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Installation Maintenance and Safety

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1. Installation Maintenance and Safety Manual Page 36 WWW TEESING COM 3170 4130700 EZ BRC FuelMaker WWW TEESING COM System Response Time type of restarting and Fault Hazard conditions Counter timer faults 29 MAX Max number of error for restarting RESTART reached supply 30 MAXFILL Max refueling time allowed for refueling 1s refueling As TIME reached 31 POWER OFF Max number of appliance reset during a H At any appliance starting refueling regeneration cycle for supply restarting reached Software faults EEPROM EEPROM writing error At any EEPROM writing 2s 2s FLASH FLASH corruption CRC error LS 2s 34 RAM RAM corruption test disabled in the first 10s of system supply 35 MAP EEPROM mapping calibration L At any appliance starting EEPROM KO parameters error supply 36 REMOTE Communication failure 10ms e COMMUNIC 37 RS 232 Corruption of packages sent to RS232 NA At any packaged received NA CRC error STATUS 38 WATCH A 260ms 25 DOG SW execution interrupted e g in case of endless loop for gt 260ms Table 11 System Response Time Continued After a refueling regeneration stop due to error At any appliance starting F F 25 25 Notes test effects if enabled are active only if system is in a precise condition in addition to table indications when the appliance is required to put itself in safe condition e Refueling Regeneration 1 3 4 5 6 7 13 14 15
2. 39 0151 Rev 4 ENG March 2013 WWW TEESING COM 3170 4130700 10ms test disabled during the first seconds of appliance supply 10ms tested only after 5 minutes running 10ms test disabled during the first seconds of appliance supply 10ms test disabled during the first seconds of appliance supply 10ms test disabled during the first seconds of appliance supply 10ms test disabled during the first seconds of appliance supply 10ms test disabled for 2s when element is ON or OFF 10ms test disabled during the first minute of system starting 10ms test disabled during the first minute of system starting 10ms test disabled during the first minute of system starting 10ms test disabled during the first minute of system starting Installation Maintenance and Safety Manual Page 34 39 0151 as BRC FuelMaker TEESING 4 WWW TEESING COM System Response Time type of restarting and Fault Hazard conditions BY PASS CONDENSER TEMPERATURE DRYER EVAPORATOR TEMPERATURE DRYER PELTIER CURRENT MOTOR TRIAC MOTOR TCO MOTOR SUDDEN PRESSURE DROP TEST Table 10 System Response Time Continued DRYER GENERAL VALVE Condenser Peltier Vaporizer or Column Heater are not working correctly or current into the condenser lt 3A With ByPass Valve on current lt 200mA or gt 2A Condenser temperature lt 55
3. Ee BRC FuelMaker Home Refueling Appliance for CNG vehicles Mod HRA G 1 5 P30 amp P36 G Gi CE oor Installation Maintenance and Safety Manual This Home Refueling Appliance HRA should only be installed and serviced by authorized and trained personnel 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 1 WWW TEESING COM 3170 4130700 TEESING 4 ES BRC FuelMaker WWW TEESING COM BRC FuelMaker M T M S r l U Via Industria 6 12062 Cherasco CN ITALY International Technical Assistance Tel 39 0172 48 68 628 0172 48 68 363 0172 48 68 623 Fax 39 0172 486 630 e mail compressorservice brc it www brcfuelmaker it North America Canada Technical Assistance Tel 1 705 341 19 23 e mail d stubbings brc it 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 2 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM SUMMARY DE d Ae n eg ei KEE 4 2 INTRODUC HON BE 5 3 PHILECMODEBS Gm 5 A TECHNICAL SPECIFICATIONS lana 6 5 INSTALLATION INSTRUCTIONS E 6 Ss CGENERALINFORMATION sas isosncnassnisnneasaysepornntatinnSssapscoaissaindaedeasapseneasssnlitinesnsdasnbosiversandesatsseibeasednttaarsantaboaivarsancseenrens 6 Dee APPLIANCE COC TION elena an 7 So HRAINSTALLATION ne ee 10 5 4 EXTERNAL GAS SENSORINSTALULATION 14 D COMMISSIONING ur aa rr 14 6 2 WNITIAL START UP RN i i 14 62 JIINSTRUCTIONSIFOR FIN
4. BRC FuelMaker WWW TEESING COM 0008 8008080000 Tabella 4 Working Hours codes 7 1 DISPLAY ERRORS In case of an error condition the system stops the HRA operation Depending on the error condition the unit may be reset or service may be required If the system considers the error condition not dangerous refuelling will restart by first pushing the STOP button to reset Panel and then the START one In case of an error code showing a possibly dangerous situation this operation will lock out and a service technician will be required to examine the unit A WARNING If software blocks HRA from operation do not disconnect electrical supply as the unit will ensure that natural gas does not accumulate to prevent damage injury and or death By keeping the STOP button pressed User s panel will display the last error code recorded A PC diagnostic software is available to display unit current parameters and Errors Archive See table below to identify error code and know the possible corrective action to carry out 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 16 WWW TEESING COM 3170 4130700 ERROR CODE Low Inlet Pressure 00001 High pressure sensor malfunction 00010 Excessive high pressure detected 10111 Excessive blow down pressure 00011 Table 5 Error diagnostics 39 0151 BRC FuelMaker CORRECTIVE ACTION Check the right inlet pressure Check that inlet m
5. C or gt 105 C Vaporizer temperature lt 55 C or gt 105 C Condenser current gt 10A Triac short circuit TCO open for excessive engine temperature Engine current lt 1A or gt 10A Unexpected outlet pressure drop Rev 4 ENG March 2013 Installation Maintenance and Safety Manual With ByPass Valve off current gt 200mA WWW TEESING COM 3170 4130700 Condenser Peltier Vaporizer or Column Heater are verified in regeneration in times Tmis_pelt Tmis_naf Tmis_col mapped parameters Condenser current verified every 10ms when is on test disabled in the first seconds of starting and for 2s when element is ON 10ms test disabled for 2s when element is ON or OFF 10ms test disabled in the first seconds of appliance starting 10ms test disabled in the first seconds of appliance starting 10ms Condenser current verified every 10ms Condenser over current verified every 10ms test disabled in the first seconds of appliance starting and for 2s when element is ON 10ms when engine is off test disabled when element is OFF 10ms when engine is on test disabled for 1s when element is ON 10ms when engine is on test disabled for 12s if Tamb lt 10 C or 7s if Tamb2 10 C when element is ON 1s during refuelling Page 35 GN TEESING g BRC FuelMaker WWW TEESING COM System Response Time type of restarting and Fault Hazard conditio
6. The cooling air inlet is equipped with a grid while the exhaust is located in the compressor upper side or rear side Start stop and monitoring are performed by the User Control Panel 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 5 WWW TEESING COM 3170 4130700 WWW TEESING COM BRC FuelMaker 4 TECHNICAL SPECIFICATIONS RSR Max Filling Pressure Min Inlet Pressure Max Inlet Pressure Nominal Flow 207 bar 3000 psig at 20 C 68 F ambient 248 bar 3600 psig at 15 C 59 F ambient 17 mbar 7 w c 35 mbar 14 w c 1 3 sm h a 20 C 0 017 bar inlet 1 01 scfm 0 5 GGE h 68 F 7 w c Electrical Supply Wiring Circuit Capacity Full Load Amperes Average Consumption 220 240 Volt AC Single Phase 50 60 Hz 15 Amp 5 5 5 0 Amp 0 85 kWh Dimensions L x P x A 762 x 356 x 330 mm 30 x14 x13 Weight 49 Kg 110 Ib packaging included Noise 40 dBa at 5 mt 16 5 ft Covering Protection Level IP 24 Operating Temperature from 40 C to 46 C 40 F 115 F Tabella 2 Technical Specification 5 INSTALLATION INSTRUCTIONS 5 1 GENERALINFORMATION Open packaging and verify the condition of the appliance in case of damage due to transportation immediately contact your local dealer Ensure that the gas supply and the electrical supply provided correspond to the values indicated on the serial number plate The Natural Gas connect
7. disconnect pipe and start HRA again waiting for its automatic stopping Check possible leakages from equipment and connection using a leak detector Pressure P30 Pressure P36 Ambient Temperature 207 7bar 3 000 100 psi 248 7 0 bar 3 600 100 psi 21 15 C 70 59 F or higher 183 7 5 bar 2 654 108 psi 229 7 5 bar 3 321 108 psi 10 C 50 F 166 8 0 bar 2 407 116 psi 211 8 0 bar 3 060 116 psi 0 C 32 F 20 C 4 F 30 C 22 F 40 C 40 F Tabella 3 Stopping Pressure compared with Ambient Temperature If ambient temperature detected is lower than 40 C 40 F or higher than 45 C 113 F the software will not allow the HRA start up for safety reasons and an error condition will be indicated on the User s Control Panel 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 14 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 6 2 INSTRUCTIONS FOR FINAL USER Before leaving installer should verify the complete installation and advise the customer not to service HRA internal components He should give user the HRA User Manual together with suitable instructions about operation error codes and what to do in the case of an error code Routine maintenance instructions should be given to the customer including hose inspection and nozzle cleaning Have the HRA User fill in the form outlining understanding of the unit The
