Hytek AdBlue ABPDS Instruction manual

S902/3
Technical Data
DISPENSER FOR AdBlue
AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V.
Applies to the following model only:
- ABPDS - ABPDS.SV
Please read carefully before commencing installation
Registered Office: HYTEK (GB) LIMITED, Delta House, Green Street, Elsenham,
Bishop’s Stortford CM22 6DS UK. Registered in England No. 1915382
Tel: +44 (0) 1279 815 600 Fax: +44 (0) 1279 812 978 email: [email protected]
Web: www.hytekgb.com

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ENVIRONMENTAL INFORMATION
European Directive 2012/19/EU requires that the equipment
bearing this symbol on the product and/or its packaging must
not be disposed of with unsorted municipal waste. The
symbol indicates that this product must be disposed of
separately from regular household waste streams. It is your
responsibility to dispose of this and other electric and
electronic equipment via designated collection facilities
appointed by the government or local authorities.
IMPORTANT WARNING NOTES
1. This dispenser MUST NOT be used to dispense petrol or other
flammable liquids and must only be used to dispense AdBlue.
2. It must not be sited adjacent to a petrol dispenser or in any
other hazardous zone.
3. On above ground storage tanks an angle check valve fitted
with the appropriate spring or pressure regulating valve must
be fitted at the tank outlet to prevent loss of fuel under gravity
in the event of vandalism or accidental damage.
4. Installation and maintenance of this equipment along with its
associated tank, pipe work and fittings should only be carried
out by qualified and competent engineers.
5. The installation must conform to all relevant electrical and local
authority regulations and standards.
6. It must not be used with other liquids or for other applications.
We will accept no warranty claims or liability if it is used for
other liquids or applications.
7. Ensure that the AdBlue supply is suitably filtered to prevent
any debris from entering the metering unit and causing damage
to the turbine.

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CALIBRATION
The meter & display on this pump unit must be calibrated
electronically to ensure accuracy and reliability. See page 7 for
instructions on how to carry out this procedure.
MOUNTING
1. Bolt the dispenser to a firm level foundation by means of the
four 13mm mounting holes in the base of the unit.
PUMPED ADBLUE SUPPLY
2. The AdBlue supply to the dispenser must not exceed a
pressure of 10 BAR (145 PSI) with a flow rate between 6 - 100
litres per minute. Check your nozzle specification to ensure the
pressure and flowrate are suitable.
3. If multiple dispensers are to be supplied from one pump an
independently controlled solenoid valve or similar must be
installed before each dispenser to prevent unauthorised
delivery of AdBlue.
PIPEWORK
4. Remove the rear panel, if necessary, and store safely.
The dispenser inlet is 1” BSP Female. Connect the pipe from
the pump to the inlet of the dispenser. Seal the joints with a
suitable thread-sealing compound. If an above ground
pipework entry point is required, an alternative entry point will
need to be made in the pedestal.
5. Connect one end of the delivery hose onto the outlet elbow,
ensuring it is sealed correctly.
6. Screw the nozzle onto the other end of the hose again,
ensuring it is sealed correctly.

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ELECTRICAL
7. Remove the cover from the 220/240V junction box.
8. Connect a constant 220/240V AC 50 Hz supply, fused at 10
amps, to the terminal block in the 220/240V supply junction box
as shown on the wiring details diagram.
NB: The dispenser must have a continual 220/240V AC
supply, even when not in use
9. A 230VAC switched motor supply rated at 10 Amps max. is
provided, to control a remote pump, motor or relay, at the
terminals labelled 230V PUMP/MOTOR OUTPUT.
10. A 12VDC switched solenoid valve supply rated at 8 W max is
provided, to control a remote solenoid valve or relay, at the
terminals labelled 12v SOLENOID OUTPUT.
11. If the dispenser is to be operated in conjunction with a fuel
control key/card system then there are two options:
SINGLE DISPENSER SETUP. The fuel control system can
interrupt/switch the live feed to the pump/motor connected to
the pedestal.
MULTI DISPENSER SETUP. Solenoid valves will need to be
fitted to the inlet feed to each dispenser. The fuel control
system can interrupt/switch the live feed to the solenoid valve
connected to each pedestal.
Make connection – Pump running
Break connection – Pump not running
12. A pulse output for connection to fuel control key/card systems
is available from the separate terminals located on the display
circuit board. This is a passive contact giving 10 or 100 pulses per
litre. Contact ratings are as follows:
Maximum current - 0.25 amps
Maximum voltage - 50 volts
Maximum power - 5 VA

