Hytek ALPHA Instruction manual

S858/4
Technical Data
ALPHA ATEX APPROVED TWIN
DIESEL PUMP WITH FUEL
CONTROL SYSTEM
Applies to ATEX Certified Alpha Twin diesel / gas oil pumps only.
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: in[email protected]
Web: www.hytekgb.com

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ENVIRONMENTAL INFORMATION
European Directives 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.
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:
II
IIII
II 2 G
MANUFACTURED TO: EN13617-1
CERTIFICATE NO: CML 15ATEX9183
2503

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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.
4. The installation must be carried out in accordance with the
requirements of EN 60079-14 and all 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. Please see page 10 for further
details.

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INSTALLATION INSTRUCTIONS
1. Check you have the following items:
1 off Alpha twin pump
2 off delivery hoses
1 off front door key
2. Open the front panels using the key provided.
3. Remove the rear panels, if necessary, and store safely.
ALPHA TWIN EXTERNAL DIMENSIONS
MOUNTING
4. Bolt the pump to a firm level foundation by means of the four
14 mm diameter-mounting holes provided.

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ALPHA TWIN BASE AND SUCTION CONNECTION
PIPEWOR
5. Connect the 11/2” diameter pipe from the tank to the suction
inlet flexible connectors of the pump. The inlet threads of the
flexible connector flanges are 11/2” BSP taper female. Seal
the joints with a suitable thread-sealing compound. Alternative
pipe work entry points, for above ground pipe work, are
provided at the rear of the pump base. Push out the plastic
cover plates 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.

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6. Connect one end of the delivery hoses into the outlet elbow.
Ensure the nylon hose-sealing washers are in place on the
hose end. It should be hand tight plus a quarter turn.
7. Screw the nozzles onto the other ends of the hoses, again
ensuring the nylon washers are in place. No other sealing
compound is necessary. Hand tight plus a quarter turn.
ELECTRICAL
8. Remove the cover from the junction box.
9. Connect two constant 220/240V AC 50 Hz supplies, fused at
16 amps, to the terminal blocks 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
10.If the Alpha is to be operated in conjunction with a key/card
system, remove the links in the junction box (shown on the
Alpha Installation Wiring Diagram) and connect so that the
control system makes and breaks the connections.
Make connection - Pump on
Break connection - Pump off
Alternatively remove the links and connect a switched live
supply (230V AC 16A max.) to each terminal 4 (shown on the
Alpha Installation Wiring Diagram)
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 separate terminals located in the junction box. This is

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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
12. Ensure all the terminal screws are tight and replace the
junction box cover.
ALPHA JUNCTION BOX WIRING DIAGRAM
PUMP 1 FC10 DISPLAY CONNECTIONS DETAILS
PUMP 1 – FC10 PUMP 2
240V AC
POWER INPUT
CONNECTOR
2345678910
BLUE
YELLOW
12V DC - RED
PULSE - GREEN
0V - BLACK
SCREEN
DATA 1 - BROWN
DATA 2 - BLUE
NOZZLE SWITCH
INPUT
PUMP PULSER
CONNS (& NOZ
SWITCH +12VDC)
RS485 DATA
CONNECTIONS
MOTOR RELAY
CONNECTIONS
0V - BLUE
12V DC - BROWN
12 3 4 5 6 7 8 9 10
12V DC - BROWN
PULSE - GREEN
0V - BLUE
SCREEN
DATA 1 - BROWN
DATA 2 - BLUE
PUMP PULSER
CONNECTIONS
RS485 DATA
CONNECTIONS
MOTOR RELAY
CONNECTIONS
0V - BLUE
12V DC - BROWN
1
INTERNAL WIRING
CONNECTIONS
SECOND PUMP CONNECTIONS
TO PUMP 2 JUNCTION BOX
(ONLY USED IF SECOND PUMP
CONNECTED)

