39.0046_Issue7_July2002_FMQ-10&FMQ-8-36&FMQ-7-42_Install&OperateInstructions

39.0046 Issue 7, July 2002

The VRA Shall Only be Installed by Trained and Certified Personnel and Shall Only be Operated by a Trained Vehicle Owner or Operator

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

FuelMaker Models FMQ-10, FMQ-8-36 & FMQ-7-42

Vehicle Refueling Appliance

Installation and Operating Instructions

Vehicle Refueling Appliance Models FMQ-10, FMQ-8-36 and FMQ-7-42

Issue 7, July 2002 39.0046

1. NO USER-SERVICEABLE COMPONENTS The FMQ-8-36 / FMQ-10 / FMQ-7-42 Vehicle Refueling Appliance (VRA) Modules (Control Module, Compression Module, Electronics Module, Motor Module) shall only be field-replaced by personnel specifically trained and authorized by FuelMaker Corporation. Do not attempt to dismantle the modules or tamper with any components. To do so will void all warranties and could result in serious injury. 2. READ INSTRUCTIONS CAREFULLY Please read this manual carefully and those of other equipment supplied prior to installation and operation. If you experience any difficulties or are unsure about any feature, contact FuelMaker’s Technical Support Group at :

1-800-263-8569 (North America) +1-416-674-3034 extension 258 (International)

3. LOCATION OF THE VRA The VRA is to be installed outdoors in non-hazardous locations as defined by the C22.1 Canadian Electrical Code (Canada), and the NFPA 70 National Electrical Code (USA). Do not install the VRA under or near a window or directly under potential gas accumulating overhangs. Leaves, snow and other debris should be kept clear of the air inlet and outlet of the VRA. Do not install the VRA beneath overhangs which can shed snow or rain directly onto the unit. The VRA and the cylinders being filled must be located so they are both exposed to the same ambient temperature during refueling.

4. FOR NATURAL GAS ONLY The VRA is for use with Natural Gas only and shall not be used for any purpose other than the refueling of cylinders certified for gas storage at a pressure of 20.7 MPa (3000 psi) or higher for the Model FMQ-10, 24.8 MPa (3600 psi) or higher for the Model FMQ-8-36, or 31.0 MPa (4500 psi) or higher for the Model FMQ-7-42. Attempts to use the VRA for any other purpose 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. Do not run vehicle engine while refueling and ensure all ignition sources are OFF (including pilot lights in recreational vehicles). Do not smoke or bring an open flame within 3 m (10 ft.) of the vehicle being refueled. 5. IF YOU SMELL GAS 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 flames. Contact an authorized service representative.

SAFETY INSTRUCTIONS

PLEASE READ CAREFULLY


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TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................................................................................ 2 TECHNICAL SPECIFICATIONS ................................................................................................................................. 3 INSTALLATION .......................................................................................................................................................... 3.1 GENERAL ….. ......................................................................................................................................................... 3.2 LOCATION OF THE VRA .................................................................................................................................... Positioning of Base .................................................................................................................................................... Vehicle Refueling Point ........................................................................................................................................... Gas and Electrical Supplies ...................................................................................................................................... Sound Levels ….. ...................................................................................................................................................... Protection from Vehicle Impact ............................................................................................................................... 3.3 INSTALLATION OF THE VRA .......................................................................................................................... Mounting to Base ...................................................................................................................................................... Low Pressure Gas Piping - Inlet Side ...................................................................................................................... High Pressure Gas Piping - Outlet Side .................................................................................................................. Manifolded Time-Fill ....................................................................................................................................... Storage ….. ....................................................................................................................................................... Vent Connection ............................................................................................................................................... Field Wiring ….. ....................................................................................................................................................... Low Voltage Operation ............................................................................................................................................ Pressure Start System (Optional) ............................................................................................................................ Field Programming ................................................................................................................................................... 4 TESTING AND COMMISSIONING .............................................................................................................................. 5 USER PANEL OPERATION - MODES ........................................................................................................................ 5.1 MODES OF THE VRA ............................................................................................................................................ 6 FAULT DIAGNOSTICS ................................................................................................................................................. 6.1 ERROR CODES ....................................................................................................................................................... 7 SERVICE…………. .......................................................................................................................................................... 7.1 SERVICE INTRODUCTION .................................................................................................................................. Service Interval ......................................................................................................................................................... Removing the VRA ................................................................................................................................................... APPENDIX A: ANCILLARY DEVICES ...............................................................................................................................


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TABLES and FIGURES Table 1 Technical Specifications ................................................................................................................................... Table 2 Shutdown Pressure vs. Ambient Temperature ............................................................................................... Table 3 User Panel Indications – Display Modes ......................................................................................................... Table 4 User Panel Indications – Error Codes ............................................................................................................. Figure 1 Service Clearances and Mounting Dimensions ............................................................................................... Figure 2 VRA Exterior – Main Components ................................................................................................................. Figure 3 Electrical Wiring ............................................................................................................................................. Figure 4 Electronics Module Components ..................................................................................................................... Figure 5 VRA Interior – Main Components .................................................................................................................. Figure 6 User Panel .........................................................................................................................................................

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TABLE OF CONTENTS (cont‘d)


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The FuelMaker model FMQ-10, FMQ-8-36, and FMQ-7-42 Vehicle Refueling Appliances (VRAs) are self-contained oil-free outdoor appliances used for Natural Gas refueling of vehicles and storage cylinders. The VRA can be configured for remote time-fill applications by connecting to a Remote Fueling Panel (RFP) or for manifolded time-fill applications by connecting to one or more Auxiliary Fueling Panels (AFP). The VRA can also be connected to a Fast-Fill Storage System for use with fast-fill applications. The model FMQ-10 is designed to fill 20.7 MPa (3000 psi) 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) fuel systems at a nominal flow rate of 12.9 m3/hr (7.6 scfm). The model FMQ-7-42 is designed to fill 29.0 MPa (4200 psi) fuel systems at a nominal flow rate of 11.6 m3/hr (6.8 scfm). The VRA contains ambient temperature sensors which allow the electronics module to determine the maximum 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.

