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3. INSTALLATION AND SETUP

©2014 Kraus Global Ltd.
Retail CNG Dispenser Manual

13



All dispensers must be equipped with an
emergency shut-off device that will

terminate the gas supply to the dispenser

in the event that the dispenser is upset or
sheared from its foundation for any

reason.



All dispensers must only be used for gas

compositions specified within

SAE J1616:

Recommended Practice for Compressed

Natural Gas Vehicle

.

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Summary of Contents for Optima

Page 1: ... 2014 Kraus Global Ltd Retail CNG Dispenser Manual i OptimaTM Dispenser Owner s Manual Kraus Global Ltd 25 Paquin Rd Winnipeg Manitoba Canada R2J 3V9 Ph 204 663 3601 ...

Page 2: ...merica American Society of Mechanical Engineers ASME Boiler and Pressure Code American Society of Mechanical Engineers ASME B31 3 Process Piping Canadian Gas Association CGA B108 NGV Refueling Stations Installation Code Canadian Standards Association CSA C22 1 Canadian Electrical Code CEC Part I National Fire Protection Association NFPA 52 Standard for Compressed Natural Gas CNG Vehicular Fuel Sys...

Page 3: ...enser hose safety 9 2 4 Maintenance safety 10 2 5 Leak test safety 11 3 INSTALLATION AND SETUP 12 3 1 Installation guidelines 12 3 2 Pre installation 14 3 2 1 Site preparation 14 3 2 2 Uncrating the dispenser 15 3 2 3 Lifting and anchoring the dispenser 16 3 3 Installation 17 3 3 1 Electrical and communication connections 17 3 3 2 Pressure line connection 17 3 3 3 Filters 18 3 3 4 Attaching the ho...

Page 4: ... 4 Component maintenance 38 4 4 1 MICON mainboard 38 4 4 2 KAF 402 solenoid inlet valve 39 4 4 3 Inline filters 39 4 4 4 Air purge system 40 5 TROUBLESHOOTING 41 5 1 MICON fault codes 41 5 2 System fault codes 45 5 3 Dispenser issues 45 5 3 1 Voltage statuses 49 APPENDIX 1 A 1 Component descriptions and specifications 1 Air purge system components 1 Power supply 5 Air purge system authorization re...

Page 5: ...CONTENTS 2014 Kraus Global Ltd Retail CNG Dispenser Manual v This page intentionally left blank ...

Page 6: ...CONTENTS 2014 Kraus Global Ltd vi Retail CNG Dispenser Manual This page intentionally left blank ...

Page 7: ...ot be relied upon for such purposes Neither Kraus Global Ltd nor any of its employees or agents are your professional advisers You should assess whether you require such advisers and additional information and where appropriate seek independent professional advice Kraus its subsidiaries and affiliates are not responsible in any manner for direct indirect special or consequential damages however ca...

Page 8: ......

Page 9: ...This manual is divided into five chapters 1 INTRODUCTION This chapter provides general information about this manual and the Retail CNG Optima dispenser 2 SAFETY This chapter provides general installation operation and maintenance safety guidelines 3 INSTALLATION AND SETUP This chapter provides installation and configuration guidelines and procedures for the Retail CNG Optima dispenser 4 OPERATION...

Page 10: ...ontrol Drawing MNG0002 MNL Engineering package o Flow schematic o Electrical schematic o Construction drawings Final inspection checklist Quality control notices Quality control information packages If you are missing any of the documents listed above or require additional assistance at any time please contact Technical Support 1 3 Contact information Kraus Global Ltd 25 Paquin Road Winnipeg Manit...

Page 11: ...or provides helpful tips and other advice on proper equipment installation usage and maintenance ATTENTION This indicator provides important notifications about the dispenser and its components CAUTION This indicator provides critical warnings that may help prevent human injury and equipment damage 1 5 Warranty information For questions or concerns regarding dispenser warranty policies please cont...

Page 12: ...e or Dual 1 7 Dispenser theory of operation This section explains how Kraus MICON NEXTGEN 1 0 pump controller and KAF 402 solenoid valves operate to control gas flow within CNG dispensers 1 7 1 MICON NEXTGEN 1 0 Kraus MICON NEXTGEN 1 0 pump controller is an inexpensive alternative to using PLC units for operating fuel dispensers For CNG dispensers the MICON takes readings from the mass flow meter ...

