Page 1 CNG Dispenser Service Manual Version 1.0.8 Compac Industries Ltd. 52 Walls Road. Penrose. Auckland 1061, New Zealand. PO Box 12 417 Penrose. Auckland 1642. New Zealand. Tel: +64 9 579 2094 Fax: +64 9 579 0635 info@compacngv.com www.compacngv.com...
Page 2 Subject to your right to use the Compac CNG procedures in this manual and exercise all due care. Dispenser, Compac does not convey any right,...
Page 3: Table Of Contents
Mounting the Dispenser ............................13 Connecting the Pipework ............................13 Attaching the High Mast (Laser Only) ........................14 Electrical Installation ..............................15 CNG Cable Requirements ............................. 15 Connecting Mains Power and Communication ...................... 16 Electrical Commissioning .............................. 17 Mechanical Commissioning ............................18 Dispenser Set-up ................................
Page 4 Dispenser Component Locator ..........................89 Hydraulic Layout ..............................90 Electrical Drawings and Component Details ........................ 91 CNG Dispenser Electrical Schematic ........................91 C4000 Power Supply Board ........................... 92 C4000 Microprocessor Board ..........................96 C4000 Temperature Pressure Interface Board CI75-B ..................112 C4000 IS Cable Connections ..........................
Page 5 Compac Industries Limited reserves the right to revise or change product specifications at any time. This publication describes the state of the CNG Dispenser at the time of publication and may not reflect the product at all times in the past or in the future.
Page 6: Document Control Information
Document Control Information Document Information and Revision History Document Details Compac CNG Dispenser Service Manual File Name and Location Current Revision Author(s) R Lacey A.Kingstone Authorised By: Release Date:27/04/11 Version Date Author(s) Revision Notes 1.0.0 12/01/2010 R Lacey Added document control information 1.0.2...
Page 7: Symbols And Units Of Measure
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.
Page 8: Safety
Observe the following electrical precautions: Always turn off the power to the CNG Dispenser before removing the box lid. Never touch wiring or components inside the CNG Dispenser with the power on. Never power up the CNG dispenser with the flameproof box lid removed.
Page 9: Introduction
Introduction The Compac CNG dispenser is designed to provide safe and reliable dispensing of CNG fuels. They are available in either single or dual hose configurations and with different flow rates. Compac CNG dispensers are controlled by a C4000 board which has many programmable features to suit your individual operation.
Page 10: Software Versions
Error 7 message changed to read in totes screen  End of sale reason flashed in unit price display at end of sale Software Version HIA29.26.0CNG onwards Kilograms dispensed display increased to three decimal places for  greater accuracy Compac Industries Ltd. Page 10 www.compacngv.com...
Page 11: Mechanical Installation
Check the high points and low points of the pipework distribution system to make sure that:  Vents have been provided on all high points.  Drains have been provided on all low points. Compac Industries Ltd. Page 11 www.compacngv.com...
Page 12: Preparing And Cleaning Pipework
Any steel, brass, or other impurities can damage the regulator and solenoid valve seals. The pipework installer is responsible for installing all pipework to the dispenser with due diligence. Compac is not responsible for any pipework external to the dispenser. Ensure that all pipework is completely clean. Any dirt trapped in the pipework can damage the valve seals and surfaces.
Page 13: Mounting The Dispenser
Refer to one of the following procedures, depending on the fitting that you are using:  SAE Fittings (see page 87)  Adjustable SAE fittings (see page 87)  Compression tube Fittings (see page 88) Compac Industries Ltd. Page 13 www.compacngv.com...
Page 14: Attaching The High Mast (Laser Only)
(6 mm Allen or Hex key required for installation) 3 x M8 spring washers 3 x M8 x 30 stainless steel socket head screw (6 mm Allen or Hex 3 x M8 flat washers key required for installation) Compac Industries Ltd. Page 14 www.compacngv.com...
Page 15: Electrical Installation
