Related Manuals for Compac CNG
Summary of Contents for Compac CNG
- Page 1 CNG DISPENSER SERVICE MANUAL CNG Dispenser Service Manual Version 1.1.4 Date: 8th December 2017...
-
Page 2: Conditions Of Use
Product procedures in this manual and exercise all due Identification section. care. Only parts supplied by or approved by Compac may ▪ Compac Industries Limited accepts no liability for be used and no unauthorised modifications to the ▪... -
Page 3: Product Identification
Product Identification 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. -
Page 4: Document Control
Document Control Document Information Document Details CNG Dispenser Service Manual G:\Masters\Manuals\Authorised Manuals\CNG File Name and Location Manuals Current Revision Author(s) J Jang Release Date: Authorised By W Zheng 27/01/2016 Revision History Version Date Author(s) Revision Notes 1.0.0 12/01/2010 R Lacey... - Page 5 1.1.2 10/03/2016 H Kleyer Updated manual for Mk2 C4000 Power Supply 1.1.3 10/03/2016 H Kleyer Updated PID 1.1.4 22/01/2018 J Jang Updated manual...
-
Page 6: Table Of Contents
Contents Conditions of Use ....................1 Product Identification ..................2 Document Control ....................3 Contents ....................... 1 Safety ........................4 Mechanical Safety ..................4 Electrical Safety ..................5 Introduction ......................6 Refuelling Modes ....................7 Dispenser Operation .................... 8 Turning the Dispenser on ................. 8 Refuelling a Vehicle ..................... - Page 7 Gas Operated Valve (option) Seal Replacement ........48 Bleed Valve Replacement ............... 52 Pressure Relief Valve Replacement ............52 KG80 Meter Replacement ............... 52 Compac Breakaway Seal Replacement ..........53 Three-Way Refuelling Valve Seal Replacement ........55 Compac Refuelling Valve Exploded View ..........57...
- Page 8 Refuelling Hose Replacement ..............58 Power Supply Fuse Replacement ............58 Power Supply Replacement ..............60 Processor Board Replacement ............... 61 Temperatuer Pressure Board Replacement (Fast Fill & Temperature compensation Units Only) ....................62 Dispenser Software Upgrade/Replacement ........... 63 Meter Replacement ................. 65 Unserviceable Parts List .................
-
Page 9: Safety
O-ring lubricant before reassembly. Dust and dirt entering components reduce the life span of the components and can affect operation. ▪ Ensure the service area is thoroughly cleaned before initiating service on CNG components. Dust and dirt entering the components reduce the life span of the... -
Page 10: Electrical Safety
Electrical 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 ▪ Never power up the CNG dispenser with the flameproof box lid removed. -
Page 11: Introduction
Introduction The Compac CNC 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 12: Refuelling Modes
Refuelling Modes Fixed Pressure Refuelling The fuel is dispensed through a fixed pressure regulator. When fuel flow reaches a minimum rate. The fuel flow is shut off. Refer to Fixed Pressure Refuelling. Fast Fill Refuelling To enable fast refuelling, the pressure in the tank is measured then a small amount of precisely measured fuel is dispensed into the tank and the pressure rise is measured. -
Page 13: Dispenser Operation
Dispenser Operation Turning the Dispenser on When the power is applied to the dispenser, the display will show PA:Use and count down from 60seconds. This start-up procedure ensures the dispenser is functioning properly before gas is dispensed. Dispenser will be ready to use when the display indicates 0. 0 0 NOTE: Before starting a fill, the software checks the status of the Stop switch. -
Page 14: Refuelling A Vehicle
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. Appropriate personal safety equipment should be worn whilst refuelling a vehicle. -
Page 15: Fast Fill Refuelling Process
Fast Fill Refuelling Process The fast fill refuelling process uses pressure sensors to calculate the quantity of gas required to fill a vehicle to a configurable target fill pressure ( The technical operation of a fast fill dispenser is as follows: ▪... -
Page 16: Temperature Compensated Refuelling Process
Temperature Compensated Refuelling Process The technical operation of a temperature compensated dispenser is as follows: ▪ Press the start button or remove the nozzle from the holster to initiate a fill. The display will indicate 888888 and then clear, at this point both the gas and value totals will display 0. -
Page 17: Reading The Dispenser Totals
Reading the Dispenser Totals To read the dispenser totals: ▪ Quickly press the Start button or nozzle switch five times on the side of the dispenser you wish to view the totals for. The total is 10 digits long. The four most significant digits are displayed on the top line and the number wraps to the second line showing the six least significant digits. -
Page 18: Electronics
The Parameter switch also enables you to view the Dispenser Software Version and End of Sale Indicators. The Compac C4000 is a microprocessor-based circuit board designed for use in liquid and gaseous fuel metering. One C4000 head is used for a single or dual LPG dispenser. - Page 19 PARAMETER K-FACTOR...
