Dispenser Manual 35835 - 1 2 PDF
Dispenser Manual 35835 - 1 2 PDF
Dispenser Manual 35835 - 1 2 PDF
Section 1 – Information
Section 2 – Installation
Section 3 – Maintenance
Contains data from the IMW quality control manual for client
dispenser.
SECTION 1
Welcome to IMW
IMW designs, manufactures and supports a full range of roll-forming products, and compressor
system products. We specialize in compressed natural gas (CNG) compressors and complete
fueling systems.
Experience gained through our general machine shop and manufacturing operations has led to
cutting-edge technologies and the know-how to meet increasingly complex demands worldwide.
State-of-the-art…
…CNG refueling systems have earned IMW a worldwide reputation for quality, performance, and reliability
through precision engineering and manufacturing. IMW uses only the highest-quality components in its systems,
including integrated PLC controls and custom-designed compressor assemblies, available exclusively from IMW
Compressor Systems. In-house capabilities and a commitment to growth ensure that our products remain
affordable.
Innovative…
…Compressor technology is the foundation of IMW’s CNG refueling systems. IMW is a pioneer in the
development and production of low-speed, non-lubricated compressors and of complete, high-volume transit
fueling systems. Our CNG compressors produce clean gas—low in oil content—while operating at low noise and
vibration levels, thereby enhancing system usability and component life, yet they boast a discharge flow capacity
equal to any compressor on the market.
INFORMATION
Should you experience any difficulty with your dispenser and all efforts have
been exhausted and all procedures shown in the trouble-shooting guide have
been carried out then service by an IMW qualified technician is available by
following the procedure listed below.
ii. Detail all corrective action that was attempted to rectify the problem
and the results if any of that action.
iii. Note the model and serial number located on the side of the
dispenser unit.
v. Date of installation
One of our qualified service technicians will be able to get your system
restored and running either by instruction over the phone or an on site visit.
DISPENSER LOCATION
COMPANY
ADDRESS CITY
PRIVINCE / STATE POSTAL CODE
PHONE No.
FAX No.
REPORTED PROBLEM
COMMENTS
CUSTOMER SIGNATURE
X DATE
IMW SERVICE TECHNICIANS SIGNATURE
X DATE
INFORMATION
b. SAFETY INSTRUCTIONS
c. GENERAL REMARKS
FILLING PROCEDURE
The IMW series CNG Dispensers are designed for fast fill refueling
of any NGV vehicle equipped with a compatible on board refueling
receptacle. A single trained person can safely use the dispenser to
refuel the NGV vehicle by following the procedure below.
1. Position the NGV vehicle such that the refueling receptacle of the
vehicle is within the range of the dispenser refueling hose.
3. Open the fill nozzle valve by rotating the handle 1/4 turn counter
clockwise.
6. Close the fill nozzle valve by rotating the handle a 1/4 turn
clockwise. As the nozzle valve is closed a small amount of gas will
be vented to atmosphere through a return line or directly at the
valve.
Important!
Visual Inspection:
The following items must be tightened, repaired or replaced as
required:
• Leaking port conditions;
• Remove excess dirt buildup;
• Clamps, guards, shields; and
Operation
Do not exceed the maximum working pressure of the hose (5000
psig, 345 Bar)
When near any pressurized area the worker shall wear eye
protection which is attached to their head, in accordance with
W.C.B. - I.H.S.R. reg. 14.21.
LOCKOUT PROCEDURE
1. The dispenser area will have a red push button switch called an
emergency shutdown (ESD) push button. The location of this device
should be made familiar to all personnel. In case of emergency,
manually depress the ESD push button. Upon depressing, all station
operation shuts down immediately. Upon ESD activation the follow will
occur:
ii. The pressure vessel storage cascade is isolated from the rest of the
station with the fail-safe emergency shutdown (ESD) valves.
iii. The sequencing valves or flow control valves in the dispenser rotate
closed isolating gas from the fill nozzle.
iv. All station operation ceases until the station electrical controls are reset.
SECTION 2
The dispenser must be provided with a suitable flat and level concrete
foundation for mounting. Recommended practice is to provide a concrete
dispenser island with a curb at least 8" above grade. The dispenser island
is also provided with a pit into which buried gas piping and electrical lines
emerge. The dispenser is then positioned and mounted over the pit for
convenient access of electrical conduit and gas piping lines into the
dispenser cabinet. The pit also extends beyond the dispenser footprint for
access. The area not covered with the dispenser cabinet is covered with a
removable steel plate recessed into the concrete top surface.
