BARTEC BENKE A Series User manual

BARTEC BENKE GmbH  Schulstraße 30  94239 Gotteszell Deutschland  Phone [phone]  Fax [phone]
e-mail: [e-mail]  internet: www.bartec-benke.de
PETRO 3003
VOLUTANK Gauging Unit
Serie A
Instruction Manual
Software version PYRAMIDE 1.21.5
BA 140918

Contents
I-1
Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
Contents
Contents Page Issue date
1Introduction _______________________________________ 1
1.1 Information about our customers documentation ___________ 1
1.2 Manufacturer Information _____________________________ 2
1.2.1 Service and Hotline of manufacturer_____________________ 2
1.2.2 Type plate _________________________________________ 2
1.3 Qualification of operating personnel _____________________ 3
2Safety precautions _________________________________ 4
2.1 Intended use _______________________________________ 4
2.2 Improper use _______________________________________ 5
2.3 Safety hazards and accident prevention __________________ 5
2.3.1 Residual hazards ___________________________________ 5
2.4 Safety notices on the gauging unit ______________________ 6
2.5 Further safety instructions _____________________________ 7
2.5.1 Conduct in the event of an emergency ___________________ 7
2.6 Rectification of faults _________________________________ 7
3System description _________________________________ 8
3.1 Construction of the gauging unit ________________________ 8
Schematic structure _________________________________ 8
3.2 Technical Data _____________________________________ 9
3.3 Dimensions ________________________________________ 9
4Storage, transport and start of operation ______________ 10
4.1 Storage and transportation of the gauging unit ____________ 10
4.2 Complete drainage of gauging unit _____________________ 10
4.3 Putting the gauging unit into operation __________________ 12
4.3.1 Requirements _____________________________________ 12
4.3.1.1 Required vehicle version _____________________________ 14
4.3.1.2 Configuring System 3003 ____________________________ 14
4.3.1.3 Gauging positions and setting for logical I/Os ____________ 15
4.3.2 Installing the PC software ____________________________ 18
4.3.2.1 Configuring the IP address ___________________________ 21
Windows XP ______________________________________ 21
Windows 7 ________________________________________ 24
4.3.3 Connections ______________________________________ 27
4.3.3.1 Power supply ______________________________________ 27
4.3.3.2 Compressed air ____________________________________ 27
4.3.3.3 Network connections ________________________________ 28
4.3.3.4 Hose connections __________________________________ 29
5Operation of the gauging unit _______________________ 30
5.1 "ALI menu" on System 3003 __________________________ 30
5.2 Hose connection from the vehicle to "IN" on the gauging unit 31
5.3 "Gauging unit" PC program ___________________________ 31
5.3.1 "Configuration" tab _________________________________ 33
5.3.2 „System 3003“ tab __________________________________ 34
5.3.3 “Manual control“ tab ________________________________ 36
5.3.4 Special function “pump over“ _________________________ 37
5.3.5 “Gauge” tab _______________________________________ 38
5.3.5.1 "Settings" _________________________________________ 38
5.3.5.2 “Overview” ________________________________________ 39
5.3.5.3 Stopping the gauging process ________________________ 43
5.3.5.4 General procedure during the gauging process ___________ 44
6Servicing, maintenance and cleaning _________________ 45
6.1 Maintenance schedule ______________________________ 45
6.2 Servicing and replacing the impeller ___________________ 46
6.3 Troubleshooting ___________________________________ 47

Contents
I-2
Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
6.4 Replacement parts _________________________________ 48
7CE mark _________________________________________ 49
8Disassembly and disposal _________________________ 49
9Appendix _______________________________________ 9-50
9.1 Hardware checklist ________________________________ 9-50
9.2 Wiring diagram ___________________________________ 9-52
All rights reserved. Subject to change without prior notice.
No part of this document may be reproduced, processed or distributed
in any form or by any means without the prior written permission of
BARTEC BENKE.
Copyright © 2018 by
BARTEC BENKE
Schulstraße 30
D-94239 Gotteszell
Document / Version:
BA 140918
PYRAMIDE 1.21.5
Valid from / Author:
18.09.2014
C. Kiener
Revised at/ by:
06.04.2018
K. Hacker
Translation:

Introduction
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
1 Introduction
1.1 Information about our customers
documentation
We supply an instruction manual which is a set of operating instructions as
required by the directive on machinery.
The owner and trained servicing personnel must have access to these oper-
ating and maintenance instructions at all times.
These operating and maintenance instructions are intended as an aid to the
user in the following ways:
● To provide an introduction to the gauging unit
● To explain the correct use of the gauging unit
● To enable optimum usage of the gauging unit
Please read this operating and maintenance instruction manual through
carefully.
It contains important information for the following purposes:
● Safe operation of the gauging unit
● Correct operation of the gauging unit
It must be duly heeded to guarantee the following:
● Safety of the operating personnel
● Prevention of dangerous situations (accidents at work)
● Proper operation of the gauging unit
BARTEC BENKE GmbH and its servants shall only be liable in case of pre-
meditation or gross negligence. The extent of liability of such cases is limited
to the amount of the order placed with BARTEC BENKE.
BARTEC BENKE shall not be liable for damages arising from disregard of
the safety instructions and from failure to comply with the operating condi-
tions. No liability shall be accepted for consequential damages.
We,BARTEC BENKE GmbH, Schulstraße 30, D-94239 Gotteszell,hereby
declare, that this product is in compliance with the essential requirements of
the relevant EU-Directives.
The EU-Declaration of conformity for this product can be obtained from
BARTEC BENKE GmbH, Schulstraße 30, D-94239 Gotteszell,
[e-mail].
The copyright to this technical documentation is held by BARTEC BENKE
GmbH.
It contains specifications and technical drawings which may not be repro-
duced either in full or in part, distributed, used without authority in order to
compete, or disclosed to others.
Exclusion of liability
Copyright
EU-Declaration of conformity

Introduction
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
1.2 Manufacturer Information
1.2.1 Service and Hotline of manufacturer
Manufacturer address: Name of company: BARTEC BENKE GmbH
Street: Schulstraße 30
Location: D-94239 Gotteszell
Phone: [phone] - 301 - 0
Fax: [phone] - 301 - 112
Internet: www.bartec-benke.de
E-Mail: [e-mail]
Document data: Instruction manual: BA 140918
Fulfilled standards and directives: acc. encl. CE declaration
1.2.2 Type plate

Introduction
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
1.3 Qualification of operating personnel
The following skills are required of persons deployed to operate the gauging
unit:
● They must be physically and mentally fit
● They must be in good health
● They must be trained to operate the machine
● They must have proved their aptitude for the job to the owner
● They must be reliable and capable of carrying out the duties assigned to
them
● The gauging unit may only be operated by trained personnel
● The scope of responsibility and the skills required of the personnel
employed at the gauging unit must be clearly set out by the owner of the
gauging unit
● Persons who are in training and who are learning to use the gauging unit
may only work on the gauging unit under the constant supervision of an
experienced person
● Before deploying the personnel, we recommend conducting a health &
safety briefing session and keeping records with staff signatures
confirming their attendance

Safety precautions
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
2 Safety precautions
The equipment operator is responsible for complying with all regulations ap-
plicable to the storage, transport and handling of liquid fuels.
All regulations and provisions shall remain in full force when operating the
equipment with PETRO units.
The PETRO units are built in compliance with the applicable regulations and
leave the factory in perfect condition. The units must be installed and ser-
viced by duly skilled and qualified personnel.
● Make sure that the information and operating conditions specified by
the manufacturer are observed.
● Follow the instructions on operating and servicing the units.
● If you notice any damage or deterioration on parts of the equipment, or
if safe operation cannot be guaranteed for other reasons, do not start
up the equipment or - if it is already running - switch it off immediately.
Notify your service centre.
● You should also contact our service technicians if you notice
malfunctions or defects during operation or if you have any doubts as
to whether the units are working properly.
● The PETRO units are not designed to replace the safety systems
installed on the tanker or by the customer (e.g. overfill monitor).
● Please make sure that the vehicle is not close to any sources of noise
or vibration during the gauging process.
2.1 Intended use
The gauging unit is designed to record geometric data of tank sections and
of the pipe system of tankers with type 3003 dipstick measuring systems.
The system is used to generate vehicle-specific and tank-specific graphs
which form the basis for exact identification of the tank contents.
The only medium which can be used for the gauging process is clean tap
water which has a certain minimum conductivity.
The gauging unit may not be used in potentially explosive areas, nor may it
be used outdoors.
Any other use or additional use shall be regarded as improper. BARTEC
BENKE GmbH shall not accept liability for damages as a result of improper
use. The user alone shall bear the risk.
Proper use also includes observance of the operating and servicing instruc-
tions and compliance with the inspection and maintenance conditions.
CAUTION! Incorrect operation or misuse shall entail risks to the following:
● Life and limb
● Property

