Compac C4000 Futra User manual

C4000 BioBlend Annex
Version 1.0.0

Conditions of Use
Compac Industries Ltd.
Page 2
www.compac.co.nz
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 this unit incorrectly or
without authorisation.
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 installing and
operating the unit 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 unit or damages resulting
from the inability to use the unit 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 unit'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 unit 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
Information in this manual shall not be deemed a
warranty, representation, or guarantee. For
warranty provisions applicable to this unit, 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 unit, 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.

iii
Contents
Conditions of Use ............................................................................................................................................................. 2
Product Identification ....................................................................................................................................................... 4
Document Control Information ........................................................................................................................................ 5
Symbols and Units of Measure........................................................................................................................................ 6
Safety - C4000 Controller.................................................................................................................................................. 7
Static Electricity Precautions.................................................................................................................................... 7
Introduction....................................................................................................................................................................... 8
Software Requirements.................................................................................................................................................... 8
Pre-installation Checks..................................................................................................................................................... 9
Tools Required....................................................................................................................................................... 10
Site Preparation............................................................................................................................................................... 11
Electrical Preparation............................................................................................................................................. 11
Pipework Preparation............................................................................................................................................. 11
Footprint................................................................................................................................................................. 13
Installation....................................................................................................................................................................... 13
Dispensing Hose and Nozzles............................................................................................................................... 14
Wiring............................................................................................................................................................................... 14
Setting up the C4000 for Static Blend (Stand Alone Pumps) ...................................................................................... 15
Setting up the C4000 for Dynamic Blend ...................................................................................................................... 16
Calibration ....................................................................................................................................................................... 17
Error Codes ..................................................................................................................................................................... 18
Last Sale Value................................................................................................................................................................ 18
Glossary of Terms........................................................................................................................................................... 19
Installation Checklist ...................................................................................................................................................... 20

Product Identification
Compac Industries Ltd.
Page 4
www.compac.co.nz
Product Identification
Manual Title
C4000 BioBlend Annex
Models Covered
C4000 BioBlend Controller
Application
Power Supply
220 - 240 VAC; 50 Hz; 10 Amp +/- 10%
Related Manuals
Title
Publication Date
C4000 Manual
February 2011
Pump Installation Sheet
Depends on pump model
Validity
Compac Industries Limited reserves the right to revise or change product
specifications at any time. This publication describes the state of the
C4000 processor 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 C4000 processor 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 ©2011 Compac Industries Limited, All Rights Reserved

Document Control Information
Compac Industries Ltd.
Page 5
www.compac.co.nz
Document Control Information
Document Information and Revision History
Document Details:
C4000 BioBlend Annex
File Name and Location:
G:\Masters\Manuals\Authorised Manuals\C4000\BioBlend
Current Revision Author(s):
R Lacey
Authorised By:
A Kingstone
Release Date: 12/10/2011
Version
Date
Author(s)
Revision Notes
1.0.0
12/10/2011
R Lacey
Initial release
Distribution
Name
Indicator
Location

Symbols and Units of Measure
Compac Industries Ltd.
Page 6
www.compac.co.nz
Symbols and Units of Measure
Symbols
Symbols are used in this manual to highlight information that is critical
to the safety of people and equipment, and for the safe and correct
operation of the Compac equipment
An extreme hazard that may result in death or injury if
proper precautions are not taken.
A reminder of safety practices or unsafe practices that
could result in personal injury or damage to associated equipment.
A reminder of safety practices or unsafe practices that
could result in damage to associated equipment and/or voids the
warranty.
Important information essential to the installation and
operation of the Compac equipment
Units of Measure
The following units of measure are used in this manual:
Unit
Measure
Pressure
Bar (bar)
Temperature
Degrees Celsius (°C)
Volume
Litres (L)
Cubic Metres (m³)
Mass
Kilograms (kg)
Length
Metres (m)
Millimetres (mm)
Microns, Micrometres (m)
Inches (")
Torque
Newton Metres (Nm)
Voltage
Volts (V)
Current
Amps (A)
Frequency
Frequency (Hz)

Safety - C4000 Controller
Static Electricity Precautions
Compac Industries Ltd.
Page 7
www.compac.co.nz
Safety - C4000 Controller
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 Compac C4000 processor.
Mechanical Safety
Observe the following mechanical precautions:
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
Observe the following electrical precautions:
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.

