HORN TECALEMIT Diesel Eco-Box II User manual

Translation of the
original operating manual
GB
Operating manual
Dispensing point
Diesel Eco-Box II
Item no.: 110300001

44 1491 101-A Diesel Eco-Box II
Copyright
© HORN GmbH & Co. KG. All rights reserved.
Text, graphics and layout copyright protected. Reproduction and copying, including in
part, only permitted with written permission. Technical changes reserved.
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Document-No.: 44 1491 001-A
As of: 04.10. 01

44 11491 101-A Diesel Eco-Box II 3
Content
1.
1.1.
1. Safety instructions
Safety instructionsSafety instructions
Safety instructions ................................
................................................................
................................................................
................................................................
..............................................................
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.............................. 4
44
4
.
..
. Technical description
Technical descriptionTechnical description
Technical description ................................
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................................................................
................................................................
.........................................................
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......................... 6
66
6
.1 Description .................................................................................................................... 6
. Appropriate Use .......................................................................................................... 6
.3 Technical Data ............................................................................................................. 6
3.
3.3.
3. Assembly instructions
Assembly instructionsAssembly instructions
Assembly instructions ................................
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................................................................
........................................................
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........................ 7
77
7
3.1 Place of installation ................................................................................................... 7
3. Assembly ....................................................................................................................... 7
4.
4.4.
4. Operation
OperationOperation
Operation ................................
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.............. 7
77
7
4.1 Commissioning and recommissioning .................................................................. 7
4. Normal operation ....................................................................................................... 8
5.
5.5.
5. Error display
Error display Error display
Error display –
––
– What to do if...
What to do if...What to do if...
What to do if... ................................
................................................................
................................................................
................................................................
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......... 9
99
9
6.
6.6.
6. Maintenance
MaintenanceMaintenance
Maintenance ................................
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....... 10
1010
10
6.1 Leak test ..................................................................................................................... 10
6. Dispensing hose ....................................................................................................... 10
6.3 Base filter ................................................................................................................... 10
6.4 Fuse .............................................................................................................................. 10
6.5 Cleaning the system ................................................................................................ 10
7
77
7.
..
. Disposal
DisposalDisposal
Disposal ................................
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................................................................
................................................................
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............... 10
1010
10
8.
8.8.
8. Declaration of Conformity
Declaration of ConformityDeclaration of Conformity
Declaration of Conformity ................................
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.............. 11
1111
11

4 44 1491 101-A Diesel Eco-Box II
1. Safety instructions
The device is a state of the art piece of equipment and has been constructed
according to recognised safety specifications. It is nevertheless possible that use of
the device will present hazards to the operator or to third parties, or may damage the
device or other property. It is therefore essential to act in accordance with these
safety instructions, and in particular with those sections identified as warnings.
Warning notices and symbols
In the operating manual, the following signs are used for highlighting important
information.
Special information for economical use of the equipment.
Special information or "dos and don'ts" for damage prevention.
Information or “dos and don'ts” for the prevention of damage to persons or
equipment.
Appropriate use
The device may only be used if it is in perfect condition, and then only for its
intended purpose, in compliance with all safety regulations, with an awareness of the
potential risks, and according to the operating manual. Any faults that may impair the
safety must be rectified immediately.
The device and its components are only to be used for handling the liquids listed and
the purpose described. Using the machine for any other purpose would constitute
inappropriate use. The manufacturer is not responsible for any loss arising as a result
of this, the risk for this is borne only by the operating company.
Organisational measures
This operating manual should always be kept readily available at the site of
operation! Each person concerned with the assembly, commissioning, maintenance
and operation of the equipment must have read and understood the entire operating
manual. It is essential that the type plate and the warning notices attached to the
device are observed, and are maintained in a fully readable condition.
Qualified personnel
The operating, maintenance and assembly personnel must be appropriately qualified
for their work. The areas of responsibility, competences and supervision of the
personnel must be precisely regulated by the operating company. If the personnel do
not have the required knowledge, they must be trained and instructed. The operating
company must also ensure that the contents of the operating manual are properly
understood by the personnel.
Waters protection
The device has been designed to handle water hazardous substances. The regulations
on the operating place (e.g. Water Resources Act WHG, = ordinance on installations for
handling of substances hazardous to water VAwS) must be adhered to.

44 11491 101-A Diesel Eco-Box II 5
Hydraulics
Only persons with special knowledge and experience with hydraulic systems may
carry out work on hydraulic parts and equipment. All lines, hoses and screw joints
should regularly be checked for leaks and visible external damage. Any damage must
be rectified immediately. Any oil spurting out can cause injuries and fire.
The relevant safety regulations for the product must be followed when handling oils,
greases or other chemical substances!
Maintenance and Service
According to the regulations of the water resources law only authorized services may
work on devices for flammable and/or water endangering substances. During such
works, appropriate tools are to be used (avoid sparking). Before any kind of work on
the device, all fuel lines are to be completely emptied and aerated.
Do not make any changes. Modifications or additions to the device which may affect
the safety cannot be carried out without consent of the manufacturer. Exclusively
genuine spare parts made by the manufacturer may be used.
Electric power
Work on the electrical equipment may only be carried out by a qualified electrician or
by trained persons under the guidance and supervision of a qualified electrician
according to electro-technical guidelines. Machine or system components, on which
inspection, maintenance or repair work is to be carried out must be de-energised.

