Page 1 CNG DISPENSER SERVICE MANUAL C5000 CNG Dispenser Service Manual Version 1.0.2 Date: 11 July 2023...
Page 2 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 C5000 CNG Dispenser Service Manual G:\Masters\Manuals\Authorised Manuals\CNG File Name and Location Manuals Current Revision Author(s) Trevor Watt Revision History Version Date Author(s) Revision Notes 1.0.0 27/08/2021 Phillip Foy C5000 CNG Manual 1.0.1 13/09/2021 V Amarakoon Updated Spare parts 1.0.2...
Page 6: Table Of Contents
Contents Conditions of Use ....................1 Product Identification ..................2 Document Control ....................3 Safety ........................1 System Design ....................... 1 Mechanical Safety ....................1 Electrical Safety ....................2 Introduction ......................3 Refuelling Modes ....................4 Fixed Pressure Refuelling ..................4 Installation ......................
Page 7 CNG Setting ......................25 Density Factor ................... 26 Ambient Temperature ..................26 Electronic Pressure Calibration points ............27 Overfill pressure Time ..................28 Maximum Flow ....................28 Changing the K-Factor ..................28 C Configuration Code ..................29 Pump settings ................... 29 Start fill mode ....................
Page 8 KG100 Meter Replacement ................. 58 Compac Breakaway Seal Replacement ............. 59 Three-Way Refuelling Valve Seal Replacement ..........61 Compac Refuelling Valve Exploded View ..........63 Refuelling Hose Replacement ................64 Power Supply Fuse Replacement ............... 64 Power Supply Replacement ................67 Processor Board Replacement ................
Page 9 Error Codes....................... 104 MODBUS Registers ................... 106...
Page 10: Safety
DANGER PRECAUTIONS You must adhere to the following safety precautions at all times when working on the Compac equipment. Failure to observe these safety precautions could result in damage to the dispenser, injury, or death. Make sure that you read and understand all safety precautions before operating the...
Page 11: Electrical Safety
CNG fuels. They are available in either single or dual hose configurations and with different flow rates. ▪ Compac CNG dispensers are controlled by a C5000 board which has many programmable features to suit your individual operation.
Page 12: 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 C5000 board which has many programmable features to suit your individual operation.
Page 13: Refuelling Modes
Refuelling Modes Fixed Pressure Refuelling In this mode an over pressure limit is set in the Dispenser. If the pressure measured at the pressure transducer is greater or equal to the limit the dispenser will end the fill.
Page 14: Installation
Installation For Installation instructions, please refer to the Installation manual. Commissioning Electrical This procedure outlines how to perform an electrical operational test before carrying out full mechanical commissioning, making sure that the dispenser is functioning correctly. Check for any damage that may have occurred in transit. Check all terminals, plugs, and chips to make sure that they are securely in place.
Page 15: Mechanical
Mechanical At the mechanical commissioning stage, the dispenser should not be pressurised. NOTE: If you find any leaks during commissioning, immediately close all the valves and de-gas the dispenser. To perform a mechanical test: Make sure that the inlet shut-off valves are closed. (These are the valves in the inlet lines at the base of the dispenser, but they are not part of the dispenser.) Check all dispenser fittings, especially the inlet connections, to make sure that they are tight.
Page 16 The dispenser and hose(s) are now fully pressurised. Use soapy water to check all fittings (including the hose fittings) for leaks. DANGER: Always de-gas the lines before tightening any fittings. Never tighten fittings while they are under pressure. Complete a few fills on a test cylinder, checking for leaks or unusual operation.
Page 17: Dispenser Set-Up
Dispenser Set-Up Parameter Switch The Parameter switch is located on the K factor board behind the main display and allows you to adjust the unit price, hose number, Pump settings high low cut off and display setting. The Parameter switch also enables you to view the Dispenser Software Version and End of Sale Indicators.