8. BlowBack algorithm activation if system was refuelling Anomaly recorded on memory ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds 2 LPT High inlet pressure System puts itself in safe ANOMALY Low Pressure condition and indicator on Transducer Fan on REFUELING high limit BlowBack algorithm indicator off activation if system was REGENERATION refuelling indicator off Anomaly recorded on Buzzer is on for memory 5 seconds HPT Excessive high pressure System puts itself in safe ANOMALY High detected condition and indicator on Pressure Fan on REFUELING Transducer BlowBack algorithm indicator off high limit activation if system was REGENERATION refuelling indicator off Anomaly recorded on Buzzer is on for memory 5 seconds Table 9 Appliance response 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 26 WWW TEESING COM 3170 4130700 High Pressure Transducer low limit AIR FLOW inadequate air flow AIR FLOW flow meter out of order INTERNAL GAS ALARM as BRC FuelMaker High pressure sensor malfunction Inadequate cooling air flow Flow meter error Combi Valve malfunction Internal gas sensor alarm System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System put
9. CERTIFICATE CERTIFICATO DI PROVA REGISTRATION No NUMERO DI REGISTRAZIONE PRODUCT PRODOTTO APPLICANT RICHIEDENTE MANUFACTURER COSTRUTTORE TRADE MARK MARCA MODEL TYPE REF MODELLO RIF DI TIPO FTA ORTON rest sresrertaciecrartecra sta risa re 827 HOME REFUELING APPLIANCE MTM S r l VIA LA MORRA 1 12062 CHERASCO CN M T M S r l MEM OR ETT ETTET ETETETT TETTE ETTE E TEL PEALE EATER TCA THA PELTLA EN THE CEE NEE TEL TELE E E TEL EEL ECC TT TELEPORT EATERY TEST RESULTS RISULTATO DELLE PROVE A sample of above product was found to be in compliance with the Technical specification s standard s listed below Un campione del prodotto specificato stato provato ed risultato conforme alle TEST REPORTS REFERENCES NO TECHNICAL SPECIFICATIONS STANDARDS RIFERIMENTO RAPPORTI DI PROVA SPECIFICHE TECNICHE NORME DI RIFERIMENTO IEC 61508 2010 50AL0D032 SIL 1 FOR ALL SAFETY FUNCTION norme specifiche tecniche qui sotto indicate DT OO CRI PETER KL KE EE EECH DETTAGLI DELLE PROVE Place and Date of issue Milan 2012 09 27 os LUOGO E DAIA DI EMISSIONE Wand de RP erie OT i IMQ This Test Certificate is the result of testing a sample of the product submitted in accordance with the provisions of the specified Technical Specifications Standards IL does not imply any judgment on the production and it does not permit the use of a mark of conformity Only full reproduction
10. CORRECTIVE ACTION Check possible cooling system obstruction Check the free movement of flow meter blade Check sensor supply voltage Replace flow meter Check sensor supply voltage Replace sensor Problem probably due to excessive line voltage brownout If line is ok disconnect electrical supply for 1 minute and connect it again If problem persists call technical support Possible high pressure pipe obstruction in case of unexpected pressure increase Call technical support Table 5 Error diagnostic Continued 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 20 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM ERROR CODE CORRECTIVE ACTION 334340 0 3 2 CORRECTIVE ACTION EEprom mapping has not been correctely recorded Disconnect electrical supply for 1 minute and connect it again Software should be reloaded onto the board Call technical support If problem persists call Mapping Error technical support System in Boot Loader Table 5 Error diagnostic Continued 6 2 SPECIAL FUNCTIONS Optional functions that can be only supplied by the manufacturer e Empty Tank function If tank is completely empty this function allows realizing a forced compression to create condition needed to overcome High Pressure Gas Leakage Compressor lays in stand by and refueling and anomaly indicators start to blink Press three t
11. PRESSURE Outlet pressure unexpected increase High pressure gas leakage E HOSE TEST System puts itself in safe condition and Fan on BlowBack algorithm activation Anomaly recorded on memory System puts itself in safe condition and Fan on Anomaly recorded on memory System puts itself in safe condition and Fan on Combi Valve on except when system verifies if pressure decreases to not dangerous values Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation Anomaly recorded on memory ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION Se NA indicator off Buzzer blinking Refueling indicators DISPLAY blinking ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds 23 RISE 24 5 Ambient temperature out of range 2 AMBIENT TEMPERATURE SENSORS Table 9 Appliance response C
12. Picture 3 Example of installation 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 7 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM PUNTO DI RIFORNIMENTO VEICOLO Picture 4 Installation Distances A breakaway device allows the hose to separate if vehicle drives away while the refuelling hose is still connected It parts in two to avoid pulling the HRA from its support In the event of a drive away while the fuelling hose is connected to the vehicle the fuelling hose connected to the vehicle can only be removed by means of a depressurizing tool Impact Protection HRA should be installed 1 5 mt 5 ft high from the floor or in a location that will ensure that there is no risk of impact from a vehicle or other objects in the vicinity In some cases such as use of a bigger vehicle such as VAN or SUV the HRA may require impact protection such as a bollard see pict 5 Always make reference local codes determined by the authorities having jurisdiction BARRIERA DI PROTEZIONE Picture 5 Impact Protection 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 8 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM COOLING FIXING AIR OUTLET BRACKET EXT GAS SENSOR z NOZZLE HOLDER optional NOZZLE BREAKAWAY EXT GAS SENSOR AND SERIAL PORT CONNECTION REFUELLING Buy HOSE COOLING AIR INLET
13. SF3 87 03 o SF4 71 86 d Q SF5 70 23 Y SF6 91 90 Table 13 Safe Failure Fraction e HFT 0 Hardware Fault Tolerance e SC 1 Systematic Capability e Tipo B Reliability data are assured for a life expectancy of 10 years 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 38 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 12 DISPOSAL RIGHT DISPOSAL At the end of the HRA s life it should be removed and disposed according to installation Country authorities having jurisdiction A suitable separate collection for the following recycle and environmental disposal helps to avoid possible negative effects on environment and health and favours re use and or recycle of HRA materials A DO NOT DISPOSE COMPRESSOR TOGETHER WITH DOMESTIC WASTE PHILL CONTAINS MATERIAL ABSORBING MERCAPTAN FROM NATURAL GAS DURING REFUELING OPERATIONS Waste from Electrical and Electronic Equipment WEEE Valid for European Union and other European Countries with waste separate collection systems This symbol on HRA or on its documents means that product should be disposed at the end of its life according to directive 2002 96 CE about waste from Electrical and Electronic Equipment WEEE and implementation in national law HRA should not be disposed as urban waste but rather be delivered to the suitable collection point for electrical and electronic equipment Phill contains material absorbi
14. TEST 29 30 MAXFILL TIME Table 9 Appliance response Continued Max filling time Counter timer faults Max allowed number of error for compressor restart System puts itself in safe condition and Fan on BlowBack enabled from last error detected if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation Anomaly recorded on memory ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual WWW TEESING COM 3170 4130700 Page 31 Ee BRC FuelMaker TEESING 4 WWW TEESING COM Appliance response in case of Diagnostic Functions intervention Max allowed number of reset e g Watch Dog in refueling regeneration passed 31 POWER OFF System puts itself in safe condition and Fan on Anomaly recorded on memory ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Software faults EEPROM EEPROM Error FLASH FLASH Error o 35 MAP Mapping Calibration error EEPROM KO Table 9 Appliance response Continued 39 0151 System puts itself in safe condition and Fan on BlowBack a