Electrical Installation CNG Cable Requirements Electrical Installation CNG Cable Requirements Cable requirements are as follows: Cable Type Requirement 3 Core Steel Wire Armour Cable 2.5mm Power 220 - 240 Volts. 50 Hz, +/-10% Core 1: 230 Volt Supply (Active). Core 2: Neutral.
Page 16: Connecting Mains Power And Communication
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. Figure 1. C4000 Power supply wiring Compac Industries Ltd. Page 16 www.compacngv.com...
Page 17: Electrical Commissioning
Press the Stop button. The solenoids switch off and the fill ends. When you release the Stop button, the dispenser resets and returns to a ready state. Compac Industries Ltd. Page 17 www.compacngv.com...
Page 18: Mechanical Commissioning
12. Use soapy water to check all fittings (including the hose fittings) for leaks. Always de-gas the lines before tightening any fittings. Never tighten fittings while they are under pressure. 13. Complete a few fills on a test cylinder, checking for leaks or unusual operation. Compac Industries Ltd. Page 18 www.compacngv.com...
Page 19: Dispenser Set-Up
The Parameter switch also enables you to view the Dispenser Software Version and End of Sale Indicators. Figure 2: Parameter and K-Factor switches. Compac Industries Ltd. Page 19 www.compacngv.com...
Page 20 C configuration in order to access the parameter code you require. C Configuration Set-Up Code Code Description CXXX61 Software Program version Unit Price CNG Sequencing rate Hose Number Code Dispenser Passcode CXXX62 Software Program version Unit Price Side A Unit Price Side B...
Page 21 A of the dispenser. is the unit price for side B of the dispenser The unit price can be set at the dispenser or set remotely with the Compac Dispenser Monitor. Error 3 If the unit price is not set will be displayed and the dispenser will not operate.
Page 22 Dispenser Set-up Parameter Switch Sequencing Rate Only available on CNG dispensers. Needs appropriate software. The sequencing rate (SE9) enables you to set the percentage level of maximum flow that sequencing occurs to the next pressure bank. There are three settings to choose from: ...
Page 23 The Hose Number ( identifies the dispensers hose(s) when the dispenser is communicating to a forecourt controller such as the Compac Dispenser Monitor. is the hose number of side A of the dispenser. is the hose number side B of the dispenser When using forecourt controller all dispenser hoses must have unique numbers.
Page 24 If set, only the dispenser software version can be viewed. If the dispenser is connected to the forecourt PC, you can access the dispenser information via the Compac Dispenser Monitor program, even if the dispenser is passcode is enabled. To Set the Dispenser Passcode Make sure that the dispenser is idle, with the nozzle in its holster.
Page 25: K-Factor Switch
The K-factor switch will offer different menu options depending on the current C Configuration Code (see page 35) The X indicates that you can achieve the displayed menu option, regardless of what the indicated part is set to. Compac Industries Ltd. Page 25 www.compacngv.com...
Page 26 C Configuration Menu Options Available C0XX61 C0XX62 C1XX61 gAin C1XX62 gAinA gAinb FpA C2XX61 gAin gAin2 fpA C2XX62 gAinA gAinb gAinA2 gAinb2 fpA C3XX61 gAin C3XX62 gAinA gAinb fpA C4XX61 gAin gAin2 fpA C4XX62 Compac Industries Ltd. Page 26 www.compacngv.com...
Page 27 K-factor on side A of the dispenser. is the meter K-factor on side B of the dispenser. The K-Factor is set during the calibration phase Meter Calibration (see page 67) and does not require adjusting during service. Compac Industries Ltd. Page 27 www.compacngv.com...
Page 28 If you want to pass over a setting without changing any digits, keep pressing and releasing the switch. The Compac factory default setting is 1.0 kg/min. Let the menu time out so that the value and quantity amounts are displayed.
Page 29 The Compac factory default setting is 40 kg/min for Car Dispensers and 60 kg/min for High flow or Bus dispensers. Let the menu time out so that the value and quantity amounts are displayed.
Page 30 If you want to pass over a setting without changing any digits, keep pressing and releasing the switch. Let the menu time out so that the value and quantity amounts are displayed. Compac Industries Ltd. Page 30 www.compacngv.com...
