Hytek AdBlue ALPHA Series Instruction manual

S709/8
Technical Data
Alpha Pump for AdBlue
®
AdBlue
®
is a registered trademark of the Verband der Automobilindustrie e.V
Applies to the following models only :
- ALPHA/40AB
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: [phone] Fax: [phone] email: [e-mail]
Web: www.hytekgb.com

S709/8
ENVIRONMENTAL INFORMATION
European Directive 2012/19/EU requires that the equipment
bearing this symbol on the product an/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 ARNING NOTES
1. This pump 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 of this equipment and its associated tank, pipe work
and fittings should only be carried out by qualified fuel
installation 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.
8. The pump must not be run beyond the stated 20-minute duty
cycle. See DUTY CYCLE section for more information.

S709/8
CALIBRATION
The meter on this pump unit must be calibrated electronically to
ensure accuracy and reliability. See page 11 for instructions on
how to carry out this procedure.

S709/8
INSTALLATION INSTRUCTIONS
1. Check you have the following items:
1 off Alpha pump for AdBlue®
1 off delivery hose
1 off front door key
1 off delivery nozzle
2. Open the front panel using the key provided.
3. Remove the rear panel, if necessary, and store safely.
MOUNTING
4. Bolt the pump to a firm level foundation by means of the four 14
mm diameter-mounting holes provided.
PIPE ORK
5. Connect the 1” dia pipe from the tank to the 1” BSP suction inlet
of the pump. Seal the joints with a suitable thread-sealing
compound. The pipe work must be sealed to the drip tray (if
fitted) to ensure no leaking AdBlue® can flow underground.
An alternative pipe work entry point, for above ground pipe work,
is provided at the rear of the pump base. Push out the plastic
cover plate if required.
6. Connect one end of the delivery hose into the outlet elbow.
Ensure the nylon hose-sealing washer is in place on the hose
end. It should be hand tight plus a quarter turn.
7. Screw the nozzle onto the other end of the hose, again ensuring
the nylon washer is in place. No other sealing compound is
necessary. Hand tight plus a quarter turn.

S709/8
ELECTRICAL
8. Remove the covers from the 220/240V supply and the external
pulse output connection junction boxes.
9. Connect a constant 220/240V AC 50 Hz supply, fused at 16
amps, to the terminal block in the 220/240V supply junction box
as shown on the wiring details diagram.
NB: The Alpha pump for AdBlue® must have a continual
220/240V AC supply, even when not in use
10. If the Alpha pump for AdBlue® is to be operated in conjunction
with a key/card system, remove the link in the 220/240V supply
junction box (shown on the Alpha AdBlue® Installation Wiring
Details) and connect so that the control system makes and
breaks the connection.
Make connection - Pump on
Break connection - Pump off
Alternatively remove the link and connect a switched live supply
(230V AC 16A max.) to terminal 4 (shown on the Alpha pump for
Adblue® Installation Wiring Details)
Live supply switched on - Pump on
Live supply switched off - Pump off
11. A pulse output for connection to key/card systems is available
from the pair of terminals located in the separate pulse output
connection junction box. This is a passive contact giving 10
pulses per litre. Contact ratings are as follows:
Maximum current -0.25 amps
Maximum voltage -50 volts
Maximum power -5 VA

S709/8
INSTRUCTIONS FOR USE
1. Remove the nozzle from the holster.
2. Place the nozzle spout in the vehicle’s 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.
DUTY CYCLE
This Alpha pump for AdBlue®unit is designed with a maximum duty
cycle of 20 minutes. The pump can only be running for a maximum
of 20 minutes at a time. The pump must then be left to cool for 20
minutes before reusing. Failure to adhere to this duty cycle may
damage the pump unit and void the warranty.

S709/8
MAINTENANCE
The Alpha pump for AdBlue®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 any filters
-Re-calibrate electronic display
METER MAINTENANCE:
If any metal swarf or particles have entered the meter and jammed the
gears, then these will need to be carefully removed to avoid damaging the
gears.
WARNING:
DO NOT USE COMPRESSED AIR THROUGH THE METER, TO AVOID ANY
DAMAGE DUE TO EXCESSIVE ROTATION.

S709/8
ALPHA PUMP FOR AdBlue® BASE AND SUCTION
CONNECTION DIAGRAMS
76.5MM DIA.
ALTERNATIVE
SUCTION HOLE
ALL DIMENSIONS IN MM
REAR VIEW
1" BSP FEMALE SUCTION INLET THREAD
22MM DIA. ALTERNATIVE
CABLE ENTRY HOLE
BASE VIEW FROM
ABOVE
FOUR 16MM DIA. MOUNTING HOLES
FRONT
25
396
456
340
305
13
500
526
83
50
280
PUMP SUCTION
INLET LOCATION
134

