Kraus CNG Fleet Manual

©2015 Kraus Global Ltd.
Fleet (High Style) CNG Dispenser Manual i

Document revision history
Document No. 267AY30.MNL.R01

Revision # Date Description
2 September, 2015  Editorial update
Code compliance
All Kraus CNG dispensers have been manufactured to comply with

the following codes and standards:
North America
 American Society of Mechanical Engineers (ASME) Boiler and Pressure
Code
 American Society of Mechanical Engineers (ASME) B31.3 – Process
Piping
 Canadian Gas Association (CGA) B108 NGV Refueling Stations
Installation Code
 Canadian Standards Association (CSA) C22.1 Canadian Electrical
Code (CEC) Part I
 National Fire Protection Association (NFPA) 52 Standard for
Compressed Natural Gas (CNG) Vehicular Fuel Systems
 National Fire Protection Association (NFPA) 70 National Electrical Code
Europe
 EN 50 014 Electrical Apparatus for Potentially Explosive Atmospheres –
General Requirements
 EN 50 018 Electrical Apparatus for Potentially Explosive Atmospheres –
Flameproof Enclosure ‘d’
 50 019 Electrical Apparatus for Potentially Explosive Atmospheres –
Increased Safety ‘e’
 50 020 Electrical Apparatus for Potentially Explosive Atmospheres –
Intrinsic Safety ‘i’
CONTENTS
CONTENTS
1. INTRODUCTION 1
1.1 About this manual 1

1.2 Additional references 2
1.3 Contact information 2
1.4 Warnings and notifications 3
1.5 Warranty information 3
1.6 The Fleet CNG dispenser 4
1.7 Dispenser theory of operation 4
TM
1.7.1 The MICON 500C 4
1.7.2 Buffer storage systems 5
1.7.3 Cascade storage systems 5
1.7.4 The Fleet unit layout 6
2. SAFETY 7
2.1 General safety 7

2.2 Filling safety 8
2.3 Dispenser hose safety 9
2.4 Maintenance safety 10
2.5 Leak-test safety 11
3. INSTALLATION AND SETUP 12
3.1 Installation guidelines 12

3.2 Pre-installation 13
3.2.1 Site preparation 13
3.2.2 Uncrating and placing the dispenser 14
3.2.3 Additional notifications 15
3.3 Installation 16
3.3.1 Electrical and communication connections 16
3.3.2 Pressure line connection 16
3.3.3 Filters 17
3.3.4 Attaching the hose 19
TM
3.3.5 MICON power-off mode 21
3.3.6 Communicator operation 22
3.4 Dispenser startup procedures 24
3.4.1 Powering the dispenser 24
3.4.2 Pressurizing the dispenser 26
3.4.3 Commissioning 27

Fleet (High Style) CNG Dispenser Manual iii
CONTENTS
4. OPERATION AND MAINTENANCE 28
4.1. Filling procedure 28

4.2 Dispenser maintenance 29
4.2.1 General dispenser maintenance guidelines 29
4.2.2 Dispenser venting procedure 30
4.2.3 Leak monitoring 31
4.3 Component maintenance 32
TM
4.3.1 MICON 500C 32
4.3.2 KAF 402™ solenoid inlet valve 34
4.3.3 Inline filters 34
5. TROUBLESHOOTING 35
TM
5.1 MICON fault codes 35
5.2 Dispenser issues 38
APPENDIX Appendix-1
A.1 Component description and specifications Appendix-1

KAF 402™ solenoid inlet valve Appendix-1
Micro Motion® CNG050 flow meter Appendix-2
Parker Parflex CNG hose Appendix-4
Fueling nozzles Appendix-5
A.2 Maintenance task list Appendix-7
GLOSSARY Glossary-1
INDEX Index-1

iv Fleet (High Style) CNG Dispenser Manual
CONTENTS
This page intentionally left blank

Fleet (High Style) CNG Dispenser Manual v
CONTENTS

vi Fleet (High Style) CNG Dispenser Manual
CONTENTS
DISCLAIMER
This manual and the information contained herein are not intended to provide
you with any advice on product design, filling station specifications, installation of
equipment, or similar matters and should not be relied upon for such purposes.
Neither Kraus Global Ltd. nor any of its employees or agents are your
professional advisers. You should assess whether you require such advisers and
additional information and, where appropriate, seek independent professional
advice. Kraus, its subsidiaries and affiliates, are not responsible in any manner
for direct, indirect, special or consequential damages however caused arising
TM
from your use of this manual and the information contained herein. MICON is a
trademark of Kraus Global Ltd.

Fleet (High Style) CNG Dispenser Manual vii
1. INTRODUCTION
1. INTRODUCTION
1.1 About this manual
Purpose
This manual was designed to provide installation, operation, and

maintenance guidelines for Kraus’ Fleet (High Style) compressed
natural gas (CNG) dispensers.
Intended users
This manual is designed to be clear, comprehensive, and available to

anyone installing, maintaining, or overseeing the operation of Kraus’
Retail CNG dispensers.
Scope
This manual is divided into five chapters:
1. INTRODUCTION
This chapter provides general information about this manual and
the Fleet CNG dispenser.
2. SAFETY
This chapter provides general safety guidelines, as well as
information regarding dispenser installation, operation, and
maintenance safety.
3. INSTALLATION AND SETUP

This chapter provides installation and configuration guidelines
and procedures for your Fleet CNG dispenser.
4. OPERATION AND MAINTENANCE

This chapter provides operation and maintenance guidelines and
procedures for your Fleet CNG dispenser.
5. TROUBLESHOOTING
This chapter provides general troubleshooting guidelines for
possible installation, operation, and maintenance issues.

Fleet (High Style) CNG Dispenser Manual 1
1. INTRODUCTION
1.2 Additional references

In addition to this manual, the following documents are also
provided with each dispenser package:
 Quick-Start Guide—The Fleet (High Style) CNG Dispenser

 MICONTM 500C Owner’s Manual
 Engineering package
o Flow schematic
o Electrical schematic
o Construction drawings
 Final inspection checklist
 Quality control notices
 Quality control information packages
If you are missing any of the documents listed above or require

additional assistance at any time, please contact our Technical
Support Department.
1.3 Contact information

Kraus Global Ltd.
25 Paquin Road
Winnipeg, Manitoba
Canada, R2J 3V9
www.krausglobal.com
Phone: 1-204-663-3601 Fax: 1-204-663-7112
Extensions:
Technical Support 212
Logistics 215
Sales 235 / 252
Finance 244 / 246
Engineering 203 / 204

2 Fleet (High Style) CNG Dispenser Manual
1. INTRODUCTION
1.4 Warnings and notifications

The following indicators provide various warnings and notifications
throughout this manual:
This indicator provides helpful tips and other advice on proper equipment
installation, usage, and maintenance.
ADVICE
This indicator provides important notifications about the system and its
components.
ATTENTION
This indicator provides critical warnings that may help prevent human
injury and equipment damage.
CAUTION
1.5 Warranty information

For any questions or concerns regarding warranty policies and
procedures for your Fleet CNG dispenser, please contact our Sales
Department.

1. INTRODUCTION
1.6 The Fleet (High Style) CNG dispenser

Kraus’ Fleet CNG dispenser is available in a one, two, or three-line
configuration. Each configuration is available for standard or high-
flow systems with a single or dual dispensing hose setup,
customizable for both buffer and cascade filling stations. Table 1
below describes these customizable features.
Table 1: Fleet dispenser configurations
Dispenser model Fleet CNG Dispenser
Storage system Buffer (1 large bank) Cascade (up to 3 banks)
Filling system Standard-flow High-flow Standard-flow High-flow
Hose configuration Single Dual Single Dual Single Dual Single Dual
1.7 Dispenser theory of operation

This section explains how the MICONTM 500C pump-controller and
KAF 402™ solenoid valves operate to control gas flow within Kraus-
CNG dispensers.
1.7.1 The MICONTM 500C
Kraus’ MICONTM 500C pump-controller is an inexpensive alternative

to using PLC units for operating fuel dispensers. For CNG dispensers,
the MICONTM takes readings from the mass flow meter, pressure
transducer, and temperature probe to determine a final fill pressure
that is based on a series of algorithms in accordance with the Ideal
Gas Law, “PV = nRT”. The result is a controlled fill of a vehicle’s CNG
tank to a safe maximum limit.
After the fueling nozzle is attached and a fill is authorized, the

MICONTM opens all KAF 402™ solenoid valve(s) and dispenses CNG
into the vehicle’s receptacle for four seconds. After the four seconds,
the MICONTM closes the valve(s) and performs a reading of the
vehicle tank pressure and ambient temperature. Based on a
combination of the initial reading and Ideal Gas Law calculations, the
MICONTM determines a target-fill-pressure.