Page 13: ... mid and high bank The low bank holds approximately 70 of the total volume of storage while the mid and high banks hold 20 and 10 respectively Upon authorization the MICON will open all three banks for 4 seconds to ensure there is sufficient gas flow to continue with the fill The banks will then close for another 4 seconds for the target fill calculation Once the target fill pressure is calculated...

Page 14: ...A single hose Retail CNG Optima dispenser Please refer to the Engineering package for a view of internal components ENCRYPTED KEYPAD LIFTING LUGS HOSE MANIFOLD VENT LINE BREAKAWAY MAIN LINE BREAKAWAY PRICE VOLUME PRICE PER UNIT DISPLAY PRESSURE POS DISPLAY HOSE NOZZLE CARD READER ENCRYPTED KEYPAD ...

Page 15: ...sers Do not smoke or allow open flames and naked lights within 15 feet or 5 meters of any gas installation Do not adjust remove or bypass any protective devices Electrical equipment and its protection must comply with the regulations applicable to the hazard of the location Transportation installation commissioning operation maintenance and repairs should only be carried out by qualified personnel...

Page 16: ...e placed in park or the emergency brake is applied for all manual transmission vehicles before allowing any fueling transactions Ensure that all vehicle ignitions electrical systems and radios including short wave communication equipment are shut off before allowing any fueling transactions Ensure the fuel receptacle is inspected and matches the dispenser filling nozzle before attempting any fueli...

Page 17: ...through the jacket o Spring guards are missing or detached from couplings o Couplings and spring guards show evidence of slippage or looseness Do not exceed the maximum recommended working pressure of the hose 5 000 psi 345 bar Do not twist kink or torque the hose assembly Never attempt to repair or re couple a damaged hose Do not use a strength member for pulling or lifting equipment ATTENTION Th...

Page 18: ...d by the inspection authority The dispenser must be powered off and completely vented unless otherwise specified Never perform welding processes near gas systems Always cover disassembled parts and openings with a clean rag paper or adhesive to keep them clean and avoid contamination Do not clean any parts with flammable solvent Clean and rinse all parts carefully with compressed air Be sure to we...

Page 19: ...penser ADVICE Never allow problems to go unreported Both your company and supplier will benefit from the full disclosure of all dispenser issues 2 5 Leak test safety Please observe the following guidelines before performing leak tests on Kraus manufactured CNG dispensers Ensure the area surrounding the dispenser being serviced is closed off to all customers and unauthorized personnel Use any appro...

Page 20: ...he dispenser pit to properly tie in the gas lines to the inline filters and manual isolation valves Where soil displacement is apparent gas connections upstream of the dispenser must be made with flexible hoses The dispenser frame enclosure must be securely bolted to a concrete foundation or to a structural steel base Adequate support must be provided for each unit of the dispensing system indepen...

Page 21: ... with an emergency shut off device that will terminate the gas supply to the dispenser in the event that the dispenser is upset or sheared from its foundation for any reason All dispensers must only be used for gas compositions specified within SAE J1616 Recommended Practice for Compressed Natural Gas Vehicle ...

Page 22: ...e in the gas lines to the inline filters and manual isolation valves Make provisions for tubing and electrical conduits prior to pouring the concrete pad Filters must be installed upstream of the dispenser Due to potential weld slag filings rust dirt and water dispensing lines should be purged to the atmosphere at the dispenser This can be done by blowing nitrogen through the lines All dispensing ...

Page 23: ...te for any damages that may have occurred during shipping If any damages are found o Take pictures of the damages o Note the damages o Contact Kraus 2 Starting with the top panel remove all screws and or nails and detach the top panel Repeat this process to remove all side panels 3 Remove all protective wrapping by hand knives and other sharp objects may damage the dispenser 4 Inspect the dispense...

Page 24: ...levises 3 Hoist the dispenser off the pallet with a suitable forklift or crane and carefully move the dispenser over the dispenser pit 4 Ensure the area directly below the dispenser is free of electrical wires tubing and other obstacles 5 Lower the dispenser slowly into the pit 6 Fasten the dispenser to the pit frame or concrete base with at the minimum NC Grade 8 steel bolts with Grade 8 steel wa...