-
Page 20: Menu Options
You may need to change the 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 (FAS,nOr,SLO) Hose Number Dispenser Passcode Code CXXX62 Software Program version... -
Page 21: Unit Price
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... -
Page 22: Sequencing Rate
Sequencing Rate NOTE: Only available on CNG dispensers. Appropriate software required. The sequencing rate (SE9) enables you to set the percentage level of maximum flow that sequencing occurs to the next pressure bank. These are three settings to choose from;... -
Page 23: Hose Number
Hose Number 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: Dispenser Software
Dispenser Software The dispenser software version ( ) is the version number of the software currently loaded in the dispensers C4000. See Dispenser Software Upgrade/Replacement for instructions on Upgrading dispenser software. To Identify the software Program Version Number: ▪ Make sure the dispenser is idle, with the nozzle in its holster. ▪... -
Page 25: End Of Sale Indicators
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 26 Check the stop switch wiring and switch operation. Refer Stop switch operated. CNG Dispenser Electrical Schematic. Twin pressure sensor values (when fitted) Check pressure sensor do not agree. calibration. Maximum flow rate exceeded.
-
Page 27: Dispenser Passcode
If set, only the dispenser software version can be viewed. NOTE: 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. -
Page 28: Troubleshooting
Troubleshooting This troubleshooting section outlines issues that you may encounter when using the dispenser, and provides recommended actions. For sites where the temperature falls below –10°C, power should only be removed from the dispenser for servicing. Problem Likely Cause(s) Recommended Action For all problems not listed here please contact your service agent After powering the For push to start dispensers... - Page 29 999999 units fault. according to where the decimal point is set. NOTE: When fixing 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 30: Fault Codes
NOTE: You should read and understand all safety precautions before operating or maintaining the Compac CNG Dispenser. NOTE: When fixing Compac CNG Dispenser faults, please follow the recommendations in this manual. Otherwise you may injure yourself and void the warranty. - Page 31 Fault Code Likely Cause Recommended Action Contact your service agent The temperature Err 13 pressure interface board is disconnected or has failed. Contact your service agent The temperature Err 14 probe has been disconnected, or is connected with wire links still in place. Contact your service agent The pressure probe Err 15...
-
Page 32: Indicator Leds
Indicator LEDs LED indicators are used to provide power, output status, and diagnostic information. - Page 35 Indicator Reference Description LEDs Indicates power is being supplied to the processor board. If it is not Power lit there is a fault on the processor power supply. Flashes when polling information is being received. Flashes when polling information is being sent.