The VRA is air-cooled and is rated for an operating ambient temperature range of -40ºC to +46°C (-40°F to +115°F). Air is drawn into the VRA through a set of louvers on the bottom of the housing and is exhausted through another set of louvers on the top of the housing (See Figure 2). The VRA has a User Panel located at the front of the unit where the current operating status and error messages are displayed. The VRA has no capacity for connecting directly to a fuel cylinder. Refueling is accomplished using one of several ancillary devices connected to the VRA (see Appendix A). If a model FMQ-8-36 or FMQ-7-42 VRA is used to fill a system designed to deliver fuel to a vehicle with a lower pressure rating, a pressure compensating system must be installed to ensure the vehicle cylinder is not over-pressurized. Serious injury or damage to the equipment may result if these precautions are not taken.

1 INTRODUCTION

2 TECHNICAL SPECIFICATIONS

GAS FMQ-10 FMQ-8-36 Maximum Discharge Pressure: Minimum Inlet Pressure: Maximum Inlet Pressure: Nominal Flow Rate (60 Hz):

20.7 MPa @ 21°C (3000 psig @ 70°F) 6.9 kPa (1.0 psig) at rated flow * 8.6 kPa (1.25 psig) at rated flow 17.0 m3/hr @ 21°C and 8.6 kPa inlet (10 SCFM @ 70°F and 1.25 psig inlet)

24.8 MPa @ 15°C (3600 psig @ 59°F) 6.9 kPa (1.0 psig) at rated flow * 8.6 kPa (1.25 psig) at rated flow 12.9 m3/hr @15°C and 8.6 kPa inlet (7.6 SCFM @ 59°F and 1.25 psig inlet)

ELECTRICAL Electrical Supply: Circuit Ampacity: Full Load Amperage (60/50 Hz): Average Power Consumption:

240 Volt AC, Single Phase, 60 Hz 220 Volt AC, Single Phase, 50 Hz

40 Amps 28/26 Amps

3.6 to 4.8 kW

MECHANICAL Dimensions (L x W x H): Unit Weight / Shipping Weight: Noise Level: Ambient Temperature Rating:

848 mm x 1228 mm x 813 mm (33” x 48” x 32”) 263 kg (580 lbs) / 308 kg (680 lbs)

66 dBA @ 5 m (16.5 ft), hemispherical field -40°C to +46°C (-40°F to +115°F)

* 1.7 kPa (0.25 psig) inlet option available

FMQ-7-42

29.0 MPa @ 16°C (4200 psig @ 61°F) 6.9 kPa (1.0 psig) at rated flow * 8.6 kPa (1.25 psig) at rated flow 11.6 m3/hr @21°C and 8.6 kPa inlet (6.8 SCFM @ 70°F and 1.25 psig inlet)

Table 1 Technical Specifications

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Before installing the VRA, ensure that both the power and gas supply have been turned off. Note: VRAs equipped with Pressure Start are AGA certified for commercial and industrial applications only in the United States of America. Inspect the unit for shipping damage and report any to your distributor as soon as possible. Please do not return product to the manufacturer without prior authorization. 3.1 GENERAL Verify that the nameplate ratings of the VRA are compatible with the electrical and gas supplies available. In Canada, the VRA shall be installed in accordance with CGA 149.1, CGA B108, C22.1 Canadian Electrical Code, Part 1 and with requirements of the authorities having jurisdiction. In the United States, the VRA shall be installed in accordance with NFPA 52 CNG Vehicular Fuel Systems, NFPA 70 National Electrical Code, NFPA 54 National Fuel Gas Code and with requirements of the authorities having jurisdiction. The Installer shall instruct the User in the proper operation of the VRA and any approved ancillary devices. Before leaving the site, the Installer shall leave the Installation and

Operating Instructions and any ancillary device manuals with the User. 3.2 LOCATION OF THE VRA Positioning of Base The VRA must be installed outdoors only. The VRAs must be mounted on a firm, level, non-combustible base such as a poured or pre-cast concrete slab placed on a suitably prepared base (e.g. crushed stone 150 mm (6") deep). It can also be placed directly onto an asphalt or other suitable hard surface. Ensure that the servicing clearances stated on the nameplate are maintained (See Figure 1). Avoid areas where damage from excessive ice build-up may occur such as building overhangs or where vegetation, snow or debris may clog the inlet or outlet air louvers. Do not install the VRA beneath overhangs which can shed snow or rain directly onto the unit. Do not install the VRA under or near a window or directly under potential gas accumulating overhangs or under/near hot air exhaust from a building.

3 INSTALLATION

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Figure 1 Service Clearances and Mounting Dimensions

750 mm (29-1/2") Mounting feet center

Rear 0.3 m (1 ft.)

Side 0.6 m (2 ft.)

Top 0.9 m (3 ft.)

Front 0.6 m ( 2 ft.)

Side 0.6 m ( 2 ft.)

1114 mm (43-7/8") Mounting feet center

Mounting Holes ½" diameter

38.1 mm (1.5")


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Local codes and regulations take precedence over any recommendations contained in these instructions. Particular attention should be paid to codes dealing with fuel storage, vehicle refueling, and permissible sound levels at the property line. Vehicle Refueling Point The refueling of cylinders is accomplished using one of several ancillary devices connected to the VRA. One or more FuelMaker Auxiliary Fueling Panels (AFPs) or Remote Fueling Panels (RFPs) can be connected to the VRA through high pressure tubing to permit single or multiple vehicle refueling stations. The VRA can also be connected to a storage system to allow for fast fill applications. The VRA is supplied with a 1/4" compression fitting to connect the high pressure tubing to these devices. The VRA contains ambient temperature sensors which allow the electronics module to adjust the maximum fill pressure delivered to the cylinder in order to prevent over-pressurization should it warm up after filling. The VRA must be installed in an area with the same ambient temperature as the cylinder being refueled. If an RFP is used to fill the cylinder, the ambient temperature sensors in the RFP override the VRA’s sensors to determine the maximum fill pressure to deliver.