15. be equipped with External Gas Sensor Optional if necessary The connector on the cable from the external gas sensor needs to be connected to port situated in the lower side of HRA next to the serial one see pict 8 Once the sensor installed you need to enable through the software Connect diagnostic tool HTTP4 Optional to the serial port following instructions under programming turn the External Interlock to ON A IMPORTANT Disconnect electrical supply for at least 1 minute after resetting the programming Failure to turn the unit off for 1 minute and restarting the HRA will not reset the programming 6 COMMISSIONING A WARNING HRA should only be commissioned by qualified personnel Local laws in force could require site and or installation inspection before starting up Contact authorities having jurisdication and gas supplier company for further requirements and information 6 1 INITIAL START UP Purge inlet pipes and equipment of air before the initial start up e Switch HRA on Open manual valve of gas inlet line Wait for the end of software control cycle Blinking Green LED becomes fixed Connect Refuelling hose nozzle to an open refuelling receptacle Push the START button and let the pipe discharge for 30seconds e Check that cooling fan is working good verifying air flow coming out from the front grille if equipped with upper casing or opening the front covering e After discharging stop compressor
16. ft sideways from any possible opening windows air inlets or priming sources and 1 mt 3 3 ft from below It is very important that the pressure relief is free from debris and that water cannot enter into the pipe and freeze Apply cap with the screen at the end of the pressure relief line or provide similar protection Stainless Steel net Please make reference to codes in force by the authorities having jurisdication about the pressure relief pipe position and pipe dimension Electrical Supply Connection Electrical installation should be properly done in accordance with the codes in force by the authorities having jurisdiction The HRA requires a 220 240VAC electric supply line that should be protected from overcurrent installed in a visible and easy to access position Check with the authorities having jurisdiction for minimum requirements and location of a shut off switch Cooling Air Ventilation System Connection The HRA is equipped with a Cooling AirVentilation system with a fan located internally in the unit The air enters from the lower grille see pict 8 and exits from either an upper vent see pict 7 or a rear vent see pict 9 used according to needs The HRA is normally provided with the rear hole closed and the upper one open An Soundproof Ventilation Kit can also be purchased see pict 12 Upper Coupler Casing Modified Coupler Lower Casing Gasket Outlet pipe Picture 12 Soundproof Ventilation Kit Pictur
17. on the same NG supply line adjust to ensure that the minimum inlet pressure to the HRA is maintained Materials installation and testing procedures should comply with applicable laws in force e g UNI CIG 7129 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 11 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM Gas pipe Outlet The HRA refuelling hose should not be replaced by unauthorized personnel not trained by BRC FuelMaker Only approved BRC FuelMaker HRA refuelling hoses can be used as use of unauthorized hoses may cause injury property damage and or death Pressure Relief connection HRA is equipped with a Pressure Relief with an outlet Gas threaded fitting Gas 3 8 see pict 9 The Pressure Relief has a cap with a screen insert to prevent intrusion of foreign bodies or ice accumulation The Pressure Relief discharges gas coming out from Safety Valve set at a max pressure of 3 barg 43 5 psi situated inside the HRA control module In the event that natural gas is released the check valve on the vehicle fuelling receptacle will require service If HRA needs to be installed in passages next to windows or next to doors you will need to connect a pipe to the pressure relief having inside min g 10 mm 3 8 and this pipe run to an area for the safe release of NG at least 3 mt above the floor or grade Safety distance from discharge point should be at least of 2 5 mt 8 2
18. 18 19 21 25 32 33 34 36 e Running refueling or regeneration started from refueling 2 e Regeneration 12 16 e Refueling 20 23 24 28 30 e All conditions 8 9 10 11 17 26 27 38 e Refueling and during the first seconds of supply 22 e Refueling Regeneration and at system starting supply 29 e At system starting supply 31 35 e No effect 37 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 37 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 11 RELIABILITY TECHNICAL DATA The tables show appliance reliability data e Ae failure probability for Safety failures e Xp op failure probability for diagnosed Dangerous failures e ou failure probability for not diagnosed Dangerous failures e Aye failure probability for failures not involving safety functions and with no effect e Diagnostic Coverage DC e Safe Failure Fraction SFF As 1 h Ap oo 1 h Ap pu 1 h Ane 1 h SF1 6 793E 06 7 882E 07 2 896E 07 2 927E 07 SF6 3 737E 07 gt ps eb Wal Y 2 020E 07 IONS 1 920E 07 funct Funzioni 1 895E 07 6 636E 06 1 122E 06 6 836E 07 2 017E 07 Table 11 Failure Probability An po Ap SF1 73 13 eb DD SF2 84 90 S O 7 SF4 71 10 Si SF5 70 10 ZS SF6 62 15 Tabella 12 Diagnostic Coverage AstAp PO AUS Ap SF1 96 32 6 E SF2 94 17 el
19. AL USER tee 15 7 FUNCTIONS OF USER S CONTROL PANEL BE 15 DA DISPLAFERRO RS O A TAN A nr 16 8 MAINTENANCE INSTRUCTIONS RR I ie 22 9 HRA REMOVAL eege 22 10 SAFETY AND DIAGNOSTIC 2 Leger KEE 23 10 1 SAFFIY FUNCEONSi a i 23 10 2 DIAGNOSTIC FU IC TON Sse tg tate cere perros stint acerca dat cesta air ran 26 li RELIABILITY TECHNICAL DATA E 38 12 DIS KT E 39 13 SEENEN 40 14 CE CONFORMITY ENEE LEE 41 15 CER TREC a EC E DEE 43 TABLES SUMMARY E fe od Mose 5 Tab lla 2 ele le Eet ee EE 6 Tabella 3 Stopping Pressure compared with Ambient Temperature 14 HE Ee eet HOUrS COGES EE 16 Table 5 Error GiaQnOstics sssccccsssssccssssssscccccssescesccsssscccsccsescessecsssescensescessesssssescesssssescesssssessessessessessessescsssssensesssseess 17 Tabella 6 Safety TUNG OW EE 23 Table 7 Appliance een KE 24 Table 8 Appliance response time i 25 TOE SAAP Tee een 26 Fable 10 System response vu E 34 Table BF A Podi lia 38 Tabella 12 Diagnostic ge e EE 38 Table 13 Safe Failure Fe CUNO EE 38 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 3 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 1 SAFETY INSTRUCTIONS e COMPONENTS ARE NON REPLACEABLE BY USER USERs SHOULD NOT CARRY OUT ANY MAINTENANCE ON INTERNAL COMPONENTS Internal components should only be maintained and overhauled at BRC FuelMaker s premises or by authorized deal
20. CMPDrying This function can be carried out before regeneration to collect humidity present into the compressor some conditions should be satisfied regeneration time refueling has started from 4s only outlet pressure lt 400 psi This function is not available for versions without dryer e Dryer GAS leakage detection Air Flow Control Versions without one of this element are available as already said Optional functions that can be enabled by the dealer after manufacturer s authorization e External gas sensor provided by the manufacturer e Max time configuration of a single compression e Pressure increase control Inadequate pressure increase e Service option enabling gradual decrease of final pressure after passing max working hours set up by the manufacturer e Configuration of compressiontime between two regenerations 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 21 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 8 MAINTENANCE INSTRUCTIONS The end user or unauthorized personnel should not access internal components for safety reasons after installation authorized personnel should close Cover applying the suitable seal provided with the handbook HRA should only kept maintained by authorized personnel suitably trained Technical service should always Compare errors shown by HRA with table 4 Try to solve problem verifying installation or replacing components Tes
21. End User should periodically verify that air inlets and discharge system are free from dirt or obstructed that refueling hose does not show abrasions or signs of breakage and that vehicle fuelling system is tested and compliant to safety regulations 7 FUNCTIONS OF USER S CONTROL PANEL Through the User s Panel you can Start Stop and Control unit Error or State Codes Panel has a START button Green a STOP button Red three LEDs Green on the left showing State of the unit Presence of Electrical Supply Refuelling Active Dryer Regeneration and Error Red and 5 LEDs on the right showing Fuel level indication Errors or Working Hours see pict 17 START STARTING REFUELING TTTTTT gt gt PRESENCE OF ELECTRICAL SUPPLY REFUELING o ACTIVE DRYER REGENERATION FUEL LEVEL INDICATORS D DN ANOMALY ERROR STOP 4 STOP STOP REFUELING Picture 17 User s Control Panel HRA is equipped with a diagnostic software constantly controlling the unit working Light indicators can show different conditions by pushing START and STOP buttons in a specific sequence 6 1 DISPLAY HRA WORKING HOURS Push STOP to reset panel then keep START and STOP buttons pressed Fuel level indicators lights will show unit working hours See table below to identify hours code see table 3 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 15 WWW TEESING COM 3170 4130700
