Compac Industries C5000 AdBlue User manual
C5000 AdBlue Kit Installation Manual
Version 1.0.2
Model:C5000 AdBlue Tank Kits
Date: 08th January 2021
Conditions of Use
Conditions of Use
▪Read this manual completely before working on,
or making adjustments to, the Compac
equipment.
▪Compac Industries Limited accepts no liability for
personal injury or property damage resulting
from working on or adjusting 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 C5000 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 C5000 processor, or
damages resulting from the inability to use the
Compac C5000 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 C5000 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 C5000 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 non-
approved parts or modifications will void all
warranties and approvals. The use of non-approved
parts or modifications may also constitute a safety
hazard.
▪Information in this manual shall not be deemed a
warranty, representation, or guarantee. For warranty
provisions applicable to the Compac C5000
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 C5000 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.
CONDITIONS
Document Control
Document Information
Manual Title
C5000 AdBlue Tank Kit Installation Manual
Current Revision Author(s)
V Amarakoon
Original Publication Date
05/11/20
Authorised By
W Zheng
Revision History
Version
Date
Author(s)
Revision Notes
1.0.0
05/11/2020
V Amarakoon
New Manual
1.0.1
25/11/2020
V Amarakoon
Updated Error Messages
Added Slave Display Configuration
1.0.2
08/01/2021
V Amarakoon
Updated terminal board connections
Added error 16
Manufactured By:
The Compac C5000 AdBlue dispenser is designed and manufactured by Compac
Industries Limited
52 Walls Road, Penrose, Auckland 1061, New Zealand
P.O. Box 12-417, Penrose, Auckland 1641, New Zealand
Phone: + 64 9 579 2094
Fax: + 64 9 579 0635
www.compac.biz
Copyright ©2015 Compac Industries Limited, All Rights Reserved
1.
Contents
Contents
Introduction.......................................................................................................... 2
Static Electricity Precautions ...............................................................................2
Pre-installation Check ..........................................................................................2
Pump Specifications .............................................................................................2
Electrical Requirements........................................................................................3
Dispensing Hoses and Nozzles.............................................................................3
Generator Power .................................................................................................. 4
Installation ........................................................................................................... 5
Typical Wiring ...................................................................................................... 7
Terminal Board Connections ................................................................................8
K-Factor Board ....................................................................................................10
Setting up the C5000 ......................................................................................... 11
K-Factor Settings ................................................................................................11
Submersible Delay (Sd).......................................................................................12
Changing the V50 Meter ID.................................................................................13
Changing the Temperature Calibration ..............................................................14
Changing the Density Calibration.......................................................................14
Changing the Slave Display Configuration.........................................................15
Parameter Switch Settings.................................................................................16
Changing the Pump Number...............................................................................16
Changing the Price..............................................................................................16
Installation Tests ............................................................................................... 17
Electrical..............................................................................................................17
Mechanical ..........................................................................................................18
AdBlue Instructions ........................................................................................... 20
Cleaning the AdBlue Nozzle................................................................................20
ZVA AdBlue Nozzle ..............................................................................................20
Meter Replacement............................................................................................ 21
Replacing the Electronic Module........................................................................21
Pairing the Electronic Module ............................................................................21
Removing the V50 Meter.....................................................................................22
Replacing the V50 Meter.....................................................................................22
Error Messages.................................................................................................. 23
2.
Introduction
Introduction
This manual contains specific instructions relating to installing AdBlue kits. For the
servicing and other information relating to non-AdBlue specific components refer to
the Compac C5000 Master Manual.
Static Electricity Precautions
Electronic components used are sensitive to static electricity. Please take anti-static
precautions.
An anti-static wrist strap should be worn and connected correctly when working on
any electronic equipment. If an anti-static wrist strap is unavailable, or in an
emergency, hold onto an earthed part of the pump/dispenser frame whilst working on
the equipment. This is not a recommended alternative to wearing an anti-static wrist
strap.
NOTE: Compac Industries Limited reserves the right to refuse to accept any circuit
boards returned, if proper anti-static precautions have not been taken.
Pre-installation Check
Once the pump is received on site, check that no damage has occurred while in transit
–in particular, damage to electronics due to vibration or jarring. All terminals and
plugs should be checked, including IC chips to ensure they are securely in place.