Page 18: How To View The Software Version
Setting Price Display Litres Display Software Version P**. * *. * * P**. * *. * * Pump Number Pna *** or pnb *** Price Pa**. * ** or pb**. * ** Pump Settings Ba **** or bb **** Low-flow cut off Lfa *** High-flow cut off xfa ***...
Page 19: Changing The Pump Number
Changing the Pump Number If the parameter switch is continually depressed, the following menu to change the pump number will appear. Each side must be numbered between 1-99. NOTE: Entering a pump number 0 will disable the pump.to the pump controller See Using the Dispenser Menus to edit these settings.
Page 20 NOTE: Each press of the Parameter 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. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
Page 21: B Pump Settings
B Pump Settings The bA setting is where you can set the dispenser in to standalone mode. Standalone mode means that the dispenser doesn’t communicate to a controller or POS. If the dispenser is in authorisation mode the dispenser will not start even if there is no controller or POS connected.
Page 22: Changing The Low-Flow Cutoff
Changing the Low-flow Cutoff A flow range is needed for each pump to dispense an accurate amount of product. If too much or too little fuel is dispensed, the meter can not accurately measure the dispensed fuel and therefore should cut off and display an end of sale message. The low-flow cutoff will end the transaction (without an error code) if flow drops below this value.
Page 23: Minimum Flow Rate
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. NOTE: The Compac factory default setting is ⁄ 1.0 �� ...
Page 24: To Adjust The Maximum Flow Rate
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. NOTE: The Compac factory default setting is 40 �� for Car Dispensers and ⁄...
Page 25: Slave Display Configuration
Slave Display Configuration Slave displays are the displays that are additional to the K-factor board display. You can have up to 4 slave displays connected to one C5000. These displays can be configured as one of the following: • Clone of the main display. This will display what is on the A side display but not error check the LCD •...
Page 26: Changing The Custom Display Configuration
D5 3201 Slave display 4 Slave display 3 Slave display 2 Slave display 1 Changing the Custom Display Configuration The custom display configuration can be used to show additional information on the unit price display. The additional information that can be shown includes the density, temperature, flowrate, and reset batch.
Page 27: Last Sale
Last Sale This menu is used to view the last sale details. It is only use when the dispenser is used for LPG 4. 7 0 529. 8...
Page 28: Electronic Totes
Electronic Totes The dispenser records electronic totes for price and dollars. To view the electronic totes, continue pressing the parameter switch until the following display is shown: La 0031 l0556. 6 1 The bottom row is a continuation of the top row – for example, the above display should be read as 00310556.
Page 29: K-Factor Switch
K-Factor Switch The K-Factor switch is located on the C5000 K-factor board. It is used to access and set up options on the dispenser. K-Factor button Parameter button K-Factor Settings A summary of the K-Factor settings can be seen below. Information on these settings and how to change them can be found on the following pages.
Page 30 **.* Ambient temperature Pressure probe 1 low *.**** Ua1l calibration point Pressure probe 1 high *.**** Ua1h calibration point Pressure probe 2 low *.**** Ua2l calibration point Pressure probe 2 high *.**** Ua2h calibration point Overpressure time **.* Maximum flow QA **** or qb **** K-Factor FA or FB...
Page 31: Dispenser Settings
Dispenser Settings The following diagram displays how to change the dispenser settings, such as the meter type, variant and minimum delivery. To get to the following menu, depress the K-Factor switch once when not in a transaction. The menu shown is for side A – if side B is required, continue depressing the K-Factor switch until the same menu for side B is reached and follow the same set up instructions.
Page 32: Meter Settings
Meter Settings This setting corresponds to the type of meter plugged in to the dispenser. Options 1-3 are for an encoder meter and depend on the channel setting of this meter. Encoder meters are used for petrol and diesel, while V50 and KG100 meters (option 4) are used for LPG, AdBlue and CNG. Some settings (such as temperature and density calibration) are only available for V50 and KG100 meters and therefore will not appear if the correct meter type is not set Variant Settings...
