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Compac CNG Service Manual

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Compac Industries Ltd.
52 Walls Road. Penrose. Auckland 1061, New Zealand. PO Box 12 417 Penrose. Auckland 1642. New Zealand. Tel: +64 9 579 2094 Fax: +64 9 579 0635 info@compacngv.com
www.compacngv.com
Compac Industries Ltd.
52 Walls Road. Penrose. Auckland 1061, New Zealand. PO Box 12 417 Penrose. Auckland 1642. New Zealand. Tel: +64 9 579 2094 Fax: +64 9 579 0635 info@compacngv.com www.compacngv.com
CNG Dispenser Service Manual
Version 1.0.8
Page 2
Conditions of Use
Read this manual completely before working on, or
making adjustments to, the Compac equipment
Compac Industries Limited accepts no liability for
personal injury or property damage resulting from working on or adjusting the CNG Dispenser incorrectly or without authorisation.
Along with any warnings, instructions, and
procedures in this manual, you should also observe any other common sense procedures that are generally applicable to equipment of this type.
Failure to comply with any warnings, instructions,
procedures, or any other common sense procedures may result in injury, equipment damage, property damage, or poor performance of the Compac equipment
The major hazard involved with operating the
Compac CNG Dispenser is electrical shock. This hazard can be avoided if you adhere to the procedures in this manual and exercise all due care.
Compac Industries Limited accepts no liability for
direct, indirect, incidental, special, or consequential damages resulting from failure to follow any warnings, instructions, and procedures in this manual, or any other common sense procedures generally applicable to equipment of this type. The foregoing limitation extends to damages to person or property caused by the Compac CNG Dispenser, or damages resulting from the inability to use the Compac CNG Dispenser, including loss of profits, loss of products, loss of power supply, the cost of arranging an alternative power supply, and loss of time, whether incurred by the user or their employees, the installer, the commissioner, a service technician, or any third party.
Compac Industries Limited reserves the right to
change the specifications of its products or the information in this manual without necessarily notifying its users.
Variations in installation and operating conditions
may affect the Compac CNG Dispenser's performance. Compac Industries Limited has no control over each installation's unique operating environment. Hence, Compac Industries Limited makes no representations or warranties concerning the performance of the Compac CNG Dispenser under the actual operating conditions prevailing at the installation. A technical expert of your choosing should validate all operating parameters for each application.
Compac Industries Limited has made every effort
to explain all servicing procedures, warnings, and safety precautions as clearly and completely as possible. However, due to the range of operating environments, it is not possible to anticipate every issue that may arise. This manual is intended to provide general guidance. For specific guidance and technical support, contact your authorised Compac supplier, using the contact details in the Product Identification section (see page v).
Information in this manual shall not be deemed a
warranty, representation, or guarantee. For warranty provisions applicable to the Compac CNG Dispenser, please refer to the warranty provided by the supplier.
Unless otherwise noted, references to brand
names, product names, or trademarks constitute the intellectual property of the owner thereof. Subject to your right to use the Compac CNG Dispenser, Compac does not convey any right, title, or interest in its intellectual property, including and without limitation, its patents, copyrights, and know-how.
Every effort has been made to ensure the accuracy
of this document. However, it may contain technical inaccuracies or typographical errors. Compac Industries Limited assumes no responsibility for and disclaims all liability of such inaccuracies, errors, or omissions in this publication.
Page 3
Contents
Document Control Information ........................................................................................................................................ 6
Symbols and Units of Measure ........................................................................................................................................ 7
Safety ................................................................................................................................................................................. 8
Introduction ....................................................................................................................................................................... 9
Software Versions ........................................................................................................................................................... 10
Mechanical Installation ................................................................................................................................................... 11
Preparing and Cleaning Pipework .......................................................................................................................... 12
Mounting the Dispenser ......................................................................................................................................... 13
Connecting the Pipework ....................................................................................................................................... 13
Attaching the High Mast (Laser Only) .................................................................................................................... 14
Electrical Installation ...................................................................................................................................................... 15
CNG Cable Requirements ..................................................................................................................................... 15
Connecting Mains Power and Communication ...................................................................................................... 16
Electrical Commissioning .............................................................................................................................................. 17
Mechanical Commissioning ........................................................................................................................................... 18
Dispenser Set-up ............................................................................................................................................................. 19
Parameter Switch ................................................................................................................................................... 19
K-Factor Switch ...................................................................................................................................................... 25
b Configuration Code ............................................................................................................................................. 34
C Configuration Code ............................................................................................................................................ 35
Dispenser Operation ....................................................................................................................................................... 36
Refuelling a Vehicle ............................................................................................................................................... 36
Reading the Dispenser Totals ................................................................................................................................ 39
Servicing .......................................................................................................................................................................... 40
Degassing the Dispenser ....................................................................................................................................... 40
Scheduled Servicing .............................................................................................................................................. 41
Filter Element Replacement ................................................................................................................................... 47
Solenoid Valve Seal Replacement ......................................................................................................................... 48
Solenoid Coil Replacement .................................................................................................................................... 51
Complete Solenoid Valve Replacement ................................................................................................................. 52
Regulator Valve Seal Replacement ....................................................................................................................... 52
Compac Breakaway Seal Replacement ................................................................................................................. 54
Three Way Refuelling Valve Seal Replacement - Old Model -Brass ...................................................................... 55
Three Way Refuelling Valve Seal Replacement - New Model - Stainless Steel .................................................... 57
Refuelling Hose Replacement ................................................................................................................................ 59
Power Supply Fuse Replacement .......................................................................................................................... 60
Power Supply Replacement ................................................................................................................................... 61
Processor Board Replacement .............................................................................................................................. 62
Temperature Pressure Board Replacement (Fast Fill & Temperature Compensation Units Only) ........................ 63
Dispenser Software Upgrade/Replacement ........................................................................................................... 64
Meter Replacement ................................................................................................................................................ 65
Unserviceable Parts List ........................................................................................................................................ 66
Page 4
Dispenser Calibration ..................................................................................................................................................... 67
Meter Calibration .................................................................................................................................................... 67
Pressure Transducer Calibration (Fast Fill & Temperature Compensated Units Only) .......................................... 69
Ambient Temperature Sensor Calibration .............................................................................................................. 70
Indicator LEDs ................................................................................................................................................................. 71
Power, Watchdog, Comms RXD and TXD LEDs ................................................................................................... 71
Diagnostic and Output LEDs .................................................................................................................................. 72
Troubleshooting .............................................................................................................................................................. 74
Problems When Dispenser is Idle .......................................................................................................................... 75
Problems Starting a Fill .......................................................................................................................................... 76
Problems Filling a Vehicle ...................................................................................................................................... 77
Solenoid Problems ................................................................................................................................................. 79
Appendix .......................................................................................................................................................................... 80
Approvals ............................................................................................................................................................... 80
Specifications .................................................................................................................................................................. 81
Model Specifications .............................................................................................................................................. 81
Technical Specifications ........................................................................................................................................ 82
Component Specifications ..................................................................................................................................... 83
Installation Diagrams ...................................................................................................................................................... 85
LEGEND Installation Diagram ................................................................................................................................ 85
LASER Installation Diagram................................................................................................................................... 86
Dispenser Fittings .................................................................................................................................................. 87
Mechanical Drawings and Component Details ............................................................................................................. 89
Dispenser Component Locator .............................................................................................................................. 89
Hydraulic Layout .................................................................................................................................................... 90
Electrical Drawings and Component Details ................................................................................................................ 91
CNG Dispenser Electrical Schematic ..................................................................................................................... 91
C4000 Power Supply Board ................................................................................................................................... 92
C4000 Microprocessor Board ................................................................................................................................ 96
C4000 Temperature Pressure Interface Board CI75-B ........................................................................................ 112
C4000 IS Cable Connections ............................................................................................................................... 114
Dispenser spare parts................................................................................................................................................... 116
Main Dispenser Parts ........................................................................................................................................... 116
Hydraulic Module Parts ........................................................................................................................................ 119
Error Codes ................................................................................................................................................................... 120
End of Sale Indicators .......................................................................................................................................... 123
Page 5
Product Identification
Manual Title
CNG Service Manual
Original Publication Date 12/01/2010
Models Covered
Standard
High Flow
Ultra-High Flow
Laser
L-CNG15
L-CNGD15
L-CNG50
L-CNGD50
L-CNG50-15
L-CNG80
L-CNGD80
L-CNG80-15
Legend
LGDCNG15
LGDCNGD15
LE3KG25D
LGDCNG50
LGDCNGD50
LGDCNG50-15
LGDCNG80
LGDCNGD80
LGDCNG80-15
Application
Compressed Natural Gas
Power Supply
Air Supply Pressure
275 or 350 bar Max
220 - 240 VAC 50 Hz 2 Amp +/­10%
5 to 10 bar ( Only required for units with air actuated valves)
Related Manuals
Title
Publication Date
Owner’s Manual
September 2010 Validity
Compac Industries Limited reserves the right to revise or change product specifications at any time. This publication describes the state of the CNG Dispenser at the time of publication and may not reflect the product at all times in the past or in the future.
Manufacturer Contact Details
The Compac CNG Dispenser is designed and manufactured by:
Compac Industries Limited 52 Walls Road, Penrose, Auckland 1061, New Zealand P.O. Box 12-417, Penrose, Auckland 1641, New Zealand
Phone: + 64 9 579 2094 Fax: + 64 9 579 0635
www.compacngv.com
Copyright ©2014 Compac Industries Limited, All Rights Reserved
Page 6
Document Control Information
Document Information and Revision History
Document Details
Compac CNG Dispenser Service Manual
File Name and Location
Current Revision Author(s)
R Lacey
Authorised By:
A.Kingstone
Release Date:27/04/11
Version
Date
Author(s)
Revision Notes
1.0.0
12/01/2010
R Lacey
Added document control information
1.0.2
08/09/2010
R Lacey
Added troubleshooting hyperlinks
1.0.3
10/02/2011
R Lacey
Added RS485 MOD-BUS & Micro Motion wiring
1.0.4
13/04/2011
R Lacey
Added RS485 wiring diagram
1.0.5
11/05/11
A.Kingstone
Corrected part numbers
1.0.6
10/02/2014
R Lacey
Added 350 Bar solenoid information
1.0.7
14/04/2014
R Lacey
Added new Temperature Pressure Board connections
1.0.8
05/05/2014
R Lacey
Added Er FLO error message
Distribution
Name
Indicator
Location
Symbols and Units of Measure
Compac Industries Ltd.
Page 7
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Symbols and Units of Measure
Symbols
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.
A reminder of safety practices or unsafe practices that
could result in personal injury or damage to associated equipment.
A reminder of safety practices or unsafe practices that could result in damage to associated equipment and/or voids the warranty.
Important information essential to the installation and operation of the Compac equipment
Units of Measure
The following units of measure are used in this manual:
Unit
Measure
Pressure
Bar (bar)
Temperature
Degrees Celsius (°C)
Volume
Litres (L)
Cubic Metres (m³)
Mass
Kilograms (kg)
Length
Metres (m)
Millimetres (mm)
Microns, Micrometres (m)
Inches (")
Torque
Newton Metres (Nm)
Voltage
Volts (V)
Current
Amps (A)
Frequency
Frequency (Hz)
Safety
Compac Industries Ltd.
Page 8
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Safety
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 Compac equipment
System Design
Ensure the system design does not allow the dispenser inlet pressure to exceed its rating. The dispenser does not include any safeties to protect against excessive inlet pressure. If necessary, suitable protective devices should be fitted prior to the dispenser inlet.
Mechanical Safety
Observe the following electrical precautions:
Never tighten a fitting under pressure, even if a fitting or joint is leaking. Always depressurise the line first
Never disassemble a fitting under pressure. Always depressurise the line first
Be very careful when disassembling frozen pipework, as gas pressure may be trapped and suddenly released. Always depressurise the lines first.
Never reuse any O-ring seals that have been in a high pressure gas atmosphere and then exposed to air. These o-rings swell and cannot be reused. Always make sure you have a new seal kit available to replace the seals before disassembly
Make sure that all internal surfaces are cleaned and that sliding surfaces are lightly greased with O-ring lubricant before reassembly. Dust and dirt entering components reduce the life span of the components and can affect operation
Make sure the service area is thoroughly cleaned before starting to service CNG components. Dust and dirt entering components reduce the life span of the components and can affect operation
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 on.
Never power up the CNG dispenser with the flameproof box lid removed.
Always turn off the power to the dispenser before removing or replacing software or memory IC's
Always take basic anti-static precautions when working on the electronics, i.e., wearing a wristband with an earth strap.
Introduction
Compac Industries Ltd.
Page 9
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Introduction
The Compac CNG dispenser is designed to provide safe and reliable dispensing of CNG fuels. They are available in either single or dual hose configurations and with different flow rates.
Compac CNG dispensers are controlled by a C4000 board which has many programmable features to suit your individual operation.
This manual contains the information required to operate and maintain your dispenser. Due to ongoing improvements and customised designs, there may be software features that are not available on your particular unit.
For clarity, this manual will refer to the "Dollars" display. If you do not use dollars please substitute this for your local currency.
Software Versions
Compac Industries Ltd.
Page 10
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Software Versions
Software Version HIA29.24.9CNG onwards
Displays error 9 messages in new format: PAUSE flashes in the kg
display and the error 9 type is shown in the unit price display.
Self checking for Error 9 faults while dispenser is idle. Displays
message if fault occurs and clears message 10 seconds after fault clears.
During fill if error 9 fault occurs the fill will stop and the error 9
message displayed for at least 120 seconds. If fault is cleared the display will continue for another 10 seconds.
If the dispenser is re-powered after an error 9 fault, the message will
show for 10 seconds after the start up PAUSE message.
When using the parameter switch, the hose number (PN) display has
been modified to also display a count of the total error 9 faults in the unit shown in the price display. Refer Parameter Switch (see page 19)
In the same mode, the display will also flash in the price/kg screen, the
last recorded reason for the end of sale and the last recorded error 9.
