Gespasa Compact 50m-230 User manual

COMPACT 50M-230

TOTEM 50M-230

MECHANICAL SUPPLY KITS

INSTRUCTION MANUAL

WARRANTY AND CONFORMITY DECLARATION

1. TECHNICAL SPECIFICATIONS

Supply kits suitable for the DIESEL transfer, composed of:

- Steel chassis

- Self-suction pump

- Mechanical meter

- 4 m hose

- Nozzle

- Noise level: LEQ

< 85 dBA (1 m)

Please see the enclosed manuals to consult the technical specifications of each kit component.

ATTENTION: Please take into account the flow of the supply kit is lower than the pump one

because of the charge losses caused by the own supply kit (nozzle, hose, adapters and so

on).

COMPACT size (approx.): 380x345x360 mm (length x width x height)

COMPACT weight: 22 kg (approx.)

TOTEM size (approx.): 385x435x1,500 mm (length x width x height)

TOTEM weight: 48 kg (approx.)

2. WARNINGS INSTALLED PUMP FLOW (l/min)*

The main aim of this manual is to advise the users how to make the kit installation and location,

how to use it and how to maintain adequately. IRON-50 230 V 40-50

Please read all the instructions carefully before using the product. The people who do

not know the instructions must not use it. * Real COMPACT and TOTEM flows

This manual describes how to use the machine according to the project hypothesis, the technical features, the types of installation, the use, the

maintenance and the training regarding to possible dangers.

The instruction manual must be considered as a part of it and keep it for future inquiries during all its working life. We suggest keeping it in a

dry and protected place.

The manual reflects the technical situation at the moment of the kit sale and cannot be considered inadequate for the reason of being updated afterwards

according to the new experiences. The manufacturer is keeping the right to update the production and the manuals without being forced to update the

production and previous manuals.

3. SECURITY INSTRUCTIONS

To use the supply kit without suffering any danger, it is essential to read and follow each and every one of the following warnings and cautions:

3.1. PLEASE FOLLOW ALL THE INSTRUCTIONS CAREFULLY. The supply kit must be connected adequately up the ground and use suitable cables

and pipes.

3.2. The broken down supply kits must be repaired in an authorized workshop or in our factory.

3.3. ATTENTION

Do not smoke near the kit or use it near a flame. This can cause an explosion and even the death.

3.4. It is advisable to install a filter in the suction to avoid solid impurities sinking in the pump and/or the meter. The absence of these impurities

means the long-life of the supply kit.

ATTENTION: If the hose and the nozzle are out in the open, in summer weather and/or in very hot countries, after the refuelling (once the supply kit is

stopped), we recommend you to open the nozzle to purge the stored up pressure in the hose.

COMPACT 50M-230 · TOTEM 50M-230 INSTRUCTION MANUAL

Otherwise the high temperature of the sun makes possible that an overpressure is created by the expansion due to the diesel and/or petrol dilation that

there is in the tubes, which could cause a retainer and mechanic element breaking of the pump and/or the meter.

3.5. RECOMMENDATION: To avoid possible retainer breaking, it is advisable to install a check valve between the 90º elbow placed in supply kit outlet

and the delivery hose. So, the retainer breakings because of the thermal expansion or an accidental delivery hose footfall are avoided.

ATTENTION: Make sure that the check valve is placed in the correct direction. The arrow must indicate the flow direction.

3.6. Whenever there is a fuel leak, please clean it immediately to avoid a possible ignition or explosion or personal injuries.

3.7. If the supply kit remains without operating in a place exposed to freezing temperatures or ice, it is necessary to empty the hoses and the pump body.

In the same way, it is advisable to make this operation if the supply kit is without operating during a long time (even though the temperature is normal).

3.8. ATTENTION

The kit must not be turned on before finishing the installation. It is strictly forbidden to put fingers or other parts of the body inside the holes.

Before starting the dismantling or assembly of the supply kit, switch it off to avoid accidental ignitions or electrical discharges.

4. INSTALLATION

The systems must be designed to work with a minimum suction height.