Pump Specifications
The AdBlue supply pump must be Adblue compatible. It must either have flooded
suction or be fitted with an air separation device to eliminate air prior to the dispenser.
Ensure the supply pump pressure does not exceed the rated pressure of the nozzle.
Refer to the diagram below:
3.
Introduction
NOTE: Pumps must be rated for AdBlue.
Electrical Requirements
Power cable: 3 Core Steel Wire Armour Cable 2.5mm2
Core 1: 230 Volt Supply (Active). Core 2: Neutral. Core 3: Earth.
Dispenser power requirements: 220 - 240 Volts. 50 Hz, +/-10%
Current draw: 25W Idle, 200W with all solenoids active.
Communications cable: 2 Core Steel Wire Armour Cable 1.5 mm2. Maximum cable
length 100 m. 12 V current loop. For connecting to controller or other dispensers
(option).
Submersible pump(s): Suitable cable for 230V solenoid switching current. 300mA
maximum load. Do not wire submersible pumps directly to C5000 Terminal Board .
Prior to pump installation, ensure that there is at least a two-metre tail on all cables.
Dispensing Hoses and Nozzles
If customer supplied hose assemblies, pylons, reels, safe breaks and nozzles are used
they must comply with the requirements outlined in AS/NZS 2229. All hoses, nozzles
and fittings that come in contact with AdBlue must be compatible with it. All dispenser
nozzles must trip shut when returned to the nozzle holder.
4.
Generator Power
Generator Power
The power output from onsite generators can cause power spikes that may damage
electrical components within the cabinet. When connecting to sites powered by
generators, please take the following precautions:
1. Install a power conditioner. Although generators are fitted with power
regulators, most are not filtered sufficiently for powering sensitive electrical
components. We recommend installing a commercial power conditioner and/or
UPS between the generator and the unit.
2. Before starting a generator, make sure the power to the unit is turned off.
3. Start the generator, let the generator reach stable operating speed and wait 30
seconds before reconnecting the power to the unit.
4. 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.
5. Isolate the unit before shutting down the generator.
5.
Installation
Installation
NOTE: Consider the limited length of the cables on the Meter and Solenoid
The drawings shown are for single units. For dual units, the solenoid and outlet are
separated and connected to the meter assembly with a tube.
6.
Installation
Installation instructions are as follows:
1. Mount the V50 Module assembly. Ensure that the meter is in the correct
orientation by checking the ‘In’ and ‘Out’ print on the base of the meter. The
meter must be installed in a horizontal orientation.
2. Connect the pump to the Inlet Manifold (1” BSP thread) shown above in the
meter manifold diagram.
3. Connect the nozzle hose to the Outlet Manifold (1” BSP thread) shown above in
the meter manifold diagram.
4. Mount the C5000 Processor Box. It is recommended to mount the bracket
without the lid initially, so that connections can be brought into the processor
box. Ensure the bracket is mounted with a minimum of 12mm clearance
above the bracket so that the lid can be fitted.
5. Mount the Flameproof Box. Note the box has four 105x185 mounting holes on
the bottom of the casing (M6 thread). A bonding wire is attached to the
flameproof box for earthing requirements.
6. Mount the DCA unit using mounting holes and glanding found on the bottom of
the unit.
7. Connect the nozzle to the microswitch. If this is supplied, it must be mounted
first.
7.
Typical Wiring
Typical Wiring
Electrical cables are terminated at the C5000 Power Supply terminal board, which is
housed in the Flameproof Enclosure. The incoming cables are terminated as shown in the
following picture. Single hose uses only the pump side A connection. Pump Comm’s
connections are only used when the dispenser is communicating to a site controller.
NOTE: Output to pump(s) goes to the pump contactor, not directly to the pump wiring.
Terminal Board
Processor Board
Power Supply PCBs
Flameproof box
8.
Typical Wiring
Terminal Board Connections
When using the C5000 electronics for dispenser application, as well as connecting the
incoming mains, the external pump contactors will have to be connected to the terminal
board.
Solenoids for side A and B can be wired in if preset and prepay options are desired.
MMA30-160STK
Secondary Solenoid
Side A Solenoid
(AdBlue)
Side B Low Flow
Side A
Primary and
Secondary Solenoids
Primary Solenoid
Side B High Flow
External Pump
External Pump
9.