Software Version HIA29.25.3CNG onwards
Removing the decimal place from the totes screen
Quick view of totes by rapidly pressing the start button three times
Modification of error 9 codes to improve diagnostics
Changed sequencing rates
Sequencing triggered by minimum flow rates
Error 7 message changed to read Er Flo in totes screen
End of sale reason flashed in unit price display at end of sale
Software Version HIA29.26.0CNG onwards
Kilograms dispensed display increased to three decimal places for
greater accuracy
Mechanical Installation
Compac Industries Ltd.
Page 11
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Mechanical Installation
Overview
The stages of mechanical installation include:
Preparing and cleaning the pipework (see page 12).
Mounting the dispenser (see page 13).
Connecting the pipework (see page 13).
Special Precautions
Ensure the system design does not allow the dispenser inlet pressure to exceed its rating. The dispenser does not include any safety mechanisms to protect against excessive inlet pressure. If necessary, suitable protective devices should be fitted prior to the dispenser inlet.
Ensure you use the correct SAE thread on the inlet pipework and do not use thread tape.
Take all possible steps to prevent water or dirt from entering the system, both during installation and in the future. Water and dirt blocks up the pipework, which can damage seals, and stop gas from flowing and valves from operating.
At 200 bar of pressure, water freezes at 15°C in natural gas, causing ice particle contamination that may damage equipment. Make surethe pipework is clean and dry before connection.
Seals that have been damaged by moisture, methanol, impurities, dirt slag etc, are not covered by warranty.
During installation, potential sources of water include:
Inlet gas.
Testing new inlet gas pipework with water, or allowing water to enter
the pipework before making the final connections.
Pumping the storage with air.
Allowing water to enter the high-pressure gas lines during installation.
If the inlet gas is likely to be saturated, install a gas drier into the compressor inlet to ensure a dew point of –32°C at 250 bar of pressure.
Do not use methanol as an anti-freeze. If used in the wrong concentrations, it causes freezing. It is also absorbs water, which can be more damaging than the water that was originally present.
Pipework
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.
Preparing and Cleaning Pipework
Mechanical Installation
Compac Industries Ltd.
Page 12
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Preparing and Cleaning Pipework
This section provides a guide to current best practice in preparing the distribution pipework that will be connected to the Compac Dispenser.
For new stations, flush the gas feed lines thoroughly to remove all welding slag, moisture, and impurities that may be present in the system.
Any steel, brass, or other impurities can damage the regulator and solenoid valve seals.
The pipework installer is responsible for installing all pipework to the dispenser with due diligence. Compac is not responsible for any pipework external to the dispenser.
Ensure that all pipework is completely clean. Any dirt trapped in the pipework can damage the valve seals and surfaces.
Clean and Degrease the Pipework
To clean and degrease the pipework:
To prepare pipework, purge the pipework with nitrogen at 200 bar vented to the atmosphere to remove dirt, moisture, and water.
1. Mix together a 10% hydrochloric acid solution, to which you have added 25%
to 50% ammonia bi-fluoride and heat to a minimum of 65°C.
Wear adequate safety gear and take adequate precautions when using chemicals. Clean up all spills in compliance with the local territory authority laws and regulations.
2. Circulate the mixture through the pipework for four hours or more, depending
on the condition of the pipework.
3. Drain the acid solution from the pipework.
4. Blow out the pipework with compressed air.
5. Flush the pipework with clean water until the pH value is neutral.
Neutralise the Pipework
To neutralise the pipework:
1. Pass a 25% citric acid solution through the pipework once, or dry out the
pipework by blowing hot air through it.
Wear adequate safety gear and take adequate precautions when using chemicals. Clean up all spills in compliance with the local territory authority laws and regulations.
2. Fill the pipework with seal oil, then drain.
3. Blow out the pipework with compressed air.
4. Blast the pipes with nitrogen at 200 bar, letting the gas expand through the
pipes.
5. Once the pipework is cleaned, seal off the system to ensure no water, dirt or
other contaminates can re-enter the pipework.
Keep the pipework venting open to the atmosphere and feed in the 200 bar of nitrogen to achieve maximum velocity.
Take care to keep pipe openings closed until the compressor is started. This prevents rusting of the pipework, and stops dirt from entering.
Mechanical Installation
Mounting the Dispenser
Compac Industries Ltd.
Page 13
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Mounting the Dispenser
The mounting points on the dispenser differ depending on whether you are installing a Legend or a Laser. Installation Diagrams (see page 85)
To mount the dispenser:
1. Make sure that the dispenser is located on a solid, horizontal foundation or plinth.
2. Seal the supply pipes to prevent dirt, moisture, or water from entering during the mounting process.
3. Mark out the mounting points on the foundation, using the correct footprint diagram for the model of dispenser being installed.
See the Legend or Laser footprint diagrams below. Installation Diagram (see page 85)
4. Secure the dispenser with 12 mm dynabolts and washers. 12 mm dynabolts have the required strength to hold the unit but up to 16 mm x 75 mm dynabolts can be used in the 20 mm footprint holes.
Connecting the Pipework
1. Make sure that your work area (including the vice, workbench, tool storage area, and floor) is totally clean of particles or previous work. Cleanliness and correct assembly practice can avoid most seal problems.
2. Make sure that the gas inlet pipes are properly supported before connection.
3. Refer to one of the following procedures, depending on the fitting that you are using:
SAE Fittings (see page 87)
Adjustable SAE fittings (see page 87)
Compression tube Fittings (see page 88)
Attaching the High Mast (Laser Only)
Mechanical Installation
Compac Industries Ltd.
Page 14
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Attaching the High Mast (Laser Only)
All high masts come pre-assembled with the dispenser and simply require connection.
To attach the high mast:
1. Remove the stainless steel screws from the side of the dispenser.
2. Attach the mast using the screws, as pictured below.
The high mast gasket and stainless steel screws are fitted
to the dispenser in the factory.
High mast assembly complete with bracket
High mast gask et
Side of display cabinet
High mast
reinforcing bracket
3 x M8 x 30 stainless steel socket head scr ew (6 mm Allen or Hex key required fo r installation)
3 x M8 x 30 stainless steel socket head scr ew (6 mm Allen or Hex key required fo r installation)
3 x M8 spring washers
3 x M8 flat wash ers
Electrical Installation
CNG Cable Requirements
Compac Industries Ltd.
Page 15
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Electrical Installation
CNG Cable Requirements
Cable requirements are as follows:
Cable Type
Requirement
Power
3 Core Steel Wire Armour Cable 2.5mm2,
220 - 240 Volts. 50 Hz, +/-10%
Core 1: 230 Volt Supply (Active).
Core 2: Neutral.
Core 3: Earth.
Power Consumption
25w Idle, 200W with all solenoids active.
Comms
Standard comms: 2 Core Steel Wire Armour Cable 1.5 mm2. Maximum cable length 100 m. 12 V current loop.
Optional RS485 comms: 4 core Steel Wire Armour (SWA) 1.5 mm two twisted pair.
Make sure that there is at least a two metre cable tail on both the incoming underground 230 V and comms cables to reach the C4000 flameproof box.
Connecting Mains Power and Communication
Electrical Installation
Compac Industries Ltd.
Page 16
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Connecting Mains Power and Communication
In sites where the electrical supply is unstable, it is
recommended that a power conditioner or UPS is installed.
To connect the dispenser:
1. Wire the power and comms to the C4000 Termination Board, as shown in the diagram below.
2. Connect the earth lead of the supply cable to the earth stud in the flameproof junction box.
All cables must be terminated with approved flameproof
glands. The thread is 20 mm.
Figure 1. C4000 Power supply wiring
Electrical Commissioning
Compac Industries Ltd.
Page 17
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Electrical Commissioning
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.
Damage to electronics occurs most commonly from
vibration and jarring.
Before beginning this test, check that no gas pressure has been applied to the dispenser inlets. The factory set-up information should be programmed into the dispenser but all K-factor and Parameter switch settings should be checked and confirmed before commissioning tests are carried out.
To perform an electrical operational test:
1. 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).
2. Turn on the power supply to the dispenser.
The displays and backlighting will illuminate, and the displays read
PA:uS:E, then count down for one minute.
The dispenser is in a ready state once the countdown is finished and the display shows 0.00.
3. With the dispenser in a ready state, check that the C4000 Microprocessor Power LED (D1) is turned on
If the dispenser is receiving information, Comms RXD LED (D6) will poll. If the dispenser responds to polls for its respective pump number/s, Comms TXD LED (D7) will also poll.
Diagnostic LED (D18) slowly flashing. (If the dispenser is
connected to an operational Controller, it flashes slowly but erratically. If the dispenser is not connected to a Controller, it flashes slowly and consistently.)
Watchdog LED (D5) is turned off
4. Press the Start button.
The display will show 888888 and the solenoids energise, initiating a fill. Check that Diodes D8, D10 and D11 turn on, indicating a signal is being sent to the triacs to open the solenoid valves.
The diagnostic LED (D18) flashes quickly when the start button is pushed or the nozzle removed from the holster to initiate a fill. When the button is released or nozzle returned to the holster it will return to the normal state and flash slowly.
5. Verify solenoid operation by listening for a click, or by using a screwdriver tip or some other metallic tool to check for a magnetic field present on the solenoid coils.
The solenoids will switch off after one minute. This is a default time­out setting in the software for situations when there is no gas flow registered.
6. Press the Stop button. The solenoids switch off and the fill ends.
When you release the Stop button, the dispenser resets and returns to a ready state.
Mechanical Commissioning
Compac Industries Ltd.
Page 18
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Mechanical Commissioning
At the mechanical commissioning stage, the dispenser should not be pressurised.
If you find any leaks during commissioning, immediately close
all of the valves and de-gas the dispenser (see page 40).
To perform a mechanical test:
1. 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.)
2. Check all dispenser fittings, especially the inlet connections, to make sure that they are tight.
Always de-gas the lines before tightening any fittings.
Never tighten fittings while they are under pressure.
3. Check that the outlet supply valve to hose 1 on the side of the dispenser (or hose 2 if you are working on side 2) is closed and the nozzle valve is closed.
4. Turn on the dispenser and wait for it to power up.
The dispenser initially displays PA:uSE. When it is ready, 0.00 is displayed.
5. Press the Start button.
If you are commissioning a dual hose dispenser, press the Start button on either side. This opens the dispenser's solenoids. The dispenser automatically shuts off after approximately one minute if no flow is detected.
6. Slowly open the inlet shut-off valves and listen for leaks. If you hear leakage, shut off the inlets immediately. If the dispenser shuts off during this process, shut off the inlet valves, restart the dispenser, and continue.
7. Once the inlet valves are fully open, allow the dispenser to time out on the 1 minute no-flow timer and shut the solenoid valves, or manually shut it down and close the solenoid valves by pressing the Stop button.
8. Press the Start button on the dispenser.
If you are commissioning a dual hose dispenser, only
press the Start button for one of the hoses.
9. Slowly open the outlet isolation valve on the side of the dispenser and listen for leaks. If you hear leakage, shut the valve immediately.
If the dispenser shuts off during this process then shut the outlet supply valve, restart the dispenser, and continue.
10. Repeat steps 8 and 9 for the second hose on a dual hose dispenser.
11. Once the outlet isolation valves are fully open, allow the dispenser to time out on the 1 minute no-flow timer and shut the solenoid valves, or manually shut it down and close the solenoid valves by pressing the Stop button.
The dispenser and hose(s) are now fully pressurised.
12. Use soapy water to check all fittings (including the hose fittings) for leaks.
Always de-gas the lines before tightening any fittings.
Never tighten fittings while they are under pressure.
13. Complete a few fills on a test cylinder, checking for leaks or unusual operation.
Dispenser Set-up
Parameter Switch
Compac Industries Ltd.
Page 19
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Dispenser Set-up
Parameter Switch
The Parameter switch is located on the C4000 processor board and allows you to adjust the unit price, hose number, sequencing rate, and password.
The Parameter switch also enables you to view the Dispenser Software Version and End of Sale Indicators.
Figure 2: Parameter and K-Factor switches.
Parameter Switch
Dispenser Set-up
Compac Industries Ltd.
Page 20
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Menu Options
Menu Options
Listed below is the order in which the Parameter switch menu options are presented. There are different menu options depending on the current setting of the C configuration code (see page 35).
The X indicates that you can achieve the displayed menu option, regardless of what the indicated part is set to. 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
P
Software Program version
Pr
Unit Price
SE9
CNG Sequencing rate (FAS,nOr,SLO)
Pn
Hose Number
Code
Dispenser Passcode
CXXX62
P
Software Program version
PrA
Unit Price Side A
PrB
Unit Price Side B
PnA
Hose Number Side A
PnB
Hose Number Side B
Code
Dispenser Passcode
Dispenser Software Version
The dispenser software version (P) is the version number of the software currently loaded in the dispensers C4000.
See Dispenser Software Upgrade/Replacement (see page 64) for instructions on Upgrading dispenser software
To Identify the Software Program Version Number
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the Parameter switch once or until P is displayed.
The system enters a diagnostic mode whereby it displays the software program version and performs a display segment test. It cycles through this program for approximately 10 seconds before reverting to the normal display.
When displaying program version data, the display panel shows P in the Dollars screen and XXXXX, in the Kilograms screen where XXXXX is the abbreviated program version number. For example: Software version
HIA29.26.0CNG will read 29260
Dispenser Set-up
Parameter Switch
Compac Industries Ltd.
Page 21
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Unit Price
The unit price (Pr, PrA and Prb) is used to calculate the total value of the quantity dispensed. The unit price can be different on each side of a dual hose dispenser.
PR or PrA is the unit price for side A of the dispenser.
Prb 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.
If the unit price is not set Error 3 will be displayed and the
dispenser will not operate.
To set the unit price
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the Parameter switch until the required unit price is
displayed. (Pr, PrA or Prb )
3. Enter in the unit price.
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.
1. Let the menu time out so that the value and quantity amounts are
displayed.
Parameter Switch
Dispenser Set-up
Compac Industries Ltd.
Page 22
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Sequencing Rate
Only available on CNG dispensers. Needs appropriate software.
The sequencing rate (SE9) enables you to set the percentage level of maximum flow that sequencing occurs to the next pressure bank.
There are three settings to choose from:
FAS: Switching to the next higher-pressure bank occurs at 40% of the
maximum flow rate for a particular bank.
nOr: Switching to the next higher-pressure bank occurs at 30% of the
maximum flow rate for a particular bank.
SLO: Switching to the next higher-pressure bank occurs at 20% of the
maximum flow rate for a particular bank.
