Compac CNG User manual

CNG DISPENSER
SERVICE
MANUAL
CNG Dispenser Service Manual
Version 1.1.4
Date: 8th December 2017

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 C4000 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 C4000 processor, or
damages resulting from the inability to use the
Compac C4000 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 C4000 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 C4000 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 C4000
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 C4000 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 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.compac.co.nz
Copyright ©2015 Compac Industries Limited, All Rights Reserved

Document Control
Document Control
Document Information
Document Details
CNG Dispenser Service Manual
File Name and Location
G:\Masters\Manuals\Authorised Manuals\CNG
Manuals
Current Revision Author(s)
J Jang
Authorised By
W Zheng
Release Date:
27/01/2016
Revision History
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
1.0.9
12/06/2015
R Lacey
Added information about air
actuated valve supplement
1.1.0
21/07/2015
R Lacey
Included Isolation valve and
gas operated valve
servicing instructions
1.1.1
20/11/2015
H Kleyer
Updated C4000 Power
Supply diagram

Document Control
1.1.2
10/03/2016
H Kleyer
Updated manual for Mk2
C4000 Power Supply
1.1.3
10/03/2016
H Kleyer
Updated PID
1.1.4
22/01/2018
J Jang
Updated manual

1.
Contents
Contents
Conditions of Use................................................................................................. 1
Product Identification.......................................................................................... 2
Document Control................................................................................................ 3
Contents ............................................................................................................... 1
Safety ................................................................................................................... 4
Mechanical Safety..................................................................................... 4
Electrical Safety ........................................................................................ 5
Introduction.......................................................................................................... 6
Refuelling Modes ................................................................................................. 7
Dispenser Operation ............................................................................................ 8
Turning the Dispenser on ......................................................................... 8
Refuelling a Vehicle ............................................................................................. 9
Fast Fill Refuelling Process .................................................................... 10
Temperature Compensated Refuelling Process..................................... 11
Reading the Dispenser Totals................................................................. 12
Electronics ......................................................................................................... 13
C4000 Processor ..................................................................................... 13
Menu Options..................................................................................................... 15
Unit Price............................................................................................................ 16
To set the unit price:............................................................................... 16
Sequencing Rate................................................................................................ 17
Hose Number...................................................................................................... 18
To Set the dispenser hose numbers:...................................................... 18
Software Version HIA29.24.9CNG onwards:........................................... 18
Dispenser Software ........................................................................................... 19
To Identify the software Program Version Number:.............................. 19
End of Sale Indicators........................................................................................ 20
To View the End of Sale indicators:........................................................ 20
Dispenser Passcode .......................................................................................... 22
To Set the Dispenser Passcode: ............................................................. 22
To Disable the Dispenser Passcode: ...................................................... 22

2.
Contents
Troubleshooting................................................................................................. 23
Fault Codes ........................................................................................................ 25
Indicator LED’s................................................................................................... 27
Servicing ............................................................................................................ 31
Degassing the Dispenser........................................................................ 31
Schedules Servicing................................................................................ 32
Checking Dispenser Operation ............................................................... 33
Checking the Sealing of the Solenoid .................................................... 33
Checking the Setting and Sealing of the Regulator............................... 33
Checking the Over-Pressure Switch Operation (Fast Fill & Temperature
Compensated Units Only)........................................................................ 34
Checking the Dispenser for Leaks ......................................................... 35
Checking the Refuelling Hoe for Leaks .................................................. 36
Checking the Isolation Ball Valve Sealing and Operation ..................... 36
Checking the Three-Way Refuelling Valve Sealing and Operation ....... 37
Draining the Coalescing Filter ................................................................ 37
Filter Element Replacement......................................................... 38
Solenoid Valve Seal Replacement .......................................................... 39
Solenoid Coil Replacement..................................................................... 42
Complete Solenoid Valve Replacement.................................................. 43
Regulator Valve Seal Replacement ........................................................ 44
Isolation Valve Seal Replacement .......................................................... 46
Gas Operated Valve (option) Seal Replacement .................................... 48
Bleed Valve Replacement ....................................................................... 52
Pressure Relief Valve Replacement ....................................................... 52
KG80 Meter Replacement ....................................................................... 52
Compac Breakaway Seal Replacement ................................................. 53
Three-Way Refuelling Valve Seal Replacement..................................... 55
Compac Refuelling Valve Exploded View............................................... 57