1. INTRODUCTION
1.7.2 Buffer storage systems
A buffer storage system comprises a large storage bank with a single

supply line to the dispenser, which is controlled by one KAF 402™
solenoid valve to start and stop gas flow.
After the target-fill-pressure is calculated, the solenoid valve remains

open for fuel delivery until the target-fill-pressure or minimum flow
setting is reached.
1.7.3 Cascade storage systems
Cascade storage systems typically consist of three separate storage

banks—a low, mid, and high bank. The low bank holds
approximately 70% of the total volume of storage, while the mid and
high banks hold 20% and 10% respectively.
Upon authorization, the MICONTM will open all three banks for 4
seconds to ensure there is sufficient gas flow to continue with the fill.
The banks will then close for another 4 seconds for the target-fill
calculation. Once the target-fill-pressure is calculated, the low-bank
will reopen and deliver fuel until the flow rate drops to a
predetermined level—set in the MICONTM. When this level is
reached, the mid-bank solenoid valve will reopen to deliver the fuel.
If more pressure is needed, the same sequence will occur to access
the high-bank until the target-fill-pressure or minimum flow setting
is reached.

1. INTRODUCTION
1.7.4 The High Style unit layout
A single-hose High Style CNG dispenser—Please refer to the Engineering package for a view of internal components

2. SAFETY
2. SAFETY
Compressed Natural Gas (CNG) can pose great danger if mishandled.

Please be sure to read and understand this section before installing,
operating, or maintaining CNG dispensers.
CAUTION
It is necessary to comply with all safety precautions and other instructions

described throughout this manual to safely install, operate, and maintain
Kraus-manufactured CNG dispensers.
ADVICE
2.1 General safety

Where it is applicable, local regulations take precedence over the
guidelines listed in this section. Please ensure that all personnel are
familiar with all applicable regulations and observe the following
guidelines when working with fuel dispensers:
 Do not smoke or allow open flames and naked lights within 15

feet or 5 meters of any gas installation.
 Do not adjust, remove, or bypass any protective devices.
 Electrical equipment and its protection must comply with the
regulations applicable to the hazard of the location.
 Transportation, installation, commissioning, operation,
maintenance, and repairs should only be carried out by qualified
personnel in accordance with the regulations for operation and
safety.
 Electrical connections must comply with applicable local
regulations.
 Piping and other components, which are not supplied by Kraus
Global Ltd., must be suitable for the respective working pressure.
If necessary, they must be tested and protected by pressure-
unloading devices.
 Systems must be entirely vented before any maintenance or
repair procedures are carried out.
 Do not store flammable materials, such as oily rags, in or around
the dispensing unit.

2. SAFETY
2.2 Filling safety

Please observe the following guidelines when overseeing the use of
all Kraus-CNG dispensers:
 Be aware of emergency procedures and emergency telephone

numbers.
 Be aware of the locations of fire extinguishers and the
“Emergency Shut Down” (ESD) buttons.
 Ensure all operators and users are properly trained before any
fueling transactions.
 Do not allow any vehicles to be unattended while fueling.
 Ensure that all automatic transmission vehicles are placed in
“park” or the emergency brake is applied for all manual
transmission vehicles before allowing any fueling transactions.
 Ensure that all vehicle ignitions, electrical systems, and radios—
including short-wave communication equipment—are shut-off
before allowing any fueling transactions.
 Ensure the fuel receptacle is inspected and matches the
dispenser filling nozzle before attempting any fueling
transactions.
 Ensure all users adhere to the operating procedures described in
Section 4.1 when fueling.
 Ensure all users are aware that pressure from the nozzle must be
vented before disengaging it from the vehicle.
 Ensure that all users replace the dispenser nozzle firmly onto the
holster immediately after refueling.

2. SAFETY
2.3 Dispenser hose safety

Please observe the following guidelines prior to installing or
maintaining CNG dispenser hoses and hose-components:
 Inspect the hose assembly before each use.

Replace the hose immediately if any of the following conditions
are observed:
o The jacket of the hose appears abnormal
o A gas leak or any reason to believe there is a gas leak
o The couplings are damaged
o The hose is damaged in any way, including cuts, cracks,
bulges, blisters, or abrasions
o The reinforcement is exposed through the jacket
o Spring guards are missing or detached from couplings
o Couplings and spring guards show evidence of slippage or
looseness
 Do not exceed the maximum recommended working pressure of
the hose: 5,000 psi; 345 bar.
 Do not twist, kink, or torque the hose assembly.
 Never attempt to repair or re-couple a damaged hose.
 Do not use a strength member for pulling or lifting equipment.
The hose assembly for Fleet CNG dispensers are designed to convey static
electricity. It is imperative that the hose assembly be properly grounded to
the CNG unit to which it is attached.
ATTENTION
For additional information about dispenser hoses, please refer to the

specification tag provided by the manufacturer or contact Kraus’ Technical
Support Department.
ATTENTION

2. SAFETY
2.4 Maintenance safety

Please observe the following guidelines prior to maintaining any
Kraus-manufactured CNG dispenser:
 Only properly trained or qualified personnel should be permitted

to maintain and repair CNG equipment. When in doubt, please
refer to the equipment supplier or service agent.
 Always adhere to the manufacturer guidelines for proper
installation and maintenance of all dispensers and dispenser-
components.
 All maintenance and repair work of pressure vessels and other
safety equipment must be conducted under the appropriate
codes, then tested and accepted by the inspection authority.
 The dispenser must be powered-off and completely vented,
unless otherwise specified.
 Never perform welding processes near gas systems.
 Always cover disassembled parts and openings with a clean rag,
paper, or adhesive to keep them clean and avoid contamination.
 Do not clean any parts with flammable solvent. Clean and rinse
all parts carefully with compressed air.
 Be sure to wear necessary safety equipment during maintenance
and repair. Eye protection is absolutely necessary when cleaning
with compressed air.
 Wear hearing, hand, and eye protection when bleeding filters
and lines. Be sure to keep body parts away from the discharge
orifice.
 Do not touch bare wires and live current-carrying parts while the
electrical system is energized.
 Never tighten or loosen any fitting when it is under pressure.
 Always use proper thread lubricants and sealant on tapered pipe
threads.
 Never turn a fitting body. Instead, hold fitting body and turn the
nut.
 After completing any work on process gas piping systems and its
components, always purge the system thoroughly with a non-
corrosive inert gas, such as nitrogen, before introducing natural
gas.
 Ensure that you have not left any tools, cleaning equipment, or
any loose parts inside the dispenser.
Never allow problems to go unreported. Both your company and supplier

will benefit from the full disclosure of all dispenser issues.
ADVICE

2. SAFETY
2.5 Leak-test safety

Please observe the following guidelines before performing leak-tests
on Kraus-manufactured CNG dispensers:
 Ensure the area surrounding the dispenser being serviced is

closed off to all customers and unauthorized personnel. Use any
appropriate barricade and signage to ensure safety.
 It is recommended that protective shields are placed around
potentially harmful areas of the dispenser being serviced.
 Service personnel must wear all appropriate safety gear, such as
helmets with eye or facial protection and body shields.

3.1 Installation guidelines

Please observe the following guidelines prior to installing any Kraus-
manufactured CNG dispenser:
 All electrical and mechanical installations must comply with the

provisions of the local authority having jurisdiction.
 All electrical installations must only be carried out by a licensed
electrical journeyman.
 All high-pressure gas connections should only be carried out by
qualified and experienced personnel.
 Safety valve discharge gases must be funneled safely away from
the working area.
 Be sure to allow room inside the dispenser pit to properly tie-in
the gas lines to the inline filters and manual isolation valves.
 The dispenser frame enclosure must be securely bolted to a
concrete foundation or to a structural steel base. Adequate
support must be provided for each unit of the dispensing system,
independent of piping, tubing, or conduit that may be connected
to the dispenser.
 A pressure relief device may be installed directly upstream of the
dispenser—in compliance with the ASME Boiler and Pressure
Vessel Code—to limit the pressure at the inlet of the dispenser to
a value no greater than the maximum working pressure of the
dispenser.
o The pressure relief device must communicate directly with
the pressure-containing component it is designed to
protect—valves between the protected component and the
inlet to the pressure relief device are not permitted.
 It is highly recommended that an emergency shut-off device that
will terminate the gas supply to the dispenser is installed in an
easily accessible area near the dispenser.
 All dispensers must only be used for gas compositions specified
within SAE J1616: Recommended Practice for Compressed Natural
Gas Vehicle.

