Piusi SUPREME BY-PASS 3000 Installation and operating instructions

Installazione, uso e manutenzione IT
by-pass 3000
BULLETINM0709EN_00
Installation, use and maintenance ENManuale di Installazione, uso e manutenzione IT
Installation, use and maintenance manual EN
BULLETINM0709ITEN_02

by-pass 3000
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EN (Translation of the original instructions)
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Bulletin M0709
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Installation, use and maintenance
CONTENTS
1 GENERAL PRECAUTIONS .................................................................................................. 40
11 SYMBOLSUSEDINTHEMANUAL..................................................................................................................... 40
12 MANUALSTORAGE................................................................................................................................................... 40
13 RIGHTSFORREPRODUCTION........................................................................................................................... 40
14 EUDECLARATIONOFCONFORMITY...............................................................................................................41
1.4.1 FACSIMILE OF THE EU DECLARATION OF CONFORMITY.................................................41
2 INSTRUCTIONS AND SAFETY NORMS.............................................................................. 42
3 TRANSPORT, HANDLING AND STORAGE.........................................................................45
31 DIMENSIONSANDWEIGHTS ............................................................................................................................... 45
32 STORAGE......................................................................................................................................................................... 46
3.2.5 AMBIENT CONDITIONS..........................................................................................................................46
4 MACHINE AND MANUFACTURER IDENTIFICATION.......................................................46
41 PLATESPOSITIONS.................................................................................................................................................... 47
5 DESCRIPTION OF MAIN PARTS..........................................................................................48
51 ELECTRICPUMPSTRUCTUREANDMAINPARTS...................................................................................... 48
5.1.1 Pump unit and electric motor .................................................................................................................48
6 TECHNICAL CHARACTERISTICS.......................................................................................50
61 PERFORMANCE.............................................................................................................................................................51
7 USE...........................................................................................................................................52
71 INTENDEDUSE..............................................................................................................................................................52
7.1.1 Fluids allowed................................................................................................................................................ 52
7.1.2 Prohibited fluids and relative hazards................................................................................................53
72 IMPROPERUSE..............................................................................................................................................................53
8 INSTALLATION ...................................................................................................................... 54
81 PRELIMINARYCHECKS ........................................................................................................................................... 54
82 PUMPPOSITIONING................................................................................................................................................. 54
83 CONSIDERATIONSCONCERNINGTHEDELIVERYANDSUCTIONLINES...................................55
8.3.1 Delivery.............................................................................................................................................................55
8.3.2 Suction..............................................................................................................................................................55
8.3.3 Accessories.....................................................................................................................................................56
84 ELECTRICALCONNECTIONS.............................................................................................................................. 56
9 FIRST START-UP AND DAILY USE........................................................................................ 58
91 FIRSTSTARTUP............................................................................................................................................................ 58
92 FIRSTPRIMING.............................................................................................................................................................60
93 DAILYUSE .......................................................................................................................................................................60
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10 MAINTENANCE..................................................................................................................... 63
101 ROUTINEMAINTENANCE...................................................................................................................................... 63
102 EXTRAORDINARYMAINTENANCE.................................................................................................................... 63
11 TROUBLESHOOTING...........................................................................................................64
111 LEDSIGNALSANDTROUBLESHOOTING .................................................................................................... 64
112 MECHANICALANDHYDRAULICPROBLEMS ............................................................................................. 65
12 SCRAPPING AND DISPOSAL................................................................................................67
13 REPLACEMENT PARTS TABLE............................................................................................ 68
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1 GENERAL PRECAUTIONS
In order to protect workers’ safety and to avoid the risk of any damage, before performing any operation,
please read and become familiar with the contents of the instruction manual.
11 SYMBOLSUSEDINTHEMANUAL
In order to signal particularly important instructions or warnings, the following symbols are used:
ELECTRICAL HAZARD
This symbol identifies the risk of electric shock from equipment powered by voltages
potentially dangerous for humans.
CAUTION
This symbol indicates accident prevention regulations addressed to operators and/or
other people concerned.
WARNING
This symbol indicates that there is a possibility of damaging the units and/or their
components.
NOTE
This symbol indicates useful information.
Read the instruction manual carefully.
