TECALEMIT HORNET W 85 H INOX User manual

Operating manual
HORNET
W 85 H INOX
Item Number: US108 601 200; US108 600 200; US108 600 300;
US108 601 400; US108 600 400; US108 600 600;
US108 601 201; US108 601 401

2 44 1672 103-E HORNET W 85 H INOX
Copyright
Be certain to read this operation manual before commissioning the device.
No guarantee claim exists for malfunctions and damages to the device caused by
insufficient knowledge of the operation manual.
© Tecalemit, inc. All rights reserved.
Text, graphics and layout copyright protected. Reproduction and copying, including in
part, only permitted with written permission. Technical changes reserved.
Service Hotline [phone]
[e-mail]
Document Number: 44 1672 103-E
As of: April 4, 2018

44 1672 103-E HORNET W 85 H INOX 3
Table of contents
1. Safety Instructions.............................................................................................. 4
2. Technical Description ......................................................................................... 6
2.1. Description / Designated Use ..............................................................................6
2.2. Product Variants ......................................................................................................6
2.3. Allowed Media..........................................................................................................7
2.4. Technical Information ............................................................................................7
3. Assembly Instructions........................................................................................ 8
3.1. Drum Transfer Pump with Suction Tube..........................................................9
3.2. Pump with IBC Console....................................................................................... 10
3.3. Installation Site...................................................................................................... 11
3.4. Note the Installation Location!......................................................................... 11
3.5. Temperature........................................................................................................... 11
3.6. Suction Hose........................................................................................................... 11
3.7. Conveyance Capacity .......................................................................................... 11
3.8. Electrical Connection ........................................................................................... 11
4. Commissioning / Operation.............................................................................12
4.1. Suction / Dry Running ......................................................................................... 12
4.2. Tank Procedure ..................................................................................................... 12
4.3. Meter FMT II or FMT 3 (optional) .................................................................... 12
5. Automatic pump nozzle A2003-ES ................................................................13
5.1. Technical Deskription.......................................................................................... 13
5.1.1. General Description .............................................................................. 13
5.1.2. Appropriate use ..................................................................................... 13
5.1.3. Function / Safety equipment............................................................. 14
5.1.4. Technical data......................................................................................... 14
5.2. Operating instructions ........................................................................................ 14
5.2.1. Installation instructions/ Commissioning...................................... 14
5.2.2. Operating instructions......................................................................... 14
5.3. Maintenance ........................................................................................................... 15
6. Error Message – What to do, if…? ..................................................................16
7. Maintenance.......................................................................................................16
7.1. Leak Test.................................................................................................................. 16
7.2. Cleaning the System ............................................................................................ 16
8. Replacement Parts ............................................................................................17
8.1. Replacement Parts Console ............................................................................... 17
8.2. Replacement Parts Drum Transfer Pump ..................................................... 18
8.3. Instructions for Replacing the Pump Rotor.................................................. 18
9. Disposal...............................................................................................................19
9.1. Return of batteries ............................................................................................... 19
10. Scale Image of the HORNET W 85 H INOX ...................................................19

4 44 1672 103-E HORNET W 85 H INOX
1. Safety Instructions
This device has been constructed per the current state of technology and in
accordance with the recognized technical safety regulations. Regardless, risks to the
user or third parties and/or damages to the device or other material assets could
result from its use. The instructions in this operation manual, especially the safety
instructions and the sections marked with warning signs, must thus be complied with.
Warning Signs and Symbols
The following symbols are used for especially important information in the operation
manual.
Special information regarding the efficient use of the device.
Special information and/or dos and don'ts for damage prevention.
Information and/or dos and don’ts for personal accident prevention or
comprehensive material damages.
Designated Use
This device may only be used when functioning free of technical problems and must
used according to its designated use, with full knowledge of the safety and hazard
risks and in consideration of the instruction manual! Malfunctions which could affect
safety must be remedied immediately.
The device and its components are to be used exclusively with the fluids listed and
the use designated. Any other use or use extending beyond is deemed as
undesignated. The manufacture is not liable for damages thus resulting; the operator
shall bear the risk alone.
Organizational Measures
The operation manual must always be kept accessible at the place of use! Every
person who is involved with the assembly, commissioning, maintenance and
operation of the device must have read and understood the complete operation
manual. The type label on the device and the warning signs on the device must be
heeded and kept in a fully legible condition.