Most installation codes require bollard protection posts for dispenser crash
protection. These can be cast into the concrete island and sized in
accordance with code requirements.
The dispenser cabinet includes mounting holes in the base frame. Bolt
down studs can be cast into the concrete to match these mounting hole
locations or the dispenser can be bolted to suit after positioning with the
use of "Hilti" type concrete fasteners.
INSTALLATION
A common practice is to install 1" Sch. 160 pipe that is buried and runs
underground to the dispenser pit at a depth of 24" to 36". The 1" Sch. 160
pipe should be yellow jacket coated and catholically protected as per local
code requirements. At the dispenser pit, the three piping lines emerge into
insulating flanges.
Important!
Filters are not sold with IMW dispensers unless ordered by the customer.
IMW dispensers are factory calibrated and tested to ensure the best quality.
IMW strongly recommends the flow meters be zeroed using the following
procedure
CAUTION:
Failure to zero the flowmeter at initial startup could cause the transmitter to
produce inaccurate signals.
1. Apply power to the IMW dispenser and allow it to warm up for at least 30 minutes
2. Allow gas to flow through the sensor for at least 10 minutes so that the sensor
temperature will equal the normal gas operating temperature.
3. Make sure the sensor is completely filled with gas
NOTE: Zeroing the flowmeter establishes the flowmeter's point of reference when
there is no flow.
The default zero time is 20 seconds.
Go to OFF-LINE MAINT
Dots will traverse the top line of the display while the zero is in progress
If the transmitter displays TEST OK, then the zero was successful. If TEST FAIL
appears, the zero procedure failed, contact your IMW service representative
immediately.
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MAINTENANCE
SECTION 3
A dome loaded regulator is used to stop the flow of gas to the NGV vehicle
at the correct temperature compensated fill pressure. The regulator shut
off pressure is controlled by pressurized natural gas in the dome of
regulator. Pressurized gas to the regulator is supplied by a small pressure
vessel called the Reference Vessel. This vessel is located inside the
cabinet of the dispenser. The pressure inside this vessel is dependent on
ambient temperature. On higher temperature days, the regulator shut of
pressure will be higher than on cooler days. This feature is used to
maintain safe dispenser final fill pressures under all temperature conditions.
If it is found that the reference vessel pressure very quickly (over the
course of a day) goes out of adjustment by more than 100 psig, then it may
be that the dome loaded regulator seals require replacing. If the dome
loaded regulator seals leak then gas from the reference vessel can escape
into the gas stream flowing to the NGV vehicle. Gas leakage may also
occur into the reference vessel from the dispensing gas stream causing a
rise in reference vessel pressure. Before rebuilding the dome load
regulator however, check for any other sources of gas leakage such as
leaking needle valves or fitting/tubing lines. If any leaks are found and
corrected, readjust the reference vessel to the correct pressure. Observe
the reference vessel pressure over a day to see if the problem has been
solved before rebuilding the dome load regulator.
MAINTENANCE
A pressure gauge on the side of the dispenser is provided for service and
maintenance personnel to check reference vessel pressure. The pressure
of the reference vessel should be checked daily to assure that the correct
pressure adjustment is being maintained
ii. Use the following table to find the correct reference vessel pressure
corresponding to the current ambient temperatures.
ii. Slowly open needle valve 2 until gas begins to bleed into reference
vessel causing the pressure gauge to rise. Once the pressure
gauge reading matches the pressure for the ambient temperature,
found on the table, close needle valve 2 and 1.
ii. Slowly open needle valve 3 until the pressure gauge reading starts
to drop. Once the pressure gauge reading matches the pressure
found on the table for the ambient temperature, close needle valve
3 and 1.
MAINTENANCE
TABLE
10 2800
12 2840
14 2880
16 2920
18 2960
20 3000
22 3040
24 3080
26 3120
28 3160
30 3200 (20 MPa)
32 3240
34 3280
36 3320
38 3360
40 3400
42 3440
44 3480
46 3520
MAINTENANCE
TABLE
104 40 2778
95 35 2734
86 30 2689
77 25 2659
68 20 2600
59 15 2555
50 10 2511
41 5 2466
32 0 2422
23 -5 2377
14 -10 2333
5 -15 2288
-4 -20 2243
-13 -25 2200
-22 -30 2154
-31 -35 2110
-40 -40 2065
Note: This table provides reference vessel adjustments for final fill pressures of 3000 psig @ 20 deg. C or
68 deg. F. At 20 deg. C the reference vessel is adjusted to 2600 psig. This adjustment will provide a
3000 psig vehicle final fill pressure. The difference in pressure between reference vessel and final fill
pressure is due to the actuator rod area on one side of the plunger. This results in unequal pressure
areas on the plunger surfaces and therefore unequal adjustment and fill pressures.