3.2 Pre-installation
Kraus CNG dispensers must be situated in such a way that there are no
obstructions, such as a wall or gate, that may entangle the dispenser
hose. This is to ensure proper functioning of the hose assembly’s
breakaway coupling.
CAUTION
3.2.1 Site preparation
Please observe the following guidelines prior to constructing the

dispenser pit:
 When preparing the site, be sure to allow room inside the

dispenser pit to properly tie-in the gas lines to the inlet filters
and manual isolation valves.
 Make provisions for tubing and electrical conduit prior to
pouring the concrete pad.
 Filters must be installed upstream of the dispenser.
 Due to potential weld slag, filings, rust, dirt, and water,
dispensing lines should be purged to the atmosphere at the
dispenser. This can be done by blowing nitrogen through the
lines.
 All dispensing lines must be purged, pressurized, and leak-
tested. Afterwards, manual isolating valves in the dispenser pit
must also be leak-tested. The dispenser must only be connected
to the lines after these have been accomplished.
Please refer to your Construction drawings for dispenser dimensions.
ATTENTION

3.2.2 Uncrating and placing the dispenser
Ensure that the dispenser crate is placed on a smooth and level surface
before removing any crate panels.
CAUTION
All dispenser packages contain additional parts, accessories, and

documents that are vital to the installation, operation, and maintenance of
the dispenser. Be sure to set these items aside in a safe and easily
accessible area.
ATTENTION Dispenser keys can be found on one of the authorization handles.
1. Inspect the crate for any damages that may have occurred during
shipping. If any damages are found:
o Take pictures of the damages
o Note the damages
2. Starting with the top panel, remove all screws and/or nails and
detach the top panel. Repeat this process to remove all side
panels.
3. Remove all protective wrapping by hand; knives and other sharp
objects may damage the dispenser.
4. Inspect the dispenser for any damages. If any damages are found,
repeat the procedure indicated in step 1.
5. Locate and review the crating check list to ensure that all items
are accounted for. If you are missing any items, please contact
Kraus’ Logistics Department.
6. Use a forklift to move the dispenser as close to the dispenser pit
as possible with the dispenser is still bolted to the bottom pallet.
7. Remove lag bolts from base rails to free the dispenser from the
bottom pallet.
8. Slide the dispenser off the pallet and onto the pit frame.
It will take at least 2 workers to ensure the dispenser is placed
safely and correctly.
9. Fasten the dispenser to the pit frame or concrete base with, at
the minimum, 1/2” NC grade-8 steel bolts.
NOTE: Please be sure to read and understand the notifications on the

following page before proceeding to any installation procedures.

3.2.3 Additional notifications
Lifting chains, straps, and other tools used to lift and anchor Kraus CNG
dispensers must be rated for at least 1,200 lbs; 545 kg.
CAUTION
Ensure there is sufficient room to complete tubing and wiring connections

before securing the dispenser to the foundation.
ADVICE
The supply ground cable must be securely connected to the dispenser

frame.
ATTENTION

3.3 Installation
3.3.1 Electrical and communication connections
Electrical installations must only be carried out by licensed electrical

journeymen.
CAUTION
All interconnection fittings and tubing are sold independently of Kraus

Global Ltd. Always adhere to manufacturer standards for appropriate
swaging and tightening specifications.
ATTENTION
The dispenser’s main electrical and communication connections are

done at the terminal strip, located in the explosion-proof junction
box in the lower cabinet of the dispenser.
Please refer to the electrical schematic in the Engineering package

for electrical and communication connection specifications.
The dispenser is shipped in “standalone mode.” It is recommended that

the dispenser remains in this mode throughout the initial power-up
process.
ATTENTION
If you are incorporating a POS or card-lock system with the dispenser,

you must disengage the dispenser from “standalone mode” by removing
the authorization jumper from the terminal strip before initial use.
Please refer to the electrical schematic in the Engineering package for
ATTENTION further details.
3.3.2 Pressure line connection
High-pressure gas connections must only be carried out by qualified and

experienced personnel.
CAUTION
Please refer to the flow schematic in the Engineering package for

pressure line connection specifications.

3.3.3 Filters
CNG may be filtered in one of two methods:
 Particulate filtration removes solid particles from gases;

ensuring only clean gas is dispensed into a vehicle.
 Coalescing filtration removes solid particles with the same
efficiency as particulate filtration, but also removes water
aerosols and droplets from gases; ensuring only clean and dry
gas is dispensed into a vehicle. This is the standard and
recommended method of filtration for all Kraus CNG dispensers.
Filter size and placement
Filter sizes and their placement depend on the configuration of the

dispenser. High-flow dispensers require large filters that may be
placed in one of the following locations:
 In the dispenser pit if it is large enough to house the filters, while

providing enough room to drain and change filter elements
 Upstream of the dispenser pit, on the dispenser supply lines
between the priority panel and the dispenser
See Figure 1 below for high-flow filter placement options.
Standard-flow dispensers use smaller filters that can often be placed

in the lower cabinet of the dispenser unless otherwise indicated.
If filters are not being supplied by Kraus Global Ltd., ensure that they are
properly rated for the dispenser’s filling system.
You may contact Technical Support for any questions regarding
dispenser configurations.
ATTENTION
Figure 1: High-flow filter placement

Filter installation guidelines
Filter housings are pressure vessels and must only be used within their
allowable working pressure, within their stated temperature range.
ATTENTION
 As pressure vessels, filter housings must be leak-tight. It is

considered good practice to use pipe sealants on fittings prior to
connecting the filter housing ports.
 Ensure the filters are visible and easily accessible for periodic
draining and maintenance.
 Install the filters on a level pipeline and mount vertically. Be sure
to leave one bowl length of clearance to allow for element
removal.
 Ensure that fittings are always inspected during servicing and
adjusted accordingly.
 Avoid swapping the heads and bowls of one filter assembly to
another.

3.3.4 Attaching the hose
Kraus CNG dispensers use Parker brand hoses and hose fittings. The
hose size is specific to the dispenser’s filling system, but is available
in various lengths. Please see the information sheet attached to the
hose package or contact our Technical Support Department for
further specifications.
Please be sure to read and understand section 2.3—Dispenser hose

safety before proceeding.
If your hose is unusable or if you have any reason to believe it may be

unusable, please contact our Technical Support Department immediately.
Do not use defective or damaged hoses.
CAUTION
If you are operating a split-pressure or split-flow dispenser, ensure that

you attach the correct hose to the proper connection.
ATTENTION
1. Remove the hose from its packaging.
2. Inspect for any defects or damages that may have occurred
during shipment. Do not use defective or damaged hoses.
3. Attach the main line to the hose manifold, located on the side and
near the top of the dispenser. Hose manifolds may be on both
sides, depending on the dispenser’s hose configuration.
4. Hand-tighten the main line fitting to the manifold so that it may
still be loose enough to turn.
5. Straighten the hose and place the nozzle into the dispenser
holster. The loose fitting should allow the hose to find its natural
resting position.
6. Tighten the main line fitting at the manifold using a backup
wrench. Hose connections do not require sealants or Teflon
tape.
7. Attach the vent line to its corresponding manifold connection
and tighten using a backup wrench.
To help avoid abrasive damage to the hoses, do not allow any part of the
hose to be in contact with the ground or dispenser while it is holstered. If
this is the case, the hose may be too long; please contact our Technical
Support Department immediately.
CAUTION

Breakaway couplings
All Kraus CNG dispenser hoses are equipped with a breakaway

safety feature. Breakaway couplings are in place to prevent the flow
of natural gas should a vehicle drive away from a dispenser while the
nozzle and hose are still connected to the vehicle’s receptacle.
If a breakaway occurs, the entire hose assembly must be examined by a

qualified service representative prior to any reconnections.
CAUTION
In the event of a breakaway, dispenser hose assemblies may only be

reconnected if the breakaway was clean; otherwise, the assembly will
have to be rebuilt using breakaway rebuild kit or completely replaced with
new parts and fittings. Please contact our Technical Support Department
before proceeding with any solution.
ATTENTION
Reconnecting procedure
1. Vent the dispenser system and hose assembly before attempting
any reconnections. Please refer to section 4.2—Maintenance for
dispenser-venting procedures.
2. Clean dirt, debris, and other obstructions from both sides of the
breakaway unit.
3. Inspect both parts of the breakaway unit. Ensure that O-ring
seals are not damaged.
Do not reconnect assemblies if any components are damaged.
4. Inspect the stationary module and ensure that the inner garter
spring is intact and properly situated in the groove.
5. Insert the breakaway unit into the stationary module by aligning
the wrench flats of the unit with the lining of the module.
6. Push the breakaway unit into the stationary module until you
feel a click.
7. Perform a leak test to ensure the system and hose assembly are
in working condition. Please refer to section 4.2—Leak
monitoring for this procedure.
Breakaway may require a specialized reconnection tool. Please contact

our Technical Support Department for questions regarding the breakaway
system.
ATTENTION

3.3.5 MICONTM power-off mode
In the absence of AC power—during a power failure, for example—

the MICONTM register will go into “battery mode” for approximately
one minute before entering “sleep mode.”
Battery mode
The dispenser’s dollar and volume displays will flash to indicate that
the dispenser has entered “battery mode.” In this state, the dispenser
is powered only by its 6-volt standby battery. After approximately
one minute without activity, the dispenser will enter “sleep mode.”
The dispenser must be placed in “battery mode” to set fuelling prices. The
TM
MICON Communicator will not engage with the dispenser while the AC
power is connected.
ATTENTION
Sleep mode
During “sleep mode,” all power is removed from the unit with the
exception of the MICONTM’s last sale, price, and totalizer memory.
The MICONTM is able to retain this data for up to six months while in
“sleep mode.”
After entering “sleep mode,” the MICONTM can be brought back to

“battery mode” by resetting the dispenser.
Resetting the dispenser

1. Lift the refueling nozzle from its holder.
2. Flip the authorization handle from the OFF position to the ON
position, and then back to the OFF position.
NOTE: The dispenser’s software version will be displayed in the PPU

display after completing the procedure above.