Safety precautions
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
2.2 Improper use
Improper use is any use above and beyond the intended use set out above.
2.3 Safety hazards and accident pre-
vention
2.3.1 Residual hazards
The gauging unit is built in conformity with the latest engineering standards
and the accepted rules of safe design. Due observance of the relevant
health & safety and accident prevention regulations can be assumed. Never-
theless, the following residual hazards still apply:
CAUTION!
● The gauging unit may topple over and roll away! Always use the unit
on a level and firm surface and take measures to prevent it from rolling
away before putting it into operation.
● The hoses can work loose during operation! Make sure the hoses are
firmly in place.
● It is possible for tanks to be overfilled in manual and automatic
operation! This can cause water damage therefore the gauging unit
should never be left unattended while in operation.
● The pump housing can overheat if the impeller runs dry! Dry
operation of the impeller is only allowed for short times to calculate the
pipe volume (< 1 min).
● The pump can be switched on without the impeller guard! Never let
the pump run without the impeller cover on, not even for servicing and
maintenance work.
● Water may remain behind in the pipes and fittings and may freeze in
certain circumstances! Drain the pipes and fittings completely before
storage and transport. Do not store or operate the unit outside.
● Risk of skidding on leaking water!

Safety precautions
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
2.4 Safety notices on the gauging unit
Danger: high voltage!
Caution: hot surface!
Wear ear defenders!

Safety precautions
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
2.5 Further safety instructions
The following safety instructions are generally applicable safety regulations.
Further safety instructions which relate to a specific function or mode of op-
eration are listed in the steps set out in these operating instructions and
must also be heeded.
2.5.1 Conduct in the event of an emergency
Press the emergency off switch immediately. The pump will stop im-
mediately.
CAUTION!
● Never remove safety equipment or make changes which render it
inoperable.
● Do not operate the gauging unit with technical defects.
● Make sure that all the warning notices at/on the gauging unit are present
and legible.
● Disconnect the power supply before servicing, repair and maintenance
work. The mains switch must be in zero position.
2.6 Rectification of faults
CAUTION!
Work on the electrical installations may only be carried out by authorised
and qualified personnel.

System description
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
3 System description
3.1 Construction of the gauging unit
Schematic structure
IN
Valve Y1
Sight glass
Vent valve
Level sensor
Pump
MID
Valve Y3
OUT1
OUT2
Valve Y4
Bypass
Valve Y2

System description
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
3.2 Technical Data
Electrical data
Power supply
AC 400 V 50 Hz max. 4 kVA
Backup fuse
Line cut-out 3x16 A (characteristic C)
A universal residual-current circuit-breaker is
recommended.
The leakage current can exceed 30 mA when the unit
is switched on!
Compressed air
6 bar to max. 8 bar
MID measuring accuracy
+-0.3% in 25l/min to 500l/min range
(but not less than +- 0.2l)
Pump output
Max. 300 l/min
Ambient conditions
Operating temperature
+15 °C … +35 °C
Storage temperature
+5 °C … +50 °C
Mechanical data
Dimensions
See dimensional drawing
Weight
Approx. 190 kg
Sound pressure level
Approx. 90 dB(A)
Hose connection
ELAFLEX MK 50 conforming to DIN EN 14420-6
(DIN 28450)
Network connection
RJ45
3.3 Dimensions