44 1672 103-E HORNET W 85 H INOX 5
Qualified Personnel
The personnel for the operation, maintenance and assembly must have the
corresponding qualifications for this work. The operator must precisely regulate the
spheres of responsibility, authority and monitoring of the personnel. If the personnel
do not possess the necessary knowledge, they must be trained and instructed. In
addition, the operator must ensure that the contents of the operation manual have
been fully understood by the personnel.
Water Protection
The device is designed to handle substances hazardous to water. The valid regulations
for the place of use (e.g. water resources act, ordinance for systems with substances
hazardous to water) are to be complied with.
Hydraulics
Only personnel with special knowledge and experience with hydraulics may work on
the hydraulic parts and equipment. All wires, hoses and screws must be checked
regularly for leaks and externally detectable damages and these must be remedied
immediately.
Squirting oil can cause injuries and fires.
Note the safety guidelines valid for the product when dealing with oils, greases and
other chemical substances!
Maintenance and Repairs
In accordance with the legal regulations, only companies specialized can be hired for
work with systems for substances hazardous to water. Do not make any modification,
additions or conversions to the system which could affect its safety with the approval
of the manufacturer. Replacement parts must correspond to the technical
requirements of the manufacturer. This is always ensured when original parts are
used.
Only the manufacturer is permitted to make manipulations of any kind to the flow
meter FMT II or FMT 3 besides changing the batteries.
Electrical Energy
Work on the electrical equipment may only be conducted by a trained electrical
technician or by trained personnel under the supervision of an electrical technician as
per the electrical engineering regulations. Machines and system components which
are to undergo inspection, maintenance and repair work must be rendered current-
less. First check that these components are voltage-free, then ground and short circuit
them, as well as insulate neighboring voltage-carrying components.

6 44 1672 103-E HORNET W 85 H INOX
2. Technical Description
2.1. Description / Designated Use
Electric hybrid pump HORNET W 85 H INOX
The HORNET W 85 H INOX is a self priming electric pump.
The HORNET W 85 H INOX is intended for use in industries, factories, gas stations and
similar facilities. It is intended for the conveying and discharge of urea AUS 32 in
accordance with ISO 22241. The pump must be firmly installed on the IBC tank or
container during operation.
The HORNET W 85 H INOX and the FMT II or FMT 3 flow Meter may not be operated
with flammable and explosive fluids with a flame point below 131°F (55°C) (hazard
classes AI, AII and B). Fluids with a flame point above 131°F (55°C) (hazard class A III)
may not be pumped if they have been heated above their flame point.
The pump has no safety device to prevent automatic restarting after interruption of
the power supply.
2.2. Product Variants
The electric pump HORNET W 85 H INOX without accessories has Item no.:
US108600200 automatic stainless nozzle with catch / with console
US108600300 plastic nozzle / with console
US108600400 automatic stainless steel nozzle without catch / 40in suction tube
US108600600 plastic nozzle / 40in suction tube
US108601200 automatic stainless nozzle with catch / with console / with FMT II
meter
US108601201 automatic stainless nozzle with catch / with console / with FMT 3
meter
US108601400 automatic stainless steel nozzle without catch / 40in suction tube /
with FMT II meter
US108601401 automatic stainless steel nozzle without catch / 40in suction tube /
with FMT 3 meter