Page 25: ... labeled ELECTRICAL is provided to allow optimum protection and direct routing to the explosion proof junction box Please refer to the electrical schematic within the Engineering package for electrical connection specifications Communication An electrical conduit labeled COMMUNICATION is provided in the lower cabinet for all communication wiring This conduit allows direct routing to the upper cabi...

Page 26: ...nd on the configuration of the dispenser High flow dispensers require large filters that may be placed in one of the following locations In the dispenser pit if it is large enough to house the filters while providing enough room to drain and change filter elements Upstream of the dispenser pit on the dispenser supply lines between the priority panel and the dispenser See Figure 1 below for high fl...

Page 27: ...3 INSTALLATION AND SETUP 2014 Kraus Global Ltd Retail CNG Dispenser Manual 19 Figure 1 High flow filter placement ...

Page 28: ... leak tight It is considered good practice to use pipe sealants on fittings prior to connecting the filter housing ports Ensure the filters are visible and easily accessible for periodic draining and maintenance Install the filters on a level pipeline and mount vertically Be sure to leave one bowl length of clearance to allow for element removal Ensure that fittings are always inspected during ser...

Page 29: ...efects or damages that may have occurred during shipment NOTE Never use defective or damaged hoses If a defect or any damage is found contact Technical Support immediately 3 Attach the main line to the hose manifold located on the side along the top of the dispenser Hose manifolds may be on both sides depending on the dispenser s hose configuration 4 Hand tighten the main line fitting to the manif...

Page 30: ...on Reconnecting procedure 1 Vent the dispenser system and hose assembly before attempting any reconnections Please refer to Section 4 2 Maintenance for dispenser venting procedures 2 Clean dirt debris and other obstructions from both sides of the breakaway unit 3 Inspect both parts of the breakaway unit Ensure that O ring seals are not damaged NOTE Never reconnect assemblies if any components are ...

Page 31: ...y purposes the upper cabinet must maintain a positive air pressure A purge switch and timer are used to trigger automatic system shutdowns and startups If the Magnehelic gauge displays a pressure lower than 0 15 dispenser electronics may not function You may need to increase the purge fan pressure or inspect the cabinet and air purge system for leaks 4 Turn on the power to the dispenser from the b...

Page 32: ...e pressure reading on the Secondary Display 3 Slowly open the inlet valve and allow 100 psi of gas to fill the dispenser NOTE Pressure may be monitored through the digital pressure gauge on the Secondary Display or the mechanical gauge attached to the sensor vent manifold 4 Close the inlet valve and flip the authorization handle to the OFF position once the pressure gauge indicates 100 psi 5 Apply...

Page 33: ... 1 Turn off the power to the dispenser from the breaker box 2 Open the upper cabinet You may need the dispenser keys to unlock the cabinet door 3 Retrieve the Manager keypad from inside the upper cabinet The Keypad is a flat magnetic keypad connected to a cable it may be found attached to the inside wall of the upper cabinet 4 Connect the keypad to the pin connector labeled KEYPAD 2 located direct...

Page 34: ... door to close while allowing use of the keypad see Figure 3 6 Ensure the cabinet door is closed and fully sealed NOTE Dispenser electronics will not function if the upper cabinet is not sufficiently pressurized 7 Turn on the power to the dispenser at the breaker box NOTE The keypad is now ready for use you may need to allow all power up sequences to complete before proceeding ...

Page 35: ... Wire Mode and save setting 4 Press the DOWN key once The display should now read 2WR ID A 5 Enter the desired Hose 1 address a value from 1 256 Press START key to save setting Figure 4 shows the display for Hose 25 address 6 Press DOWN key once The display should now read 2WR ID B 7 Enter the desired Hose 2 address a value from 1 256 Press START key to save setting 8 These settings will not take ...

Page 36: ...3 INSTALLATION AND SETUP 2014 Kraus Global Ltd 28 Retail CNG Dispenser Manual 3 4 5 Configuring the POS System Preliminary view Additional features to be included later ...

Page 37: ...ss allows for traceable verification and ensures a systematic approach to minimizing any commissioning oversights A commissioning sign off sheet is included within your dispenser package This form must be completed signed and sent to Kraus Global Ltd within 30 days of commissioning otherwise the warranty may be voided Complete forms may be mailed or faxed to Kraus Global Ltd using the following in...

