Compac C5000 User manual

CNG DISPENSER
SERVICE
MANUAL
C5000 CNG Dispenser Service Manual
Version 1.0.2
Date: 11th July 2023

Conditions of Use
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 equipment
incorrectly or without authorization.
▪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 C5000 processor 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 C5000 processor, or
damages resulting from the inability to use the
Compac C5000 processor, 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 C5000 processor'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 C5000 processor
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.
▪Only parts supplied by or approved by Compac may
be used and no unauthorised modifications to the
hardware of software may be made. The use of non-
approved parts or modifications will void all
warranties and approvals. The use of non-approved
parts or modifications may also constitute a safety
hazard.
▪Information in this manual shall not be deemed a
warranty, representation, or guarantee. For warranty
provisions applicable to the Compac C5000
processor, 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 C5000 processor,
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.

Product Identification
Product Identification
Validity
Compac Industries Limited reserves the right to revise or change product specifications at any
time. This publication describes the state of the product at the time of publication and may not
reflect the product at all times in the past or in the future.
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
Manufactured By:
The Compac C5000 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
Email: [email protected]
www.compac.biz
Copyright ©2015 Compac Industries Limited, All Rights Reserved

Document Control
Document Control
Document Information
Document Details
C5000 CNG Dispenser Service Manual
File Name and Location
G:\Masters\Manuals\Authorised Manuals\CNG
Manuals
Current Revision Author(s)
Trevor Watt
Revision History
Version
Date
Author(s)
Revision Notes
1.0.0
27/08/2021
Phillip Foy
C5000 CNG Manual
1.0.1
13/09/2021
V Amarakoon
Updated Spare parts
1.0.2
11/07/2023
Trevor Watt
Added MODBUS registers

Document Control
Contents
Conditions of Use................................................................................................. 1
Product Identification.......................................................................................... 2
Document Control................................................................................................ 3
Safety ................................................................................................................... 1
System Design.......................................................................................................1
Mechanical Safety.................................................................................................1
Electrical Safety ....................................................................................................2
Introduction.......................................................................................................... 3
Refuelling Modes ................................................................................................. 4
Fixed Pressure Refuelling .....................................................................................4
Installation ........................................................................................................... 5
Commissioning .................................................................................................... 5
Electrical................................................................................................................5
Mechanical ............................................................................................................6
Dispenser Set-Up ................................................................................................. 8
Parameter Switch..................................................................................................8
Menu Options ........................................................................................................8
How to View the Software Version .......................................................................9
Changing the Pump Number...............................................................................10
Unit Price .............................................................................................................10
B Pump Settings..................................................................................................12
Changing the Low-flow Cutoff............................................................................13
Changing the High-flow Cutoff...........................................................................13
Minimum Flow Rate ............................................................................................14
To Adjust the Minimum Flow Rate .............................................................14
Maximum Flow Rate ...........................................................................................14
To Adjust the Maximum Flow Rate.............................................................15
Changing the b Setting .......................................................................................15
Slave Display Configuration................................................................................16
Assigning a number to slave display ..........................................................16
Changing the Custom Display Configuration .....................................................17
Last Sale..............................................................................................................18
Electronic Totes...................................................................................................19
K-Factor Switch ..................................................................................................20
K-Factor Settings............................................................................................... 20
Dispenser Settings ..............................................................................................22
Meter Settings...........................................................................................23
Variant Settings .........................................................................................23
Quantity Settings .......................................................................................23
Meter ID ...............................................................................................................23
Meter Temperature Calibration ..........................................................................23
Meter Density Calibration ...................................................................................24
Target fill pressure..............................................................................................24
Overfill pressure..................................................................................................25

Document Control
CNG Setting .........................................................................................................25
Density Factor ...........................................................................................26
Ambient Temperature .........................................................................................26
Electronic Pressure Calibration points........................................................27
Overfill pressure Time.........................................................................................28
Maximum Flow....................................................................................................28
Changing the K-Factor........................................................................................28
C Configuration Code ..........................................................................................29
Pump settings ...........................................................................................29
Start fill mode............................................................................................29
Changing COMMS................................................................................................30
GPIO K Factor settings ........................................................................................30
Remote push to start .................................................................................32
Output .......................................................................................................32
Frequency .................................................................................................32
Duty Cycle.................................................................................................33
Pulse value ..........................................................................................................34
Dispenser Operation .......................................................................................... 35
Turning the Dispenser on....................................................................................35
Refuelling a Vehicle ............................................................................................35
To Refuel a Vehicle....................................................................................35
Reading the Dispenser Totals.............................................................................36
Servicing ............................................................................................................ 37
Degassing the Dispenser ....................................................................................37
Degas the Dispenser .................................................................................37
Schedules Servicing............................................................................................38
Weekly Checks..........................................................................................38
Suggested 6-monthly or 400 Compressor Run Hour Service ......................38
Suggested Yearly or 8000 Compressor Run Hour Service ..........................38
Checking Dispenser Operation ...........................................................................39
Checking the Sealing of the Solenoid ................................................................39
Checking the Setting and Sealing of the Regulator...........................................39
Checking the Over-Pressure Operation..............................................................40
Checking the Dispenser for Leaks .....................................................................41
Checking the Refuelling Hose for Leaks ............................................................42
Checking the Isolation Ball Valve Operation......................................................42
Checking the Three-Way Refuelling Valve Operation........................................43
Draining the Coalescing Filter ............................................................................43
Filter Element Replacement....................................................................44
Solenoid Valve Seal Replacement ......................................................................45
Solenoid Coil Replacement .................................................................................48
Complete Solenoid Valve Replacement..............................................................49
Regulator Valve Seal Replacement ....................................................................50
Isolation Valve Seal Replacement ......................................................................52
Gas Operated Valve (option) Seal Replacement ................................................54

