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CNG Gen 1 BOC FSM Installation Manual

1. d n raz san uba asa 38 mmm 38 PUO Cylinder Initial Pressurization CNG Cylinder Valve Initial Interface Leak Test 39 Filling your Fuel Storage Module iii 41 Low Ambient Temperature Vehicle Refueling nennen nnne nennt nnne nnne nnns 43 Relueling Proble me u uuu y l ll l aaa pa oa an b 44 45 Fuel Cylinder Venting MM 46 Appendix A 48 Appendix B System Mechanization ener 54 Appendix C Wiring Diagrams U u alana dad 55 Appendix D FSM Final Inspection Form UU u U nean sensns ann nans aane 61 QUANTU M CNG Gen 1 BOC FSM Installation Manual This Page Intentionally Left Blank VI QUANTUM T CNG Gen 1 BOC FSM Installation Manual Introduction The Back Of Cab BOC fuel storage module is designed to store Compressed Natural Gas CNG The FSM holds 3 cylinders which are contained within a vertical structure and protected with a lightweight fiberglass housing Each cylinder is configured with an individual PRD manifold assembly and thermal relief valves The FSM features both standard fill and fast fill valves The
2. ES id x m Ce m od gt lt x n gt p HI IZ n R E E m7 M f Kai m gU 555 5 iki 5 i n I mmn n REAR L E D LIGHTING DISCONNECT M P 150 2 WAY Tl lt users rw ELECTRICAL SCHEMATIC PA COMMON GND DA ELECTRICAL INTERFACE CONNECTION E x FREIGHTLINER PIGTAIL WIRING 116269 56 QUANTUM Q CNG Gen 1 BOC FSM Installation Manual BOC LOAD L E D LIGHTING 1 LOCATED ON THE BACK SIDE OF THE FIBERGLASS COVER PASSENGER SIDE BOC LOAD L E D LIGHTING 2 LOCATED ON THE BACK SIDE OF THE FIBERGLASS COVER DRIVERS SIDE m LED ING BOC 2 SW BO PL leg LED BOC 2 LIGHTING GND DK GN ELECTRICAL SCHEMATIC LOAD LIGHT VVIRING QT 806 LOAD LIGHTS WIRING 116273 59 CNG Gen 1 BOC FSM Installation Manual REGULATOR CV102 SOLENOID VALVE GT150 QT FLASHING CAN DISCONNECT LOCATED BETWEEN THE FRAME RAILS UNDER THE BOC TANK MODULE 0 TIE MALE SEALED CONNECTOR TO WIRE HAINESE o M WT x 70 PIN CONTROLLER BOC 14 WAY DISCONNECT 60 REGULATOR LINE PRESSURE SENSOR LOCATED BETWEEN THE FRAME RAILS UNDER THE TANK PACKAGE 4 me FILL BOX L E D LIGHTING LOCATED ON DRIVERS SIDE FRAME RAIL ON TOP OF THE FILL BOX BOC LOAD L E D LIGHTING 1 LOCATED ON THE BACK SIDE OF THE FIBERGLASS COVER PASSENGER SIDE b na BOC LOAD
3. Replace the O ring before filling the cylinder 5 Connect the CNG fill nozzle to the fill valve and follow the instructions displayed on the fuel dispenser 6 When finished fueling disconnect the fill nozzle return it to the dispenser and put the fill valve cap back on the fill valve 42 QUANTUM TECH O CNG Gen 1 BOC FSM Installation Manual Low Ambient Temperature Vehicle Refueling Never pressurize a CNG cylinder that is not restrained by approved brackets properly mounted or otherwise acceptably restrained to prevent movement while under pressure Failure to observe this warning may result in death or serious injury Performing this procedure when the fuel storage module is less than 0 F 18 C may result in damage to the components within the FSM Allow the FSM to warm to room temperature gt 60 F 13 C for a minimum of 12 hours before pressurizing Failure to follow this requirement may result in minor or moderate injury as well as damage to components Fueling in low ambient temperatures may cause freezing concerns and potential flow restrictions within the fuel storage module Fueling in low ambient temperatures may result in potential flow restrictions as ice begins to form inside the fuel lines and components In some cases the fuel flow may be restricted or entirely blocked due to ice build up If the lines are blocked with ice the ice must thaw before flow resumes Cold a
4. there may be pre existing holes drilled into the frame If pre existing holes are in the location where the base mount of the FSM is to be mounted then the following should be addressed e Pre existing holes in the frame should be marked and drilled into the FSM base mount The drill should be the same size as the pre existing hole in the frame Do not enlarge any holes Insert fasteners through the holes and torque the fasteners to appropriate specifications Pre existing holes drilled into the FSM base mount with fasteners does not substitute use of the M16 fasteners provided with the installation kit e f a 11 16 base mount hole one that uses the M16 bolt from the installation kit needs to be relocated then mark and drill a hole in the new location following the Hole Location Guidelines in this manual There must be one 11 16 hole or equivalent in each of the four quadrants as shown in the illustration on the right A 5 8 bolt Grade 8 or better is a suitable replacement to the M16 bolt supplied with the installation kit if required For special considerations contact Quantum Technical Assistance at 800 816 8691 28 QUANTUM T CNG Gen 1 BOC FSM Installation Manual FSM Installation 1 Secure the truck making sure the wheels are chocked and is on level ground i TOP m x 81 8mm 2 Locate the FSM mount positions on the vehicle frame following the General Sys
5. FSM Installation Manual System Overview The Gen 1 BOC CNG fuel storage module was designed to be installed on the Class 7 and 8 heavy duty trucks with a maximum frame width as defined in the General System Specifications section of this manual The installation of this CNG fuel storage module may require minor adjustments or alterations of the vehicle to ensure a durable and safe installation This document outlines the procedure to install the Gen 1 BOC CNG fuel storage module on Class 7 and 8 heavy duty trucks The primary components of the CNG fuel storage module are e CNG Fuel Storage Cylinders Type 4 Manual Fuel Tank Shut off Valves Standard CNG Fill Valve High Flow CNG Fill Valve High Pressure Regulator Fuel Gauge Module System Design and Operation The fuel storage module contains fuel storage cylinders thermal relief devices fiberglass housing and Type 4 cylinder mounting brackets The CNG fuel storage cylinders used in this fuel storage module are Type 4 cylinders which are wrapped in carbon fiber The cylinder is shipped empty and must be properly pressurized and purged prior to service Refer to the Start Up Procedure section of this manual for more information Q General Vehicle Requirements QUANTUM CNG Gen 1 BOC FSM Installation Manual DANGER Inadequate distance between the FSM and trailer trailer gap may result in damage to the FSM Always maintain adequate distance betwee
6. QUANTUM CNG Gen 1 BOC FSM Installation Manual Verify the area of the vehicle where the FSM will be installed is clear of any obstructions or components that may contact or damage the FSM Check the area of the frame where the FSM will be mounted and note any obstructions or components that may contact the FSM Relocate components as necessary per the manufacturer s instructions Also inspect for any brackets or features on the frame rail that may interfere with the FSM This includes any additional inner and or outer support rails that may have been added to the frame Additional rail supports that have been added may affect the bolt length requirements If the truck has an auxiliary in frame battery box then it must be relocated if the box is directly under the FSM Off gases from the batteries may otherwise accumulate within the covers of the FSM creating a potential hazardous situation The in frame battery box should never be directly under the FSM If the truck is equipped with a pogo stick assembly then the assembly may need to be relocated to clear the fuel storage module 24 QUANTUM GIES CNG Gen 1 BOC FSM Installation Manual Step 4 Inspect Heat Sources Due to the construction of the FSM and the location of the CNG cylinder relief devices Quantum has an additional requirement to add additional heat shielding if a heat source is within 5 127mm of the CNG cylinder covers or
7. TOP Actual Size Do Not Scale When Printing 3 2 81 82mm 11 16 17 50mm 2 36 60mm e D 9 2 36 60mm 1 97 50mm 1 97 50mm 10 6 6 CNG Gen 1 BOC FSM Installation Manual QUANTUM 3 8 LINE 4 MV 102 MV 101 gt d F N TANK 1 TANK VALVE 1 2 LINE 9 3 8 LINE 7 A 3 8 LINE X f Appendix B System Mechanization 3 8 LINE PT102 I mam Ar gt lt En LEGEND GAS CONTROL RESIGN CONDITIONS CODE NFPAS2 NGV 3 1 PRO 1 VALVES 3600 PSI WETTED MATERIALS IUBE COMPONENT BODIES 316 STAINLESS STEEL VALVE SEATS PEEK OR VESPEL DIAPHRAGMS 316 SS DESIGN TEMPERATURE 40 6 TO 85 C F105 54 QUANTUM Q CNG Gen 1 BOC FSM Installation Manual Appendix C Wiring Diagrams FILL BOX L E D LIGHTING LOCATED ON DRIVERS SIDE FRAME RAIL ON TOP OF THE FILL BOX ELECTRICAL SCHEMATIC FILL PANEL LIGHTING WIRING QT_BOC_FILL_PNL_LIGHT_WIRING 116273 55 CNG Gen 1 BOC FSM Installation Manual PACCAR 8 WAY DISCONNECT FOR CNG VEHICLES VEMICLE_CHASSIS_NOCE_GND 10 DK LOW VOLTAGE DISC 12V BATT 1 90 OR SOL 1 10 Co Qu IGN SOL PWP FK C PW 5 LAN LC BOC MODULE 14 VVAY DISCONNECT TEMP WARN SIGACAPS OFF 80 ww gt M nr GAUGE SEND