12 MANUALSTORAGE
This manual must be intact and completely readable. The final users, as well as the qualified technicians
authorised to installation and maintenance must be able to view it at any time.
13 RIGHTSFORREPRODUCTION
THIS MANUAL BELONGS TO PIUSI S.p.A.
All rights for reproduction are reserved for PIUSI S.p.A.
The text cannot be used in other printed documents unless expressly authorised in written form by PIUSI
S.p.A. © PIUSI S.p.A. WHOLE OR PARTIAL REPRODUCTION OF THIS MANUAL IS FORBIDDEN.
PIUSI S.p.A. is the exclusive owner of all rights envisaged by applicable laws, including the rules concerning
copyrights. All the rights deriving from such norms belong to PIUSI S.p.A.
Reproduction, publication, editing, transcription, public disclosure, distribution, sale in any form, translation
and/or processing, loan, and any other activity concerning this manual, also partial, are reserved by law
to PIUSI S.p.A.
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14 EUDECLARATIONOFCONFORMITY
1.4.1 FACSIMILE OF THE EU DECLARATION OF CONFORMITY
The undersigned: PIUSI S.p.A
Via Pacinotti 16/A z.i. Rangavino
46029 Suzzara – Mantua – Italy
DECLARES on its own responsibility, that the equipment described below:
Description: Pump designed to dispense diesel
Model: By-pass 3000 SUPREME
Serial number: see the Lot Number on the plate affixed to the product
Year of construction: See the production year on the plate stamped on the product.
Complies with the following legislation:
-Machine Regulations
-Electromagnetic compatibility
-Electrical and electronic equipment
-Radio equipment
The technical file is at the disposal of the competent authorities in response to a motivated request made to
PIUSI S.p.A. or upon receipt of a request sent to the following
email address: [e-mail].
THE ORIGINAL DECLARATION OF CONFORMITY IS SUPPLIED SEPARATELY IN CONJUNCTION
WITH THE PRODUCT
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2 INSTRUCTIONS AND SAFETY NORMS
FIREHAZARD
If there are flammable liquids in the working area, flammable vapours may be present and
may cause fire or explosion during use.
EXPLOSION HAZARDS
To eliminate fire and explosion hazards use the equipment only in well ventilated places.
Keep work area free of debris, including rags and spilled or open containers of solvent and
gasoline. Do not plug or unplug power cords or turn lights on or off when flammable fumes
are present. Keep a working fire extinguisher in the work area.
RISKOFFIREANDEXPLOSION
This product is NOT SUITABLE for installation and use in Classified Areas subject to the
presence of potentially explosive atmospheres.
PIUSI 3000 SUPREME has not been designed to comply with the ATEX directive or to
operate in potentially explosive atmospheres or for dispensing flammable liquids with a
flash point of < 55°C / 131°F (e.g. petrol).
To avoid static electricity build-up, the metal parts of this equipment must have a protective
earth connection.
Improper installation or use of the equipment may result in danger of electric shock. All
electrical equipment in the work area must have a protective earth connection. Stop
operation immediately if static sparking occurs or if you feel a shock. Do not use the
dispenser until you have identified and rectified the issue.
You must avoid any contact between the electrical power supply and the fluid to be
pumped
Install the equipment in a sheltered location.
Do not switch on the fluid dispensing equipment with damaged electrical parts, such
as cables, or damaged hydraulic parts, such as the suction/delivery pipe or the delivery
nozzle.
Call the maintenance technicians immediately and replace all damaged parts before
using the equipment.
NOSMOKING
Do not smoke near the fuel transfer pump and do not use the pump near naked flames.
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PRECAUTIONSFORUSE
PERSONALPROTECTIONEQUIPMENTFEATURES
Wear personal protection equipment that is:
- suitable to the operations to be performed;
- resistant to the various cleaning products used.
PERSONALPROTECTIVEEQUIPMENTTOBEWORN
Safety shoes
Protective gloves
Safety glasses
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OTHERSAFETYDEVICES
INSTRUCTIONMANUAL
- Do not operate the unit when fatigued or under the influence of drugs or alcohol.
- Do not leave the work area while equipment is energised or in operation.
- Turn off the equipment when not in use.
- Do not alter or modify the equipment. Alterations or modifications may void agency
approvals and create safety hazards.
- Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot
surfaces.
- Do not twist the hose or use a stronger hose.
- Keep children and animals away from the working area.
- Respect all safety norms in force.
- Do not exceed the maximum working pressure or temperature of the component with
the lowest system rating.
- See the technical specifications in all machine manuals.
- Use liquids and solvents that are compatible with the wet parts of the unit. See the
technical specifications in all machine manuals. Read the manufacturer’s warnings for
liquids and solvents. To obtain more information about the material, request the Safety
Data Sheet (MSDS) from your MC distributor or dealer.
- Check the unit every day. Repair or replace worn or damaged parts immediately with
original manufacturer’s spare parts only.
- Make sure that the unit is classified and approved in accordance with the regulations
for the environment in which it is used.
- Use only the unit for its intended purpose. Contact your Dealer for more information.
TOXICFLUIDORFUMESHAZARD
For issues arising from the treated product with eyes, skin, inhalation and ingestion refer
to the safety data sheet of the fluid used
Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
Prolonged contact with the product may cause skin irritation; during delivery phases,
always wear protective gloves.
EQUIPMENTMISUSE
Do not use the equipment for uses other than those for which it is designed and built. All
different uses may be hazardous for property, animals, or persons.
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3 TRANSPORT, HANDLING AND STORAGE
FOREWORD
Given the reduced weight and size of the pumps, they can be handled without the need for any lifting gear.
The pumps are carefully packed before shipping.
Upon receipt, check the packaging and store in a dry place.
31 DIMENSIONSANDWEIGHTS
MODEL OVERALL WEIGHT (Kg) PACKAGING DIMENSIONS (mm)
PIUSI SUPREME Max 8 kg 230 x 160 x H160 300 x 300 x H170
400 x 400 x H200
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32 STORAGE
-Store in a dry, covered place.
-Keep the unit away from dirt and vibrations.
3.2.2 AMBIENT CONDITIONS
TYPE PIUSI SUPREME
Storage humidity: Max 90%
Storage temperature: Min -20 °C
Max +60 °C
4 MACHINE AND MANUFACTURER IDENTIFICATION
The PIUSI SUPREME stations are equipped with an identification plate attached to the frame:
- Model.
- Serial number / year of manufacture.
- Technical data.
- CE marking.
- Manual code.
CAUTION: before installing, always make sure the type of dispensing system is correct and suitable
for the available power supply (Voltage/Frequency).
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41 PLATESPOSITIONS
The dispensing system is equipped with adhesive decals containing key information for the operator. Make
sure the decals do not deteriorate or become detached from the equipment over time.
NOTE: should this occur, please contact customer service and request replacements for any
damaged or missing decals, then affix the new decals in their designated positions.
Decals are as follows:
CE plate with technical data:
Corner label plate applied on the box
FAC SIMILEFAC SIMILE
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5 DESCRIPTION OF MAIN PARTS
51 ELECTRICPUMPSTRUCTUREANDMAINPARTS
The PIUSI 3000 SUPREME, together with the BP3000 specifications, integrates dispensing management
functions, in particular:
5.1.1 Pump unit and electric motor
Made up of a BP3000 12/24V pump and an electronic controller.
PUMP
Self-priming rotary vane volumetric pump, equipped with by-pass valve.
MOTOR
Enclosed brush motor powered by low voltage direct current with protection rating IP55 according to CEI-
EN 60034-5, directly flanged to the pump casing.
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ELECTRONIC CONTROLLER
For managing dispensing operations, controlling operator access via Bluetooth interface (BLE 4.0 and
later versions) or i-Button key.
It allows users to monitor pump status by means of the interface LEDs on the top cover.
NOTE: for more detailed information on the PIUSI SUPREME Smartphone connection and
communication methods, see the manual for the PIUSI 3000 SUPREME system management App,
which can be consulted directly via the App.
NOTE: there are different types of configurations for the PIUSI 3000 SUPREME product which
allow you to enable new functions or expand the number of usable operators.
More details on configurations are available in the App manual.