44 1672 103-E HORNET W 85 H INOX 7
2.3. Allowed Media
All variants of the HORNET W 85 H INOX pump can convey urea solution AUS 32 in
accordance with ISO 22241 and water.
No other media may be conveyed!
Please note the safety data sheet of your medium.
2.4. Technical Information
HORNET W 85 H INOX
Motor AC Motor Output 780 W
Rated Current
9.5 A
Voltage
120 V / 60 Hz
Duty Cycle 100 %
Protection
Class
IP 54
Pump Type
Hybrid Pump
Pump Volume
max. 12.5 gpm
Conveyance Pressure max. 36 psi*
(2.5 bar)*
Suction Height max. 13 in
Dimensions (HxWxD)
10 1/3”x8.1”x4 ½”
(261x206x116mm)
Suction Ports 3/4“ BSP
Environmental
Temperature
-14°F to 104°F
(-10°C to 40°C)
Pressure Ports 3/4“ BSP
Media Temperature
-20°F to 104°F
(-7°C to 40°C)
Sound Pressure Level max. 80 dB(A)
Weight
ca. 8.15 lb
(3.7 kg)
*Viscosity and system-
dependent

8 44 1672 103-E HORNET W 85 H INOX
3. Assembly Instructions
The W 85 H INOX is delivered in the following
equipment variants:
•Pump with IBC console
•Drum transfer pump
•Pump without accessories
+ Optional flow meter FMT II or FMT 3

44 1672 103-E HORNET W 85 H INOX 9
3.1. Drum Transfer Pump with Suction Tube
1. In order to suspend the nozzle valve, the
nozzle valve holder (3) must first be
placed on the pump chamber and
attached with a 2" nut (4).
2. Place the drip tube (5) (included) in the
nozzle valve holder. Now place the
nozzle valve in the drip tube.
3. Attach the suction tube (1) to the suction
side. Only tighten the suction tube hand-
tight!
4. Guide the clamping nut (2) onto the
suction tube.
5. Attach the pressure hose (7) to the hose
nozzle (6) an tighten the hose clamp.
6. Now insert the suction tube into the container
and tighten the clamping nut. Be sure that the
suction tube is completely clean, to avoid
pollution of the container content.
7. The suction tube will be inserted down to the floor
of the container and secured with the clamping
nut.
8. Secure the container against falling.
1
2
6
7
5
3
4

10 44 1672 103-E HORNET W 85 H INOX
3.2. Pump with IBC Console
1. Place the drip tube (included) under the discharge tube of the tap.
2. Screw the fully assembled dispensing tube (remove sealing plugs!) on the hose barb (3)
of the volume meter and suspend the nozzle in the holder.
3. Position the console (1) of the cover plate of
the IBC so that the console is resting on
the side.
4. Hook the belt (2) on the opposite side.
5. Now a suitable coupling can be mounted on the suction tube (4), for example a Micro
Matic©coupling. Connect the Coupling to the suction connection of the IBC. Be sure that
the coupling and the suction tube is clean, to avoid pollution of the IBC contend.
3
1
2
4

44 1672 103-E HORNET W 85 H INOX 11
3.3. Installation Site
The pump is designed for installation within building and outdoors. The installation
site should be selected so that flawless operation and maintenance are ensured. The
pump can either installed directly on the tank or drum.
The national regulations for Systems with Substances Hazardous to Water must be
complied with.
3.4. Note the Installation Location!
The suction tube will be on the bottom if the installation is correct.
In other installation locations the IP protection will be decreased and the cooling may
be reduced. The operator must prevent the penetration of water by using, for
example, an additional housing. The duty cycle and/or the maximum permissible
environmental and media temperature will be decreased in the event of reduced
cooling.
3.5. Temperature
The pump may be operated at environmental temperatures from 14 to +104°F (-10°C
to 40°C) and media temperatures from 20 to +104°F (-7°C to 40°C). Condensing
humidity must be avoided. The pump system was flushed with demineralized water
in the factory, so the pump system should not be stored at temperatures below 32°F
(0°C).
3.6. Suction Hose
The suction hose must positioned rising from the container to the pump in accordance
with the regulations (WHG and VAwS) (see also section 3.5).
3.7. Conveyance Capacity
The pump is designed for operation with tap hose DN19, nozzle A2003 and nozzle
urea.
The installation of longer tap hoses or small cross sections reduces the conveyance
capacity and may overload the pump. We recommend a max. 26´ (8m) tap hose.
3.8. Electrical Connection
The pump is operated with alternating current 120v / 60Hz. The electricity
consumption is 750W. The pump is equipped with a safety plug.