S709/8
ALPHA PUMP FOR AdBlue® INSTALLATION
IRING DIAGRAM
ALPHA MAIN JUNCTION BOX INSTALLATION WIRING DETAILS
CONSTANT SUPPLY
220 / 240V AC
FUSE - 16A
230V
MOTOR
OUTPUT
SUPPLIED WITH LINK FITTED BETWEEN TERMINALS 4 AND 5.
KEY/CARD CONTROL
SYSTEM RELAY
220/240V AC
16A MAX
*
ALTERNATIVE PUMP
CONTROL - KEY/CARD
CONTROL SYSTEM
SWITCHED LIVE SUPPLY
220/240V AC 16 A MAX
L
E
L
N
L
1 32
*
5
E
4
N
76
L N
8
E
220/240V CONNECTIONS
AUTH. 220-240V
INPUT
PULSE
OUTPUT
1 32
COM
REL
OPT
KEY/CARD CONTROL
SYSTEM PULSE
INPUT TERMINALS
50V 0.25A MAX
COMMON
OPTO
ISOLATED
RELAY
PULSE OUTPUT CONNECTIONS

S709/8
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: Upper line of LCD display shows previous delivery
Lower line of LCD display shows ongoing total
Nozzle removed: Upper line shows “all eights” then “all zeros”
Lower line shows “FUELLING”
Pump starts
Fuel drawn: Upper line shows litres dispensed
Lower line shows “FUELLING”
Nozzle Returned: Pump stops
Upper line of LCD display shows previous delivery
Lower line of LCD display shows ongoing total
FEATURES
OPERATION

S709/8
1. Ensure the nozzle is stowed in the holster
and the dispenser is isolated from any fuel
management systems.
2. Remove calibration button cover bolt from
rear of display / calculator housing (if
fitted).
3. Gently push and hold the calibration button
using a small screwdriver or similar tool.
CALIBRATION PROCEDURE - (MUST BE CARRIED OUT TO
ENSURE PUMP ACCURACY)

S709/8
4. Release the calibration button when
the totaliser display shows VER
followed by the version number on the
lower line of the display.
5. The lower line will show the following
in a looping sequence:
1 PULSE CHANNEL - Single channel
pulser connected
2 PULSE CHANNEL - Two channel
pulser connected
REED PULSER - Reed switch pulser
connected
Press calibration button once when desired option is displayed.
Select 2 PULSE CHANNEL for Weights & Measures Alpha, REED
PULSER for Alpha fitted with PULS.E18 reed switch pulser (pre August
2003) or AdblueAlpha and 1 PULSE CHANNEL for all other Alpha
versions.
6. The lower line will show the following
in a looping sequence:
LITRES – Display measures in litres.
GALLONS – Display measures in
gallons (Imperial or US)
Press calibration button once when
desired option is displayed.
7. The lower line will show the following
in a looping sequence:
BACKLIGHT ON – backlight on
constantly.
BACKLIGHT OFF – backlight off.
ON FOR FUELLING – backlight only
on during fuelling.
Press calibration button once when
desired option is displayed.
00000.0
CALIB
VER 4.
00
00000.0
CALIB
1 PULSE CHANNEL
00000.0
CALIB
LITRES
00000.0
CALIB
BACKLIGHT ON

S709/8
8. The lower line will show the following
in a looping sequence:
1 DECIMAL PLACE - One decimal
place on display
2 DECIMAL PLACE - Two decimal
places on display
Press calibration button once when
desired option is displayed.
9. The lower line will show the following
in a looping sequence:
REED RELAY 10 - Ten pulse per litre
reed relay output.
OPTO OUTPUT 10 - Ten pulse per
litre opto-isolated output.
OPTO OUTPUT 100 - One hundred
pulse per litre opto-isolated output.
Press calibration button once when
desired option is displayed.
10. The lower line will show the following
in a looping sequence:
TANK SW UNUSED – No “tank
empty” switch connected.
TANK SW IS TA.F – “Tank empty”
switch connected is Hytek TA.F type.
TANK SW NOT TA.F – “Tank empty”
switch connected is standard
“normally closed” float switch.
11. The lower line will show the following
in a looping sequence:
LEAK SW UNUSED – No “pump leak”
switch connected.
LEAK SW IS TA.F – “pump leak”
switch connected is Hytek TA.F type.
LEAK SW NOT TA.F – “pump leak”
switch connected is standard
“normally open” float switch.
00000.0
CALIB
1 DECIMAL PLACE
00000.0
CALIB
OPTO OUTPUT 10
00000.0
CALIB
TANK SW IS TA.F
00000.0
CAL
IB
LEAK SW IS TA.F

S709/8
12. The lower line will show the following
In a looping sequence:
NOZ 2 SW UNUSED – No additional
/remote nozzle switch connected.
2nd NOZ SW N/O– Additional nozzle
switch is normally open type.
2nd NOZ SW N/C – Additional nozzle
switch is normally closed type.
13. The lower line will show the following
in a looping sequence:
STAND ALONE - Pump external
serial interface not used. SELECT
THIS OPTION
CONFIG NETWORK – Configure
serial network. DO NOT SELECT
14. The lower line will show the following
in a looping sequence:
SAVE AND EXIT – Save all settings
entered and return to normal
operation.
CALIBRATE PUMP – Continue and
calibrate pump with 20 litre measure.
ABANDON CONFIG – Do not save
any settings entered and return to
normal operation.
15. If CALIBRATE PUMP was selected
TAKE NOZZLE will be shown.
Take the nozzle (the lower line will
show DISPENSE 20L) and dispense
20 litres into a calibrated test
measure.
16. Once 20 litres have been dispensed
hang up the nozzle. The lower line
should show CALIBRATION OK. If
there is an error in the calibration the
relevant error message will be
displayed.
00000.0
CALIB
NOZ 2 SW UNUSED
00000.0
CALIB
STAND ALONE
00000.0
CALIB
CALIBRATE PUMP
00000.0
CALIB
DISPENSE 20L
00000.0
CALIB
CALIBRATION OK

