Kraus Optima Owner's Manual
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Kraus Optima Owner's Manual

Kraus Optima Owner's Manual

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TM
Optima
Dispenser
Owner's Manual
Kraus Global, Ltd.
25 Paquin Rd.
Winnipeg, Manitoba, Canada
R2J 3V9
Ph. 204-663-3601
©2014 Kraus Global Ltd.
Retail CNG Dispenser Manual
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  • Page 1 Optima Dispenser Owner’s Manual Kraus Global, Ltd. 25 Paquin Rd. Winnipeg, Manitoba, Canada R2J 3V9 Ph. 204-663-3601 ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 2 Description June 2017 Editorial updates and corrections, Production release. Code compliance Kraus CNG dispensers are manufactured to comply with the following codes and standards: North America  American Society of Mechanical Engineers (ASME) Boiler and Pressure Code  American Society of Mechanical Engineers (ASME) B31.3 – Process Piping ...

  • Page 3: Table Of Contents

    1.1 About this manual 1.2 Additional references 1.3 Contact information 1.4 Warnings and notifications 1.5 Warranty information 1.6 The Retail CNG Optima™ dispenser 1.7 Dispenser theory of operation ® 1.7.1 MICON NEXTGEN 1.0 1.7.2 Buffer storage systems 1.7.3 Cascade storage systems 1.7.4 The Retail unit layout...
  • Page 4 A.1 Component descriptions and specifications Air purge system components Power supply Air purge system/authorization relay Micro Motion® CNG050 flow meter KAF 402™ solenoid inlet valve Fueling nozzles A.2 Maintenance task list GLOSSARY INDEX ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 5 CONTENTS This page intentionally left blank ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 6 CONTENTS This page intentionally left blank ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 7 Neither Kraus Global Ltd. nor any of its employees or agents are your professional advisers. You should assess whether you require such advisers and additional information and, where appropriate, seek independent professional advice.

  • Page 9: Introduction

    (CNG) Optima™ dispensers. Intended users This manual is designed to be clear, comprehensive, and available to anyone installing, maintaining, or overseeing the operation of Kraus’ Retail CNG Optima™ dispensers. Scope This manual is divided into five chapters: 1.

  • Page 10: Additional References

    1. INTRODUCTION 1.2 Additional references In addition to this manual, the following document is also provided with each dispenser package:  Quick-Start Guide—Optima™ CNG Dispenser (RFD.010) The following documents are available on request:  MICON NEXTGEN 1.0 Owner’s Manual (MNG0001.MNL) ®...

  • Page 11: Warnings And Notifications

    This indicator provides important notifications about the dispenser and its components. ATTENTION This indicator provides critical warnings that may help prevent human injury and equipment damage. CAUTION 1.5 Warranty information For questions or concerns regarding dispenser-warranty policies, please contact Sales. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 12: The Retail Cng Optima™ Dispenser

    1. INTRODUCTION 1.6 The Retail CNG Optima™ dispenser The Retail CNG Optima™ dispenser is available in a single or multiple-line configuration. Each configuration is available in standard, high or split-flow systems; P30, P36, or split-pressure; single or dual hose setup; and buffer or cascade sequencing.

  • Page 13: Buffer Storage Systems

    If more pressure is needed, the same sequence will occur to access the high- bank until the target-fill-pressure or minimum flow setting is reached. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 14: The Retail Unit Layout

    1. INTRODUCTION 1.7.4 The Retail unit layout A single-hose Retail CNG Optima™ dispenser—Please refer to the Engineering package for a view of internal components LIFTING LUGS HOSE MANIFOLD VENT LINE BREAKAWAY MAIN LINE BREAKAWAY ENCRYPTED KEYPAD PRICE, VOLUME, PRICE PER UNIT DISPLAY...

  • Page 15: General Safety

    Electrical connections must comply with applicable local regulations.  Piping and other components, which are not supplied by Kraus Global Ltd., must be suitable for the respective working pressure. If necessary, they must be tested and protected by pressure- unloading devices.

  • Page 16: Filling Safety

    Ensure all users are aware that pressure from the nozzle must be vented before disengaging it from the vehicle.  Ensure that all users replace the dispenser nozzle firmly onto the holder immediately after refueling. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 17: Dispenser Hose Safety

    CNG unit it is attached to. ATTENTION For additional information about dispenser hoses, please refer to the specification tag provided by the manufacturer or contact Technical Support at 204-663-3601, ext.212. ATTENTION ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 18: Maintenance Safety

     Do not touch bare wires and live current- carrying parts while the electrical system is energized.  Never tighten or loosen any fitting when it is under pressure. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 19: Leak Test Safety

    ADVICE 2.5 Leak test safety Please observe the following guidelines before performing leak tests on Kraus-manufactured CNG dispensers:  Ensure the area surrounding the dispenser being serviced is closed off to all customers and unauthorized personnel.