From software version HIA29.25.3CNG onwards the
sequencing rates are as follows:
FAS: Switching to the next higher-pressure bank occurs at 60% of the
maximum flow rate for a particular bank or when the flow rate drops to 5 kg/min, whichever occurs first.
nOr: Switching to the next higher-pressure bank occurs at 40% of the
maximum flow rate for a particular bank or when the flow rate drops to 3 kg/min, whichever occurs first.
SLO: Switching to the next higher-pressure bank occurs at 20% of the
maximum flow rate for a particular bank or when the flow rate drops to 1 kg/min, whichever occurs first.
The dispenser leaves the factory with the FAS setting.
To set the sequencing rate
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the Parameter switch (17 or more times) until SE9
xxx is displayed.
3. Enter the sequencing rate. Each press of the Parameter switch passes
you over a digit in the 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.
4. The displayed sequencing rate is now selected and operation of the
dispenser will be affected immediately. The displays will reset after a ten (10) second timeout.
Dispenser Set-up
Parameter Switch
Compac Industries Ltd.
Page 23
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Hose Number
The Hose Number (Pn, PnA and Pnb) identifies the dispensers hose(s) when the dispenser is communicating to a forecourt controller such as the Compac Dispenser Monitor.
Pn or PnA is the hose number of side A of the dispenser.
Pnb is the hose number side B of the dispenser
When using forecourt controller all dispenser hoses must have unique numbers.
To Set the dispenser hose numbers
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the Parameter switch until the required hose
number is displayed. (Pn, PnA or Pnb )
3. Enter the hose number.
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.
4. Let the parameter menu time out so that the value and quantity amounts are displayed.
Software Version HIA29.24.9CNG onwards
From this version of software onwards the hose number (PN) display has been modified to also display the following information:
A count of the total error 9 faults in the unit shown in the price
display.
The display will also flash in the price/kg screen, the last recorded
reason for the end of sale and the last recorded error 9.
This information can be used to as a diagnostic aid to check whether error 9 faults are occurring on a regular basis.
Parameter Switch
Dispenser Set-up
Compac Industries Ltd.
Page 24
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Dispenser Passcode
The dispenser passcode (Code and PASS) enables you to limit the access to sensitive settings found under the parameter and K-factor switches.
If set, only the dispenser software version can be viewed.
If the dispenser is connected to the forecourt PC, you can access the dispenser information via the Compac Dispenser Monitor program, even if the dispenser is passcode is enabled.
To Set the Dispenser Passcode
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the Parameter switch until Code is displayed.
3. Enter the new passcode.
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.
4. Let the menu time out so that the value and quantity amounts are displayed.
The dispenser is now passcode protected. Store the passcode in a secure place.
To Disable the Dispenser Passcode
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the Parameter switch until PASS is displayed.
3. Enter the current password.
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.
4. Press and release the Parameter switch until Code is displayed.
5. Clear the password by setting it to 000000.
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.
6. Let the menu time out so that the value and quantity amounts are displayed.
The dispenser passcode is now disabled.
Dispenser Set-up
K-Factor Switch
Compac Industries Ltd.
Page 25
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K-Factor Switch
The K-Factor switch is located on the C4000 indicator board. It is used to access and set up options on the C4000 dispenser. (The order in which they appear here is not the order is which they should be set).
Some settings are only used in temperature compensated
systems, and dual hose dispensers.
Menu Options
The K-factor switch will offer different menu options depending on the current C Configuration Code (see page 35)
The X indicates that you can achieve the displayed menu option, regardless of what the indicated part is set to.
Figure 3: Parameter and K-Factor switches.
K-Factor Switch
Dispenser Set-up
Compac Industries Ltd.
Page 26
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C Configuration
Menu Options Available
C0XX61
dSf f LfA HfA Sp b C
C0XX62
dSf fA Fb LFA HFA Lfb Hfb SP b C
C1XX61
dsf f fpA PLA rA E u gAin LFA HfA gC Sp b C
C1XX62
dSf fA fb LfA HfA E uA ub gAinA gAinb FpA pLA rA fpb pLb rb Lfb Hfb 9C Sp b C
C2XX61
dsf f LfA HfA E u u2 gAin gAin2 fpA pLA rA 9C sp b C
C2XX62
dSf fA fb LfA HfA Lfb Hfb E uA ub uA2 ub2 gAinA gAinb gAinA2 gAinb2 fpA PLA rA fpb pLb rb gC Sp b C
C3XX61
dsf f LfA HfA u gAin FpA 9C sp b C
C3XX62
dsf fA fb LfA HfA uA ub gAinA gAinb fpA fpb Lfb Hfb 9C sp b C
C4XX61
dsf f LfA HfA u u2 gAin gAin2 fpA gC sp b C
C4XX62
dsf fA fb LfA HfA Lfb Hfb uA ub
Dispenser Set-up
K-Factor Switch
Compac Industries Ltd.
Page 27
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Density Factor
The density factor (dSF) 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.
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 density factor.
When the required unit of measure is kg the density factor
should be set to 1. In this case the display will show the
measured quantity in kg
When another unit of measure is required, the density factor
should be set to the ratio between the required unit of measure and kgs. In this case the display will show the measured
quantity (kg) / density factor (unit of measure/kg )
For example if you wish to show the display in pounds:
1 pound = 0.4535 Kg so the density factor is entered as 0.4535. If 1 Kg is now dispensed the display will now read 1 / 0.4535 = 2.205 pounds.
Adjusting the Density factor
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Open the access panel and remove the cover of the C4000 processor box, which is illustrated in the Dispenser Component Locater section (see page 89).
3. Press the K-Factor switch once and release.
The display shows dSF X.XXXX, which is the current density factor setting for the dispenser that you are commissioning.
4. Enter the required Density Factor.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
Meter K-Factor
The meter K-Factor (FA and Fb) is a meter correction factor used to ensure the displayed quantity is correct.
F or FA is the meter K-factor on side A of the dispenser.
Fb is the meter K-factor on side B of the dispenser.
The K-Factor is set during the calibration phase Meter Calibration (see page 67) and does not require adjusting during service.
K-Factor Switch
Dispenser Set-up
Compac Industries Ltd.
Page 28
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To adjust the meter K-Factor
1. Make sure that the dispenser is idle, with the nozzle in its holster.
Press and release the K-Factor switch until the required meter K-factor is shown (F or FA or Fb )
1. Enter the required K-Factor.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
Minimum Flow Rate
The minimum flow rate (LFA and LFb) is the low flow cut-off at the end of the fill.
LFA is the minimum flow rate of side A of the dispenser.
LFb is the minimum flow rate of side B of the dispenser.
These values are adjustable and can be set between 0.5 - 9.9 kg/min.
Do not set the minimum flow rate so that it is equal to or
above the maximum flow rate.
To adjust the Minimum Flow Rate
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the K-Factor switch until the required minimum
flow rate is displayed. ( LFA or LFb )
3. Enter the new minimum flow rate.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
The Compac factory default setting is 1.0 kg/min.
4. Let the menu time out so that the value and quantity amounts are displayed.
Maximum Flow Rate
The maximum flow rate (HFA and HFb) is the high flow cut-off for when the flow through the dispenser is too high.
HFA is the maximum flow rate of side A of the dispenser.
HFb is the maximum flow rate of side B of the dispenser
These values are adjustable and can be set between 5 - 99 kg/min.
Do not set the maximum flow rate so that it is equal to or
below the minimum flow rate.
Dispenser Set-up
K-Factor Switch
Compac Industries Ltd.
Page 29
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To adjust the Maximum Flow Rate
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until the required maximum flow rate is displayed. (HFA or HFb )
3. Enter the new maximum flow rate.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
The Compac factory default setting is 40 kg/min for Car Dispensers and 60 kg/min for High flow or Bus dispensers.
4. Let the menu time out so that the value and quantity amounts are displayed.
Ambient Temperature (Temperature Compensated Units Only)
The ambient temperature (E) is the temperature inside the dispenser measured by the temperature probe.
The ambient temperature is set at the factory during the calibration phase and does not usually require adjusting during service.
To adjust the Ambient Temperature
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the K-Factor switch until E displayed.
3. Enter in the new ambient temperature as measured.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
Electronic Pressure Reading (Fast Fill & Temperature Compensated Units Only)
The Electronic pressure reading (u, uA, ub, uA2 and ub2) is taken from the pressure transducer in the dispenser’s utility manifold.
u, uA and uA2 relate to the readings of pressure transducers one and
two (where fitted) on side A of the dispenser.
ub and ub2 relate to the readings of pressure transducers one and two
(where fitted) on side B of the dispenser.
The electronic pressure reading can be adjusted during pressure transducer calibration to bring it in line with the actual value.
K-Factor Switch
Dispenser Set-up
Compac Industries Ltd.
Page 30
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To adjust the electronic pressure reading
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the K-Factor switch until the required pressure
reading is shown (u, uA, ub, uA2 or ub2 )
3. Enter in the new pressure.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. 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.
Dispenser Set-up
K-Factor Switch
Compac Industries Ltd.
Page 31
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Pressure Transducer Gain (Fast Fill & Temperature Compensated Units Only)
The pressure transducer gain (GAinA, GAinb, GAinA2 and
GAinb2) is a correction factor used to ensure the pressure transducer is
correctly calibrated. Typical values for the gain are usually close to
0.4000.
GAinA and GAinA2 relate to the gains of pressure transducers one
and two (where fitted) on side A of the dispenser.
GAinb and GAinb2 relate to the gains of pressure transducers one
and two (where fitted) on side B of the dispenser.
The pressure transducer gain is set during the calibration phase and does not require adjusting during service
To adjust the Pressure Transducer Gain
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the K-Factor switch until the required gain is
shown (GAinA, GAinb, GAinA2 or GAinb2 )
3. Enter in the new gain.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. 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.
Target Fill Pressure (Fast Fill & Temperature Compensated Units Only)
The target fill pressure (FPA and FPb) is the final desired vehicle fill pressure after filling and temperature compensation. The units of measure are in bar.
FPA is the target fill pressure of side A of the dispenser.
FPb is the target fill pressure of side B of the dispenser.
Do not set the target fill pressure so that it is above the
maximum fill pressure.
To adjust the Target Fill Pressure
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until the required target fill
pressure is displayed flow rate is displayed. ( FPA or FPb )
3. Enter the new target fill pressure.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
K-Factor Switch
Dispenser Set-up
Compac Industries Ltd.
Page 32
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Maximum Fill Pressure (Temperature Compensated Units Only)
The maximum fill pressure (PLA and PLb) is the upper limit for temperature compensated filling. The units of measure are in bar.
PLA is the maximum fill pressure of side A of the dispenser.
PLb is the maximum fill pressure of side B of the dispenser
This is only used in temperature compensated dispensers.
Do not set the maximum fill pressure so that it is below the
target fill pressure.
To adjust the Maximum Fill Pressure
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until the required target fill pressure is displayed flow rate is displayed. ( PLA or PLb )
3. Enter the new maximum fill pressure.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
Vehicle Tank Temperature Rise (Temperature Compensated Units Only)
Vehicle Tank Temperature Rise (rA and rb) is used to compensate for temperature rise in the gas during a fill. As the tank fills, the temperature of the gas rises. The lighter the tank, the greater the temperature rise will be.
rA is the vehicle tank temperature rise of side A of the dispenser.
rb is the vehicle tank temperature rise of side B of the dispenser
Typical values for these may be:
Car filling = 20 [heavy steel cylinder].
Bus/Truck filling = 30 [lighter carbon wrapped Aluminium cylinder].
To adjust the Vehicle Tank Temperature Rise
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until the required vehicle tank temperature rise is displayed. ( rA or rb )
3. Enter the new vehicle tank temperature rise.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
Dispenser Set-up
K-Factor Switch
Compac Industries Ltd.
Page 33
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Gas Composition (Temperature Compensated Units Only)
The gas composition (GC) refers to what the gas is composed of. This affects the temperate compensation calculations
To adjust the Gas Composition
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until GC is displayed.
3. Enter the new gas composition.
1 = Biogas / Methane.
2 = CNG.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
Display Resolution
The display resolution (SP) refers to the location of the decimal point. The value, quantity and price per unit display may have none, one, two or three digits displayed after the decimal point, depending upon the currency.
To adjust the Resolution
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until the unit display shows SP.
3. Enter the new resolution. Do this by pressing the K-Factor switch five times. On the fifth time hold the switch down until the decimal point is in the correct place.
There are four positions that the decimal point can be located, allowing the price/kg to be set to the formats8.888, 88.88,
888.8 or 8888
4. Let the menu time out so that the value and quantity amounts are displayed.
If the K-Factor switch is not pressed for 10 seconds
the menu item will time out.
If either the value or the quantity displays ever reach 999.
99 or 9999 . 9 or 99999 units, the dispenser will stop dispensing.
b Configuration Code
Dispenser Set-up
Compac Industries Ltd.
Page 34
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b Configuration Code
The b configuration code (b) is a secondary configuration code that changes display options and the forecourt communication operation.
To Adjust b Configuration Code
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until b is displayed.
3. Enter the new b configuration.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
In stand-alone operation/monitor mode [b 0XXX], the dispenser operates even when not connected to a site Controller. If it is connected to a controller, it will only dispense gas when authorised by the controller. If the controller is turned off and the dispenser power is cycled off and on, the dispenser will operate in standalone mode.
In Controller mode [b 1XXX], the dispenser only operates if it is connected to a site Controller. Transactions are displayed.
Flow mode [b XX2X] is used to view the current flow rate of the gas. When this mode is set FLO will appear in the value display and the
current flow rate value will appear in the unit price display. This is used for testing only and not during normal dispenser operation.
Dispenser Set-up
C Configuration Code
Compac Industries Ltd.
Page 35
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C Configuration Code
The C configuration code (C) changes the operation of the dispenser. It is the last setting accessed through the K-Factor switch, but it must be set first so that other settings can be selected correctly.
The configuration code has been factory set and should not be changed. If the memory gets wiped and you need to re-enter it, the configuration is written on the yellow label on the C4000 processor board cover.