Page 31 If you want to pass over a setting without changing any digits, keep pressing and releasing the switch. Let the menu time out so that the value and quantity amounts are displayed. Compac Industries Ltd. Page 31 www.compacngv.com...
Page 32 If you want to pass over a setting without changing any digits, keep pressing and releasing the switch. Let the menu time out so that the value and quantity amounts are displayed. Compac Industries Ltd. Page 32 www.compacngv.com...
Page 33  1 = Biogas / Methane.  2 = CNG. Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed.
Page 34: Configuration Code
When this mode is set will appear in the value display and the current flow rate value will appear in the unit price display. This is used for testing only and not during normal dispenser operation. Compac Industries Ltd. Page 34 www.compacngv.com...
Page 35: C Configuration Code
10 bar of the second. Fast fill mode measures the pressure, but not the temperature. FPb) The dispenser fills to the configurable target fill pressure (FPA or Compac Industries Ltd. Page 35 www.compacngv.com...
Page 36: Dispenser Operation
Dispenser Operation Refuelling a Vehicle There can be up to three storage banks for CNG refuelling. During filling the dispenser sequences through these banks from low to high as the pressure in the vehicle cylinder increases and the flow rate drops.
Page 37 Fast, Normal or Slow rates using the Parameter menu. The factory setting is normally set to Fast. Refer to Sequencing Rate (see page The vehicle fill pressure is restricted to the regulator set pressure, this is normally set at 200 bar in the factory. Compac Industries Ltd. Page 37 www.compacngv.com...
Page 38 The amount of gas (KGf1) to completely fill the vehicle to calculated as follows: KGf1 = (KG2 – KG1) x (FPA – P1) / (P2 – P1). The dispenser fills to KGf1 and stops. This is the end of the fill. Compac Industries Ltd. Page 38 www.compacngv.com...
Page 39: Reading The Dispenser Totals
There will two digits on the top ($) display and six digits on the lower (kg) display For dual dispensers, the A or B side will be indicated in the unit price display. Compac Industries Ltd. Page 39 www.compacngv.com...
Page 40: Servicing
Isolate the dispenser by closing the inlet gas supply valves at the base Degass the Dispenser of the unit or at the priority panel. Fill one or more CNG bottles until the dispenser pipework is completely depressurized. Ensure that the isolation valve remains open during this process.
Page 41: Scheduled Servicing
 Check the C4000 flameproof box lid is bolted down tight and all glands are tight.  Check the zero point and calibration of the dispenser pressure transducers (fast fill & temperature compensation only). Compac Industries Ltd. Page 41 www.compacngv.com...
Page 42  When the hose is empty check that the flow has stopped. If the flow does not stop, the seals in the final stage solenoid will need to be replaced. (see page 48) Compac Industries Ltd. Page 42 www.compacngv.com...
Page 43 Adjust the pressure up clockwise or down anticlockwise to 200 bar. If the pressure on the gauge does not remain stable, the regulator valve seal is leaking and will have to be replaced (see page 52). Valve Adjuster (use 8 mm Hex Key) Compac Industries Ltd. Page 43 www.compacngv.com...
Page 44 Check the dispenser End of Sale indicator states that the fill has ended because of over-pressure. End of Sale Indicators (see page 122) Reset the over-pressure cut-off point to its original value. Compac Industries Ltd. Page 44 www.compacngv.com...
Page 45 Serious injury may result if components are removed while the dispenser is under pressure. Replace the hose (see page 59) if it is damaged or leaking. Compac Industries Ltd. Page 45 www.compacngv.com...
Page 46 Allow all oil and water to drain from the filter. If excessive amounts of oil and water are present, remove and replace the coalescing filters (see page 47). Screw in the drain plug and repeat steps 1 to 4 for all additional filters. Compac Industries Ltd. Page 46 www.compacngv.com...
Page 47: Filter Element Replacement
Always use O-ring lubricant to prevent damage to the O- rings. Screw in the filter bowl(s) Check the dispenser for leaks. (see page 45) Filter Bowl O-ring Seal Filter Element Filter Bowl Drain Plug Compac Industries Ltd. Page 47 www.compacngv.com...
Page 48: Solenoid Valve Seal Replacement
