Professional Documents
Culture Documents
FuelMaker Corporation
70 Worcester Road, Toronto, Ontario, Canada M9W 5X2
Technical Support (North America): 1-800-263-8569
Technical Support (International): +1-416-674-3034 (extension 258)
Internet: www.fuelmaker.com
SAFETY INSTRUCTIONS
PLEASE READ CAREFULLY
The FMQ-8-36 / FMQ-10 / FMQ-7-42 Vehicle Refueling The VRA is for use with Natural Gas only and shall not be
Appliance (VRA) Modules (Control Module, used for any purpose other than the refueling of cylinders
Compression Module, Electronics Module, Motor certified for gas storage at a pressure of 20.7 MPa (3000
Module) shall only be field-replaced by personnel psi) or higher for the Model FMQ-10, 24.8 MPa (3600 psi)
specifically trained and authorized by FuelMaker or higher for the Model FMQ-8-36, or 31.0 MPa (4500 psi)
Corporation. or higher for the Model FMQ-7-42. Attempts to use the
VRA for any other purpose could result in serious
Do not attempt to dismantle the modules or tamper with injury.
any components. To do so will void all warranties and
could result in serious injury. The VRA may be used for residential, commercial and
industrial applications only in accordance with the
requirements of the authorities having jurisdiction.
2. READ INSTRUCTIONS CAREFULLY
Do not run vehicle engine while refueling and ensure all
Please read this manual carefully and those of other ignition sources are OFF (including pilot lights in
equipment supplied prior to installation and operation. recreational vehicles). Do not smoke or bring an open
flame within 3 m (10 ft.) of the vehicle being refueled.
If you experience any difficulties or are unsure about any
feature, contact FuelMaker’s Technical Support Group at :
5. IF YOU SMELL GAS
1-800-263-8569 (North America)
+1-416-674-3034 extension 258 (International) Shut off the manually-operated valve in the gas supply to
the VRA. If possible, close the manual gas valve of the
storage cylinder being refueled. Extinguish any open
3. LOCATION OF THE VRA flames. Contact an authorized service representative.
TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................................................................ 1
3 INSTALLATION .......................................................................................................................................................... 2
7 SERVICE…………. .......................................................................................................................................................... 18
1 INTRODUCTION
The FuelMaker model FMQ-10, FMQ-8-36, and FMQ-7-42 The VRA is air-cooled and is rated for an operating ambient
Vehicle Refueling Appliances (VRAs) are self-contained oil- temperature range of -40ºC to +46°C (-40°F to +115°F). Air
free outdoor appliances used for Natural Gas refueling of is drawn into the VRA through a set of louvers on the bottom
vehicles and storage cylinders. The VRA can be configured of the housing and is exhausted through another set of louvers
for remote time-fill applications by connecting to a Remote on the top of the housing (See Figure 2). The VRA has a
Fueling Panel (RFP) or for manifolded time-fill applications User Panel located at the front of the unit where the current
by connecting to one or more Auxiliary Fueling Panels operating status and error messages are displayed.
(AFP). The VRA can also be connected to a Fast-Fill Storage
System for use with fast-fill applications. The VRA has no capacity for connecting directly to a fuel
cylinder. Refueling is accomplished using one of several
The model FMQ-10 is designed to fill 20.7 MPa (3000 psi) ancillary devices connected to the VRA (see Appendix A).
fuel systems at a nominal flow rate of 17 m3/hr (10 scfm).
The model FMQ-8-26 is designed to fill 24.8 MPa (3600 psi) If a model FMQ-8-36 or FMQ-7-42 VRA is used to fill a
fuel systems at a nominal flow rate of 12.9 m3/hr (7.6 scfm). system designed to deliver fuel to a vehicle with a lower
The model FMQ-7-42 is designed to fill 29.0 MPa (4200 psi) pressure rating, a pressure compensating system must be
fuel systems at a nominal flow rate of 11.6 m3/hr (6.8 scfm). installed to ensure the vehicle cylinder is not over-
The VRA contains ambient temperature sensors which allow pressurized. Serious injury or damage to the equipment
the electronics module to determine the maximum may result if these precautions are not taken.
temperature compensated fill pressure the VRA will deliver to
the storage cylinder. This prevents over-pressurization of the
fuel cylinder should it warm up after being filled.