To adjust the C Configuration Code
1. Make sure that the dispenser is idle, with the nozzle in its holster
2. Press and release the K-Factor switch until C is displayed.
3. Enter the new C configuration see diagram below.
Each press of the K-Factor switch passes you over a digit in a setting, making the digit blink. Holding the switch down for more than a second changes whichever digit is currently displayed. If you want to pass over a setting without changing any digits, keep pressing and releasing the switch.
4. Let the menu time out so that the value and quantity amounts are displayed.
The PED pressure monitor mode checks the pressure probe
against the pressure limit (PLA), plus 10% during the fill.
Temperature compensation mode modifies the target pressure, based on the ambient temperature. This can be implemented with one or two pressure probes per hose. Two pressure probes are used for redundancy to check that the pressure of the first probe is within 10 bar of the second.
Fast fill mode measures the pressure, but not the temperature. The dispenser fills to the configurable target fill pressure (FPA or FPb).
Refuelling a Vehicle
Dispenser Operation
Compac Industries Ltd.
Page 36
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Dispenser Operation
Refuelling a Vehicle
There can be up to three storage banks for CNG refuelling. During filling the dispenser sequences through these banks from low to high as the pressure in the vehicle cylinder increases and the flow rate drops.
Wearing appropriate personal safety equipment is
recommended while refuelling a vehicle.
To refuel a vehicle:
1. Press the start button or remove the nozzle from the holster to initiate a fill.
The display will show 888888 and then clear, at this point both the gas and value totals will display 0.00
2. Connect the refuelling nozzle to the vehicle
3. Open the nozzle refuelling valve to commence filling.
4. The dispenser will emit a long beep signalling the end of the fill, at this point the gas total display flashes Fin.
5. Close the refuelling valve.
Closing the valve shuts off the gas from the dispenser. It also vents the gas between the refuelling valve and coupling to the dispenser vent point.
6. Disconnect the nozzle from the vehicle.
7. Return the refuelling nozzle to the nozzle holder.
Dispenser Operation
Refuelling a Vehicle
Compac Industries Ltd.
Page 37
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Fixed Pressure Refuelling Process
The technical operation of a fixed pressure refuelling dispenser is as follows:
1. Press the start button or remove the nozzle from the holster to initiate a fill.
The display will show 888888 and then clear, at this point both the gas and value totals will display 0.00
2. Connect the refuelling nozzle to the vehicle
3. The refuelling valve is opened and the filling commences as follows:
If the vehicle tank pressure is less than low bank pressure,
gas flows from the low bank.
When the vehicle tank pressure equals the low bank
pressure but is less than the medium bank pressure, gas flows from the medium bank.
When the vehicle tank pressure equals the medium bank
pressure but is less than the high bank pressure, gas flows from the high bank.
4. When the flow rate drops below the minimum flow rate (LFA or
LFB while filling from the high bank, the flow ceases, ending the
fill.
The sequencing rate between banks can be varied for Fast, Normal or Slow rates using the Parameter menu. The factory setting is normally set to Fast. Refer to Sequencing Rate (see page
22)
The vehicle fill pressure is restricted to the regulator set pressure, this is normally set at 200 bar in the factory.
Refuelling a Vehicle
Dispenser Operation
Compac Industries Ltd.
Page 38
www.compacngv.com
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 (FPA).
The technical operation of a fast fill dispenser is as follows:
1. Press the start button or remove the nozzle from the holster to
initiate a fill.
The display will show 888888 and then clear, at this point both the gas and value totals will display 0.00
2. Connect the refuelling nozzle to the vehicle
3. The refuelling valve is opened and when flow is detected the
solenoids shut immediately. Pressure reading (P1) and amount dispensed (KG1) is recorded.
4. If the vehicle is within 20 bar of the target pressure (FPA), no
filling takes place.
5. The solenoids are opened and filling continues as follows:
If P1 was less than 50 bar, the fill will continue for 20
seconds.
If P1 was greater than 50 bar but less than 100 bar, the fill
will continue for 14 seconds.
If P1 was greater than 100 bar but less than 150 bar, the fill
will continue for 10 seconds.
If P1 was greater than 150 bar but less than 180 bar, the fill
will continue for six seconds.
6. The solenoids shut and pressure reading (P2) and amount
dispensed (KG2) are recorded.
7. The amount of gas (KGf1) to completely fill the vehicle to FPA is
calculated as follows:
KGf1 = (KG2 – KG1) x (FPA – P1) / (P2 – P1).
8. The dispenser fills to KGf1 and stops. This is the end of the fill.
Dispenser Operation
Reading the Dispenser Totals
Compac Industries Ltd.
Page 39
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Temperature Compensated Refuelling Process
The technical operation of a temperature compensated dispenser is as follows:
1. Press the start button or remove the nozzle from the holster to
initiate a fill.
The display will show 888888 and then clear, at this point both the gas and value totals will display 0.00
2. Connect the refuelling nozzle to the vehicle
3. The refuelling valve is opened and when flow is detected the
solenoids shut immediately. Pressure reading (P1) and amount dispensed (KG1) are recorded.
4. The compensated fill pressure is calculated. If the vehicle is
within 20 bar of this pressure, no filling takes place.
5. The solenoids are opened and filling continues as follows:
If P1 was less than 50 bar, the fill will continue for 20
seconds.
If P1 was greater than 50 bar but less than 100 bar, the fill
will continue for 14 seconds.
If P1 was greater than 100 bar but less than 150 bar, the fill
will continue for 10 seconds.
If P1 was greater than 150 bar but less than 180 bar, the fill
will continue for six seconds.
6. The solenoids shut and pressure reading (P2) and amount
dispensed (KG2) are recorded.
7. The amount of gas (KGf1) to completely fill the vehicle to Pf is
calculated as follows:
KGf1 = (KG2 – KG1) x (Pf – P1) / (P2 – P1).
8. The dispenser fills to KGf1 and stops. This is the end of the fill.
Reading the Dispenser Totals
To read the dispenser totals:
1. 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.
The dispensed amount will be shown on the display for 10 seconds. This will be shown as:
d Followed by a 10 digit Total
The dispensed quantity will then be shown next and will be displayed for 10 seconds. This will be shown as:
L Followed by a 10 digit Total
From software version HIA29.25.3CNG onwards the decimal place has been removed from the tote. There will two digits on the top ($) display and six digits on the lower (kg) display
For dual dispensers, the A or B side will be indicated in the unit price display.
Degassing the Dispenser
Servicing
Compac Industries Ltd.
Page 40
www.compacngv.com
Servicing
Degassing the Dispenser
When replacing or servicing dispenser hydraulics the dispensers must be de-gassed.
Degass the Dispenser
1. Isolate the dispenser by closing the inlet gas supply valves at the base
of the unit or at the priority panel.
2. Fill one or more CNG bottles until the dispenser pipework is completely
depressurized. Ensure that the isolation valve remains open during this process.
Open the bleed valve on the utility manifold (where fitted) to remove any remaining gas inside the dispenser.
Servicing
Scheduled Servicing
Compac Industries Ltd.
Page 41
www.compacngv.com
Scheduled Servicing
Weekly checks
Check the sealing and operation of the three-way refuelling valve (see page 46).
Check the sealing and operation of the solenoids. Refer to: Checking the Sealing of the Solenoid (see page 42)
Check the sealing and setting of the regulator. (see page 43)
Drain the Coalescing Filter (see page 46).
Suggested 6-monthly or 4000 compressor run hour service
Check the dispenser for leaks (see page 45).
Check the Coalescing filter elements, replace if necessary. (see page 47)
Check damage and electrical continuity of Refuelling Hoses
Replace Breakaway seals
Replace 3-way refuelling valve seals and inspect ball for scratches and wear. Replace ball if necessary. (see page
55)
Replace refuelling probe O-rings. Check that the probe is not damaged or bent, replace if necessary
OEM Nozzles and Breakaways - Refer to manufacturer’s instructions
Suggested yearly or 8000 compressor run hour service
In addition to all the checks listed in the 6-month service, carry out the following:
Dismantle and clean the solenoid valves. Replace the seals and O-rings (see page 48).
Dismantle and clean the regulator valves. Replace the seals and O-rings (see page 52).
Check the dispenser calibration. Meter Calibration (see page 67).
Check the C4000 Processor Board is clean, dry and dust free.
Check the UPS and voltage stabiliser supplying power to the dispenser is working according to the manufacturer’s
specifications.
Check the C4000 flameproof box lid is bolted down tight and all glands are tight.
Check the zero point and calibration of the dispenser pressure transducers (fast fill & temperature compensation
only).
Scheduled Servicing
Servicing
Compac Industries Ltd.
Page 42
www.compacngv.com
Checking Dispenser Operation
To check that the dispenser is operating correctly:
1. Fill two gas bottles.
2. 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.
When the hose is empty check that the flow
has stopped. If the flow does not stop, the seals in the final stage solenoid will need to be replaced. (see page 48)
Servicing
Scheduled Servicing
Compac Industries Ltd.
Page 43
www.compacngv.com
Checking the Setting and Sealing of the Regulator
Before you start, make sure you have:
An 8mm hex key
When you are undertaking this check, the dispenser must be
turned on and pressurised.
To check the setting and sealing of the regulator:
1. Hang up the nozzle and check that the three-way valve is closed.
2. Press the start button to initiate a fill and open the solenoids
3. Check that the pressure gauge is at the setpoint reading (typically 200 bar).
4. Check that the pressure gauge reads at a steady state, rather than creeping after a fill.
If the pressure gauge is not reading the correct setpoint:
Insert an 8mm hex key into the top of the regulator body.
Adjust the pressure up clockwise or down anticlockwise to 200 bar.
If the pressure on the gauge does not remain stable, the regulator valve seal is leaking and will have to be replaced (see page 52).
Valve Adjuster (use 8 mm Hex Key)
Scheduled Servicing
Servicing
Compac Industries Ltd.
Page 44
www.compacngv.com
Checking the Over-Pressure Switch Operation (Fast Fill & Temperature Compensated Units Only)
To check the operation of the Over-Pressure cut off.
1. Access the K-Factor switch on the C4000 processor.
2. Obtain the over-pressure settings, PLa (for side A) and PLb (for side B), as per the K­Factor Switch Settings section (see page
25).
3. Set the over-pressure cut-off point to below the regulator pressure or target fill pressure
(FPA ,,FPb).
For example, if the regulator pressure is 220 bar, then set the over-pressure to 100 bar. An exact value is not required; just make sure that the value is significantly lower than the regulator pressure.
4. Start a fill. The dispenser should stop shortly after the fill begins.
5. Check the dispenser End of Sale indicator states that the fill has ended because of over-pressure. End of Sale Indicators (see page 122)
6. Reset the over-pressure cut-off point to its original value.
Servicing
Scheduled Servicing
Compac Industries Ltd.
Page 45
www.compacngv.com
Checking the Dispenser for Leaks
Before you start, make sure you have:
Soapy water
To check the dispenser for leaks:
Be careful not to spray or drip water into any of the dispenser electronics when checking for leaks.
1. Apply soapy water to all joins in the assemblies and fittings on the inside and outside of the dispenser, including the hose.
If bubbles form, there is a leak with that assembly or fitting. The fitting may require tightening or the seals might need to be replaced.
You must isolate the gas supply and depressurise the dispenser before disassembling any component or adjusting any fitting. Serious injury may result if components are removed while the dispenser is under pressure.
Threaded SAE Fittings (see page
87).
Adjustable Threaded SAE Fittings
(see page 87).
Compression Fittings (see page
88).
2. To remedy a leak, refer to the appropriate section, depending on the leak is location.
3. After checking for leaks, wipe any excess water off the dispenser to prevent corrosion.
Checking the Refuelling Hose for Leaks
Before you start, make sure you have:
Soapy water
To check the refuelling hose:
1. Visually check the refuelling hose for damage, such as fraying and cuts.
2. Apply soapy water to all valves and connections.
If bubbles form, there is a leak in that assembly or fitting. The fitting may require tightening or the seals might need to be replaced.
You must isolate the gas supply and depressurise the dispenser before disassembling any component or adjusting any fitting. Serious injury may result if components are removed while the dispenser is under pressure.
3. Replace the hose (see page 59) if it is damaged or leaking.
Scheduled Servicing
Servicing
Compac Industries Ltd.
Page 46
www.compacngv.com
Checking the Isolation Ball Valve Sealing and Operation
Before you start, make sure you have:
Soapy water
To check the operation of the isolation ball valve:
1. Close the isolation valve.
2. Open the dispenser access door.
3. Open the bleed valve on the utility manifold block (where fitted) and bleed the gas from the refuelling hose.
4. Close the bleed valve once the hose is degassed.
5. Start a fill.
If the pressure gauge starts to move, the isolation ball valve is leaking or passing gas.
6. Apply soapy water to the valve.
If bubbles form, there is a leak in the assembly or fitting. The fitting may require tightening or the seals might need to be replaced.
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. (see page 55)
Check the Operation of the Three-Way Refuelling Valve
To check the operation of the three-way refuelling valve, do a test fill to check that the valve is filling the vehicle, and venting properly when you disconnect it from the vehicle.
If bubbles form, there is a leak, in which case you should replace the three-way refuelling valve seals. (see page 55)
Draining the Coalescing Filter
Before you start, make sure you have:
a 3/16" hex key
To drain the coalescing filter:
1. De-gas the dispenser (see page 40).
2. Open the dispenser access doors.
3. Unscrew the drain plug from the bottom of the filter cover.
4. Allow all oil and water to drain from the filter.
If excessive amounts of oil and water are present, remove and replace the coalescing filters (see page 47).
5. Screw in the drain plug and repeat steps 1 to 4 for all additional filters.
Servicing
Filter Element Replacement
Compac Industries Ltd.
Page 47
www.compacngv.com
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
1 x filter bowl O-ring seal
O-ring lubricant
Remove the coalescing filter
1. Degas the dispenser (see page 40).
2. Drain the coalescing filters (see page 46) if they have not been drained already.
3. Unscrew the filter bowl(s) with a spanner on the 22mm hex nut at the base of the filter bowl.
4. Remove the filter element.
5. Clean all oil and dirt off the components with a clean cloth.
Install the new coalescing filter
1. Insert the new filter element and lubricated filter bowl O-ring seal.
O-rings that are subjected to natural gas at high pressure swell when exposed to air. Once swollen, they cannot be reused and must be replaced.