3.
Contents
Refuelling Hose Replacement................................................................. 58
Power Supply Fuse Replacement........................................................... 58
Power Supply Replacement.................................................................... 60
Processor Board Replacement ............................................................... 61
Temperatuer Pressure Board Replacement (Fast Fill & Temperature compensation
Units Only) ............................................................................................... 62
Dispenser Software Upgrade/Replacement........................................... 63
Meter Replacement................................................................................. 65
Unserviceable Parts List ......................................................................... 65
Dispenser Calibration ........................................................................................ 66
Meter Calibration .................................................................................... 66
Pressure Transducer Calibration (Fast Fill & Temperature Compensated Units Only)
................................................................................................................. 68
Ambient Temperature Sensor Calibration.............................................. 69
Appendix ............................................................................................................ 70
Specifications .................................................................................................... 71
Model Specifications .............................................................................. 71
Technical Specifications......................................................................... 72
Component Specifications...................................................................... 74
Mechanical Drawings........................................................................................ 77
Dispenser Component Locator ............................................................... 77

4.
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.

5.
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 C4000 board which has many
programmable features to suit your individual operation.

6.
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 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.

7.
Refuelling Modes
Refuelling Modes
Fixed Pressure Refuelling
The fuel is dispensed through a fixed pressure regulator. When fuel flow reaches a
minimum rate. The fuel flow is shut off. Refer to Fixed Pressure Refuelling.
Fast Fill Refuelling
To enable fast refuelling, the pressure in the tank is measured then a small amount of
precisely measured fuel is dispensed into the tank and the pressure rise is measured.
From these figures, the volume of the tank is calculated, and the tank filled rapidly to
this level. When the tank is full the flow is shut off by a solenoid valve. Refer to Fast Fill
Refuelling Process.
Temperature Compensated Refuelling
In cold environments, a tank filled to maximum pressure may exceed its maximum
pressure if the temperature rises. To prevent overfilling, a thermometer measures
ambient temperature and reduces the maximum fill pressure to eliminate this
possibility. Refer to Temperature Compensated Refuelling Process.

8.
Dispenser Operation
Dispenser Operation
Turning the Dispenser on
When the power is applied to the dispenser, the display will show PA:Use and
count down from 60seconds. This start-up procedure ensures the dispenser is
functioning properly before gas is dispensed.
Dispenser will be ready to use when the display indicates 0.00
NOTE:Before starting a fill, the software checks the status of the Stop switch. If the
switch is latched on, the display will flash STOP and will not allow the fill to proceed
until the switch is reset. The switch can be reset by rotating the Stop switch in a
clockwise direction.

9.
Refuelling a Vehicle
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.
Appropriate personal safety equipment should be worn whilst refuelling a vehicle.
To refuel a vehicle
▪Press the start button or remove the nozzle from the holster to initiate a fill.
▪The display will show 888888 and clear, at this point both the gas and
value totals will display 0.00
▪Connect the refuelling nozzle to the vehicle.
▪Open the nozzle refuelling valve to commence filling.
▪The dispenser will emit a long beep signalling the end of the fill, at this point
the gas total display flashes Fin.
▪Close the refuelling valve.
NOTE: 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.
▪Disconnect the nozzle from the vehicle.
▪Return the refuelling nozzle to the nozzle holder.