2 TECHNICAL SPECIFICATIONS
GAS FMQ-10 FMQ-8-36 FMQ-7-42
Maximum Discharge Pressure: 20.7 MPa @ 21°C (3000 psig @ 70°F) 24.8 MPa @ 15°C (3600 psig @ 59°F) 29.0 MPa @ 16°C (4200 psig @ 61°F)
Minimum Inlet Pressure: 6.9 kPa (1.0 psig) at rated flow * 6.9 kPa (1.0 psig) at rated flow * 6.9 kPa (1.0 psig) at rated flow *
Maximum Inlet Pressure: 8.6 kPa (1.25 psig) at rated flow 8.6 kPa (1.25 psig) at rated flow 8.6 kPa (1.25 psig) at rated flow
Nominal Flow Rate (60 Hz): 17.0 m3/hr @ 21°C and 8.6 kPa inlet 12.9 m3/hr @15°C and 8.6 kPa inlet 11.6 m3/hr @21°C and 8.6 kPa inlet
(10 SCFM @ 70°F and 1.25 psig inlet) (7.6 SCFM @ 59°F and 1.25 psig inlet) (6.8 SCFM @ 70°F and 1.25 psig inlet)
ELECTRICAL
MECHANICAL
Verify that the nameplate ratings of the VRA are compatible Ensure that the servicing clearances stated on the
with the electrical and gas supplies available. In Canada, the nameplate are maintained (See Figure 1).
VRA shall be installed in accordance with CGA 149.1, CGA
B108, C22.1 Canadian Electrical Code, Part 1 and with Avoid areas where damage from excessive ice build-up may
requirements of the authorities having jurisdiction. In the occur such as building overhangs or where vegetation, snow
United States, the VRA shall be installed in accordance with or debris may clog the inlet or outlet air louvers. Do not
NFPA 52 CNG Vehicular Fuel Systems, NFPA 70 National install the VRA beneath overhangs which can shed snow or
Electrical Code, NFPA 54 National Fuel Gas Code and with rain directly onto the unit.
requirements of the authorities having jurisdiction.
Do not install the VRA under or near a window or directly
The Installer shall instruct the User in the proper operation under potential gas accumulating overhangs or under/near
of the VRA and any approved ancillary devices. Before hot air exhaust from a building.
leaving the site, the Installer shall leave the Installation and
Mounting Holes
Side ½" diameter
0.6 m (2 ft.)
Side
0.6 m ( 2 ft.)
Front
0.6 m ( 2 ft.)
38.1 mm (1.5")
Port for Remote Shutter for Port for Remote Start Cable Air Intake
Panel (R410) Cable Electrical Cable (1/2” conduit knock-out for Louvers
conduit termination.) Mounting
Lid - Electronics Module Foot
REAR OF UNIT
Figure 2 VRA Exterior – Main Components
39.0046 3 Issue 7, July 2002
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
than 66 dBA (hemispherical field) at a distance of 5 m It is important to clean any contaminants such as cutting oil,
(16.5ft). Be aware that some local codes restrict the sound rust, and metal shavings out of the interior of the gas inlet
pressure level at the property line. Units should not be piping. Pipe dope and other sealing compounds must not
located where direct or reflected noise is aimed at enter the piping. Ream and debur all piping and tubing
neighboring windows or other building openings. Avoid before final assembly.
locating the unit near a sound reflecting surface or between
buildings which are close together. The VRA must be connected to the gas supply using 1" or
larger pipe (1-1/4" or larger with 7” w.c. option). In order
to prevent operation with excessively low pressures at the
Protection from Vehicle Impact gas inlet to the VRA (e.g. as a result of a partially closed
shut-off valve), the VRA has been equipped with a low-
If the VRA must be located where it may be struck, provision pressure switch.
must be made to protect the VRA from damage. Typically,
2m (7 ft) long, 100 mm (4 in) diameter concrete filled steel The VRA may shut down due to low inlet pressure when
posts spaced no more than 0.6 m (2 ft) apart are sunk 1 m other gas loads (e.g. furnace, water heaters, etc.) draw from
(3.5 ft) into the ground between the VRA and the flow of the gas supply system. The utility regulator set should be
traffic to act as a barrier against impact. Heavy squared provided by the local gas utility with the orifice/spring/
timbers may also be used. The local gas distribution utility setting appropriate for the maximum gas load that the system
should be consulted to determine what practice is locally will experience. The Installer shall ensure that the VRA and
accepted by the authorities having jurisdiction. integral low-pressure cut-off switch operate so as to prevent
a piping system pressure loss in excess of that specified in
CAN/CGA B149.1 Natural Gas Installation Code in Canada
3.3 INSTALLATION OF THE VRA or NFPA 54 in the United States.
It is extremely important to properly ream and debur all IMPORTANT: The low inlet pressure regulator upstream
tubing and pipe to prevent any potential restrictions to the of the VRA must be sized correctly for the rated flow.
flow of gas through the system. Ensure that all oil, metal Pressure at the inlet to the VRA must be in accordance
shavings and other debris are removed from the tubing with the rating plate specifications. Run the VRA while
before final assembly. simultaneously operating all major gas appliances on the
User's system in order to verify the regulator setting. If the
Mounting to Base VRA shuts down from low inlet pressure, the gas regulator
must be re-adjusted.