Typical Wiring
MMA30STK
MA30STK
Side B Solenoid
Side A Solenoid
Side B
Side A
Side A Solenoid
Side A
Side A Solenoid
External Pump
External Pump
External Pump
10.
Typical Wiring
K-Factor Board
Both the Parameter switch and K-Factor switch are found on the K-Factor board. Meters and air
switches are also connected to this board. See below for the location of these.
Side A Connections
Connect Air
Switch to here
Connect Meter
to here
Connect
Nozzle Switch
to here
Connect
Sump Switch
to here
Connect optional
mechanical totes
to here
Bus out system
cables
Parameter Switch
K-Factor Switch
11.
Setting up the C5000
Setting up the C5000
K-Factor Settings
The settings that can be accessed from the K-Factor switch are shown below. Not all of these
will need to be changed during installation, therefore information on the following pages refers
only to the settings that must be changed. Once the pump has been installed, if further
customisation of the unit is desired, refer to the C5000 Manual.
Setting
Price display
Litres display
Dispenser settings. These are
set in the factory and should
not be changed.
bA or bB
Set to 1000 to inhibit
standalone operation, (use
***1for purge mode)
Meter ID
ID-A or id-b
******
Temperature calibration
E-a or e-b
**.*
Density calibration
D15-a or d15-b
***.*
Maximum flow
QA **** or qb ****
K-Factor
FA or FB
***.****
Dispenser setting
c-a or c-b
*****4* for V50 meter ,
******4for AdBlue
Solenoid delay
5da *** or 5db ***
b Setting
B****
Slave display
D5 ****
Preset rounding
Prla*.** or prlb*.**
prxa*.** or prxb*.**
Flow time out
n-a *** or n-b ***
12.
Setting up the C5000
Changing the K-Factor
The K-Factor is used to calibrate product flow. It is a ratio of litres dispensed per revolution of
the meter. The K-Factor may need to be calibrated after periods of time. To calibrate the pump,
dispense fuel into a certified measuring container and compare the display value with the one
dispensed.
Example:
Display shows 10.00 True volume 20.00
To calculate the correct K-Factor from the information above; firstly, record the existing K-
Factor.
𝑁𝑒𝑤 𝐾 𝐹𝑎𝑐𝑡𝑜𝑟 = 𝐸𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝐾 𝐹𝑎𝑐𝑡𝑜𝑟 ∗ 𝐷𝑖𝑠𝑝𝑒𝑛𝑠𝑒𝑑 𝐴𝑚𝑜𝑢𝑛𝑡
𝐷𝑖𝑠𝑝𝑙𝑎𝑦𝑒𝑑 𝐴𝑚𝑜𝑢𝑛𝑡
= 𝐸𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝐾 𝐹𝑎𝑐𝑡𝑜𝑟 ∗ 20
10
= 𝐸𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝐾 𝐹𝑎𝑐𝑡𝑜𝑟 ∗ 2
To change the K-Factor, depress the K-Factor switch repeatedly until the following display is
shown. To increment a digit, press and hold the parameter switch when the desired digit is
flashing. Repeat this procedure for side B if applicable.
Submersible Delay (Sd)
This is the time delay from when the submersible pump starts to when the solenoids in the
dispenser open to allow time for the leak detector to reset.
This is factory set by Compac at 005 (five seconds).
If problems are experienced with the leak detector tripping, firstly check that the solenoid delay
is still set and then, if necessary, make it longer as follows.
fA
001.0000
13.
Setting up the C5000
To change the solenoid delay, depress the K-Factor switch repeatedly until the following display
is shown. To increment a digit, press and hold the parameter switch when the desired digit is
flashing. Repeat this procedure for side B if applicable.
Changing the V50 Meter ID
All V50 meters have a specific ID which must match the ID recorded in the dispenser settings.
This is a 6-digit number which can be found on the meter.
If the IDs do not match, the dispenser will return an error.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
As meter IDs are only relevant for V50 operation, this option will not show if the meter is not set
to V50. Therefore, it will not be shown for hoses dispensing diesel.
id-A
802060
5da 005
14.
