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Summary of Contents for Compac CNG
- Page 1 CNG Loading Post Installation and Service Manual Version 1.0.0 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...
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Page 2: Conditions Of Use
The Subject to your right to use the Compac CNG foregoing limitation extends to damages to person or equipment, Compac does not convey any right,... -
Page 3: Table Of Contents
Preparing and Cleaning Pipework .......................... 11 Mounting the Loading post ............................. 12 Connecting the Pipework ............................13 Electrical Installation ..............................13 CNG Cable Requirements ............................. 13 Connecting Mains Power ............................14 Electrical Commissioning .............................. 15 Mechanical Commissioning ............................16 Set-up ....................................17 Parameter switch .............................. - Page 4 Technical Specifications ............................50 Component Specifications ............................. 51 Hydraulic Layout – Loading Post ........................... 53 Spare parts ..................................55 Loading post Spare Parts............................55 Fuses ..................................56 Error Codes ..................................57 End of Sale Indicators ............................59 Compac Industries Ltd. Page 4 www.compacngv.com...
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Page 5: Product Identification
Compac Industries Limited reserves the right to revise or change product specifications at any time. This publication describes the state of the CNG Loading post 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 Control Information Document Information and Revision History Document Details Compac Loading Post Installation and Service Manual File Name and Location Current Revision Author(s) R Lacey Authorised By: Release Date: Version Date Author(s) Revision Notes 1.0.0 05/05/2014 R Lacey New manual Compac Industries Ltd. -
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 unit before removing the box lid. Never touch wiring or components inside the CNG Loading post with the power on. Never power up the CNG unit with the flameproof box lid removed. -
Page 9: Introduction
The Compac CNC loading post is designed to provide safe and reliable metered filling of CNG tanks from a supply tank. Compac CNG loading posts are controlled by a C4000 board and use the reliable Compac KG80 flow meter. This manual contains the information required to operate and maintain your loading post. -
Page 10: 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 10 www.compacngv.com... -
Page 11: 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 post with care. Compac is not responsible for any pipework external to the loading post. Ensure that all pipework is completely clean. Any dirt trapped in the pipework can damage the valve seals and surfaces. -
Page 12: Mounting The Loading Post
Secure the loading post with 12 mm dynabolts and washers. 12 mm dynabolts have the required strength to hold the unit but up to 16 mm dynabolts can be used in the 19 mm footprint holes. Compac Industries Ltd. Page 12 www.compacngv.com... -
Page 13: Connecting The Pipework
Make sure that the gas outlet pipes are properly supported before connection. 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. -
Page 14: Connecting Mains Power
(Comms option is not available) 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. Typical wiring Compac Industries Ltd. Page 14 www.compacngv.com... -
Page 15: Electrical Commissioning
Press the Stop button. The solenoids switch off and the fill ends. When you release the Stop button, the loading post resets and returns to a ready state. Compac Industries Ltd. Page 15 www.compacngv.com... -
Page 16: Mechanical Commissioning
Never tighten fittings while they are under pressure. Check that the outlet supply valve is closed and the nozzle valve is closed. Connect the nozzle to a tank containing CNG. Turn on the post and wait for it to power up. PA:uSE. -
Page 17: Set-Up
The K-Factor switch is located on the C4000 indicator board. You can use this switch to set the density factor (changing the units the display reads in) and the meter calibration. Figure 1: Parameter and K-Factor switches. Compac Industries Ltd. Page 17 www.compacngv.com... - Page 18 Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch. Compac Industries Ltd. Page 18 www.compacngv.com...
- Page 19 The Compac factory default setting is 40 kg/min or 60 kg/min depending on application. Let the menu time out so that the value and quantity amounts are displayed.