Prepare the base as explained in Section 3.2. The VRA is
equipped with adjustable leveling feet. The four feet can be
adjusted by turning the nut on the foot with a 1-1/8" hex High Pressure Gas Piping - Outlet Side:
wrench. A carpenter’s level may be placed on top of the Manifolded Time-Fill
unit to assist in the leveling operation. Lag Bolts (3/8" or
7/16") and anchors must be used to secure the VRA feet to The VRA has a 1/4" bulkhead compression fitting at the rear
the base; the locations of the mounting bolt holes in the VRA of the unit to connect to the refueling point through high
base are indicated in Figure 1. It is very important to bolt pressure outlet tubing. All tubing and fittings must be
the VRA to the base to prevent movement of the unit and to approved and must conform with CGA B108 in Canada or
prevent undue stress on the inlet piping. NFPA52 in the United States. The VRA is equipped with a
check valve to maintain the blowdown capacity of the unit.
Low Pressure Gas Piping - Inlet Side Refer to the Installation and Operating Instructions for the
refueling equipment.
The gas supply is connected to the VRA via an NPT nipple
provided (See Figure 2). A coupling and transition fittings The fill hose assembly must be equipped with an AGA/CGA
need to be field-supplied in order to adapt to the supply NGV1 Type 2 or 3 refueling nozzle that is approved for
piping system. Where the supply piping is fixed to a wall, a Natural Gas “Slow-Fill” applications. The nozzle must seal
flex connector may be required to prevent noise transmission reliably throughout the temperature range and conditions
into the building. A shut-off valve and test port are required anticipated for the location. An integral normally-closed
in the inlet piping to the VRA to facilitate servicing of the poppet valve in the nozzle is absolutely essential as it must
unit. maintain a positive pressure in the VRA’s blowdown system
at all times; air must not migrate up the fill hose and into the
39.0046 4
Issue 7, July 2002
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
blowdown vessel during standby. Vent Connection
AGA/CGA NGV1 Type 2 and 3 approved nozzles are A 3/8" NPT vent connection (See Figure 2) is protected
available from FuelMaker Corporation. The fill hose from blockage by ice or insects by a screen fitting. The
incorporates a fitting and a seal to connect the refueling Vent discharges any gas released by the pressure relief
nozzle. Various adapters are available from FuelMaker to valve in order to protect the blowdown system from over-
facilitate the attachment of various nozzles, including pressurization. If the VRA must be installed near building
angular or straight take-offs. The fill hose is pre-coiled to openings, a 10 mm (3/8") minimum inside diameter steel
allow it to be stored neatly. vent line (or equivalent) must be connected to the 3/8" NPT
vent connection and routed to a safe place for discharge as
required by local codes. The maximum allowable length for
At the completion of each refueling cycle the high pressure a 10 mm (3/8”) remote vent line is 5m (17 ft) to protect the
gas contained in the tubing inside the VRA is discharged into low pressure switch from over-pressurization. Be sure to
the blowdown vessel (See Figure 5). This procedure reduces transfer the screen fitting to the end of the remote vent line
the pressure at the outlet of the VRA allowing the (if applicable) to protect it from blockage. Contact
compression module to be safely restarted. FuelMaker if a longer remote vent line is required.
Field Wiring
CAUTION: The high pressure tubing is not blown down;
high pressure remains in the tubing and hoses at all The VRA has been wired at the factory and is ready for
times and caution must be exercised when servicing the connection to the customer’s electrical supply. Armoured
tubing, hoses, nozzles or high pressure fittings. cable consisting of two #8 gauge copper wires plus a ground
(AWG8) is recommended for bringing power from the main
electrical panel to the VRA. The cable must be routed inside
When VRAs are connected to a manifolded system with the VRA through the opening at the rear panel (see Figure 2)
AFPs or RFPs the line must be equipped with a Pressure to the electronics module (See Figure 4). There is a 3/4"
Relief Valve and Purge Valve. This will allow the fill hose opening at the rear of the electronics module dedicated to
to be reconnected in the event of a breakaway. routing the electrical supply.