Gas and Electrical Supplies The VRA requires a dedicated 240 Volt, 40 Amp, 60 Hertz (or 220 Volt, 40 Amp 50 Hertz), Single Phase electrical supply, see figure 3 for typical electrical installation schematics. Lower input voltage to the VRA can cause the unit to overheat and shut off during warm weather - see Field Wiring section in this manual. The required flow rate for the Natural Gas supply for the model FMQ-10 is approximately 17.0 m3/hr (10 scfm), for the model FMQ-8-36 is approximately 13.6 m3/hr (8.0scfm), and for the model FMQ-7-42 is approximately 11.9 m3/hr (7.0 scfm) at a supply pressure between 6.9 and 8.6 kPa (1.0 and 1.25 psig). Higher pressure may damage the controls module or cause the compression module to overheat and shut off. Consideration should be given to the cost of wiring and piping in determining the location of the VRA. The VRA should only be installed in areas where the local gas utility provides relatively dry gas, typically with not more than 110mg/m3 (7 lbs per million cubic feet) of water vapor. To avoid wet gas problems, especially when the VRA is connected to storage, a low pressure molecular sieve gas dryer should be installed upstream of the VRA. Sound Levels The VRA is designed to ensure a sound pressure level of less

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Figure 2 VRA Exterior – Main Components

Top Lid

Vent Connection 3/8” NPT

Shutter for Electrical Cable

Port for Remote Start Cable (1/2” conduit knock-out for conduit termination.)

Air Intake Louvers

Lid - Electronics Module

Air Outlets Louvers

REAR OF UNIT

User Panel

Port for Remote Panel (R410) Cable

Mounting Foot

L.P. Gas Inlet, 1” NPT (1-1/4” NPT with 7” w.c. option

Programming Port

H.P. Gas Connection, 1/4" Tube


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than 66 dBA (hemispherical field) at a distance of 5 m (16.5ft). Be aware that some local codes restrict the sound pressure level at the property line. Units should not be located where direct or reflected noise is aimed at neighboring windows or other building openings. Avoid locating the unit near a sound reflecting surface or between buildings which are close together. Protection from Vehicle Impact If the VRA must be located where it may be struck, provision must be made to protect the VRA from damage. Typically, 2m (7 ft) long, 100 mm (4 in) diameter concrete filled steel posts spaced no more than 0.6 m (2 ft) apart are sunk 1 m (3.5 ft) into the ground between the VRA and the flow of traffic to act as a barrier against impact. Heavy squared timbers may also be used. The local gas distribution utility should be consulted to determine what practice is locally accepted by the authorities having jurisdiction. 3.3 INSTALLATION OF THE VRA It is extremely important to properly ream and debur all tubing and pipe to prevent any potential restrictions to the flow of gas through the system. Ensure that all oil, metal shavings and other debris are removed from the tubing before final assembly. Mounting to Base 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 wrench. A carpenter’s level may be placed on top of the 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 base; the locations of the mounting bolt holes in the VRA base are indicated in Figure 1. It is very important to bolt the VRA to the base to prevent movement of the unit and to prevent undue stress on the inlet piping.

Low Pressure Gas Piping - Inlet Side The gas supply is connected to the VRA via an NPT nipple provided (See Figure 2). A coupling and transition fittings need to be field-supplied in order to adapt to the supply piping system. Where the supply piping is fixed to a wall, a flex connector may be required to prevent noise transmission into the building. A shut-off valve and test port are required in the inlet piping to the VRA to facilitate servicing of the unit.

It is important to clean any contaminants such as cutting oil, rust, and metal shavings out of the interior of the gas inlet piping. Pipe dope and other sealing compounds must not enter the piping. Ream and debur all piping and tubing before final assembly. 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 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-pressure switch. The VRA may shut down due to low inlet pressure when other gas loads (e.g. furnace, water heaters, etc.) draw from the gas supply system. The utility regulator set should be provided by the local gas utility with the orifice/spring/setting appropriate for the maximum gas load that the system will experience. The Installer shall ensure that the VRA and 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 or NFPA 54 in the United States. IMPORTANT: The low inlet pressure regulator upstream of the VRA must be sized correctly for the rated flow. Pressure at the inlet to the VRA must be in accordance with the rating plate specifications. Run the VRA while simultaneously operating all major gas appliances on the User's system in order to verify the regulator setting. If the VRA shuts down from low inlet pressure, the gas regulator must be re-adjusted. High Pressure Gas Piping - Outlet Side: Manifolded Time-Fill The VRA has a 1/4" bulkhead compression fitting at the rear of the unit to connect to the refueling point through high pressure outlet tubing. All tubing and fittings must be approved and must conform with CGA B108 in Canada or NFPA52 in the United States. The VRA is equipped with a check valve to maintain the blowdown capacity of the unit. Refer to the Installation and Operating Instructions for the refueling equipment. The fill hose assembly must be equipped with an AGA/CGA NGV1 Type 2 or 3 refueling nozzle that is approved for Natural Gas “Slow-Fill” applications. The nozzle must seal reliably throughout the temperature range and conditions anticipated for the location. An integral normally-closed poppet valve in the nozzle is absolutely essential as it must maintain a positive pressure in the VRA’s blowdown system at all times; air must not migrate up the fill hose and into the