The equivalent maximum suction height is 4.5 m for diesel. (This equivalence is the vertical distance from the bottom of the suction tube to the inlet tube of

the supply kit plus the wastages by friction in the vertical and horizontal route of the tube, the elbows etc). It is necessary to install a retention valve of 1” –

1 1/4” suitable for diesel. The top drop levels will affect the flow, cause the pump-accelerated fatigue, and the possibility of “cavitation” will drastically

increase.

All the supply kits can be installed on aerial or buried tanks. TOTEM FIXATION DRAWING

4.1. General

Before assembling the supply kit, please check there are the following elements in the installation:

- Flexible hose to join the suction group with the suction pipe

- Cable according to the current regulation with 2x2.5 mm² + T mechanical protection

- Enough space: A service station must be placed in a wide space to allow the vehicle movement.

You have to take into account the space exigencies, both for the assembly and its maintenance.

TOTEM KIT FIXATION:

The TOTEM must be fixed by 4 point with M8 screws with its own washers. Please see the drawing.

COMPACT/MSGM KIT FIXATION:

The COMPACT must be fixed in a pedestal or wall support with M6 screws. The hole placing

depends on each model.

4.2. Buried tank

The tank must be at a depth of 60 cm from the ground level to hold the suction elevation at the

minimum.

4.3. Base

Install a concrete base with enough space for the suction tube and the electrical cables.

4.4. Suction tube

Use a tube on the suction line, in accordance with the regulation, with suitable elbows and couplings,

forming articulated joints over the tank or below the supply kit to prevent the tank settlement from

freezing.

ATENCIÓN:

Remove the suction hole plug of the hydraulic group before connecting the flexible tube.

The horizontal suction line must be 45 cm below, and, if it is possible, it must have a continuous drop to the tank of 1-2 %.

In the suction tube of the supply kit you must assemble an angle valve if it is a buried tank, or an anti-siphon valve in the event of the aerial tanks.

4.5. Ventilation tank tube

Use the tube to allow the tank ventilation in accordance with the regulation. The joints must be articulated, and the tube must stick out a minimum of 0.5 m

over the ground level. On its top it must have the protection against the rain. In the event of tanks with a capacity lower than 10,000 litres, you can use a 1

1/2” tube.

The horizontal tube sections must have a light drop to the tank.

4.6. Electric installation

IT IS OBLIGATORY TO INSTALL A MOTOR PROTECTION DEVICE FOR THE EQUIPMENT WARRANTY ACCORDING TO THE

EN 60947 RULE, SUITABLE FOR THE SUPPLY KIT POWER AND CONSUMPTION.

Precaution: A qualified electrician, who knows the right electrical codes and regulations at local level, must do the cables and the electrical installation.

The supply kit must be adequately earthen and use suitable tubes and cables.

Warning: The above given information is to help the installer. It is on a general sense so that it can include a wide range of applications. This information

is the result of many working years, and it can be considered like exact and trustworthy. However, TOT COMERCIAL SA does not assume the

responsibility derived from its use.

5. CALIBRATION AND OPERATION INSTRUCTIONS

Please read the enclosed meter or controller operation manuals for its calibration and operation. To get the best results, the supply kit must be installed

according to that described in this INSTALLATION section. For its initial starting, please let the nozzle open during some seconds. Then the pump will be

primed.

6. MAINTENANCE

ATTENTION

Check the hose and the nozzle to see whether these are worn or damaged. The hoses or nozzles in bad state can be a potential

risk of insecurity and/or attempt against the environment.

COMPACT 50M-230 · TOTEM 50M-230 INSTRUCTION MANUAL

7. REPAIR

The authorized repair workshops are the only ones which can repair the motor in bad state. The supply kit has to be cleaned and drained before its

delivery. If a supply kit is used by mistake with fluids not derived from diesel, it has to be thinned as many times as it is necessary and enclosed a note

indicating the chemical substances, which have been pumped with this unit. The supply kit, which does not contain these specifications, will be admitted

neither in the workshops nor in the factory. When you order spare parts, make sure that you give the code number of the spare part and the supply kit

serial number. Only on this way you will receive the adequate spare part.