Storage The termination can be made using any of the cable glands
specified for the selected cable. If the size of the cable
The VRA can be connected to a Fast-Fill Storage System gland is less than 3/4", a proper reducer must be used.
with 1/4” stainless steel high pressure tubing. The Fast-Fill
Storage System incorporates a check valve at the high The electrical wiring must comply with the latest revision of
pressure inlet to the storage tanks. When connecting the the Canadian Electrical Code Part 1 in Canada, or the
VRA to a Fast-Fill Storage System, refer to the Installation National Electrical Code NEC in the United States and the
and Operating Instructions for that product. requirements of the authority having jurisdiction. Each
branch circuit from the service panel feeding the VRA
should be protected from over-current by a separate 2 pole
CAUTION: High pressure tubing between the VRA and 40 amp circuit breaker or time delay fuse disconnect. In
the Fast-Fill Storage System is not blown down; high addition to the over-current protection device, a disconnect
pressure remains in this stainless steel tubing at all times switch (rated 40 Amps minimum) must be installed within
and caution must be exercised when servicing the tubing sight and within 30 feet of the VRA. Refer to Figure 3 for
or pressure fittings. details of electrical wiring.
VRA VRA
Disconnects
(Min. 240 V 40A)
Service Panel
Min. Circuit Breaker
Rating 240 V AC 40A
To make electrical connections, Line 1 and Line 2 wires when the VRA unit is running at full pressure and when all
must be routed directly to the terminals of the input power other power consuming devices connected to the User’s
contactor (See Figure 4). Use 2.5 Nm (22 in-lbs) torque to supply transformer are operating. If voltage values of
properly secure wires at the terminals. The Ground wire 230/200 Volts or lower are measured at the terminals of the
must be connected to the ground lug located in the input power contactor, the transformer must be adjusted to
electronics module. provide a line voltage above 230/200 Volts and as close as
possible to the 240/220 Volt specification of the unit. An
When connected to a Fast-Fill Storage System, the VRA is alternative to increasing the line voltage is to use an
controlled by an Emergency Shutdown Device (ESD). Refer appropriately sized Buck Boost transformer.
to the Fast-Fill Storage System Installation and Operating
Instructions manual for further details.
At some installations, there is a potential that the 240/220 VRAs equipped with the Pressure Start option will re-start
volt (60/50 Hz) line voltage to the VRA can drop to values automatically and fill a fast-fill storage system or manifold
below 230/200 Volts when the supply transformer gets line. All VRAs are equipped with automatic temperature
loaded with other power consuming devices on site. On compensation and will shut down at a maximum pressure
warm days, this can cause the unit to shut down due to the determined by the ambient temperature sensed at the VRA
overheating of the motors. (See Table 2). When connected to a fast-fill storage system
or manifold line, the Pressure Start System continuously
Upon installation of the VRA, measure the line voltage at the monitors the line pressure and turns the VRA on when the
input power contactor in the electronics module (see Figure line pressure drops below a pre-determined level.
4). The supply voltage must NOT be below 230/200 Volts
39.0046 6
Issue 7, July 2002
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Field Programming The field programmer can be connected to the electronics
module via the port located on the upper electronics board
A field programmer is available from FuelMaker (See Figure 2). To connect the field programmer, remove
Corporation to allow the installer or service personnel to the termination plug installed in the programming port. For
change the following parameters in the field: programming procedures follow the instructions included
• recognition of Remote Panel connected to the VRA with the field programmer. The limited fill time option is a
measure to detect possible leaks (e.g. through damaged hose
• recognition of an External Interlock (eg. Natural Gas
etc.). A shorter fill time setting ensures greater safety in the
Detector) connected
case of a leak. Select the shortest possible fill time suitable
• maximum Fill Time for the application. The unlimited fill time should be used
only in the case of very large storage and frequent vehicle
• Pressure Start drop setting
refueling. The User must be made aware that leakage will
Upon receipt of a new VRA, the parameters have been not be monitored when using this setting.
factory set to:
• Remote Panel not connected
After changing any of the settings, a power reset must be
• External Interlock Device not connected performed. Power down the VRA at the main electrical
• maximum Fill Time unlimited switch for 15 seconds and turn ON again. If this
procedure is not followed, the unit will not start. “07 ”
• Pressure Start Drop 30 bar (400 psig) if shipped with will be shown on the display.
Pressure Start Option .