22. INLET AND VENT FITTINGS Picture 6 Frontal View COOLING AIR INLET VENT FITTING 3 8 W GAS INLET Sa E CA Ta Rm FITTING 1 2 SERIAL PORT REFUELLING HOSE EXT GAS PONER CONNECTOR JUPPE optional CABLE Picture 7 Hard Mount Brackets Picture 8 Lower View 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 9 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM TAPPO USCIT POSTERIORE RAFFREDDAMENTO SPALLA CON GANCIO E AMMORTIZZATORI STAFFE DI SUPPORTO FISSAGGIO AD ANGOLO gt n FISSAGGIO LINEARE Picture 9 Support Kit with Soft Mount Vibration and Noise Suppression 5 3 HRA INSTALLATION Wall installation Determine the best mounting method for the HRA from the preceding information If it s equipped with hard mount brackets see pict 7 use brackets holes as a template If it s equipped with Soft Mount Vibration and Noise Suppression see pict 9 the kit will include No 2 Support Brackets No 4 90 Fixing Brackets with Threaded Bush No 4 Linear Fixing Brackets with Threaded Bush No 1 Bracket Fixing Device The HRA can be built in installed between wall studs using the 90 Fixing Brackets or on a flat surface using the Linear Fixing Brackets Use the template found in the Accessories Box to mark the brackets mounting holes and the Cooling Rear Outlet vent path if necessary Attach the mounting bracket to the wall do no
23. INTERNAL GAS ALARM INTERNAL GAS ALARM EXTERNAL GAS SENSOR OPTIONAL DRYER GENERAL BY PASS VALVE DRYER CONDENSER TEMPERATURE E BRC FuelMaker Calibration Internal gas sensor Error External gas sensor alarm Dryer malfunction ByPass Valve malfunction Dryer condenser temperature out of range Table 9 Appliance response Continued 39 0151 Appliance response in case of Diagnostic Functions intervention Wrong Internal gas sensor System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory WWW TEESING COM 3170 4130700 WWW TEESING COM ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer on AN
24. M 10 SAFETY AND DIAGNOSTIC FUNCTIONS 10 1 SAFETY FUNCTIONS The following table shows appliance safety functions They are indicated by the letter SF Safety Function followed by a progressive index Leaks detection on Gas high pressure line Humidity elimination through Dryer function Gas Leakage detection Inlet pressure detection and verification of limits allowed Outlet pressure control and monitoring Tabella 6 Safety functions Safety functions Operation mode Phase involved Application Protection Low demand mode Control and monitoring Continuous mode dryer periodically activated Regeneration Protection Low demand mode Protection Low demand mode Protection Low demand mode Protection Low demand mode Control and monitoring Continuous mode Refueling Outdoor Indoor CNG dew point Outdoor Indoor Refueling Regeneration Always except for the first minute from starting Refueling Regeneration Refueling Outdoor Regeneration First seconds from Starting Refueling Outdoor Indoor The following table shows system response when a Safety function is broken hazard System puts itself in safe condition o Engine off o Combi Valve off eventually switched on again in case of Blowback anomaly detected o All Dryer actuators off Peltier Condenser Vaporizer if Nafion function is disabled o Buzzer indic
25. OMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer on ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer on ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Medium 90 High 90 Medium 90 Page 28 Ee BRC FuelMaker Appliance response in case of Diagnostic Functions intervention DRYER EVAPORATOR TEMPERATURE Dryer vaporizer temperature out of range DRYER PELTIER CURRENT Excessive Peltier absorption Condenser MOTOR TRIAC MOTOR TCO MOTOR Table 9 Appliance response Continued Triac error Engine overtemperature TCO Engine Overcurrent 39 0151 System puts itself in safe condition and Fan on Vaporizer switching off even if Vaporizer function is enabled BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on Anomaly recorded on memory System puts itself in safe condition and Fan on Engine relay opening BlowBack
26. algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory WWW TEESING COM 3170 4130700 ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Rev 4 ENG March 2013 Installation Maintenance and Safety Manual TEESING 4 WWW TEESING COM Medium 90 High 90 High 90 High 90 High 90 Page 29 Ee BRC FuelMaker TEESING 4 WWW TEESING COM Appliance response in case of Diagnostic Functions intervention SUDDEN PRESSURE DROP TEST Outlet high pressure unexpected drop BLOWDOWN Excessive BlowDown pressure BLOWBACK Back pressure BlowBack SUDDEN
27. anual valve is open Check the adequate diameter of supply pipe Check reducer if present Disconnect electrical supply for 1 minute and connect it again If anomaly persists call technical support Disconnect electrical supply for 1 minute and connect it again If anomaly persists call technical support Possible high pressure gas inlet from tank Try to stop and restart the appliance every 5 10 minutes If problem persists close vehicle manual valve call technical support Do not use vehicle until anomaly has been detected ERROR CODE Engine Overvoltage 00101 Int Gas Sensor Alarm 00110 Ambient temperature out of range 01110 Inadequate Pressure Increase 00111 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual WWW TEESING COM 3170 4130700 WWW TEESING COM CORRECTIVE ACTION Check that voltage range is included between 216 V AC and 252 VAC Check right connection to the electrical supply line Check possible external Cause Refueling fitting Vehicle equipment Refueling pipe Gas Inlet pipe Material stored into refueling area If no causes are found close gas manually and call technical support Ambient temperature out of max allowed threshold _ Tamb lt 45 C _ Tamb gt 55 C Temperature sensor malfunction Call technical support Check possible leakages Safety Disconnection device Refuelin
28. ators fan engine relay and blow back managed according to the specific safety function 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual ByPass Valve Column heater Diaphragm Heater Page 23 WWW TEESING COM 3170 4130700 la BRC FuelMaker WWW TEESING COM Appliance response in case of Safety Function Intervention Safety function System response User s Interface Response System puts itself in safe condition ANOMALY indicator on anes REFUELING indicator off CHEN l o REGENERATION indicator off BlowBack algorithm activation Buzzer is on for 5 seconds Anomaly recorded on memory Dryer function gas dehumidifier always activated Dryer regeneration uses Engine ByPass Valve Combi Valve should be off Fan Diaphragm Vaporizer Column Heater Condenser Peltier If anomaly is detected during regeneration system puts itself in safe condition the specific response depends on the kind of anomaly System puts itself in safe condition and ANOMALY indicator on SF3 Fan on REFUELING indicator off BlowBack algorithm activation if REGENERATION indicator off system was refuelling Buzzer on Anomaly recorded on memory ANOMALY indicator off if there are no anomalies detected REFUELING indicator off REGENERATION indicator on if there are no anomalies detected Buzzer off if there are no anomalies detected System puts itself in safe condit
29. e 13 Casings 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 12 WWW TEESING COM 3170 4130700 E BRC FuelMaker WWW TEESING COM In case of an outdoors installation install the lower casing if supplied and the upper top casing see pict 13 following installation instructions In case of an indoors installation when using the upper exhaust vent open the frontal covering insert modified coupler supplied in its suitable housing fix it with the two screws and close covering again Install a 127 mm 5 pipe using gasket supplied see pict 14 then route the vent piping outside It is mandatory to install Lower Casing on HRA Picture 14 Coupler Picture 15 External Hood If using the exhaust vent rear hole the template provide in the accessory kit will allow you to mark out an exit hole hole 170 mm 6 7 while installing mounting brackets Remove the rear exhaust cap and secure it onto the upper hole housing Place coupler on rear hole using the two screws supplied We suggest to use an external grille as shown in picture in order to avoid air entering into the discharge duct causing defaults or block of HRA see pictures 15 and 16 Picture 16 Ventilation with Rear hole 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 13 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 5 4 EXTERNAL GAS SENSOR INSTALLATION HRA can