8. actual size of the drill templates printed from the manual if used Circle YES NO Verify all other measurements to ensure the FSM will fit the target area Circle YES NO Have all sources for obstructions been resolved uuu Circle YES NO Have all sources for heat been resolved r Circle YES NO You vvill need the follovving information available to ensure the system once installed vvill be a safe and legal installation e Vehicle frame width outside of frame to outside of frame e Distance from the back of the driver s cab to the FSM e Distance from the FSM to the kingpin e Specifications for the fuel storage module Refer to General System Specifications in this manual Once you have determined that the fuel storage module can be properly installed and meet all the necessary requirements you can proceed with drilling the frame to support the FSM 26 CNG Gen 1 BOC FSM Installation Manual Step 6 Frame Drilling Guidelines QUANTUM T The drilling of the frame side member presents no unusual difficulty Standard high speed steel drills of good quality vvill serve provided they are sharpened properly and not overheated during sharpening or use It is recommended to follow these guidelines when drilling holes in vehicle frames Use existing holes whenever possible Do not weld filler pieces i
9. contact Quantum Fuel Systems Technologies Worldwide Inc 25242 Arctic Ocean Drive Lake Forest CA 92630 USA Tel 949 930 3400 Fax 949 930 3401 All information illustrations and specifications are based on the latest product information available at the time of printing Quantum Fuel Systems Technologies Worldwide Inc reserves the right to make changes at any time without notice This information is the intellectual property of Quantum Fuel Systems Technologies Worldwide Inc and may not be altered in any way This information is protected by the copyright laws of the United States of America and other countries and may not be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying and recording without the prior written permission of Quantum Fuel Systems Technologies Worldwide Inc 2015 Quantum Fuel Systems Technologies Worldwide Inc Q Hovv to Use This Manual QUANTUM CNG Gen 1 BOC FSM Installation Manual TECHNOLOGIE S This supplement contains information specific to the Back Of Cab BOC CNG fuel storage module FSM It does not explain everything you need to know about working with CNG equipment You must use this installation manual along with the service manual for the other installed components Only then will you be able to properly install and operate your equipment This manual contains informat
10. sources within 8 204 mm of the FSM cylinders that are unshielded Refer to FSM Cover Modifications in this manual for additional information and instructions 26 Complete the FSM Final Inspection Form found in the back of this manual Refer to Appendix D In this manual for the form 32 QUANTUM Fi E CNG Gen 1 BOC FSM Installation Manual Slave Cylinder Connection Some FSMs may be ordered with a slave cylinder assembly which will require installation A slave cylinder stub out pipe is available for purchase in the Accessories section of this module The T Connection will be fitted with an O ring face seal cap Remove the cap and connect the slave cylinder stub out pipe to the T Connection Attach all support hardware Once the stub out pipe has been installed a line must be fabricated to connect the stub out pipe on the FSM to the slave cylinder 33 Q FSM Cover Modifications Modification of the fuel storage module covers may result in creating a potentially hazardous condition It is not recommended to modify the covers Any cover modification may compromise the integrity of FSM covers QUANTU M CNG Gen 1 BOC FSM Installation Manual Once you have determined the FSM will physically fit in the target area on the
11. system pressure alter the manual shut off valve Printed in USA CNG Pressure Gauge 1 4 Turn Manual Shut Off Valve Standard NGV1 CNG Fill Valve High Flow ISO 14469 2 CNG Fill Valve 771005 Fuel Gauge Module 1 Electrical Connector Interface 2 Fuel Control Module Manual 5 0ff Valve CNG Gen 1 BOC FSM Installation Manual Before Filling Your Vehicle inspel the CNG fuel Fill nozzle for wear damage or cx tamination Inspei the CNG fill valve for any wear damage or cor tamination Inspei tha fill valve O ring for damage Alway Install the fill valve cap when the fill is comple 3 Fill Valve Fast Fill Valve If CHG is detected from the opposite fuel fill valve during refueling immediately stop the refueling procedure and remove the fuel fill nozzle from the vehicle Failure to follow this instruction may result in death or serious injury mm 12 QUANTUM GIES CNG Gen 1 BOC FSM Installation Manual Safety Valves 5500 CNG Fuel Storage Cylinder Manual Valve Top Cylinder CNG Fuel Storage Cylinder Manual Valve Middle Cylinder CNG Fuel Storage Cylinder Manual Valve Bottom Cylinder 1 4 Turn Manual Shut Off Valve 13 CNG Gen 1 BOC FSM Installation Manual T L E Q Covers Access Door 2 Front Cover 1 3 Right Side Cover 4 Left
12. to relocate the heat source the heat source is within 8 204 mm of the FSM cylinders adjustments MUST be made in the installation to Increase the distance between the heat source and the FSM See your truck equipment supplier for heat shielding solutions 25 Q Step 5 Installation Checklist QUANTUM CNG Gen 1 BOC FSM Installation Manual Refer to the illustrations and dimensions in the General System Specifications section of this manual to answer the items on the checklist below Distance from outside of rail to the outside of rail Gap between the FSM mount and the outside of rails iii lir liq sla i o CENT Circle YES NO Distance from the back of the driver s cab to the FSM cccccccccccececcccccececcccccecececuceesecscauauaesecseauaenerscavaeass Does this distance exceed the minimum specification Circle YES NO Distance from the FSM to the kingpin Does this distance exceed the minimum specification Circle YES NO Verify the locations of the holes to be drilled in the frame are appropriate Circle YES NO Verify the
13. AP 1 8 GAP gap is less than 1 16 Shims must be installed equally to both mounting flanges of the base on the same side of the vehicle li may be necessary to match drill the shims to the frame and base mount There are 2 1 8 shims and 2 1 16 shims included vvith the FSM kit Additional shims can be purchased if required Part numbers for shims can be found in the Accessories section of this manual 30 CNG Gen 1 BOC FSM Installation Manual IMPORTANT If existing holes are to be used the supplied hardware may not be sufficient for full nut engagement New hardware may be required if additional length is necessary 16 17 20 21 22 23 24 Lubricate the 11 16 both threads with 10w oll Install the fasteners through the mount holes on the FSM and the holes drilled through the frame Each fastener must include a bolt flat washer and a locking nut The bolts should be installed from the frame side of the assembly with the nuts and washers against the FSM mounts Always torque the nut versus the bolt when possible Tighten to 180 lb ft 244 N m Do not use a pneumatic impact tools to install any hardware Connect the coolant lines to the regulator using the two clamps provided with the installation kit The hot coolant line must be placed on the IN line port The cool line must be connect to the OUT line port The lines may need to be trimmed routed and clamped prope
14. ER SIG 80 PR wM m ALS VEL S m KV DELPHI 1204797 12047901 M M E MALE G DEUTSCH 6 15 14SN 1017 nuc 8 013 MOS REAR L E D LIGHTING DISCONNECT M P 150 4 WAY hi PANEL LED Sw FWR si LEO LIGHTING COMMON GNO 1 DK GN D rr LOAD LED SW Pw SW rv 2 ELECTRICAL SCHEMATIC 12162144 12162307 ELECTRICAL INTERFACE CONNECTION FEMALE MALE PACCAR PIGTAIL WIRING 116224 56 QUANTUM Q CNG Gen 1 BOC FSM Installation Manual VEHICLE CHASSIS CND 1 BC VOINCLE CHASSIS CND 2 06 DK l n SOL FWR 1 1 0 AR PWR MO 2 INSTRUMENT GhD 60 DK gt 60_PKWH 5 GAUGE LOAD LIGHTS 5W 00 GY VOLVO 8 WAY DISCONNECT FOR CNG VEHICLES 255 CHM RESISTOR jam BOC MODULE 14 WAY DISCONNECT WET e ADe DESTSCH MDP26 19 45N 1017 uc k REAR L E D LIGHTING DISCONNECT M P 150 2 WAY BAO LIGHTS Sm MO GY ELECTRICAL SCHEMATIC ELECTRICAL INTERFACE CONNECTION LED LIGHTING COWMON GND 80 GN gt Won VOLVO PIGTAIL WIRING 116227 57 CNG Gen 1 BOC FSM Installation Manual FREIGHTLINER 8 WAY DISCONNECT FOR CNG VEHICLES VEMRO I CHASSIS ND VINE OMASSIN GND 2 mA sot FW 1 3 0 le t n 2 LI BOC MODULE 14 WAY DISCONNECT GALIGE PR WH n V 1 5 d i r n b