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blowdown vessel during standby. AGA/CGA NGV1 Type 2 and 3 approved nozzles are available from FuelMaker Corporation. The fill hose incorporates a fitting and a seal to connect the refueling nozzle. Various adapters are available from FuelMaker to facilitate the attachment of various nozzles, including angular or straight take-offs. The fill hose is pre-coiled to allow it to be stored neatly. At the completion of each refueling cycle the high pressure gas contained in the tubing inside the VRA is discharged into the blowdown vessel (See Figure 5). This procedure reduces the pressure at the outlet of the VRA allowing the compression module to be safely restarted. The VRA can also be connected to other VRAs via manifold adapter assemblies and tubing. To disconnect a vehicle from a manifolded system, the fill hose assembly must be equipped with a Nozzle Vent Valve. This will relieve the pressure in the fill nozzle to allow disconnection. CAUTION: The high pressure tubing is not blown down; high pressure remains in the tubing and hoses at all times and caution must be exercised when servicing the tubing, hoses, nozzles or high pressure fittings. When VRAs are connected to a manifolded system with AFPs or RFPs the line must be equipped with a Pressure Relief Valve and Purge Valve. This will allow the fill hose to be reconnected in the event of a breakaway. Storage The VRA can be connected to a Fast-Fill Storage System with 1/4” stainless steel high pressure tubing. The Fast-Fill Storage System incorporates a check valve at the high pressure inlet to the storage tanks. When connecting the VRA to a Fast-Fill Storage System, refer to the Installation and Operating Instructions for that product. CAUTION: High pressure tubing between the VRA and the Fast-Fill Storage System is not blown down; high pressure remains in this stainless steel tubing at all times and caution must be exercised when servicing the tubing or pressure fittings.

Vent Connection A 3/8" NPT vent connection (See Figure 2) is protected from blockage by ice or insects by a screen fitting. The Vent discharges any gas released by the pressure relief valve in order to protect the blowdown system from over-pressurization. If the VRA must be installed near building openings, a 10 mm (3/8") minimum inside diameter steel 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 a 10 mm (3/8”) remote vent line is 5m (17 ft) to protect the low pressure switch from over-pressurization. Be sure to transfer the screen fitting to the end of the remote vent line (if applicable) to protect it from blockage. Contact FuelMaker if a longer remote vent line is required. It is extremely important to install the remote vent line in such a way that rain or snow cannot enter the tubing and freeze. Terminate the vent line in a downwards-facing “U” or “goose neck” to prevent rain or snow from entering the line. Do not allow ice to build up at the open vent connection or the remote vent line termination. The vent line must remain clear to be able to vent gas and protect the blowdown system from over-pressurization. Field Wiring The VRA has been wired at the factory and is ready for connection to the customer’s electrical supply. Armoured 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 the VRA through the opening at the rear panel (see Figure 2) to the electronics module (See Figure 4). There is a 3/4" opening at the rear of the electronics module dedicated to routing the electrical supply. The termination can be made using any of the cable glands specified for the selected cable. If the size of the cable gland is less than 3/4", a proper reducer must be used. The electrical wiring must comply with the latest revision of the Canadian Electrical Code Part 1 in Canada, or the National Electrical Code NEC in the United States and the 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 40 amp circuit breaker or time delay fuse disconnect. In addition to the over-current protection device, a disconnect switch (rated 40 Amps minimum) must be installed within sight and within 30 feet of the VRA. Refer to Figure 3 for details of electrical wiring.

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To make electrical connections, Line 1 and Line 2 wires must be routed directly to the terminals of the input power contactor (See Figure 4). Use 2.5 Nm (22 in-lbs) torque to properly secure wires at the terminals. The Ground wire must be connected to the ground lug located in the electronics module. When connected to a Fast-Fill Storage System, the VRA is controlled by an Emergency Shutdown Device (ESD). Refer to the Fast-Fill Storage System Installation and Operating Instructions manual for further details. Low Voltage Operation At some installations, there is a potential that the 240/220 volt (60/50 Hz) line voltage to the VRA can drop to values below 230/200 Volts when the supply transformer gets loaded with other power consuming devices on site. On warm days, this can cause the unit to shut down due to the overheating of the motors. Upon installation of the VRA, measure the line voltage at the input power contactor in the electronics module (see Figure 4). The supply voltage must NOT be below 230/200 Volts

when the VRA unit is running at full pressure and when all other power consuming devices connected to the User’s supply transformer are operating. If voltage values of 230/200 Volts or lower are measured at the terminals of the input power contactor, the transformer must be adjusted to provide a line voltage above 230/200 Volts and as close as possible to the 240/220 Volt specification of the unit. An alternative to increasing the line voltage is to use an appropriately sized Buck Boost transformer. Pressure Start System (Optional) VRAs equipped with the Pressure Start option will re-start automatically and fill a fast-fill storage system or manifold line. All VRAs are equipped with automatic temperature compensation and will shut down at a maximum pressure determined by the ambient temperature sensed at the VRA (See Table 2). When connected to a fast-fill storage system or manifold line, the Pressure Start System continuously monitors the line pressure and turns the VRA on when the line pressure drops below a pre-determined level.

Figure 3 Electrical Wiring

Service Panel Min. Circuit Breaker

Rating 240 V AC 40A

Disconnects (Min. 240 V 40A)

VRA VRA


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Field Programming A field programmer is available from FuelMaker Corporation to allow the installer or service personnel to change the following parameters in the field: • recognition of Remote Panel connected to the VRA

• recognition of an External Interlock (eg. Natural Gas Detector) connected

• maximum Fill Time

• Pressure Start drop setting

Upon receipt of a new VRA, the parameters have been factory set to:

• Remote Panel not connected

• External Interlock Device not connected

• maximum Fill Time unlimited

• Pressure Start Drop 30 bar (400 psig) if shipped with Pressure Start Option .