Always use O-ring lubricant to prevent damage to the O­rings.
2. Screw in the filter bowl(s)
3. Check the dispenser for leaks. (see page 45)
Filter Bowl O-ring Seal
Filter Element
Filter Bowl
Drain Plug
Solenoid Valve Seal Replacement
Servicing
Compac Industries Ltd.
Page 48
www.compacngv.com
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.
For applications where the gas has a high oil content, a special piston with an O ring seal is available. If you are having problems, discuss this option with your service agent. If the special piston is used for low oil content gas, no harm will occur but the service life of the seal may be shortened.
Before you start, make sure you have:
A seal kit - Part number FC-SK-0001
1 x Teflon valve seal
1 x solenoid top O-ring seal
1 x gas return line O-ring seal
O-ring lubricant
Solenoid piston - Part number FC-VLV-PSTN-0001 (optional standard)
Solenoid piston – Part number FC-VLV-PSTN-S2 (optional high oil)
Solenoid top service kit standard. Part number FC-SVK-0003 (replace
valve top if leak detected through stem)
Solenoid top service kit - low temperature option (-40 degrees C). Part
number FC-SVK-0004 (replace valve top if leak detected through stem)
Never remove or service the stem. If it is leaking, it must be replaced using the appropriate top service kit.
Cleanliness is essential. When working on the open solenoid assembly, cover the opening with a cloth to prevent dust and dirt from entering.
O-rings that are subjected to natural gas at high pressure swell when exposed to air. Once swollen, they cannot be reused and must be replaced.
The Nitrile O-rings have a life span of over 10 years from cure date but improper handling of these O-rings before use can shorten their useful life. O-rings will deteriorate if exposed to ozone or ultraviolet light so keep in original packaging and away from UV light. If in unsure about their condition, do not use old O-rings and order new ones.
It is not necessary to remove the solenoid body from the dispenser to service the solenoid seals.
Remove the Old Solenoid Valve Seals
1. De-gas the dispenser (see page 40).
2. Switch off the power supply to the dispenser.
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.
3. Unscrew the solenoid coil retaining nut and move the coil out of the way.
4. Remove the six cap screws from the solenoid top.
Do not remove the angled grub screw from the solenoid top. This is epoxied in place during manufacture and should never be removed.
5. Remove the solenoid top and remove the old top O-ring seal and gas return O-ring.
Servicing
Solenoid Valve Seal Replacement
Compac Industries Ltd.
Page 49
www.compacngv.com
6. Remove the solenoid spring.
7. Screw an M6 cap screw into the solenoid piston to withdraw it from the solenoid body.
8. 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.
9. Discard the old valve seal.
10. Clean all oil and dirt off the components with a clean cloth and check that the bleed hole is not blocked.
11. While the solenoid is apart, inspect the solenoid piston centre seal and piston for wear, scratching or damage. Replace piston if required.
Solenoid Valve Seal Replacement
Servicing
Compac Industries Ltd.
Page 50
www.compacngv.com
Install new Solenoid Valve Seals
1. Place the new valve seal and seal retainer on the cap screw.
2. Taking care not to damage the piston, hold the flat part of the piston to prevent rotation, and then screw the M6 cap screw into the bottom of the piston.
3. Insert a new gas return O-ring.
4. Insert the piston back into the solenoid body.
5. Insert the solenoid spring.
6. Replace the solenoid top O-ring seal.
7. Place the solenoid top back on the solenoid body, making sure that the locating dowel is engaged.
8. Screw in and tighten the six cap screws.
9. Replace the solenoid coil.
10. Re-power and re-gas the dispenser then check for leaks and correct operation of the valve. Refer to page 18.
Servicing
Solenoid Coil Replacement
Compac Industries Ltd.
Page 51
www.compacngv.com
Solenoid Coil Replacement
Before you start, make sure you have:
Replacement solenoid coil FC-COIL-0005 (Compac S2-350)
Solenoid coils are not interchangable between models. Make
sure you order the correct one by quoting the dispenser serial number. To replace obsolete coils, the entire solenoid will need replacing.
Remove the Solenoid Coil
1. De-gas the dispenser (see page 40).
2. Switch offand isolate the power supply to the dispenser.
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.
3. Remove the flameproof box lid to gain access to the C4000 power supply board.
4. Disconnect the appropriate solenoid coil wiring from the C4000 power supply board.
Take basic anti-static precautions by wearing a wristband
with an earth strap.
5. Loosen the gland on the flameproof box that is clamping the solenoid coil lead and pull the lead out of the gland.
Undo the nut on the top of the solenoid valve that is securing the coil and remove the coil from the top of the valve
Install the New Solenoid Coil
1. To install a new solenoid coil, reverse the procedure above.
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).
Complete Solenoid Valve Replacement
Servicing
Compac Industries Ltd.
Page 52
www.compacngv.com
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-
VALVE-0036) or
Solenoid valve 350 bar low temperature option (FC-VALVE-0037)
Solenoid valves are supplied without coils. If you need the coil it
must be ordered as well.
Cleanliness is essential. When working on the open pipes and solenoids, cover the openings with a clean, lint-free cloth to prevent dust and dirt from entering.
Remove the Old Solenoid Valve
1. De-gas the dispenser (see page 40).
2. Switch off the power supply to the dispenser.
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.
3. Undo the nut and remove the solenoid coil. See page 51.
4. Undo the gland nuts connecting the solenoid valve to the pipework and
manifold and remove valve
Replacing Solenoid Valve
1. Ensuring all surfaces are clean and any sealing plugs are removed from
the valve, reconnect the pipework and tighten the gland nuts.
2. Replace the solenoid coil.
3. Repower and re-gas the unit, check for leaks and test for correct
operation. Refer to page 11.
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
Servicing
Regulator Valve Seal Replacement
Compac Industries Ltd.
Page 53
www.compacngv.com
Remove the Old Regulator Valve Seals
1. De-gas the dispenser (see page 40).
2. Open the dispenser access doors.
3. Unscrew the spring tube by placing a 1 ¼" spanner on the machine hex nut
at the top of the spring tube.
Do not unscrew the valve adjustment nut. The spring remains at the set tension.
1. Unscrew the bottom plug in the regulator body.
2. Using a hex key inserted into the base of the piston to stop the piston from
twisting sideways and being damaged, push the piston downwards out the bottom of the regulator body.
3. Hold the piston by the 8 mm flat and remove the M6 cap screw from the
bottom.
The M6 cap screw has a special hole through it. Never substitute it for a normal cap screw.
Install New Regulator Valve Seals
1. Install the new valve seal. Make sure that the larger flat side of the seal
faces upwards.
A
B
DETAIL B
Regulator O-Ring Teflon Back-Up Ring
DETAIL A
Teflon Back-Up Ring
Regulator O-Ring
Make sure that the flat face of the seal
faces up
O-rings that are subjected to natural gas at high pressure swell when exposed to air. Once swollen, they cannot be reused and must be replaced.
The Nitrile O-rings have a life span of over 10 years from cure date but improper handling of these O-rings before use can shorten their useful life. O-rings will deteriorate if exposed to ozone or ultraviolet light so keep in original packaging and away from UV light. If in unsure about their condition, do not use old O-rings and order new ones.
2. Lever off the two regulator O-rings and two Teflon back-up rings.
3. Install two new regulator O-rings and two new Teflon back-up seals.
The back-up rings go on the outside of the O-rings.
Always use O-ring lubricant on the O-rings to increase the service life.
4. Reassemble the piston.
5. Push the piston back up into the regulator body with a hex key.
Compac Breakaway Seal Replacement
Servicing
Compac Industries Ltd.
Page 54
www.compacngv.com
Keep the piston straight, rotate it clockwise to prevent the new O-ring from catching or ripping.
6. Screw in the bottom plug.
7. Screw on the spring tube until tight.
8. Check the setting and sealing of the regulator (see page 43) for correct pressure.
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. Both have metal to metal seats that are not affected by dirt.
Before you start, make sure you have:
Obtain the following replacement parts and ancillary equipment:
A seal kit - Part number FC-SK-0011
3 x O-rings
2 x probe O-rings
O-ring lubricant
Reassemble the Breakaway
In the event of a breakaway, check the O-rings in the male end of the breakaway for damage.
If they are damaged, replace the breakaway QBCI seals by following the steps below.
Replace the Breakaway QBCI-09 Seals
To replace the breakaway seals:
1. Remove the old O-rings.
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.
2. Replace the old O-rings with the new lubricated O-rings.
Always use O-ring lubricant to prevent the O-rings from being damaged.
If the breakaway parts under gas pressure for no apparent reason check that the pressure relief hole is clear. If the pressure relief hole is blocked, gas pressure will force the male and female ends apart.
Reconnect the Breakaway
To reconnect the breakaway:
1. Make sure that both male and female receptacle breakaway parts are clean before reassembly.
2. Check that the pressure relief hole is clear.
If the pressure relief hole is not clear, gas pressure will
force the male and female ends to part.
3. Firmly connect the female and male connectors.
If the breakaway is not connected correctly when gas
pressure is applied, it will come apart completely.
Servicing
Three Way Refuelling Valve Seal Replacement - Old
Model -Brass
Compac Industries Ltd.
Page 55
www.compacngv.com
Three Way Refuelling Valve Seal Replacement - Old Model ­Brass
Important note
This valve was superseded by a new, improved valve in 2008. Please see
Compac technical bulletin CTB10015 for more information.
Before you start
Obtain the following replacement parts and equipment:
Seal Kit Part Number is FC-SK-0008 or FC-SK-0009
6 x ARP O-rings (Shore Nitrile 90).
1 x Ball Shaft Seal.
1 x Teflon Back Up Washer.
1 x Teflon Back Up Seal.
1 x Ball Seal.
1 x Nitrided ball ( FC-SK-0009 kit only)
Remove the Three Way Valve Seals.
Take care when disassembling the valve, as a lot of parts look similar.
De-pressurise the valve and remove it from the hose assembly.
Disassemble the valve, as per the figure on the next page.
Clean all components with a clean dry lint free rag.
O-rings that are subjected to Natural Gas at high pressure swell
when exposed to air. Once swollen they must be replaced.
Blow compressed air (100 psi) through all ports to remove any impurities that
may damage the seals in operation.
Wear appropriate safety eye wear when using compressed air.
Install New Three way Valve Seals
Cut the handle shaft back-up ring on an angle so it can be fitted onto the shaft.
Check that the back-up rings are free of burrs and sharp edge.
Position the seals in the appropriate slots on the handle shaft.
O-rings that are subjected to Natural Gas at high pressure. Swell
when exposed to air. Once swollen they must be replaced.
Insert the handle shaft into the valve body from the bottom.
Insert the ball shaft into the valve body from the bottom.
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.
Place the handle on the handle shaft and screw in the grub screw to lock it in
place.
Three Way Refuelling Valve Seal Replacement - Old Model -Brass
Servicing
Compac Industries Ltd.
Page 56
www.compacngv.com
Compac Refuelling Valve Exploded View
Servicing
Three Way Refuelling Valve Seal Replacement - New
Model - Stainless Steel
Compac Industries Ltd.
Page 57
www.compacngv.com
Three Way Refuelling Valve Seal Replacement - New Model ­Stainless Steel
Important note
The new Compac three way valve uses a different seal kit to the old
version. Please make sure you identify the valve before disassembling it to make sure you have the correct seal kit available.
For more information please see Compac Technical bulletin CTB10015
Before you start
Obtain the following replacement parts and equipment:
Seal Kit Part Number is FC-SK-0049
Three way valve ball spindle is FC-SVK-0002 (optional)
Remove the three way valve seals.
Take care when disassembling the valve, as a lot of parts look similar.
1. De-pressurise the valve and remove it from the hose assembly.
2. Disassemble the valve, as per the figure on the next page.
Clean all components with a clean dry lint free rag.
O-rings that are subjected to Natural Gas at high pressure. Swell
when exposed to air. Once swollen they must be replaced.
3. Blow compressed air (100 psi) through all ports to remove any impurities that may damage the seals in operation.
Wear appropriate safety eye wear when using compressed air.
Install New Three way Valve Seals
1. Cut the handle shaft back-up ring on an angle so it can be fitted onto the shaft
Check that the back-up rings are free of burrs and sharp edge.
2. Position the seals in the appropriate slots on the handle shaft.
O-rings that are subjected to Natural Gas at high pressure swell
when exposed to air. Once swollen they must be replaced.
3. Insert the handle shaft into the valve body from the bottom.
4. Insert the ball shaft into the valve body from the bottom. Note: Ensure that the slotted handle shaft and ball shaft engage.
5. Insert the ball shaft seals in both sides of valve body.
6. Insert the ball shaft retainers in either side of the valve body until the retainer face meets with body of the valve.
7. Place the handle on the handle shaft and screw in the grub screw to lock it in place.
Three Way Refuelling Valve Seal Replacement - New Model - Stainless Steel
Servicing
Compac Industries Ltd.
Page 58
www.compacngv.com
Compac Refuelling Valve Exploded View
16
17
15
2
1
4
5
3
6
12
11
13
8
14
7
10
9
11
12
13
14
8
9
8
10
7
15
16
17
12
11
14
8
8
7
10
9
13
1
5
4
4
3
2
6
Retainer Nut “B” assembly
Retainer Nut “A” assembly
Shaft/Spindle assembly
Servicing
Refuelling Hose Replacement
Compac Industries Ltd.
Page 59
www.compacngv.com
Refuelling Hose Replacement
Remove refuelling hose
1. De-gas the dispenser (see page 40).
2. Undo the JIC hose connection at the dispenser's outlet block.
3. Undo the connection between the hose and the nozzle assembly
Install new refuelling hose
1. Attach the nozzle assembly to the new hose.
2. Attach the new hose to the dispenser at the outlet block.
3. Regas the dispenser and push the Start button to fill the new hose
assembly with gas.
4. Check all hose connections for leaks by applying soapy water mixture and looking for bubbles.
Power Supply Fuse Replacement
Servicing
Compac Industries Ltd.
Page 60
www.compacngv.com
Power Supply Fuse Replacement
There are three fuses used in the C4000 power supply,
and each fuse has a different rating.
Before you start, make sure you have:
The following fuses with these ratings:
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 (see page 92).
Every new dispenser is supplied with one spare fuse
of each value located on the inside of the flameproof box lid.
