O. Box 12-417, Penrose, Auckland 1641, New Zealand Phone: + 64 9 579 2094 Fax: + 64 9 579 0635 www.compac.co.nz Copyright 2013 Compac Industries Limited, All Rights Reserved
Contents Product Identification... ii Document Control Information... 4 Introduction... 5 Safety... 6 Installation... 7 Tools Required... 7 Pre-installation Checks... 8 Site Preparation... 8 Mounting Preparation... 9 Electrical Preparation... 10 Precautions if Using Generator Power... 10 Electrical Connection... 11 Wiring Diagram Control Unit... 12 Modem Connections... 13 Powering up... 14 Checking Pump Prices... 14 Power on Tests... 15 Checking Authorisation Methods... 15 Checking Card Reader... 15 Checking USB Module... 15 Checking Transactions are Uploaded... 16 Finishing Up... 16 Spare Parts... 16 Installation Checklist... 17 Page 3
Document Control Information Document Control Information Document Information and Revision History Document Details: File Name and Location: Current Revision Author(s): ComTank Installation Sheet G:\Masters\Installation Sheets\ComTank Installation Sheet R Lacey Authorised By: Tim Mayson Release Date: 04/11/2013 Version Date Author(s) Revision Notes Distribution Name Indicator Location Compac Industries Ltd. Page 4 www.compac.co.nz
Introduction Introduction The Compac ComTank is a diesel fuel dispenser authorisation and reporting device designed to be flush-fitted to a wall, fuel tank or in the side of a shipping container. It is designed to be connected to Compac Master series pumps. ComTank specific Master series pumps with remote displays and nozzle holders are available to allow users to fully customise the location of authorisation panel, pump display, hose outlet and nozzle holder to suit their site requirements. Features include: Effective solution for tanks and pumps that need to be securely locked Ideal for portable installations Control interface for Master mechanical components Remote mountable nozzle holders Commercial or Retail display, with the option of remote mountable additional display Single or Dual Hose Choice of stainless steel panels (for corrosive situations) or gold passivated mild steel Authorisation Options PIN pad Electronic Tag (HID, itrack or CWID - Compac Wireless Identifier- key tag or nozzle tag) Swipe card Transaction Downloading Options USB stick CompacOnline Tank Gauging Options Veeder-Root Fafnir Vega Franklin Options may vary depending on application. These installation instructions refer specifically to the ComTank authorisation unit and related hardware. For detailed instructions on the installation, setup and calibration of pumps and for the operation of the authorisation and reporting systems, refer to their specific manual. Compac Industries Ltd. Page 5 www.compac.co.nz
Safety Safety You must adhere to the following safety precautions at all times when working on this unit. Failure to observe these safety precautions could result in electrical or mechanical damage to the unit or injury or death to yourself or bystanders. Make sure that you read and understand all safety precautions before installing, servicing or operating this unit. Failure to follow safety instructions may invalidate any warranty. Mechanical Safety Observe the following mechanical precautions: During installation, take care that the unit is well supported and cannot fall over. required. Take care with handling sharp edges, wear gloves where Make sure that the service area is thoroughly clean when servicing. Dust and dirt entering the components may reduce the life span of the components and can affect operation. Electrical Safety Observe the following electrical precautions: Always turn off the power to the unit before commencing work on any wiring. Never touch wiring or components inside the high voltage area with the power on. Be aware that capacitors and back up batteries may power the unit even after mains power is removed. Always turn off the power to the unit at the mains switch before removing or replacing software or memory ICs. Always take basic anti-static precautions when working on the electronics, i.e., wearing a wristband with an earth strap. Environmental Safety Observe the following environmental precautions: Take care that you clean up after working on the unit. Remove and carefully dispose of any waste. Any spills must be cleaned up and disposed of in an approved manner. Any spillage of fuel must be handled to minimise the risk of fire or explosion. Major spills must be reported to the local environmental authorities. Site Safety Observe the following precautions when on site: Personal safety is the responsibility of the site manager and technician. Personal protective equipment appropriate to the situation is to be worn and if required, the working area appropriately cordoned off with cones, tape and/or barriers. When working on or near flammable goods areas take all precautions to avoid sources of ignition. These instructions are intended as a guide only. It is the responsibility of the technician and the site manager to manage safety in accordance with local regulations and best safe site practice. Compac Industries Ltd. Page 6 www.compac.co.nz