Setting up the C5000
Changing the Temperature Calibration
The temperature calibration can be used to adjust the temperature being retrieved from the
meter, if this is not the actual temperature of the product being dispensed. The actual
temperature of product being dispensed should be entered in this menu. This will be used to
adjust new temperatures returned from the meter.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
As only V50 meters return temperature readings, this option is only for V50 operation and will
not appear if the meter is not set to V50. Therefore, it will not be shown for hoses dispensing
diesel.
Changing the Density Calibration
The density calibration can be used to adjust the density being retrieved from the meter, if this is
not the actual density of the product being dispensed. The actual density of product at 15 °C
being dispensed should be entered in this menu. This will be used to adjust new densities
returned from the meter.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
As only V50 meters return density readings, this option is only for V50 operation and will not
appear if the meter is not set to V50. Therefore, it will not be shown for hoses dispensing diesel.
E-A
15.0
D15-a
997.0
15.
Setting up the C5000
Changing the Slave Display Configuration
Slave displays can be configured as, a clone of the main display, to show side A, or to show side
B. Otherwise, it can be disabled. Slave display configuration is a two-step process.
1. Change D5 setting to assign a side to the slave display
2. Assign the correct number to the slave display by changing the slave display board dip
switches.
The first digit from the right correlates to slave display 1, and so on. In this example, slave
display 1 –clone, slave display 2 –disabled, slave display 3 - side A, slave display 4 - side B.
NOTE: Each digit can have 4 different values, each value has a different meaning.
Assigning a number to slave display
Slave display numbers can be set with dip switch 2 and 3 on the slave display board. Use the
following table as a guide to configure the slave displays
Slave Display
Switch 1
Switch 2
Switch 3
1
OFF
OFF
OFF
2
OFF
OFF
ON
3
OFF
ON
OFF
4
OFF
ON
ON
CAUTION : Make sure the device is powered off before attempting to change the dip switches
Slave display 4
Slave display 3
Slave display 2
Slave display 1
0–Disabled
1–Clone
2–Side A
3–Side B
D5 3201
16.
Setting up the C5000
Parameter Switch Settings
Changing the Pump Number
If the parameter switch is continually depressed, the following menu to change the pump
number will appear. Each side must be numbered between 1-99.
NOTE: Entering a pump number 0 will disable the pump.
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A and B.
Changing the Price
A price must be set before the dispenser can be used.
Set the price in dollars per litre. To set the price, the dispenser needs to be set to standalone
mode by changing BA for side A or/and BB for side B to1***.After setting up a price,
change the BA or/and BB setting back to authorization mode (0***).
See Using the Dispenser Menus to edit these settings.
pna 000
pa01.234
17.
Installation Tests
Installation Tests
Electrical
This procedure outlines how to perform an electrical operational test, making sure that the
dispenser is functioning correctly. Check for any damage that may have occurred in transit.
Check all terminals, plugs, and chips to make sure that they are securely in place.
NOTE: Damage to electronics occurs most commonly from vibration and jarring.
Before beginning this test, check that fuel has not been applied to the dispenser. The factory
set-up information should be programmed into the dispenser.
For the location of LEDs, required for this operations test, see page 35 of the C5000 manual.
To perform an electrical operational test:
1. Make sure that the inlet shut-off valves are closed (these are the valves in the inlet lines
at the base of the dispenser, but they are not part of the dispenser).
2. Turn on the power supply to the dispenser. Set the dispenser in purge mode (b setting
to ***1).
3. With the dispenser in a ready state, check that the C5000 processor board Power LED
is turned on.
NOTE: If the dispenser is receiving information, RD LED on the K-Factor board will be on. If the
dispenser responds to polls for its respective pump number/s, TD LED will also be on.
4. Lift the nozzle. The display will show purge and the solenoids will energise, starting
the pump motor. Check that three output LEDs (T1-7) turn on, indicating a signal is
being sent to the triacs to open the solenoid valves. The LEDs that will turn on vary
depending on the application.
5. The diagnostic LED (K-factor board) flashes quickly when the start button is pushed, or
the nozzle removed from the holster to initiate a fill. When the button is released, or the
nozzle returned to the holster it will return to the normal state and flash slowly.
6. Verify solenoid operation by listening for a click, or by using a screwdriver tip or some
other metallic tool to check for a magnetic field present on the solenoid coils.
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