Remove C4000 power supply fuse(s):
1. Degas the dispenser (see page 40).
2. Switch off the power supply to the dispenser.
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.
3. Remove the flameproof box lid.
4. Remove the blown fuse and discard.
Take basic anti-static precautions by wearing a wristband with an earth strap.
Install new C4000 power supply fuse(s):
1. Replace the blown fuse element with a new one of equal type and rating.
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.
2. Replace the flameproof box lid, ensuring that the O-ring in the lid engages in its associated groove.
3. Turn on the power to the dispenser.
Do not power up the dispenser with the flameproof box
lid removed.
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).
Servicing
Power Supply Replacement
Compac Industries Ltd.
Page 61
www.compacngv.com
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
1. De-gas the dispenser (see page 40).
2. Switch off the power supply to the dispenser.
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.
3. Remove the flameproof box lid to gain access to the C4000 power supply board.
Take basic anti-static precautions by wearing a
wristband with an earth strap.
4. Disconnect the incoming power wiring from the phase and neutral terminals, and from the earth bar.
5. Remove all of the solenoid and communications plugs on the top of the C4000 power supply board, with the wiring still intact.
6. Remove the screws that are securing the earth bar, taking care not to lose any of the spacers or other mounting hardware.
7. Remove the two screws on the other end of the C4000 power supply board.
8. Carefully slide out the C4000 power supply board to gain access to the plugs on the IS Cable that connect into the bottom PCB, and unplug these.
Completely remove the C4000 power supply board.
Install the New C4000 Power Supply
1. To install the new C4000 power supply, reverse the procedure above
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. Switches are easily knocked out of position during service. The C4000 Power Supply Board section (see page 92) shows the appropriate switch settings used on the dispenser.
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).
It should not be necessary to recalibrate the dispenser. However, in some locations, this may be legally required as per the Calibrate the Meter section (see page 67).
Processor Board Replacement
Servicing
Compac Industries Ltd.
Page 62
www.compacngv.com
Processor Board Replacement
Before you start
Obtain the following replacement parts
Replacement C4000 Processor part number F-CP-C4PROCES-A
Remove the C4000 Processor board
1. De-gas the dispenser (see page 40).
2. Remove the cover of the C4000 enclosure.
3. If possible, record all the set-up data by accessing the Parameter switch (SW1) and the K-Factor switch (SW2). The Software Set-Up and Upgrade section (see page 19) contains details on obtaining this information.
4. Switch off the power supply to the dispenser.
5. Remove both the EPROM and memory chips Dispenser Software Upgrade/Replacement (see page 64)
Take basic anti-static precautions by wearing a
wristband with an earth strap.
6. Unplug all wiring from the C4000 microprocessor board and remove the board from its position.
Take basic anti-static precautions by wearing a
wristband with an earth strap.
Install New C4000 Processor
1. Put the new board in place of the old one, and plug all the wiring back in the same order as before.
2. Refit the EPROM and memory chips, as per Dispenser Software Upgrade/Replacement (see page 64)
3. Check dispenser operation Checking Dispenser Operation (see page
42)
It should not be necessary to recalibrate the dispenser.
Servicing
Temperature Pressure Board Replacement (Fast Fill &
Temperature Compensation Units Only)
Compac Industries Ltd.
Page 63
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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
1. De-gas the dispenser (see page 40).
2. Switch off the power supply to the dispenser.
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.
3. Access the temperature pressure board.
Take basic anti-static precautions by wearing a wristband with an earth strap.
Unplug all wiring from the temperature pressure board and remove the board from its position.
Install New Temperature pressure board
1. Put the new board in place of the old one, and plug all the wiring back in the same order as before.
2. Turn the power to the dispenser back on.
3. Check Dispenser operation. Checking Dispenser Operation (see page
42)
It should not be necessary to re-calibrate the dispenser unless a pressure transducer or temperature probe needs to be replaced.
Dispenser Software Upgrade/Replacement
Servicing
Compac Industries Ltd.
Page 64
www.compacngv.com
Dispenser Software Upgrade/Replacement
You can only upgrade the dispenser software by replacing the EPROM chip. Follow this software upgrade procedure for all CNG Dispensers that use the C4000 Microprocessor.
Before working on the dispenser electronics, take basic anti-
static precautions by wearing a wristband with an earth strap.
Record Set-up Data and Tote Information
1. Access the C4000 Microprocessor PCB by opening the front panel.
2. Record all the set-up data by accessing the Parameter switch (SW1) and the K-Factor switch (SW2). Refer to Parameter Switch Settings (see page 19) and K-Factor Switch Settings (see page 25) to obtain this information.
The following data is required from the Parameter switch (SW1):
Dispenser pump price (see page 21).
Dispenser pump number (see page 23).
Dispenser sequencing rate.
Software Program number (see page 20), if you are upgrading to a
new version.
The following data is required from the K-Factor switch (SW2):
The K-Factor (see page 27). There is a value for side A and side B
in dual hose dispensers.
The temperature (see page 29).
The Set Resolution (see page 33). This sets the number of decimal
places after the decimal point.
The pressure values. ( Record if applicable: u uA uA2 ub
ub2 )
The pressure gain. (Record if applicable: GAin GAinA 9Ainb
GAinA2 GAinb2 )
Configuration Code C (see page 35).
Configuration Code b (see page 34).
The Density Factor (see page 27).
3. Record the tote information by pressing the nozzle switch or start button quickly five times
Remove the software EPROM
1. Turn off the dispenser.
2. Remove the software EPROM chip, using an EPROM extractor.
Install new software EPROM
1. 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. This leaves a gap of two pins from the top of the chip to the top of the socket. Pin 1 of the EPROM is then located in the top left corner (pin 3 of the socket).
2. Turn on the dispenser.
3. Check that the initial set-up data and tote information is the same.
If the initial set-up data is different, re-enter this information, as per Parameter Switch Settings (see page 19) and K-Factor Switch Settings (see page 25).
4. Check the dispenser operation Checking Dispenser Operation (see page
42)
Servicing
Meter Replacement
Compac Industries Ltd.
Page 65
www.compacngv.com
Meter Replacement
Before you start, make sure you have:
A new Compac meter F-D-METER-KG80T
Remove the Meter
1. De-gas the dispenser (see page 40).
2. Remove the tubing from the meter inlet and outlet.
3. Unscrew the SAE fittings from the meter inlet and outlet.
4. Unplug the meter connections to the C4000 processor.
5. Undo the four bolts that hold the meter on the dispenser frame.
6. Remove the meter.
Install new Meter
1. Reverse the steps above to install the new meter.
2. Enter the new meter K-Factor into the C4000 processor Meter K Factor (see page 27)
3. Check the dispenser calibration with the master meter. Refer: Meter Calibration (see page 67)
Figure 4: Processor, software and memory chip location.
Unserviceable Parts List
Servicing
Compac Industries Ltd.
Page 66
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Unserviceable Parts List
The following parts are unserviceable on site and have to be returned to Compac for servicing.
Part
Comment
KG meter
The 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 K­Factor on the C4000 head.
C4000 power supply
C4000 CPU Board
Nozzles
Solenoid stem
Replacing the solenoid stem seal requires special tooling.
Dispenser Calibration
Meter Calibration
Compac Industries Ltd.
Page 67
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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.
The K-Factor for each new dispenser is factory set
and usually does not need to be changed.
Test the meter accuracy
Record the dispensers current density factor and set it to read out in kg Density Factor (dSF) (see page 27)
1. Test the meter accuracy using Calibration Test Fill Procedure ­Method 1 (see page 68) or Calibration Test Fill Procedure - Method 2 (see page 68)
Calculate the meter K-Factor
1. Make sure that the dispenser is idle, with the nozzle in its holster.
2. Press and release the K-Factor switch nine times.
The display shows the K-Factor as F X.XXXX (single nozzle dispenser) or FA X.XXXX (Side A of a dual nozzle dispenser).
To view the K-Factor for side B, quickly press and release the K- Factor switch eight more times when viewing side A. The display shows Fb X.XXXX (side B of a dual nozzle dispenser).
With a dual dispenser, it’s easier to set side A first.
3. Calculate the new K-Factor with the following formula:
New K-Factor = Existing K-Factor x True quantity
Displayed amount
For example:
Existing K-Factor = 0.98
Displayed amount = 5.80 kg
True quantity = 6.00 kg
New K-Factor = 0.98 x 6.00
5.80
= 1.0138 (4 decimal places)
Input dispenser settings
1. Input the new meter K-factor (FA & Fb) (see page 27)
Set the density factor back to its original value. (dSF) (see page 27)
Meter Calibration
Dispenser Calibration
Compac Industries Ltd.
Page 68
www.compacngv.com
Calibration Test Fill Procedure (Method 1)
Method 1 of checking calibration involves filling a gas bottle and comparing the read-out scale reading with the dispenser display reading.
Before you start, make sure you have:
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):
1. Put the CNG cylinder on the scales.
2. Empty the CNG cylinder by venting it to the atmosphere.
Always vent cylinders in a safe manner and safe location.
3. Zero the TARE read-out on the scales.
4. Fill the CNG cylinder from the dispenser.
5. Compare the read-out weight (True Quantity) on the scales 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.
Calibration Test Fill Procedure (Method 2)
Method 2 of checking calibration involves filling a vessel and comparing a master meter reading with the dispenser display readings.
This method assumes that the master meter is sufficiently accurate and reliable enough to be considered a good reference.
Before you start, make sure you have:
A master meter
To carry out the calibration test fill procedure (Method 2):
1. Plug the dispenser refuelling probe into the master meter, and then plug the master meter refuelling probe into a vehicle to fill.
2. Turn on the master meter valve, if applicable, and reset to zero.
3. Fill the vehicle from the dispenser.
4. Turn off the dispenser refuelling valve and master meter valve, if applicable.
5. 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.
Dispenser Calibration
Pressure Transducer Calibration (Fast Fill & Temperature
Compensated Units Only)
Compac Industries Ltd.
Page 69
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Pressure Transducer Calibration (Fast Fill & Temperature Compensated Units Only)
Calibrating the dispenser pressure transducers involves two steps:
1. Determine the transducer gain. Compare the dispensers gauge pressure to its electronic pressure reading to determine and set the correct transducer gain.
2. Adjust the transducer gain by adjusting the dispenser’s electronic pressure reading to match the actual pressure.
The pressure transducers are calibrated at the factory and
usually do not require recalibration.
Determine transducer gain
1. Degas the dispenser (see page 40) and close all outlet isolation valves
2. View and note down the current transducer gain (TG) setting for the transducer to be tested. Pressure Transducer Gain (see page 31)
3. Turn on the gas to the dispenser.
4. Remove the nozzle from its holster or press the start button, allowing gas to pass through the dispenser.
5. Slowly open the outlet isolation valve and watch as the pressure gauge begins to rise. Shut the valve when the reading is approximately 100 bar.
6. Hang up the nozzle.
7. View and record the electronic pressure reading for the pressure transducer. This value is D1.
8. Record the value on the dispenser gauge. This value is TG1.
9. Remove the nozzle from its holster again or press the start button.
10. Increase the gauge pressure to approximately 200 bar.
11. Hang up the nozzle.
12. View and record the electronic pressure reading for the pressure transducer. This value is D2.
13. Record the value on the dispenser gauge. This value is TG2
14. Calculate the new gain using the following formula:
Adjust the transducer gain
Input the new gain. Refer Pressure Transducer Gain (see page 31)
Adjust the electronic pressure offset
Adjust the electronic pressure reading to equal that displayed on the dispensers pressure gauge using the following procedure:
1. Use the "K" factor switch to display the pressure reading.
2. Press and hold the "K" factor switch to change the display to equal the pressure on the gauge.
3. Allow the "K" factor setting to time out.
4. Re-check the pressure at 100 and 200 bar gauge pressure to see if display and gauge read the same.
Ambient Temperature Sensor Calibration
Dispenser Calibration
Compac Industries Ltd.
Page 70
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Ambient Temperature Sensor Calibration
Calibrating the Ambient Temperature Sensor involves:
1. Comparing the dispensers stated temperature to the actual temperature.
2. Adjusting the ambient temperature reading if it is found to be incorrect.
Test the sensor accuracy
Using a calibrated temperature meter, determine the temperature of the body of the dispenser Ambient temperature sensor.
Access the current dispenser ambient temperature reading (see page 29).
Adjust dispenser reading
Adjust the dispenser’s ambient temperature reading to match that of the
calibrated temperature meter (see page 29).
Indicator LEDs
Power, Watchdog, Comms RXD and TXD LEDs
Compac Industries Ltd.
Page 71
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Indicator LEDs
Power, Watchdog, Comms RXD and TXD LEDs
The power, watchdog, comms RXD and TXD LEDs indicate the operational state of the dispenser.
LED Indicators
LED
Reference
Lit When
Power
D1
The processor board has power.(on)
Watchdog
D5
The watchdog circuit has been triggered. This indicates that there is a fault on the processor board.(on)
RXD
D6
Polling information has been received. (flashes on/off)
TXD
D7
The C4000 processor responds to polls for its respective hose number(s).(flashes on/off)
Diagnostic and Output LEDs
Indicator LEDs
Compac Industries Ltd.
Page 72
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Diagnostic and Output LEDs
The diagnostic and output LEDs indicate the operational state of the dispenser.
Diagnostic LED
The diagnostic LED D18 flashes in three different states when the processor is working properly, as outlined in the table below.
State
LED Flashes
When
1
Slowly and consistently.
The hose is idle and in stand­alone mode.
2
Slowly but erratically.
The hose is idle and communicating with a Controller.
3
Quickly.
Start button is being pressed or the nozzle has been lifted from its holster.
Output LED
The 10 output LEDs (D8-D17) pictured correspond to the output triacs, which engage power terminals (T1-T10).
When the output triac switches on and engages a power terminal, the corresponding output LED lights up. When the power is disengaged, the LED is not lit.
The output LEDs can be used to troubleshoot problems with the components supplied by the power terminals.
The table below outlines which LED is associated to which power terminal and the component that it controls.
LED
Power Terminal
Component Controlled
D8
T1
Solenoid Low Bank Side A.
D9
T2
Spare.
D10
T3
Solenoid Medium Bank Side A.