Installation Installation You must be properly qualified, trained and authorised to install this unit. Ensure you are qualified to perform each of the operations described. Security To help prevent unauthorised tampering, it is recommended that tamper resistant fasteners be used and that all wiring outside the cabinet is enclosed. Tools Required Tools Power Tools Electrical Tools Diagnostic Equipment Safety Equipment Other Equipment It is expected that installers will carry a comprehensive tool kit including: Metric and imperial spanners Metric and imperial socket set Metric and imperial allen keys Torx and security torx keys Phillips, pozidriv and flat blade screwdrivers Electric drill (observe site safety protocols when using power tools) Wire cutters Wire stripper Crimping tool EPROM extractor Multimeter Earthing wrist strap Remote pump display to enable easier pump setup. Laptop with fully charged battery and wireless modem LAN cable Fully charged cell phone Test cards and/or authorisation keys High visibility vest or jacket Personal protective equipment (PPE) Boots, gloves, goggles, hearing protection, hard hat etc. Cones, barriers, tape to secure your working area Step ladder Torch Cable ties Cleaning spray and clean cloths The above list is a suggested minimum. It is recommended that you read the manual thoroughly and include any other equipment that may assist you in completing the job safely and quickly. Compac Industries Ltd. Page 7 www.compac.co.nz
Pre-installation Checks Pre-installation Checks Transit Damage Tampering Vibration Site Issues Once the unit is received on site, inspect the unit for the following: Shipping damage to housing, display or any other equipment. Water damage to components Report any damage to the transport company and to the help desk. Take photographs if required. Inspect for: Evidence of tampering with the unit especially card reader or unauthorised wiring. Report any concerns to the help desk. Take photographs if required. Inspect terminals, plugs and IC chips to check they are securely in place and have not loosened due to vibration. Check that all wiring and pipework has been installed correctly and is undamaged. Report issues to site manager. Inappropriate installation may void the warranty. If uncertain, contact your Compac agent for advice. Site Preparation Refer to the Site Audit document if supplied. To ensure maximum operating life, care should be taken when installing the ComTank components. Considerations should include: The card reader and PIN pad should face away from the prevailing wind especially in dusty or wet areas. In areas experiencing extremes of weather (heat, cold, wind, rain, salt spray etc.) consideration should be given to installing additional shelter. The rear of the displays and the electrical components must be protected from dust, water or high humidity. Any protective surrounds that are constructed must also allow for adequate cooling. Inappropriate installation may void the warranty. If uncertain, contact your Compac agent for advice. Compac Industries Ltd. Page 8 www.compac.co.nz
Mounting Preparation Mounting Preparation The ComTank unit needs to be mounted to a flat, steel plate prepared with a cut-out and fastener holes as per drawing below. A steel template marked with the appropriate dimensions is available as an option from Compac. Holes are drilled to clear M6 (6 mm diameter) studs. Ensure your mounting plate is thin enough to allow you to put the washers and nuts on the end of the 20mm long studs. The plate the ComTank is mounted on should be rust protected if it is not made from stainless steel. Ensure there is sufficient access to allow the installer and service people to comfortably remove the cover from the rear of the unit and perform service work. A minimum clearance of 850 mm is recommended. Figure 1 ComTank Panel Cutout. Note: Do not cut to outer lines. If installing ComTank pumps as part of the installation, refer to the ComTank Pump Installation Sheet for pump, display and nozzle holder mounting instructions. Compac Industries Ltd. Page 9 www.compac.co.nz