Reset Button
Control Module Remote Device
Connection Connection Ambient Temperature Sensors
Hourmeters (1 4)
Motor Module
Temperature Sensors
Connections (1 4)
Motor Module
Connections (1 4)
Input Power
Contactor
Input Power
Connection
240/220 VAC
4
Fan Module Connections Electrical Cable Ground Lug
1 Passthrough
Electronics
Compression Module #1 Module
Compression Module #4 (cowl removed)
Compression Module #2
Bucket
Compression Module
Motor Module
18.3 MPa / 2660 psig @ 10°C / 50°F 23.2 MPa / 3370 psig @ 10°C / 50°F 27.4 MPa / 3978 psig @ 10°C / 50°F
16.6 MPa / 2410 psig @ 0°C / 32°F 21.0 MPa / 3050 psig @ 0°C / 32°F 24.7 MPa / 3586 psig @ 0°C / 32°F
15.0 MPa / 2180 psig @ -10°C / 14°F 18.8 MPa / 2730 psig @ -10°C / 14°F 22.0 MPa / 3193 psig @ -10°C / 14°F
13.3 MPa / 1930 psig @ - 20°C / -4°F 16.5 MPa / 2390 psig @ -20°C / -4°F 19.3 MPa / 2801 psig @ -20°C / -4°F
11.6 MPa / 1690 psig @ -30°C / -22°F 14.3 MPa / 2073 psig @ -30°C / -22°F 16.6 MPa / 2408 psig @ -30°C / -22°F
10.0 MPa / 1450 psig @ -40°C / -40°F 12.1 MPa / 1754 psig @ -40°C / -40°F 13.9 MPa / 2016 psig @ -40°C / -40°F
Note: Pressure readout may vary ± 1 MPa / 145 psig from the above theoretical values.
When the VRA is first started, the 2 digit LED display will The mode displayed on the user panel describes the state of
briefly display “88 ” and the cooling fans will begin the VRA (what the unit is doing now or how the last fill
operating. Next, the display will start cycling 0 in a cycle was terminated). It is appears on the User Panel as a
clockwise direction. After approximately 10 seconds, the combination of LED characters.
compression modules will start in sequence, one at a time.
The starting sequence takes approximately 50 seconds to The mode is displayed as long as the condition is present.
complete.
Operating Modes
2 Digit LED User Display
Running Ready
Full Cooling
STATUS
88
## Error Code Refer to Operating Instructions for Corrective Action
Normal Operation
0 Unit is running. VRA will shut down automatically when cylinder is full
Running
0 or when a critical error is detected.
FL Tank Full Full condition was reached and the VRA shut down normally on the last fill cycle.
00 Ready The unit was just powered up. The VRA may be operated as usual.
88 LED Check LED display test. The VRA may be operated as usual.
6 FAULT DIAGNOSTICS
6.1 ERROR CODES In general, it is good practice to power the VRA down for 15
seconds to reset all internal data before any tests are
An Error Code contains information about the nature of a performed.
fault in the VRA.
When more than one error occurs, the VRA will display all of
The Error Codes are retrieved by viewing the LED Display the errors in sequence.
on the User Panel
WARNING: Apply extreme caution when pressing the
The error code will continue to be displayed until the fault Reset button. HIGH VOLTAGE is present in some
has been corrected. Certain error codes will lock-out the components of the electronics module. DO NOT TOUCH
VRA. When this happens, press and hold the reset button on any other components of the electronics module to avoid
the electronics module for 5 seconds and then power the unit serious injury or death.
down. Restore power after 15 seconds.
ca
Factory Calibration of Contact your Local Authorized Dealer.
Electronics Module
Required
The last fill cycle was terminated by a To restart the VRA the Reset Button (the white but-
cs
fault in the VRA. Retrieve Error Codes ton on the Control Board - see Figure 4 for loca-
Call for Service to determine specific cause of message. tion) must be pressed.
Maximum allowable pressure limit has Test ambient temperature sensor circuit.
pR
Factory Programming of
Electronics Module
Required
01
Pressure regulator set too low. Test Low Pressure Switch circuit.
Insufficient Inlet Pressure Insufficient diameter of the inlet pipe. Refer to rating plate on the VRA
The control module not compatible Refer to the Diagnostics and Field Service
with the pressure system. Instructions manual.
LPS switch faulty.
02
Low Input Power Voltage below 208 Volts Test fuses and circuit breakers.
Warning Refer to section 3.3 Field Wiring.
03
Low Input Power Voltage below 187 Volts Test fuses and circuit breakers.
Shutdown Refer to section 3.3 Field Wiring.
Leak in the high pressure connections. Check integrity of the high pressure lines.
Low flow of the VRA. Test flow of compression modules.
04
Maximum Running Time Maximum Fill Time parameter Program the Maximum Fill Time appropriate to the
Exceeded programmed too short for current ap- volume of vehicle tank (Slow Fill) or consumption
plication. of gas (Fast Fill). Refer to the Diagnostics and Field
Service Instructions manual.
Leak in the high pressure connections. Check for leaks.
Initial fill of a very large storage. Restart the VRA until pressure reaches 30 bar (435
psig) or isolate part of the storage to achieve a
faster rise of the fill pressure or restrict flow to the
05
Insufficient Pressure Rise storage to create back pressure grater than 30 bar
below 30 bar (435 psig) (435 psig). Check if all compression modules are
running and correct.
Low flow of the VRA. Test flow. Refer to the Diagnostics and Field
Service Instructions manual for the test procedure.