D11
T4
Solenoid High Bank Side A.
D12
T5
Spare.
D13
T6
Solenoid Low Bank Side B.
D14
T7
Solenoid Medium Bank Side B.
D15
T8
Finished dispensing. (Turns off when the nozzle is stowed.)
D16
T9
Solenoid High Bank Side B.
D17
T10
Error indication.
The Solid State Relays (Triacs) Layout and Function part of the C4000 Supply Board section (see page 92) show the physical locations of triacs and power terminals.
Indicator LEDs
Diagnostic and Output LEDs
Compac Industries Ltd.
Page 73
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Diagnostic and Output LEDs
Troubleshooting
Compac Industries Ltd.
Page 74
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Troubleshooting
This troubleshooting section outlines issues that you may encounter when using the dispenser, and provides recommended actions to help you correct these problems.
To help quickly diagnose possible problems you should check the dispensers End of sales indicator End of Sale indicators (see page 122) and review the Error Codes (see page 120).
For sites where the temperature falls below –10°C, power should only be removed from the dispenser for servicing.
When servicing a Compac CNG Dispenser fault, please follow the recommendations and safety information in this manual. Failure to do this may cause injury or void the warranty.
The troubleshooting items have been divided into the following categories:
Problems When Idle
Problems Starting a Fill
Problems Filling a Vehicle
Solenoid Problems
Troubleshooting
Problems When Dispenser is Idle
Compac Industries Ltd.
Page 75
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Problems When Dispenser is Idle
Problem
Likely Cause(s)
Recommended Action
After powering the dispenser,
PA:uSE is displayed and the
countdown from 60 doesn't start.
For push to start dispensers the start
button is held down.
Release the start button.
The nozzle is not stowed or the nozzle switch is active.
Correctly stow the nozzle.
The dispenser pressure gauge creeps past 200 bar when the dispenser is not in use.
The regulator centre seal is damaged.
Replace the Regulator Valve Seals
(see page 52)
The solenoid piston seal is damaged.
Replace the Solenoid Valve Seal
(see page 48)
The C4000 electronics are not working. The indicator LEDs are off and nothing happens when you lift the nozzle (i.e., no beeps
or 888888 is displayed).
Unacceptable voltage spikes are causing the fuses on the C4000 to blow.
Fit a voltage-stabilising UPS to the
dispenser.
Replace the power supply fuses
(see page 60)
There is low input voltage.
Turn the dispenser off and then on
again.
Check the power supply connections
and input voltage to the dispenser with a multimeter. A voltage­stabilising UPS will be required.
The Output LED T10 is ON.
An error state exists.
Remedy the cause of the error (i.e.,
Display, Memory, or KG meter) by checking the Fault Codes section (see page 120).
Clear the error by quickly pressing
the start button or nozzle switch five times to view the totes.
The watchdog LED D5 is illuminated.
A processing fault has occurred.
Turn the power to the dispenser off
and then on again to reset the watchdog.
If the light still illuminates, there is a
fault on the C4000 microprocessor board, such as a loose memory chip or a broken track.
Replace C4000 memory and
software chips
Replace C4000 processor board
A display LCD segment is always on or always off.
Faulty display unit.
Replace Display PCB
Problems Starting a Fill
Troubleshooting
Compac Industries Ltd.
Page 76
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Problems Starting a Fill
Problem
Likely Cause(s)
Recommended Action
When the start button is pressed the dispenser does not
display 888888 and reset for the next fill.
The dispenser hose numbers have not been set.
Set the dispenser hose numbers.
Hose Number (see page 23)
The start button or nozzle switch is faulty, stuck, or broken.
Check that the Diagnostic LED (D18)
flashes quickly when you operate the start button or nozzle switch, to make sure that the C4000 is registering the button or switch.
Check that the nozzle switch is
operating correctly and is not broken, and that the mechanism is free to move in and out.
Replace the button or switch if
necessary.
The connection between the forecourt controller and dispenser communications connection is faulty.
Check the polling of the
communicator LEDs on the C4000 to determine the quality of the connection between the dispenser and forecourt controller.
The C4000 Microprocessor Board is faulty.
If none of the above suggestions
resolve the problem, replace the C4000 Microprocessor Board. (see page 62)
Gas will not flow
There is no power to the solenoid.
Establish the reason why there is no
power to the solenoid from the Solenoid Problem section (see page
79), and then implement the recommended action.
The solenoid coil is burnt out.
Establish the reason for burn-out from
the Solenoid Problem section (see page 79), and then implement the recommended action.
The solenoid valve is stuck
Clean the solenoid and replace the
valve seals.
The check valve is stuck
Clean the check valve and replace
the valve seals
The regulator piston is stuck
Clean the regulator and replace the
valve seals (see page 52).
Water in the gas has turned to ice, blocking the gas flow. (Wet gas causes freezing blocks in cold conditions, regardless of filtering.)
Pour boiling water onto the pipework
where the freezing has occurred until the ice has thawed and the gas can flow.
Contact your gas supplier
The Over-Pressure switch has been activated (if present).
Check the pressure on the pressure
gauge.
If it exceeds 215 bar, the over­pressure safety will have shut down power to the solenoid but not the electronics and metering.
Clean the regulator and replace the
valve seals (see page 52).
De-gas the dispenser to reduce the
pressure.
Troubleshooting
Problems Filling a Vehicle
Compac Industries Ltd.
Page 77
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Problems Filling a Vehicle
Problem
Likely Cause(s)
Recommended Action
The dispenser is under filling the vehicle
The medium or high bank solenoid is not opening.
See Solenoid Problem Troubleshooting
section
The storage pressure in the cascades service station pressure banks is lower than 200 bar, causing the dispenser to receive less gas than it should.
This is not a dispenser fault.
The filters are blocked.
Remove and replace the coalescing filters.
Water in the gas mains has caused freezing, blocking the pipes.
Pour hot water on the frozen part of the
dispenser.
Install a drier into the gas main.
Fast fill or temperature compensation variables are incorrectly set
Check pressure transducers are calibrated
and all parameters are correct
Replace transducers if they cannot be
calibrated
The regulator pressure is set too low.
Adjust the regulator set pressure Check the
Setting and Sealing of the Regulator (see page 43)
The dispenser stops filling the vehicle after approximately 1kg of gas has been dispensed
The over pressure switch is faulty
Check the End of sale indicator to confirm
there is a problem with the over pressure switch.
Check the wiring to the switch and switch
operation. Replace switch if no fault is found in the wiring.
The over pressure switch link has come loose in J12
Check the End of sale indicator to confirm
there is a problem with the over pressure switch.
Check the link in J12 is still in place and the
contacts are clean.
The dispenser is over filling the vehicle
The regulator pressure is set too high.
Adjust the Regulator set pressure Check the
Setting and Sealing of the Regulator (see page 43)
The regulator seal is worn out.
Clean the regulator and replace the valve
seals (see page 52).
Fast fill or temperature compensation variables are incorrectly set
Check pressure transducers are calibrated
and all parameters are correct
Replace transducers if they cannot be
calibrated
The dispenser is slow filling the vehicle.
Moisture in the gas mains has caused freezing in one or more of the valves. (This often occurs when water has not been cleared out of the gas pipes after testing.)
Pour boiling water onto the pipework where
the freezing has occurred until the ice has thawed and the gas can flow.
Contact your gas supplier
The preset display is flashing after a fill.
The solenoid has not closed and the preset amount has been exceeded.
The preset display will stop flashing when the next fill is started.
See Solenoid Problem Troubleshooting
section
Gas flows but does not read up on the display.
The C4000 needs to be reset
Re-power dispenser.
Solenoid valves are not closing at the end of a fill when the dispenser stops metering because of dirt and/or water contamination.
Clean the solenoid and replace the valve
seals.
The meter is faulty and has stopped
Replace the meter (see page 65).
Problems Filling a Vehicle
Troubleshooting
Compac Industries Ltd.
Page 78
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Problem
Likely Cause(s)
Recommended Action
recording flow.
The dispenser stops at
9999.99, 99999.9, or 999999 units according to
where the decimal point is set.
The dispenser will stop dispensing if either the value or the quantity displays ever reach these values.
Hang up the nozzle to reset the display and
restart. This is not a dispenser fault.
Troubleshooting
Solenoid Problems
Compac Industries Ltd.
Page 79
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Solenoid Problems
Problem
Likely Cause(s)
Recommended Action
The solenoid is not opening
Check that the power is reaching the coil and it is energising. Place a screwdriver (or similar metal object) over the top of the coil and feel the magnetic field created by the energised coil.
If there is no magnetic field check the
LED for the triac. If the triac LED light is coming on check that the triac is delivering power.
If the triac is delivering power but the
coil is not energising then the coil is burnt out. Replace the solenoid coil and, using the troubleshooting information below, investigate why it has failed.
The solenoid coil is burnt out
See the solenoid coil is burnt out
section below.
The solenoid piston seals are damaged, jamming the piston in the closed position.
Clean the solenoid and replace the
valve seals.
The solenoid is not closing
The solenoid piston seals are damaged, jamming the piston in the open position.
Clean the solenoid and replace the
valve seals.
There is dirt or water in the gas supply, jamming the piston in the open position
Clean the solenoid and replace the
valve seals.
Change the filter and remove the water
source or install a drier.
The solenoid is not sealing
The solenoid piston seals are damaged.
Clean the solenoid and replace the
valve seals.
There is dirt or water in the gas supply.
Clean the solenoid and replace the
valve seals.
Change the filter and remove the water
source or install a drier.
The solenoid coil is burnt out
Dirt or water in the solenoid has prevented the armature from rising and opening the solenoid, resulting in the solenoid coil heating up and burning out.
Replace the solenoid coil
Clean the solenoid and replace the
valve seals.
Change the filter and remove the water
source or install a drier.
High voltage or voltage spikes have caused the solenoid coil to burn out
Fit a voltage stabilising UPS to the
dispenser power supply
Replace the solenoid coil
Coil has been removed from solenoid and energised, causing the coil to burn out
Replace the solenoid coil
Finally
If the solenoid is still not working reliably
Fit the solenoid top service kit. Refer to
valve seal replacement (see page 48)
Approvals
Appendix
Compac Industries Ltd.
Page 80
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Appendix
Approvals
The C4000 electronic head 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 C4000 lid and the flameproof junction box lid.
ATEX Approval Marking on the Equipment
Equipment or Protective System
EC - Type Examination Certificate Number
 2 G EEx d  A T3 (T
amb
= -25°C to + 55°C)
A Type C4000 Control Unit
Baseefa03ATEX0612
(2)G [EEx ib] A (-25°C ≤ Ta ≤ 80°C)
C4000 Power Supply Unit PCB CI138 & CI139
Baseefa03ATEX0684X
G EEx ib A T3 (-25°C ≤ Ta ≤ 80°C)
(CWIT Aerial only:-  1G EEx ia A T3
C4000 Fuel Dispenser Control Unit
Baseefa03ATEX0683X
The Compac CNG equipment is also PED approved for use up to 275 bar.
PED Approval Marking on the Equipment
Equipment
EC - Type Examination Certificate Number
Cat. II Group I
Filter housing, Solenoid, & various Dispenser models.
SGS UK Ltd. 0790/025074
Specifications
Model Specifications
Compac Industries Ltd.
Page 81
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Specifications
Model Specifications
There are various CNG Dispenser models and options available.
The models include:
Legend frame or Laser frame.
The options include:
One, two, or three line.
Single or dual hose.
Fixed pressure final fill cut-off or temperature compensated final fill cut-off.
Standard, high, or ultra-high flow.
Model numbers
Standard
High Flow
Ultra-High Flow
Laser
Single
L-CNG15
L-CNG50
L-CNG50-15
L-CNG80
L-CNG80-15
Dual
L-CNGD15
L-CNGD50
L-CNGD80
Legend
Single
LGDCNG15
LGDCNG50
LGDCNG50-15
LGDCNG80
LGDCNG80-15
Dual
LGDCNGD15
LGDCNGD50
LGDCNGD80
LE3KG25D (Pakistan only)
Technical Specifications
Specifications
Compac Industries Ltd.
Page 82
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Technical Specifications
Operating Conditions
Compac CNG Dispensers (excluding hose assembly) are designed to operate within the atmospheric environment. Gas parameters are outlined below.
CNG Dispensers require the following operating conditions:
Air temperature range
- 25 °C to + 55 °C
Air humidity range
10% to 95%
Gas type
High pressure natural gas (CNG)
Gas temperatures
- 40 °C to + 80 °C (continuous)
- 55 °C to + 80 °C (intermittent)
Maximum Water Dew Point
- 32 °C at 250 bar
Maximum Working Pressure (Inlet)
275 bar (350 bar option)
General Specifications
Power Requirements
230V +/-10%, 50Hz, 2A
Specific Specifications
Standard Model
High-flow Model
Ultra high-flow Model
Flow
(The maximum flow rate is not only determined by the type of dispenser but also depends on the size of the refuelling hose, the model of the breakaway, the type of refuelling nozzle, and the vehicle coupling.)
1 – 15 kg /min
1-50 kg /min
1 – 80 kg /min
Pressure rating
(350 bar options utilise air actuated valves and require a compressed air supply.)
275 bar
(350 bar option)
275 bar
(350 bar option)
350 bar
Accuracy
+/- 1.0%
+/- 1.0%
+/- 1.0%
Meter
Compac KG80 coriolis
mass flow
Compac KG80 coriolis
mass flow
Compac KG80 coriolis
mass flow
Internal Pipework
1/2”
1/2”
1/2” or 3/4"
Refuelling hose
3/8”
1/2”
1/2” or 3/4"
In-line breakaways
Various available
Various available
Heavy duty
Refuelling valve
NGV1 or NZ 7/16" probe
NGV1 or NGV2
NGV2
Laser (without hoses or high masts)
830W x 450D x 1608H
830W x 450D x 1608H
830W x 450D x 1608H
Legend (without hoses)
850W x 425D x 2355H
850W x 425D x 2355H
850W x 425D x 2355H
Minimum flow cut-off
0.5 -10 kg/min (settable)
0.5 -10 kg/min (settable)
0.5 -10 kg/min (settable)
Maximum flow cut-off
10 - 99 kg/min (settable)
10 - 99 kg/min (settable)
10 - 99 kg/min (settable)
Specifications
Component Specifications
Compac Industries Ltd.