Document Control
Bleed Valve Replacement ...................................................................................58
Pressure Relief Valve Replacement....................................................................58
KG100 Meter Replacement .................................................................................58
Compac Breakaway Seal Replacement .............................................................59
Three-Way Refuelling Valve Seal Replacement.................................................61
Compac Refuelling Valve Exploded View ...............................................63
Refuelling Hose Replacement.............................................................................64
Power Supply Fuse Replacement .......................................................................64
Power Supply Replacement................................................................................67
Processor Board Replacement ...........................................................................68
Temperature Pressure Board Replacement .......................................................69
Dispenser Software Upgrade/Replacement.......................................................70
Meter Replacement .............................................................................................72
Unserviceable Parts List .....................................................................................72
Dispenser Calibration ........................................................................................ 73
Meter Calibration ................................................................................................73
Calibration Test Fill Procedure (Method 1)..................................................73
Calibration Test Fill Procedure (Method 2)..................................................74
Pressure Transducer Calibration........................................................................75
Ambient Temperature Sensor Calibration..........................................................75
Indicator LEDs.................................................................................................... 77
Appendix ............................................................................................................ 78
Specifications .................................................................................................... 79
Model Specifications...........................................................................................79
Technical Specifications.....................................................................................80
Component Specifications..................................................................................82
Hydraulic Layout ................................................................................................ 85
Dispenser Fittings.............................................................................................. 86
Connecting SAE Fittings......................................................................................86
Connecting Adjustable SAE fittings ............................................................86
Connecting Compression Tube Fittings ......................................................87
Electrical Drawings............................................................................................ 88
CNG Dispenser Electrical Schematic..................................................................88
Power Supply ..................................................................................................... 89
Incoming Mains ................................................................................................. 90
Solid State Relays (Triacs)..................................................................................91
Auxilliary Output for Fill active and Beacon lights ............................................91
GPIO wiring for remote push to start .................................................................91
C5000 K-Factor Board.........................................................................................93
Temperature Pressure Board..............................................................................94
Dispenser Spare Part......................................................................................... 94
Main Dispenser Spare Parts ...............................................................................95
Main Dispenser Parts Location...........................................................................96
Other Dispenser Parts Not Shown in Drawing ............................................97
Hydraulic Module Parts.......................................................................................98
Troubleshooting............................................................................................... 100
End of Sale Indicators...................................................................................... 102

Document Control
Error Codes....................................................................................................... 104
MODBUS Registers........................................................................................... 106

1.
Safety
Safety
DANGER PRECAUTIONS
You must adhere to the following safety precautions at all times when working on the
Compac equipment. Failure to observe these safety precautions could result in
damage to the dispenser, injury, or death.
Make sure that you read and understand all safety precautions before operating the
Compac equipment
Failure to take adequate safety precautions could result in explosion, injury and loss of
life.
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 line before using.
▪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.
▪Ensure the service area is thoroughly cleaned before initiating service on CNG
components. Dust and dirt entering the components reduce the life span of the
component and affect future operations.

2.
Safety
Electrical Safety
Observe the following electrical precautions:
▪Always turn off the power to the CNG Dispenser before removing the box lid.
Never touch wiring or components inside the CNG Dispenser with the power
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. The Compac CNC dispenser is
designed to provide safe and reliable dispensing of CNG fuels. They are
available in either single or dual hose configurations and with different flow
rates.
▪Compac CNG dispensers are controlled by a C5000 board which has many
programmable features to suit your individual operation.

3.
Introduction
Introduction
The Compac CNC dispenser is designed to provide safe and reliable dispensing of CNG
fuels. They are available in either single or dual hose configurations and with different
flow rates.
Compac CNG dispensers are controlled by a C5000 board which has many
programmable features to suit your individual operation.
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.

4.
Refuelling Modes
Refuelling Modes
Fixed Pressure Refuelling
In this mode an over pressure limit is set in the Dispenser. If the pressure measured at
the pressure transducer is greater or equal to the limit the dispenser will end the fill.