Solenoid Valve Seal Replacement Solenoid Valve Seal Replacement These instructions refer to the current Compac S2-350 solenoid valve. The solenoids are available in several types: Standard, high oil and low temperature. Always quote the dispenser serial number when ordering parts and check the model number on the valve body before installation.
Page 49 10. Clean all oil and dirt off the components with a clean cloth and check that the bleed hole is not blocked. 11. While the solenoid is apart, inspect the solenoid piston centre seal and piston for wear, scratching or damage. Replace piston if required. Compac Industries Ltd. Page 49 www.compacngv.com...
Page 50 Screw in and tighten the six cap screws. Replace the solenoid coil. 10. Re-power and re-gas the dispenser then check for leaks and correct operation of the valve. Refer to page 18. Compac Industries Ltd. Page 50 www.compacngv.com...
Page 51: Solenoid Coil Replacement
Solenoid Coil Replacement Before you start, make sure you have:  Replacement solenoid coil FC-COIL-0005 (Compac S2-350) Solenoid coils are not interchangable between models. Make sure you order the correct one by quoting the dispenser serial number. To replace obsolete coils, the entire solenoid will need replacing.
Page 52: Complete Solenoid Valve Replacement
Servicing Complete Solenoid Valve Replacement Complete Solenoid Valve Replacement These instructions refer to the current Compac S2-350 solenoid valve. This replaces all previous solenoids. Before you start, make sure you have:  Solenoid valve standard 350 bar model (FC-VALVE-0035) or ...
Page 53 The back-up rings go on the outside of the O-rings. Always use O-ring lubricant on the O-rings to increase the service life. Reassemble the piston. Push the piston back up into the regulator body with a hex key. Compac Industries Ltd. Page 53 www.compacngv.com...
Page 54: Compac Breakaway Seal Replacement
Compac Breakaway Seal Replacement This section describes how to replace the seal in a QBCI model breakaway. The Compac Breakaway QBCI is only used on 15 kg/min models or on models where the vent is returned to the dispenser. The excess flow end (female) and check valve end (male) should not require servicing.
Page 55: Three Way Refuelling Valve Seal Replacement - Old Model -Brass
 This valve was superseded by a new, improved valve in 2008. Please see Important note Compac technical bulletin CTB10015 for more information. Before you start Obtain the following replacement parts and equipment: Seal Kit Part Number is FC-SK-0008 or FC-SK-0009 ...
Page 56 Servicing Three Way Refuelling Valve Seal Replacement - Old Model -Brass Compac Refuelling Valve Exploded View Compac Industries Ltd. Page 56 www.compacngv.com...
Page 57: Three Way Refuelling Valve Seal Replacement - New Model - Stainless Steel
Three Way Refuelling Valve Seal Replacement - New Model - Stainless Steel  The new Compac three way valve uses a different seal kit to the old Important note version. Please make sure you identify the valve before disassembling it to make sure you have the correct seal kit available.
Page 58 Servicing Three Way Refuelling Valve Seal Replacement - New Model - Stainless Steel Compac Refuelling Valve Exploded View Retainer Nut “A” assembly Retainer Nut “B” assembly Shaft/Spindle assembly Compac Industries Ltd. Page 58 www.compacngv.com...
Page 59: Refuelling Hose Replacement
Attach the new hose to the dispenser at the outlet block. Regas the dispenser and push the Start button to fill the new hose assembly with gas. Check all hose connections for leaks by applying soapy water mixture and looking for bubbles. Compac Industries Ltd. Page 59 www.compacngv.com...
Page 60: Power Supply Fuse Replacement
F2 = 0.25 A  F3 = 1.0 A  OR Compac fuse kit F-C4PWR-FUSEKIT Fuse locations are displayed on the C4000 Power Supply Board (see page 92). Every new dispenser is supplied with one spare fuse of each value located on the inside of the flameproof box lid.
Page 61: Power Supply Replacement
O-ring of the same size and specification (176 N70). It should not be necessary to recalibrate the dispenser. However, in some locations, this may be legally required as per the Calibrate the Meter section (see page 67). Compac Industries Ltd. Page 61 www.compacngv.com...
Page 62: Processor Board Replacement
Refit the EPROM and memory chips, as per Dispenser Software Upgrade/Replacement (see page 64) Check dispenser operation Checking Dispenser Operation (see page It should not be necessary to recalibrate the dispenser. Compac Industries Ltd. Page 62 www.compacngv.com...