6 44 1491 101-A Diesel Eco-Box II
2. Technical description
2.1 Description
The Diesel Eco-Box II is an electrically driven dispensing point suitable for heating
and diesel oil in hazard class A III from overground tanks.
2.2 Appropriate Use
The Diesel Eco-Box II may not be operated with flammable and explosive liquids in
hazard classes AI, AII and B. Liquids in hazard class A III may not be used if they are
heated up above their flashpoint. Operation of the Diesel Eco-Box II is not permitted
in areas at risk of explosion. There is a risk of explosion!
The temperature range of the pumped liquid may not fall below -10°
°°
°C or exceed
+40°
°°
°C.
The electrical pumps are self-drawing. Continuing dry running can lead to destruction
of the pump blades!
Operation of the dispensing point without a base filter can lead to destruction of
important components in the pump!
The pump does not have a protective device against automatic start-up after an
interruption to the supply voltage.
2. Technical Data
Year of construction See type label
Medium temperature -10 - +40 °C
Environmental temperature - 0 - +40 °C
Connection thread G 1"
Nominal pump pressure 1.5 bar
Overflow valve set at 1.8 bar
Nominal drawing height: 1.6 m
Nominal pump rate 55 l/min
Voltage 30 V 50 Hz
Nominal motor power 0.33 kW
Speed 700 min
-1
Protection class IP 54

44 11491 101-A Diesel Eco-Box II 7
. Assembly instructions
.1 Place of installation
The place of installation should be selected so that fault-free operation is guaranteed.
Furthermore, it must be accessible for maintenance work.
.2 Assembly
1. Check all parts for any residues of packaging material before assembly.
. Screw the dispensing hose with the outer thread G1“ into the outlet on the left of
the housing. Screw the other end of the dispensing hose into the rotating hose
joint on the dispensing valve.
3. The suction side must be equipped with a tight fitting base filter.
4. Attention must be paid that the pre-mounted return hose (PU4), is inserted with
the suction hose into the tank opening (lever protection).
5. If a base filter with suction hose is part of the scope of supply, then slide the
supplied base filter onto the pipe of the suction hose as far as it goes and fix with
the clip. Pay attention to the tight fit of the base filter (tighten the clip).
6. Connections are to be checked for tightness after assembly.
The installation of a check valve in the suction line is prohibited unless pressure
relief is provided.
4. Operation
4.1 Commissioning and recommissioning
Longer dry run periods (> 1min) are generally to be avoided otherwise the pump
blades can be destroyed.
1. Connect the voltage supply using the mains plug.
. Hold the dispensing valve in a tank, in the container return flow or in a
collection container. Open the dispensing valve on the dispensing lever until
bubble-free delivery is achieved.
3. Suspend the dispensing valve in the holder. The motor switches off.
The dispensing point may only be operated under supervision.

8 44 1491 101-A Diesel Eco-Box II
4.2 Normal operation
Avoid dry running (>1 min).
With the dispensing valve closed and the pump filled with medium, it may be
operated for a maximum of 1 minute otherwise it can lead to excessive heating and
destruction of the pump blade.
After the filling process, the dispensing valve must be placed back in the holder.
The dispensing hose should not remain lying on the ground to avoid damages (e.g.
due to being driven over).
A defective hose can cause impurities.
If leaks occur on the dispensing point and in the lines and dispensing valve, operation
must be stopped immediately and the fault addressed.
1. Connect the voltage supply using the mains plug.
. Hold the dispensing valve in the filling container or insert in the vehicle tank
and press up dispensing lever according to the required flow amount or lock in
place with the fixing clip.
The automatic dispensing valve switches off automatically when the tank is
filled. If the filling process should be stopped beforehand, release the
dispensing lever or briefly raise and release the lever if it has been locked in
place.
3. Suspend the dispensing valve in the holder. The motor switches off.
Also refer to the operating manual for the automatic dispensing valve A2010 and the
operating manual for the counter Z 00.

44 11491 101-A Diesel Eco-Box II 9
5. Error display – What to do if...
... the pump switches on and off in sequence?
–The pump is dry running and starting up after each time the pump chamber has
cooled down. Switch the pump off and address the cause of dry running.
… the pump won't draw?
–The tank is empty.
–Check the suction line and all screw connections on the drawing side for leaks and
reseal if necessary.
… the pump won't switch on?
–The mains plug is not plugged in.
–The cable is damaged.
… the delivery rate is too slow?
–The base filter is dirty.
–Very cold and viscose mediums are difficult to draw which results in slow delivery
rates. The temperature range of the delivery liquid may be too low.
… the pump switches off during operation?
–The thermal overload protection on the electric motor has been triggered. It
automatically resets after cooling down. The cause of overheating is to be
addressed.
In cases of excessive noise development, further operation is only permitted after
addressing the cause!

10 44 1491 101-A Diesel Eco-Box II
6. Maintenance
The dispensing point is generally requires low care and maintenance. The mains plug
must be disconnected at the beginning of any maintenance work.
6.1 Leak test
The unit and the other components in the system are to be regularly checked for
leaks and damages and sealed if necessary.
6.2 Dispensing hose
Dispensing holes can be simply replaced by loosening the screw connections.
6. Base filter
The filter is to be cleaned at regular intervals. To do this, disconnect the base filter
from the suction hose then rinse it out and blow through with compressed air. Then
mount the base filter as described in the assembly chapter.
6.4 Fuse
The motor on the dispensing point is protected with a thermal fuse in the motor coil
that automatically resets after the motor has cooled down.
6.5 Cleaning the system
In case of any external dirt, carefully clean the device with suitable cleaning agents
and do not use any aggressive detergents. Rinse with diesel to clean the inside parts
and pipelines.
7. Disposal
The device is to be emptied completely and the liquids properly disposed of in case it
is taken out of service.
The equipment is to be disposed of properly when taken permanently out of service:
- Return old metal for recycling.
- Return plastic parts for recycling.
- Return electronic waste for recycling.
The water legal regulations are to be followed.