Page 33: Meter Density Calibration
15. 0 Meter Density Calibration The density calibration can be used to adjust the density being retrieved from the meter, if this is not the actual density of the product being dispensed. The actual density of product at 15 °C being dispensed should be entered in this menu.
Page 34: Overfill Pressure
Overfill pressure The Overfill pressure is the pressure that the dispenser will end the fill at. This setting is used with the deb setting(time is seconds over the overfill pressure) to ajust the final fill pressure. 200. 0 CNG Setting The CNG setting is specific settings for the CNG application.
Page 35: Density Factor
Density Factor The density factor (d5F) is used to set the format of the quantity that is displayed. For KG, a density factor of 1.000 is used. For other units of measure, different density factors are required. 1. 0 000 To determine the correct density factor for the unit of measure you would like to use on the read-out, consider the following: The dispenser read-out displays the measured quantity in KG divided by the...
Page 36: Electronic Pressure Calibration Points
15. 0 Electronic Pressure Calibration points The Electronic pressure calibration points (ua1l, ua1h, ua2l and ua2h) are used to calibrate the pressure transducer in the dispenser’s utility manifold. ua1l is the lower pressure calibration point and ua1h is the upper pressure calibration point.
Page 37: Overfill Pressure Time
Overfill pressure Time This in the number of seconds that the current pressure needs to be over the overfill pressure before the fill will end. 01. 0 Maximum Flow If this setting is left at 0000 the maximum flow, or Qmax, is 40 kg/minute by default. This setting is used for weights and measures.
Page 38: C Configuration Code
4 – Push to start 2 – Dual Pump settings This sets the number of hoses setup in the C5000. After setting this setting the number of settings in the parameter and the K-Factor switch will change. Start fill mode This sets how the fill is started.
Page 39: Changing Comms
Mode 1 = 5 digit Pump Protocol 0 = 6 digit 0 = Disabled 1 = Compac Channel 2 = PEC 0,1 (default) and 2 3 = Gilbarco Change the Protocol and the mode to match the controller’s settings. Channel 1 is the default channel for dispensers (channel number should always match the with the comms board terminal block used).
Page 40 GPi0 0000 Inputs Setting Duty Cycle Setting 0-0 Off 0-50% 1-1 Channel Encoder 1-10% 2-2 Channel Encoder 2-20% 3-3 Channel Encoder 3-30% 4-Switch Input 4-40% 5-Remote Push to start 5-50% 6-60% Output Settings 7-70% 0-0 off 8-80% 1-Volume (Litres/Kg’s) 9-90% 2-Amount (Dollars) Inputs Setting 0-1KHz...
Page 41: Remote Push To Start
Remote push to start The setting on the K Factor board to enable the remote push to start is GPIO XXX5. When remote push to start is enabled the dispenser will start a transaction when the input is pulled high for at least 0.5 seconds.
Page 42: Duty Cycle
Duty Cycle The duty cycle setting gives the ability to set the percentage of the pulse high and low. The default setting is 50%. The pulse length is determined by the following formula. Example Duty cycle set to 50% Frequency set to 1KHz (1000 pulses/sec) ��...
Page 43: Pulse Value
Pulse value The pulse value setting sets what a pulse is worth. When the output is set to volume the lowest volume a pulse can be set to is 00001 which is 10 ml. If the output is set to amount the lowest amount a pulse can be set to is 00001 which is 1 cent or 0.01 dollars.
Page 44: Dispenser Operation
Dispenser Operation Turning the Dispenser on When the power is applied to the dispenser, the display will show Hold. 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 Refuelling a Vehicle Appropriate personal safety equipment should be worn whilst refuelling a vehicle.
Page 45: Reading The Dispenser Totals
Reading the Dispenser Totals To read the dispenser totals: ▪ Quickly press the 5tart 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 46: Servicing
Servicing Degassing the Dispenser When replacing or servicing dispenser hydraulics the dispensers must be de-gassed. Degas the Dispenser 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.