12 44 1672 103-E HORNET W 85 H INOX
4. Commissioning / Operation
The user must wear suitable protective clothing (eye protection, hand protection) is
the risk of spraying exists during operation. You can find more information on the
safety datasheet of the pump medium.
The system is rinsed with demineralized water at the factory and the storage
temperature thus may not fall below 32°F (0°C). The system must be above 41°F (5°C)
for commissioning.
The HORNET W 85 H INOX electric pump may only be operated under supervision.
4.1. Suction / Dry Running
The HORNET W 85 H INOX pump works according to the self priming hybrid pump
principle.
The suction process should be completed after a few seconds. If the pump has not
taken in any medium after ca. 30 seconds, a problem exists (e.g. suction hose is
leaking, tank is empty, suction height is too great).
If this occurs, the pump must be turned off immediately and the problem must be
remedied.
The pump has thermal dry running protection which automatically turns off the
pump. The pump must be turned off after triggering the thermal dry running detector
in order to prevent it from unintentionally starting again, as the pump will start up
again after cooling.
Please ensure that pump is not run dry for an extended period of time. For the first
use, the nozzle valve should be opened above a suitable container and then the start
switch of the pump should be pressed. The conveyance system is free of air if no air
bubbles escape the nozzle valve with the medium. This also applies for continued
suction after refilling the container or changing the container.
4.2. Tank Procedure
Turn on the pump => pump will automatic suck in the medium.
Filling the vehicle tank and/or container.
Turn off the pump; place the tap nozzle aside.
Avoid long periods of operation with a closed tap nozzle!
Please note: The minimum tap quantity is 1.3 gallons (5 l)!
4.3. Meter FMT II or FMT 3 (optional)
Please note the operation manual of the FMT II or FMT 3.

44 1672 103-E HORNET W 85 H INOX 13
5. Automatic pump nozzle A2003-ES
5.1. Technical Deskription
5.1.1. General Description
The automatic pump nozzle A2003-ES in an automatically-closing full hose nozzle for
the dispensing of fluids listed under no. 2.2 The A2003-ES automatic nozzle have
been tested in accordance with the DIN EN 13012 standard.
The standard features of the nozzle include: a safety switching-off and a covering
that protects against wear and cold conditions.
The type A2003-ES nozzle is made of stainless steel with an outlet diameter of 3/4”
(19mm)
5.1.2. Appropriate use
The automatic nozzle is state of the art manufactured and is failsafe.
However hazards can arise from this product if it is not used according to
specifications.
Each person concerned with the assembly, commissioning, maintenance and
operation of the automatic nozzle must have read and understood the entire manual.
The automatic nozzle of type A2003-ES is only to be used for dispensing aqueous
urea AUS32 as per ISO 22241 (DEF)!
Using the machine for any other purpose would constitute inappropriate use. The
manufacturer shall not be liable for any resultant losses or damages; the risk shall be
borne by the operating company alone in such cases.
Adherence to the assembly, commissioning, operating and maintenance conditions
prescribed by the manufacturer also qualifies as proper use.
The automatic nozzle may only be used on dispensing installations with motor driven
pumps. The volumetric flow of the delivery pump may not exceed 10.5 gpm (40
l/min) or fall below 3.1 gpm (12 l/min).
The zero delivery inlet pressure must not exceed 50 psi (3.5 bar). The minimum
operating pressure is 10 psi (0.7 bar). The local safety and accident prevention
regulations apply to the operation of the automatic nozzles.