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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
4 Storage, transport and start
of operation
4.1 Storage and transportation of the
gauging unit
The gauging unit may only be transported with suitable lifting gear capable
of bearing its weight.
Gross weight as specified on type plate. Crane transport is not permitted.
Do not allow the wheels on the gauging unit to bear the weight during stor-
age and transportation.
4.2 Complete drainage of gauging unit
The unit must be completely drained after every gauging process.
Open the "Manual control" tab on the PC and then open the IN and OUT1 or
OUT2 valves (depending on which hose is connected).
Then select the relevant direction of rotation and speed of the pump (e.g.
70%) and start the pump.
Leave the pump switched on until no more water can be seen in the sight
glass and the -10B1 sensor is no longer wet.
Switch the pump off and close the inlet and outlet valves.

Storage, transport and start of operation
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
The water still remaining in the pipes can be discharged via the ball valve on
the gauging unit. Open the ball valve to drain the residual water.
Ball valve closed
Ball valve open
NOTE:
It can take some time to drain the unit.
The ball valve is fitted with a safety clip to prevent accidental opening.

Storage, transport and start of operation
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
4.3 Putting the gauging unit into opera-
tion
Always check the gauging unit for damage before putting it into operation.
Take measures to prevent the gauging unit from rolling away. Two castors
are fitted with brakes which can be applied for this purpose.
4.3.1 Requirements
The following requirements must be met in order to be able to use the gaug-
ing unit:
● The gauging unit is supported from vehicle version PYRAMIDE 1.21.5
onwards.
● System 3003 must be installed and configured ready for operation.
● The vehicle air must be connected in such a way that all the necessary
valves can be operated.
● The power on the gauging unit must be connected.
● The air on the gauging unit must be connected.
● The vehicle must be connected to the gauging unit by means of an
Ethernet cable.
● The gauging PC must be connected to the gauging unit by means of an
Ethernet cable.
● The gauging PC must have a static IP address.
● The gauging PC must have current ALI software.
● The hose connecting the vehicle to the "IN" port on the gauging unit must
be consistently inclined at all times.
CAUTION!
● The gauging unit must not be operated in potentially explosive areas.
● Under no circumstances should the PC be locked or the user changed
during operation.

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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
● Gauing into an external tank:
The gauging process can only be completed successfully if the contents
are pumped into another chamber or into an external tank because the
contents need to be pumped back into the original chamber to calculate
the pipe volume! In this case, before reaching the minimum dipstick
height, the hose must be switched to a tank from which the contents can
be pumped out again. The available volume must be sufficient to fill the
chamber which is being measured up to 100 mm above the minimum
dipstick level.
 The PC has to be prevented from switching to sleep mode:
Windows 7:
Control Panel  All Control Panel Items Power Options:

Storage, transport and start of operation
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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
Windows XP:
Control Panel  Power Options
- Under no circumstances should the PC be locked, be switched to Hibernate
state or the user changed during operation.
- The PC should always be operated with power plugged in.
4.3.1.1 Required vehicle version
The gauging unit and the applicable software can be used from vehicle ver-
sion Pyramide 1.21.5 onwards. Older vehicle applications are NOT support-
ed!
4.3.1.2 Configuring System 3003
System 3003 must be installed and configured ready for operation.
The tilt valve (log. 26) and the bottom valves of the chambers which are to
be emptied/filled are required for the gauging process.
The left control (log. 14) and the right control (log. 20) may also be required,
where fitted and necessary for the gauging process.
The dipstick interface must also be configured and all the dipsticks set up
correctly.

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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
4.3.1.3 Gauging positions and setting for logical I/Os
The gauging unit must be connected differently (right/left) and certain logical
outputs will also need to be connected depending on the design of the vehi-
cle.
Left-left design (left fill | left discharge):
Left control (log. 14)
Right control (log. 20)
Direct outlet group valve (log. 9)

API manually open/close

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Instruction Manual PETRO 3003 VOLUTANK Gauging unit BA 140918
Left-left-right design (left fill/discharge | right discharge):
Left control (log. 14)
Right control (log. 20)
Direct outlet group valve (log. 9)

API manually open/close