8. WARRANTY

1. All the products manufactured by TOT COMERCIAL SA have a WARRANTY of 12 (twelve) months from their purchase, against any manufacturing

defect.

2. TOT COMERCIAL SA guarantees, in the warranty period, the change/the devolution of the defective part or product. This material must be sent with

prepaid freight to our factory or any appointed technical service. After our technical inspection, it will be determined whether the responsibility is from

the manufacturer, the user, the installer or the delivery transport.

3. The warranty does not cover: Inadequate use, negligence, corrosion, abuse, manipulation or the wrong installation of the products, a use of non-

original spare parts or not concerning to the specific pattern. All the manufactured and/or commercialized equipment must be installed according to the

given instructions by the manufacturer.

4. The accessories and the products not manufactured by TOT COMERCIAL SA are liable for their original manufacturer’s warranty.

5. Because of the constant innovations and development, TOT COMERCIAL SA keeps the right to modify the specifications of its products and publicity,

without prior notice.

9. CONFORMITY DECLARATION

Manufacturer: TOT COMERCIAL sa Partida Horta d'Amunt s/n Apartado Correos nº 149

25600 BALAGUER (Lleida) SPAIN

DECLARES:

Under its own responsibility the supplied product:

FUEL SUPPLY KIT

Trademark: GESPASA

Model:

COMPACT 50M-230 TOTEM 50M-230

It is in accordance with the following legislative and/or regulative documents:

DIRECTIVES No. and date

2006/42/CE: on machine safety EN ISO 12100:2012

EN 809:1999+A1:2010

- This Declaration will lose its validity in case that any modification is made without the explicit manufacturer's consent.

Balaguer (Lleida), November 2017

Andreu Pané

COMPACT 50M-230 · TOTEM 50M-230 INSTRUCTION MANUAL

No. DESCRIPTION CODE No. DESCRIPTION CODE

1 M-4x12 DIN. 912 SCREW 805400035 12 CONNECTION BOX 000201503

2 PUMP BODY COVER 003504000 13 SWITCH 000206017

3 58x3 NBR JOINT 803101061 14 FAN 000201504

4 F211 ROLLER 000002210 15 FAN COVER 000201507

5 5-BLADE SET 000002109 16 0.25 kW MOTOR 000201502

6 SEGER RING INT.30 800303012 17 M-6x126 STUD 000201506

7 PUMP FILTER 003502001 18 BEARING 804603004

8 BYPASS VALVE 805606102 19 OUTSIDE RETENTION RING 804600013

9 12x26x7 RETAINER 804600012 20 IRON-50 230 V BYPASS SPRING 000002007

10 4x4x10 SHAFT KEY 000002002 21 IRON-50 230 V PUMP BODY 003503002

11 3 m 230 V CONNECTION CABLE WITH INJECTED PLUG 800900010

TECHNICAL SPECIFICATIONS

- IRON-50 230 V pump of grey foundry with filter built-in. Self-suction.

- Eccentric with self-adjusting blades

- With bypass recirculation

- Motor: 0.25 kW 230 VAC self-ventilated 50/60 Hz single-phase

- Noise level: LEQ

< 85 dBA (1 m)

- Continuous duty – IP-55 Protection

- Consumption: 1.2-2 A

- 3000 rpm

- Bypass pressure: 2-2.5 bar

- Connection through F1” threads and flanges

- It has a self-cleaning steel filter of 350 µm (micron)

- NOTE: When using an automatic nozzle, the flow will be reduced.

FLUID COMPATIBILITY

The IRON-50 230 V pumps are especially for the diesel transfer; they must not be used to transfer other liquids.

This pump is suitable for its use on the agriculture, building, public works and industry.

COMPACT 50M-230 · TOTEM 50M-230 INSTRUCTION MANUAL

PROBLEM GUIDE

BREAKDOWN POSSIBLE CAUSE SOLUTION

The tank is full. The pump is

working, but the liquid does not go

out through the automatic nozzle.