MAINTENANCE
1. Open the fill valve and vent valve and bleed any gas left in the hose
assembly. Close the vent valve and fill valve.
2. Inspect the fill nozzle, hose, breakaway coupling and housing for
damage and repair/replace as necessary.
4. Open the vent needle valve at the fill pressure gauge, inside the
dispenser, and vent the gas between the emergency shut off valve
and disconnect coupling so that the coupling can be reconnected.
Close the vent valve.
7. Slowly open the emergency shut off valve to re-pressurize the hose.
2. Open the vent valve inside the dispenser cabinet at the fill pressure
gauge. Close the vent valve.
8. Slowly open the emergency shut off valve to re-pressurize the hose.
MAINTENANCE
SECTION 4
Includes:
- Product Specification
- General Arrangement
- Piping Diagrams
- Electrical Schematic
- Miscellaneous Diagrams
- Component Compliances
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12 11 10 9 8 7 6 5 4 3 2 1
C IMW INDUSTRIES LTD. 2005-06-21
REVISION HISTORY
DO NOT USE AS THE BASIS
H H
FOR MANUFACTURE OR SALE OF
APPARATUS WITHOUT REV. DATE BY REFERENCE
PERMISSION.
712 1068
28 1/32" 42 1/32"
G G
1x ESD
PUSHBUTTON
3LINE
FLIP-UP REGISTER
FRONT
COVER
FIXED
BACK
PANEL
F KEYPAD F
OPERATOR
PANEL
PRESSURE
GAUGE
2x EMERGENCY
HOLSTER MANUAL
2141±12.70 SHUT-OFF
84 5/16"±1/2" 2063 VALVE
81 7/32"
E 1689 E
66 1/2"
ON/OFF
SWITCH
2X REMOVABLE
1343 ACCESS PANEL
52 7/8"
1177
46 5/16"
1041
41"
911
35 7/8"
D D
A A
C C
LEFT FRONT (SIDE 1) RIGHT BACK (SIDE 2)
216 483
8 1/2" 19"
NOTES
102
4" 1. TYPICAL FEATURES SHOWN. REFER TO SALES CONTRACT FOR SPECIFIC DETAILS .
B 2. DUAL HOSE DISPENSER SHOWN.
B
16
4x 5/8"
356
14"
DIMENSIONING & TOLERANCING PER IMW Industries Ltd.
ASME Y14.5M-1994. U.S.O.: Chilliwack, BC, Canada
TITLE
DISPENSER CABINET
UNITS INCHES X/X ±1/16
FILE. NO.
FINISH 64 MICRO IN. .X ±.1 REF. STANDARD SIZE REV
040-00031-0012-00
A SECTION A-A INNER RADI .020 MAX. .XX
.007±.002 .XXX
±.01
±.005
DR.
CK.
CW 2005/06/21
D DWG. NO.
MRP ID
A A
OUTER
EDGE X 45° ANGLES ±.5 AP. SCALE 1:8 WEIGHT 304707.750 SHEET 1 / 1
12 11 10 9 8 7 6 5 4 3 2 1
! #
&
!
#
! #
&"!
#
!66
.7+,182
10 12
IMW COMPRESSOR
7 8 9
4 5 6
1 2 3
GRN/YEL
MARKING (EXAMPLE ONLY)
WHT
WHT
BRN
RED
RED
BLK
BLK
BU
RED
BLK
SEE
PAGE 2
ESD ESD COM COM TERMINAL STRIP
TERMINALS PROVIDED 1 2 1 2
1 2 2 4 6 7 9 10 12 PROVIDED IN DISPENSER
IN IMW COMPRESSOR ELECTRICAL JUNCTION BOX
x2
x5
x3
113
114
3 X ½” FNPT HOLES
1. POWER SUPPLY (BY OTHERS)
2. COMMUNICATIONS PORT (BY OTHERS)
ADALET JUNCTION BOX 3. EMERGENCY STOP PUSHBUTTON
COMPONENT LAYOUT
INTRINSICALLY SAFE
AREA SEPARATED BY
MIN 2" OR SUITABLE
METAL BARRIER
TITLE:
IMW 3000 PUMP CONTROL
D
SOLENOID VALVE
REF. STANDARD DISPENSER
DR. TJ 2005-12-08 SIZE FILE. NO. DUAL HOSE SINGLE LINE
DISPENSER ELECTRICAL CLASSIFICATION
CK. A DWG. NO.