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13. Ensure all the terminal screws are tight and replace the
junction box covers.
DISPLAY CONNECTION DIAGRAM
MAINS JUNCTION BOX CONNECTION DIAGRAM

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INSTRUCTIONS FOR USE
1. Remove the nozzle from the holster.
2. Place the nozzle spout in the AdBlue tank.
3. Squeeze the nozzle trigger to dispense fuel.
On completion of the delivery release the trigger and replace
the nozzle in the holster.
MAINTENANCE
The dispenser should require minimum maintenance in normal
regular use, but as with all mechanical apparatus regular servicing
will prolong its life and ensure maximum efficiency & reliability.
The following should be carried out every 12 months or 1 million
litres which ever comes first.
- Isolate power supply
- Inspect & clean or replace inlet filter
- Re-calibrate electronic display
METER MAINTENANCE:
If any metal swarf or particles have entered the meter and jammed the
turbine then the meter will need to be carefully removed for inspection and
cleaning.
WARNING:
DO NOT USE COMPRESSED AIR THROUGH THE METER, TO AVOID ANY
DAMAGE DUE TO EXCESSIVE ROTATION.

S902/3
ALP.DISP2 ELECTRONIC DISPLAY/CALCULATOR
6-digit backlit Main LCD display: Up to 9999.99 or 99999.9 litres per
delivery
8-digit backlit totaliser LCD display: Up to 99999999 litres
Display retained during power failure
Stand-by mode: Main LCD display shows previous delivery
Totaliser LCD display shows ongoing total
Nozzle removed: Main LCD display shows “all eights” then “all zeros”
Totaliser LCD display shows “FUELLING”
Pump starts
Fuel drawn: Main LCD display shows litres dispensed
Totaliser LCD display shows “FUELLING”
Nozzle Returned: Pump stops
Main LCD display shows previous delivery
Totaliser LCD display shows ongoing total
FEATURES
OPERATION

S902/3
1. Ensure the nozzle is stowed in the holster
and the dispenser is isolated from any
fuel management systems.
2. On the rear of the pedestal there is a
black cap, remove this cap to gain access
to the calibration button.
3. Using a long, thin screwdriver gently push
and hold the calibration button.
CALIBRATION PROCEDURE - (MUST BE CARRIED OUT TO
ENSURE PUMP ACCURACY)

S902/3
4. Release the calibration button when the
totaliser display shows VER followed by
the version number on the lower display.
5. The totaliser display will show the
following in a looping sequence:
CH 1 - Single channel pulser connected
CH 2 - Two channel pulser connected
REED - Reed switch pulser connected
Press calibration button once when
desired option is displayed.
Select REED for AdBlue pedestal.
6. The totaliser display will show the
following in a looping sequence:
1 DP - One decimal place on display
2 DP - Two decimal places on display
Press calibration button once when
desired option is displayed.
7. The totaliser display will show the
following in a looping sequence:
RELAY 10 - Ten pulse per litre reed
relay output.
OPTO 10 - Ten pulse per litre opto-
isolated output.
OPTO 100 - One hundred pulse per litre
opto-isolated output.
Press calibration button once when
desired option is displayed.

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8. The totaliser display will show the
following in a looping sequence
STD ALONE - Pump external serial
interface not used.
NET - To set the pump identity number
(1-8) if serial interface used to connect
to a fuel control system.
EXT ID - To set the pump identity
number (1-16) if serial interface used to
connect to fuel control system.
Press calibration button once when
desired option is displayed.
a. If NET or EXT ID were selected
above, the pump identity number must
be selected from the looping sequence.
Press calibration button once when
desired option is displayed.
b. The totaliser display will show the
following in a looping sequence:
BR 9600 RS485 communication
Baud rate 9600
BR 19200 RS485 communication
Baud rate 19200
BR 38400 RS485 communication
Baud rate 38400
9. If STD ALONE was pressed in 8. above
the totaliser display will show NOZZLE.
To save any changes made so far but to
avoid carrying out the following 20 litre
calibration, press the calibration button
once to continue directly to point 12.
below.