3.3.6 Communicator operation
Kraus dispenser packages include a Communicator remote for

setting dispenser prices and reading totalizers; this section describes
both procedures. For additional uses and operation of the
Communicator, please refer to the MICONTM 500C Manual, also
located in your dispenser package.
NOTE: Your purchase may also include a MICONTM 500C Info-Pac

controller. Please refer to the MICONTM 500C Programming Manual
for operating instructions.
Setting prices
1. Place the dispenser in “battery mode” by disconnecting the AC
power to the MICONTM from the breaker box. The volume and
dollar displays will flash when the dispenser enters “battery
mode.”
2. Ensure the dispenser’s authorization handle is in the OFF
position and the refueling nozzle is placed in its holder.
3. Aim the Communicator to the optical sensor, located to the right
of the PPU display; see Figure 2 below.
4. Press and hold the SET button on the Communicator. Starting
with the .0 digit, the number will count up until the button is
released.
5. Release the SET button when the count reaches the desired
number.
6. Press the SEL button to proceed to the next digit and repeat step
4 and step 5 until the full price is entered.
7. Ensure the correct price-per-unit has been entered and then
restore the AC power.
Red light indicator Optical sensor
Figure 2: The MICONTM display

Reading totalizers
1. Ensure the dispenser’s authorization handle is in the OFF
position and AC power is connected.
2. Aim the Communicator to the optical sensor, located to the right
of the PPU display; see Figure 2.
3. Press and hold the SEL button on the Communicator. The red
light indicator, to the left of the PPU display, will flash as the
MICONTM receives the Communicator’s signal and the dollar sales
total is displayed. The sales total is preceded by the “dI”
indicator.
4. Press the SEL button again to show the volume total. The volume
total is preceded by the “U I” indicator.
At this point, the SEL button will allow you to toggle back and
forth between volume and dollar totals.
The dollar sale and volume totals use a ten-digit display that begins at the
“total sale” display and continues to the “unit sale” display. See Figure 3
below.
ATTENTION
The total dollar sale display below reads The total unit sale display below reads
“$782564.93” “96154.823” units
Figure 3: Sales and volume total displays
Resetting totalizers
Totalizers must be reset once the maximum dollar sales total or

volume total is reached, which occur at “dI: 99999999.99” and
“UI: 9999999.999” respectively. After reaching any one of these
totals, the dispenser will terminate the current fueling transaction
and disallow any further authorizations.
Performing a “cold-start” will reset all totalizers—please refer to the

MICONTM 500C Manual for this procedure.

3.4 Dispenser startup procedures
3.4.1 Powering the dispenser
The following procedure describes the initial startup process. Please

ensure that all electrical and mechanical connections have been
properly installed and you have read and understood Chapter 2—
Safety before proceeding.
The dispenser is shipped in “standalone mode.” It is recommended that

the dispenser remains in this mode throughout the initial power-up
process.
ATTENTION
1. Locate the actuator shaft(s) protruding from the MICONTM
head(s).
NOTE: For shipping and storage purposes, the MICONTM 500C is

placed in “battery-save mode.” The dispenser will not operate
properly while in this mode.
2. Remove the cotter pin from the actuator shaft.

3. Rotate the actuator shaft until the beveled edge is facing
upwards. This disengages the MICONTM from “battery-save
mode.”
4. Replace the cotter pin.
5. Remove the bottom panels of the dispenser to access the lower
cabinet.
6. Close all manual filter inlet valves, vent valves, and manual shut-
off valves.
7. Turn-on the power from the breaker box.
NOTE: The dispenser will display a power-up sequence and

countdown from 25 seconds. After the countdown, the volume and
dollar displays will read zero.
TM
If you encounter errors, please refer to Chapter 5 or the MICON 500C
Manual for a description of fault codes and recommended actions.
ATTENTION
8. Remove the refueling nozzle from its holder and flip the
authorization handle upwards to the ON position.
NOTE: The volume and dollar displays will flash all 8’s as the
dispenser authorizes.

Procedure continues on the following page

3.4.1 Powering the dispenser (continued)
9. Flip the authorization handle back to the OFF position and

replace the refueling nozzle into its holder.
10. Set the dispenser prices; see the Communicator operation section
in this chapter or the MICONTM 500C Manual for this procedure.
3.4.2 Pressurizing the dispenser
Please ensure that the dispenser has been properly powered-up and
you have read and understood Chapter 2 of this manual before
proceeding.
To ensure peak performance, all Kraus CNG dispensers should be leak-

tested before initial operation. The first leak test should be done while
initially pressurizing the dispenser.
ADVICE
1. Open all manual shut off valves.
2. Flip the authorization handle to the ON position. This will enable
you to see the pressure reading through the pressure gauge.
3. Slowly open the inlet valve and allow 100 psi of gas to fill the
dispenser.
If your dispenser has two or three-inlet lines, begin this procedure with
the low-bank and repeat it for the mid-bank, then high-bank.
ATTENTION
4. Close the inlet valve and flip the authorization handle to the OFF
position once the pressure gauge indicates 100 psi.
5. Apply a leak detector to all fitting connections—we recommend
using Snoop® Liquid Detector.
NOTE: If any leaks are detected, please refer to section 4.2—

Maintenance for leak repair procedures.
6. If no leaks are found, reauthorize the dispenser by flipping the

authorization handle up to the ON position.
7. Slowly reopen the valve to allow 500 psi of gas to fill the
dispenser.
Procedure continues on the following page

3.4.2 Pressurizing the dispenser (continued)
8. Close the valve once the pressure gauge indicates 500 psi and
reapply the leak detector. See the previous Note if leaks are
detected.
9. Repeat this process at 500 psi increments until the regular
operating pressure is reached. Repeat the process for each
subsequent inlet valve.
After this procedure, your dispenser should be ready for fueling

operations. Please contact our Technical Support Department for
any questions or concerns.
3.4.3 Commissioning
Commissioning is necessary to ensure all dispenser systems,

including all components, are installed and function properly, and
are successfully turned over. Documenting the commissioning
process allows for traceable verification and ensures a systematic
approach to minimizing any commissioning oversights.
A commissioning sign-off sheet is included within your dispenser

package. This form must be completed, signed, and sent to Kraus
Global Ltd. within 30 days of commissioning, otherwise the warranty
may be voided.
Completed forms may be mailed or faxed to Kraus Global Ltd. using

the following information:
Kraus Global Ltd.

25 Paquin Road
Winnipeg, MB
Canada, R2J 3V9
Fax: 1-204-663-7112

4.1. Filling procedure

The following is the procedure for filling CNG approved vehicles with
the Retail CNG dispenser. Ensure all users observe the guidelines
described in Section 2.2 and adhere to this procedure when fueling.
Ensure all personnel, including users, are aware of emergency shut-down

buttons prior to operating CNG fuel dispensers.
ADVICE
1. Ensure the vehicle is in “park” or the parking brake is applied,
and the vehicle ignition is turned OFF.
2. Inspect the vehicle’s receptacle and the dispenser hose and
nozzle. Do not proceed with fueling or allow further use of the
dispenser if any damages or signs of tampering are found; you
may contact our Technical Support Department for further
assistance: 1-204-663-3601 (ext. 212).
3. Remove the dust plug from the vehicle’s CNG receptacle.
4. Lift the refueling nozzle from the holder.
5. Connect the refueling nozzle to the vehicle receptacle.
6. Turn the valve on the nozzle to FILL.
7. Flip the authorization handle up to the ON position; fueling will
begin after a three-second beep.
Note the following during gas delivery:

 Gas delivery may create a loud whining sound. This is due to the
pressure differential between the dispenser and the vehicle’s storage
bank. This is normal and is not a cause for concern.
 There may be noticeable pauses as the dispenser accesses multiple
ATTENTION storage banks; delivery is not complete until the dispenser beeps for
three full seconds.
8. Flip the authorization handle back down at the end of delivery; a

three-second beep will signify the end of delivery.
9. Turn the valve on the nozzle to VENT. This will vent a small
amount of gas into the atmosphere and allow you to disconnect
the nozzle.
10. Replace the nozzle onto the holder.
11. Replace the dust plug into the vehicle’s CNG receptacle.

