Ablue_Manual_Annex

Ablue_Manual_Annex
Adblue Manual Annex
Version 1.0.6
Conditions of use Adblue

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 C4000 processor
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 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.
ii

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 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.
Contents
Symbols and Units of Measure ........................................................................................................................................ 4
Overview ............................................................................................................................................................................ 5
Safety - C4000 Controller.................................................................................................................................................. 6
Static Electricity Precautions .................................................................................................................................... 6
Electrical Commissioning ................................................................................................................................................ 7
Cable Requirements ................................................................................................................................................ 8
Connecting Mains Power and Communication ........................................................................................................ 9
Electrical Comissioning C4000 Adblue .................................................................................................................. 10
Electrical Operation Test ........................................................................................................................................ 11
Mechanical Commissioning and Air Purge................................................................................................................... 12
Typical K factor settings................................................................................................................................................. 13
Cleaning AdBlue Nozzle ................................................................................................................................................. 14
Precautions when using Generator Power ................................................................................................................... 15
AdBlue Footprints ........................................................................................................................................................... 16
MMA30S Footprint ................................................................................................................................................. 16
MMA30S - Narrow Footprint .................................................................................................................................. 17
MMA 30-80S Footprint ........................................................................................................................................... 18
Spare Parts ...................................................................................................................................................................... 19
iii
Product identification Adblue
Manual Title
Adblue Manual Annex
Publication Date
August 2010
Application
Compac Adblue Dispenser
Related Manuals
C4000 Master Manual
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.
Manufacturer Contact
Details
The Compac 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.co.nz
Copyright ©2014 Compac Industries Limited, All Rights Reserved
ii
Document Control Information
Document Information and Revision History
Document Details
Adblue Manual Annex
File Name and Location
Current Revision Author(s)
A.Kingstone
Authorised By:
Fred Schreuder
Version Date
Author(s)
Release Date:15/06/10
Revision Notes
1.0.0
20/05/2010 A.Kingstone
Initial Release
1.0.1
15/06/2010 A.Kingstone
Updated software revision reference
1.0.2
16/06/10
A.Kingstone
Added Footprint
1.0.3
03/08/10
A.Kingstone
Added purge tool part number
1.0.4
28/11/2012 R Lacey
Added nozzle rinsing procedure
1.0.5
28/05/2013 R Lacey
Added footprints for MMA30S MMA30-80S MMA30S Narrow
1.0.6
14/04/2013 R Lacey
Included software update to display “Air” when air in system.
Distribution
Name
Indicator
Location
iii
Symbols and Units of Measure
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 (")
Compac Industries Ltd.
Torque
Newton Metres (Nm)
Voltage
Volts (V)
Current
Amps (A)
Frequency
Frequency (Hz)
Page 4
www.compac.co.nz
Overview
Overview
The Compac Adblue dispenser uses a V40 coriolis mass flow meter to
measure product flow into a vehicle. There are differences in the way this
dispenser is setup, calibrated and serviced compared to standard liquid fuel
dispensers
This manual applies to Adblue dispensers using software version
HIA29253_Adblue $9FC0 only.
This manual should be read in conjunction with the Compac C4000 service
manual as it only contains extra information specific to the Adblue version
of the dispenser.
Compac Industries Ltd.
Page 5
www.compac.co.nz
Safety - C4000 Controller
Static Electricity Precautions
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 antistatic 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.
Compac Industries Ltd.
Page 6
www.compac.co.nz
AdBlue Flow Rates
AdBlue Flow Rates
Care must be taken when selecting suitable pumps for AdBlue to ensure
that maximum flow rate is achieved without excessive pressure that may
damage the nozzle.
Use the chart below to guide your selection noting that pipe length and
nozzle selection may also affect flow rates.
Note: The standard ZVA AdBlue nozzle has a maximum working pressure of 3.5 bar
(50 psi).
Compac Industries Ltd.
Page 7
www.compac.co.nz
Electrical Commissioning
Cable Requirements
Electrical Commissioning
Cable Requirements
Cable requirements are as follows:
Cable Type
Power
Requirements
3 Core Steel Wire Armour Cable 2.5mm2,
220 - 240 Volts. 50 Hz, +/-10%
Core 1: 230 Volt Supply (Active).
Core 2: Neutral.
Core 3: Earth.
Dispenser:
25w Idle, 200W with all solenoids active.
Pumps with one motor (40 and 80 lpm Single hose)
Motor start current = 30 amps, run current = 6 amps
Pumps with two motors -40 and 80 lpm Dual pumps and 160 lpm Single hose pumps
Motor start current = 30 amps, run current = 6 amps
(software prevents both motors starting simultaneously)
2 Core Steel Wire Armour Cable 1.5 mm2. Maximum cable length 100 m. 12 V current loop.
Comms
Make sure that there is at least a two metre cable tail on both the incoming
underground 230 V and comms cables to reach the C4000 flameproof box.
If using generator power refer to: Precautions when using generator power (see page 15).
Compac Industries Ltd.
Page 8
www.compac.co.nz
Electrical Commissioning
Connecting Mains Power and Communication
Connecting Mains Power and Communication
In sites where the electrical supply is unstable, it is
recommended that a power conditioner or UPS is installed.
To connect the dispenser:
1.
Wire the power and comms to the C4000 Termination Board, as shown
in the diagram below.
2.
Connect the earth lead of the supply cable to the earth stud in the
flameproof junction box.
All cables must be terminated with approved flameproof
glands. The thread is 20 mm.
Refer C4000 Master Manual for all other connections.
Compac Industries Ltd.
Page 9
www.compac.co.nz
Electrical Commissioning
Electrical Comissioning C4000 Adblue
Electrical Comissioning C4000 Adblue
This procedure outlines how to perform an electrical operational test before
carrying out full mechanical commissioning and 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.
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 have been programmed
into the dispenser but all K-factor and Parameter switch settings should be
checked and confirmed before commissioning tests are carried out.
Compac Industries Ltd.
Page 10
www.compac.co.nz
Electrical Commissioning
Electrical Operation Test
Electrical Operation 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.
3.
With the dispenser in a ready state, check that the C4000
Microprocessor Power LED (D1) is turned on
If the dispenser is receiving information, Comms RXD
LED (D6) will poll. If the dispenser responds to polls for its respective
pump number/s, Comms TXD LED (D7) will also poll.