S902/3
10. Take nozzle. The totaliser display will
show FUELLING and the pump will
start. When main display shows 000000
dispense precisely 20 litres of fuel
(using a measure can).
The main display will show pulses
clocking up.
11. Hang the nozzle back into the holster.
12. If the totaliser display shows CALIB OK
press the calibration button for two
seconds to return to normal operation.
The Alpha dispenser is now calibrated.
If the totaliser shows CAL FAIL or
ERROR press the calibration button for
two seconds to return to normal
operation. The Alpha dispenser has
NOT been calibrated. Repeat
calibration procedure.
20L

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ERRORS
If an error occurs ERROR (followed by a number) is shown on the
totaliser display. The error codes are classified as follows:
ERROR 1 The pulser has run too fast (in excess of 300 pulses
per second)
ERROR 2 The meter has turned without the nozzle being
removed
ERROR 3 A time delay of 60 seconds or more has occurred
between any of the stages of the calibration sequence
ERROR 4 One of the pulse transmitter’s pulse trains has been
interrupted.
ERROR 5 The meter has run backwards during a delivery
ERROR 6 The pulser has been disconnected
The error condition is maintained until the nozzle is returned to its
holster, for at least 2 seconds, and then removed again to restart the
fuelling sequence.

S902/3
DISPENSER BASE AND INLET CONNECTIONS
All dimensions stated are approximate.

S902/3
INLET CONNECTION
All dimensions stated are approximate.
5
3
0
mm
ABPDS.S
V
–
Solenoid
valve fitted.
ABPDS
–
No
Solenoid
,
check valve fitted.
4
3
0
mm
45mm
BLANK
FOR PIPE
ACCESS

S902/3
EXTERNAL DIMENSIONS All dimensions stated are approximate.
1520mm
350
mm
340mm
NOZZLE
DEPENDANT
260
mm

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EXTERNAL VIEW All dimensions stated are approximate.
1
2
3

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INTERNAL VIEW – ABPDS (No solenoid valve fitted)
4
10
5
6
7
9
8

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INTERNAL VIEW – ABPDS.SV (No solenoid, check valve fitted)
LOCATION OF
OPTIONAL
SOLENOID VALVE,
IF FITTED.

S902/3
PARTS LIST
DRG
REF
PART DESCRIPTION PART NO.
EXTE
RNAL COMPONENTS
1
LCD DISPLAY UNIT
(LCD BOARD)
ALP.PCB.LCD
LCD DISPLAY UNIT (MAINS BOARD)
ALP.PCB
.
MAIN.W
2
NOZZLE BOOT WITH SWITCH
A
LP
.NOZBOOT.A
3
OUTLET
ELBOW
EL
B.4FFSS
INTERNAL COMPONENTS
4
BLAN
K
FOR CALIBRATION HOLE
BLANK.08
5
JUNCTION BO
X
ABPDS.JBOX
JUNCTION BOX
230V
OUTP
UT RELAY
ABPDS.RELAY
6
JUNCTION BOX GLAND
GLND.M20
7
PULSER UN
I
T
K24.ABP
8
1” S/S STRAINER
YSTR.1S
9
1” S/S LEVER BALL VALVE
LBV.4S
10
1” S/S
CHECK VALVE
CHK.1S
11
SOLENOID VALVE ASSEMBLY
(OPTIONAL)
ALP.SOLVAL.AB

S902/3
E.C. DECLARATION OF CONFORMITY
Company Name: Hytek (GB) Ltd
Address: Delta House, Green Street
Elsenham, Bishops Stortford
Hertfordshire, CM22 6DS, UK
Date of Issue: 22nd March 2019
Equipment Details: AdBlue Dispenser
ABPSD
Applicable Directives: 2014/30/EU EMC Directive
& Standards EN 61000-6-3:2007 (+A1)
Electromagnetic compatibility (EMC) - Part 6-3:
Generic stds - Emission standard for residential,
commercial and light-industrial environments
EN 61000-6-2:2005
Electromagnetic compatibility (EMC) Part 6-2:
Generic standards - Immunity for industrial
environments
2014/35/EU Low Voltage Directive
2006/42/EC Machinery Directive
2014/68/EU Pressure Equipment Directive
2012/19/EU Waste Electrical & Electronic
Equipment Regulations
2011/65/EU Restriction of Hazardous
Substances Directive (RoHS2)
Declaration Number: EU146/1
On behalf of the above-named company, I declare under our sole
responsibility that, on the date the equipment accompanied by this
declaration is placed on the market, the equipment conforms with all
technical and regulatory requirements of the above listed directives.
Clive Wellings Technical Manager
THE INFORMATION CONTAINED IN THIS DOCUMENT IS PROTECTED BY COPYRIGHT © AND
PROPERTY LAWS AND IS THE SOLE PROPERTY OF HYTEK (GB) LTD. ANY REPRODUCTION IN PART
OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF HYTEK (GB) LTD IS PROHIBITED.
AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V.
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