Compac C4000 BioBlend User manual

BioBlend Installation Manual
Version 1.0.2
Model: C4000 BioBlend Controller
Date: 7th December 2018

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 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 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 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.

CONDITIONS
Product Identification
Specifications
Models Covered
This manual applies to the C4000 BioBlend controller.
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 BioBlend 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
Email: [email protected]
www.compac.biz
Copyright ©2015 Compac Industries Limited, All Rights Reserved

Document Control
Document Control
Document Information
Manual Title
BioBlend Installation Manual v.1.0.1
Current Revision Author(s)
R Liu
Original Publication Date
12/10/2011
Authorised By
W Zheng
Revision History
Version
Date
Author(s)
Revision Notes
1.0.0
12 Oct 2011
R Lacey
Initial release
1.0.1
12 Nov 2018
S Laycock
Updated format, added
footprints and hydraulics
for MR400S
1.0.2
07 Dec 2018
R Liu
Updated Contact
Information

2.
Contents
Contents
Safety ................................................................................................................... 3
Static Electricity Precautions ...............................................................................3
Introduction.......................................................................................................... 4
Software Requirements ........................................................................................4
Pre-installation .................................................................................................... 5
Tools Required ......................................................................................................5
Site Preparation ................................................................................................... 6
Electrical Preparation ...........................................................................................6
Pipework Preparation ...........................................................................................6
Footprints............................................................................................................. 9
Master PN3 MR160S .............................................................................................9
Master PN3 MR400S ...........................................................................................10
Installation ......................................................................................................... 11
Dispensing Hose and Nozzles.............................................................................11
Wiring ..................................................................................................................11
Supply Pumps .....................................................................................................11
Hydraulics .......................................................................................................... 12
Typical Cycle .......................................................................................................12
Setting up the C4000 ......................................................................................... 15
Static Blend .........................................................................................................15
Dynamic Blend ....................................................................................................15
Calibration.......................................................................................................... 16
Error Codes......................................................................................................... 17
Installation Checklist......................................................................................... 18

3.
Safety
Safety
You must adhere to the following safety precautions at all times when working on the Compac
C4000 processor. Failure to observe these safety precautions could result in damage to the
Compac C4000 processor, injury, or death.
Make sure that you read and understand all safety precautions before operating the Compac
C4000 processor.
Mechanical Safety
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.
Electrical Safety
Always turn off the power to the Compac C4000 processor before opening the flame proof box.
Never touch wiring or components inside the high voltage area with the power on.
Always turn off the power to the Compac C4000 processor 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.
The C4000 head, and its associated circuits and wiring, is a certified piece of electrical
equipment approved for use in a hazardous area (Class 1 Zone 1, Group IIA T3). Only parts
identical to those covered by the certification may be used where the integrity of the intrinsic
safety may be affected. All circuit boards are to be repaired only by Compac Industries Ltd.
Static Electricity Precautions
Electronic components used are sensitive to static. Please take anti-static precautions.
All circuit boards must be carried and transported in static-shielded bags. 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.
Compac Industries Limited reserves the right to refuse to accept any returned circuit boards if
proper anti-static precautions have not been taken.