30. e following directives Si dichiara inoltre che il VRA della BRC FuelMaker soddisfa le seguenti normative e Test Report EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements e Risk Assessment as per EN 1050 amp List of Hazards as per ISO 12100 EN292 e Machinery Directive 2006 42 CE List of Essential Health and Safety Requirements Applicable Standards for the Adopted Solutions e Machinery Directive 2006 42 CE Description of problem and solution e CSA Test Report 159937 1799097 Project 1799097 Performance testing to cover HRA for residential indoor and outdoor installation and operation e CSA Test Report 159937 1799099 Project 1799099 Evaluation of the Controller Module with Integral Power Supply e CSA Test Report 159937 1805736 Project 1875401 Evaluation of the of the Safety Control Software e CSA Test Report 159937 1601190 Project 1898919 Evaluation of Cable Pass Through e CSA Test Report 159937 1591887 Project 1591887 Electromagnetic Compatibility of HRA for residential and commercial installation and operation Mariano Costamagna Date et OLI Ped The Legal Representative Data ff Legale R sential CRE OECD y Costamag E 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 42 WWW TEESING COM 3170 4130700 15 39 0151 modS87G 0 6201 Mad IMQ CERTIFICATE SIL 1 BRC FuelMaker WWW TEESING COM TEST
31. elf in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory No system response because the problem only concerns communication with diagnostic interface System switches off and then restarts TEESING g WWW TEESING COM Supply indicator blinking ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Diagnostic interface disconnected or problems in displaying parameters Supply indicator blinking for system restarting e DC shown in table is the Diagnostic Coverage concerning failures for diagnosed block as a whole while DC shown in FMEDA should be the specific value of single failure mode e Intable DC 90 has been conservatively used even in case of DC High The following table shows time intervals of diagnostic functions and system response times in case of violation this estimates software and actuators response time Test interval does not consider sensors response time input acquisition time including average calculation and software filters implemented that change from input to input according to the kind test duration The system can carry out manual automatic restarting in the same refueling regeneration cycle after a fault hazard detection The first
32. ers Do not open or tamper with modules or the warranty will be invalidated tampering with or opening modules could be dangerous and cause damage to the compressor and cause serious injury or even death e READ CAREFULLY BEFORE INSTALLATION HRAs should only be installed by trained and personnel authorized by BRC FuelMaker Please read carefully the manual provided before installation and use If you have any questions or concerns during installation please contact BRC FuelMaker Technical Support e LOCATION OF HOME REFUELLING APPLIANCE HRA HRAs can be installed both indoors Garage and outdoors in safe and protected areas as per installation instructions and local jurisdictional codes The HRA and vehicle have to be located in the same ambient temperature during the refuelling operation to ensure correct temperature compensation See Table 2 for temperature compensated maximum fuelling pressures e REFUELING APPLIANCE FOR CNG Compressed Natural Gas VEHICLES ONLY Do not use HRA for any other purpose or it may results in serious injury and or death to and also cause serious damage to structures Vehicle gas cylinder should be certified for storing CNG at a 3600 psig or 250 Bar pressure or higher HRA is suitable for residential applications and all installations must comply with installation manuals and local jurisdictional code requirements e REFUELING INSTRUCTIONS Do not refuel with engine turned on and be sure that any possible
33. ety Manual Page 24 WWW TEESING COM 3170 4130700 la BRC FuelMaker WWW TEESING COM System Response Time Safety function Test Interval Response Time After 6 seconds from refueling repeated after 36 seconds if first test fails repeated after the Empty Tank if enabled every 130 min of refueling and when outlet pressure is 97 of the final allowed one and the system is refueling from at least 5 min Dryer function is always enabled during compression when gas passes through Regeneration enabled every lapse of time expected between two SF2 regenerations if outlet pressure is gt 400 PSI As If filling final pressure has been gt 400PSI and at least 75 of max time between two regenerations is elapsed and system is in stand by from at least 30 min mm About every 10ms except during the first 8 SF3 2s minute of refueling a eh SF4 2s seconds of refueling About every 10ms except during the first SF5 seconds of refueling pressure higher limit is 725 verified only after at least 5 min running About every 10ms final pressure is verified during refueling About every 10ms outlet pressure sensor limit are verified except during the first seconds of refueling About every 1s during refueling Unexpected increase drop of outlet pressure 5s after the end of refueling and during the first seconds of supply about after 6 sec BlowBack is enabled if test KO system repeats after 16 sec a
34. g fitting Vehicle filling point This same error can occur if vehicle tank is almost empty Partially refill tank Try to restart the appliance many times Page 17 BRC FuelMaker ERROR CODE CORRECTIVE ACTION ERROR CODE Check Supply voltage Possible air inlets obstruction Air discharge dimension min 125 mm max length 15 mt with max 3 changes of direction Engine Overtemperture High Pressure Drop 00100 01000 Disconnect electrical supply for 1 minute and connect it again If anomaly persists call technical support Bypass valve Malfunction 11000 Combi valve Malfunction 10110 Dryer Condenser or vaporizer or heater malfunctioning Call technical support Dryer condenser temperature out of range 11001 Dryer Malfunction 10000 Dryer vaporizer temperature out of range lt 55 C or gt 105 C Call technical support Dryer vaporizer temperature Excessive Peltier absorption out of range 11011 11010 Table 5 Error diagnostic Continued WWW TEESING COM CORRECTIVE ACTION Check possible leakages Safety Disconnection device Refueling fitting Vehicle equipment and filling point Disconnect electrical supply for 1 minute and connect it again If anomaly persists call technical support Dryer condenser temperature out fo range lt 55 C or gt 105 C Call technical support Disconnect electrical supply for 1 minute and connect
35. ignition source is absent Do not smoke or expose to open flames during refuelling e IF YOU SMELL GAS Open all windows and doors in the location of the HRA if the unit is installed indoors Immediately close the manual valve on natural gas supply line and if possible the valve on the vehicle cylinder Switch off any possible ignition sources and contact an Authorized Service Centre e REFUELING HOSE The refuelling hose must be protected from damage and abrasion After refuelling your car ensure that the refuelling nozzle is returned to its holder In case of hose and connector abrasions or wear contact your Authorized Technical Centre for service A WARNING DO NOT USE SOLVENT OR AGGRESSIVE CHEMICAL AGENTS FOR CLEANING THE OUTSIDE USE DETERGENTS OR DOMESTIC GENTLE SOAP 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 4 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 2 INTRODUCTION HRA has been developed for both indoors Garage and outdoors installation for compressing Natural Gas for vehicle use Model P30 is designed to refuel at a pressure of 207 bar 3 000 psi at 20 C 68 F ambient temperature with a Nominal Flow of 1 3 sm h at 50 Hz 1 01 scfm 0 5 GGE h at 60 Hz Model P36 is designed to refuel at a pressure of 248 bar 3 600 psi at 15 C 59 F ambient temperature with a Nominal Flow of 1 3 sm h at 50 Hz 1 01 scfm 0 5 GGE h at 60 Hz A HRA is equ