- There is created an air chamber in the

delivery line, and the automatic nozzle

cannot be opened.

- remove the automatic nozzle from the hose. Start the pump until it is

primed, and the liquid automatically goes out. Then install again the

automatic nozzle.

The pump works, but no fluid

comes out. - problem in suction line

- opened bypass valve

- blade friction

- retainer leak

- blade or roller wear

- blocked outlet pipe or nozzle

- motor breakdown

- check loss in suction line.

- remove and check the valve.

- verify blades to see whether these are worn out.

- change the retainer.

- check roller and blades whether they are worn out, and replace them

- check whether the pump outlet pipe, the hose, the nozzle and the filter

are blocked or not.

- the rotor must turn anticlockwise, looking at the pump from the heading;

if not, return it for repairing

The pump makes noise, but it

does not work. - dirt inside the pump, blade friction

- motor breakdown - clean pump inside.

- return for repairing to the factory.

Low flow rate - excess of dirt in filter

- problem in suction line or in delivery

- the bypass is blocked.

- blade friction

- blade or roller wear

- dirtiness on the red adaptor

- disassemble and clean the filter.

- verify suction line to check whether there are leakages or restrictions,

or not; it may be too narrow, too long or no hermetic.

- remove and check bypass valve. Clean it.

- verify blades to see whether these are worn out.

- verify blades and roller whether these are worn out or there is

something wrong, and replace them.

- clean the inner sieve.

The pump works slowly making

strange noise. - wrong voltage current

- motor breakdown - verify inlet voltage.

- return for repairing to the factory.

The motor stops or is burning. - low voltage current

- solid impurities inside the pump - verify inlet voltage.

- disassemble and clean the pump.

The motor heats up excessively. - it pumps high viscosity fluids.

- blocked filter

- narrow suction/delivery tube

- motor breakdown

- these fluids only can be pumped for a short period.

- remove and clean filter.

- replace with an adequate tube.

- return for repairing to the factory.

The motor does not start. - there is no electricity.

- motor breakdown

- switch connection not lined up /

connected

- verify inlet current.

- return for repairing to the factory.

- adjust connection switch/connect.

Leak of liquid - connection joint in bad state

- mechanical seal in bad state - verify all connection joints.

- replace the mechanic seal.

COMPACT 50M-230 · TOTEM 50M-230 INSTRUCTION MANUAL

No. DESCRIPTION CODE No. DESCRIPTION CODE

1 INLET/OUTLET HOLE PLUGS 320004001 19 NUMERATION COVER 320004014

2 24x3.5 JOINT 803100022 20 M-4 RING 800300001

3 D. 5.28x1.78 JOINT 803100024 21 D. 3.5x9.5 DIN.7981 ZINC-PLATED SCREW 805404002

4 REGULATION PROTECTION PLUG 320004004 22 NUMERATION 320005002

5 D. 9.5x1.5 mm JOINT 803100045 23 CONICAL GEAR 320001002

6 10x47 FLOW SCREW 320004006 24 D. 3.69x1.78 JOINT 803100023

7 HOUSING FIXATION SUPPORT 320004007 25 GEAR WHEEL RING 320001005

8 METER HOUSING 320004008 26 GEAR WHEEL 320001003

9 80x3 VITON JOINT 803101025 27 DOUBLE PINION 320001004

10 MEASURING CHAMBER 320002000 28 MEASURING CHAMBER 320002001

11 D.2x16 DIN. 6325 PIN 804000001 29 NUTATING DISC 320002002

12 BLACK FRAME 320004010 30 TOP COVER 320002003

13 SPECIAL SQUARE VITON JOINT 320704011 31 COVER LEVER 320002004

14 CENTRAL COVER 320004012 32 MEASURING BOX SUPPORT 320002006

15 M-5x22 DIN. 912 SCREW 805400008 33 GEAR MEASURING UNIT PINION 320002005

16 RESET DRIVE 320005001 34 D.7 x D.4x6 SLEEVE 320004016

17 D.4.2x9.5 DIN.7981 ZINC-PLATED SCREW 805404003 35 4x15 LEVER SHAFT 320002007

18 3-DIGIT PLATE 320004013

1. TECHNICAL SPECIFICATIONS

MG-80 Volumetric Mechanical Meter

Accuracy: ±1 %

Connections: 1” GAS (BSP) inlet, with three optional positions

1” GAS (BSP) outlet, with two optional positions

Meter: Mechanical. 999 litres partial indicator (3 digits)