4.
Introduction
Introduction
The Compac C4000 BioBlend controller has been specifically adapted to enable the dispensing
of customised mixtures of diesel and bio-diesel fuels.
Using two pumps and solenoids, bio-diesel and diesel are drawn from their respective tanks and
blended at a ratio of between 20% to 40% bio-diesel to diesel in 5% increments.
The blend can be selected in two ways:
1) Static Blend. This is set in the C4000 using the parameter switch menu and is used for stand
alone pumps with no fuel management system connected. Blend ratios in 5% increments from
B20 (20% bio-fuel) to B40 (40% bio-fuel).
2) Dynamic Blend. The blend ratio is set on each fuel card and sent from the ComFMS board to
the C4000. Gradients in 5% can be set from B20 (20%) to B40 (40%).
The system works by turning on both pump motors and then pulsing the primary and secondary
solenoids of the bio-fuel circuit to achieve the correct blend ratio. Two meters are used, one for
each fuel. The combined total of fuel delivered through both meters is displayed on the main
pump display.
The total flow rate of the pump will vary depending on the blend selected. At a low ratio of bio-
fuel the flow rate will be lower as the majority of the blend will be supplied by the diesel pump
and motor. As the ratio of bio-diesel increases, the total flow rate will increase as the flow will
be a combination of both pumps and motors.
NOTE: The pump is designed to dispense mineral diesel with the addition of bio-diesel. It is not
designed to dispense 100% bio-diesel if the mineral diesel tank is empty. Meter errors and fuel
overflow through the air eliminator may occur if this is attempted.
Software Requirements
For the system to operate correctly special software must be used in the C4000 processor board
and the ComFMS board if applicable. The blend percentage can only be controlled through a
Compac fuel management system, it is not able to be controlled by a 3rd party system.
Software versions are:
C4000: HIA29253_BLEND
ComFMS: EAB01828_BLEND

5.
Pre-installation
Pre-installation
Transit Damage
Once the unit is received on site, inspect the cabinet for the following:
▪Shipping damage to cabinet, 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.
Tampering
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.
Vibration
Inspect terminals, plugs and IC chips to check they are securely in place and have not loosened
due to vibration.
Site Issues
Check that all wiring and pipework has been installed correctly and is undamaged. Report
issues to site manager.
Tools Required
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 impact drill with conventional and masonry drill bits
▪Wire cutters
▪Wire stripper
▪Crimping tool
▪EPROM extractor
▪Multimeter
▪Earthing wrist strap
▪Laptop with fully charged battery and wireless modem
▪LAN cable
▪Fully charged cell phone
▪Test cards and/or authorisation keys
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.

6.
Site Preparation
Site Preparation
Refer to the Site Audit document if supplied.
To ensure maximum operating life, care should be taken when siting the dispenser.
Considerations should include:
▪The unit is not designed to be constantly exposed to the elements. A canopy or shelter
should be installed to protect it.
▪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.
▪On heavy vehicle sites, mounting the unit on a raised pad and/or installing bollards to
help protect from damage.
▪The base needs to be attached to a smooth, level surface of sufficient strength to
securely hold the retaining bolts or fasteners.
Electrical Preparation
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 mm2Steel Wire Armour (SWA) cable
•Comms: 2 core 1.5 mm2Steel Wire Armour (SWA) cable
There should be a minimum of a 2 metre tail for all wiring.
NOTE: The length of the communications cable must not exceed 100 metres.
Pipework Preparation
Pipework should be laid in accordance with local regulations.
To obtain maximum flow on a self contained pump, observe the following guidelines:
▪Total length of horizontal piping between tank and pump should be no longer than 18
metres.
▪Piping specifications: For 40 L/min pumps, use 1½” galvanized or approved non-
metallic pipe. For 80 L/min pumps use 2” galvanized or approved non-metallic pipe.
▪Only one pumping unit is permitted for each underground pipe. Do not use tee joints to
connect two pumps into one pipe.
▪Pipe must slope up from the tank to the pump (approximately 15 mm per metre). Pipe
should be straight and supported along its length.
▪All horizontal piping must be buried at least 450mm below ground level.
▪The area under the pumping unit(s) must be filled with sand or dirt as far up the suction
line as possible. Use water to pack the sand or dirt when put in place.
▪Avoid asphalt drive surfaces covering the piping. Asphalt increases heat absorption
causing vapour lock.