The field programmer can be connected to the electronics module via the port located on the upper electronics board (See Figure 2). To connect the field programmer, remove the termination plug installed in the programming port. For programming procedures follow the instructions included with the field programmer. The limited fill time option is a measure to detect possible leaks (e.g. through damaged hose etc.). A shorter fill time setting ensures greater safety in the case of a leak. Select the shortest possible fill time suitable for the application. The unlimited fill time should be used only in the case of very large storage and frequent vehicle refueling. The User must be made aware that leakage will not be monitored when using this setting. After changing any of the settings, a power reset must be performed. Power down the VRA at the main electrical switch for 15 seconds and turn ON again. If this procedure is not followed, the unit will not start. “07 ” will be shown on the display.

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Figure 4 Electronics Module Components

Remote Device Connection

External Interlock

Input Power Contactor

Input Power Connection 240/220 VAC

Ground Lug

Reset Button

LED Status Display

Ambient Temperature Sensors Control Module Connection

Motor Module Connections (1 4)

4 Fan Module Connections 1

Hourmeters (1 4)

Motor Module Temperature Sensors Connections (1 4)

Electrical Cable Passthrough


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Electronics Module

Controls Module with Blow Down Vessel

Figure 5 VRA Interior - Main Components

Compression Module

Gas Inlet Fitting

Motor Module

Motor Cable Passthrough

Pocket for storing Hourmeter

Compression Module #4 (cowl removed)

Compression Module #3



Bucket


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To commission (and service) the VRA, an approved high pressure 20.7 MPa (3000 psig), 24.8 MPa (3600 psig) or 29.0 MPa (4200 psig) test cylinder assembly (Test Kit) with a nominal volume of 2 liters is required. A 20.7 MPa (3000 psig) Test Kit (P/N TK-4), 24.8 MPa (3600 psig) Test Kit (TK-36), and a 29.0 MPa (4200 psig) Test Kit (TK-42) are available from FuelMaker Corporation. The test kits are supplied with a receptacle, a hand-operated vent valve, a calibrated pressure gauge, and a pressure relief device. TK-4 and TK-36 test kits are equipped with a refueling re-ceptacle that mates with the CGA/AGA NGV 1 20.7 MPa (3000 psig) or 24.8 MPa (3600 psig) fill nozzles respec-tively. TK-42 test kits are equipped with a unique receptacle profile. Purge the Natural Gas supply piping of air as follows:

• Attach the fill hose to the Test Kit via the refueling noz-

zle, and then open the vent valve.

• Verify that the cooling fans are operating by checking for air flow out of the top of each of the Air Outlet Shrouds.

• Purge the VRA of air by running it on natural gas and venting the gas through the Test Kit vent valve until the odourant is detected (approximately 30 seconds).

Note: A gas dryer will remove the odourant from the gas for the first 50 hours of operation after installation or a recharge. Therefore, run the unit for 30 seconds to purge the system during this time.

• After purging, close the vent valve and allow the VRA to

fill the test cylinder until the VRA shuts off with the "Full" indication on the User Panel (e.g. “FL” display). The Test Kit cylinder should be full within 3 minutes, and the shut-off pressure should be within the allowable limits for ambient temperature as indicated in Table 2.

• If the shutdown pressure is out of tolerance then refer to the Diagnostic and Field Service Instructions.

Following installation, the fittings should be leak-tested us-ing a suitable portable gas detector or soap solution. The high pressure connections should be leak-checked while the VRA is in operation filling the Test Kit cylinder in the range of 19.0 - 20.7 MPa (2750 – 3000 psig) for a model FMQ-10, 23.8 - 24.8 MPa (3400 - 3600 psig) for a model FMQ-8-36 or 27.6 - 29.0 MPa (4000 - 4200 psig) for a model FMQ-7-42. As a minimum, the following locations must be leak-tested: • All inlet piping connections

• All high pressure tubing connections including the high pressure tubing, breakaway fitting(s) and refueling noz-zle(s)

• The screen fitting at the end of the vent line (small leaks from the pressure relief valve may not be detected by the VRA's fault diagnostic system). Ensure that the leak-detection fluid does not freeze and block the vent line.

Safety precautions require that the internal components of the VRA be inaccessible to the User and other unauthorized persons. Ensure that all panels and fasteners are installed before leaving site.

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Table 2 Shutdown Pressure vs. Ambient Temperature

FMQ-10 FMQ-8-36

20.7 MPa @ 21°C (3000 psig @ 70°F) 24.8 MPa / 3600 psig @ 15°C / 59°F

18.3 MPa / 2660 psig @ 10°C / 50°F 23.2 MPa / 3370 psig @ 10°C / 50°F

16.6 MPa / 2410 psig @ 0°C / 32°F 21.0 MPa / 3050 psig @ 0°C / 32°F

15.0 MPa / 2180 psig @ -10°C / 14°F 18.8 MPa / 2730 psig @ -10°C / 14°F

13.3 MPa / 1930 psig @ - 20°C / -4°F 16.5 MPa / 2390 psig @ -20°C / -4°F

11.6 MPa / 1690 psig @ -30°C / -22°F 14.3 MPa / 2073 psig @ -30°C / -22°F

10.0 MPa / 1450 psig @ -40°C / -40°F 12.1 MPa / 1754 psig @ -40°C / -40°F

Note: Pressure readout may vary ± 1 MPa / 145 psig from the above theoretical values.