10.
Refuelling a Vehicle
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:
▪Press the start button or remove the nozzle from the holster to initiate a fill.
oThe display will indicate 888888 then clear, at this point both the
gas and value totals will display 0.00.
▪Connect the refuelling nozzle to the vehicle.
▪The refuelling valve is opened and when flow is detected the solenoids shut
immediately. Pressure reading󰇛󰇜and amount dispensed󰇛󰇜is recorded.
▪The solenoids are opened and filling continues as follows:
oIf was less than 50bar󰇛󰇜, the fill will continue for 20
seconds.
oIf was greater than 50bar but less than 100bar󰇛  󰇜,
the fill will continue for 14 seconds.
oIf was greater than 100bar but less than 150bar
󰇛  󰇜, the fill will continue for 10 seconds.
oIf was greater than 150bar but less than 180bar
󰇛  󰇜r, the fill will continue for 6 seconds.
▪The solenoids shut and pressure reading󰇛󰇜and amount dispensed 󰇛󰇜
are recorded.
▪The amount of gas to completely fill the vehicle to FPA is calculated as
follows:

󰇛󰇜 󰇛 󰇜
󰇛󰇜
▪The dispenser fills to 
and stops. This is the end of the fill.

11.
Refuelling a Vehicle
Temperature Compensated Refuelling Process
The technical operation of a temperature compensated dispenser is as follows:
▪Press the start button or remove the nozzle from the holster to initiate a fill.
The display will indicate 888888 and then clear, at this point both the
gas and value totals will display 0.00.
▪Connect the refuelling nozzle to the vehicle.
▪The refuelling valve is opened and when flow is detected the solenoids shut
immediately. Pressure reading 󰇛󰇜and amount dispensed 󰇛󰇜are
recorded.
▪The compensated fill pressure Ptc is calculated. If the vehicle is within 20 bar
of this pressure, no filling takes place.
▪The solenoids are opened, and filling continues as follows:
oIf was less than 50bar󰇛󰇜, the fill will continue for 20
seconds.
oIf was greater than 50bar but less than 100bar
󰇛  󰇜, the fill will continue for 14 seconds.
oIf was greater than 100bar but less than 150bar
󰇛  󰇜, the fill will continue for 10 seconds.
oIf was greater than 150bar but less than 180bar
󰇛  󰇜r, the fill will continue for 6 seconds.
▪The solenoids shut and pressure reading 󰇛󰇜and amount dispensed 󰇛󰇜
are recorded.
▪The amount of gas 󰇛󰇜to completely fill the vehicle to 
is calculated as
follows:

󰇛󰇜  󰇛
󰇜
󰇛󰇜
▪The dispenser fills to 
and stops. This is the end of the fill.

12.
Refuelling a Vehicle
Reading the Dispenser Totals
To read the dispenser totals:
▪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:
dFollowed by a 10-digit total (eg. d**********).
The dispensed quantity will then be shown next and will be displayed for 10
seconds.
This will be shown as:
LFollowed by a 10-digit total (eg. L**********).
NOTE: From software version HIA29.25.3CNG onwards the decimal place has been
removed from the tote. There will be 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.

13.
Electronics
Electronics
C4000 Processor
The Parameter switch is located on the C4000 processor board and allows you to
adjust the unit price, horse number, sequencing rate and password.
The Parameter switch also enables you to view the Dispenser Software Version and
End of Sale Indicators.
The Compac C4000 is a microprocessor-based circuit board designed for use in liquid
and gaseous fuel metering. One C4000 head is used for a single or dual LPG
dispenser. The C4000 accepts inputs from the V50 meter. It converts the V50 meter
output to litres, which are corrected to litres at 15°C and displayed with the price and
total of the sale on the retail LCD display.
NOTE: Wait at least 30 seconds from powering up the C4000 before starting a fill.
Failure to do this will result in a "density” error.
The parameter and K-Factor switches are used to configure the dispenser’s C4000
processor. Changes made can affect how the dispenser operates and can result in it
becoming inoperable. Only make changes when you understand what you are
changing.
The parameter and K-Factor switches are located on the C4000 board, which is in the
dispenser cabinet and covered by a metal panel. The K-Factor switch is sealed to
prevent tampering.

14.
Electronics
PARAMETER
K-FACTOR

15.
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.
The Xindicates 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 Password
To change the value of a selected digit, hold down the K-Factor switch. This will cause
the digit to cycle through (0,9). Releasing the K-Factor switch will select the digit.
The K-Factor switch must be resealed after use to prevent unauthorised access.
NOTE: Before altering any K-Factor switch settings, ensure the nozzles are hung up,
and the dispenser is idle.