Page 63: Temperature Pressure Board Replacement (Fast Fill & Temperature Compensation Units Only)
Turn the power to the dispenser back on. Check Dispenser operation. Checking Dispenser Operation (see page It should not be necessary to re-calibrate the dispenser unless a pressure transducer or temperature probe needs to be replaced. Compac Industries Ltd. Page 63 www.compacngv.com...
Page 64: Dispenser Software Upgrade/Replacement
Dispenser Software Upgrade/Replacement Dispenser Software Upgrade/Replacement You can only upgrade the dispenser software by replacing the EPROM chip. Follow this software upgrade procedure for all CNG Dispensers that use the C4000 Microprocessor. Before working on the dispenser electronics, take basic anti- static precautions by wearing a wristband with an earth strap.
Page 65: Meter Replacement
Meter Replacement Before you start, make sure you have:  A new Compac meter F-D-METER-KG80T De-gas the dispenser (see page 40). Remove the Meter Remove the tubing from the meter inlet and outlet. Unscrew the SAE fittings from the meter inlet and outlet.
Page 66: Unserviceable Parts List
The KG meter:  have firmware upgraded approved service agents.  Can only be serviced by Compac.  Has no set-up functions.  Is self-characterising. The only function performed in the set-up is setting the K- Factor on the C4000 head.
Page 67: Dispenser Calibration
5.80 = 1.0138 (4 decimal places) Input the new meter K-factor ( & ) (see page 27) Input dispenser settings Set the density factor back to its original value. ( ) (see page 27) Compac Industries Ltd. Page 67 www.compacngv.com...
Page 68 To carry out the calibration test fill procedure (Method 1): Put the CNG cylinder on the scales. Empty the CNG cylinder by venting it to the atmosphere. Always vent cylinders in a safe manner and safe location. Zero the TARE read-out on the scales.
Page 69: Pressure Transducer Calibration (Fast Fill & Temperature Compensated Units Only)
Press and hold the "K" factor switch to change the display to equal the pressure on the gauge. Allow the "K" factor setting to time out. Re-check the pressure at 100 and 200 bar gauge pressure to see if display and gauge read the same. Compac Industries Ltd. Page 69 www.compacngv.com...
Page 70: Ambient Temperature Sensor Calibration
Ambient temperature sensor. Access the current dispenser ambient temperature reading (see page 29). Adjust dispenser reading Adjust the dispenser’s ambient temperature reading to match that of the calibrated temperature meter (see page 29). Compac Industries Ltd. Page 70 www.compacngv.com...
Page 71: Indicator Leds
The watchdog circuit has been triggered. This indicates that there is a fault on the processor board.(on) Polling information has been received. (flashes on/off) The C4000 processor responds to polls for its respective hose number(s).(flashes on/off) Compac Industries Ltd. Page 71 www.compacngv.com...
Page 72: Diagnostic And Output Leds
Solenoid High Bank Side B. Error indication. The Solid State Relays (Triacs) Layout and Function part of the C4000 Supply Board section (see page 92) show the physical locations of triacs and power terminals. Compac Industries Ltd. Page 72 www.compacngv.com...
Page 73 Indicator LEDs Diagnostic and Output LEDs Compac Industries Ltd. Page 73 www.compacngv.com...
Page 74: Troubleshooting
For sites where the temperature falls below –10°C, power should only be removed from the dispenser for servicing. When servicing a Compac CNG Dispenser fault, please follow the recommendations and safety information in this manual. Failure to do this may cause injury or void the warranty.
Page 75: Problems When Dispenser Is Idle
 Replace C4000 memory software chips Replace C4000 processor board   Replace Display PCB A display LCD segment is Faulty display unit. always on or always off. Compac Industries Ltd. Page 75 www.compacngv.com...
Page 76: Problems Starting A Fill
 Clean the regulator and replace the valve seals (see page 52).  De-gas the dispenser to reduce the pressure. Compac Industries Ltd. Page 76 www.compacngv.com...
Page 77: Problems Filling A Vehicle
Solenoid valves are not closing at the seals. end of a fill when the dispenser stops metering because of dirt and/or water contamination.  Replace the meter (see page 65). The meter is faulty and has stopped Compac Industries Ltd. Page 77 www.compacngv.com...