-
Page 36: Servicing
Isolate the dispenser by closing the inlet gas supply valves at the base 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 37: Schedules Servicing
Schedules Servicing Weekly-checks Check the sealing and operation of the three-way refuelling valve. Check the sealing and operation of the solenoids. Check the sealing and setting of the regulator. Drain the Coalescing Filter. Suggested 6-monthly or 400 compressor run hour service Check the dispenser for leaks. -
Page 38: Checking Dispenser Operation
Checking Dispenser Operation To check that the dispenser is operating correctly: Fill two gas bottles. Check that: The bottles fill to the desired pressure. The dispenser fills to the preset value. The displays and gauges are working Checking the Sealing of the Solenoid De-gas the hose by opening the 3 way valve. -
Page 39: Checking The Over-Pressure Switch Operation (Fast Fill & Temperature Compensated Units Only)
Valve Adjuster (use 8 mm Hex Key) Checking the Over-Pressure Switch Operation (Fast Fill & Temperature Compensated Units Only) To check the operation of the Over-Pressure cut off: Access the K-Factor switch on the C4000 processor. Obtain the over-pressure settings, PLa (for side A) and PLb (for side B), as per the K-Factor Switch Settings section. -
Page 40: Checking The Dispenser For Leaks
Checking the Dispenser for Leaks Before you start, make sure you have: Soapy water To check the dispenser for leaks: CAUTION: Be careful not to spray or drip water into any of the dispenser electronics when checking for leaks. Apply soapy water to all joins in the assemblies and fittings on the inside and outside of the dispenser, including the hose. -
Page 41: Checking The Refuelling Hoe For Leaks
Checking the Refuelling Hoe for Leaks Before you start, make sure you have: Soapy water To check the refuelling hose: Visually check the refuelling hose for damage, such as fraying and cuts. Apply soapy water to all valves and connections. If bubbles form, there is a leak in that assembly or fitting. -
Page 42: Checking The Three-Way Refuelling Valve Sealing And Operation
Checking the Three-Way Refuelling Valve Sealing and Operation Before you start, make sure you have: Soapy water Check the Sealing of the Three-Way Refuelling Valve To check the sealing of the three-way refuelling valve, apply soapy water to the valve. If bubbles form, there is a leak, in which case you should replace the three-way refuelling valve seals. -
Page 43: Filter Element Replacement
Filter Element Replacement The coalescing filters are designed to trap dirt, moisture, oil, and other debris that may damage the valve seals. Before you start, make sure you have: A seal kit - Part number FC-FIL-0001 ▪ 1 x filter ▪... -
Page 44: 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 45 Remove the Old Solenoid Valve Seals De-gas the dispenser. Switch off the power supply to the dispenser. DANGER: Never remove any electrical components without first switching off the power to the dispenser. Failure to turn off the power could result in an electric shock.
- Page 46 Taking care not to damage the piston, hold the flat part of the piston with a spanner to prevent rotation, then unscrew the M6 x 12 mm cap screw from the bottom of the piston. This releases the solenoid seal retainer and valve seal.
-
Page 47: Solenoid Coil Replacement
Solenoid Coil Replacement Before you start, make sure you have: Replacement solenoid coil FC-COIL-0005 (Compac S2-350). NOTE: 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 48: 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 Solenoid valve 350 bar O ring seal option for high oil content gasses (FC-... -
Page 49: Regulator Valve Seal Replacement
Regulator Valve Seal Replacement Before you start, make sure you have: A regulator seal kit - Part Number FC-SK-0002 ▪ 2 x regulator O-ring seals ▪ 2 x Teflon back-up ring ▪ 1 x Teflon valve seal O-ring lubricant Remove the Old Regulator Valve Seals De-gas the dispenser. - Page 50 Install New Regulator Valve Seals Install the new valve seal. Make sure that the larger flat side of the seal faces upwards. Teflon Back-Up Ring Regulator O-Ring DETAIL A Make sure that the flat face of the seal faces up Regulator O-Ring Teflon Back-Up Ring DETAIL B...
-
Page 51: Isolation Valve Seal Replacement
Isolation Valve Seal Replacement NOTE: Please make sure you identify the valve before disassembling it to make sure you have the correct seal kit available. Complete valve is part number FC-Valve-0001 Before you start Obtain the following replacement parts and equipment: FC-SK-0010 Parker Isolation Valve Seal Kit Refer to Spare Parts list for other items that you may need. - Page 52 Replace the isolation valve seals CAUTION: Take care to keep all parts clean while assembling. Apply a light coating of approved grease to the ball then replace the ball and ball seat sub-assemblies, making sure the slot in the ball is at the top.
