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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 FuelMakers 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
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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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 ...............................................................................................................................

Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046

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 (contd)
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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 m
3
/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 m
3
/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 m
3
/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 -40C to +46C (-40F to +115F). 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 @ 21C (3000 psig @ 70F)

6.9 kPa (1.0 psig) at rated flow *

8.6 kPa (1.25 psig) at rated flow

17.0 m
3
/hr @ 21C and 8.6 kPa inlet
(10 SCFM @ 70F and 1.25 psig inlet)
24.8 MPa @ 15C (3600 psig @ 59F)

6.9 kPa (1.0 psig) at rated flow *

8.6 kPa (1.25 psig) at rated flow

12.9 m
3
/hr @15C and 8.6 kPa inlet
(7.6 SCFM @ 59F 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
-40C to +46C (-40F to +115F)
* 1.7 kPa (0.25 psig) inlet option available
FMQ-7-42
29.0 MPa @ 16C (4200 psig @ 61F)

6.9 kPa (1.0 psig) at rated flow *

8.6 kPa (1.25 psig) at rated flow

11.6 m
3
/hr @21C and 8.6 kPa inlet
(6.8 SCFM @ 70F and 1.25 psig inlet)


Table 1 Technical Specifications
1
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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
2
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 m
m
(43-7/8") M
ounting feet center
Mounting Holes
" diameter
38.1 mm (1.5")
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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 VRAs 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 m
3
/hr (10 scfm), for
the model FMQ-8-36 is approximately 13.6 m
3
/hr (8.0scfm),
and for the model FMQ-7-42 is approximately 11.9 m
3
/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/m
3
(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
3
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
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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 carpenters 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 VRAs blowdown system
at all times; air must not migrate up the fill hose and into the
4
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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 customers 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.

5
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
6
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 Users
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
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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.
7
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
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
8
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
Compression Module #2
Compression Module #1
Bucket
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
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.
9
Table 2 Shutdown Pressure vs. Ambient Temperature
FMQ-10 FMQ-8-36
20.7 MPa @ 21C (3000 psig @ 70F) 24.8 MPa / 3600 psig @ 15C / 59F
18.3 MPa / 2660 psig @ 10C / 50F 23.2 MPa / 3370 psig @ 10C / 50F
16.6 MPa / 2410 psig @ 0C / 32F 21.0 MPa / 3050 psig @ 0C / 32F
15.0 MPa / 2180 psig @ -10C / 14F 18.8 MPa / 2730 psig @ -10C / 14F
13.3 MPa / 1930 psig @ - 20C / -4F 16.5 MPa / 2390 psig @ -20C / -4F
11.6 MPa / 1690 psig @ -30C / -22F 14.3 MPa / 2073 psig @ -30C / -22F
10.0 MPa / 1450 psig @ -40C / -40F 12.1 MPa / 1754 psig @ -40C / -40F
Note: Pressure readout may vary 1 MPa / 145 psig from the above theoretical values.
FMQ-7-42
29.0 MPa / 4200 psig @ 16C / 60F
27.4 MPa / 3978 psig @ 10C / 50F
24.7 MPa / 3586 psig @ 0C / 32F
22.0 MPa / 3193 psig @ -10C / 14F
19.3 MPa / 2801 psig @ -20C / -4F
16.6 MPa / 2408 psig @ -30C / -22F
13.9 MPa / 2016 psig @ -40C / -40F
4 TESTING AND COMMISSIONING
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
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.
10
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
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
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
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
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
Contact your Local Authorized Dealer.
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.
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
13
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.
Contact your Local Authorized Dealer.
15
Incompatible Compression
Module Pressure Rating
(Compression Module 1)

Contact your Local Authorized Dealer.
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.
20
Less Than 100 Hours to
Service Interval
(Compression Module 2)
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.
Table 4 Error Codes (continued)
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
14
Table 4 Error Codes (continued)
LED Display / Description Possible Cause Corrective Action
21
Excessive Surface
Temperature
(Motor Module 2)
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.
22
Excessive Motor
Temperature
(Motor Module 2)
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.
23
Faulty Hourmeter
Compression Module 2 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.
24
Service Interval Overdue
Compression Module 2 operating
beyond mandatory service interval.
Contact your Local Authorized Dealer.
25
Incompatible Compression
Module Pressure Rating
(Compression Module 2)