999999 litres totalizer (6 digits)

Resistance Pressure: 13 bar

Test Pressure: 6 bar

Max. Operating Pressure: 3,5 bar

Measuring Chamber: Disc fireproof

Made of: Non-toxic recyclable plastic with Viton-nitrilic joints and fire-proof chamber

Max. Ambient Temperature: 60 ºC

Additional Adapters: It can be supplied with special male/female adapters in NPT, BSW, BSF, BRIGGS thread sizes

DESIGN FACTORS

1” GAS (BSP) Female Inlet and Outlet Threads are part of the housing. It has 3 inlets. They can be seen from the back: frontal, left side and bottom. It also

has 2 outlets. They can be seen from the back: right side and top.

COMPACT 50M-230 · TOTEM 50M-230 INSTRUCTION MANUAL

The meter is given with a horizontal inlet and outlet. Nevertheless, the user can change their position in a short time, the plugs of the desired direction

must be taken out and put them on the non-desired direction. The inner threads have joints that guarantee the sealing; you must only tighten them till its

locking, giving up pastes, liquids, and sealing products.

The MG-80 meters are for private use. The MG-80 Volumetric Mechanical Meters has two numeration types:

- Partial with three big numbers where you can read up to 999 litres. It can be reset through a lateral wheel after each transfer.

- 6-digit totalizer with capacity of 999.999 litres; after that and with its operation, it is automatically reset, starting the program again.

2. CALIBRATION

The meters are precalibrated in the factory. IT IS ADVISABLE TO MAKE A CALIBRATION ONCE IT IS INSTALLED. Each liquid type has its own density

and viscosity. To achieve a trustworthy measurement, it is advisable that the recalibration is done with a homologated test tube or dekalitre. It can be used

a container from which we have to know its capacity.

Calibration procedure

2.1. For an exact calibration, the meter, the hose, the nozzle and the pump must be full of liquid and free of air. This is achieved emptying from 10 to 20

litres of liquid and closing the nozzle, without stopping the pump until the operation is finished.

2.2. Fill the homologated dekalitre recipient until the exact measurement (10 or 20 litres).The bigger the recipient is, the better calibration accuracy you

have.

The calibration process must be done with the nozzle totally open. Never calibrate it with the nozzle half opened.

2.3. If the quantity does not correspond with the emptied liquid on the recipient, it needs to be calibrated.

2.4. To make this operation, take out the plug (4) and turn the screw (6) clockwise. Then the flow percentage decreases. If you turn it anticlockwise, it

increases. A complete turn varies the measurement more or less in 0,4 litres, per each 10 litres.

2.5. If we want to guarantee a correct calibration, we have to repeat it three or four times. If the result is correct, a good adjustment will be achieved and

the meter will be ready to work. Do not exceed 3.5 bar pressure, and do not work less than 1 bar.

2.6. The MG-80 meter can work by gravity or with pump. Remember that the suitable minimum pressure is 1 bar with a minimum flow of 15 l/min, and with

an accuracy of ±1 %. If you decide to use it by gravity, it can give errors on the measurement due to the different liquid heights in the tank. We recommend

you to always install a pump.

3. PROBLEM GUIDE

BREAKDOWN POSSIBLE CAUSE SOLUTION

Litres are passing but the numeration does

not count. - there are impurities on the measuring

chamber. - clean the measuring chamber (10).

Loss of liquid - Allen screws loose

- because of the overpressure the joint has

been moved.

- joint breaking

- tighten up Allen screws (15).

- replace joint (9 or 13).