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Page 20: C Configuration Code
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 20 www.compacngv.com... -
Page 21: Reading The Loading Post Totals
The dispensed quantity will then be shown next and will be displayed for 10 seconds. This will be shown as: Followed by a 10 digit Total. This is the kilograms dispensed (unless another unit measure has been set using the Density Factor switch). Compac Industries Ltd. Page 21 www.compacngv.com... -
Page 22: Cng Loading
CNG Loading CNG Loading Wearing appropriate personal safety equipment is recommended while loading CNG. Gloves, safety glasses and/or face shield, hearing protection and non-static generating clothing should be worn. Vehicles should be switched off and any potential sources of ignition removed. -
Page 23: Servicing
When the remaining gas has vented, either wait for the solenoid to time out or press the Stop button. When there is no pressure left in the system, close the inlet, outlet and vent line valves. Compac Industries Ltd. Page 23 www.compacngv.com... -
Page 24: Scheduled Servicing
Check the loading post calibration. Meter Calibration (see page 40). Check the C4000 Processor Board is clean, dry and dust free. Check the C4000 flameproof box lid is bolted down tight and all glands are tight. Compac Industries Ltd. Page 24 www.compacngv.com... - Page 25 Serious injury may result if components are removed while the post is under pressure. After checking for leaks, wipe any excess water off the loading post to prevent corrosion. Compac Industries Ltd. Page 25 www.compacngv.com...
- Page 26 If bubbles form, there is a leak, in which case you should replace the three-way refuelling valve seals. Compac Industries Ltd. Page 26 www.compacngv.com...
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Page 27: Solenoid Valve Seal Replacement
Solenoid top service kit - Part number FC-SVK-0001 (optional) Never remove or service the stem. If it is leaking, it must be returned to Compac for service. When working on the open solenoid assembly, cover the opening with a cloth to prevent dust and dirt from entering. - Page 28 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 if required. Compac Industries Ltd. Page 28 www.compacngv.com...
- Page 29 Insert the solenoid spring. Insert a new solenoid top O-ring seal. Place the solenoid top back on the solenoid body, making sure that the locating dowel is engaged. Screw in the six M6 cap screws. Compac Industries Ltd. Page 29 www.compacngv.com...
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Page 30: Solenoid Coil Replacement
Before replacing the lid on the flameproof box, make sure that the O-ring is not damaged and is seated properly in its groove. If the O-ring is damaged and needs replacing, replace it with an O-ring of the same size and specification (176 N70). Compac Industries Ltd. Page 30 www.compacngv.com... -
Page 31: 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 loading post. -
Page 32: Three Way Refuelling Valve Seal Replacement
Screw the ball shaft retainers into either side of the valve body hand tight. Use a torque wrench to tighten the retainer to 25ft/lb / 34Nm Place the handle on the handle shaft and screw in the grub screw to lock it in place. Compac Industries Ltd. Page 32 www.compacngv.com... - Page 33 Servicing Three Way Refuelling Valve Seal Replacement Compac Refuelling Valve Exploded View Retainer Nut “A” assembly Retainer Nut “B” assembly Shaft/Spindle assembly Compac Industries Ltd. Page 33 www.compacngv.com...
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Page 34: Refuelling Hose Replacement
Attach the new hose to the loading post at the outlet block. Check all hose connections for leaks by applying soapy water mixture and looking for bubbles. See page 25. Compac Industries Ltd. Page 34 www.compacngv.com... -
Page 35: Power Supply Replacement
O-ring is not damaged, and is seated properly in its groove. If the O-ring is damaged and needs replacing, replace it with an O-ring of the same size and specification (176 N70). Compac Industries Ltd. Page 35 www.compacngv.com... -
Page 36: C4000 Processor Board Replacement
Refit the EPROM and memory chips, as per Loading Post Software Upgrade/Replacement (see page 37) Check loading post operation (see page 25). It should not be necessary to recalibrate the loading post. Compac Industries Ltd. Page 36 www.compacngv.com... -
Page 37: Software Upgrade/Replacement
If the initial set-up data is different, re-enter this information, as per Parameter Switch Settings (see page 17) and K-Factor Switch Settings (see page 17). Check the loading post operation Checking Post Operation (see page Compac Industries Ltd. Page 37 www.compacngv.com... -
Page 38: Meter Replacement
Meter Replacement Before you start, make sure you have: A new Compac meter F-D-METER-KG80T Remove the Meter De-gas the loading post (see page 23). Remove the tubing from the meter inlet and outlet. Unscrew the SAE fittings from the meter inlet and outlet. -
Page 39: 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 40: Loading Post Calibration
5.80 = 1.0138 (4 decimal places) Input the new meter K-factor ( ) (see page 18) Input loading post settings Set the density factor back to its original value. ( ) (see page 18) Compac Industries Ltd. Page 40 www.compacngv.com... - Page 41 A CNG cylinder with a fill and release valve To carry out the calibration test fill procedure (Method 1): Put an empty CNG cylinder on the scales and take note of its weight. Fill the CNG cylinder via the loading post.