15. FSM covers are equipped with rear load lighting and a fill box light The operating temperature for the fuel storage module has a range between 40 C to 85 C This manual provides information for the Gen 1 Back Of Cab model About Compressed Natural Gas Natural gas is a by product of oil drilling and coal mining but it can also be harvested independently from natural gas fields It can be used as a motor fuel in two forms Compressed Natural Gas CNG and Liquefied Natural Gas LNG Natural gas is lighter than air If a leak were to develop the gas would rise and disperse through the atmosphere giving little chance for ignition Compare that to gasoline and diesel fuel both of which are dense liquids that tend to pool and are easily ignitable When CNG is burned in the engine it produces low emissions This means less smog less air pollution and cleaner air This makes CNG a promising motor fuel for the future Raw natural gas is odorless so a distinctive odorant that smells very much like strong sulfur is added prior to distribution This strong odor makes the presence of a leak very easy to detect If an odor is detected which has been added for your safety please inspect the vehicle for the source of the concern and repair as needed Natural gas itself is a safer fuel than either gasoline or diesel fuel It has a limited range of flammability meaning it requires the correct mixture of air and fuel to burn somewhere in the 5 to 15 pe
16. FSM may occur The installer must first determine distances A B and C and then fit the application to leave adequate clearance to the vehicle components for service and assembly IMPORTANT If the truck is equipped with an adjustable 5 wheel assembly then place the assembly into the forward most position when making the following measurements Measure 106 2692mm from the back of the drivers cab down the frame rail to the kingpin A This will determine if the truck has enough space to accommodate a FSM Then measure 70 1778mm from the kingpin up the rail towards the FSM This is the minimum clearance needed for the trailer with or without a reefer C B C A total allowable area for the FSM Refer to the measurements in the General Vehicle Requirements section of this manual DANGER Inadequate distance between the FSM and trailer may result in damage to the FSM Always maintain adequate distance between the FSM and trailer at all times Failure to maintain adequate distance between the FSM and trailer may result in death or serious injury The remaining area to mount the FSM will become important if the FSM system must be positioned to avoid obstacles and heat sources mentioned in the upcoming chapters Before proceeding the installer should consult all federal state and local regulations to ensure the installation will comply with all requirements 23 Q Step 3 nspect for Obstructions
17. L E D LIGHTING 2 ELECTRICAL INTERFACE CONNECTION Smee OOOO QUANTUM 06 FUEL MODULE 116219 QUANTUM E OLOGI CNG Gen 1 BOC FSM Installation Manual Appendix FSM Final Inspection Form Date Technician v LLLI EI LI QUANTUM x ee r3 EL Quantum FSM Final Cylinder SN Mileage X Needs Repair N Not Applicable Inspect Completed FSM And Note Any Damage Verify Cylinder Strap Spring Installed Height Is Properly Adjusted Verify All Critical Fasteners Have Been Properly Tightened Verify Adequate FSM Clearance To Vehicle Components Verify Any Openings Or Gaps In The FSM Covers Will Not Allow Debris Intrusion Verify All Heat Sources Are A Minimum of 5 127 mm From the FSM Verify Any Heat Source Closer Than 8 203mm To The FSM Cylinders Have Been Shielded Verify Cylinder Inspection Label Has Been Completed And Installed Purge Fuel Storage Cylinders Fill and Leak Check the Fuel Storage Module Comments 61 Notes QUANTUM CNG Gen 1 BOC FSM Installation Manual Revision History Revision X1 Review Draft Revision X2 Preliminary Draft Revision X3 Artwork content and data updates Revision X4 Torque updates added illustrations packing list added shim updates stub out pipe info updated lifting point section updated and drill info updated Added initial fill purge leak check and fill
18. QUANTUM E FM LJ 2 CNG Gen 1 Back Of Cab FSM nstallation Manual Printed April 20 2015 Rev A QUANTUM T CNG Gen 1 BOC FSM Installation Manual Preface This manual contains information and instructions required for the installation of the Quantum Fuel Systems Technologies Worldwide Inc CNG fuel storage and compression system A thorough and complete understanding of the information and instructions contained in this manual is required for the installation and continued safe operation of the system Read this manual from cover to cover and keep it for future reference The system must only be installed and serviced by trained and certified technicians who have read and understood this manual Individual operator training is the responsibility of the company firm or organization placing the system in service Reading this manual does not constitute certification This manual contains Cautions and Notices that must be observed at all times to reduce the risk of personal injury during operation or installation Improper installation procedures may damage the system or make the system unsafe to operate These Cautions and Notices are not all inclusive Quantum Fuel Systems Technologies Worldwide Inc cannot possibly warn of all the potentially hazardous consequences caused by a failure to follow these instructions you need further information or have any questions please
19. Side Cover 5 Rear Cover 14 QUANTUM TECHNOLOGIES CNG Gen 1 BOC FSM Installation Manual O Line Identification Lines from the fuel storage module bulkhead are located below the FSM next to the electrical interface connector The lines are identified below 1 CNG Outlet Regulated 5 8 37 Flare 2 Coolant In Out 5 8 Bib 3 Coolant n Out 5 8 Bib 4 CNG Inlet 5 CNG Pressure Sensor 6 PRD Vent Always have protective caps covering the lines when they are not connected to the vehicle to prevent foreign matter from entering the system Load Light Connector The load lights have a pigtail connector at the base of the cover to the left of center The connector must be disconnected whenever the rear cover is removed from the BOC Power to the load lights is supplied through the main electrical interface located at the base of the front cover on the fuel storage module behind the fill panel 15 Q QUANTUM CNG Gen 1 BOC FSM Installation Manual Label Locator Always replace any damaged or missing labels m m sar rum Fir amia ronie ri a fr le ma mamaman ra sss Venting of the pressure from this system requires the use of special instructions or tools that can be obtained from the manufacturer QUANTUM TECHNOLOGIES Quantum Technologies Inc 949 930 3400 QTService qtww com Failure to follow these instructions will resu
20. Tool Requirements In addition to standard technician tools and safety equipment the following tools and supplies are required to install the fuel storage module Hand Tools Tape Measure 1 8 Hole Punch 3 8 Torque VVrench Ib ft 1 2 Torque Wrench lb ft 5 8 Open End Wrench 11 16 Drill Bit with 1 2 Shank 11 16 Crowfoot 11 16 Angle Open End Wrench 13 16 Angle Open End Wrench 13 16 Crowfoot 18 Socket Extension Equipment Tools Drill with 1 2 Chuck 9 Digital Caliper Inert Gas 6K Cylinder w Regulator Lines and CNG fill nozzle Lifting Straps or Chain Rated to 3000 05 Electronic Gas Detector Magnetic Base Drill Press Recommended Fork Lift Recommend Metal Base Mount Drill Template Special Service Tools Cylinder Installation Support Fixture Fluid Requirements Shop Supplies Snoop Leak Detection Fluid Parker O Lube Zinc Rich Primer Fast Drying Enamel Paint 10w Oil 10 QUANTUM Fi E CNG Gen 1 BOC FSM Installation Manual Components Locator FSM System FSM Front Cover PRD Vent Lines CNG Cylinder Valve Qty 3 CNG Cylinder Qty 3 Fill Panel LEE 11 QUANTUM Q Fill Panel Manufactured by QUANTUM TECHNOLOGIES CNG Fuel Only Service Pressure 24821 kPa 3 600 psig see instructions on fuel container for inspection and service life This gauge indicates
21. a fill panel or if the FSM is a slave module the FSM is equipped with a fill panel then the part identification label is located on the inner left portion of the fill panel assembly If the FSM is a slave module then the part identification label can be located inside the cylinder access panel on the frame QUANTUM T CNG Gen 1 BOC FSM Installation Manual Table of Contents 1 2 2 0 o nn A o SAA 4 OVOEM na aska 5 5 System Design General Vehicle 85 ULU ua was awas kna ei ras enta ene 6 General FSM 5 00010 06 uuu uu q daaa Dad ratio 8 installer Qualificalions a i lla 10 POO m m 10 eo lO APA PP A 11 Packaging Contents and Assembly ui 18 18 OC u rr Emm 19 TOUS C u in m n s s 20 nn E Lo 21 cs le a l 21 Step 1 Measure Frame Width ei 22 Step 2 Measure FSM Clearance ei 23 24 Step 3 Inspect for ODSTrUCTIONS 25 Step 4 Inspect Heat SOUrCES Step 5 Installation Checklist 00 26 27 Step 6 Frame Drilling Guidelines Slave Gyvinder Onu a 33 34 FOM FUD PoCodulo alma na dane te ab alana
