Compac CNG User manual

Compac Industries Ltd.
52 Walls Road. Penrose. Auckland 1061, New Zealand.
PO Box 12 417 Penrose. Auckland 1642. New Zealand.
Tel: [phone] Fax: [phone] [email protected]
www.compacngv.com
Compac Industries Ltd.
52 Walls Road. Penrose. Auckland 1061, New Zealand.
PO Box 12 417 Penrose. Auckland 1642. New Zealand.
Tel: [phone] Fax: [phone] [e-mail]
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
www.compacngv.com
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
www.compacngv.com
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
www.compacngv.com
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
www.compacngv.com
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