36. imes in three seconds START button to enable this function in case of fault procedure the High Pressure Gas Leakage error is shown During compression refueling indicator is on while the anomaly one is blinking At the end of compression a leakage test is carried out If there are no leaks anomaly indicator switch off and compressor keep compressing on the contrary the High Pressure Gas Leakage error is shown and compressor stops Empty Tank function can be interrupted through the STOP button at any time the High Pressure Gas Leakage error is shown During the Empty tank phase anomaly indicator is blinking user s monitoring is suggested e Final Pressure Compensation function according to temperature If temperature changes final refueling pressure changes according to the installation Country s laws in force This function can be disabled if not required e Regeneration Bypass function If a dryer error persists during regerenation compressor stops this operation and allows restoring system compression functions During regeneration bypass regeneration indicator is blinking If regeneration ends successfully bypass the indicator will swcith off e Diaphragm Vaporizer function Nafion function If diaphragm temperature is lower than 5 C this function switches diaphragm heater on It will switch off when temperature goes beyond the 7 C It is necessary to avoid possible freezing of water present into the diaphragm e
37. ion and Fan on except for flow meter error and max number of restarting allowed after an anomaly detected not yet achieved BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and ANOMALY indicator on Fan on REFUELING indicator off BlowBack algorithm activation if REGENERATION indicator off system was refuelling Buzzer is on for 5 seconds Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation Anomaly recorded on memory ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Table 7 Appliance response In case of BlowBack enabled error buzzer emits an intermittent sound In case of BlowBack enabled and or detected error refueling indicators DISPLAY start to blink The following table shows time intervals of safety functions and system response times in case of violation this estimates software and actuators response time Test interval does not consider sensors response time input acquisition time including average calculation and software filters implemented that change from input to input according to the kind test duration 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Saf
38. ion should be properly done using suitable piping following installation and testing procedures in accordance with all codes in place by the authorities have jurisdiction A shut off valve must be installed on the gas supply line and with a pressure regulator if the supply pressure exceeds the max value allowed Electrical installation should be properly done in accordance with codes determined by the authorities having jurisdiction Natural Gas must be odorised The installation of a HRA must comply with all codes determined by the authorities having jurisdiction and those outlined in this manual in each case the more stringent rule must be followed A me installation of a HRA must comply with all codes determined by the authorities having jurisdiction and those outlined in this manual in each case the more stringent rule must be followed Noise Phill HRA soundproof version emits roughly 40 dBA Hemispheric Field at a distance of 5 m 16 5 ft The installer should ensure that no noise regulations are in place by the authorities having jurisdiction Avoid installing a HRA next to neighbours windows or walls that can amplify noise 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 6 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 5 2 APPLIANCE LOCATION Structure requirements HRA weighs roughly 43 Kg 95 Ib and should be installed on a wall or a structure made of non combustible
39. ipped with Internal Gas Sensor Air Flow Switch and Internal Dryer 3 PHILL MODELS emm E77HRAG15P E77HRAG15P E77HRAG1I5P 30 P36 30B P36B 30L 36L 15 1 5 1 5 1 5 1 5 DESCRIPTION STANDARD FULL EQUIPPED BASIC SMART LOCATION Indoor Indoor Indoor Indoor Gui Gaidar outdoor outdoor outdoor outdoor INTERNAL DEVICES Internal Gas Detector Air Flow ves wm mno YES ES Y ES Tabella 1 Phill models A WARNING Phill models without the gas dryer Smart and Basic are available but they can be used only if the gas is already dried We recommend to use gas with dew point at the maximum delivery pressure of 5 C lower than the minimum ambient temperature WARNING In case of outdoor installation with adequate ventilation the Phill Smart use without the internal gas detector is allowed The Phill software is designed for the constant monitoring of the all compressor components The software checks for the pressure increasing as well as the maximum filling pressure compensation in reference to the ambient temperature in order to avoid overpressures due to external temperature rising after filling The automatic compensation system is determined by the temperature sensor installed on the main board function activated by the manufacturer The Phill is air cooled and admits operating temperature between 40 C 40 F and 45 C 113 F The Phill ventilation system operates through a fan located in the compressor lower side
40. it again If anomaly persists call technical support 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 18 WWW TEESING COM 3170 4130700 ERROR CODE Inadequate Cooling Air Flow 01001 Max Refueling Time 01010 High Inlet Pressure 01011 High Pressure Gas Leakage 01100 BRC FuelMaker CORRECTIVE ACTION Check Possible cooling air inlets obstruction Air discharge dimension min 125 mm max length 15 mt with max 3 changes of direction Fan Check possible leakages Refueling fitting Vehicle equipment Refueling pipe Restart the appliance Check conformity of gas supply line pressure to technical specifications Check the right kind and setting of reducer if present Check possible obstructions or damages Safety Disconnection device Refueling fitting Vehicle filling point Refueling pipe ERROR CODE Ext Gas Sensor Alarm 01101 Memory error EPROM FLASH RAM 11111 8 8 Back Pressure 22222 Start Button Error 10001 WWW TEESING COM CORRECTIVE ACTION Check possible external cause Refueling fitting Vehicle equipment Refueling pipe Gas Inlet pipe Material stored into refueling area Eliminate leakage source close manual valve and call authorized technical support Disconnect electrical supply for 1 minute and connect it again If anomaly persists call tech
41. ledged only if the purchasing receipt will be sent by fax or mail at the moment of the intervention request BRC FuelMaker Warranty Dept Fax 39 0172 486 630 E mail Compressorservice brc it This warranty will not cover a Fair wear and tear b Damages deliberately caused or due to negligence c Damages caused by inobservance of working instruction or by a wrong installation d Damages on non functioning components that do not jeopardize the regular machine work scratches and difference in colours included e Accidental damages caused by foreign body or substance especially included the non standard composition of the gas supplied to the machine gas quality f Repairs carried out by unauthorized assistance centres or repairs realized with non original spare parts g Damages caused by transportation 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 40 WWW TEESING COM 3170 4130700 Sech BRC FuelMaker WWW TEESING COM 14 CE CONFORMITY DECLARATION Tel 39 017248681 BRC FuelMaker Fax 39 0172593113 M T M S r l FA Via La Morra n 4 12062 Cherasco CN _ Italy BRC FuelMaker CE DECLARATION OF CONFORMITY DICHIARAZIONE DI CONFORMITA CE Application of Council Directives 2006 42 CE Machinery Directive Direttive comunitarie applicate 2006 95 CE Low Voltage Equipment 2004 108 CE The EMC Directive 97 23 CE PED Directive Notified body charged of the confor
42. lgorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on WWW TEESING COM 3170 4130700 ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Supply indicator blinking ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Low 60 Low 60 Medium 90 LOW 60 Page 32 Ee BRC FuelMaker Appliance response in case of Diagnostic Functions intervention MAP EEPROM KO Mapping Calibration error REMOTE COMMUNIC STATUS Remote communication error RS 232 CRC error Watch Dog function Table 9 Appliance response Continued Notes System puts itself in safe condition and Fan on System puts its
43. material able to support min 90 kg 198 Ib The support frame has been designed to reduce noise and vibration transmission to the wall Vehicle Refueling Point A HRA must be installed next to the vehicle being refuelled due to an automatic temperature compensation system between outlet and ambient temperature pressures always consider the max length of refuelling pipe and do not obstruct pedestrian crossing or passages Choose a location to install a HRA on the basis of the vehicle refuelling point and HRA location in order to ensure proper operation of the hose breakaway device in the event of a driveaway while the hose is connected see pict 2 3 4 Service Clearances Be sure that Services Clearances are observed see pict 1 If Service Clearances cannot be observed please contact Technical Support Avoid areas that may allow possible gas accumulation such as overhangs and or eaves Avoid areas next to vegetation that could obstruct air grilles or subject to the possible damage due to falling material Picture 1 Service Clearances AREA INSTALL ABILE AREA NON CONSIDERABILE PER L INSTALLAZIONE MANDRINO 00 A PUNTO DI RIFORNIMENTO VEICOLO Lt PUNTO DI RIFORNIMENTO VEICOLO d 25 3 5 7 ze lt OLIRIO ONMIONVIN IUAV TIVLSNI VI AREA NON CONSIDERABI PER L INSTALLAZIONE 06 ONIHONYVIW IUGOWVITYLSNI VI PORTA DEL BOX PORTA DEL BOX Picture 2 Example of installation
