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.