-
Page 53: Gas Operated Valve (Option) Seal Replacement
Gas Operated Valve (option) Seal Replacement CAUTION: Follow all safety precautions listed at the front of this manual. Before doing any work on the valve, ensure that the power is off and the system pressure is reduced to atmospheric levels. Ensure that the pressure is removed from both the inlet and outlet ports of the valve and from the air supply line. - Page 54 Use a pick to pull out the stem seal and discard. Undo the end cap, remove the valve seat and discard it. Turn the valve stem to the “Closed” position then tap on the end of the ball valve with a wooden or soft plastic dowel (BV ASST) to remove it. Discard the ball.
- Page 55 Service kit Suggested service tools Replacement Thoroughly clean and dry the valve body and end cap. Place the new O-ring on the end cap and lubricate with the supplied grease. Put an anti-seize compound on the threads. Fit the new valve seat making sure it is seated properly. Insert the valve stem into the valve body and pull it upwards until it clicks into place.
- Page 56 With the valve stem in the “Closed” position, insert the ball so the slot engages with the stem. Insert the second valve seat Install the end cap and tighten to 60 N/m Install the valve stem gland then the lock tab and nut. Tighten nut to 3 N/m and bend the lock tab to stop the nut undoing Hold the valve stem with pliers and open and close the valve four or more times to bed in the seal.
-
Page 57: Bleed Valve Replacement
Bleed Valve Replacement The bleed valve seldom gives problems and is not serviceable For a replacement valve and instructions if required, contact your Compac service agent with your Model and Serial numbers Pressure Relief Valve Replacement The pressure relief valve seldom gives problems and is not serviceable... -
Page 58: 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 59 Replace the Breakaway Seals To replace the breakaway seals: Remove the old O-rings. NOTE:If you are dismantling the quick breakaway valve, make sure that you have a spare seal kit available. O-rings that are subjected to natural gas at high pressure swell when exposed to air and must be replaced. Replace the old O-rings with the new lubricated O-rings.
-
Page 60: Three-Way Refuelling Valve Seal Replacement
Three-Way Refuelling Valve Seal Replacement NOTE: Make sure you identify the valve before disassembling it to make sure you have the correct seal kit available. For more information see Compac Technical bulletin CTB10015. Before you start Obtain the following replacement parts and equipment:... - Page 61 Insert the handle shaft into the valve body from the bottom. Insert the ball shaft into the valve body from the bottom. Note: Ensure that the slotted handle shaft and ball shaft engage. Insert the ball shaft seals in both sides of valve body. Insert the ball shaft retainers in either side of the valve body until the retainer face meets with body of the valve.
-
Page 62: Compac Refuelling Valve Exploded View
Compac Refuelling Valve Exploded View Retainer Nut “A” assembly Retainer Nut “B” assembly Shaft/Spindle assembly... -
Page 63: Refuelling Hose Replacement
▪ F1 = 0.5 A ▪ 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 NOTE: Every new dispenser is supplied with one spare fuse of each value... - Page 64 Remove C4000 power supply fuse(s): Degas the dispenser. Switch off the power supply to the dispenser. DANGER: Never remove any electrical components without first switching off the power to the dispenser. Failure to turn off the power could result in an electric shock.
-
Page 65: Power Supply Replacement
Power Supply Replacement Before you start Obtain the following replacement parts Replacement Power Supply part number F-CP-C4PWR-ASSEM Remove the C4000 Power Supply De-gas the dispenser. Switch off the power supply to the dispenser. DANGER: Never remove any electrical components without first switching off the power to the dispenser. -
Page 66: Processor Board Replacement
Install the New C4000 Power Supply To install the new C4000 power supply, reverse the procedure above CAUTION: Make sure that the triac snub switches SW1, SW2, & SW4 are left in the factory set position 2 (Low Current Output) after you have completed all procedures. -
Page 67: Temperatuer Pressure Board Replacement (Fast Fill & Temperature Compensation Units Only)
Temperature Pressure Board Replacement (Fast Fill & Temperature compensation Units Only) Before you start Obtain the following replacement parts Replacement Temperature and Pressure board part number : F-CP-CNG-TEMP Remove the Temperature pressure board De-gas the dispenser. Switch off the power supply to the dispenser. DANGER: Never remove any electrical components without first switching off the power to the dispenser. -
Page 68: 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. CAUTION: Before working on the dispenser electronics, take basic anti- static precautions by wearing a wristband with an earth strap. - Page 69 Remove the software EPROM Turn off the dispenser. Remove the software EPROM chip, using an EPROM extractor Install new software EPROM Plug in the new software EPROM, checking that all of the legs are correctly located in the socket. The chip should be located as far to the bottom of the socket as possible.