14 44 1672 103-E HORNET W 85 H INOX
5.1.3. Function / Safety equipment
The closing valve of the A2003-ES automatic nozzle can only be opened manually
using the control lever. An automatic shutdown occurs as a result of negative
pressure or shaking when
- the tank is full, i.e. fuel fills the sensor jet on the outlet pipe.
- the nozzle is held vertically (see fig. B).
- the nozzle with control lever set falls to the ground.
Switching-off can also be performed manually by releasing the holding clip (if
present) on the control lever.
5.1.4. Technical data
5.2. Operating instructions
The A2003-ES automatic nozzle is ready for use. No adjustment or lubrication needs
to be carried out.
5.2.1. Installation instructions/ Commissioning
1. When installing the nozzle, do not attach tools to the nozzle or the protective
bracket. Use the wrench only on the hose connection.
2. Attach the optional hose swivel joint supplied to the nozzle, making sure to fit the
seal (flat seal or o-ring).
3. To avoid damage, do not overtighten the screwed connections. Do not use Telefon
sealing tape.
4. After completing the installation, vent the pump nozzle and check the connections
under pressure for leaks. Check the shutdown function in all possible control
lever positions.
5.2.2. Operating instructions
Smoking is generally prohibited, also when drawing off diesel and heating oil and
aqueous AUS32. Sources of ignition, such as fire, flying sparks etc., must be
eliminated.
If the A2003-ES automatic nozzle is operated with a system other than the one
supplied by us, a suitable pressure limiter must be installed because the automatic
nozzle closes with pressure (max. operating pressure 50.8 psi (3.5 bar) )!
1. Insert the outlet pipe into the tank filler pipe to the extent that it will remain
securely in the tank filler pipe (see fig. A). This also ensures that the nozzle shuts
down when the fuel tank is full. Be sure that the nozzle is completely clean, before
starting filling the tank.
Length approx. 17.7” (450mm)
Minimum operating pressure 10 psi (0.7 bar)
Zero delivery pressure of the pump max. 50 psi (3.5 bar)
Dispensing volume flow
min. 3.1 gpm (12 l/min)
max. 10.6 gpm (40 l/min) (A2003-ES)

44 1672 103-E HORNET W 85 H INOX 15
Fig. A
2. For product variants with a holding clip guide the latter towards the protective
bracket and latch the control lever.
3. Once the nozzle has automatically shut
down, tilt the nozzle towards the tank for a few seconds until the last drops have
dripped out of the outlet pipe. This is also to be recommended when the filling
procedure is ended manually.
4. If the nozzle can only be locked as shown in fig. B, it is not possible to fill the fuel
tank. The nozzle shuts down immediately. Guide the nozzle in the direction of the
arrow (see fig. B) to a position as shown in fig. A. The nozzle must be held in this
position throughout the filling procedure. Items 2 and 3 apply accordingly.
If small amount are subsequently filled manually and when filling with the control
lever locked, the volume flow may be less than the minimum allowed. In this case,
the automatic shutdown of the nozzle can no longer work reliably! The fuel tank may
be overfilled.
The filling process must be supervised even when using an automatically-closing
nozzle!
5.3. Maintenance
1. Make sure that the sensor jet on the outlet pipe is always open. The nozzle does
not work if the sensor jet is dirty. Any dirt particles can be removed using a
suitable wire.
2. Always hang up the nozzle securely after use so that it cannot fall. Handle the
automatic pump nozzle with care.
3. Greasing or oiling is not necessary.
4. The automatic nozzles A2003-ES for AUS32 use should be cleaned regularly with
warmed distilled water.
Outlet pipe
Sensor jet,
sensor pipe
Holding clip
Control lever
Protective bracket
Swivel joint
Fig. B