22. allation Manual proper procedures are not followed during fuel cylinder venting serious injury or death could occur Read and understand all safety information before proceeding with the release of pressurized gas Refer to mportant Safety Information in this manual It is also strongly recommended that the local fire authority be consulted to ensure all local regulations are followed All CNG Fuel Cylinders installed in an enclosed area require venting to the outside of the vehicle Venting systems must meet the requirements of applicable local VENT STACK codes or venting regulations Due to the design of Type 4 fuel cylinders there will always be low levels of permeation that may result in a GROUND fuel odor in the vehicle if mounted in a passenger EARTH compartment 1 4 TURN VALVE 0 042 ORIFICE Quantum does not recommend mounting Type 4 cylinders in enclosed passenger compartments If a GAUGE type 4 cylinder will be mounted in a passenger compartment the entire cylinder and valve connections CYLINDER 2 should be covered vvith a vent bag or system to CYLINDER capture and route any gas that escapes from the VALVE cylinder to the outside of the passenger compartment Venting Storage Cylinders Operating the system with the system vent valve in the open position and with the end cap removed may result in a fuel leak verify the valve is in the closed position and the end cap is secure before fi
23. ce and emissions levels 43 Refueling Problems QUANTUM CNG Gen I BOC FSM Installation Manual the system cannot be refueled check for the following e The refueling system is not operating properly o Refer to the refueling system operating instructions e Refueling nozzle not properly engaged on the fill receptacle o Verify nozzle is fully engaged e Cylinders already full o Verify CNG level in the cylinders using the pressure gauge cylinders have higher pressure than the refueling system o Check the system pressure available from the refueling system and check it against the CNG pressure in the cylinders the items above have been checked and the system still will not take fuel the system may require service 44 QUANTUM TECHNOLOGIE CNG Gen 1 BOC FSM Installation Manual Leak Checking the System CNG is extremely flammable If something ignites it you could be severely burned Keep sparks flames and ignition sources a minimum of 5 meters from CNG Ensure work area is well ventilated Always wear proper eye and hearing protection when working with pressurized gas Use explosion proof drop lights when working on gaseous fueled systems Failure to follow these basic safety guidelines may result in serious personal injury or death Before proceeding with this or any repair or maintenance read and understand the mportant Safety Information contained in the fron
24. covers Altering the covers may compromise the covers integrity to protect the fuel storage module a fastener absolutely must be added or replaced in the fuel storage module covers the fasteners must not contact the CNG fuel cylinders Any fastener that is added to the CNG fuel storage module covers shall not point toward the CNG fuel cylinder In the event of an accident these fasteners may damage the CNG fuel cylinder DO NOT USE self drilling or pointed fasteners to secure covers or components to the CNG fuel storage module covers Debris and Impact Protection An opening has been made in the FSM cover for access to the interior If the cover is not secured or left open debris may enter the interior of the and potentially damage the CNG cylinders or FSM components Cover Damage a cover becomes damaged contact Quantum for a replacement Be sure to have the serial number for the cover available when ordering 37 Q QUANTUMI T E Z Fi a m L 3 m E Start Up Procedure QUANTUM CNG Gen 1 BOC FSM Installation Manual Purge Instructions The purge process dilutes the contents of the cylinder to a level that significantly limits the potential flammability range of any gases present in the cylinder Purging the CNG cylinder is an important step that should be performed before a cylinder is filled with CNG and or any time the cylinder has been open to atmosph
25. ere Cylinder purging should also be performed to dilute the CNG concentrations within the cylinder any time a cylinder has been drained and will require service or shipping Do not allow atmosphere to enter the fuel storage cylinder during purging The fuel storage cylinder pressure should remain higher than atmospheric pressure during the purging process Introduction of atmosphere oxygen in the cylinder may create a combustible mixture that if ignited may result in serious injury or death NOTICE Quantum recommends the use of clean dry inert gas Nitrogen gt 99 5 purity for this procedure If it is necessary to use flammable gas this procedure should be performed after the CNG cylinder vehicle installation is completed Prior to the initial fill with CNG or any service the cylinder should be purged Only perform the purge process when the ambient temperature is above O F 18 C If cylinder was stored at temperatures below 0 F 18 C allow cylinder to warm up to room temperature gt 60 F 15 C before proceeding A recommended purge procedure can be found in the CNG Cylinder Installation and Maintenance Manual available at www gtww com service To vent the purge gas from the fuel storage module refer to the Fuel Cylinder Venting procedure in this manual 38 QUANTUM TECHNOLOGIE CNG Gen 1 BOC FSM Installation Manual Cylinder Initial Pressurization CNG Cylinder Valve Initial Interface Leak Test Neve
26. fuel storage module to prevent heat transfer The FSM should be thoroughly shielded from any heat sources that may radiate to the fuel storage module 34 CNG Gen 1 BOC FSM Installation Manual Vertical Exhaust Stack Configuration In the illustration to the right a number of heat related issues need to be addressed to make this a safe and approved installation for a vertically mounted exhaust stack See your truck equipment supplier for heat shielding solutions If a heat source such as an exhaust system component is located less than 5 127mm from any FSM cover B an additional heat shield and or a thermal insulating material MUST be placed between the heat source and the CNG fuel storage module A 8 5 5 C e f a direct heat source such as an exhaust system component is located less than 8 204mm from the CNG fuel cylinder or PRD valve A and there is no shield between the heat source and the CNG cylinder a heat shield MUST be installed e The exhaust stack outlet C must have a minimum clearance of 5 127mm above the FSM If adequate clearances cannot be achieved between the FSM and the vehicle exhaust system components it will be necessary to relocate the exhaust system componenis 35 QUANTUM E E Q Horizontal Exhaust Stack Configuration QUANTUM CNG Gen 1 BOC FSM Installation Manual In the illustration to the rig
27. g on truck frame height and the type of lifting fixture used 19 Q Torque Specifications QUANTUM CNG Gen I BOC FSM Installation Manual Fuel Line OF all SNESS sonnir A Mm 60 Ib ft 81N m Hex Flange M6 1 0 FSM Covers ii 62 Ib in 70dN m M8 1 25 FSM Covers 7 7 62 Ib in 70dN m 63 lb ft 85N m Mo ee Salan 81 Ib ft 110N m M16 FSM to Frame 10w Lubricant Required 180 Ib ft 244N m e uec ERR See Note 1 Note 1 The strap nut is tightened until the installed height of the spring on each end of the cylinder strap is 1 23 0 08 31mm 2mm with the cylinder pressure below 500 psi 34 5 bar The straps for Gen 1 BOC are preset during assembly and are not adjustable 20 QUANTUM TECHNOLOGIES CNG Gen 1 BOC FSM Installation Manual Q Vehicle Compatibility The Gen 1 BOC FSM is designed for Class 7 and 8 trucks with a maximum frame width of as defined in the General System Specifications All clearances must be adhered to per the General System Specifications of this manual Always comply with federal state and local regulations when installing the FSM onto a vehicle Frame Preparation This FSM has been designed as a generic fuel storage module for Class 7 and 8 trucks Any application deviation may require modifications to the steps below The installation instructions are intended to guide a knowledgeable and experienced CNG technician thro
28. ht a number of heat related issues need to be addressed to make this a safe and approved installation for a horizontally mounted exhaust stack A horizontal heat shield is standard on all units However see your truck equipment supplier for heat shielding solutions if more heat shielding is required e f a heat source such as an exhaust system component is located less than 5 127mm from any FSM cover B an additional heat shield and or a thermal insulating material MUST be placed between the heat source and the CNG fuel storage module B 5 Doo e a direct heat source such as an exhaust system component is located less than 8 203mm from the CNG fuel cylinder or PRD valve A and there is no shield between the heat source and the CNG cylinder a heat shield MUST be installed e he exhaust stack outlet C must have a minimum clearance of 12 305mm behind the FSM e You will note that the exhaust components are positioned under the FSM covers allowing the CNG cylinder to be subjected to direct heat rising from the exhaust If this opening is not properly shielded the fuel storage module and or components could be damaged If adequate clearances cannot be achieved between the FSM and the vehicle exhaust system components it will be necessary to relocate the exhaust system components 36 CNG Gen 1 BOC FSM Installation Manual Mounting to FSM Covers No modifications are recommended to the