Signalling LEDs
Bluetooth connection
i-Button reader
Flow meter turbine
System information
References in the error
coding table
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6 TECHNICAL CHARACTERISTICS
Signal Standard conditions Limits Note
Power supply input 12V24V DC
1. Min voltage
10V
2. Max voltage
30V
The minimum voltage is
understood to be measured at the
probes during pump operation at
maximum load (delivery closed)
Motor voltage 12V Rated current =
15 A
Electronic Key
Interface
YELLOW key (i-Button):
Enabling input from PIUSI
electronic key
Operator keys are registered
on the PIUSI SUPREME App by
means of a manual procedure.
It is possible to configure the
presence or not of said key.
Fuses F1 (VDC power supply input) 25A (delayed)
IP Protection
Rating IP 55
Working
temperature From -20° C to +50°C
Storage
temperature From -20° C to +60°C
Relative humidity < 90%
Memory storage
The Electronic Controller
can store:
-Up to 500 operators
-Up to 500 dispensing
cycles
The number of operators
depends on the Add-On package
purchased
Maximum pressure 1.2 bar
Noise level <74dB(A)
Maximum fluid
temperature
(Diesel) 50 °C
Maximum fluid
Viscosity (Diesel) 11cSt
Weight (with
cable) Max 8 kg
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61 PERFORMANCE
The performance diagram shows the expected flow rate based on back pressure.
Operating point
Flow rate Voltage Absorption 4 meters of 3/4" hose K33 flow meter Manuale nozzle Automatic nozzle
A - (Maximum flow rate) 50 l/min 12 V 15 A
24 V 8 A
B - (High flow rate) 48 l/min 12 V 16 A
24 V 8.5 A
C - (Rated conditions) 46 l/min 12 V 17 A
24 V 9 A
D - (By-pass) 012 21 Delivery closed
24 12
CAUTION: the curve refers to the following operating conditions:
Fluid: Diesel - Temperature: 20 C°
Suction conditions The pipe and position of the pump in relation to the fluid level is such that a
negative pressure of 0.3 bar is generated at the rated flow rate.
With different suction conditions, higher negative pressure values can be created which reduce the
flow rate due to the back pressure values. To achieve optimum performance it is very important to
reduce suction pressure losses to a minimum by following the instructions below:
• keep the suction pipe as short as possible;
• avoid unnecessary bends or restrictions in the pipes;
• keep the suction filter clean;
• use a pipe of suitable diameter.
Compression (bars)
Flow rate (l/min)
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7 USE
71 INTENDEDUSE
PIUSI 3000 SUPREME is a system designed to
manage fluid dispensing for private use.
Dispensing management is controlled by the PIUSI
SUPREME App.
Use for the management of other systems is neither
envisaged or permitted.
CAUTION: ambient conditions for use
Ambient temperature: min -20°C / max
+50°C.
Relative humidity: max 90%.
The temperature limits indicated apply to the
pump components and must be observed to
avoid any damage or malfunctions.
WARNING: ELECTRIC CONNECTIONS
THE SYSTEM MUST BE POWERED BY A SAFE SOURCE: BATTERY OR POWER SUPPLY UNIT
WITH SAFETY TRANSFORMER.
The rated values of the supply voltages are indicated in the table provided in the heading
“TECHNICAL SPECIFICATIONS”.
WARNING: WORK CYCLE
The pumps have been designed for continuous use.
The electronic controller progressively reduces the motor rotation speed in order to contain the
internal temperature.
7.1.1 Fluids allowed
TYPE PIUSI SUPREME
DIESEL at following VISCOSITY from 2 to 11cSt (at a temperature of 37.8°C)
in accordance with UNI EN 590
PARAFFINIC DIESEL HVO & XTL (GTL/BTL/CTL/PTL)
in accordance with standard EN 15940:2019
Flash point (FP) 55°C
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7.1.2 Prohibited fluids and relative hazards
TYPE DANGER
PETROL FIRE – EXPLOSION
FLAMMABLE LIQUIDS with FP < 55°C FIRE – EXPLOSION
LIQUIDS WITH VISCOSITY > 20 cSt MOTOR OVERLOAD
WATER PUMP OXIDATION
FOOD LIQUIDS CONTAMINATION OF THE SAME
CORROSIVE CHEMICAL PRODUCTS PUMP CORROSION - HARM TO PEOPLE
SOLVENTS FIRE - EXPLOSION - DAMAGE TO SEALS
72 IMPROPERUSE
CAUTION: it is absolutely forbidden to use mobile phones when dispensing fuel or liquids that emit
flammable vapours or that in any case create potentially explosive atmospheres or inside any area
classified as an ATEX zone as per current regulations.