Diagnostic LED (D18) slowly flashing. (If the dispenser is
connected to an operational Controller, it flashes slowly but
erratically. If the dispenser is not connected to a Controller, it
flashes slowly and consistently.)

Watchdog LED (D5) is turned off
4.
Remove the meter encoder lead from J3 on the C4000 processor
board and plug in the meter dummy plug supplied with the dispenser
(Part number F-CU-ENC-ABL-PT)
5.
Lift the nozzle
The display will show 888888 and the solenoids will energise,
starting the pump motor. Check that Diodes D8, D10 and D11 turn on,
indicating a signal is being sent to the triacs to open the solenoid
valves.
The diagnostic LED (D18) 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 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.
7.
The solenoids will switch off after four minutes. This is a default timeout setting in the software for situations when there is no fuel flow
registered.
8.
Hang the nozzle, remove the meter dummy plug from J3, then plug the
meter encoder wiring back into J3
9.
Lift the nozzle again. The display will show 888888 and the
solenoids will energize, starting the pump motor. If the solenoids do
not energize and the message Air is shown on the screen it indicates
there may be air in the meter or pipework. This is normal, and the air
will be purged when the dispenser is mechanically commissioned.
10. To clear the error code, re-power the dispenser and the move on to the
Mechanical commissioning of the Dispenser.
Compac Industries Ltd.
Page 11
www.compac.co.nz
Mechanical Commissioning and Air Purge
Electrical Operation Test
Mechanical Commissioning and Air Purge
This procedure outlines how to perform a mechanical operational test and
making sure that the dispenser is functioning correctly. Before testing the
unit, 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.
Damage to electronics and mechanical parts occurs most
commonly from vibration and jarring.
To test the unit please carry out the following tests:
An encoder dummy plug is required to purge the air from the
system during the mechanical commissioning.
1.
Make sure that the electrical commissioning tests have been carried
out and the solenoid operation has been verified before carrying out the
following tests.
2.
Slowly open the fuel supply valves to the dispenser, checking for any
leaks.
3.
Turn on the power supply to the dispenser.
4.
Remove the meter encoder lead from J3 on the C4000 processor
board and plug in the meter dummy plug supplied with the dispenser (
Part Number F-CU-ENC-ABL-PT)
5.
Lift the nozzle
The display will show 888888 and the solenoids will energise,
starting the pump motor. Check that Diodes D8, D10 and D11 turn on,
indicating a signal is being sent to the triacs to open the solenoid
valves
6.
Check all the dispenser fittings, solenoids and pipework for leaks.
7.
Slowly dispense fuel from the dispenser, being careful to shield
yourself from splashes as there may be air in the fuel causing it to
spray from the nozzle. During this time the dispenser will NOT count up
as the encoder dummy plug is plugged into the C4000.
8.
The solenoids will switch off after four minutes. This is a default timeout setting in the software for situations when there is no fuel flow
registered. If this happens, hang the nozzle and then lift it to start a
new transaction and continue delivering fuel
9.