Static Electricity Precautions
Introduction
Compac Industries Ltd.
Page 8
www.compac.co.nz
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 0% 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 B00 (0% 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% gradients from B00 (0%) 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
com50 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.
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

Pre-installation Checks
Static Electricity Precautions
Compac Industries Ltd.
Page 9
www.compac.co.nz
Pre-installation Checks
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.
Inappropriate installation may void the warranty. If uncertain, contact
your Compac agent for advice.

Tools Required
Pre-installation Checks
Compac Industries Ltd.
Page 10
www.compac.co.nz
Tools Required
Tools
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
Power Tools
Electric impact drill with conventional and masonry drill bits
Electrical Tools
Wire cutters
Wire stripper
Crimping tool
EPROM extractor
Multimeter
Earthing wrist strap
Diagnostic Equipment
Laptop with fully charged battery and wireless modem
LAN cable
Fully charged cell phone
Test cards and/or authorisation keys
Safety Equipment
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
Other Equipment
Step ladder
Torch
Cable ties
Dynabolts or suitable fasteners to suit the base material
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.

Site Preparation
Electrical Preparation
Compac Industries Ltd.
Page 11
www.compac.co.nz
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
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.
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

Pipework Preparation
Site Preparation
Compac Industries Ltd.
Page 12
www.compac.co.nz
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
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.
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.
The air switch is not to be disconnected. Disconnection will void NSC
and TMU approvals.
The air eliminator chamber is not to be piped back to the tank. This will
prevent it from working and may damage the pump.

Installation
Footprint
Compac Industries Ltd.
Page 13
www.compac.co.nz
Footprint
Flanges are labelled A and B. Connect flange A to the mineral diesel
tank and flange B to the bio diesel tank.
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
Wiring
Compac Industries Ltd.
Page 14
www.compac.co.nz
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

Setting up the C4000 for Static Blend (Stand
Alone Pumps)
Dispensing Hose and Nozzles
Compac Industries Ltd.
Page 15
www.compac.co.nz
Setting up the C4000 for Static Blend (Stand
Alone Pumps)
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. b15 is a 15% 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.
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.

Dispensing Hose and Nozzles
Setting up the C4000 for Dynamic Blend
Compac Industries Ltd.
Page 16
www.compac.co.nz
Setting up the C4000 for Dynamic Blend
Set the default bio-fuel blend ratio if required. Refer Setting up the C4000 for Stand
Alone BioBlend. (see page 15)
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. B10 is a 10% bio-diesel to 90% diesel blend ratio.
Blend ratios must be in steps of 5% and not exceed 40% bio-diesel.
A sample card file is shown below:

Calibration
Dispensing Hose and Nozzles
Compac Industries Ltd.
Page 17
www.compac.co.nz
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 10% in the B config (b10)
9. Do a couple of test fills and confirm you get a 10% blend. This can be done by
filling a 20L pail and then checking after the fill that approx 2 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 everything works and you are still getting the correct blend
ratio.
Calibration Codes
Code
C = 00001
Calibration mode –Meter side A
C = 00002
Calibration mode –Meter side B
C = 00003
Blend mode –Both meters
All other C config codes are disabled.