Page 78 The dispenser will stop dispensing if restart. 9999.99 99999.9 either the value or the quantity , or This is not a dispenser fault. displays ever reach these values. 999999 units according to where the decimal point is set. Compac Industries Ltd. Page 78 www.compacngv.com...
Page 79: Solenoid Problems
Coil has been removed from solenoid and energised, causing the coil to burn If the solenoid is still not working reliably  Fit the solenoid top service kit. Refer to Finally valve seal replacement (see page 48) Compac Industries Ltd. Page 79 www.compacngv.com...
Page 80: Appendix
G EEx ib A T3 (-25°C ≤ Ta ≤ 80°C) Control Unit   1G EEx ia A T3 (CWIT Aerial only:- The Compac CNG equipment is also PED approved for use up to 275 bar. EC - Type Examination PED Approval Marking on the Equipment Equipment Certificate Number ...
Page 81: Specifications
Specifications Model Specifications Specifications Model Specifications There are various CNG Dispenser models and options available. The models include:  Legend frame or Laser frame. The options include:  One, two, or three line.  Single or dual hose.  Fixed pressure final fill cut-off or temperature compensated final fill cut-off.
Page 82: Technical Specifications
Specifications Technical Specifications Technical Specifications Operating Conditions Compac CNG Dispensers (excluding hose assembly) are designed to operate within the atmospheric environment. Gas parameters are outlined below. CNG Dispensers require the following operating conditions: Air temperature range - 25 °C to + 55 °C...
Page 83: Component Specifications
Solenoid valve SCI-12-SS 3/4” SAE female inlet. The high flow solenoid valve is designed to control the flow of gas in a CNG Dispenser. 3/4" SAE female outlet. Between the inlet and outlet, the valve opens 275 bar max. with a differential pressure of more than 275 bar.
Page 84 Isolation ball valve Parker 2-way 8 series ball valve Microprocessor C4000 The Compac C4000 processor controls all the electronics in the dispenser. Display GD1, GD2 or The display has six 1" digits for price, six 1" digits for quantity and four 3/4" digits for unit price.
Page 85: Installation Diagrams
Installation Diagrams LEGEND Installation Diagram Installation Diagrams LEGEND Installation Diagram Compac Industries Ltd. Page 85 www.compacngv.com...
Page 86: Laser Installation Diagram
Installation Diagrams LASER Installation Diagram LASER Installation Diagram Compac Industries Ltd. Page 86 www.compacngv.com...
Page 87: Dispenser Fittings
Dispenser Fittings Aside from some NPT fittings located in the utility manifold, all fittings used in a Compac CNG Dispenser are SAE. Some SAE fittings are adjustable to allow for rotational positioning of components such as solenoids. Nipples, tees, and elbows are used, but the procedure is the same for each.
Page 88 Reassemble the fitting, tightening it by hand and then a further 1/4" turns with the appropriate spanner. Correctly made tube should not need to be sprung into position. Compac Industries Ltd. Page 88 www.compacngv.com...
Page 89: Mechanical Drawings And Component Details
Mechanical Drawings and Component Details Dispenser Component Locator Mechanical Drawings and Component Details Dispenser Component Locator The C4000 Dispenser Power supply is housed in a flameproof box. All other components are simply located in enclosures. See below. Compac Industries Ltd. Page 89 www.compacngv.com...
Page 90: Hydraulic Layout
KG80 Mass Flow Meter Hose from Breakaway to Nozzle Isolation Valve Refueling Nozzle Assembly Manifold Block Assembly Manifold Block Pressure Gauge (Optional) Inlet Outlet Pressure Transducer (Temperature compensated models only) Pressure Relief Valve Bleed Valve Compac Industries Ltd. Page 90 www.compacngv.com...
Page 91: Electrical Drawings And Component Details
Electrical Drawings and Component Details CNG Dispenser Electrical Schematic Electrical Drawings and Component Details CNG Dispenser Electrical Schematic Compac Industries Ltd. Page 91 www.compacngv.com...
Page 92: C4000 Power Supply Board
230Vac inputs (phase logic and phase triac) are normally linked. These inputs can be separated if necessary. Comms Triac Snubber Dip Switches Switches Wire link 20Vac Comms 230Vac Triac Test Fuses Inputs Outputs Input Compac Industries Ltd. Page 92 www.compacngv.com...