29. ing the FSM in low ambient temperatures All information illustrations and specifications are based on the latest product information available at the time of printing Quantum Fuel Systems Technologies Worldwide Inc reserves the right to make changes at any time without notice This information is the intellectual property of Quantum Fuel Systems Technologies Worldwide Inc and may not be altered in any way This information is protected by the copyright laws of the United States of America and other countries and may not be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying and recording without the prior written permission of Quantum Fuel Systems Technologies Worldwide Inc 2015 Quantum Fuel Systems Technologies Worldwide Inc QUANTUM Y 2 T PSI LA L Quantum Technologies Worldwide Inc 25242 Arctic Ocean Drive Lake Forest CA 92630 Tel 949 930 3400 Fax 949 930 3401 www gtww com info gtww com
30. ion for the Gen 1 BOC CNG fuel storage module QUANTUM T E 3 3 CNG Gen 1 BOC FSM Installation Manual Ordering Parts To purchase repair or replacement parts for the Gen 1 CNG Fuel Storage Module 115696 116353 116785 contact your local Quantum sales representative Technical Assistance For questions regarding the installation maintenance and service for the Gen 1 CNG Fuel Storage Module contact Quantum Technical Assistance at 800 816 8691 Price List Published prices are accurate at the time of print and are subject to change without notice For part pricing contact your local Quantum sales representative Q QUANTU M CNG Gen 1 BOC FSM Installation Manual Module Identification Generation 1 e 115696 Fill Panel e 116353 Fill Panel e 116785 No Fill Panel Slave All of the generation 1 BOC FSMs will have two exposed lift hooks 1 located at the top front of the module There are two additional lift hooks located under the rear cover The FSM has been designed with 4 lift points to safely lift and maneuver the module for service maintenance and or inspection as needed Models with a fill panel 2 can be visually identified with a configuration as shown in the illustration to the right The slave model will not have any fill panel The part identification label 3 will be located in two separate locations depending on whether the FSM is equipped with
31. lling or operating the system Failure to follow this instruction may result in serious injury or death 1 Close the manual shut off valves on all fuel cylinders Refer to Fuel Storage Cylinder Manual Shut off in this manual 2 Confirm the system vent valve 1 has been turned to the clockwise so that the handle is perpendicular to the line This is the closed position 3 Remove the valve port end cap 2 on the outlet port 46 QUANTUM TECHNOLOGIES CNG Gen 1 BOC FSM Installation Manual 22 The vent hose must be equipped with a 0 04 1 06mm orifice to prevent damage to the cylinder valve 4 Connect the vent line 5 Open the manual shut off valves on the fuel cylinders to be vented 6 Slowly open the system vent valve by turning the valve handle counter clockwise so that the handle is parallel vvith the vent line 7 Drain the fuel cylinder to approximately 10 psig 5 psig 1 7 bar 0 3 bar 8 If the cylinder valve is to be serviced purge the remaining CNG from the fuel cylinder Refer to Purge Instructions in this manual 9 After the venting and purge procedures are complete verify the manual shut off is closed by turning the valve clockwise until it stops 10 Close the system vent valve 1 so that it is perpendicular to the line as shown 11 Remove the vent line 12 Reinstall the valve port end cap 2 and torque to 22 lb ft 30 Nm 47 CNG Gen 1 BOC FSM Installa
32. lt in death or serious injury Printed in USA 114270 A 16 QUANTUM TECHNOLOGIES CNG Gen 1 BOC FSM Installation Manual Q QUANTU M CNG Gen 1 BOC FSM Installation Manual TECHNOLOGIES Packaging Contents and Assembly The FSM will be shipped on a pallet and must be handled and stored vertically The system will be fully assembled and will require disassembly of the rear cover and side covers before installation The contents of the delivery will include e 1 Fuel Storage Module Gen 1 BOC e Frame Install Kit O O O O O 2Hose Clamps Coolant e 1lnterface Harness Accessories 16 Screws Hex Flange M16 16 Nuts Crimp Hex Flange M16 16 Washers M16 2 Shims 1 16 2 Shims 1 8 The FSM will have several optional accessories available Part Number Manual Reference Description 0060606060 Stub Out Pipe Kit for Slave Module 116228 Slave Cylinder Connection 1 16 Shim 0 0625 1 6mm 116161 001 Shim Installation 1 8 Shim 0 125 3 2mm 116161 002 Shim Installation p 10 CNG Low Pressure Flex Hose 116574 003 12 CNG Low Pressure Flex Hose 116574 004 LU 18 CNG Low Pressure Flex Hose 116574 006 5040 18 QUANTUM T E Z Fi CNG Gen 1 BOC FSM Installation Manual Module Lifting DANGER Lifing the FSM with a single strap is not recommended Always use at least two straps that are rated and capable
33. mbient temperatures may have an effect on system components causing them to temporarily change size and shape Quantum fuel storage modules are designed to operate at temperatures as low as 40 F 40 C Both the rate of fueling and cold ambient temperatures may drop the temperature within the FSM below 40 F 40 C When this happens the soft parts that seal the system may be lose their ability to seal against metallic components which may have changed size and shape The CNG within the system may escape past the seals and out to atmosphere Gas escaping past the seals will create a dangerous condition and may damage the fuel storage module components Filling at a slower rate in cold ambient temperatures will make it less likely for components to change size and shape Faster fill rates will create a larger pressure drop which will significantly lower the temperature of the fuel as it passes through the system Faster fill rates may result in dropping the temperature beyond the 40 F 40 C limit Also the quality of fuel has an effect on line freezing Quantum builds all fuel storage modules to be compatible with SAE J1616 quality CNG SAE J1616 1 0 Water content and other corrosion precursors heavier hydrocarbons which may condense within the fuel container particulate matter oil and energy content need to be controlled in order to minimize corrosion and provide satisfactory low temperature vehicle operation performan
34. n the FSM and trailer trailer gap at all times Failure to maintain adequate distance between the FSM and trailer may result in death or serious injury Dimensions Minimum Distance Between Cab and Kingpin A 106 2692mm Minimum Distance Between Cab and FSM B 5 127mm Minimum Distance Between FSM and Kingpin C 70 1778mm Verify measurement vvith the 5ih vvheel in the forvvard most position Trailers vvith non standard 42 or 48 kingpins may require additional wheelbase and clearance VVeight MIE m s uu 1700 lbs 771 Kg 2500 lbs 1134 Kg Electrical Requirements VO T m o si 12 16 VDC Nominal ULU s a so s s s 2A a a i 3 5 A BOO Elecirical Connector Deutsch HDP30 18 14 PN Coolant Minimum Coolant P OM N A GPM UOolant TYDE ne ta Glycol Phosphate Based Coolant Fitting 1706 60 eio 5 8 Hose Bib Antifreeze Protection eae A aqui lt 40 F 40 C Fuel Fuel Outlet COMMECION pirati rai 12 37 Flare Stainless Steel QUANTUM Fi E CNG Gen 1 BOC FSM Installation Manual Exhaust Minimum Distance Between Vertical Exhaust Stack and FSM AO 5 127mm Minimum Distance Between Vertical Exha
35. n the fili is comgkl 1 DM L1 CNG Fuel Only service Pressure 24821 kPa 3 600 psig See instructions on fuel container for inspection and service life Manual 51 0ff Valve Fill Valve Fast Fill Valve rom the opposite fuel Till valve during refueling im son This gauge indicates system Chet bita ei eti 01 from the vehicle Failure dn folle pressura aher he ma miai shot valve ihis instruction may result in death or serious injury 41 WARNING QUANTUM CNG Gen 1 BOC FSM Installation Manual If a leak is detected immediately stop filling the system Failure to follow this instruction may result in serious injury or death If while filling the vehicle a leak is detected through the fill valve that is not currently being used or anywhere else in the system the fill process should be stopped immediately They system should not be filled until the leak or leaking component has been repaired or replaced Because CNG is a gas the amount stored in the CNG fuel cylinder depends on pressure and temperature The CNG fuel system uses a service pressure of 3 600 psi 24 8 MPa at 70 F 21 C Many CNG fuel stations in the United States presently operate at this pressure However some stations in the United States and all stations in Canada presently operate at 3 000 psi 20 7 MPa This lower refueling pressure will reduce the capacity of your fuel storage system by about 1596 Also a fast fill station heats and e