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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
56 421 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
PUMP 2 DISPLAY CONNECTION DIAGRAM
INSTRUCTIONS FOR USE
1. See additional document for using the FC10 fuel control unit.
2. Remove the nozzle from the holster.
3. Place the nozzle spout in the fuel tank.
4. Squeeze the nozzle trigger to dispense fuel.
5. 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 filters
- Inspect & clean or replace nozzle filters
- Inspect & replace if necessary the V-belts
- Check motor pulley grub screws are tight
- Re-calibrate electronic displays

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

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PUMP 1 – FC10 FUEL CONTROL CALIBRATION
Please use the GREEN engineer’s calibration tag to calibrate
Pump 1 – FC10 Fuel Control Unit. (Stock code FC.TAGC)
PUMP 2 – ALPHA DISPLAY CALIBRATION
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.
00000.0
CALIB
VER 4.00
00000.0
CALIB
1 PULSE CHANNEL
00000.0
CALIB
LITRES
00000.0
CALIB
BACKLIGHT ON

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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)
00000.0
CALIB
1 DECIMAL PLACE
00000.0
C
ALIB
OPTO OUTPUT 10
00000.0
CALIB
TANK SW IS TA.F
00000.0
CALIB
LEAK SW IS TA.F

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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.
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

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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
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.
DISPLAY CONNECTION DIAGRAM

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USING THE FC10 FUEL CONTROL UNIT
ALPHA PUMP TERMINAL FEATURES
The Alpha Pump Terminal, pictured below is fitted into the front of the
Alpha fuel dispenser.
FEATURES:
Display: This shows pump totals as well as user information and
instructions. The display is backlit to allow the pump to be
used in all light conditions.
Keypad: Used to enter information such as odometer readings and
PIN codes.
Data Tag This is where the Data Tag is inserted by the user to
Reader Slot: initiate the dispensing of fuel.

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THE ALPHA PUMP TERMINAL IN STANDBY MODE
This is when the Alpha Pump Terminal is powered up, with the display
illuminated, but not in use.
DISPLAY INFORMATION:
Total Pump 1: This is the number shown in the top left-hand corner of
the display screen. It is the total amount of fuel dispensed
by pump 1 since installation.
Time and Date: This is shown in the centre at the top of the display screen
It will cycle between the Time & Date and the site name.
Total Pump 2: This is only active if an additional pump is connected to
the ALPHA FC10. The pump 2 total is shown in the top
right-hand corner of the display screen. It is the total
amount of fuel dispensed by pump 2 since installation.
Last These are shown in the dark coloured box in the centre
Transaction of the display screen. They include the Data Tag ID
number of the last user, the amount of fuel delivered, the
time and date the fuel was delivered and vehicle MPG.
Last Amount This is shown in large text at the bottom of the display.
Dispensed:

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FUELLING FROM THE ALPHA PUMP TERMINAL
THE FUELLING PROCEDURE:
a.) Insert Data Tag into the Data Tag Reader Slot. The display will show
the Data Tag ID number and the registration number of the vehicle the
Data Tag is allocated to.
b.) If a message for the vehicle user is stored on the system it will be
displayed. The "ENT" key on the keypad must be pressed, to
acknowledge the message, before fuel can be drawn.
c.)If entry of the vehicle's odometer reading is required the display will
show "PLEASE ENTER CURRENT ODOMETER". The last odometer
reading entered for this vehicle will also be shown if this feature has
been enabled in the Fuel Manager software. Type the current vehicle
odometer reading, on the keypad, followed by pressing the "ENT" key.
d.) If entry of a driver's identity PIN number is required the display will
show "PLEASE ENTER DRIVER ID". Type the identity PIN number of
the driver, on the keypad, followed by pressing the "ENT" key.
e.) If an additional pump is connected to the ALPHA FC10 and all the
access protocol entered has been accepted then the display will show
“PLEASE SELECT A PUMP……”. Type the number of the pump to be
used (1 or 2).
f.) "REMOVE DATA TAG" will be shown on the display.
g.) Remove the Data Tag from the Data Tag Reader Slot. The display will
now show "PLEASE FUEL AT THE PUMP".
h.) Remove the nozzle from the pump nozzle holster, place in the vehicle
fuel tank filler and draw fuel.
i.) The amount of fuel dispensed will be shown on the display.
j.) On completion of the fuel delivery replace the nozzle in the pump
nozzle holster.
k.)The amount of fuel taken will be retained on the display screen until a
Data Tag is inserted into the Data Tag Reader Slot.