Repeat steps 4 through 6 until the fuel flows without any air being
present, then hang the nozzle
10. Remove the dummy encoder plug and re-install the V40 meter encoder
plug.
11. Lift the nozzle and slowly dispense fuel from the dispenser. The display
and tote should increment when fuel is flowing.
12. The dispenser can now be calibrated. Refer to the C4000 Master
Manual for calibration instructions..
Compac Industries Ltd.
Page 12
www.compac.co.nz
Typical K factor settings
Electrical Operation Test
Typical K factor settings
Below are a list of the typical K factor settings in an Adblue dispenser.
Please refer to the documentation supplied with your dispenser as there
will be slight differences due to meter calibration and dispenser setup.
Setting
Value
Description
F
1.000
Approximate value. Read the actual value of the V40 meter cover
Sd
000
Solenoid delay in seconds. Default value is zero
n
000
No Flow Timeout. Defaults to 240 seconds if no value is set.
PCuT
0.00
Preset cut. Set to a larger value if you are having problems with the unit
overrunning a preset value.
Sr
0.000
Screen Resolution. Default value is 0.000
b
0000
Set to 1000 to inhibit standalone operation
C
00001
Configuration code. Always set to 00001
Compac Industries Ltd.
Page 13
www.compac.co.nz
Cleaning an AdBlue Nozzle
Electrical Operation Test
Cleaning an AdBlue Nozzle
If AdBlue evaporates it may form crystals around the dispenser nozzle. A
build up of crystals can block the air passage causing the nozzle to
continuously trip off.
If this occurs, rinsing the nozzle in a bucket of warm water will dissolve the
crystals and unblock the air passage.
To avoid contamination of the AdBlue, thoroughly dry the nozzle after
rinsing.
ZVA AdBlue Nozzle
The ZVA AdBlue nozzle with a magnetic safety catch is commonly used on
AdBlue dispensers. The following image is included for reference. For
further information refer to ZVA direct.
Compac Industries Ltd.
Page 14
www.compac.co.nz
Precautions when using Generator Power
Electrical Operation Test
Precautions when 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 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.
Start up
1.
Before starting a generator, make sure the power to the unit is turned
off.
2.
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.
Shut down
Isolate the unit before shutting down the generator.
Compac Industries Ltd.
Page 15
www.compac.co.nz
AdBlue Footprints
MMA30S Footprint
AdBlue Footprints
MMA30S Footprint
Compac Industries Ltd.
Page 16
www.compac.co.nz
AdBlue Footprints
MMA30S - Narrow Footprint
MMA30S - Narrow Footprint
Compac Industries Ltd.
Page 17
www.compac.co.nz
AdBlue Footprints
MMA 30-80S Footprint
MMA 30-80S Footprint
Compac Industries Ltd.
Page 18
www.compac.co.nz
Spare Parts
MMA 30-80S Footprint
Spare Parts
This spare parts list only covers parts specific to Adblue dispensers. For all
other major parts please refer to the C4000 Master manual.
Part Number
Description
F-D-METER-KG
KG V40 Mass flow meter
F-G-SS8-IMC-12V
KG meter inlet tube fitting with Viton oring
F-GSKT-O/C-25V
Pipe outlet gasket with 25mm hole
F-GSKT-SF901V
Viton solenoid flange gasket
F-SOLND-3/4AB
3/4" solenoid with viton seals for Adblue use
F-CU-ENC-ABL-PT
Encoder dummy plug used for air purge and testing
Compac Industries Ltd.
Page 19
www.compac.co.nz
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