36. nto any unused holes of the chassis frame Do not flame cut holes Do not drill holes into the restricted areas of the frame rails is not recommended to remove the factory installed huck bolts To prevent the forming of cracks from the drilled holes the holes must always be deburred by 45 chamfering on both sides and subsequently treated with primer and paint Add hardware to the existing open holes and torque to specification Hole Location Guidelines The following recommendations should be considered when determining where to drill the holes in the frame members Never drill holes in the flanges of the frame members Never drill holes in the tapered end of the rear frame cutoff The drilling of holes less than 2 51mm from a bend in the chassis frame is not recommended Maintain a minimum distance of 2 8 times the diameter of the largest hole between holes There should not be more than three holes located on a vertical line Bolt holes should be no larger than is required for the size of bolts being used in no instance larger than 11 16 17 5 mm reinforcements are used avoid drilling holes closer than 2 0 inches 51 mm from the ends of the reinforcement 27 B gt 2 8 D D diameter of the larger hole gt 50 mm or B which ever is greater Q FSM Base Mount Hole Location Considerations QUANTUM CNG Gen 1 BOC FSM Installation Manual In some instances
37. ocedure then vent the cylinder following the Fuel Cylinder Venting procedure in this manual 40 ANTUM E Hk L CNG Gen 1 BOC FSM Installation Manual Filling your Fuel Storage Module To ensure proper system operation it is recommended that the CNG system is filled with CNG that meets SAE J1616 specifications Compressed Natural Gas CNG is extremely flammable If something accidentally ignites it you could be badly burned Keep sparks flames and smoking materials away from natural gas Do not smoke if you are near natural gas or refueling your vehicle Compressed Natural Gas CNG is stored in the fuel cylinder at pressures up to 3 600 psi 24 8 MPa at 70 F 21 C To prevent personal injury Never fill to a pressure greater than 3 600 psi 24 8 MPa at 70 F 21 C Never fill a leaking or damaged cylinder The fill valve panel is located on the fuel storage module end panel assembly The fuel system is equipped with two fill valves a standard NGV 1 compliant 3600 psi fill valve 1 and a high flow 3600 psi ISO 14469 2 compliant fill valve 2 Either fill valve may be used with no additional actions required by the system operator Manufactured by Before Filling Your Vehicle Lie ONG fuel fill pazzie for wear damage r ci Mamination thee CNG fill valve for any wear damage of cor amination M ci IE O ring for damage Alvy install the fill valve cap whe
38. of holding the FSM Failure to lift with two capable straps will result in death or serious injury The fuel storage module has four 4 lift points supplied two under the cover and two that protrude through the cover It is recommended that the FSM be lifted using all four supplied lift points to allow for proper handling and ease of installation The FSM may be lifted by the two 2 exposed lift points only but the assembly will not hang properly and may be difficult to install The chain or straps must exceed 3000 lbs 1361kg lifting capacity all REAR COVER REMOVED The FSM has a dry weight of 1700 bs 771 Kg and will require lifting equipment that can safely sustain that weight The photo to the right shows a configuration that can safely lift the FSM This is not the only option to lift the FSM but it does permit the FSM to be maneuverable during the installation process The front cover must remain on the FSM during the installation process The 2 lift points that protrude through the front cover are highlighted in the photo to the right Use protective coverings so that the chain does not damage the Class A paint finish on the cover or the CNG cylinders i FRONT COVER INSTALLED ta 8 The total ceiling clearance recommended to lift the FSM is 15 ft 4 6m Be sure the shop has a lift and adequate ceiling clearance to install the FSM onto the frame of the truck Lifting clearance will vary dependin
39. omer requirements e Step 1 Measure Frame Width Step 2 Measure FSM Clearance Step 3 Inspect for Obstructions Step 4 Inspect for Heat Sources Step 5 Installation Checklist Step 6 Frame Drilling Guidelines 21 Q Step 1 Measure Frame VVidth QUANTUM CNG Gen 1 BOC FSM Installation Manual Verify the overall width of the fuel storage module will fit in the allocated space and the area where the FSM is to be installed is free of parts brackets bolts or components that may contact or damage the FSM Verify the width of the vehicle frame is large enough to accept the FSM with appropriate clearance The overall dimensions for the FSM are contained in this manual Refer to General System Specifications in this manual for additional information 22 QUANTUM T CNG Gen 1 BOC FSM Installation Manual Step 2 Measure FSM Clearance Confirm that the space between the cab and the kingpin A meets the minimum requirement as specified in the General Vehicle Requirements section in this manual Verify the FSM will have adequate clearance from the rear wall of the driver s cab to the front of the FSM assembly B and the FSM to the kingpin C The FSM must maintain a minimum distance of 5 127mm between the FSM and the rear wall of the drivers cab The location where the FSM will be mounted must have this minimum clearance or damage to both the driver s cab and
40. orking with pressurized gas Use explosion proof drop lights when working on gaseous fueled systems Failure to follow these basic safety guidelines could result in serious death or personal injury CNG is stored at pressures up to 3 600 psi 25 MPa Verify all pressure is properly vented from any fuel cylinder or fuel line before proceeding with disassembly Failure to properly vent fuel system components could result in serious injury When filling your vehicle keep sparks flames and ignition sources a minimum of 5 meters from the refueling area which could result in minor or moderate injury including the risk for severe burns e Do not smoke near CNG or while refueling a system e Turn the system s electrical system OFF while refueling e Refuel CNG fuel cylinders in a well ventilated area e Keep mobile phones at a distance from the refueling area Do not fill the fuel storage module with CNG if the cylinder pressure is less than 363 psi 2 5 MPa AND the cylinder temperature is less than 31 F 35 C Allow the fuel storage module temperature to rise above 31 F 35 C before filling Refueling under these conditions may cause personal injury and equipment or system damage Failure to refuel under these conditions could result in minor or moderate injury Using a common automotive or plumbing O ring as a replacement part could cause a leak while operating the system on CNG Use only CNG certified O rings from an autho
41. ounts PACCAR 116353 001 34 2 869mm Width Between Mounts Volvo Mack 116353 003 33 8 859mm Width Between Mounts PACCAR 1 2 Crossover 116353 005 34 2 869mm Refer to the Label Locator section in this manual for location information to the part number specific to the fuel storage module QUANTUM T E Z Fi m CNG Gen 1 BOC FSM Installation Manual FRONT Dimensions Distance Between FSM Mount and FSM Front Cover A 2 0 51mm Distance Between Bolt Centerlines B 15 7 400mm Width of Base Mount C ieee 8 204mm Distance Between FSM Mount and FSM Rear Cover 2 0 51mm Depot FOM MOUAE CE RR 10 5 267mm Q QUA NTUM CNG Gen 1 BOC FSM Installation Manual TECHNOLOGIE Installer Qualifications To successfully install the FSM the installer should meet or exceed the minimum requirements indicated below 2 3 Must have the ability to read understand and follow the instructions contained in the CNG Fuel Storage Module Installation manual Must have knowledge of all local state and federal regulations and standards applicable for installing CNG systems Must have a basic understanding of CNG fuel system installations