  • Page 20: Installation Guidelines

    3. INSTALLATION AND SETUP 3. INSTALLATION AND SETUP 3.1 Installation guidelines Please observe the following guidelines prior to installing any Kraus- manufactured CNG dispenser:  All electrical and mechanical installations must comply with the provisions of the local authority having jurisdiction.
  • Page 21  All dispensers must only be used for gas compositions specified within SAE J1616: Recommended Practice for Compressed Natural Gas Vehicle. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 22: Pre-Installation

    3. INSTALLATION AND SETUP 3.2 Pre-installation Kraus CNG dispensers must be situated in such a way that there are no obstructions, such as a wall or gate, that may entangle the dispenser hose. This is to ensure proper functioning of the hose assembly’s breakaway coupling.

  • Page 23: Uncrating The Dispenser

    5. Remove lag bolts from base rails to free the dispenser from the bottom pallet. 6. Locate and review the crating check list to ensure that all items are accounted for. If you are missing any items, please contact Technical Support at 204-663-3601, ext.212. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 24: Lifting And Anchoring The Dispenser

    3. INSTALLATION AND SETUP 3.2.3 Lifting and anchoring the dispenser Kraus CNG dispensers weigh at least 1,200 lbs/545 kg; be sure all lifting and anchoring equipment are suitable for the weight. CAUTION 1. Locate the lifting lugs on top of the dispenser. A step-stool or step-ladder may be required to get a full view.

  • Page 25: Installation

    3.3.1 Electrical and communication connections Electrical installations must only be carried out by licensed electrical journeymen. CAUTION All interconnection tubings and fittings are sold independently of Kraus Global Ltd. Always adhere to manufacturer standards for appropriate swaging and tightening specifications.

  • Page 26: Filters

    Standard-flow dispensers use smaller filters that can often be placed in the lower cabinet of the dispenser unless otherwise indicated. If filters are not being supplied by Kraus Global Ltd., ensure that they are properly rated for the dispenser’s filling system.
  • Page 27 3. INSTALLATION AND SETUP Figure 1: High-flow filter placement ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 28  Ensure that fittings are always inspected during servicing and adjusted accordingly.  Avoid swapping the heads and bowls of one filter assembly to another. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 29: Attaching The Hose

    3. INSTALLATION AND SETUP 3.3.4 Attaching the hose Kraus CNG dispensers use Parker brand hoses and hose fittings. Hose sizes are specific to dispenser configurations, but are available in various lengths. Please see the information sheet attached to the hose package or contact Technical Support at 204-663-3601, ext.212 for further specification.
  • Page 30 3. INSTALLATION AND SETUP Breakaway couplings All Kraus CNG dispenser hoses are equipped with a breakaway safety feature. Breakaway couplings are in place to prevent the flow of natural gas should a vehicle drive away from a dispenser while the nozzle and hose are still connected to the vehicle’s receptacle.

  • Page 31: Startup Procedures

    The digital pressure gauge, located on the secondary display to the right of the main display, will display the Kraus Global logo during power-up. The power-up cycle is complete when the secondary display will display a pressure gauge and a flow rate gauge.

  • Page 32: Pressurizing The Dispenser

    Please be sure to read and understand Chapter 2—Safety before proceeding. To ensure peak performance, all Kraus CNG dispensers should be leak- tested before initial operation. The first leak test should be done while initially pressurizing the dispenser.

  • Page 33: Connecting The Manager-Keypad

    3-line display. (see Figure 1). The arrow in Figure 2 points to the position of the pin connector on the back of the dispenser display. Figure 2: Manager-keypad pin connector behind the dispenser display ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 34 7. Turn on the power to the dispenser at the breaker box. NOTE: The keypad is now ready for use; you may need to allow all power-up sequences to complete before proceeding. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 35: Enabling 2-Wire Mode And Setting Pump/Hose Ids

    Wait a moment for the system to complete the restart and the new 2-wire configuration should take effect. Figure 4 - Display for Hose 1, address 25 ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 36: Configuring The Pos System

    3. INSTALLATION AND SETUP 3.4.5 Configuring the POS System Preliminary view – Additional features to be included later. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 37: Commissioning

    This form must be completed, signed, and sent to Kraus Global Ltd. within 30 days of commissioning, otherwise the warranty may be voided. Complete forms may be mailed or faxed to Kraus Global Ltd. using the following information: Kraus Global Ltd.