Dispensing Hose and Nozzles
Error Codes
Compac Industries Ltd.
Page 18
www.compac.co.nz
Error Codes
Error codes 7, 8 and 9 now have an “A” or “B” prefix with the A prefix denoting an
error on the mineral fuel side and “B” being used for the Bio Diesel errors
An Air switch error is displayed as „A Air‟ or „b Air‟
If the pump is not able to deliver the blend or the blend percentage being delivered
differs more than 3% from the requested ratio, the C4000 will stop both motors and
display a „blend” error. If this happens the user needs to check all supply valves and
fuel levels. They can then re-authorise the pump and attempt another delivery, the
equipment does not need to be re-powered to clear the error.
Refer to the C4000 Master Manual for a complete list of error codes.
Last Sale Value
Using the parameter switch, scroll past the pump number. The display will show last
sale values for: Meter A (diesel) litres in the Amount display, Meter B (bio-diesel)
litres in the Litres display, and the blend ratio used in the unit price display.
For commercial pumps with a Litres only display, the dispensed quantity of bio-
diesel only will be displayed in the litres display.

Glossary of Terms
Dispensing Hose and Nozzles
Compac Industries Ltd.
Page 19
www.compac.co.nz
Glossary of Terms
TERM
DESCRIPTION
ATG
Automatic Tank Gauging
Class 1 Zone 0
An area in which an explosive-gas atmosphere is present continuously or is present for
long periods.
Class 1 Zone 1
An area in which an explosive-gas atmosphere is likely to occur in normal operation.
Class 1 Zone 2
An area in which an explosive-gas atmosphere is not likely to occur in normal operation,
and if it does occur it will exist for short periods only.
ComFutra
A model of pump mounted authorisation terminal made by Compac.
CPU
Central Processing Unit.
CWID
Compac Wireless Identifier.
DCA
Driveway Card Acceptor - A type of pump authorisation terminal made by Compac.
Encoder
A device that translates rotary motion into electronic pulses. Often referred to as a pulser.
Head
Dispenser calculator/Indicator. C4000 PCB, complete with power supply.
HID
Transponder key authorisation system
Intrinsically safe circuit
A circuit in which any spark or any thermal effect produced in the test conditions
prescribed in the relevant standard (which includes normal operation and specified fault
conditions) is incapable of causing ignition of a given explosive atmosphere.
Intrinsically safe
electrical equipment
Electrical equipment in which all the circuits are intrinsically safe. The equipment may be
self-contained or may form part of an intrinsically safe electrical system.
Intrinsically safe
electrical system
An assembly of interconnected items of electrical equipment in which the circuits or parts
of circuits, intended to be used in an explosive atmosphere, are intrinsically safe circuits.
LED
Light emitting diode.
Memory chip
EPROM chip that stores parameters and/or transaction & totals.
OPT
Outdoor Payment Terminal - A type of authorisation terminal designed for credit card
applications made by Compac.
PCB
Printed Circuit Board.
RAS
Retail Authorisation Station - Authorisation terminal designed for manned sites
Via
'Plated through hole' in a PCB that enables tracks to swap sides on a PCB.
Software chip
EPROM chip with label indicating program version.

Dispensing Hose and Nozzles
Installation Checklist
Compac Industries Ltd.
Page 20
www.compac.co.nz
Installation Checklist
Version 1.0.0.
Covers Compac DCA, Comfutra, Card King and Controller units.
Site number and name:
Date:
Installer name and phone number:
Terminal ID 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
Yes
No
Check unit is undamaged and has not been tampered with.
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.
Power on
Checks
Yes
No
Check that the CE board, FMS board, pinpad, printer, cardreader, router and
modem all power up.
Check pumps are re-priced to the current fuel price.
Check that different fuels are correctly priced on all hoses.
Transaction
Checks
Yes
No
Complete transaction using white card/CWID/HID/Pin authorisation methods
Complete transaction using credit card (credit card DCA only).
Check that all hoses can be selected and authorised by the unit.
Check all hoses stop on or before the pre-authorised value (credit card DCA only).
Receipt Checks
(where fitted)
Yes
No
Check that the correct $, L and fuel grade are printed on the receipt.
Check the date, time and header information is correct.
USB Module
Checks (where
fitted)
Yes
No
Check the supplied USB key is recognised by the unit.
Select "Get Transactions" and check that transactions are uploaded to the USB key.