42. oving cylinder from room temperature environment Failure to follow this requirement may result in injury 39 When a cylinder is pressurized from empty a small quantity of AIR not fuel is compressed out from between the liner and composite shell This may cause bubbling around the surface of the shell and or the end bosses during leak tests This is a normal condition known as permeation and the bubbling should subside typically within 30 minutes If there is any doubt leave the cylinder pressurized overnight If the pressure is unchanged and the bubbling has subsided this is considered normal permeation of entrapped air QUANTUM CNG Gen 1 BOC FSM Installation Manual You may also observe some cracking or popping sounds coming from the cylinder during the initial pressurization If the liner has settled away from the shell during shipping some cracking or popping noises may be heard during the initial fill you may also be hearing the shell of the cylinder settling as it is pressurized If there is no damage to the cylinder and no fuel leakage is detected there should be no concern pressurizing the cylinder a leak is detected immediately stop filling the system Failure to follow this instruction may result in serious injury or death If while filling the vehicle a leak is detected through the fill valve that is not currently being used or anywhere else in the system the fill process should be
43. r pressurize a CNG cylinder that is not restrained by approved brackets properly mounted or otherwise acceptably restrained to prevent movement while under pressure Failure to observe this warning may result in death or serious injury Compressed Natural Gas CNG is extremely flammable If something accidentally ignites it you could be badly burned Keep sparks flames and smoking materials away from natural gas Do not smoke if you are near natural gas or refueling your vehicle Compressed Natural Gas CNG is stored in the fuel cylinder at pressures up to 3 600 psi 24 8 MPa at 70 F 21 C To prevent personal injury Never fill to a pressure greater than 3 600 psi 24 8 MPa at 70 F 21 C Never fill a leaking or damaged cylinder Verify any equipment used is rated for the highest pressure that can be generated during the procedure Failure to do so may result in injury Failure to follow the initial pressurization instructions may irreversibly damage the fuel storage cylinder leading to CNG leakage Fuel leakage may result in personal injury or damage to the vehicle Performing this procedure when the CNG cylinder temperature is less than 0 F 18 C may result in damage to the cylinder Allow the CNG cylinder to warm to room temperature gt 60 F 13 C for a minimum of 12 hours before pressurizing If ambient conditions where test is performed are less than 0 F 18 C complete the procedure within Y hour after rem
44. rcent range and an ignition temperature of approximately 1100 F Compare that to gasoline and diesel fuel which both have lower concentrations of flammability and lower temperatures of ignition Q Safety QUANTUM CNG Gen 1 BOC FSM Installation Manual Important Safety Information This is the safety alert symbol t is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury DANGER WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury N OTI CE NOTICE is used to address practices not related to personal iniury CAUTION without the safety alert symbol is used to address practices not related to personal injuries Read the safety precautions in this manual before servicing this system Failure to do so could result in death or serious injury QUANTUM T CNG Gen 1 BOC FSM Installation Manual CNG is extremely flammable If something ignites it you could be severely burned Keep sparks flames and ignition sources a minimum of 5 meters from CNG Ensure work area is well ventilated Always wear proper eye and hearing protection when w
45. rized source If something ignites the leak you could be burned Failure to use a certified O ring could result in minor or moderate injury Q Safety Features QUANTUM CNG Gen 1 BOC FSM Installation Manual The CNG fuel system has been engineered to the highest standard to ensure occupant safety in any circumstance The system utilizes e Stainless steel fuel lines and fittings Type 4 composite fuel cylinders Over temperature protection Manual lock off valves Electronic lock off valve within the regulator assembly In the Event of Equipment Fire a fire should occur in the vicinity of the cylinder system the thermal relief devices located in the module may be activated If any of the relief devices activates a very rapid venting of gas may occur If a fire caused the activation and the cylinder is full of a flammable gas it is likely that the gas exiting the relief line will ignite which may be very dangerous Even if the gas does not ignite debris blown about by the gas jet could be dangerous and the loud noise caused by the rapid venting could cause hearing damage the relief devices activates then evacuate the area immediately and call the appropriate authorities Once any of the relief devices have been activated the FSM or all of the cylinders must be returned to Quantum Technologies for inspection disposition and service QUANTUM T CNG Gen 1 BOC
46. rly Connect the CNG line to the regulator as identified in the Line Identification section of this manual Be sure to route and secure the lines properly the FSM is being connected to another CNG cylinder install the stub out pipe kit for the slave cylinder at this time If not proceed to the next step The slave cylinder stub out pipe kit can be purchased if needed Refer to the Accessories section of this manual for part numbers Details can be found in the Slave Cylinder Connection section in this manual Connect the interface harness supplied with the installation kit to the Deutsch HDP24 18 14PN L017 electrical connector on the front of the FSM Perform a Start Up Procedure following the Start Up Procedure section of this manual Install the rear cover Tighten fasteners to 62 7OdNm Install the side covers and torque to 62 lb in 70dNm QUANTUM TECHNOLOGIE 31 Q QUANTUM CNG Gen 1 BOC FSM Installation Manual 25 Inspect the completed fuel storage module assembly and installation look for any areas that may require additional shielding to protect against road debris contamination or heat exposure Use the following criteria when inspecting the completed assembly for proper clearances and shielding e ls any portion of the fuel storage cylinder or cover closer than 5 127mm from any other component or assembly Are there any heat
47. s painted and has a Class A finish it will take 2 persons to safely remove the rear cover Finally carefully set the covers in a location where they will not get damaged 29 Q QUANTUM CNG Gen I BOC FSM Installation Manual 11 Locate the 4 lift points on the FSM Refer to the Module Lifting section within this manual for more information 12 Connect the chain straps or lifting fixture to the rear lifting points 13 Connect the chain straps or lifting fixture to the front lifting points The front cover will still be on the FSM so care must be taken not to damage the Class A finish of the front cover 14 Using a minimum of 2 people position the FSM onto the frame of the truck Align the holes on bl the FSM with the holes drilled into the frame COVER REMOVED Ja NL DANGER The FSM has been approved to be installed with the front of the FSM facing forward The correct installed position can be confirmed vvith the fill panel on the driver s side of the frame Failure to install the FSM in the correct approved position may result in death or serious injury 15 Slide one side of the frame so that it is flush with the FSM base mount The other side of wa the frame may have a gap that exceeds 1 16 3 x If the gap is greater than 1 16 then a shim will les need to be installed m mm A Insert the appropriate number of shims until the ZERO G
48. stopped immediately They system should not be filled until the leak or leaking component has been repaired or replaced The recommended steps for this procedure are outlined in order below 1 Ensure that the fuel storage module is properly installed in a vehicle or retained in a appropriate test fixture before proceeding 2 Connect the gas supply to the CNG cylinder or the system fill valve 3 Slowly fill to 30 bar 430 psig while listening for gross leakage Re test and repair any leaks discovered When leak test is successfully passed vent the system through the vent circuit These steps validate the equipment setup and operation for testing the CNG cylinder valve PRD interface Test all connections and interfaces in the circuit with a liquid leak test fluid Observe all connections and interfaces for bubble formation over a two minute period If no bubbles are present continue with procedure If bubbles are found close the supply valve and vent the system by opening the vent circuit 1 4 turn valve and repair any leak s before proceeding 4 Increase the cylinder pressure to 100 bar 1450 psig Re test and repair any leaks discovered When leak test is successfully passed vent the system through the vent circuit These steps validate the equipment setup and operation for testing the CNG cylinder valve PRD interface Test all connections and interfaces in the circuit with a liquid leak test fluid 5 If inert gas was used for this pr