07 Power Reset Required Programmable settings have changed. Turn power off for 5 seconds, then restore power.
08
Sudden Pressure Drop to
Below 30 bar g (435 psig) Test Combination Valve. See Section 5.3 of the Diag-
nostics and Field Service Instructions manual for the
test procedure.
Fill hose / tubing between the VRA and Check hose for length, compare to specification.
filled tank too long.
Leaking check valve at the vehicle Test check valves for leaks.
09
Excessive Blowdown receptacle or at the storage.
Pressure Plugged vent connection to the Con- Check vent outlet for debris or ice, inspect tubing for
trol Module. sharp bends.
Contact your Local Authorized Dealer.
10
Less Than 100 Hours to
Service Interval mandatory service interval of 4000 next 100 hours or module will be locked out.
(Compression Module 1) hours. Contact your Local Authorized Dealer.
Cooling fan not operating or at Check fan operation. Test motor circuit continuity.
reduced capacity.
11
Excessive Surface
Temperature Input voltage out of specified range. Check for low voltage.
(Motor Module 1) Low air flow over compression Check inlet air flow. Ensure that there is no blockage
module. of air intake vents.
Cooling fan not operating. Check fan operation. Test motor circuit continuity.
Input voltage out of specified range. Check for low voltage.
12
Excessive Motor
Temperature Reduced air flow over compression Check inlet air flow. Ensure that there is no blockage
(Motor Module 1) module. of air intake vents.
Motor module shorted. Test motor module circuit.
13
Compression Module 1 incompatible Check type of the Compression Module - CPQ2 for
Faulty Hourmeter to the pressure system. FMQ-10, CPQ2-36 for FMQ-8-36, and CPQ2-42 for
Hourmeter damaged. FMQ-7-42. Test Hourmeter.
14
Compression Module 1 operating Contact your Local Authorized Dealer.
Service Interval Overdue beyond mandatory service interval.
15
Incompatible Compression
Module Pressure Rating
(Compression Module 1)
16
Surface Temperature
Sensor Failure Contact your Local Authorized Dealer.
(Motor Module 1)
19
Ruptured Burst Disc High pressure transducer failure. Test HPT circuit.
(Compression Module 1) Contact your Local Authorized Dealer.
20
Less Than 100 Hours to
Service Interval mandatory service interval of 4000 next 100 hours or module will be locked out.
(Compression Module 2) hours. Contact your Local Authorized Dealer.
21
Cooling fan not operating or at Check fan operation. Test motor circuit
Excessive Surface reduced capacity. continuity.
Temperature Input voltage out of specified range. Check for low voltage.
(Motor Module 2) Low air flow over compression Check inlet air flow. Ensure that there is no
module. blockage of air intake vents.
22
Cooling fan not operating. Check fan operation. Test motor circuit
Input voltage out of specified range. continuity.
Excessive Motor
Reduced air flow over compression Check for low voltage.
Temperature
module. Check inlet air flow. Ensure that there is no
(Motor Module 2)
Motor module shorted. blockage of air intake vents.
Test motor module circuit.
23
Compression Module 2 incompatible Check type of the Compression Module - CPQ2
Faulty Hourmeter to the pressure system. for FMQ-10, CPQ2-36 for FMQ-8-36, and
Hourmeter damaged. CPQ2-42 for FMQ-7-42. Test Hourmeter.
24
Compression Module 2 operating Contact your Local Authorized Dealer.
Service Interval Overdue beyond mandatory service interval.
25
Incompatible Compression Contact your Local Authorized Dealer.
Module Pressure Rating
(Compression Module 2)
26
Surface Temperature Test surface temperature sensor circuit.
Sensor Failure Contact your Local Authorized Dealer.
(Motor Module 2)
29
Ruptured burst disc. Test Compression Module flow rate.
Ruptured Burst Disc High pressure transducer failure. Test HPT circuit.
(Compression Module 2) Contact your Local Authorized Dealer.
30
Less Than 100 Hours to Compression modules have a Compression Module requires replacement within
Service Interval mandatory service interval of 4000 the next 100 hours or module will be locked out.
(Compression Module 3) hours. Contact your Local Authorized Dealer.
31
Cooling fan not operating or at Check fan operation. Test motor circuit
Excessive Surface reduced capacity. continuity.
Temperature Input voltage out of specified range. Check for low voltage.
(Motor Module 3) Low air flow over compression Check inlet air flow. Ensure that there is no
module. blockage of air intake vents.
32
Cooling fan not operating. Check fan operation. Test motor circuit
Input voltage out of specified range. continuity.
Excessive Motor
Reduced air flow over compression Check for low voltage.
Temperature
module. Check inlet air flow. Ensure that there is no
(Motor Module 3)
Motor module shorted. blockage of air intake vents.