Precautions if Using Generator Power Electrical Preparation The ComTank control unit requires its own wiring from the power supply. Power and communication cables must meet or exceed local regulation requirements. If no local regulations exist, we recommend as a minimum: Power: 3 core 2.5 mm 2 Steel Wire Armour (SWA) cable Comms (standard current loop): 2 core 1.5 mm 2 Steel Wire Armour (SWA) cable The length of the communications cable must not exceed 100 metres. Precautions if Using Generator Power The power output from onsite generators can cause power spikes that may damage electrical components within the cabinet. When connecting to sites powered by generators, please take the following precautions: Install a power conditioner. Although generators are fitted with power regulators, most are not filtered sufficiently for powering sensitive electrical components. We recommend installing a commercial power conditioner and/or UPS between the generator and the unit. Starting up. Before starting a generator, make sure the power to the unit is turned off. Start the generator, let the generator reach stable operating speed and wait 30 seconds before reconnecting the power to the unit. For units where the generator starts and stops on demand, install a delay timer or PLC to automatically isolate the unit until the operating speed and consistent power output is achieved. Isolate the unit before shutting down the generator. Compac Industries Ltd. Page 10 www.compac.co.nz
Electrical Connection Electrical Connection Cable requirements 230V Mains Pump Comms ComTank control unit power: 3 Core Steel Wire Armour Cable 2.5mm 2. 230 Volts, 10A, 50 Hz Pump comms (standard current loop): 2 core Steel Wire Armour (SWA). Pump comms (RS485): 3 core Steel Wire Armour (SWA). Refer to the wiring diagram on page 12. Connect the incoming mains as follows: All terminals marked N are common. All terminals marked P are common. Connect the Earth to the busbar at the bottom of the cabinet. Connect the pump comms cable(s) to the terminals on the DIN rail. Nozzle switches Tank Gauging (option) If pumps do not communicate on start up, swap the wires over. The nozzle switch cable is pre-wired to the pump. Plug into the socket(s) on the nozzle switch(es) making sure the correct cable is connected to the nozzle.. Coil and neatly cable tie any excess cable out of the way. Tank gauging if fitted should be wired to the Tx, Rx and G terminals. If tank level does not appear on your administration program after initial setup swap the Tx and Rx wires. All wires entering the unit should be glanded and secured to prevent stressing the terminals. Compac Industries Ltd. Page 11 www.compac.co.nz
Wiring Diagram Wiring Diagram Compac Industries Ltd. Page 12 www.compac.co.nz
Modem Connections Modem Connections Cellular Modem The cellular modem (if fitted) is prewired and only requires a SIM card to be fitted. To fit the SIM card 1. Depress the small yellow button on the top of the cell modem. 2. Remove the black plastic SIM card-holder. 3. Insert the SIM card. 4. Refit the SIM card holder. There is a red diagnostic LED on the end of the Cell modem which will initially be permanently on but will start to flash when the Cell Modem is connected to the Network. Compac Industries Ltd. Page 13 www.compac.co.nz
Powering up Modem Connections Powering up When all connections have been made and checked. Install the protective perspex cover over the terminals. Where regulations require, a registered electrician must check and approve connections. Connect power to the unit and turn on the circuit breaker. Check that the PIN pad screen (if fitted) is illuminated and boots up. If the unit is controlled via the internet, contact your help desk and confirm that the unit is on line. Confirm the on-line pump pricing. Checking Pump Prices Pricing via USB Module Pricing via Internet The following is a brief overview for technicians who are experienced in the installation and setup of similar equipment. Specific instructions for each option are either supplied or available from Compac. The ComTank unit controls the pricing at the pumps. In most circumstances the pricing information is sent to the unit either via a USB key or via the internet using Netbase or CompacOnline. Start up your laptop, insert the Compac USB key and open the Price file. Check the price is correct. If not, change it and save. Insert the key into the USB module, select Set Price and confirm. Turn off the unit and the pumps, connect the pump communications wires and repower. Check that the pricing on each hose is correct. Confirm that the unit is on line and that the help desk has installed all updates. Write down the on-line price(s). Turn off the unit and the pumps, connect the pump communications wires and repower. Check that the price on each hose matches the on-line price. Compac Industries Ltd. Page 14 www.compac.co.nz