Page 38: ...t the refueling nozzle from the holder 5 Connect the refueling nozzle to the vehicle receptacle 6 Follow the prompts on the POS display you may be required to complete a payment transaction before a fill can be authorized 7 Turn the valve on the nozzle to FILL 8 Flip the authorization handle up to the ON position fueling will begin after a three second beep ATTENTION Note the following during gas ...

Page 39: ...e main application when running in programming mode Each MICON control board has a unique root access username and password that is programmed at the factory While in programming mode configuration parameters in the manager menu and pricing menu are also enabled The price per unit line of the primary display will display CFG in the lower left corner to indicate that the board is in programming mod...

Page 40: ...ng mode This allows a user to connect via serial and login to perform software updates or other maintenance tasks Programming Mode Switch Figure 3 4 Programming Switch Location After shutting down the dispenser ensure that the area is known to be safe and free of hazardous gasses before opening the dispenser If the environment cannot be reliably verified as being safe then allow at least 5 minutes...

Page 41: ...ls This connection is highlighted below in Figure 3 5 4 Feed the keypad cable through the top of the dispenser door Close the door over the cable The door should seal around the cable 5 Restore power to the dispenser The purge system timer will restore power to the MICON after the internal pressure is adequate and enough time has elapsed for several air turns to have occurred If power does not res...

Page 42: ...CON enclosure located in the centre of the dispenser If the dispenser has already been sealed by a weights and measures inspector it may be necessary to break the lead seals 4 Toggle the programming switch located at the center of the intrinsic safety module Please see Figure 3 4 The switch should be in the rightmost position 5 Replace the sealing bolts and close the dispenser door Disconnect the ...

Page 43: ...hours and other times when the dispenser will not be in use Ensure that all valves gauges and displays are free of obstructions Clean the dispenser on a regular basis Avoid using pressurized water Perform daily checks for signs of leakage Perform leak inspections of all hoses and fittings every six months with an approved leak detector fluid Ensure that all leaks are repaired by qualified personne...

Page 44: ...vessels to the dispenser 6 Slowly loosen the vent valves at least 3 to 4 turns to vent the trapped gases in the dispenser NOTE Read the pressure gauges to confirm the gas is being vented CAUTION Do not touch any venting pipes throughout this procedure Rapidly expanding gases may cause sub zero temperature drops within the vent stacks which may cause cold burns NOTE At this point only gases upstrea...

Page 45: ...indicate a leak Be sure to note or mark the locations where leaks are found 4 If leaks are found vent gas from the dispenser see Dispenser venting procedure and proceed with repairing the leak CAUTION If a leak appears downstream of a sequencing valve you must authorize a fill to vent the trapped gas Continue authorizing a fill until the pressure gauge reads 0 psi and all venting sounds have cease...

Page 46: ...s section provides guidelines and important notifications regarding the maintenance of vital dispenser components 4 4 1 MICON mainboard ATTENTION Should the MICON Mainboard or any other circuit board need replacing please contact Kraus Global Technical Support at 204 663 3601 ext 212 ...

Page 47: ...F 402 solenoid valves for any maintenance or reparation purposes They are sold separately from any dispenser systems please contact our sales or technical support department at 204 663 3601 ext 212 for any questions 4 4 3 Inline filters CNG filtering is a balanced continuous and steady state condition occurring at or below rated flow In order to maintain high efficiency filtration for your CNG dis...

Page 48: ...y cause explosion The air purge system uses a purge fan to maintain a positive air pressure of at least 0 15 inches of water in the upper cabinet otherwise the dispenser system is automatically shutdown A Magnehelic gauge located in the lower cabinet is used to monitor this pressure Purge fan filter maintenance guidelines Inspect and clean the purge fan filter once a month To clean rinse the filte...

Page 49: ...es a list of fault code clearing procedures and Table 5 2 provides a list of fault code summaries with appropriate troubleshooting suggestions When a fault occurs any current transaction will be ended and the MICON will enter the error state While in the error state the fault code is displayed The current transaction details can be obtained via the console and will also be displayed again once the...