  • Page 38: Filling Procedure

    10. Turn the valve on the nozzle to VENT. This will vent a small amount of gas into the atmosphere and allow you to disconnect the nozzle. 11. Replace the nozzle onto the holder. 12. Replace the dust plug into the vehicle’s CNG receptacle. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 39: Programming The Micon

    3. Toggle the programming switch located at the center of the intrinsic safety module. Please see Figure 3.4. The switch should be in the rightmost position. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 40 To access the programming mode switch, it may be necessary to break weights and measures sealing on the MICON enclosure. ® This ensures that any settings that could affect the accuracy of the MICON cannot be changed once sealed. ® ATTENTION ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 41 The keypad connector is keyed and will only connect to the display in one orientation. ATTENTION The keypad connection is designed to be intrinsically safe. This allows for the safe operation of the keypad on the outside of the dispenser. ATTENTION ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 42: Disabling Programming Mode

    6. Restore power to the dispenser and allow it to boot. The dispenser should now be in normal operating mode. The letters “CFG” should NOT be displayed on the third line of the primary displays. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 43: Dispenser Maintenance

     Depending on installation requirements, we recommend that inline filter elements are checked and replaced two weeks after initial installation.  Check filter elements every month and replace when necessary. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 44: Dispenser Venting Procedure

    NOTE: Sequencing valves are only opened for 4 seconds at a time; you may need to authorize a fill several times to vent all trapped gases. Continue authorizing a fill until the pressure gauge reads 0 psi and all venting sounds have ceased. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 45: Leak Monitoring

    4. Continue pressurizing the dispenser and testing for leaks at 500 psi intervals until the dispenser reaches regular operating pressures. NOTE: Repeat steps 1 – 3 if leaks are discovered. If leaks persist, contact our Technical Support Department at 204-663-3601, ext.212. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 46: Component Maintenance

    ® 4.4.1 MICON mainboard ® Should the MICON Mainboard or any other circuit board need replacing, please contact Kraus Global Technical Support at 204-663-3601, ext. 212. ATTENTION ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 47: Kaf 402™ Solenoid Inlet Valve

    4. OPERATION AND MAINTENANCE 4.4.2 KAF 402™ solenoid inlet valve Kraus’ KAF 402™ solenoid valve has been specifically engineered for high-pressure CNG service. It is constructed of materials suitable for use with natural gas and is rated for a burst pressure in excess of 25,000 psi.

  • Page 48: Air Purge System

    4. OPERATION AND MAINTENANCE 4.4.4 Air purge system Kraus’ Retail CNG dispensers incorporate an air purge system to ensure the open electronics in the upper cabinet are protected from potential gas leaks that may cause explosion. The air purge system uses a purge fan to maintain a positive air pressure of at least 0.15...

  • Page 49: Micon

    Figure 5.1: Example Error Code Please contact our Technical Support Department at 204-663-3601, ext.212, for any issues not covered in Tables 5.1 and 5.2 below. ADVICE ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 50 2. Flip the authorization handle down to the OFF position, then back up to the ON position. – OR – activate the manual reset switch (MRST) – OR – write to the corresponding error bit in the Modbus register mapping. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 51 94 MET2 SC Meter 2 short Mass flow meter has drawn Check meter wiring. Reboot dispenser. If problem persists ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 52 LEDs are lit. Reboot dispenser and/or console system. If error reoccurs or persists, contact technical support at 204-663-3601, ext. 212, for additional troubleshooting. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 53: System Fault Codes

    Technical Support Department at 204-663-3601, ext.212, for any issues not covered in Table 5.3 below. Only trained and qualified service personnel should attempt any troubleshooting and service work to any CNG electrical and mechanical components. CAUTION ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 54 • POS pump-ID is not set • Ensure pump-IDs are properly configured see section 3.4 of the manual • POS-ID is not configured • Ensure POS-IDs are properly configured—see section 3.4 of the manual • ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 55 - contact Tech. Support for more information • Temperature probe is not • Compare displayed reading correctly temperature to actual ambient temperature. If there are discrepancies, contact Tech. Support for further assistance ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 56 Please contact our Technical Support Department at 204-663-3601, ext.212, for any issues not covered in Table 5.3 above. ADVICE ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...

  • Page 57: Voltage Statuses

     Ground to N  115 – 120V AC  n/a  Power supply  Ground to L  115 – 120V AC  n/a  V+ to V-  24V DC  n/a ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual...
  • Page 58 This page intentionally left blank...