Page 47: Schedules Servicing
Check the UPS and voltage stabiliser supplying power to the dispenser is working according to the manufacturer’s specifications. Check the C5000 flameproof box lid is bolted down tight and all glands are tight. Check the zero point and calibration of the dispenser pressure transducers.
Page 48: 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 49: Checking The Over-Pressure Operation
Valve Adjuster (use 8 mm Hex Key) Checking the Over-Pressure Operation To check the operation of the Overfil Pressure cut off: Access the K-Factor switch on the K-Factor board. Obtain the overfill pressure settings 0pa Set the overfill pressure cut-off point to below the regulator pressure. Set the over pressure time to (deb) 01.0 or 1 second.
Page 50: 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 51: Checking The Refuelling Hose For Leaks
Checking the Refuelling Hose 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 52: Checking The Three-Way Refuelling Valve Operation
Checking the Three-Way Refuelling Valve 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 53: 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 54: Solenoid Valve Seal Replacement
Check the dispenser for leaks. 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 55 NOTE: It is not necessary to remove the solenoid body from the dispenser to service the solenoid seals. To 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.
Page 56 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 57: Solenoid Coil Replacement
Failure to turn off the power could result in an electric shock. Remove the flameproof box lid to gain access to the C5000 Terminal board. Disconnect the appropriate solenoid coil wiring from the C5000 Terminal board board.
Page 58: 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 59: 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 To remove the old regulator valve seals: De-gas the dispenser.
Page 60 To install the 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...
Page 61: 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 62 CAUTION: Wear appropriate safety eye wear when using compressed air. To 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 63: 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 64 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. Push the valve stem down into the valve and remove it from the valve body.
Page 65 Service kit Suggested service tools To replace the valve: 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.
Page 66 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 67: 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 68: 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 69 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 70: 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 71 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 72: Compac Refuelling Valve Exploded View
Compac Refuelling Valve Exploded View Retainer Nut “A” assembly Retainer Nut “B” assembly Shaft/Spindle assembly...
Page 73: Refuelling Hose Replacement
Check all hose connections for leaks by applying soapy water mixture and looking for bubbles. Power Supply Fuse Replacement NOTE: There are three fuses used in the C5000 Flame proof box. Before you start, make sure you have the following fuses with these ratings: ▪ F1 = 1.6 A ▪...
Page 74 Remove the blown fuse and discard. CAUTION: Take basic anti-static precautions by wearing a wristband with an earth strap. To install the new C5000 terminal board fuse(s): Replace the blown fuse element with a new one of equal type and rating.
Page 75 CAUTION: You must use the correct rating when replacing a fuse. The correct ratings are printed next to each fuse on the printed circuit board. Using the incorrect fuse rating may compromise the intrinsic safety of the dispenser. Replace the flameproof box lid, ensuring that the O-ring in the lid engages in its associated groove.
Page 76: Power Supply Replacement
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. Remove the flameproof box lid to gain access to the C5000 power supply board. CAUTION: Take basic anti-static precautions by wearing a wristband with an earth strap.
Page 77: Processor Board Replacement
CAUTION: Take basic anti-static precautions by wearing a wristband with an earth strap. Undo the screws that hold any coms or GPIO board into the C5000 processor board. Undo the screws that hold the C5000 processor board in the flameproof box and remove the C5000 processor board.
Page 78: Temperature Pressure Board Replacement
Do up the screws that hold the C5000 processor board in the flameproof box. Do up the screws for any coms or GPIO board into the C5000 processor board. Reinstalled the lid on the flameproof box DANGER: Before replacing the lid on the flameproof box, make sure that the O-ring is not damaged, and is seated properly in its groove.