Page 83
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Component Specifications
See below for information on serviced equipment.
Equipment Item
Compac Code
Specifications
Description
Coalescing filters
Grade 10 Coalescing Filter
The coalescing filters are designed to trap dirt, moisture, oil, and other debris that may damage the valve seals. A Grade 10 coalescing filter will remove 95% of liquid aerosols in the 0.3 to 0.6 micron range.
Compac filter/check valve
FCVCI-12-SS
3/4” SAE female inlet. 2 x 3/4” SAE female
outlets. 350 bar max.
The filter/check valve prevents back-flow from the high storage to the medium and low storage and from the medium storage to the low storage.
The valve has a metal to metal seat and should not leak or require servicing.
Solenoid valve
SCI-12-SS
3/4” SAE female inlet.
3/4" SAE female outlet.
275 bar max.
The high flow solenoid valve is designed to control the flow of gas in a CNG Dispenser.
Between the inlet and outlet, the valve opens with a differential pressure of more than 275 bar.
Regulator valve
RCI-12-SS
3 x 3/4" SAE female inlets.
3/4" SAE female outlet.
275 bar max.
The regulator is a high flow valve, designed to limit the outlet pressure of the dispenser.
In the fixed pressure dispenser, the regulator limits the final fill pressure to 200 bar.
In the temperature compensating dispenser, the regulator acts as a safety device to limit the amount of over-pressure if the main solenoid fails to shut off at the correct pressure.
Three-way refuelling valve
RVCI-04
1/4" NPT ports
250 bar max.
The three-way valve is designed specifically for refuelling CNG vehicles. The inlet, outlet, and exhaust ports are designed to be used as shown in the figure in the Dispenser Component Location section (see page 89). Do not re-pipe the valve in a different configuration.
Nozzles
7/16" NZ Probe
1-15 kg/min
1/4" NPT port.
In New Zealand, the probe complies with NZS
5425.1.
In Australia, the probe complies with AS/NZS
2739.
OPW CT1000
1-50 kg/min
9/16" SAE inlet port
200 bar max.
Nozzles allow refuelling for high pressure NGV applications.
OPW CT5000
1-80 kg/min
7/8" SAE inlet port
250 bar max.
Nozzles allow refuelling for high pressure NGV applications.
Inline breakaways
QBCI-09
1-15 kg/min
9/16" SAE inlet & outlet ports
Brass inline breakaway with reconnectable design.
OPW ILB- 1
1-50 kg/min
9/16" SAE inlet & outlet ports.
250 bar max.
150 to 200 lbs. (668 to 890 N) breakaway force.
Inline breakaway with reconnectable design. Corrosion-Resistant with high flow for all NGV-1 nozzles.
OPW ILB-5
1-80 kg/min
7/8" SAE inlet & outlet ports.
310 bar max.
150 to 200 lbs. (668 to 890 N) breakaway
Inline breakaway with reconnectable design. Corrosion-Resistant with high flow quick fuelling of large storage vehicles.
Component Specifications
Specifications
Compac Industries Ltd.
Page 84
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force.
Isolation ball valve
Parker 2-way 8 series ball valve
Microprocessor
C4000
The Compac C4000 processor controls all the electronics in the dispenser.
Display
GD1, GD2 or GD3
The display has six 1" digits for price, six 1" digits for quantity and four 3/4" digits for unit price. (Available with one, two or three unit price displays.)
Pressure Gauge
Dual scale pressure gauges are available with psi and either bar, MPa, or kPa. CE Approved
Hose
Parker single and twin line hose.
3/8", 1/2" or 3/4".
The hose is specifically designed to dissipate static electrical build-up and wear resistance. Each hose assembly must be properly grounded.
The temperature range for the hose is -40 to +66°C.
Installation Diagrams
LEGEND Installation Diagram
Compac Industries Ltd.
Page 85
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Installation Diagrams
LEGEND Installation Diagram
LASER Installation Diagram
Installation Diagrams
Compac Industries Ltd.
Page 86
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LASER Installation Diagram
Installation Diagrams
Dispenser Fittings
Compac Industries Ltd.
Page 87
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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.
Fitting replacement and servicing
When replacing, disassembling or tightening fittings:
1. De-gas the dispenser (see page 40).
2. Switch off the power supply to the dispenser.
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.
3. Make sure that your work area (including the vice, workbench, tool storage area, and floor) are totally clean of particles or previous work. Cleanliness and correct assembly practice can avoid most seal problems.
4. Make sure that the gas inlet pipes are properly supported before connection.
5. Refer to one of the following procedures, depending on the fitting that you are using:
Connect Threaded SAE Fittings (see page 87).
Connect Adjustable threaded SAE Fittings (see page 87).
Connect Compression Fittings (see page 88).
Connecting SAE Fittings
1. Inspect the components ensuring that the threads and sealing faces are clean and undamaged.
2. Lubricate the O-ring with a light oil
3. Screw the components together by hand until the O-ring touches the face of the port.
4. Tighten the fitting firmly with a suitable spanner.
Never use thread tape on SAE parallel fittings.
Connecting Adjustable SAE fittings
1. Inspect the components ensuring that the threads and sealing faces are clean and undamaged.
2. Lubricate the O-ring with a light oil
3. Back off the lock nut fully so that the O-ring and washer are on the plain shank of the fitting.
4. Screw the components together by hand until the O-rings touch the faces of the ports.
5. Position the components to the desired alignment.
6. Hold the fitting in position and firmly tighten the lock nut.
Never use thread tape on SAE parallel fittings.
Dispenser Fittings
Installation Diagrams
Compac Industries Ltd.
Page 88
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Connecting Compression Tube Fittings
1. Ensure the end of the tube is square, not deformed, clean and free from burrs inside and out.
2. Remove the nut from the fitting and ensure the two ferrules are present and correctly orientated.
3. Replace the nut and insert the tube ensuring it is located hard up against the internal shoulder of the fitting
4. Pre-swage the tube by tightening the nut by hand and then a further 1 1/4" turns
5. Disassemble the fitting and inspect the pre-swaging. The ferrules should square and unable to be removed from the tube
6. Reassemble the fitting, tightening it by hand and then a further 1/4" turns with the appropriate spanner.
Correctly made tube should not need to be sprung into position.
Mechanical Drawings and Component Details
Dispenser Component Locator
Compac Industries Ltd.
Page 89
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Mechanical Drawings and Component Details
Dispenser Component Locator
The C4000 Dispenser Power supply is housed in a flameproof box. All other components are simply located in enclosures. See below.
Hydraulic Layout
Mechanical Drawings and Component Details
Compac Industries Ltd.
Page 90
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Hydraulic Layout
GA
MB
Inlet
Outlet
BV
Manifold Block Assembly
MBA
FV Filter Check Valve
SV Solenoid Valve.
RV Regulator Valve
KG KG80 Mass Flow Meter
IV Isolation Valve
GA
MB Manifold Block
GA Pressure Gauge
TR Pressure Transducer
PR Pressure Relief Valve
BV Bleed Valve
TR
(Temperature compensated models only)
OB Outlet Block
HB Hose from Outlet to Breakaway
BA Inline hose breakaway coupling
HN Hose from Breakaway to Nozzle
RA Refueling Nozzle Assembly
IN1
RV1KG1
KG2
SV5
SV6
SV1
SV2
SV3
SV4RV2
IV2
FV2
FV1
FV3
Low Bank Inlet
SIDE A SIDE B
OB2
MBA
IN2
Medium Bank Inlet
IN3
High Bank Inlet
BA2
RA2
HB2
HN2
IV1
OB1
MBA
BA1
RA1
HB1
HN1
(Two and Three Line Models)
(Optional)
(Three Line Models Only)
(See Below)
(Dual Hose Models Only)
Electrical Drawings and Component Details
CNG Dispenser Electrical Schematic
Compac Industries Ltd.
Page 91
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Electrical Drawings and Component Details
CNG Dispenser Electrical Schematic
C4000 Power Supply Board
Electrical Drawings and Component Details
Compac Industries Ltd.
Page 92
www.compacngv.com
C4000 Power Supply Board
General layout diagram
VCC
RED
BLK
DTR
DCD
CTS
GND
TXDP
DTRP
GND
N
T10
T7NT9
T8NT6
T5
N
T3
T2
N
T1
T4
N
PH
NEUTRAL
NEUTRAL
NEUTRAL
SW1
SW2
SW4
SW3
FUSE “F3”
( 1 AMP )
FUSE “F1”
( 0.5 AMP )
FUSE “F2”
( 0.25 AMP )
230Vac inputs (phase logic
and phase triac) are normally linked.
These inputs can be separated
if necessary.
Wire link
Triac Snubber
Switches
Comms
Dip Switches
Comms
Inputs
230Vac Triac
Outputs
20Vac
Test
Input
Fuses
Electrical Drawings and Component Details
C4000 Power Supply Board
Compac Industries Ltd.
Page 93
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C4000 IS Cable CNG Outputs
The C4000 controls the solid state relay switch. Solid state relay switches control the C4000 220-240 volt outputs.
Solid State Relays (Triacs)
There are 10 separate solid state relays (small triacs) on the C4000 PCB. The output terminals for these triacs are T1 to T10. See below for information about the use of these outputs.
Power Terminal
Function
T1
Solenoid Low Bank Side A
T2
Spare
T3
Solenoid Medium Bank Side A
T4
Solenoid High Bank Side A
T5
Spare
T6
Solenoid Low Bank Side B
T7
Solenoid Medium Bank Side B
T8
Spare
T9
Solenoid High Bank Side B
T10
Auxiliary Output for Compressor Controller
Fuses
Fuse
Rating
Comment
F1
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.
F2
0.25 A
F3
1.0 A
C4000 Power Supply Board
Electrical Drawings and Component Details
Compac Industries Ltd.
Page 94
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Electrical Drawings and Component Details
C4000 Power Supply Board
Compac Industries Ltd.
Page 95
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Comms Dipswitches
Dipswitch SW3 on the C4000 Power Supply sets the comms for either the Compac or Gilbarco protocol.
Locate the dipswitch settings as shown in the diagram below, depending on which protocol is adopted.
In addition to setting the dipswitches, the Gilbarco protocol requires an interface PCB, as well as special software and wiring configuration. The C4000 IS Cable Connections section (see page 114) contains the Gilbarco wiring configurations.
ON
1 2 3 4
ON
1 2 3 4
COMPAC COMMS
1 - ON 2 - OFF 3 - ON 4 - OFF
GILBARCO PROTOCOL
1 - ON 2 - OFF 3 - ON 4 - OFF
REQUIRES INTERFACE PCB, SPECIAL SOFTWARE, & WIRING
Triac Snubber Switches
Triac snubber switches are used to switch different snubber circuits across the solid state relays. On CNG Dispensers, these (SW1, SW2, and SW4) must always be set to low current output (2).
C4000 Microprocessor Board
Electrical Drawings and Component Details
Compac Industries Ltd.
Page 96
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C4000 Microprocessor Board
The Compac C4000 head is operated by a software program in an EPROM (which is located on the processor board). This program has several operational configurations, one of which must be selected using the set-up devices on the C4000 PCB.
These set-up devices (located on the drawing) are:
The Parameter switch.
The K-Factor switch.
The board shown below is Issue E. For older dispenser board layout information, contact Compac by using the contact details in the Product Identification section (see page v).
Electrical Drawings and Component Details
C4000 Microprocessor Board
Compac Industries Ltd.
Page 97
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Terminal
Function
Terminal
Function
J1
Comms test
J9
Power for KG meters
J2A
To power supply
J10
Totes
J2B
To power supply
J11
Buzzer
J3
Input from KG meter side A
J12
Nozzle switches
J4
Input from KG meter side B
J13
Not used
J5
Preset module side A
J14
Not used
J6
Preset module side B
J15
Not used
J7
Displays
J16
Not used
J8
Temperature pressure module (for temperature and pressure compensation only)
J17
Backlighting
C4000 Microprocessor Board
Electrical Drawings and Component Details
Compac Industries Ltd.
Page 98
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J1 Cable Connection
For de-bug use only. No link required.
J2A Cable Connection
Illustrated in the C4000 IS Cable Diagrams section (see page 114).
J2B Cable Connection
Illustrated in the C4000 IS Cable Diagrams section (see page 114).
J3 - J17 Cable Connections
5
6
3 4
1 2
B02
B01
B00
GND
VCC
7 8
5 6
3 4
1 2
Red / White B02
Blue / White B01
Green / White B00
White / Black GND
Green / Black VCC
Red / Black ENC0
* Colour coding for KG Meter wiring is shown.
(J4 is not used for a Single Hose
Dispenser )
7 8
5 6
3 4
1 2
J4 *
Red / White B02
Blue / White B01
White / Black GND
Green / Black VCC
Red / Black ENC0
5 6
3 4
1 2
B02
B01
B00
GND
VCC
** Pins 7 & 8 (not shown) have a jumper link fitted
across them. (J6 is not used for a Single Hose
Dispenser)
J3 *
J5 **
J6 **
Electrical Drawings and Component Details
C4000 Microprocessor Board
Compac Industries Ltd.
Page 99
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7 8
5 6
3 4
1 2
15 16
13 14
11 12
9 10
23 24
21 22
19 20
17 18
VDSP **
PDIN1 **
PCLK **
PDIN0 *
DCLK **
DPD0 **
DDL1 **
GND **
GND **
31 32
29 30
27 28
25 26
5
6
3 4
1 2
SCL
SDA
* Side A Display Outputs
** Side B Display
Outputs (not used for a
Single Hose Dispenser)
J7
J8
C4000 Microprocessor Board
Electrical Drawings and Component Details
Compac Industries Ltd.
Page 100
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11
12
9 10
7 8
5 6
3 4
1 2
Tote B VCC **
Tote B TOTE1 **
VCC
TOTE0
12 11
14 13
16 15
18 17
4 3
6 5
8 7
10 9
2 1
Green VP
White GND
Black GND
Screen GND
** Side B Tote Outputs ( Not used for a Single
Hose Dispenser )
* Colour coding for KG Meter wiring is shown.
(On a Dual Hose Dispenser an additional
PCB - CI165 plugs into J9 to allow the
connection of two KG Meters)
J9 *
J10
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