4.2 Dispenser maintenance
Please read and understand section 2.4—Maintenance safety before

performing any maintenance on fuel dispensers.
CAUTION
Be sure to note and report all dispenser issues. It is considered good

practice to use a maintenance log sheet to document all dispenser issues
and repairs.
ADVICE
4.2.1 General dispenser maintenance guidelines
 Please refer to the Maintenance task list within the Appendix for a
detailed maintenance schedule.
 Shut off all manual isolation valves in the dispenser pit after
hours and other times when the dispenser will not be in use.
 Ensure that all valves, gauges, and displays are free of
obstructions.
 Clean the dispenser on a regular basis. Avoid using pressurized
water.
 Perform daily checks for signs of leakage.
 Perform leak inspections of all hoses and fittings every six
months with an approved leak detector fluid. Ensure that all
leaks are repaired by qualified personnel immediately.
 Perform monthly hose inspections. Check for abrasions, swelling,
flatness, cuts, damaged couplings, and other abnormal signs.
Replace the hose immediately if any abnormalities are found.
 Depending on installation requirements, we recommend that
inline filter elements are checked and replaced two weeks after
initial installation.
 Check filter elements every month and replace when necessary.

4.2.2 Dispenser venting procedure
All Kraus CNG dispensers must be completely vented prior to any

maintenance work, including leak-testing and repairs.
CAUTION
1. Isolate the dispenser by placing highly visible signs or physical
barriers to avoid traffic through the immediate area.
2. Ensure the refueling nozzle is replaced in its holder.
3. Ensure there is still power to the dispenser. The dispenser must
be electrically functional to operate the solenoid valves.
4. Ensure the manual vent valves, located along the hose-side of the
dispenser, are open (ON position).
5. Close all manual filter inlet valves to terminate gas flow to the
dispenser from the storage vessels.
6. Slowly loosen the vent valves at least 3 to 4 turns to allow the gas
in the dispenser to escape.
NOTE: Read the pressure gauges to confirm the gas is being vented.
Do not touch any venting pipes throughout this procedure. Rapidly

expanding gases may cause sub-zero temperature drops within the vent
stacks, which may cause cold burns.
CAUTION
NOTE: At this point, only gases upstream of the sequencing valves,

including gas inside the hoses, have been vented; there may still be
gases trapped downstream of the sequencing valves down to
the filter isolation valves.
7. Lift the authorization handle to authorize a fill. This will open the
sequencing valves, allowing the trapped gases to escape.
NOTE: Because the solenoid valves are only open for 4 seconds at a
time, you may need to authorize a fill several times to vent all
trapped gases. Continue authorizing a fill until the pressure gauge
reads 0 psi and all venting sounds have ceased.
Although the dispenser may be completely vented, it is considered good

practice to maintain a proper wrenching technique when loosening
threaded fittings and dispenser components.
ADVICE

4.2.3 Leak monitoring
Leaks in dispenser equipment may develop within the first few

weeks of operation and, therefore, must be closely monitored
throughout that time. Thereafter, routinely scheduled maintenance
must be carried out to correct and prevent further leaks.
NEVER TIGHTEN, LOOSEN, OR ATTEMPT TO REMOVE A PRESSURIZED

FITTING.
CAUTION
Leak-testing procedure
1. Remove the bottom panels of the dispenser to access the lower
cabinet.
2. Apply a leak detector to all fitting connections—we recommend
using Snoop® Liquid Leak Detector.
3. Thoroughly inspect all fitting connections for bubbles, which
indicate a leak. Be sure to note or mark the locations where leaks
are found.
4. If leaks are found, vent gas from the dispenser—see Dispenser-
venting procedure—and proceed with repairing the leak.
If a leak appears downstream of an inlet valve, you must authorize a fill to

vent trapped gases. Continue authorizing a fill until the pressure gauge
reads 0 psi and all venting sounds have ceased.
CAUTION
Leak repairing procedure

1. Ensure the dispenser is completely vented.
2. Loosen and retighten the fittings where leaks are found; most
fittings can be repaired simply by tightening it.
3. Pressurize the dispenser to 100 psi and reassess all fitting
connections with a leak detector.
NOTE: Refer to step 4 of the Leak-testing procedure if further leaks

are discovered.
4. Continue pressurizing the dispenser and testing for leaks at 500

psi intervals until the dispenser reaches regular operating
pressures.
NOTE: If leaks persist, contact our Technical Support Department.

4.3 Component maintenance
4.3.1 MICONTM 500C
This section provides guidelines and important notifications

regarding the maintenance of vital dispenser components
TM
MICON mainboard
The following steps are guidelines for replacing the MICONTM

mainboard.
Ensure that the replacement mainboard has identical software parameter

configurations as the previous mainboard.
ATTENTION
1. Record totalizer readings and MICONTM parameters, as they will
be erased once the main power and battery power are
disconnected.
NOTE: Please refer to the MICONTM 500C Owner’s Manual for

Communicator operations and procedures and the Info-Pac
Programming Manual for Info-Pac operations.
2. Disconnect the AC power from the breaker box.

3. Remove the cover from the MICONTM’s explosion-proof housing.
4. Place the handle actuator shaft in the BATTERY OFF position.
5. Remove the two screws securing the mainboard to the enclosure.
6. Disconnect all connectors and harnesses until the mainboard is
free.
NOTE: Be sure to note or have an understanding of these

connections, as they must be reconnected to the replacement
mainboard. You may refer to the Info-Pac Programming Manual for
connector designation.
7. Install replacement mainboard by reversing this procedure.

Ensure that you have:
o Secured all previous connections
o Replaced both screws to secure mainboard to the enclosure
o Placed the handle actuator shaft back to the BATTERY ON
position
o Replaced the cover of the explosion-proof housing
8. Use the Info-Pac to reconfigure the MICONTM to your preferred
parameters.
9. Reconnect the AC power to the MICONTM from the breaker box.

TM
MICON standby battery
The MICONTM’s mainboard includes a low battery detection circuit

that causes the red status indicator on the front display to flash
approximately once per second when the battery is low.
Under normal operating conditions, the 6-volt standby battery

should last up to five years. The battery’s lifespan may be shortened
due to an improper charging voltage, a defective battery, or
prolonged use.
The standby battery also discharges during shipping or storage, and

therefore, may require up to 8 hours to fully charge depending on the
extent of discharge.
ATTENTION
If a low battery is detected, use a voltmeter to measure the charging-

circuit, located inside the MICONTM’s explosion-proof lid. The voltage
should measure approximately 7 volts with the AC power on. If this
is the case, then the battery may be defective or is worn out and
must be replaced. If the voltage measures much higher or lower, the
mainboard may be defective and should be replaced.
TM
MICON standby battery replacement procedure
1. Remove the MICONTM mainboard by following step 2 to step 6 of
The MICONTM mainboard replacement procedure.
2. Remove the wingnut and bracket holding the battery in place.
3. Disconnect the positive and negative leads from the battery.
4. Remove the current battery.
5. Install the replacement battery by reversing this procedure.
Ensure that you have:
o Reconnected the positive and negative leads to the battery
o Replaced the bracket and wingnut securing the battery in
place
o Replaced the MICONTM mainboard
6. Measure the battery charging voltage; voltage should be at
approximately 7 volts.

4.3.2 KAF 402™ solenoid inlet valve
Kraus’ KAF 402™ solenoid valve has been specifically engineered for
high-pressure CNG service. It is constructed of materials suitable for
use with natural gas and is rated for a burst pressure in excess of
25,000 psi.
To ensure the proper solenoid valve(s) are in proper working

condition please observe the following maintenance guidelines:
 The valve(s) must be leak-tested after every 35,000 cycles or

every six months, whichever comes first.
 The valve(s) must be rebuilt at least once every three years by
qualified service personnel and in accordance with the rebuild
procedure described in the KAF 402™ rebuilding specification
sheet.
Rebuild kits are required to properly rebuild KAF 402™ solenoid valves
for any maintenance or reparation purposes. They are sold separately
from any dispenser systems; please contact our sales or technical
support department for any questions.
ATTENTION
4.3.3 Inlet filters
CNG filtering is a balanced, continuous, and steady state condition

occurring at or below rated flow. In order to maintain high-efficiency
filtration for your CNG dispenser, ensure that the bowl is kept clean
and free of waste build-up.
Filter element replacement procedure

1. Depressurize the system.
2. Open filter drain valve to ensure all pressure has been vented.
3. Unthread and remove the bowl—set it aside in a secure location.
4. Remove and discard clogged filter element and O-ring.
5. Install new element.
6. Install new O-ring. Lightly lubricate O-ring using clear silicon-
based grease.
7. Apply a thin layer of anti-seize onto the filter bowl threads.
8. Thread the filter bowl to the head, making sure not to pinch O-
ring.