Test motor module circuit.
33
Compression Module 3 incompatible Check type of the Compression Module - CPQ2
Faulty Hourmeter to the pressure system. for FMQ-10, CPQ2-36 for FMQ-8-36, and
Hourmeter damaged. CPQ2-42 for FMQ-7-42. Test Hourmeter.
34
Compression Module 3 operating Contact your Local Authorized Dealer.
Service Interval Overdue beyond mandatory service interval.
35
Incompatible Compression Contact your Local Authorized Dealer.
Module Pressure Rating
(Compression Module 3)
36
Surface Temperature
Sensor Failure Contact your Local Authorized Dealer.
(Motor Module 3)
39
Ruptured burst disc. Test Compression Module flow rate.
Ruptured Burst Disc High pressure transducer failure. Test HPT circuit.
(Compression Module 3) Contact your Local Authorized Dealer.
40
Less Than 100 Hours to
Service Interval mandatory service interval of 4000 the next 100 hours or module will be locked out.
(Compression Module 4) hours. Contact your Local Authorized Dealer.
Cooling fan not operating or at Check fan operation. Test motor circuit continuity.
41
Excessive Surface reduced capacity. Check for low voltage.
Temperature Input voltage out of specified range. Check inlet air flow. Ensure that there is no
(Motor Module 4) Low air flow over compression blockage of air intake vents.
module.
Cooling fan not operating. Check fan operation. Test motor circuit continuity.
42
Excessive Motor Input voltage out of specified range. Check for low voltage.
Temperature Reduced air flow over compression Check inlet air flow. Ensure that there is no
(Motor Module 4) module. blockage of air intake vents.
Motor module shorted. Test motor module circuit.
Compression Module 4 incompatible Check type of the Compression Module - CPQ2 for
45
Incompatible Compression
Module Pressure Rating
(Compression Module 4)
Test surface temperature sensor circuit.
46
Surface Temperature
Sensor Failure Contact your Local Authorized Dealer.
(Motor Module 4)
49
Ruptured burst disc. Test Compression Module flow rate.
Ruptured Burst Disc High pressure transducer failure. Test HPT circuit.
(Compression Module 4) Contact your Local Authorized Dealer.
50
Input Power Contactor Replace Electronics Module.
Failure Contact your Local Authorized Dealer.
54
Test supply voltage and fuses.
Run Relay Failure (Motor 4) Replace Electronics Module.
Contact your Local Authorized Dealer.
55
Test supply voltage and fuses.
Start Relay Failure (Motor 1) Replace Electronics Module.
Contact your Local Authorized Dealer.
56
Test supply voltage and fuses.
Start Relay Failure (Motor 2) Replace Electronics Module.
Contact your Local Authorized Dealer.
57
Test supply voltage and fuses.
Start Relay Failure (Motor 3) Replace Electronics Module.
Contact your Local Authorized Dealer.
58
Test supply voltage and fuses.
Start Relay Failure (Motor 4) Replace Electronics Module.
Contact your Local Authorized Dealer.
59
Test supply voltage and fuses.
Start Contactor Failure Replace Electronics Module.
Contact your Local Authorized Dealer.
60
Check electronics module lid clearance.
Start/Stop button Failure Replace Electronics Module.
Contact your Local Authorized Dealer.
61
Test input voltage.
Reference Voltage Failure Replace Electronics Module.
Contact your Local Authorized Dealer.
62
Test ambient temperature sensor circuit.
Ambient Temperature Sensor
Replace Electronics Module.
Failure
Contact your Local Authorized Dealer.
63
Test ambient temperature sensor circuit.
Ambient Temperature Out of
Replace Electronics Module.
Range
Contact your Local Authorized Dealer.
64
Test combi valve circuit.
Combi Valve Failure Replace Controls Module or Electronics Module.
Contact your Local Authorized Dealer.
65
Test combi valve circuit.
Combi Valve Relay Failure Replace Electronics Module or Controls Module.
Contact your Local Authorized Dealer.
70
No Communication with Replace RFP. Refer to RFP Installation and
Remote Fueling Panel (RFP). Operating Instruction manual.
Contact your Local Authorized Dealer.
71
RFP Detected But not Reprogram RFP.
Programmed Contact your Local Authorized Dealer.
72
Check interface cable and connections.
RFP Reference Voltage
Replace RFP.
Failure
Contact your Local Authorized Dealer.
73
Test RFP ambient temperature sensor circuit.
RFP Ambient Temperature
Replace RFP.
Sensor Out of Range
Contact your Local Authorized Dealer.
74
Start VRA manually.
RFP / RS / IS Start Signal
Replace start option.
Failure
Contact your Local Authorized Dealer.