Page 50: ...to the ON position OR activate the manual reset switch MRST OR write to the corresponding error bit in the Modbus register mapping E 76 E 96 1 Correct the source of the error See Table 5 2 2 Activate the manual reset switch MRST E 97 1 Correct the source of the error See Table 5 2 2 Flip the authorization handle down to the OFF position then back up to the ON position OR activate the manual reset ...

Page 51: ...hen the dispenser is static then replace transmitter If pressure reading is not fluctioating but is reading differently than the pressure gauge check that the MICON pressure full scale setting matches the full scale of the transmitter 78 AT RANGE Ambient temperature sensor out of range Ambient temperature sensor has gone outside of the MICON operating temperature range 40o C to 50o C If the temper...

Page 52: ... internal error An internal mass flow error has occurred Check log file for meter internal error code Reboot dispenser If problem persists or reoccurs replace mass flow meter 97 CONS COM Console communications error An error has occurred with the console POS communications system Check console communications wiring Check to make sure that console communications modules in the junction box are powe...

Page 53: ...se refer to Table 5 3 for all troubleshooting matters Please contact our Technical Support Department at 204 663 3601 ext 212 for any issues not covered in Table 5 3 below CAUTION Only trained and qualified service personnel should attempt any troubleshooting and service work to any CNG electrical and mechanical components ...

Page 54: ...in storage Vehicle fill line valve is closed Inspect vehicle fill line valve Low bank inlet valve is stuck closed Rebuild low bank solenoid valve contact Tech Support for more information Low bank coil is faulty Rebuild low bank solenoid valve Price volume display does not reset upon authorization Authorization handle proximity switch is faulty or disconnected Inspect the functionality of componen...

Page 55: ...lve remains open during temperature compensation target fill calculation Rebuild low bank solenoid valve Dispenser overfills vehicles MICON parameters are not properly configured Review MICON configurations You will require for this procedure contact Tech Support for more information Temperature probe is not reading correctly Compare displayed temperature to actual ambient temperature If there are...

Page 56: ...meters Tech Support for more information Pressure transmitter is faulty Replace pressure transmitter contact Tech Support for more information Pressure gauge does not correspond with vehicle gauge Pressure transmitter is faulty Replace pressure transmitter contact Tech Support for more information Faulty vehicle gauge Observe the pressure of the dispenser pressure gauge vehicle pressure gauge and ...

Page 57: ... your dispenser issues please contact our Technical Support Department for further assistance 1 204 663 3601 ext 212 Table 5 4 Voltage Status Table COMPONENT VOLTAGE STATUS AUTHORIZATION Component Reading position Voltage handle OFF Voltage handle ON Authorization proximity switch n a 5V DC 0V DC COMPONENT VOLTAGE STATUS PULSE Component Reading position Voltage Frequency during fuel delivery CNG05...

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Page 59: ... 50 60 Amps 1 85 2 05 RPM 1320 1430 CFM 549 Free Air 60HZ Purge fan ducting installation guidelines Depending on site and atmospheric conditions condensation may form in the ducting from the purge fan to the dispenser cabinet as well as in the cabinet enclosure itself This is caused by excessive moisture in the purge air supply Since conditions vary from site to site it is not possible to address ...

Page 60: ...he higher the risk of condensation given the increased time for purge air to cool within the ducting Both temperature differential and run length should be considered together In some cases it may not be possible to eliminate condensation within the purge air ducting due to site conditions and climate A common solution is to slope the ducting into a sump pit along its run Accumulated condensate wi...

Page 61: ...ressure protection note Temperature limits 20 to 140 F 6 67 to 60 C Size 4 101 6mm diameter dial face Weight approx 3 25 lb 1 5 kg Approvals CE UL CSA FM Pressure switch The Dwyer 1950 Series Pressure Switch operates as the trigger that initiates power to all dispenser electronics The pressure switch is located in the lower cabinet and is programmed to detect a specific level of air pressure which...

Page 62: ... relay which sends the signal to the terminal hub in the upper cabinet Specifications H3YN 2 4 4 Z H3YN 21 41 41 Z Time ranges 0 1s to 10 min 1s 10s 1 min 10 min max 0 1 min to 10 h 1 min 10 min 1h 10h max Operating mode ON delay interval flicker OFF start flicker ON start selectable with DIP switch Accuracy of operating time 1 FS max 1 s range 1 10 ms max Setting error 10 50 ms FS max Reset time ...