5. TROUBLESHOOTING
5. TROUBLESHOOTING
5.1 MICONTM fault codes

In the event of a MICONTM -related malfunction, the MICONTM will
display an error code in the PPU display. This section provides a
description of all MICONTM error codes and possible solutions to
remedy the errors.
Table 2 below provides a summary of all MICONTM fault codes,

possible causes, and recommended actions for addressing the errors.
Table 3 provides a list of procedures for clearing MICONTM error code

messages from the PPU display.
Table 2: MICONTM fault code summaries
ERROR
DESCRIPTION POSSIBLE CAUSE RECOMMENDED ACTION
CODE
 co26  Pulser fault  Pulser is missing or  Not applicable when using
disconnected CNG050 mass flow meter
 If fault occurs, use the MICON
TM
Info-Pac to set “Pulser” option to

conduit-s
 co27  Pulser buffer overflow  Input pulses coming in  Ensure the MICON in count
TM
fault may be faster than and multiplier values are set to

TM
what the MICON factory settings
500C is rated to  Ensure that mass flow meter
handle frequency and rate factors are
set to factory settings
 co28  Display disconnect  LCD display lost  Check all display harness
fault connection connections between display
TM
and MICON mainboard
 If all connections are good,
replace LCD display
 co29  CPU fault  Corrupt CPU  Perform cold start on MICON
TM
500C Replace CPU chip

 co30  Excessive reverse  Pulser is connected  Not applicable when using
count fault backwards CNG050 mass flow meter
 co40  Power failure during  AC power  Flip authorization handle to the
sale fault disconnected during a OFF position and restore power
transaction
 co51  Excess flow fault  A hose is ruptured  Check hose for ruptures or any
 Flow rate has other damage
 If no hose damage is present,
TM
exceeded MICON
500C max flow setting max flow setting may need to be
TM
adjusted using MICON Info-
Pac

5. TROUBLESHOOTING
Table 2: MICONTM fault code summaries (continued)

ERROR
DESCRIPTION POSSIBLE CAUSE RECOMMENDED ACTION
CODE
 co76  Pressure transmitter  Pressure transmitter  Check wire connection at
range fault has gone beyond its transmitter and all harness
4-20 mA range connections
 Use MICON Communicator to
TM
display P1 pressure—if the

pressure is fluctuating more
than 50 psi when dispenser is
static, then replace transmitter
 If pressure is not fluctuating, but
reading different pressure than
pressure gauge, check that the
pressure scaling in the
TM
MICON is set to factoring
setting or is set the same as the
scaling on the transmitter
 co77  Pressure transmitter 2  Pressure transmitter 2  See co76 remedies
range fault has gone beyond 4-20  If secondary transmitter is not
mA range being used, ensure that
TM
MICON PTX2 option is set to
disab
co78  Ambient temperature  Probe has open or  Check probe connections
probe fault shorted circuit  Replace probe
co79  Gas temperature  Gas temperature  Not used in CNG application
transducer range fault transducer has gone  If error code is present, ensure
out of operating range TM
that MICON TRX TEMP
option is set to disab
 Pressure transmitters  Pressure transmitters  Ensure that MICON PTX2
TM
co80
1 and 2 tolerance fault PTX1A and PTX2A option is set to disab
have exceeded a 3%  Only used in European
difference in readings applications
co81  Air purge or pressure  Loose harness or  Check harness connection on
TM
switch kill fault jumper connection is MICON mainboard
on 10-pin harness  Check that jumper is connected
on the I.S. harness connector
co82  Excess flow fault  A hose rupture has  Check hose for ruptures or other
occurred damages
 Flow rate exceeding  If no hose damage is present,
TM
MICON 500C max max flow setting may need to be
TM
flow setting adjusted using MICON Info-
Pac
co86  Pressure transmitter  Pressure transmitter  NOT APPLICABLE
1B out of range 1B has gone beyond
4-20 mA range
co87  Pressure transmitter  Pressure transmitter  NOT APPLICABLE
2B out of range 2B has gone beyond
4-20 mA range
co90  Pressure transmitter  Pressure transmitters  NOT APPLICABLE
1B and 2B out of range PTX1B and PTX2B
have exceeded a 3%

5. TROUBLESHOOTING
difference in readings
Table 3: MICONTM fault code clearing procedures

ERROR CODE SUMMARY OF FAULT CLEARING ACTIONS
1. Correct the source of error—see Table 3.
co26 – co30 2. Flip the authorization handle down to the OFF position, then back up to the
ON position.
co51 2. Flip the authorization handle down to the OFF position, then back up to the
ON position—or—activate the manual reset switch (MRST).
co76 – co90
2. Activate MRST.
Please contact our Technical Support Department at 1-204-663-3601 for

any issues not covered in the tables above.
ADVICE

5. TROUBLESHOOTING
5.2 Dispenser issues
Only trained and qualified service personnel may attempt any

troubleshooting and service work to any CNG electrical and mechanical
components.
CAUTION
Table 4: Troubleshooting dispenser issues

ISSUE POSSIBLE CAUSE(S) RECOMMENDED ACTION(S)
 Dispenser allows CNG flow into  Low-bank inlet valve is stuck  Rebuild low-bank solenoid
vehicle without authorization open valve—see Component
maintenance section in
Chapter 4
 Dispenser authorizes and  Manual shutoff valve is closed  Ensure the manual shut off
display resets, but no CNG flow  Filter isolation valves are closed valve is in the open position
present  Ensure the filter isolation valves
 Hose nozzle is faulty
are in the open position
 No gas supply from storage
 Ensure CNG nozzle is in good
 Vehicle fill line valve is closed working order
 Dispenser low-bank valve is  Check if storage gas supply is
stuck closed present
 Low-bank coil is faulty  Ensure all vehicle line valves
are open
 Rebuild low-bank solenoid
valve, see Component
Chapter 4
 Display does not reset upon  Dispenser handle micro-switch  Check function of authorization
authorization is faulty micro-switch
 Dispenser authorization harness  Ensure that authorization
is disconnected harness connections are good
 If “standalone” mode is  Ensure that authorization
engaged, authorization jumper jumper is in place and
may not be in place terminations are tight
 POS or card-lock system is not  Ensure POS or card-lock
allowing authorization, system is properly connected
disconnected, or not properly and configured
configured  Ensure hose ID in MICON
TM
is
 POS pump ID is not set set to match POS
 Display does not show readings  Loose or disconnected wires on  Ensure that all wire connections
while fueling Mass Flow Meter or in main are correct
electrical explosion proof box  Refer to Micro Motion Prolink to
 Faulty mass flow meter diagnose problem
 Faulty MICON  Replace MICON
TM TM
mainboard mainboard
 Display stops counting within 5  Low-bank inlet valve remains  Rebuild low-bank solenoid
– 10 seconds of authorization, open during temperature valve—see Component
but CNG continues to flow compensation end-of-fill maintenance section in
calculation Chapter 4

5. TROUBLESHOOTING
Table 4: Troubleshooting dispenser issues (continued)

ISSUES POSSIBLE CAUSE POSSIBLE SOLUTION
 Dispenser overfills vehicles  MICON parameters are not  Ensure that the MICON
TM TM
is
configured properly correctly configured
 Temperature probe is not  Compare displayed temperature
reading correctly to actual ambient temperature to
 Low-bank inlet valve is stuck ensure that the temperature
open probe is reading correctly
 Pressure transmitter is faulty  Rebuild low-bank solenoid
valve, see Component
Chapter 4
 Compare pressure transmitter to
pressure gauge to see if there
are discrepancies
 Dispenser under-fills vehicles  MICON parameters are not  Ensure that the MICON
TM TM
is
configured properly correctly configured
 Temperature probe is not  Compare displayed temperature
reading correctly to actual ambient temperature to
 Micon is ending transactions on ensure that the temperature
min. flow conditions probe is reading correctly
 MICON
TM
min. flow is set too  Storage supply may not be
high sufficient to continue transaction
and terminate on min. flow
 Temperature probe is faulty conditions
 Compare displayed temperature
to actual ambient temperature to
ensure that the temperature
probe is reading correctly
 Pressure gauge does not  Faulty dispenser gauge  Confirm the dispenser’s
correspond with vehicle gauge  Faulty vehicle gauge pressure gauge accuracy by
comparing it with the pressure
transmitter reading using the
TM
MICON Communicator, see
TM
MICON 500C Manual
 Compare dispenser pressure
gauge, vehicle pressure gauge
and dispenser pressure
transmitter to determine if
vehicle gauge is accurate
 Replace pressure gauge
For any issues or concerns not covered in the table above or any other
troubling matters concerning the installation, operation, and maintenance
of Kraus CNG dispensers, please contact our technical support
department at 1-204-663-3601.
ADVICE