S709/8
ERRORS
If an error occurs ERROR, followed by a brief description is shown on the
lower display. The errors are classified as follows:
FLOW TOO FAST The pulser has run too fast (in excess of 300 pulses
per second)
UNAUTH FLOW The meter has turned without the nozzle being
removed
CALIBRATE FAIL A time delay of 2 minutes or more has occurred during
the 20 litre calibration.
PULSER SIGNAL One of the pulse transmitter’s pulse trains has been
interrupted.
PULSE REVERSE The meter has run backwards during a delivery
PULSER POWER 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.
TIMEOUT
If, during a delivery, no fuel is dispensed for 2 minutes the display will show
TIMEOUT alternating with REPLACE NOZZLE and the pump will stop
running until the nozzle is returned to its holster, for at least 2 seconds, and
then removed again to restart the fuelling sequence.

S709/8
SOLENOIDP/OUT
COM GND
12V
PULSE IN
REED OPT +12V
DC
CH1CH2 GND
GND IN 12V
NOZZLE SWITCHES
GND SW GND SW GND SW
TANK LEAK EXT GND + -
COMMS
5 6 421 3
0V - BLACK (W&M BROWN)
AND SCRN
10:1 /
100:1
PULSE
OUTPUT
PULSE
TRANSMITTER
INPUT
NOZZLE
SWITCH
INPUT
OPTO ISOLATED - GRN/YEL
REED RELAY - BLUE
COMMON - BROWN
GREEN/BLUE
YELLOW
+12VDC - RED (W&M GREEN)
CH 1 - YELLOW (W&M WHITE)
CH 2 - GREEN (W&M YELLOW)
12V DC SOL.
OUTPUT
(WEIGHTS &
MEASURES
VERSION
ONLY)
0V - BLUE
+12VDC - BROWN
RED
21 3 21 21 321 3421 3
LIVE
220/240 VAC
MOTOR RELAY
OUTPUT
1 1 232
220/240 VAC
POWER
INPUT
EARTH
LIVE - BLACK
NEUTRAL - GREY
NEUTRAL
AC INPUT
PUMP
DISPLAY /
CALCULATOR
VIEWED FROM
REAR
CALIBRATION
BUTTON
DISPLAY CONNECTION DIAGRAM

S709/8
ALPHA PUMP FOR AdBlue® EXTERNAL DIMENSIONS
SIDE NOZZLE HOLSTER
FRONT NOZZLE HOLSTER

S709/8
ALPHA PUMP FOR AdBlue® EXTERNAL VIE
8
1
11
3
5
2
10 6
9
7

S709/8
ALPHA PUMP FOR AdBlue®
PARTS LIST
DRG.
REF
PART DESCRIPTION PART NO. 40AB
EXTERNAL COMPONENTS
1 LCD DISPLAY UNIT ALP.DISP.PCB.3A
2 LOCK (x 2) ALP.LOCK3
3 NOZZLE HOLSTER WITH
SWITCH
ALP.NOZBOOT.A
4
DOOR KEY
209.KEY
5 OUTLET ELBOW ELB.4MFSS.T
6 SIDE ACCESS PANEL ALP.ACCPAN3
7
MOUNTING BASE
ALP.BASE3
8 TOP CAP ALP.CAP3
9 DOOR ALP.DOORASS3A
DOOR – FRONT NOZZLE
HOLSTER ALP.DOORASS.F3A
10
SIDE PANEL
ALP.SPAN.BL3
11 SIDE PANEL WITH HOSE
OUTLET
ALP.SPANH3
SIDE PANEL WITH HOSE
OUTLET – FRONT HOLSTER
ALP.SPANH.F3
INTERNAL COMPONENTS
13
DOOR STAY*
ALP.DSTAY
14 DISPLAY COVER* ALP.DISPCOV3A
15 PUMP UNIT (COMPLETE)* AB.P
16
PUMP MOUNTING FRAME (x 2)*
ALP.PFRAME3
17 PUMP MOUNTING PLATE* ALP.BKT.AB3
18 PULSE METER* FMOGABP
19
JUNCTION BOX*
ALP.DBOX3
20 RELAY (INSIDE JUNCTION
BOX)*
ALP.RELAY
*Not shown on illustration

S709/8
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: 18
th
January 2018
Equipment Details: Alpha AdBlue



Pump
ALPHA/40AB
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: EU032/4
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