FMQ-7-42

29.0 MPa / 4200 psig @ 16°C / 60°F

27.4 MPa / 3978 psig @ 10°C / 50°F

24.7 MPa / 3586 psig @ 0°C / 32°F

22.0 MPa / 3193 psig @ -10°C / 14°F

19.3 MPa / 2801 psig @ -20°C / -4°F

16.6 MPa / 2408 psig @ -30°C / -22°F

13.9 MPa / 2016 psig @ -40°C / -40°F

4 TESTING AND COMMISSIONING


Issue 7, July 2002 39.0046

The VRA is started automatically whenever certain conditions are met depending upon the start options installed (see Appendix A). The VRA will stop when the storage cylinder has been filled to the maximum temperature compensated pressure is reached, or when a critical error is encountered. The user panel of the VRA has a 2 digit LED display where the current operating status and error messages are shown. When the VRA is first started, the 2 digit LED display will briefly display “88 ” and the cooling fans will begin operating. Next, the display will start cycling 0 in a clockwise direction. After approximately 10 seconds, the compression modules will start in sequence, one at a time. The starting sequence takes approximately 50 seconds to complete. Upon shut-down at maximum pressure, the display indicates ”FL”. The pressure in the fill nozzle must be reduced before the it may be removed from the cylinder. Turn the nozzle vent valve to the “VENT” position and wait several seconds for the pressure in the nozzle to drop before disconnecting

the refueling hose assembly. The cooling fans will continue to operate for 10 minutes after the VRA shuts down. The display will light alternating corners (upper right and lower left) while the cooling process continues. 5.1 MODES OF THE VRA The mode displayed on the user panel describes the state of the VRA (what the unit is doing now or how the last fill cycle was terminated). It is appears on the User Panel as a combination of LED characters. The mode is displayed as long as the condition is present.

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5 USER PANEL OPERATION - MODES

Figure 6 User Panel

STATUS

Full

Running

Error Code Refer to Operating Instructions for Corrective Action

Call For Service Error can not be Reset by Operator

Cooling

Ready

CS

##

Air Inlet for Temperature Sensor

2 Digit LED User Display Operating Modes

Error Modes

88


Issue 7, July 2002 39.0046 11

LED Display / Description Action

Normal Operation

0 0

Running Unit is running. VRA will shut down automatically when cylinder is full 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.

0 0

Cooling Unit is cooling. The VRA may be operated as usual.

88 LED Check LED display test. The VRA may be operated as usual.

Table 3 User Panel Indications –Display Modes

6.1 ERROR CODES An Error Code contains information about the nature of a fault in the VRA. The Error Codes are retrieved by viewing the LED Display on the User Panel The error code will continue to be displayed until the fault has been corrected. Certain error codes will lock-out the VRA. When this happens, press and hold the reset button on the electronics module for 5 seconds and then power the unit down. Restore power after 15 seconds.

In general, it is good practice to power the VRA down for 15 seconds to reset all internal data before any tests are performed. When more than one error occurs, the VRA will display all of the errors in sequence. WARNING: Apply extreme caution when pressing the Reset button. HIGH VOLTAGE is present in some components of the electronics module. DO NOT TOUCH any other components of the electronics module to avoid serious injury or death.

6 FAULT DIAGNOSTICS


Issue 7, July 2002 39.0046 12

Table 4 User Panel Indications – Error Codes

LED Display / Numeric Code

Description Possible Cause Corrective Action

ca Factory Calibration of Electronics Module Required

Contact your Local Authorized Dealer.

cs Call for Service The last fill cycle was terminated by a fault in the VRA. Retrieve Error Codes to determine specific cause of message.

To restart the VRA the Reset Button (the white but-ton on the Control Board - see Figure 4 for loca-tion) must be pressed.

pl Pressure limit Maximum allowable pressure limit has been reached due to a failure in the unit

Test ambient temperature sensor circuit.

pR Factory Programming of Electronics Module Required


01 Insufficient Inlet Pressure

Main shut-off valve closed at the inlet to the VRA. Pressure regulator set too low. Insufficient diameter of the inlet pipe. The control module not compatible with the pressure system. LPS switch faulty.

Open the valve. Check regulator setting to ensure adequate flow. Test Low Pressure Switch circuit. Refer to rating plate on the VRA Refer to the Diagnostics and Field Service Instructions manual.

02 Low Input Power Voltage Warning

Main Input Power Voltage has dropped below 208 Volts

Test supply voltage. Test fuses and circuit breakers. Refer to section 3.3 Field Wiring.

03 Low Input Power Voltage Shutdown

Main Input Power Voltage has dropped below 187 Volts

Test supply voltage. Test fuses and circuit breakers. Refer to section 3.3 Field Wiring.

04 Maximum Running Time Exceeded

Leak in the high pressure connections. Low flow of the VRA. Maximum Fill Time parameter programmed too short for current ap-plication.

Check integrity of the high pressure lines. Test flow of compression modules. Program the Maximum Fill Time appropriate to the volume of vehicle tank (Slow Fill) or consumption of gas (Fast Fill). Refer to the Diagnostics and Field Service Instructions manual.

05 Insufficient Pressure Rise below 30 bar (435 psig)

Leak in the high pressure connections. Initial fill of a very large storage. Low flow of the VRA.

Check for leaks. 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 storage to create back pressure grater than 30 bar (435 psig). Check if all compression modules are running and correct. 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.


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LED Display / Description Possible Cause Corrective Action

08 Sudden Pressure Drop to Below 30 bar g (435 psig)

Damage to the high pressure connections. Failure of the Combi-Valve.

Check for leaks. Test High Pressure Transducer circuit. Test combi-valve circuit. Test Combination Valve. See Section 5.3 of the Diag-nostics and Field Service Instructions manual for the test procedure.

09 Excessive Blowdown Pressure

Fill hose / tubing between the VRA and filled tank too long. Leaking check valve at the vehicle receptacle or at the storage. Plugged vent connection to the Con-trol Module.

Check hose for length, compare to specification. Test check valves for leaks. Check vent outlet for debris or ice, inspect tubing for sharp bends. Contact your Local Authorized Dealer.

10 Less Than 100 Hours to Service Interval (Compression Module 1)

Compression modules have a mandatory service interval of 4000 hours.

Compression Module requires replacement within the next 100 hours or module will be locked out. Contact your Local Authorized Dealer.

11 Excessive Surface Temperature (Motor Module 1)

Cooling fan not operating or at reduced capacity. Input voltage out of specified range. Low air flow over compression module.

Check fan operation. Test motor circuit continuity. Check for low voltage. Check inlet air flow. Ensure that there is no blockage of air intake vents.