5. TROUBLESHOOTING
Kraus Global Inc.

High Style CNG Dispenser Manual Appendix-41
APPENDIX
APPENDIX
A.1 Component description and specifications
KAF 402™ solenoid inlet valve
The Kraus model KAF 402™ solenoid valve has been specifically
engineered for high-pressure CNG service. It is a unique valve that
features a high flow rate; a high-pressure rating; a compact design;
and low power requirements, meaning that it does not require the
assistance of a lifting coil and relay. These features make this panel
mount control valve an excellent choice for sequencing or ESD
applications in natural gas dispensing systems.
The KAF 402™ series is available in North American (N) and

KAF 402™ solenoid valve European (E) models. The KAF 402™-N is approved by the CSA,
designed to the ASME code, and complies with NFPA 52 and CGA
B108 standards. The KAF 402™-E is TÜV and ATEX approved, and
complies with European PED standards.
Technical data (N) (E)

Operation 2-way solenoid valve, normally closed
Design pressure 5,000 psi 345 bar
Operating pressure range—TÜV
73 to 5,000 psi 5 to 345 bar
approved values
Test pressure 6,000 psi 414 bar
Burst pressure 25,000 psi 1,700 bar
Operating temperature—CSA
-40°F to +150°F -40°C to +66°C
approved values
Operating temperature—TÜV
-40°F to +122°F -40°C to +50°C
approved values
Flow coefficient (Cv) 3.3
Inlet and outlet ports SAE-8 (3/4 – 16) G1/2” ISO228/1
Electrical specifications (N) (E)

½” NPT DIN Cable
Connection
(North American) (European)
Power consumption 10 Watts (average)
Materials
Body 7075 Aluminum, Anodized Seat 304 Stainless Steel
Piston PEEK Seals Nitrile

Fleet (High Style) CNG Dispenser Manual Appendix-1
APPENDIX
Micro Motion® CNG050 flow meter
The Micro Motion® CNG050 is a Coriolis mass flow meter designed

specifically for measuring CNG. The meter’s refined accuracy and
sensitivity allow users the flexibility of using the sensor for standard
automobile dispenser configurations or high-flow dispensers for
heavy duty fleets.
Flow specifications
(1)
Mass Standard volume
3
lb/min kg/min SCFM Nm /hr
Flow range 2 to 220 1 to 100 40 to 4444 68 to 7550
Zero stability 0.02 0.009
(2)(3)
Batch accuracy ±0.50% of batch
(2)
Repeatability ±0.30% of rate
(1) CNG with SG = 0.66 at 60°F (15.5°C) and 14.73 psia (1 bar-a).
(2) In terms of percent of total batch delivered on CNG.
(3) Accuracy is under typical CNG batch/dispensing conditions. Typical
batch/dispensing conditions are defined as those where the flow rate is greater
than 4lbs/min or 109kg/hr.
Pressure ratings
psi bar
Flow tube rating 5,000 345
(1)
Pressure limits 5,000 345
Union to NPT
adapter piece rating 4,600 317
(2)
House rating Housing is not rated for pressure containment.

PED compliance Sensor complies with council directive 97/23/EC of
29-May-1997 on Pressure equipment
(1) All fittings are rated to 5,000 psi (345 bar) – the Union SWG type fitting according
to ASME B31.3, and the SAE fitting according to SAE J1453.
(2) Pressure rating of the additional adapter piece (#12 O-ring face seal to female
NPT) that is provided with process connection option 239.

Appendix-2 Fleet (High Style) CNG Dispenser Manual
APPENDIX
Micro Motion® CNG050 flow meter (continued)
Environmental limits
°F °C
Process fluid
-40 to +257 -40 to +125
temp. limits
CSA and MMI
Ambient temp.
standard -40 to +140 -40 to +60
limits (no approval)
ATEX
5 to 95% relative humidity, non-condensing at
Humidity limits
140°F / 60°C
Meets IEC 68.2.6, endurance sweep, 5 to 2,000 Hz, 50
Vibration limits
sweep cycles at 1.0 g
Weight
Sensor with core
16 lbs / 7 kg
processor
Sensor with
integrally mounted 18 lbs / 8 kg
transmitter
Materials
(1)
Wetted parts 316L stainless steel
Sensor housing 304L stainless steel
Core processor CF-3M stainless steel or polyurethane-painted
housing aluminum; NEMA 4X (IP65)
(1) General corrosion guidelines do not account for cyclical stress and therefore
should not be relied upon when choosing a wetted material for your Micro
Motion® flow meter. Please refer to Micro Motion’s corrosion guide for material
compatibility information.
Micro Motion® CNG050

APPENDIX
Parker Parflex CNG hose
Parker’s Parflex refueling hose is specifically designed for the

transmission of CNG. Its electrically conductive nylon core and fiber
reinforcement help to eliminate static build-up while maintaining
maximum pressure and flexibility. The hose also incorporates a
polyurethane jacket to protect it from abrasions and other outdoor
elements, including ultraviolet light.
Description Specification
(1) (2)
Part # 5CNG-8 5CNG-12
Minimum inside diameter ½ inch 13 mm ¾ inch 19 mm

.9 1.15
Maximum outside diameter inches
23 mm inches
29 mm
Working maximum pressure 5,000 psi

7½
Minimum bend radius 4 inches 102 mm
inches
191 mm
Weight .21 lbs/ft .31 kg/m .24 lbs/ft .36 kg/m
Permanent crimp fitting 58 Series 58H Series

(1) Sizing used for standard-flow dispensers
(2) Sizing used for high-flow dispensers
Construction
Tube Electrically conductive nylon
Reinforcement Fiber
Cover Polyurethane
Operating parameters
Temperature range -40°F to +180°F ; -40°C to +82°C
Vacuum rating 28 inch Hg
Minimum burst
4x maximum working pressure
pressure
The total resistance, measured from end to end, must be less than 1
megaohm for assemblies up to 15 feet in length and less than 5 megaohm
for any length or combination of lengths greater than 15 feet.
CAUTION

APPENDIX
Fueling nozzles
Kraus CNG dispensers are compatible with Type 1 and Type 2

nozzles for use in either NGV1 (passenger vehicles) or NGV2 (large
fleet vehicles) refueling applications. The following are some
examples of commonly used nozzles; please contact your
salesperson or our Technical Support Department for ordering
information and other details.
Type 1 nozzle
The Type 1 nozzle incorporates an integrated vent valve that allows for safe
venting and detaching in a single motion.
WEH-TK16, a Type 1 nozzle for NGV1 applications OPW CT1000S, a Type 1 nozzle for NGV1
applications
WEH-TK17, a Type 1 nozzle for NGV1 applications OPW CT5000S, a Type 1 nozzle for NGV2
applications
Type 2 nozzle
The Type 2 nozzle must be coupled with an external vent valve that requires yout
to vent the gas before choosing to disconnect the nozzle from the vehicle’s
receptacle.
Staubli-CMV 08, a Type 2 nozzle for NGV1 applications

APPENDIX

APPENDIX
A.2 Maintenance task list

SCHEDULE MAINTENANCE TASK
 Inspect fill hoses and breakaway components
AT STARTUP  Tighten all electrical terminal connections and check all harness connections
 Dispenser leak test
 Inspect the dispenser and all of its components. If any damages are found,
vent, disconnect AC power, and disallow further use until maintenance
DAILY authority can repair the damages.
 Drain dispenser filters
2 WEEKS AFTER  Change filter elements—it is common that above normal amounts of debris or
STARTUP liquids from newly installed pressure lines may be present
 Inspect fill nozzle seals for leaks and wear

 Inspect flow control or sequencing valves during filling operation
EVERY 2 WEEKS
 Inspect the sequencing valves for leaks
 Inspect fill hoses and hose breakaway components
 Change dispenser filters
 Dispenser leak test
EVERY 6 MONTHS
 Visual leak inspection of pressure relief device—if internal leakage has
occurred there will be visible frosting on the outlet tubing
 Tighten all electrical terminal connections and check all harness connections
 Rebuild sequencing valve
EVERY YEAR
 Inspect fill nozzle valve, rebuild if necessary
 Inspect pressure regulator, rebuild if necessary
EVERY 2 YEARS  Replace fill hose
EVERY 5 YEARS  Recertify pressure relief device