Page 79: Dispenser Software Upgrade/Replacement
Make sure the Dip switches are the same as the board that was taken Turn the power to the dispenser back on. Check Dispenser operation. Checking Dispenser Operation. NOTE: It should not be necessary to re-calibrate the dispenser unless a pressure transducer or temperature probe needs to be replaced.
Page 80 Install the USB stick for the software that you want to install. If there is a coms or GPIO card installed on the C5000 processor board, you might have to remove it. Reinstalled the lid on the flameproof box...
Page 81: 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 K-Factor...
Page 82: 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 83: Calibration Test Fill Procedure (Method 2)
Certified weighing scales with a read-out accuracy of +/- 20 g or better and a range of 0 – 120 kg 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.
Page 84: Pressure Transducer Calibration
Pressure Transducer Calibration Calibrating the dispenser pressure transducers is done by setting the Pressure probe calibration points. The following procedure is how to set these points. NOTE: The pressure transducers are calibrated at the factory and usually do not require recalibration. To set pressure probe calibration points Degas the dispenser and close all outlet isolation valves Turn on the gas to the dispenser.
Page 85 Adjust the dispenser’s ambient temperature reading to match that of the calibrated temperature meter.
Page 86: Indicator Leds
Flashes when receiving Combus messages. This indicates the C5000 processor is sending messages to K-Factor board Flashes when sending messages on the Combus Provides diagnostic information Diag (see below).
Page 87: Appendix
Appendix The C5000 is ATEX approved for use in a Class 1, Zone 1 hazardous area. Dispensers are wired to Class 1, Zone 1 Australian and European standards. Approval numbers appear on labels attached to the C5000 and the flameproof junction box lid.
Page 88: 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 89: 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 90 (350 bar option) (350 bar option) valves and require a compressed air supply.) +/- 1.0% Accuracy +/- 1.0% +/- 1.0% Compac Compac KG100 Compac KG100 Meter KG100coriolis mass coriolis mass flow coriolis mass flow flow 1/2” or 3/4" Internal Pipework 1/2”...
Page 91: Component Specifications
Component Specifications See below for information on serviced equipment. Equipment Compac Specifications Description Item Code The coalescing filters are designed to trap dirt, moisture, oil, and other debris that may damage the valve Coalescing Grade 10 seals. A Grade 10 coalescing filter...
Page 92 Equipment Compac Specifications Description Item Code The three-way valve is designed specifically for refuelling CNG vehicles. The inlet, outlet, and Three-way 1/4" NPT ports exhaust ports are designed to be refuelling RVCI-04 250 bar max. used as shown in the figure in the...
Page 93 Equipment Compac Specifications Description Item Code The display has six 1" digits for GD1, GD2 or price, six 1" digits for quantity and Display four 3/4" digits for unit price. (Available with one, two or three unit price displays.) Dual scale pressure gauges are...
Page 94: Hydraulic Layout
Hydraulic Layout...
Page 95: 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 96: Connecting Compression Tube Fittings
CAUTION: Never use thread tape on SAE parallel fittings. Connecting Compression Tube Fittings Ensure the end of the tube is square, not deformed, clean and free from burrs inside and out. Remove the nut from the fitting and ensure the two ferrules are present and correctly orientated.
Page 97: Electrical Drawings
Electrical Drawings CNG Dispenser Electrical Schematic...
Page 98: Power Supply
Power Supply The C5000 power supply is found within the flameproof box, located on the unit. The power supply contains the processor board and the terminal board. Processor Board Terminal Board Power Supply PCBs Flameproof box...
Page 99: Incoming Mains
Incoming Mains Incoming mains connections should be brought in to the terminal board. An emergency stop connection, if desired, can also be wired into the terminal board, shown below. This will be in place of the normal loop between the triac and main phases. Wires have standard colours which are shown.
Page 100: Solid State Relays (Triacs)
Solid State Relays (Triacs) There are 7 separate solid state relays (small triacs) on the C5000 terminal board. The output terminals for these triacs are T1 to T7. See below for information about the use of these outputs. Power Terminal...