Power on Tests Checking Authorisation Methods Power on Tests Depending on the setup of the unit, you will need to perform a number of tests. Checking Authorisation Methods Units can be authorised in a wide variety of ways: No authorisation required. Unit just records transactions. PIN pad authorisation. Customer enters a PIN number and/or odometer reading to authorise pumps. Fuel card authorisation. Customer swipes their issued fuel card. A PIN number and/or odometer reading may or may not be requested. Credit card authorisation. Customer swipes credit card to authorise pumps. HID or CWID key authorisation. Customer passes a coded RFI key in front of a reader. CWID nozzle authorisation. A CWID key is attached to the vehicle filler and a reader is attached to the pump nozzle. Inserting the nozzle into the filler authorises the pump. itrack reader authorisation. A unit attached to the vehicle authorises the pumps as it pulls into the forecourt. All authorisation methods set up on the unit will need to be tested. Checking Card Reader Check the card reader to see if it reads approved cards. Swipe a test card and check that a transaction can be made. The card is inserted with the stripe to the top and on the right hand side. Do this for all types of approved cards. Checking USB Module The USB module allows downloading of pricing updates and authorised card numbers and uploading of transactions. Perform a test transaction and print a receipt for each hose. Insert the Compac Supplied USB key into the reader. At the prompt, choose Get Transactions. Wait while the transactions are uploaded then remove key. Insert the Key into your laptop, open the Transactions folder and see if you can see the recorded transactions. Check that the receipt information matches the transaction information. Compac Industries Ltd. Page 15 www.compac.co.nz
Checking Transactions are Uploaded Finishing Up Checking Transactions are Uploaded Contact the your Netbase or CompacOnline administrator and check that your test transactions and any customer transactions that have taken place have been recorded correctly on Netbase or CompacOnline. For USB equipped units, download your test transactions and check that the information recorded matches the information on the receipts. Finishing Up When you are confident the site is trading correctly, complete the installation checklist. If you do not have one, a copy is attached at the end of these instructions. Fax the installation sheet to Compac as soon as you can. Replace and fasten the cover on the back of the ComTank unit and any pump covers that may have been removed. Remove all tools, clean the unit, pick up all debris and tidy the surrounding area. Remove any barriers or cones. Contact help desk and tell them that you are about to leave the site. Spare Parts Order spare parts from your Compac agent. You must quote the model and serial number of the unit. Compac Industries Ltd. Page 16 www.compac.co.nz
Installation Checklist Checking Transactions are Uploaded Installation Checklist Version 1.0.0. ComTank. Site number and name: Date: Installer name and phone number: Serial number: When a new unit is being installed use the following checklist to make sure the unit is fully operational. Check each box or write N/A where not applicable. Refer to the relevant installation manual for procedures. Mechanical Checks Check unit is undamaged and has not been tampered with. Yes No Is the unit in a sheltered position and facing away from the prevailing wind and rain? Check all panels are securely fastened using tamper-proof fastenings where supplied. Check that all cable entries to unit are through glands and unused glands are sealed. Power on Checks Check that the CE board, FMS board, pinpad, printer, cardreader, router and modem all power up. Yes No Check pumps are re-priced to the current fuel price. Check that different fuels are correctly priced on all hoses. Transaction Checks Complete transaction using white card/cwid/hid/pin authorisation methods Yes No Check that all hoses can be selected and authorised by the unit. USB Module Checks (where fitted) Check the supplied USB key is recognised by the unit. Yes No Select "Get Transactions" and check that transactions are uploaded to the USB key. Compac Industries Ltd. Page 17 www.compac.co.nz
Checking Transactions are Uploaded Installation Checklist CompacOnline Checks (when connected) Check the site appears on CompacOnline. Yes No Check that transactions have been recorded on CompacOnline. Tank Gauging Checks (where fitted) Check that tanks are set up in CompacOnline and that correct levels are being reported. Yes No Check that the correct products are assigned to the correct tanks. Customer Training Check site attendants understand refuelling procedures. Yes No Check that site administrators understand how to obtain transactions and administer cards. Final Checks Yes No Notes Ensure all cables are plugged back in after remote accessing. Tidy up all rubbish and clean the exterior of the unit before leaving. If one or more of these tests fail, contact the Compac help desk or your service centre so the problem can be logged and parts issued if required. To validate warranty and receive future help desk assistance please fax both sides of this form to:+64 9 579 0635 or post to: Compac Industries Ltd, PO Box 12 417 Penrose, Auckland 1642, New Zealand. Report any damage immediately to Compac Industries on: +64 9 579 2094. Any site safety issues should be reported immediately to the site manager. Compac Industries Ltd. Page 18 www.compac.co.nz