7.
Site Preparation
▪Static lift must not exceed 3 metres (vertical distance from the product level in the tank
to the centre of the pump unit).
▪To absorb ground movement from settling of the tank, frost heaving of the ground or
pump island settling, a swing joint must be used in the supply line at the tank and
directly underneath the dispenser. Three additional directional changes using elbows
are permitted.
▪Piping must hold a 3.4 Bar (50PSI) pressure test for a minimum of 10 minutes.
Refer to the footprint drawings for pump installation details.
Check Valve
A Check Valve must be installed at the tank end of the suction pipe on the top of the tank in a
serviceable location. Many clients install an extra check valve at the inlet to the pump. It is
important neither of the check valves interfere with the flow of fuel. They must be adequately
sized.
Swing Joint
Vent pipe
Fill pipe
18 metres maximum
3 metre
maximum lift
Check Valve

8.
Site Preparation
CAUTION: The pump inlet must not be pressurised at any time. This will cause fuel to flow from
the air eliminator. Unregulated connection to an above ground tank will cause pressurisation.
CAUTION: For above ground tanks a regulator valve such as a Tokheim valve or similar device
MUST be used so that the inlet of the pump cannot become pressurised at any time.
NOTE: The air switch is not to be disconnected. Disconnection will void NSC and TMU approvals.
NOTE: The air eliminator chamber is not to be piped back to the tank. This will prevent it from
working and may damage the pump.
Above Ground
Storage tank
Shut-off valve
Solenoid valve
(wire so that valve
is open only when
the pump motor is
running)
Tokheim valve
(mounted directly
under pump)
Shear section
level with bottom
of base
Pipe vent to top of
storage tank or vent
to atmosphere -
Do not plug

9.
Footprints
Footprints
Master PN3 MR160S

10.
Footprints
Master PN3 MR400S

11.
Installation
Installation
Refer to your individual pump installation sheets for mounting diagrams.
The two inlets on the base of the dispenser are labelled A and B. Ensure that the inlet A is
connected to the (mineral) diesel tank and the inlet B is connected to the bio-diesel tank.
Dispensing Hose and Nozzles
The unit may or may not be supplied with dispensing hose and nozzle assemblies.
The dispensing equipment shall be installed to prevent the delivery hose from contacting the
ground when not in use.
If customer supplied hose assemblies, pylons, reels, safe breaks and nozzles are used they
must comply with the requirements outlined in AS/NZS 2229
Wiring
For general wiring instructions, refer to the C4000 Master Manual.
On the C4000 Power Supply the motors and solenoids are connected to the following terminals:
▪Mineral pump motor is T1
▪Mineral solenoids are T2 and T3
▪Bio pump is T4
▪Bio solenoids are T5 and T6
On the C4000 Board the meters are connected to the following terminals:
▪Mineral meter plugs into J3
▪Bio Diesel meter plugs into J4
Supply Pumps
The Bioblend gauge must always be 2 PSI higher than the diesel gauge. These can be adjusted
by setting supply pumps. The location of the gauges can be seen in Hydraulics (see page 12.)

12.
Hydraulics
Hydraulics
Component
Function
Diesel and Biodiesel gauges
These show the pressure of the supply pumps. Ensure the
biodiesel gauge is always 2 psi higher than the diesel
gauge.
COM 50, 125, 250 meters
Measure the flow of biodiesel and diesel.
Biodiesel and Diesel filters
Fuel is passed through these before being dispensed.
Solenoids
Provide on/off flow control for both diesel and biodiesel.
Typical Cycle
The following table describes a typical hydraulic cycle.
Operator Action
What happens at the dispenser
Lift the nozzle
The C4000 activates the pumps. The solenoids open and
the fill commences.
Nozzle lever opened.
Diesel is continuously dispensed, and the biodiesel
solenoid pulses on and off to ensure the correct blend
ratio is delivered. Fuel flow is metered.
After 10 litres is dispensed, the blend ratio is checked,
and then continuously monitored. If an incorrect ratio is
being dispensed an error will occur.
Nozzle lever closed and nozzle
is hung up.
The solenoids close and the pumps stop after the fill has
ended.