Page 101 Ground 24 volt Pulse Stop signal from Start signal signal open open from PLC collector collector output output...
Page 102: C5000 K-Factor Board
The Compac C5000 K-Factor board is the Main Calculator in the Compac Dispenser. It communicates to the KG100 meter to get the current mass and returns it to the C5000 Processor board. It also reads the Start and stop buttons for both sides (side A and side The Compac C5000 K-Factor board also is a user interface enabling the setup operation of the dispenser .
Page 103: Temperature Pressure Board
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 104: Main Dispenser Spare Parts
Electromechanical Tote With 200mm Cable F-CP-PRESET-3KMB 3 Key Membrane Keypad - Horizontal F-CP-PRESET-3KMV 3 Key Membrane Keypad - Vertical F-CP-C5K-PSET C5000 Preset interface board C5000 Temperature/Pressure board CI507 F-CP-C5K-CNG-TP F-CP-C5K-KFACT C5000 K-Factor board CI502 FC-GAUGE-0001 Dual Scale Pressure Gauge, Units Of Measure In "bar + psi"...
Page 105: Main Dispenser Parts Location
Item Part Number Description FC-PBSW-ESTOP Red Stop Button With Mushroom Head FC-PBSW-START Green Start Button F-D-MTR350-C5 KG100 Mass Flow Meter Compac Hydraulic Module See Hydraulic Module Spare Parts Main Dispenser Parts Location...
Page 106: Other Dispenser Parts Not Shown In Drawing
Other Dispenser Parts Not Shown in Drawing Part Number Description C5000 MS5200 CNG PRESSURE SENSOR F-CU-CNGPRMS5200 F-CU-CNG-TEMPSEN CNG Temperature Sensor F-CP-C5K-TERM C5000 Termainal board CI504 F-CP-C5K-GPIO C5000 GPIO board CI518 F-CP-C5K-PROCES C5000 Proessor board CI500 F-CP-C5K-PS C5000 Power supply CI505...
Page 107: Hydraulic Module Parts
NGV2 CNG Refuelling Nozzle OPW CT5000S (Includes 3/8" Tube To CT5000S 1/8" NPTF Stainless Steel Fitting For Vent Tube) FC-BWY-0001 QBCI-09 Compac Inline Quick Breakaway 9/16" SAE Ports (Not For Vent Line Use) FC-BWY-0003 QBCI-09 Compac Inline Quick Breakaway FC-SK-0011...
Page 108 Part Number 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...
Page 109: Troubleshooting
Recommended Action For all problems not listed here please contact your service agent Fit a voltage-stabilising Unacceptable voltage spikes The C5000 electronics are UPS to the dispenser. are causing the fuses on the not working. The indicator Contact your service C5000 to blow.
Page 110 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. 101.
Page 111: End Of Sale Indicators
The dispenser was stopped by a remote Check that the point of sale is device such as a Point of Sale (POS) or not sending a stop command Compac Communicator. and is correctly configured. Maximum display value reached. Check display resolution (Sr) setting.
Page 112 Number Meaning Checks Main display not detected. This is caused by a fault in the display or a bad See above. connection in the display wiring loom. The pressure at the first measurement Check for blockage in the fuel was within 20bar of the calculated delivery hose, breakaway or maximum pressure.
Page 113 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 114 Error Code Likely Cause Recommended Action 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 has been disconnected. Establish why the 5top switch was operated. 5TOP The 5top switch is latched on.
Page 115 MODBUS Registers Register Type Access Designation Operational Notes 0100 Operation Flags 0101 Unit Price 0102 Current Quantity 3dp implied 0104 Current Amount 2dp implied 0106 BCD12 Hose Quantity 00+ 5 BYTES BCD 0109 BCD12 Hose Amount 00+ 5 BYTES BCD 0112 Pressure Live, Transducer...

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