44. mity assessment CSI S p A V le Lombardia 20 20021 BOLLATE MI N Id 0497 Terms of CE certificate according to B procedure PED 0497 612 06 Terms of CE certificate according to D procedure PED 0497 613 06 Manufacturer s Name MTM S r l Societ Unipersonale Costruttore Manufacturer s Address Via La Morra n Indirizzo del costruttore 12062 Cherasco Cn Italia Equipment Type Vehicle Refuelling Appliance Tipologia apparecchiatura Apparecchio di erogazione ad uso privato di Gas Naturale per autotrazione Trade Name Model Nos HRA P30 G1 5 HRA P36 Gi 3 Modello Trade Mark BRC FuelMaker Marchio Standard s to which Conformity is Declared Normative applicabili a cui si dichiara la conformit Standard beseripio O S amp Q EN 60335 1 2002 Household and similar electrical appliances Safety Part General requirements UNI EN ISO 12100 UNI EN ISO 12100 2 ag List of Essential Health and Safety Requirements ER ESR Z006042 CE Applicable Standards for the Adopted Solutions H A 4 G List of Hazards assessment d UNIENISO 14121 2009 Safery of machinery Principles for risk assessment EN 0950 1 2001 EE Technology Equipment Safety Part General requirements ee amp EN 0730 1 _ Automatic electrical controls for household and similar use General requirements Automatic electrical controls for household and similar use Part 2 Particular re
45. nd then after every 15 min test can be forced by pressing STOP button When system starts refueling regeneration process software carries out the blow down SF1 2s SF6 2s Table 8 Appliance response time In case of condition violation the system reacts putting itself in safe condition just in case of refuelling or regeneration With Running we intend refueling or regeneration started from a refueling process 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 25 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 10 2 DIAGNOSTIC FUNCTIONS The following table shows diagnostic functions and system response when a Fault Hazard is detected System puts itself in safe condition o Engine off o Combi Valve off eventually switched on again in case of Blowback anomaly detected o All Dryer actuators off Peltier Condenser ByPass Valve Column heater Diaphragm Heater Vaporizer if Nafion function is disabled o Buzzer indicators fan engine relay and blow back managed according to the specific Hazard Fault detected The table also shows Diagnostic Coverage of single functions Appliance response in case of Diagnostic Functions intervention Device ue User s interface Diagnostic Description System response function response Coverage Hazard LPT Low inlet pressure System puts itself in safe Low Pressure condition and Transducer Fan on low limit
46. ng mercaptan from natural gas durint refueling operations In case of wrong HRA disposal you will be responsible for it in accordance with laws in force 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 39 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM 13 WARRANTY CERTIFICATE WARRANTY CONDITIONS M T M Srl guarantees products for 24 months starting from the date of purchasing within the limit of 2 000 working hours Purchasing should be proved by a fiscally valid receipt issued by the seller fiscal ticket invoice or transportation bill identifying the product the date of purchasing and or delivery During the whole warranty period M T M Srl engages itself to a restore faulty products assuming all burdens of expenses concerning spare parts and transportation b replace faulty products not usefully repairable e g when repair will cost more than replacement GENERAL CONDITIONS In order to benefit from warranty the user will contact the seller and or installer that will repair the machine having ascertained the working defect If seller and or installer cannot solve the problem the machine will be forwarded to BRC FuelMaker that will repair it or replace it with a new one at its own discretion The machine will be returned to BRC FuelMaker in its original packaging lack of this packaging will automatically cause the warranty forfeiture Warranty will be acknow
47. nical support Do not disconnect electrical supply Do not force refueling fitting disconnection from vehicle Try to stop and restart HRA every 5 10 minutes If problem persists close vehicle manual valve call technical support Do not use vehicle until anomaly has been detected Check Connections Adapter board Cables Try to stop and restart the appliance If problem persists replace user s control panel Table 5 Error diagnostic Continued 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 19 WWW TEESING COM 3170 4130700 ERROR CODE Stop Button Error 10010 Int Gas Sensor Error 10011 TRIAC Error 10101 Remote Communication Error 11101 BRC FuelMaker CORRECTIVE ACTION ERROR CODE Check Connections Adapter board E Cables dl Try to stop and restart the appliance If problem persists replace user s control panel Flow Meter Error 01111 Check and clean internal gas sensor Check connections Check sensor supply voltage Replace sensor Wrong Int Gas Sensor Calibration 10100 Disconnect electrical supply for 1 minute and connect it again If anomaly persists call technical support POWER OFF Error 11110 Possible communication failure of tao remove device check connection If connection is ok call technical support Unexpected pressure increase 11100 WWW TEESING COM
48. ns BLOWDOWN Excessive BlowDown pressure A When a refueling ora ia regeneration starts BLOWBACK Back pressure BlowBack 5s after the refueling stop 2s and during the first seconds of supply after about 6 sec BlowBack activates if test KO system repeats after 16 sec then every 15 min you can force test by pressing STOP SUDDEN Unexpected outlet pressure increase 1s during refueling PRESSURE RISE HOSE TEST High pressure gas leakage After 6 seconds refueling repeated after 36 seconds if first test fails repeated after empty tank if enabled every 130 min refueling and when outlet pressure is 97 of the final one allowed and system is refueling from at least 5 min Hardware fault Amb temp 45 C or gt 55 C Difference of temperature between the two sensors gt 8 C 25 AMBIENT TEMPERATURE 10ms test disabled in the first seconds of appliance starting 10ms 2s when start signal is present except if during the first minute of system starting is in Map Cal error SENSORS START Start button pressed for gt 30s BUTTON STOP Stop button pressed for gt 30s BUTTON 10ms when stop signal is present except if during the first minute of system starting is in Map Cal error Pressure management faults PRESSURE Inadequate outlet pressure increase 10 minute refueling 2s RISE TEST Table 10 System Response Time Continued 39 0151 Rev 4 ENG March 2013
49. ontinued 39 0151 Hardware fault System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory Rev 4 ENG March 2013 Installation Maintenance and Safety Manual WWW TEESING COM 3170 4130700 ANOMALY indicator on REFUELING indicator off Low REGENERATION 60 indicator off Buzzer is on for 5 seconds Page 30 TEESING 4 EZ BRC FuelMaker WWW TEESING COM Appliance response in case of Diagnostic Functions intervention STOP BUTTON START button error System puts itself in safe Anomaly recorded on memory indicator off Buzzer is on for 5 seconds START BUTTON condition and ANDA Fan on is system was neler on refueling regenerating neers i ai S DEn 6 indicator off Low SE REGENERATION 60 activation if system was Deag indicator off refuelling Buzzer is on for Anomaly recorded on 5 seconds memory Stop button failure ANOMALY System puts itself in safe WEEN PEMP REFUELING condition and ie Can off indicator off Low REGENERATION 60 Pressure management faults Inadequate pressure System puts itself in safe condition and Fan on BlowBack algorithm activation Anomaly recorded on memory ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds MAX RESTART 26 27 28 PRESSURE RISE
50. ould not be lower than 17 mBar 7 w c or higher than the one indicated by technical information plate in order to avoid damages to the appliance Install a pressure regulator on the inlet line if necessary Gas installation should be properly done by trained and certified personnel A manual shut off valve should be installed in an easy to access position on gas pipe In addition a dirt trap and test port need to be installed before the inlet to the HRA unit Gas inlet pipe is connected to the HRA through the GAS threaded fitting supplied see pict 8 In case where inflexible NG supply pipe is fixed to the wall we suggest using a flex pipe from the pipe to the connection on the HRA to prevent the transmission of vibration and noise to the building Pipes and connectors should be free from rust oil shavings and metallic chards Liquid or rubber sealant products should not obstruct pipe In case of supply low pressure 17 mBar 7 w c pipe should have minimum diameter 1 if pipe is shorter than 3 mt 10 ft you can use a pipe HRA could switch off if other home appliances are working at the same time e g Stove Heating on the same supply line Regulators installed by gas suppliers and for use at the HRA should be equipped with a device to adjust the supply line flow and be tested when all natural gas appliances are running Check the regulator adjustment by running the HRA compressor and all other home appliances working