12 Excessive Motor Temperature (Motor Module 1)

Cooling fan not operating. Input voltage out of specified range. Reduced air flow over compression module. Motor module shorted.

Check fan operation. Test motor circuit continuity. Check for low voltage. Check inlet air flow. Ensure that there is no blockage of air intake vents. Test motor module circuit.

13 Faulty Hourmeter Compression Module 1 incompatible to the pressure system. Hourmeter damaged.

Check type of the Compression Module - CPQ2 for FMQ-10, CPQ2-36 for FMQ-8-36, and CPQ2-42 for FMQ-7-42. Test Hourmeter.

14 Service Interval Overdue Compression Module 1 operating beyond mandatory service interval.


15 Incompatible Compression Module Pressure Rating (Compression Module 1)


16 Surface Temperature Sensor Failure (Motor Module 1)

Test surface temperature sensor circuit. Contact your Local Authorized Dealer.

19 Ruptured Burst Disc (Compression Module 1)

Ruptured burst disc. High pressure transducer failure.

Test Compression Module flow rate. Test HPT circuit. Contact your Local Authorized Dealer.




Table 4 Error Codes (continued)


Issue 7, July 2002 39.0046 14


LED Display / Description Possible Cause Corrective Action


































Issue 7, July 2002 39.0046 15

LED Display / Number Code



























50 Input Power Contactor Failure

Test supply voltage. Replace Electronics Module. Contact your Local Authorized Dealer.

51 Run Relay Failure (Motor 1) Test supply voltage and fuses.

Replace Electronics Module. Contact your Local Authorized Dealer.







Issue 7, July 2002 39.0046 16





55 Start Relay Failure (Motor 1) Test supply voltage and fuses.








59 Start Contactor Failure Test supply voltage and fuses.


60 Start/Stop button Failure Check electronics module lid clearance.


61 Reference Voltage Failure Test input voltage.


62 Ambient Temperature Sensor Failure

Test ambient temperature sensor circuit. Replace Electronics Module. Contact your Local Authorized Dealer.

63 Ambient Temperature Out of Range

Test ambient temperature sensor circuit. Replace Electronics Module. Contact your Local Authorized Dealer.

64 Combi Valve Failure Test combi valve circuit.

Replace Controls Module or Electronics Module. Contact your Local Authorized Dealer.

65 Combi Valve Relay Failure Test combi valve circuit.

Replace Electronics Module or Controls Module. Contact your Local Authorized Dealer.

70 No Communication with Remote Fueling Panel (RFP).

Check interface cable and connections. Replace RFP. Refer to RFP Installation and Operating Instruction manual. Contact your Local Authorized Dealer.

71 RFP Detected But not Programmed

Reprogram RFP. Contact your Local Authorized Dealer.

72 RFP Reference Voltage Failure

Check interface cable and connections. Replace RFP. Contact your Local Authorized Dealer.



Issue 7, July 2002 39.0046 17



73 RFP Ambient Temperature Sensor Out of Range

Test RFP ambient temperature sensor circuit. Replace RFP. Contact your Local Authorized Dealer.

74 RFP / RS / IS Start Signal Failure

Start VRA manually. Replace start option. Contact your Local Authorized Dealer.

75 RFP Stop Signal Failure Stop VRA manually.

Replace RFP Contact your Local Authorized Dealer.

76 No Communication with RS / IS

Check interface cable and connections. Start VRA manually. Contact your Local Authorized Dealer.

78 External Interlock Detected But Not Programmed

Check external interlock programming. Contact your Local Authorized Dealer.

79 External Interlock Failure

Test external interlock circuit. Contact your Local Authorized Dealer.

80 Incompatible Remote Device Start VRA manually.

Replace electronics module. Contact your Local Authorized Dealer.

81 No Communication With Pressure Start System

Start VRA manually. Test pressure start circuit. Contact your Local Authorized Dealer.

82 Pressure Start Failure Start VRA manually.

Test pressure start circuit. Contact your Local Authorized Dealer.

83 No communication with P50 option.

Test shut down pressure against ambient temperature.

88 Display Test

None

90 Controls Module HPT Failure

High pressure Transducer has failed. Test HPT circuit.


91 Incompatible Controls Module Pressure Rating


92 Blowdown System Failure

Fill hose / tubing between the VRA and filled tank too long. Control circuit of the Combi Valve failure.

Check hose for length, compare to specification. Test Combi Valve. Check vent line for blockages. Inspect vehicle check valve.

99 Power Was Interrupted Check that Disconnect Switch and Breaker

are on at all times. Test supply voltage.



Issue 7, July 2002 39.0046

7 SERVICE

7.1 SERVICE INTRODUCTION Safety precautions require that the VRA’s internal components be inaccessible to the User and other unauthorized personnel. Accordingly the top lid and the electronics module lid must be re-installed by authorized service personnel before they leave the site. Only authorized service representatives may service the VRA at the User’s premises. Any detailed service not described in this document must only be carried out by FuelMaker Corporation Service Staff at a factory service facility. Service undertaken by unauthorized persons may cause the VRA to operate incorrectly and may result in damage, serious injury or death. Service Interval At the time of publication, FuelMaker Corporation requires that each compression module be serviced after every 4000 hours of running time. Depending on the local gas quality or technical advancements, the service interval may be increased beyond 4000 hours in the future. Either 10, 20, 30 or 40, depending upon which compression module is involved, will appear on the User Panel display indicating to the User that the unit must be serviced within the next 100 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). The following modules must be serviced or reconditioned at one of FuelMaker Corporation’s service facilities only:

• Compression Module (required after 4000 hours, or if a fault is indicated by the diagnostics)

• Controls Module (if a fault is indicated by the

diagnostics) • Electronics Module (if a fault is indicated by the

diagnostics) • Motor Module (if a fault is indicated by the diagnostics) • Cooling Fan (if noisy or vibrating excessively, or if a

fault is indicated) All normal safety precautions must be observed when undertaking on-site service and replacement of VRA modules.