5.
Installation
Installation
For Installation instructions, please refer to the Installation manual.
Commissioning
Electrical
This procedure outlines how to perform an electrical operational test before carrying out
full mechanical commissioning, making sure that the dispenser is functioning correctly.
Check for any damage that may have occurred in transit. Check all terminals, plugs, and
chips to make sure that they are securely in place.
NOTE: 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 hold.
The dispenser is in a ready state once the hold is finished, and the display
shows 0.00.
3. With the dispenser in a ready state.
Press the Start button.
The display will show 888888 and the solenoids energise, initiating a fill.
On the K factor board check that the output leds T1 T2 and T3 turn on,
indicating a signal is being sent to the triacs to open the solenoid valves.
The diagnostic LED (D9) 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.
4. 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 10 seconds. This is a default time-out setting
in the software for situations when there is no gas flow registered.
5. 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.

6.
Commissioning
Mechanical
At the mechanical commissioning stage, the dispenser should not be pressurised.
NOTE: If you find any leaks during commissioning, immediately close all the valves and
de-gas the dispenser.
To perform a mechanical test:
- Make sure that the inlet shut-off valves are closed. (These are the valves in the
inlet lines at the base of the dispenser, but they are not part of the dispenser.)
- Check all dispenser fittings, especially the inlet connections, to make sure that
they are tight.
DANGER: Always de-gas the lines before tightening any fittings. Never tighten fittings
while they are under pressure.
- 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.
- Turn on the dispenser and wait for it to power up.
The dispenser initially displays holD.When it is ready, 0.00 is displayed.
- Press the star button.
NOTE: 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 10 seconds if no flow is detected.
- 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.
- Once the inlet valves are fully open, allow the dispenser to time out on the 10
second no-flow timer and shut the solenoid valves, or manually shut it down
and close the solenoid valves by pressing the stop button.
- Press the start button on the dispenser.
NOTE: If you are commissioning a dual hose dispenser, only press the Start button for
one of the hoses.
- 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.
- Repeat steps 8 and 9 for the second hose on a dual hose dispenser.
- Once the outlet isolation valves are fully open, allow the dispenser to time out on
the 10 second no-flow timer and shut the solenoid valves, or manually shut it
down and close the solenoid valves by pressing the stop button.

7.
Commissioning
The dispenser and hose(s) are now fully pressurised.
- Use soapy water to check all fittings (including the hose fittings) for leaks.
DANGER: Always de-gas the lines before tightening any fittings. Never tighten fittings
while they are under pressure.
- Complete a few fills on a test cylinder, checking for leaks or unusual operation.

8.
Dispenser Set-Up
Dispenser Set-Up
Parameter Switch
The Parameter switch is located on the K factor board behind the main display and
allows you to adjust the unit price, hose number, Pump settings high low cut off and
display setting.
The Parameter switch also enables you to view the Dispenser Software Version and
End of Sale Indicators.
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.
The *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.














 








  
 

























 







































 





















 












 












 


 




























Parameter button
K-Factor button

9.
Dispenser Set-Up
Setting
Price Display
Litres Display
Software Version
P**.**.**
P**.**.**
Pump Number
Pna *** or pnb ***
Price
Pa**.*** or pb**.***
Pump Settings
Ba **** or bb ****
Low-flow cut off
Lfa ***
High-flow cut off
xfa ***
Heat of compression
hCA**
b Setting
B ****
Slave display
D5 ****
Custom display
Dc ****
Dp
Du
Last Sale
**.**
A ***.*or b ***.*
Electronic Totes
LA **** or da ****
lb **** or da ****
L****.**
d****.**
How to View the Software Version
Pressing the parameter switch once will show the software version.
The dispenser will then run through a segment test.
P01.00.00
p01.00.00

10.
Dispenser Set-Up
Changing the Pump Number
If the parameter switch is continually depressed, the following menu to change the
pump number will appear. Each side must be numbered between 1-99.
NOTE: Entering a pump number 0 will disable the pump.to the pump controller
See Using the Dispenser Menus to edit these settings. Use the procedure for both side A
and B.
Unit Price
The unit price (PA)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.
The unit price can be set at the dispenser or set remotely via a POS or controller
NOTE: If the unit price is not set Error 3 will be displayed and the dispenser will
not operate.
To set the unit price:
- Make sure that the dispenser is idle, with the nozzle in its holster.
- Press and release the Parameter switch until the required unit price is
displayed (PA).
- Enter in the unit price.
pna 000
pa01.234

11.
Dispenser Set-Up
NOTE: Each press of the Parameter switch passes you over a digit in a setting, making
the digit blink. Holding the switch down for more than a second changes whichever digit
is currently displayed. If you want to pass over a setting without changing any digits,
keep pressing and releasing the switch.
- Let the menu time out so that the value and quantity amounts are displayed.