  • Page 59: Component Descriptions And Specifications

     Ideally, purge air delivered to the dispenser should be maintained as close as possible to the ambient outdoor air temperature. Guidelines continue next page ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual Appendix-1...
  • Page 60 For all purge fan installation and maintenance concerns, please contact our Technical Support Department at 204-663-3601, ext.212. ADVICE ©2014 Kraus Global Ltd. Appendix-2 Retail CNG Dispenser Manual...
  • Page 61 @ 125 VAC, 1/4 HP @ 250 VAC, 60 Hz. Electrical connections 3 screw type, common, normally open and normally closed 1/8” female NPT Process connections Weight (approx.) 3.25 lb (1.5 kg) Approvals CE, UL, CSA, FM ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual Appendix-3...
  • Page 62 Electrical: DPDT – 500,000 operation mins. (5 A at 250 VAC, resistive load at 1,800 operations/h) 4PDT – 200,000 operation mins. (H3YN-4-Z/-41-Z: 100,000 operation mins.) Weight (approx.) 50 g Air purge system relay See Air purge system/authorization relay. ©2014 Kraus Global Ltd. Appendix-4 Retail CNG Dispenser Manual...

  • Page 63: Power Supply

    160 Ω Coil resistance Power consumption 1.35 VA (60Hz) 1.25 VA Max. operating freq. Mechanical: 100,000 operations/hr; Electrical: 360 operations/hr (under rated load) Approvals UL E22575; CSA L15734 Weight (approx.) 51 g ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual Appendix-5...

  • Page 64: Micro Motion® Cng050 Flow Meter

    ASME B31.3, and the SAE fitting according to SAE J1453. (2) Pressure rating of the additional adapter piece (#12 O-ring face seal to female NPT) that is provided with process connection option 239. ©2014 Kraus Global Ltd. Appendix-6 Retail CNG Dispenser Manual...
  • Page 65 (1) General corrosion guidelines do not account for cyclical stress and therefore should not be relied upon when choosing a wetted material for your Micro Motion® flow meter. Please refer to Micro Motion’s corrosion guide for material compatibility information. ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual Appendix-7...

  • Page 66: Kaf 402™ Solenoid Inlet Valve

    APPENDIX KAF 402™ solenoid inlet valve The Kraus model KAF 402™ solenoid valve has been specifically engineered for high-pressure CNG service. It is a unique valve that features a high flow rate; a high-pressure rating; a compact design; and low power requirements, meaning that it does not require the assistance of a lifting coil and relay.

  • Page 67: Fueling Nozzles

    APPENDIX Fueling nozzles Kraus CNG dispensers are compatible with Type 1 and Type 2 nozzles for use in either NGV1 (passenger vehicles) or NGV2 (large fleet vehicles) refueling applications. The following are some examples of commonly used nozzles; please contact your salesperson or our Technical Support Department for ordering information and other details (204-663-3601, ext.212).

  • Page 68: Maintenance Task List

    EVERY YEAR  Inspect fill nozzle valve, rebuild if necessary  Inspect pressure regulator, rebuild if necessary  Replace fill hose EVERY 2 YEARS  Recertify pressure relief device EVERY 5 YEARS ©2014 Kraus Global Ltd. Appendix-10 Retail CNG Dispenser Manual...
  • Page 69 (may not be apply to Retail dispensers). ESD. Emergency Shut-Down; a safety feature that allows users to terminate all power and gas flow to immediate fuel dispensers—ESD buttons are not standard features, but Kraus CNG dispensers are equipped with ESD terminals that can enable this function.
  • Page 70 GLOSSARY KAF 402™. A Kraus-original solenoid valve, engineered specifically for high-pressure CNG applications; see also Solenoid valve. Mainboard. A circuit-board housing vital electrical components, such as the CPU MICON NEXTGEN 1.0 . A Kraus-manufactured pump-controller ® O-ring. A small, circular elastic joint used to seal or fill space between mating components.
  • Page 71 GLOSSARY Rebuild kit. A Kraus package including parts and instructions necessary to rebuild a dispenser component, such as a solenoid valve; sold separately from dispenser packages SAE J1616. A standard developed by SAE International that describes recommended practices for using compressed natural gas as fuel for vehicles.
  • Page 73 1; Appendix-5 gauge voltage, 40, 41, 43 Magenhelic, 22, 37, Appendix-1 pressure, 22, 23, 33 grounded, 10 warnings, 3 warranty, 3, 28 Intended users, see users keys, 15, 24, 35 ©2014 Kraus Global Ltd. Retail CNG Dispenser Manual Index-1...
  • Page 74 This page intentionally left blank ©2014 Kraus Global Ltd. All Rights Reserved Printed in Canada...

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