GLOSSARY
GLOSSARY
B
Bar. A metric unit of pressure; 1 bar = 14.5038 psi.
Breakaway. A CNG hose feature that allows the hose to break apart and cease gas flow in
the event that a vehicle drives away while the dispenser nozzle is still connected the
vehicle’s receptacle.
Buffer storage system. A fuel storage system consisting of a single large storage bank,
generally used, but not limited to, large vehicles, such as buses and trucks.
C
Card-lock system. A security system incorporated into a dispenser to prevent any
unauthorized use. Fleet/fuel cards are required to authorize a transaction.
Cascade storage system. A fuel storage system consisting of two or three storage banks
pressurized at different levels. The storage banks are used sequentially in a pre-determined
sequence.
CNG. Compressed Natural Gas; an alternative, and considered a more environmentally

friendly, fuel used to substitute petrol (gasoline), diesel, and propane.
CNG050. A mass flow meter designed to measure CNG flow, manufactured by Micro
Motion®.
Coalescing filtration. A filtration method that separates water aerosols and droplets, as
well as solid particles, from gases; the standard and recommended method of filtration for
all Kraus CNG dispensers.
Communicator. A standard MICONTM remote used to set dispenser prices and check
totalizer readings.
E
ESD. Emergency Shut Down; a dispenser feature that terminates all power to major
components, when activated, to disallow further gas flow and use of dispensers. ESD
buttons are not standard features, but Kraus CNG dispensers are equipped with ESD
terminals that can enable this function.
H
High-flow dispenser. A CNG filling system designed to quickly refuel vehicles.
High Style. A Kraus-original dispenser frame.

Fleet (High Style) CNG Dispenser Manual Glossary-1
GLOSSARY
I
Info-Pac. A MICONTM 500C remote-control programmer.
K
KAF 402™. A Kraus-original solenoid valve, engineered specifically for high-pressure CNG
applications; see Solenoid valve.
M
Mainboard. The MICONTM’s main circuit board housing critical electrical components, such
as the CPU; also known as the motherboard.
MICONTM 500C. A Kraus-manufactured pump-controller—an inexpensive alternative to

using PLC units to operate fuel dispensers; see also Pump-controller.
O
O-ring. A small, circular elastic joint used to seal or fill space between mating components.
P
Particulate filtration. Particulate filtration is a filtration method designed to remove solid
particles from gases.
PLC. Programmable Logic Controller; a computer used to automate electromechanical

processes, such as dispensers and assembly lines.
POS system. Point-of-Sale system; a system that allows fuel station attendants to control
and authorize fuel dispensers from their terminal.
Pressure vessel. A sealed container designed to hold gases or liquids at a considerably

higher pressure than that of the ambient atmosphere.
PSI. Pound-force per Square Inch; a unit of pressure.
Pump-controller. An electronic device used to control the voltage supplied to the fuel-
pump and other signals used within the fuel-pump.
R
Rebuild kit. A Kraus package that includes parts and instructions necessary to rebuild a
dispenser component, such as a solenoid valve. Rebuild kits are sold separately from
dispenser packages.

Glossary-2 Fleet (High Style) CNG Dispenser Manual
GLOSSARY
S
SAE J1616. A standard developed SAE International that describes recommended practices
for using compressed natural gas as fuel for vehicles.
Solenoid valve. An electromechanically controlled valve. For CNG dispensers, it is used to

control gas flow from the storage banks to a vehicle’s receptacle.
Split-flow. A single fuel dispenser with one hose designed for a standard-flow filling
system and another designed for a high-flow filling system.
Split-pressure. A single fuel dispenser designed to dispense fuel at two different pressures.
Standard-flow dispenser. A CNG filling system designed to refuel passenger vehicles.
T
Totalizer. A function within the MICONTM 500C that sums up the total dollar and volume
sales.

Fleet (High Style) CNG Dispenser Manual Glossary-3
INDEX
INDEX
A M
Actuator shaft, 24, 32 Mainboard, 32, Glossary-2
Mass flow meter, 4, 2, Appendix-1, See
B CNG050
TM
Bar, 9, Appendix-1,Appendix- 2, Glossary-1 MICON 500C, 2, 4, 22, 24, Glossary-2,
Battery, 32, 33 See Pump-controller
Battery mode, 21, 22
O
Battery-save mode, 24
Breakaway, 13, 20, Appendix-7, Glossary-1 O-ring, 20, 31, Glossary-2
Buffer storage system, 4, Glossary-1
P
C Particulate filtration, 17, Glossary-2
Card-lock system, 16, 37, Glossary-1 Pit frame, 13, 14
Cascade storage system, 5, Glossary-1 PLC, 4, Glossary-2
CNG, 1, 4, 7, 17, 31, Glossary-1 POS system, 16, Glossary-2
CNG050, 35, Appendix-2, Appendix-3, PSI, 9, 25, 26, 29, Glossary-2
Glossary-1, See mass flow meter Pump-controller, 4, Glossary-2,
TM
Coalescing filtration, 17, Glossary-1 See MICON 500C
Communicator, 21, 22, Glossary-1
R
Compressed natural gas, 1, 7, 12, See CNG
Rebuild kit, 20, 31, Glossary-2
E
S
ESD, 8, Glossary-1
SAE J1616, 12, Glossary-3
F Sleep mode, 21
Filter, 10, 12, 17, 18, 31 Solenoid valve, 4, 29, 31, Appendix-1,
Glossary-3, See KAF 402™
H Split-flow, 19, Glossary-3
Standalone mode, 16, 24
High Style, 1, 4, 6, Glossary-1
Standard-flow dispenser, 17, Glossary-3
High-flow dispenser, 17, 2, Glossary-1
I T
Totalizer, 21, 23, 32, Glossary-3
Info-Pac, 22, Glossary-2
K U
Uncrating, 14
KAF 402™, 4, 31, Appendix-1, Glossary-2,
See Solenoid valve
V
L Venting, 29, Appendix-5
Leak, 11, 25, 30
W
Warranty, 3, 26

Fleet (High Style) CNG Dispenser Manual Index-1
All Rights Reserved
Printed in Canada

Kraus CNG Fleet Manual

Uploaded by

Copyright:

Available Formats

Kraus CNG Fleet Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Kraus CNG Fleet Manual

Uploaded by

Copyright:

Available Formats

©2015 Kraus Global Ltd.

Fleet (High Style) CNG Dispenser Manual i

Document No. 267AY30.MNL.R01

All Kraus CNG dispensers have been manufactured to comply with

1.1 About this manual 1

2.1 General safety 7

3. INSTALLATION AND SETUP 12

3.1 Installation guidelines 12

©2015 Kraus Global Ltd.

4. OPERATION AND MAINTENANCE 28

4.1. Filling procedure 28

A.1 Component description and specifications Appendix-1

©2015 Kraus Global Ltd.

This page intentionally left blank

©2015 Kraus Global Ltd.

This page intentionally left blank

©2015 Kraus Global Ltd.

©2015 Kraus Global Ltd.

1.1 About this manual

This manual was designed to provide installation, operation, and

This manual is designed to be clear, comprehensive, and available to

This manual is divided into five chapters:

3. INSTALLATION AND SETUP

4. OPERATION AND MAINTENANCE

©2015 Kraus Global Ltd.

1.2 Additional references

 Quick-Start Guide—The Fleet (High Style) CNG Dispenser

If you are missing any of the documents listed above or require

1.3 Contact information

©2015 Kraus Global Ltd.

1.4 Warnings and notifications

1.5 Warranty information

©2015 Kraus Global Ltd.

1.6 The Fleet (High Style) CNG dispenser

Storage system Buffer (1 large bank) Cascade (up to 3 banks)

Filling system Standard-flow High-flow Standard-flow High-flow

1.7 Dispenser theory of operation

1.7.1 The MICONTM 500C

Kraus’ MICONTM 500C pump-controller is an inexpensive alternative

After the fueling nozzle is attached and a fill is authorized, the

©2015 Kraus Global Ltd.

1.7.2 Buffer storage systems

A buffer storage system comprises a large storage bank with a single

After the target-fill-pressure is calculated, the solenoid valve remains

1.7.3 Cascade storage systems

Cascade storage systems typically consist of three separate storage

©2015 Kraus Global Ltd.

1.7.4 The High Style unit layout

©2015 Kraus Global Ltd.

Compressed Natural Gas (CNG) can pose great danger if mishandled.

It is necessary to comply with all safety precautions and other instructions

2.1 General safety

 Do not smoke or allow open flames and naked lights within 15

©2015 Kraus Global Ltd.

2.2 Filling safety

 Be aware of emergency procedures and emergency telephone

©2015 Kraus Global Ltd.

2.3 Dispenser hose safety

 Inspect the hose assembly before each use.