-
Page 70: Meter Replacement
The KG meter: KG meter Can have its firmware upgraded by 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 71: Dispenser Calibration
Dispenser Calibration Meter Calibration Calibrating the meter involves: ▪ Comparing the dispensers stated amount dispensed to actual amount dispensed. ▪ Adjusting the K-Factor if accuracy is not within the required tolerance. NOTE: The K-Factor for each new dispenser is factory set and usually does not need to be changed. - Page 72 A CNG cylinder with a fill and release valve 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. DANGER: Always vent cylinders in a safe manner and safe location.
-
Page 73: Pressure Transducer Calibration (Fast Fill & Temperature Compensated Units Only)
Fill the vehicle from the dispenser. Turn off the dispenser refuelling valve and master meter valve, if applicable. Compare the master meter read-out (True Quantity) with the dispenser display (Display Amount). If the results are not within 0.5% of each other, you will need to change the calibration, as per the Calculate and Set the New K-Factor section Pressure Transducer Calibration (Fast Fill &... -
Page 74: Ambient Temperature Sensor Calibration
����2 − ����1 ������ �������� = ���� ∗ ��2 − ��1 Adjust the transducer gain Input the new gain. Refer Pressure Transducer Gain. Adjust the electronic pressure offset Adjust the electronic pressure reading to equal that displayed on the dispenser’s pressure gauge using the following procedure: Use the "K"... -
Page 75: Appendix
C4000 Fuel Dispenser Control Unit (CWIT Aerial only:- 1G EEx ia A T3 The Compac CNG equipment is also PED approved for use up to 275 bar. PED Approval Marking EC - Type Examination Equipment on the Equipment Certificate Number Filter housing, Solenoid, &... -
Page 76: 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 lines. ▪ Single or dual hose. ▪ Fixed pressure final cut-off or temperature compensated final fill cut-off. -
Page 77: 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: CNG Dispensers require the following operating conditions: Air temperature range - 25 °C to + 55 °C... - Page 78 (350 bar option) (350 bar option) valves and require a compressed air supply.) +/- 1.0% Accuracy +/- 1.0% +/- 1.0% Compac KG80 Compac KG80 Compac KG80 Meter coriolis mass flow coriolis mass flow coriolis mass flow 1/2” or 3/4" Internal Pipework 1/2”...
-
Page 79: Component Specifications
The high flow solenoid valve is 3/4” SAE female designed to control the flow of inlet. Solenoid SCI-12-SS gas in a CNG Dispenser. 3/4" SAE female valve Between the inlet and outlet, the outlet. valve opens with a differential 275 bar max. - Page 80 1-80 kg/min (668 to 890 N) breakaway force. Isolation Parker 2-way 8 series ball valve ball valve The Compac C4000 processor Microproces C4000 controls all the electronics in the dispenser. The display has six 1" digits for GD1, GD2 or price, six 1"...
- Page 81 Equipment Compac Code Specifications Description Item unit price displays.) Dual scale pressure gauges are Pressure available with psi and either bar, Gauge MPa, or kPa. CE Approved The hose is specifically designed Parker single to dissipate static electrical build- and twin line up and wear resistance.
-
Page 82: Mechanical Drawings
Mechanical Drawings Dispenser Component Locator NOTE: The C4000 Dispenser Power supply is housed in a flameproof box. All other components are simply located in enclosures. See below. - Page 83 SIDE A SIDE B (Dual Hose Models Only) High Bank Inlet (Three Line Models Only) Medium Bank Inlet (Two and Three Line Models) (See Below) Low Bank Inlet Filter Check Valve Outlet Block Solenoid Valve. Hose from Outlet to Breakaway Regulator Valve Inline hose breakaway coupling KG80 Mass Flow Meter...
Need help?
Do you have a question about the CNG and is the answer not in the manual?
Questions and answers