Contact your Local Authorized Dealer.
26
Surface Temperature
Sensor Failure
(Motor Module 2)
Test surface temperature sensor circuit.
Contact your Local Authorized Dealer.
29
Ruptured Burst Disc
(Compression Module 2)
Ruptured burst disc.
High pressure transducer failure.
Test Compression Module flow rate.
Test HPT circuit.
Contact your Local Authorized Dealer.
30
Less Than 100 Hours to
Service Interval
(Compression Module 3)
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.
31
Excessive Surface
Temperature
(Motor Module 3)
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.
32
Excessive Motor
Temperature
(Motor Module 3)
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.
33
Faulty Hourmeter
Compression Module 3 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.
34
Service Interval Overdue
Compression Module 3 operating
beyond mandatory service interval.
Contact your Local Authorized Dealer.
35
Incompatible Compression
Module Pressure Rating
(Compression Module 3)

Contact your Local Authorized Dealer.
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
15
LED Display /
Number Code
Description Possible Cause Corrective Action
36
Surface Temperature
Sensor Failure
(Motor Module 3)
Test surface temperature sensor circuit.
Contact your Local Authorized Dealer.
39
Ruptured Burst Disc
(Compression Module 3)
Ruptured burst disc.
High pressure transducer failure.
Test Compression Module flow rate.
Test HPT circuit.
Contact your Local Authorized Dealer.
40
Less Than 100 Hours to
Service Interval
(Compression Module 4)
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.
41
Excessive Surface
Temperature
(Motor Module 4)
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.
42
Excessive Motor
Temperature
(Motor Module 4)
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.
43
Faulty Hourmeter
Compression Module 4 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.
44
Service Interval Overdue
Compression Module 4 operating
beyond mandatory service interval.
Contact your Local Authorized Dealer.
45
Incompatible Compression
Module Pressure Rating
(Compression Module 4)

Contact your Local Authorized Dealer.
46
Surface Temperature
Sensor Failure
(Motor Module 4)
Test surface temperature sensor circuit.
Contact your Local Authorized Dealer.
49
Ruptured Burst Disc
(Compression Module 4)
Ruptured burst disc.
High pressure transducer failure.
Test Compression Module flow rate.
Test HPT circuit.
Contact your Local Authorized Dealer.
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.
52
Run Relay Failure (Motor 2)
Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
53
Run Relay Failure (Motor 3)
Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
Table 4 Error Codes (continued)
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
16
LED Display /
Number Code
Description Possible Cause Corrective Action
54
Run Relay Failure (Motor 4)

Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
55
Start Relay Failure (Motor 1)

Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
56
Start Relay Failure (Motor 2)

Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
57
Start Relay Failure (Motor 3)

Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
58
Start Relay Failure (Motor 4)

Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
59
Start Contactor Failure

Test supply voltage and fuses.
Replace Electronics Module.
Contact your Local Authorized Dealer.
60
Start/Stop button Failure

Check electronics module lid clearance.
Replace Electronics Module.
Contact your Local Authorized Dealer.
61
Reference Voltage Failure

Test input voltage.
Replace Electronics Module.
Contact your Local Authorized Dealer.
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.
Table 4 Error Codes (continued)
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
17
LED Display /
Number Code
Description Possible Cause Corrective Action
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.
Contact your Local Authorized Dealer.
91
Incompatible Controls
Module Pressure Rating

Contact your Local Authorized Dealer.
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.
Table 4 Error Codes (continued)
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
Issue 7, July 2002 39.0046
7 SERVICE
7.1 SERVICE INTRODUCTION

Safety precautions require that the VRAs 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 Users
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 Corporations 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.


18
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
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 VRAs 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
19
Vehicle Refueling Appliance
Models FMQ-10, FMQ-8-36 and FMQ-7-42
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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