16 44 1672 103-E HORNET W 85 H INOX
6. Error Message – What to do, if…?
... The pump turns itself successively on and off?
The pump is running dry and automatically turns itself back on after the pump
chamber has cooled. Turn off pump and remove the cause of the dry running. Possible
causes: Empty container or improperly installed coupling.
... The bottom of the pump is leaking?
The O ring of the pump chamber or the suction ports are leaking and must be
replaced.
... The pump is leaking at the pressure ports?
Check that the screws on the pressure side are tight and reseal them if necessary.
... The pump is not sucking (e.g. first use, longer period of non-use)?
Check the suction hose and all screws on the suction side for leaks and reseal them if
needed.
... The conveyance capacity is too low?
Air is also being sucked in.
... the flow meter is clearly showing more than the dispensed quantity?
The suction hose has a leakage and the sucked air is also counted. Reseal the suction
hose and clean the coupling.
In the event of disproportionate noise, further operation is only allowed after the
cause of this has been remedied!
7. Maintenance
The HORNET W 85 H INOX is nearly maintenance-free, however, the following work
should be conducted regularly in order to ensure flawless operation.
7.1. Leak Test
The device and the other components of the system are to be checked regularly for
leaks and damages and are to be repaired if needed.
The sealing side from the quick-coupling shall be regularly cleand!
7.2. Cleaning the System
In the event of external dirt on the device, disconnect it from the electrical network
and carefully clean it with a mild household cleaning product. Do not use any
aggressive cleaning products or solvents.
!

44 1672 103-E HORNET W 85 H INOX 17
8. Replacement Parts
8.1. Replacement Parts Console
Pos. Quantity Item No. Designation
10 1 816 720 003 Pump with meter connection
20 1 816 720 004 Pump with hose connection
30 1 514 980 093 Belt with spring and hooks
40 1 515 610 012 Drip tube
50 1 814 988 019 Tap hose including
Hose clamp
Anti-kink spring
Hose shell
60 1 252 711 020 Tap valve urea without catch / without rotatable
fittings incl. WHG
70 1 252 711 021 Tap valve urea with catch / without rotatable
fittings without WHG
80 1 252 350 000 Plastic valve urea with rotatable fittings
90 1 814 980 016 Rotable fittings stainless steel
100 1 816 720 002 Suction hose
110 1 816 428 003 Pump rotor including O ring for pump chamber
INOX

18 44 1672 103-E HORNET W 85 H INOX
8.2. Replacement Parts Drum Transfer Pump
Not listed item numbers are the same as with the IBC console Pumps.
Pos. Quantity Item No. Designation
10 1 816 158 001 Suction tube with clamping nut and O ring
20 1 816 428 006 Tap valve holder including
Drip tube
IG2“ nut
30 1 209 051 000 Clamping nut
8.3. Instructions for Replacing the Pump Rotor
1. Loosen the four screws (1) at the bottom of the
pump chamber.
2. Remove the suction housing (2) and replace the
rotor (3).
3. Always replace the O ring (4) when replacing the
rotor.
4. After properly positioning the rotor and replacing
the O ring, place the suction housing back on the
pump chamber (5).
5. Now tighten the four screws with a torque of 3.0
Nm (26 lbf in).
6. The suction housing can now be fixed in a position
with the four screws on the pump chamber.
Pos. Quantity Product No. Designation
3 1 404 108 150 O ring
4 1 515 560 029 Rotor
The pump and the flow meter may only be repaired and replaced by authorized service
partners.
5
1
2
3
4

44 1672 103-E HORNET W 85 H INOX 19
9. Disposal
The device is to be emptied completely and the liquids properly disposed of in case it
is taken out of service.
The equipment is to be disposed of properly when taken permanently out of service:
- Return old metal for recycling.
- Return plastic parts for recycling.
- Return electronic waste for recycling.
The water legal regulations are to be followed.
9.1. Return of batteries
Batteries must not be disposed of with the domestic waste. Batteries can be returned
free of charge via a suitable collecting point or to the dispatch stores. Consumers are
legally obliged to return used batteries.
Batteries that contain harmful substances are marked with a crossed out dustbin (see
above) and the chemical symbol (Cd, Hg or Pb) of the heavy metal that is decisive for
the classification as containing harmful substances:
1. “Cd” stands for cadmium.
2. “Pb” stands for lead.
3. “Hg” stands for mercury.
10.Scale Image of the HORNET W 85 H INOX

20 44 1672 103-E HORNET W 85 H INOX
TECALEMIT Inc.
6324 Greens Road
Humble, Texas
77396
T
281-446-7300
F
281-619-5613
[email protected]
www.tecalemitusa.com