Page 63: ...ay The TE Connectivity K10P 11A15 120 and K10P 11D55 24 General purpose Relay is used for various dispenser applications Two 110 120V AC relays are used to receive signals from the pressure timer and transmit signals to the terminal hub where electrical power is distributed to all dispenser electronics These relays are located beside the pressure timer in the lower junction box They are part of th...

Page 64: ...ch accuracy 2 3 0 50 of batch Repeatability 2 0 30 of rate 1 CNG with SG 0 66 at 60 F 15 5 C and 14 73 psia 1 bar a 2 In terms of percent of total batch delivered on CNG 3 Accuracy is under typical CNG batch dispensing conditions Typical batch dispensing conditions are defined as those where the flow rate is greater than 4lbs min or 109kg hr Pressure ratings psi bar Flow tube rating 5 000 345 Pres...

Page 65: ...sweep 5 to 2 000 Hz 50 sweep cycles at 1 0 g Weight Sensor with core processor 16 lbs 7 kg Sensor with integrally mounted transmitter 18 lbs 8 kg Materials Wetted parts 1 316L stainless steel Sensor housing 304L stainless steel Core processor housing CF 3M stainless steel or polyurethane painted aluminum NEMA 4X IP65 1 General corrosion guidelines do not account for cyclical stress and therefore s...

Page 66: ...pproved by the CSA designed to the ASME code and complies with NFPA 52 and CGA B108 standards The KAF 402 E is TÜV and ATEX approved and complies with European PED standards Technical data N E Operation 2 way solenoid valve normally closed Design pressure 5 000 psi 345 bar Operating pressure range TÜV approved values 73 to 5 000 psi 5 to 345 bar Test pressure 6 000 psi 414 bar Burst pressure 25 00...

Page 67: ...601 ext 212 Type 1 nozzle The Type 1 nozzle incorporates an integrated vent valve that allows for safe venting and detaching in a single motion WEH TK16 Type 1 nozzle for NGV1 applications OPW CT1000S Type 1 nozzle for NGV1 applications WEH TK17 Type 1 nozzle for NGV1 applications OPW CT5000S Type 1 nozzle for NGV2 applications Type 2 nozzle The Type 2 nozzle must be coupled with an external vent ...

Page 68: ...f debris or liquids from newly installed pressure lines may be present EVERY 2 WEEKS Inspect fill nozzle seals for leaks and wear Inspect flow control or sequencing valves during filling operation Inspect the sequencing valves for leaks Inspect fill hoses and hose breakaway components EVERY 6 MONTHS Change dispenser filters Dispenser leak test Visual leak inspection of pressure relief device if in...

Page 69: ...s The storage banks are used sequentially in a pre determined sequence CNG Compressed Natural Gas an environmentally friendly fuel alternative to petrol gasoline diesel and propane CNG050 A mass flow meter consisting of transmitters and sensors designed to measure CNG flow manufactured by Micro Motion Coalescing filtration A filtration method that separates water aerosols and droplets as well as s...

Page 70: ...fuel station attendants to control and authorize fuel dispensers from their terminal Also includes a user interface that incorporates a card reader keypad and screen display that allows customers to make retail transactions at the dispenser Positive pressure An air pressure greater than that of its surrounding environment used as an engineering technique to isolate an area from outside contaminant...

Page 71: ...cles Solenoid valve An electromechanically controlled valve for CNG dispensers it is used to control gas flow from the storage banks to a vehicle receptacle Split flow A single fuel dispenser with one hose designed for a standard flow filling system and another designed for a high flow filling system Split pressure A single fuel dispenser designed to dispense fuel at two different pressure options...

Page 72: ......

Page 73: ...enance 32 Particulate 18 placement 18 purge fan 37 size 18 G gauge Magenhelic 22 37 Appendix 1 pressure 22 23 33 grounded 10 I Intended users see users K keys 15 24 35 L lockout 24 M menu Diagnostic Startup Menu 27 MICON NEXTGEN 1 0 4 see MICON MICON 35 38 N notifications 3 P pit frame 14 16 pump door node 24 26 purge fan 22 37 Appendix 1 Purpose 1 S SAE J1616 13 screw thread 16 storage system s b...

Page 74: ...This page intentionally left blank 2014 Kraus Global Ltd All Rights Reserved Printed in Canada ...

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