MRP ID
ED-D010-05
CLASS I DIV I GROUP D
AP. SCALE: none REV: A SHEET: 1 of 2
INTRINSICALLY SAFE AREA
LOGIC BOARD
LGC21 v4.1
SERIAL LOOP
COMMUNICATIONS
DISPLAY 1 & 2
RED
PRESSURE 1
WHT
TRANSMITTER 2
HOSE 1
RED
PRESSURE 1
WHT
TRANSMITTER 2
HOSE 2
KE KE
YP YP
AD AD
HO /SW H /S
SE ITC OSE WITC
1 H 2 H
A(+)
A(-)
RS485 TO FLOW METER
RIBBON CABLE
RIBBON CABLE
CA-GC21-02B
CA-GC21-02A
GRN
BRN
BU
120-24V POWER SUPPLY KEYPAD KEYPAD
FTMM50 v2.0 GRN/YEL HOSE 1 HOSE 2
BRN
BU
HOSE 1 HOSE 2
120-24V POWER
AUTHORIZE SW AUTHORIZE SW
SUPPLY
FTGC21-BKI v2.0
WHT
RED
RED
RED
BLK
BLK
BLK
BLK
11 12 13 14 11 12 13 14
RED
BLK
WHT
BLK
WHT
BLK
BLK
1 4 1 4
2 3 2 3
MICROMOTION MICROMOTION
CNG 50 HOSE 1 CNG 50 HOSE 2
IMW Industries Ltd.
IMW Chilliwack, BC, Canada
TITLE:
IMW 3000 PUMP CONTROL
SOLENOID VALVE
REF. STANDARD DISPENSER
DR. TJ 2005-12-08 SIZE FILE. NO. DUAL HOSE SINGLE LINE
CK. A DWG. NO.
MRP ID
ED-D010-05
AP. SCALE: none REV: A SHEET: 2 of 2
MANUFACTURER'S CERTIFICATE OF QUALITY
In order to comply with decreto 4570 of December 12, 2005 issued by the Ministry of Commerce, Industry and Tourism Colombia,
we are herby issuing a certificate of conformity for the following products:
This dispenser(s) are manufactured to comply with the requirements as defined in NTC 4820 and NTC 4823.
Type: CNG Dispenser Use: Dispense Natural Gas Set Pressure: 2900 PSIG
Model: IMW3000XH-2 Date Of Manufacture: July, 2009
Serial #: 35835-1-2
IMW Industries Ltd. certifies that this dispenser is manufactured with new materials and components only, and is designed and
certified in accordance with the applicable codes and standards set forth for the manufacture of CNG equipment in North America
(Table 1).
IMW Industries Ltd. certifies that all electrical components incorporated into this equipment are approved by the Canadian
Standards Association (CSA) or Underwriter’s Laboratories (UL) and are suitable for the environment in which they are used.
IMW Industries Ltd. certifies that this equipment is suitable for the purpose for which it was designed and can be operated safely
when used in accordance with the manufacturer’s instructions and recommendations.
The equipment referenced on the certificate has been manufactured / assembled in Canada.
TABLE 1
COMPONENT / ASSEMBLY CODE / STANDARD CERTIFICATION
Dispenser piping and tubing. CSA B51-03, ASME/ANSI B31.3 Manufactured under CSA B51-03 quality system
Filter housing ( if applicable) CSA B51-03, ASME Sec VIII Div 1 Manufactured under CSA B51-03 quality system
Relief valves ASME UV stamped
Hoses for Natural Gas Vehicles and CSA/ANSI/IAS NGV 4.2-1999
Breakaway Devices for Natural Gas CSA/ANSI/IAS NGV 4.4-1999
Manually Operated Valves for Natural Gas CSA/ANSI/IAS NGV 4.6-1999
Compressed Natural Gas Vehicle (NGV) Addenda A-M97; Addenda B-M98;
NGV Dispensing Systems CSA/ANSI/IAS NGV 4.1-1999
Natural Gas Fueling Station Reciprocating CSA/ANSI NGV 4.8-2002
Electrical components CSA and or UL CSA and or UL
Electrical wiring NFPA52, CSA C22.1-01 Canadian Elec. Code, NFPA70 Comply in design/manufacturing
NGV Dispenser construction System NFPA 52, CSA12.5 Comply in design/manufacturing
Martin Loffler
Quality Assurance Manager
www.imw.ca
IMW Industries Ltd. 43676 Progress Way, Chilliwack, BC, Canada V2R 0C3 Tel: 604-795-9491 Fax: 604-792-3806 [email protected]
FO-QC-2007-001 Rev.2 Page 1 of 1