Mobile phones must therefore remain outside this area or be switched off.
WARNING: only use the switch on the pump in the event of an emergency!
Do not use the switch as a standard method of stopping the dispensing process.
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NOK
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8 INSTALLATION
81 PRELIMINARYCHECKS
-Check that all components are present. Ask the manufacturer for any missing pieces.
-Check that the machine has not been damaged in any way during transport or storage.
-Carefully clean the suction and delivery ports, removing any dust or residual packaging material.
-Check that the electrical data matches the values indicated on the dataplate.
-It is advisable to install a suction filter.
82 PUMPPOSITIONING
CAUTION: THE MOTORS ARE NOT EXPLOSION-PROOF.
Do not install in areas where flammable vapours may be present.
It is the installer’s responsibility to ensure the system is fitted with the accessories needed for the
correct and safe use of the pump. Choosing accessories which are unsuitable for the use as described
above can cause damage to the pump and/or injury to people and/or pollution.
Install the pump in a well-ventilated place to avoid the build-up of flammable vapours.
The motor must be installed in such a way that correct cooling is ensured: it is advisable to leave at
least 30mm of clearance on all sides of the motor casing.
The pump must be firmly secured in place using the fixing bracket provided and the relative fixing
screws.
The pump can be installed in a horizontal or vertical position, keeping the electronics compartment
cover in a vertical position or facing upwards. This will reduce the risk of water collecting in the
electronics compartment.
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83 CONSIDERATIONSCONCERNINGTHEDELIVERYANDSUCTION
LINES
8.3.1 Delivery
The recommended delivery pipe must have a minimum internal diameter of 19mm and a maximum length of
6 metres. The combination of pipe length, pipe diameter, diesel flow rate and the line accessories installed,
can create back pressure values that exceed the maximum envisaged values resulting in a significant
reduction in the flow delivered.
In such cases, to ensure correct operation of the pump, resistance in the system must be reduced, using
shorter and/or wider diameter piping and line accessories with lower resistance (e.g. an automatic nozzle
for higher flow rates).
8.3.2 Suction
The recommended suction pipe must have a minimum internal diameter of 19mm and a maximum length
of 3 metres. Self-priming type pumps are characterized by a good suction capacity. During the start-
up phase, with the suction pipe empty and the pump primed with fluid, the electric pump unit is capable
of sucking in liquid with a maximum difference in height of 2 metres. It is important to point out that
priming can take for up to 1 minute and that if there is an automatic dispensing nozzle this may prevents the
evacuation of air from the installation and therefore impede correct priming.
CAUTION: it is always advisable to carry out priming operations without the automatic nozzle,
checking that the pump is priming correctly.
It is always advisable to install a bottom valve to prevent the suction pipe from emptying and to keep
the pump primed. In this way, subsequent start-up operations will be immediate.
When the system is in operation, the pump can work with a negative pressure at the suction port of
up to 0.5 bar, over which cavitation phenomena may occur resulting in a drop in flow rate and a rise
in the level of noise generated by the system. In view of the above, it is important to guarantee low
negative pressure at pump intake by using short pipes with a diameter that is equal to or wider than
the recommended diameter, reducing bends to a minimum and using large section intake filters and
bottom valves with the least resistance possible.
CAUTION: it is very important to keep the suction filters clean because they increase system
resistance when clogged.
The difference in height between the pump and the fluid level must be kept as low as possible and in
any case within the 2-metre limit envisaged for the priming phase. If this height is exceeded, always
install a bottom valve to allow filling of the suction pipe and use pipes with a wider diameter. In any
case, it is advisable not to install the pump with height differences exceeding 3 meters.
CAUTION: if the suction tank is higher than the pump, it is advisable to fit a siphon breaker valve to
prevent any accidental diesel leakage.
Size the installation in order to contain any overpressure caused by water hammer.
It is good plant engineering practice to install vacuum and pressure gauges immediately upstream
and downstream of the pump so that it is possible to verify that operating conditions are within the
envisaged range.
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