13.
Hydraulics
PN3 MR160S
COM50 Meter
COM125 Meter
Mounting Bracket
Biodiesel Solenoid
Diesel Solenoids
Diesel Gauge
Biodiesel Gauge
Outlet
Biodiesel Filter
Diesel Filter

14.
Hydraulics
PN3 MR400S
Com250 Meter
Solenoids
Outlet
Diesel Gauge
Com125 Meter
Biodiesel Gauge
Biodiesel Filter

15.
Setting up the C4000
Setting up the C4000
Static Blend
For pumps that are not connected to a card management system, the C4000 must be set up to
dispense the correct blend using the Parameter Switch.
Refer to C4000 Master Manual to find the location of the parameter switch.
STEP
ACTION
RESULT
1
Ensure that the nozzle is hung
up
Dispenser in idle state
2
Press the parameter switch 9
times
The blend ratio is displayed in the following
format: bXX where XX is the current blend
ratio percentage. Eg. B20 is a 20% blend.
3
Press and hold the Parameter
switch.
The blend ratio number will step up in
increments of 5% until the maximum ratio of
40% is reached. If the parameter switch is
held after this, the ratio will return to zero
and start stepping up again.
4
When the ratio is correct,
release the Parameter switch.
After approximately 10 seconds the display
will return to the normal dispenser display.
NOTE: If dynamic (fuel card controlled) blends are used, the set figure will become the default
blend setting if the fuel card does not have a blend ratio set.
Dynamic Blend
Set the default bio-fuel blend ratio if required.
In your card files use the "Owner Details 1" column to manage the individual blend ratios using
the following format: BXX where XX is the percentage bio-diesel to diesel blend required. Eg.
B25 is a 25% bio-diesel to 75% diesel blend ratio. Blend ratios must be in steps of 5% and
between 20 and 40% bio-diesel.
A sample card file is shown below:

16.
Calibration
Calibration
To calibrate a BioBlend dispenser use the following procedure:
Refer to C4000 Master Manual for detailed instructions.
1. Change the B configuration to b0000 as it will be set to inhibit standalone. (b1000 is
standard)
2. Change the C config to be C00001
3. Disconnect the communications from the FMS board or simply turn off the power switch
in the ComFutra head and then re-power the pump to put it into standalone mode
4. Calibrate the Mineral side of the dispenser using the normal calibration procedures.
Refer to C4000 manual.
5. Change the C Config to be C00002
6. Calibrate the mineral side of the dispenser using normal calibration procedures
7. Change the C Config to C00003 to enable the blend
8. Check the Blend is set to 20% in the B config (b20)
9. Do a couple of test fills and confirm you get a 20% blend. This can be done by filling a
20L pail and then checking after the fill that approx 4 litres of bio-fuel is shown in the
Litres display by using the Last Sale Value function of the Parameter menu.
10. Change the B configuration back to b1000 to re-enable inhibit standalone, reconnect the
comms and turn on the ComFutra head.
11. Wait a few minutes for the ComFutra to boot up then do a test fill or two using a card to
confirm that the dispenser is working correctly and you are still getting the correct blend
ratio.
Calibration Codes
NOTE: All other C config codes are disabled.
Code
C = 00001
Calibration mode –Meter side A
C = 00002
Calibration mode –Meter side B
C = 00003
Blend mode –Both meters

17.
Error Codes
Error Codes
See the following table for error codes for the unit. Some codes will have a prefix ‘A’ or ‘B’
depending on the side. A indicates an error on the mineral fuel side, and B indicates an error on
the bio diesel side.
Error Code
Fault
Action
Err 3
No price or pump number set.
Set the pump number or:
Set a price at the pump or at the
controller.
Err 7
Excess flow.
Max Flowrate exceeded.
Err 8
Excess reverse rotation of encoder.
Check product is not flowing back
into the tank once the delivery has
finished.
Err 9
Faulty or disconnected meter
encoder.
1. Check that encoder is plugged in.
2. Replace encoder PCB on meter.
Err 10
Configuration Lost.
Reconfigure C4000. Refer to C4000
manual.
Err 12
C4000 memory failure.
Change memory IC.
F-AD-DS1225 (not applicable to
Futra.)
Ped
Abd
Display error.
1. Check display cable for loose
wires/crimps.
2. Replace display PCB.
air
Air detected in the system
Air purge is required
blend
The pump is not able to deliver the
blend, or the blend percentage
being delivered differs more than
3% from the requested ratio
Check all supply valves and fuel
levels. Re-authorise the pump and
attempt another delivery