Page 93 Electrical Drawings and Component Details C4000 Power Supply Board C4000 IS Cable CNG Outputs The C4000 controls the solid state relay switch. Solid state relay switches control the C4000 220-240 volt outputs. Solid State Relays (Triacs) There are 10 separate solid state relays (small triacs) on the C4000 PCB.
Page 94 Electrical Drawings and Component Details C4000 Power Supply Board Compac Industries Ltd. Page 94 www.compacngv.com...
Page 95 & WIRING Triac Snubber Switches Triac snubber switches are used to switch different snubber circuits across the solid state relays. On CNG Dispensers, these (SW1, SW2, and SW4) must always be set to low current output (2). Compac Industries Ltd.
Page 96: C4000 Microprocessor Board
C4000 Microprocessor Board C4000 Microprocessor Board The Compac C4000 head is operated by a software program in an EPROM (which is located on the processor board). This program has several operational configurations, one of which must be selected using the set-up devices on the C4000 PCB.
Page 97 Nozzle switches Input from KG meter side B Not used Preset module side A Not used Preset module side B Not used Displays Not used Temperature pressure module (for Backlighting temperature and pressure compensation only) Compac Industries Ltd. Page 97 www.compacngv.com...
Page 98 (J4 is not used for a Single Hose Dispenser ) J5 ** J6 ** ** Pins 7 & 8 (not shown) have a jumper link fitted across them. (J6 is not used for a Single Hose Dispenser) Compac Industries Ltd. Page 98 www.compacngv.com...
Page 99 DCLK ** DPD0 * DPD0 ** DDL1 ** DDL0 * GND * GND ** GND ** GND * ** Side B Display * Side A Display Outputs Outputs (not used for a Single Hose Dispenser) Compac Industries Ltd. Page 99 www.compacngv.com...
Page 100 PCB - CI165 plugs into J9 to allow the connection of two KG Meters) Tote B VCC ** Tote A TOTE0 Tote A Tote B TOTE1 ** ** Side B Tote Outputs ( Not used for a Single Hose Dispenser ) Compac Industries Ltd. Page 100 www.compacngv.com...
Page 101 Switches. (Side B not used for a Single Start A Hose Dispenser) Start A NZSW0 Start B GND ** ** Side B Stop & Start Inputs. (Not used for a Single Hose Dispenser) Start B NZSW1 ** Compac Industries Ltd. Page 101 www.compacngv.com...
Page 102 Electrical Drawings and Component Details C4000 Microprocessor Board RS485 MOD-BUS Wiring for Micro Motion Meter The following changes are made to standard Compac dispensers to allow the use of RS485 communication with a Micro Motion meter. C4000 Power Supply An RS485 Board is fitted inside the Power supply flame proof box.
Page 103 Electrical Drawings and Component Details C4000 Microprocessor Board C4000 IS Cable for RS485 MOD-BUS Compac Industries Ltd. Page 103 www.compacngv.com...
Page 104 Electrical Drawings and Component Details C4000 Microprocessor Board Compac Industries Ltd. Page 104 www.compacngv.com...
Page 105 Electrical Drawings and Component Details C4000 Microprocessor Board C4000 with RS485 MOD-BUS Wiring Compac Industries Ltd. Page 105 www.compacngv.com...
Page 106 Electrical Drawings and Component Details C4000 Microprocessor Board RS485 Forecourt Wiring The following changes are made to standard Compac C4000 wiring to allow the use of RS485 communication with other devices. C4000 Power Supply An RS485 Board is fitted inside the Power supply flame proof box.
Page 107 Electrical Drawings and Component Details C4000 Microprocessor Board Compac Industries Ltd. Page 107 www.compacngv.com...
Page 108 Electrical Drawings and Component Details C4000 Microprocessor Board Compac Industries Ltd. Page 108 www.compacngv.com...
Page 109 At the site controller, the terminals may be named: RS485A = TXDP and RS485B = DTRB. GND = Ground or Earth. The C4000 box contains mains voltage power. Always isolate before removing the lid. Compac Industries Ltd. Page 109 www.compacngv.com...
Page 110 All wiring entering the C4000 flameproof box must be glanded in accordance with your local regulations. Take all precautions to ensure water or moisture does not enter the box and that the box is properly sealed when finished. Compac Industries Ltd. Page 110 www.compacngv.com...
Page 111 Electrical Drawings and Component Details C4000 Microprocessor Board C4000 with RS485 Forecourt Wiring Compac Industries Ltd. Page 111 www.compacngv.com...
Page 112: C4000 Temperature Pressure Interface Board Ci75-B