51. quirements for temperature sensing controls Functional safety of electrical electronic p 7 EN 60730 2 9 KR EN 61508 9 UL1998 a C0 NGVI ISO 14469 EL 14 CSA126 04 ___________ Ds AGA290 O O O O O O 16 NFPA 52 2006 __ AGROG 1992 i Approval Requirements for Vehicle Refuelling Appliances IDN C222 No 182 3 M1987 Special Lise Attachment Plugs Receptacles amd Connectors 20 C22 2 No 14 95 R2000 ip Safety Power Conversion Equipment 24 CI2 2 No 236 M2008 Heating and Cooling Equipment 7 ogprammable electronic safety related SVSLETTIS 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 41 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM BRC FuelMaker Tel 39 017248681 MTM Srl Fax 39 0172593113 Via La Morra n fa 12062 Cherasco CN _ Italy BRC FuelMaker EN 58022 1998 A 2000 __ Electromagnetic Immuni 6 EN 55014 I Discontinuous Test frenenie Immunity standard for residential Commercial and light imdustrial environments EN 610004 2 lee EN 6100043 Radi EN 6100044 cF Generic Emission standard for residential Commercial and lig i industrial environments E 34 EN61000 4 11 er 35 EN 61000 3 2 Harmonic EN 61000 3 3 1995 ni A 2001 Flicker We hereby declare that the BRC FuelMaker Vehicle Refuelling Appliance conforms to th
52. s in running condition refueling or regeneration started from a refueling process In any other case such as regeneration automatically started from a stand by after a filling only manual restarting is possible The table also shows Fault Hazard conditions System Response Time type of restarting and Fault Hazard conditions Device Fault Hazard condition Error Response Number Test Interval function type time 1 2s LPT Low Pressure Transducer low limit LPT Low Pressure Transducer high limit HPT High Pressure Transducer high limit HPT High Pressure Transducer low limit AIR FLOW inadequate air flow AIR FLOW flow meter out of order COMBI VALVE INTERNAL GAS ALARM INTERNAL GAS ALARM INTERNAL GAS ALARM EXTERNAL GAS SENSOR OPTIONAL Hazard Inlet Pressure lt 3 5 water column Inlet Pressure gt 20 water column Outlet Pressure gt 2 of max allowed pressure Sensor signal under voltage lt 0 4V Air Flow position incoherent with fan condition Fan on and Air Flow down Air Flow position incoherent with fan condition Fan off and Air Flow up With Combi Valve on current lt 300mA or gt 2A With Combi Valve off current gt 300mA Gas concentration gt 20 LEL Gas sensor reference voltage lt 1V o gt 3 2V Gas sensor heat current lt 25mA o gt 90mA Gas concentration gt 20 LEL Table 10 System response time
53. s itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on except for max number of restarting after anomaly is passed BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory System puts itself in safe condition and Fan on BlowBack algorithm activation if system was refuelling Anomaly recorded on memory TEESING 4 WWW TEESING COM Appliance response in case of Diagnostic Functions intervention ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer is on for 5 seconds ANOMALY indicator on REFUELING indicator off REGENERATION indicator off Buzzer on Table 9 Appliance response Continued 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 27 WWW TEESING COM 3170 4130700
54. s of this Certificate are allowed without written permission of IMQ Questo Certificato di Prova d it risultato delle prove effettuate sul campione di prodotto presentato seguendo le prescrizioni della corrispondente norma specifica tecnica citata Fsso non knplica un giudizio sulla produzione e non permette l uso di un marchio di conformit Solo fa completa riproduzione del Certificato permessa senza l autorizzazione scritta dell To IMQ Sp a Societ a socio unica 20138 Milana Via Quintillano 43 tel 0250734 fa fax 0250991500 info ima it vuam REECH Res MI 1595884 Registro Imprese MI 12898410159 C F P I 12898410159 Capitale sociale 4 000 000 euro Rev 4 ENG March 2013 Installation Maintenance and Safety Manual WWW TEESING COM 3170 4130700 Page 43
55. starting can only be manual The following table shows in error type column the kind of restarting determined by corresponding fault hazard Type A automatic restarting after 15s Type B automatic restarting when anomaly has been solved and at least after 15s from its detection Type C automatic restarting after 10minutes you can advance restarting manually Type D manual restarting Type E manual restarting if anomaly has been solved Type F automatic restarting is possible but a switching off lt 1 minute is necessary If system is not reset appliance cannot restart if you press stop and then start the system starts a new cycle but error is promptly detected because the anomaly can only be erased through a compressor reset Type G manual restarting is possible but a switching off lt 1 minute is necessary If system is not reset restarting is impossible Type H some anomalies prevent from restarting system should be reset by switching off gt 1minute or through the STOP 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 33 WWW TEESING COM 3170 4130700 BRC FuelMaker Type l some anomalies reset restarting and cancel this function Type L some anomalies reset restarting and cancel this function blocking the system if anomaly persists just a reset can unblock the system WWW TEESING COM Note automatic restarting is possible only if system i
56. t HRA to verify if problems have been eliminated Close and seal HRA A WARNING Any other operation not described in this manual should only be carried out by BRC FuelMaker at its premises Any service completed by UNAUTHORIZED personnel will invalidate the warranty and may cause damage to the compressor serious injury and or death BWN kA Ordinary Maintenance Inspection Periodically check the outlet pressure to ensure proper operation see table 2 verify that refuelling hose does not show abrasions cutting or swelling replace it if necessary Always check refuelling nozzle and breakaway device replace them if necessary Check that pressure relief and front rear air inlets are free from material or ice Any attempt to tamper with or open modules can cause damage to property serious injury and or death and will invalidate the warranty 9 HRA REMOVAL If you need to remove the unit follow these instructions e Check that Electric Supply button is OFF and gas inlet valve closed e Check the absence of voltage on electric supply cable and disconnect it e Disconnect Inlet and Discharge pipe from HRA verifying the absence of overpressures close fittings e Pack HRA with its original packaging For further information please feel free to contact Technical Service 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 22 WWW TEESING COM 3170 4130700 la BRC FuelMaker WWW TEESING CO
57. t tighten screws completely and hang compressor in place on the mounting brackets being careful with to ensure rear hooks ensuring the bracket is correctly mounted Once mounted correctly and perpendicular tighten bracket screws and close the mounting lock plate A WARNING Wall mounts must support the HRA weight and be able to support the unit in the event of a vehicle driveaway while connected to the Phill ensuring that the breakaway on the hose will disconnect safely Affix nozzle holder to the wall next to the HRA see pict 11 39 0151 Rev 4 ENG March 2013 Installation Maintenance and Safety Manual Page 10 WWW TEESING COM 3170 4130700 BRC FuelMaker WWW TEESING COM VITI DI BLOCCAGGIO GUSCIO Picture 10 Fixing Screws Picture 11 Nozzle Holder Mounting Once correctly mounted open the front cover of the HRA by removing the 5 cover screws Loosen the three transportation mounts see pict 10 but do not remove or attempt to remove these mounts The screws are mounted to rubber grommets to hold the internal components in place during shipment A WARNING HRA can be seriously damaged if you do not loosen the 3 transportation screws In case having to ship the HRA tighten the 3 transportation screws again before shipping in order to avoid any damage Gas pipe Inlet HRA should be installed where natural gas network assures a max humidity ratio of 110 mg m 0 24 Ib 20 C 4 F DewPoint Inlet pressure sh

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