49. t of this manual Use this procedure if a CNG fuel system leak is suspected The system can be checked for leaks after initial power up at idle or while the system is operating Always leak check the fuel system after any service that disturbs fuel carrying components has been performed CNG gas is lighter than air and will rise When using a hand held detector always check above lines and fittings for best results 1 Start the system to ensure all fuel lines are pressurized IMPORTANT When leak checking a system is it strongly recommended that the high pressure side is checked at several pressure points i e 500 psi 1500 psi 3000 psi 3600 psi as leaks may be present at lower pressures and not at higher pressures 2 Check the fuel system for leaks by using a CNG gas detector ultrasonic leak detector or Snoop If using a gas detector run the detectors probe along the top of all lines joints and fittings Any leaks detected should be repaired before the unit is returned to service 45 Q Fuel Cylinder Venting Failure to use an orifice in the venting system may subject the fuel storage module to extremely low temperatures during venting resulting in severe damage to or failure of these components Use the orifice specified by this procedure when venting the fuel storage module Failure to follow this instruction may result in death or serious injury and damage components QUANTUM CNG Gen 1 BOC FSM Inst
50. tem Specifications mentioned in this manual A 3 Verify that the FSM will have adequate clearance around all sides and from the kingpin 11 16 17 50 mm 5 90 4 Mark the hole locations The bolt pattern and 150 0mm template for the FSM mount can be found in Appendix A Make sure that the bolt pattern is 100 0mm level with the frame and not level with the ground Measure the bolt pattern only to be level to the frame 5 Confirm there are no obstructions on the frame and ensure the area inside the frame is clear of components or lines that may be damaged during the drilling operation 6 Drill the marked holes for the FSM mounts The holes should be drilled to 11 16 17 5mm or to match the existing holes 7 Clean any burrs from the holes and coat the holes with a zinc rich primer or equivalent anti corrosion coating NOTICE The fuel storage module covers are painted and are categorized as Class A finish Follow all protective guidelines when working with Class A finishes 8 Unpack the FSM from its shipping container The FSM will be fully assembled within the container 9 Unscrew the rear FSM cover and side covers Disconnect the electrical connectors for the load lights on the rear cover There is a connector at the base of the rear panel which separates the load lights from the main harness of the FSM 10 Remove the grab handles and associated hardware The rear cover i
51. tion Manual UANTUIM CHNOLOG ore Appendix A FSM Mount Templates TOP NOT TO SCALE 19 69 SOOmm 23 62 600mm 26 69 678mm 255 65mm 3 94 100mm 8 03 204mm 48 QUANTUM allation Manual Actual Size Do Not Scale When Printing 3 22 81 6mm 9 CNG Gen 1 BOC FSM Inst LL LLL ul La a a IN DRM lg IND LLLLLLLLLLLL SG CC C a ul CCCCCCNODERIZ CCC gg LINDA Ll ICCCCCCCAWARk ZA CNG Gen 1 BOC FSM Installation Manual UANTUM C 4 O L 03 G 0 1 54 39 1mm T P NOT TO SCALE 26 7 678 2mm 1 97 50mm 3 94 100mm 19 69 500mm 1 97 50mm 3 94 100mm 1 54 39 1mm 10 5 266 7mm 5 91 150mm 50 CNG Gen 1 BOC FSM Installation Manual QUANTU M 1 97 50mm Actual Size Do Not Scale When Printing 3 2 81 82mm l 11 16 17 50mm 1 97 50mm CNG Gen 1 BOC FSM Installation Manual UANTUM Q9 TOP NOT TO SCALE 26 7 678 2mm 1 54 39 1mm 1 97 50mm 8 02 203 8mm 3 94 100mm 19 69 500mm 1 97 50mm 3 94 100mm 4 72 120mm 1 54 39 1mm 9 23 234 5mm 52 CNG Gen 1 BOC FSM Installation Manual QUANTU M
52. ugh the necessary steps to install the FSM Be sure to inspect the frame for prior damage rust welds areas missing paint and or reinforcement plates These indicators could mean that the frame s structural integrity may be compromised Compliance of the installation to all federal state and local regulations is ultimately the responsibility of the installer It is the responsibility of the installer to ensure the vehicle being equipped with the FSM is in good condition and that installation of this system will not create a hazard or cause damage to the vehicle IMPORTANT Before you begin the installation process of the fuel storage module you should verify the installed assembly will meet all your customer requirements and regulatory requirements that may be applicable There are a number of considerations when determining where to place the FSM on the vehicle frame e Wil the width of the frame be within the mount specification range for the FSM Are there any heat sources in close proximity to the FSM Will there be enough clearance between the FSM and the trailer Are there any cross members or support structures that would interfere with the FSM Will any of the accessories interfere with the BOC installation Will an auxiliary battery storage unit located under the FSM need to be relocated Below are a few steps that will help you determine if the FSM can be successfully installed and meet all the Quantum regulatory and cust
53. ust Stack Outlet and FSM B 5 127mm Minimum Distance Between Horizontal Exhaust Stack and FSM G 8 203mm Minimum Distance Between Horizontal Exhaust Stack Outlet and FSM D 12 305mm 7 i 4 A 2 kian mal Dimensions Maximum Distance Outside of Frame to Outside of Frame A 34 5 876mm Minimum Allowable Width 33 75 857mm Q General FSM Specifications QUANTUM CNG Gen I BOC FSM Installation Manual The Gen 1 BOC FSM has three different base mounts which will vary in width These mounts are defined below and are identified with a 001 003 and 005 You will need to confirm that the FSM width which is identified by the part number fits the frame of the truck Dimensions Depth of CNG Fuel Storage Module A i 30 7 780mm Depth of CNG Fuel Storage Module with Handles B 33 8 859mm Maximum Width Between Mounts nnns nnn nnn 34 5 876mm Width of CNG Fuel Storage Module D nennen nnn nnn 84 3 2142mm Height of the CNG Fuel Storage Module E ii 93 0 2362mm Width C Part Number Width Between M
54. vehicle you must also inspect for components or brackets on the frame that may interfere with the FSM covers or may even become an abrasion hazard for the CNG cylinder You must also evaluate the environment for heat sources the FSM should be mounted at least 5 127mm from any heat source In the event a heat source is in close proximity to the FSM covers or the cylinder is exposed to direct heat from the heat source steps MUST be taken to protect the FSM and the CNG cylinder NFPA 52 States 6 3 2 1 Fuel supply containers shall be protected with a means to prevent damage that can occur due to road hazards loading unloading direct sunlight exhaust heat and vehicle use including accidental cargo leakage 6 3 7 Fuel supply containers located less than 8 in 200 mm from the exhaust system shall be shielded against direct heat Important Failure to adequately insulate or protect the fuel storage module and its components may result in damage to the fuel storage module or its components resulting in potential fuel leakage lt is the responsibility of the installer to ensure that the fuel storage module and its components are protected against debris and direct heat sources The following guidelines must be observed before the vehicle is operated using this fuel storage module Heat Sources Inspect the FSM cover clearances per the General System Specifications section in this system possible move all heat sources away from the
55. xpands the natural gas during refueling A fast fill can reduce the capacity of your fuel storage system by about 1596 A system refueled using a slow fill overnight dispenser is not subject to this condition and should receive a full fill Fast filling using the high flow fill receptacle may also result in a decreased fuel capacity due to the additional heat generated in the cylinder by the faster filling times Some fast fill CNG fuel stations provide temperature compensated refueling This means that the fuel station will automatically adjust refueling pressure if the outside temperature is very hot or very cold For example on a very hot day 100 F 38 C the fuel station may provide a refueling pressure of about 4 000 psi 27 6 MPa This is normal and does not indicate a problem To fill your vehicle with CNG fuel do the following 1 Turn off the engine and set the parking brake 2 Turn off all equipment that may produce heat sparks or flame 3 Remove the fill valve cap and any debris from the fill valve 4 Inspect the fill valve O ring Make sure the O ring is seated in the groove Never connect the fill nozzle to the valve if the O ring is missing or damaged Refer to Fill Receptacle O Ring Inspection in this manual Attempting to fill a Compressed Natural Gas CNG fuel system that has a missing or damaged O ring is dangerous Natural gas can leak If the natural gas is accidentally ignited you or others could be injured

CNG Gen 1 BOC FSM Installation Manual

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