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Page 42: 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 42 www.compacngv.com... -
Page 43: Diagnostic And Output Leds
The table below outlines which LED is associated to which power terminal and the component that it controls. Power Component Terminal Controlled Solenoid. Finished dispensing. (Turns off when the nozzle is stowed.) Error indication. Compac Industries Ltd. Page 43 www.compacngv.com... -
Page 44: Troubleshooting
For sites where the temperature falls below –10°C, power should only be removed from the loading post for servicing. When servicing a Compac CNG Loading post fault, please follow the recommendations and safety information in this manual. Failure to do this may cause injury or void the warranty. -
Page 45: Problems When Post 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 45 www.compacngv.com... -
Page 46: Problems Starting A Fill
(if present). If it exceeds 215 bar, the over- pressure safety will have shut down power to the solenoid but not the electronics and metering. De-gas the loading post to reduce the pressure. Compac Industries Ltd. Page 46 www.compacngv.com... -
Page 47: Problems Filling
9999.99 99999.9 if either the value or the quantity , or This is not a loading post fault. displays ever reach these values. 999999 units according to where the decimal point is set. Compac Industries Ltd. Page 47 www.compacngv.com... -
Page 48: 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 27) Compac Industries Ltd. Page 48 www.compacngv.com... -
Page 49: Appendix
G EEx ib A T3 (-25°C ≤ Ta ≤ 80°C) 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... -
Page 50: Specifications
Specifications Technical Specifications Specifications Technical Specifications Compac CNG Loading Posts (excluding hose assembly) are designed to operate within the atmospheric environment. Gas parameters are outlined below. They require the following operating conditions: Air temperature range - 25 °C to + 55 °C... -
Page 51: 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 loading post. 3/4" SAE female outlet. Between the inlet and outlet, the valve opens 275 bar max. - Page 52 The hose is specifically designed to dissipate hose. static electrical build-up and wear resistance. Each hose assembly must be properly grounded. 3/8", 1/2" or 3/4". The temperature range for the hose is -40 to +66°C. Compac Industries Ltd. Page 52 www.compacngv.com...
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Page 53: Hydraulic Layout - Loading Post
Specifications Hydraulic Layout – Loading Post Hydraulic Layout – Loading Post Compac Industries Ltd. Page 53 www.compacngv.com... - Page 54 FCVCI-12-SS Grade 10 Coalescing Filter Element And Filter Bowl O-ring FC-VALVE-0012 FCVCI-12-ss Complete Filter/Check Valve With Grade 10 Coalescing Filters FC-SK-0005 FCVCI-12-SS Check Valve Seal Kit FC-SK-0002 RCI-12-SS Regulator Valve Seal Kit FC-VALVE-0015 RCI-12-SS Complete Regulator Valve Compac Industries Ltd. Page 54 www.compacngv.com...
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Page 55: Spare Parts
Compac loading posts. They are not an exhaustive list of all possible parts for current or historical models. If a part you want to order is not listed, please contact the Compac spare parts department for a complete listing. -
Page 56: Fuses
Fuse Rating Comment 0.5 A Fuses F1, F2, and F3 should be 5 x 20 mm glass normal blow type, and should comply with IEC127, 35 Amp minimum rupture current. 0.25 A 1.0 A Compac Industries Ltd. Page 56 www.compacngv.com... -
Page 57: Error Codes
10 seconds for each section of tote data. You should read and understand all safety precautions before operating or maintaining Compac CNG equipment. When servicing Compac CNG equipment, please follow the recommendations in this manual. Otherwise you may injure yourself and void the warranty. - Page 58 Ab d The main display is not correctly. communicating correctly. Check the condition of the display cabling and make sure that no wires have come out of the plugs. Replace display if necessary. Compac Industries Ltd. Page 58 www.compacngv.com...
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Page 59: 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.
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