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*Not shown on illustration
ALPHA
ATEX
TWIN PARTS LIST
REF PART DESCRIPTION PART NUMBER
EXTERNAL COMPONENTS
1 TOP CAP ALP.CAP3T
2
FC10 OR ALPHA LCD DISPLAY UNIT
CONTACT HYTEK
3 NOZZLE HOLSTER WITH SWITCH (X2) ALP.NOZBOOT.A OR
ALP.NOZBOOT.FC10
4
OUTLET ELB
OW (X2)
ELB.4FFCR
5A
DOOR (X2)
ALP.DOORASS3A
OR
ALP.DOOR.FC3
5B
DOOR (FRONT NOZZLE OPTION)* (X2)
ALP.DOORASS.F3A
6
MOUNTING BASE
ALP.BASE3T
7
UPPER PANEL (x 2)
ALP.UPAN3T
8A
SIDE PANEL WITH HOSE OUTLET (X2)
ALP.SPANH3
8B SIDE PANEL WITH HOSE OUTLET*
(FRONT NOZZLE OPTION) (X2)
ALP.SPANH.F3
9
LOCK (x 4)
ALP.LOCK3
OR
ALP.LOCK.FC
10
DOOR KEY
209.KEY
OR
ALP.KEY.FC
INTERNAL COMPONENTS
11
JUNCTION BOX
ALP.DBOX3T
12 RELAY (INSIDE JUNCTION BOX)*
CHECK VOLTAGE
!
ALP.RELAY (230V) OR
ALP.FC10.RELAY
(12V)
13
PULSER (X2)
PULS.30A
14 4 PISTON METER (2 REV PER LITRE) (X2) 209A.METER.REP
15 AIR SEPARATOR OUTLET FLOAT
CHAMBER (X2)*
MINIVENT
16
PUMP UNIT (COMPLETE) (X2)
209A.PASSY
17
REAR PANEL (LEFT SIDE)
ALP.SPANR3
18
PUMP MOUNTING FRAME (x 2)
ALP.PFRAME3
T
19
MOTOR
MOT.E75.ATEX
20
INLET FLANGE (X2)*
FLNG
21
DISPLAY COVER (X2)
ALP.DISPCOV3A
22
OUTLET CHECK VALVE (X2)
CHK.1A.DRILL
23
REAR PANEL (RIGHT SIDE)
ALP.SPANR3T
24
CENTRE STRUT (X2)
ALP.STRUT
25
PUMP MOUNTING PLATE (x 4)
ALP.PPLATE3
26A
PULLE
Y (50 LPM)
PULL.2C
26B
PULLEY (70 LPM)
PULL.25C
26C
PULLEY (90 LPM)
PULL.3C
27A
PULLEY BELT (50 LPM)*
VBLT.275
27B
PULLEY BELT (70 LPM)*
VBLT.28
27C
PULLEY BELT (90 LPM)*
VBLT.285
28
FLEXIBLE SUCTION CONNECTOR (X2)
TTLB
29
INLET GASKET (X2)*
GSK.TRI
30
DOOR STAY (X2)*
ALP.DSTAY3
31
SIDE ACCESS PANEL (X2)*
ALP.ACCPAN3
32
CHECK VALVE (1 PER PUMP UNIT)*
209EP.21
33
BYPASS VALVE (1 PER PUMP UNIT)*
209EP.29
34
PUMP UNIT VANES (6 PER PUMP UNIT)*
209EP.38
35
PUMP UNIT FILTER (1 PER PUMP UNIT)*
209EP.3