Hytek ALPHA Series Instruction manual

S810/7
Technical Data
ALPHA ATEX APPROVED
DIESEL PUMP
Applies to the following models only:
-ALPHA/50A -ALPHA/50FA -ALPHA/50LA
-ALPHA/70A -ALPHA/70FA -ALPHA/70LA
-ALPHA/90A -ALPHA/90FA -ALPHA/90LA
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

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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.
PRODUCT DESCRIPTION
This pump is ATEX certified to dispense diesel or other liquids
classed as category 3 in accordance with European Regulation
No. 1272/2008. It bears the following certification marking and
number:
IMPORTANT WARNING NOTES
1. 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.
2. This pump must only be used to dispense diesel or other
liquids classed as category 3 in accordance with European
Regulation No. 1272/2008. It must not be used to dispense
petrol or any other liquid with a similar flash point.
3. Installation of this equipment and its associated tank, pipe
work and fittings should only be carried out by qualified fuel
installation engineers.
II 2 G
MANUFACTURED TO: EN13617-1
CERTIFICATE NO: CML 15ATEX9183
2503

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4. The installation must be carried out in accordance with the
requirements of EN 60079-14 the latest relevant electrical and
local authority regulations and standards.
5. 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.
CALIBRATION
The meter on this pump unit must be calibrated electronically to
ensure accuracy and reliability.

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INSTALLATION INSTRUCTIONS
1. Check you have the following items:
1 off Alpha pump
1 off delivery hose
1 off front door key
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.
NB: If the optional drip tray is to be fitted to the pump it
must be sealed to its foundation, with a suitable
elastomeric substance, to prevent leaked fuel "wicking"
back underneath the pump. To maintain the
environmental integrity of the drip tray any possible leak
path through the pump mounting holes must also be
sealed.

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PIPEWORK
5. Connect the 11/2” diameter pipe from the tank to the suction
inlet flexible connector of the pump. The inlet thread of the
flexible connector flange is 11/2” BSP taper female. 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
fuel 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.
NB:On above ground tanks an angle check valve fitted
with the appropriate spring or an anti-syphon valve must
be fitted in the suction line to prevent spillage or leakage
in the event of damage.
6. Connect the delivery hose and selected ATEX approved
nozzle to the pump outlet in accordance with the instructions
supplied with the individual components. Ensure the nylon
hose-sealing washers are in place on the hose end. It should
be hand tight plus a quarter turn.

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ELECTRICAL
7. Remove the covers from the junction box.
8. Connect a constant 220/240V AC 50 Hz supply, fused at 16
amps, to the terminal block in the junction box as shown on
the wiring details diagram.
NB:The Alpha pump must have a continual 220/240V AC
supply, even when not in use
9. If the Alpha is to be operated in conjunction with a key/card
system, remove the link in the junction box (shown on the
Alpha Installation Wiring Diagram) 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
Installation Wiring Diagram)
Live supply switched on - Pump on
Live supply switched off - Pump off
10. A pulse output for connection to key/card systems is available
from the separate terminals located in the junction box. 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
11.Ensure all the terminal screws are tight and replace the
junction box covers.

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INSTRUCTIONS FOR USE
1. Remove the nozzle from the holster.
2. Place the nozzle spout in the fuel tank.
3. Squeeze the nozzle trigger to dispense fuel.
On completion of the delivery release the trigger and replace
the nozzle in the holster.

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MAINTENANCE
The Alpha 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 pump filter
-Inspect & clean or replace nozzle filter
-Inspect & replace if necessary the V-belt
-Check motor pulley grub screw is tight
-Re-calibrate electronic display

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ALPHA BASE AND SUCTION CONNECTION DIAGRAMS
1 1/2" BSP TAPER FEMALE
THREADED STANDARD
TRIANGULAR SUCTION
FLANGE ALIGNED
WITH SUCTION HOLE
IN BASE
76.5MM DIA.
ALTERNATIVE
SUCTION HOLE
SLOTTED TO
BOTTOM OF
BASE
ALL DIMENSIONS IN MM
REAR VIEW
1 1/2" STAINLESS STEEL FLEXIBLE
CONNECTOR (SUPPLIED AS STANDARD)
22MM DIA. ALTERNATIVE
CABLE ENTRY HOLE
BASE VIEW FROM
ABOVE
FOUR 15MM DIA.
MOUNTING HOLES
SUCTION INLET
LOCATION
FRONT
32396
460
340
215
13
500
526
133
44
105
82

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ALPHA INSTALLATION WIRING 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.
REMOVE LINK FOR REMOTE KEY/CARD CONTROL
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
13 2*5
E4 N7
6
L N 8 E
220/240V CONNECTIONS
AUTH. 220-240V
INPUT PULSE
OUTPUT
13 2
COM
REL
OPT
KEY/CARD CONTROL
SYSTEM PULSE
INPUT TERMINALS
50V 0.25A MAX
COMMON
OPTO
ISOLATED
RELAY
PULSE OUTPUT CONNECTIONS

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ALPHA EXTERNAL DIMENSIONS
SIDE NOZZLE HOLSTER
ALPHA EXTERNAL DIMENSIONS
FRONT NOZZLE HOLSTER

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ALPHA SIDE ACCESS PANEL VIEW
33
20 34
25
21
ALPHA PUMP UNIT FILTER LOCATION
PUMP UNIT
FILTER LOCATION
AS VIEWED FROM
THE FRONT

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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

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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)

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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.
CALIB
CALIB
CALIB
CALIB

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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*
(*Feature coming soon)
TANK SW NOT TA.F –“Tank
empty” switch connected is standard
“normally closed” float switch*
(*Feature coming soon)
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*
(*Feature coming soon)
LEAK SW NOT TA.F –“pump leak”
switch connected is standard
“normally open” float switch*
(*Feature coming soon)
CALIB
CALIB
CALIB
CALIB

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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.
CALIB
CALIB
CALIB
CALIB
CALIB

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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.

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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

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ALPHA EXTERNAL VIEW
8
1
11
3
5
2
10 6
9
7