CON 6 Temperature Probe Side A CON 7 Temperature Probe Side B CON 9 Pressure Transducer B2 (Bus dispensers) CON 5 Connection to J8 on C4000 board Board plugs into J9 on C4000 board Compac Industries Ltd. Page 112 www.compacngv.com...
Page 113 Electrical Drawings and Component Details C4000 Temperature Pressure Interface Board CI214D CON1 & CON2 Screen (GND) +5v (VCC) Signal CON3 & CON4 Signal CON5 +5v (VCC) VCC Link Compac Industries Ltd. Page 113 www.compacngv.com...
Page 114: C4000 Is Cable Connections
Red / Green * Blue / Red * Black / White / Red PERIPH (VP) Orange / Green PERIPH (VP) Screen White / Black / Red * Red / Black / White Green / Black / White Compac Industries Ltd. Page 114 www.compacngv.com...
Page 115 Black / White / Red Orange / Green Blue / White Black / Red White Black C4000 IS Cable - Gilbarco Interface Option Black White Red / Green White / Black / Red VIS (VCC) Compac Industries Ltd. Page 115 www.compacngv.com...
Page 116: Dispenser Spare Parts
Dispenser spare parts The following lists contain the most commonly used spare parts and kits for Servicing Compac Dispensers. They are not an exhaustive list of all possible parts for current or historical Dispensers. If a part you want to order is not listed, please contact the Compac spare parts department for a complete listing.
Page 117 Dispenser spare parts Main Dispenser Parts Main Dispenser Parts Location Compac Industries Ltd. Page 117 www.compacngv.com...
Page 118 RVCI-04 Compac 3 Way Valve (Complete) 1/4" NPT Female Ports (for discontinued brass body valve) FC-SK-0008 RVCI-04 Compac 3 Way Valve Seal Kit Without Steel Ball (for discontinued brass body valve) FC-SK-0009 RVCI-04 Compac 3 Way Valve Seal Kit With Steel Ball (for discontinued brass body valve)
Page 119: Hydraulic Module Parts
Description FC-COIL-0001 SCI-12-SS solenoid coil (Parker) With 3 metre lead FC-COIL-0005 S2 -350 solenoid coil (Compac) with 3 metre lead FC-VALVE-0035 S2-350 Complete 350 bar standard solenoid (Without Coil ) FC-VALVE-0036 S2-350 Complete 350 bar solenoid with O ring piston (Without Coil )
Page 120: Error Codes
10 seconds for each section of tote data. You should read and understand all safety precautions before operating or maintaining the Compac CNG Dispenser. When servicing Compac CNG Dispenser, please follow the recommendations in this manual. Otherwise you may injure yourself and void the warranty.
Page 121 There is a pressure difference of 10 (see page 31) bar or more between the pressure probes.  The colon disappears when the :0.0 The dispenser's power supply has nozzle lifted next been turned off and back on since the Compac Industries Ltd. Page 121 www.compacngv.com...
Page 122 As above. PE P There is multi-price display parity error.  As above. PS d There is a main display parity error.  As above. PS P There is a multi-price display parity error. Compac Industries Ltd. Page 122 www.compacngv.com...
Page 123: End Of Sale Indicators
The end of sale indicator allows you to determine the reason why the last fill ended. This can be very useful for fault finding and diagnostics. Recent versions of CNG software will flash the end of sale indicator in the price per litre window at the end of each fill during normal operation. Older versions of software will need to use the procedure below to view the end of sale indicator.
Page 124 The pressure at the third measurement exceeded the Check for blockage in the fuel delivery hose, calculated maximum pressure. breakaway or vehicle pipework. Twin pressure sensor values (when fitted) do not agree. Check pressure sensor calibration. Compac Industries Ltd. Page 124 www.compacngv.com...
Page 125 Error Codes End of Sale Indicators Compac Industries Ltd. Page 125 www.compacngv.com...

Compac CNG Service Manual

Document Control Information

Symbols and Units of Measure

Safety

Introduction

Software Versions

Mechanical Installation

Electrical Installation

Electrical Commissioning

Mechanical Commissioning

Dispenser Set-Up

Dispenser Operation

Servicing

Dispenser Calibration

Indicator Leds

Troubleshooting

Appendix

Specifications

Installation Diagrams

Mechanical Drawings and Component Details

Electrical Drawings and Component Details

Dispenser Spare Parts

Error Codes

Quick Links

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Questions and answers

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Summary of Contents for Compac CNG

Table of Contents