75
Stop VRA manually.
RFP Stop Signal Failure Replace RFP
Contact your Local Authorized Dealer.
76
Check interface cable and connections.
No Communication with
Start VRA manually.
RS / IS
Contact your Local Authorized Dealer.
78
External Interlock Detected Check external interlock programming.
But Not Programmed Contact your Local Authorized Dealer.
79
Test external interlock circuit.
External Interlock Failure
Contact your Local Authorized Dealer.
80
Start VRA manually.
Incompatible Remote Device Replace electronics module.
Contact your Local Authorized Dealer.
81
Start VRA manually.
No Communication With
Test pressure start circuit.
Pressure Start System
Contact your Local Authorized Dealer.
82
Start VRA manually.
Pressure Start Failure Test pressure start circuit.
Contact your Local Authorized Dealer.
83
No communication with P50 Test shut down pressure against ambient
option. temperature.
90
Controls Module High pressure Transducer has failed. Test HPT circuit.
HPT Failure Contact your Local Authorized Dealer.
91
Incompatible Controls
Contact your Local Authorized Dealer.
Module Pressure Rating
Fill hose / tubing between the VRA Check hose for length, compare to specification.
92
and filled tank too long. Test Combi Valve.
Blowdown System Failure
Control circuit of the Combi Valve Check vent line for blockages.
failure. Inspect vehicle check valve.
Check that Disconnect Switch and Breaker
7 SERVICE
7.1 SERVICE INTRODUCTION Removing the VRA
Safety precautions require that the VRA’s internal If for any reason the entire VRA needs to be removed:
components be inaccessible to the User and other
unauthorized personnel. Accordingly the top lid and the
• All normal safety precautions must be observed when
electronics module lid must be re-installed by authorized
disconnecting the VRA.
service personnel before they leave the site. Only authorized
service representatives may service the VRA at the User’s • Turn off the electrical power supply to the VRA.
premises.
• Disconnect the power supply wires from the electronics
Any detailed service not described in this document must module (See Figure 4).
only be carried out by FuelMaker Corporation Service Staff
at a factory service facility. Service undertaken by • Remove the power supply cable from the unit.
unauthorized persons may cause the VRA to operate
• Turn off and disconnect the gas supply.
incorrectly and may result in damage, serious injury or
death.
• Release the pressure inside the blow-down system by
loosening the high pressure tubing to the inlet side of
Service Interval
the check valve.
At the time of publication, FuelMaker Corporation requires
• Plug the gas inlet and vent connections before
that each compression module be serviced after every 4000
transporting the VRA to prevent the contamination of
hours of running time. Depending on the local gas quality or
internal components.
technical advancements, the service interval may be
increased beyond 4000 hours in the future. Either 10, 20, 30
• Undo the lag bolts at the mounting feet of the VRA.
or 40, depending upon which compression module is
involved, will appear on the User Panel display indicating to
• The whole unit is now ready to be lifted with a forklift
the User that the unit must be serviced within the next 100
or a crane using sling harnesses.
hours. If the compression module is not serviced soon, the
fill pressure and/or flow may be reduced, and the VRA may
shut down in “Call for Service” mode (CS).
39.0046 19
Issue 7, July 2002
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
the VRA. FuelMaker offers the model FF350 Fast Fill Stor- To achieve a fill closer to the ideal vehicle tank pressure,
age System to provide fast-fill capability to a VRA installa- the storage system is typically divided into 3 banks which
tion. are tapped sequentially. When the first bank has equalized
pressure with the vehicle tank, the second bank is con-
The storage cylinders are kept pressurized and have a larger nected. When it has finished, the third bank is connected
volume than the vehicle tank so the fueling cycle will take and equalized to complete the fill cycle. Switching between
seconds or minutes instead of hours. The pressure start banks is handled by the operator turning a manual valve.
system in the VRA monitors the pressure in the storage cyl-
inders and will restart when a sufficient pressure drop is de- If the pressure start system is not installed in the VRA, an
tected. In this configuration, the VRA replenishes the gas in Integrated Start option is available. The integrated start
the storage cylinders and not in the vehicle. system is installed in the FF350 and will start the VRA to
replenish the cylinders when the main valve is moved from
The maximum pressure in the vehicle tank will not be as the first to second position. The VRA will shut down when
high as with time-fill applications since the maximum pres- the maximum temperature compensated pressure is reached
sure has already been reached in the storage system. The in the storage cylinders.
existing pressure is equalized between the storage and vehi-
cle tanks, so the maximum pressure reached by the end of
the fill cycle will be lower. Topping off the tank is possible
with the FF350 by a control on the storage system that al-
lows a direct connection to the VRA.
39.0046 20
Issue 7, July 2002