Removing the VRA If for any reason the entire VRA needs to be removed:

• All normal safety precautions must be observed when disconnecting the VRA.

• Turn off the electrical power supply to the VRA.

• Disconnect the power supply wires from the electronics module (See Figure 4).

• Remove the power supply cable from the unit.

• Turn off and disconnect the gas supply.

• Release the pressure inside the blow-down system by loosening the high pressure tubing to the inlet side of the check valve.

• Plug the gas inlet and vent connections before transporting the VRA to prevent the contamination of internal components.

• Undo the lag bolts at the mounting feet of the VRA.

• The whole unit is now ready to be lifted with a forklift or a crane using sling harnesses.

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Issue 7, July 2002 39.0046

APPENDIX A: ANCILLARY DEVICES

The VRA has no capacity to connect a refueling hose assem-bly and no user accessible controls to start or stop the unit. Additional ancillary devices are required to connect to fuel cylinders and to control the VRA’s operation. A.1 PRESSURE START This is the standard configuration for the VRA and may only be used with a pressurized manifold. A high pressure trans-ducer within the housing of the VRA continuously monitors the pressure in the manifold line and will signal the electron-ics module to restart the compression modules when a suffi-cient drop in pressure is detected. The pressure start drop setting is programmed into the electronics module using a Field Programmer. Fueling points (i.e. remote fueling panels or auxiliary fuel-ing panels) must still be provided to connect the refueling hose assemblies to. When filling a cylinder, the refueling nozzle is attached to the receptacle and the nozzle vent valve is turned to the “FILL” position. The compressed natural gas in the mani-fold line will flow into the cylinder and the pressure in the line will drop. When a sufficient drop in pressure is de-tected, the VRA will start and continue to run until the pres-sure reaches the maximum temperature compensated value. A.2 REMOTE FUELING PANEL A remote fueling panel (RFP) is connected to a VRA through high pressure tubing and provides a means to connect to the cylinder for refueling. The RFP is typically installed in-doors. The RFP incorporates a manifold block which can accept one or two refueling hose assemblies. An RFP also houses a control panel with “START” and “STOP” buttons and 3 warning lights to display the current status of the VRA. The RFP also incorporates ambient temperature sensors which override those in the VRA when determining the maximum temperature compensated pressure to deliver to the cylinder. When an RFP is to be used, the electronics module in the VRA must be programmed to accept input from the RFP. Only a one RFP may be connected to a single VRA. An RFP may be used without a pressurized manifold system if the total length of tubing between the RFP and the VRA does not exceed certain limits (refer to the RFP manual for more details).

Connect the refueling nozzle to the cylinder and, where equipped, turn the nozzle vent valve to the “FILL” position. Push the “START” button to activate the VRA and begin the fueling cycle. The unit will shut down automatically when the cylinder reaches its maximum temperature compensated pressure. The VRA can also be shut down by pushing the “STOP” button. The 3 LEDs show the current operating status of the VRA and will display some of the error codes generated by the VRA. Refer to the RFP manual for more details. A.3 AUXILIARY FUELING PANEL The Auxiliary Fueling Panel (AFP) is similar to the RFP as it provides a means to connect up to 2 refueling hose assem-blies. The AFP does not contain the user panel or ambient temperature sensors of the RFP. Multiple AFPs may be connected to one or more VRAs as the customer requires. If mounted indoors, an AFP must be installed in conjunction with an RFP. An AFP may be used without a pressurized manifold system if the total length of tubing between the AFP and the VRA does not exceed specified limits (refer to the AFP manual for more details) and if another ancillary device is installed which controls the operation of the VRA (i.e. RFP, remote start). When used with a pressurized manifold (i.e. Pressure Start), connect the refueling nozzle to the receptacle and turn the nozzle vent valve to the “FILL” position. When used with other start devices, connect the refueling nozzle to the recep-tacle and activate the other system (i.e. push the “START” button on the RFP or remote start system). A.4 REMOTE START The VRA has no means for the user to start or stop the unit. A Remote Start System (RSS) adds a “START” button at a location near to the fueling point. Pressing the button will start all of the VRAs connected to that switch. The VRA(s) will continue to run until the maximum temperature compen-sated pressure is reached in the cylinder. A.5 FAST FILL & INTEGRATED START Time-fill, also called Direct-Fill applications take time to fill a cylinder. Shorter filling times can be achieved by using pressurized storage cylinders to fill a vehicle tank instead of

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Issue 7, July 2002 39.0046

the VRA. FuelMaker offers the model FF350 Fast Fill Stor-age System to provide fast-fill capability to a VRA installa-tion. The storage cylinders are kept pressurized and have a larger volume than the vehicle tank so the fueling cycle will take seconds or minutes instead of hours. The pressure start system in the VRA monitors the pressure in the storage cyl-inders and will restart when a sufficient pressure drop is de-tected. In this configuration, the VRA replenishes the gas in the storage cylinders and not in the vehicle. The maximum pressure in the vehicle tank will not be as high as with time-fill applications since the maximum pres-sure has already been reached in the storage system. The 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.

To achieve a fill closer to the ideal vehicle tank pressure, the storage system is typically divided into 3 banks which are tapped sequentially. When the first bank has equalized pressure with the vehicle tank, the second bank is con-nected. When it has finished, the third bank is connected and equalized to complete the fill cycle. Switching between banks is handled by the operator turning a manual valve. If the pressure start system is not installed in the VRA, an Integrated Start option is available. The integrated start system is installed in the FF350 and will start the VRA to replenish the cylinders when the main valve is moved from the first to second position. The VRA will shut down when the maximum temperature compensated pressure is reached in the storage cylinders.

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Documents

39.0046_Issue7_July2002_FMQ-10&FMQ-8-36&FMQ-7-42_Install&OperateInstructions