Tokheim Pas v3 User manual

PAS V3

Pumping Unit

Component

Technical Manual

Document Ref 903647-001

Rev - 3

08/2008

Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

Great care has been taken in the preparation of this manual however Tokheim

shall not be liable for any misunderstanding, errors and/or loss or defect

arising from the use of this manual.

Tokheim shall not be liable for damage to the product, nor for personal or

third party injury, caused by incorrect use of the product or by attempts to

maintain or to repair the product by parties other than those fully trained by

Tokheim or by its accredited third party representatives.

Please contact your nearest service department, at the relevant address

printed on the back cover of this manual, should any aspect of this manual

be unclear.

to,and residing in this manual belong to Tokheim. No part of this

document may be reproduced in any form without the express written

permission of Tokheim.

Tokheim reserves the right to apply changes to this document and the

equipment without further notice.

Issue B

Document Ref 903647-001 Rev 3 1

Component Technical Manual PAS V3 Pump for Fuel Dispensers

Date Revision Page Issue Reason

01/03/2002 1 All A Original Issue

13/04/2006 2 All B Copyright and disclaimer notice added;

contents updated; pages renumbered;

drawings redrawn; new pages inserted; revised

addresses

3 2-2 C New tech info added (min inlet vacuum)

28/08/2008 2-5 Above ground tank applications added

REVISION RECORD

2Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

This page is intentionally blank

Issue B

Document Ref 903647-001 Rev 3 3

Component Technical Manual PAS V3 Pump for Fuel Dispensers

Issue B

CONTENTS

1 GENERAL..................................................................................................................... 1-2

1.1 Definitions ............................................................................................................1-2

1.2 Configurations ......................................................................................................1-2

2 OPERATING DESCRIPTION................................................................................... 2-2

2.1 Technical Characteristics .....................................................................................2-2

2.2 Alignment of the Pump ........................................................................................2-3

2.3 Schematic Diagram of Operating Principles ........................................................2-4

2.4 Schematic Diagram References ..........................................................................2-4

2.5 Operating Description ..........................................................................................2-5

2.5.1 Pumping, Filtration & By-Pass ............................................................2-5

2.5.2 Above GroundTankApplications ........................................................2-5

2.5.3 Air Separation......................................................................................2-6

2.5.4 Outlet Valve .........................................................................................2-6

2.5.5 Recovery Chamber..............................................................................2-6

2.5.6 Vent to Atmosphere .............................................................................2-7

2.5.7 Draining of the PAS.............................................................................2-7

2.5.8 V-beltTransmission .............................................................................2-7

2.5.9 Motors..................................................................................................2-8

3 FAILURE DIAGNOSIS............................................................................................... 3-2

3.1 Failure Diagnosis ..................................................................................................3-2

3.2 Flow Charts..........................................................................................................3-3

3.2.1 No Fuel Flow .......................................................................................3-3

3.2.2 Reduced Fuel Flow ..............................................................................3-4

3.2.3 Uneven Fuel Flow................................................................................3-5

3.2.4 Closing of the Overflow Valve ............................................................3-6

3.2.5 Excessive Noise...................................................................................3-7

4 TROUBLESHOOTING .............................................................................................. 4-2

4.1 Outlet Pressure ....................................................................................................4-2

4.2 Inlet Pressure .......................................................................................................4-2

4.3 Air Vent................................................................................................................4-3

4.4 InternalAir Entry in the Pump .............................................................................4-3

4.5 External Problems up-stream the PAS ................................................................4-4

4.6 Excessive Head Loss...........................................................................................4-4

4.7 Air Entry on the Pipework to the Storage Tank...................................................4-5

5 SPARE PARTS AND MAINTENANCE TOOLS.................................................... 5-3

5.1 Frequently Used Spare Parts ...............................................................................5-3

5.2 Exploded Views and Parts Lists ..........................................................................5-4

5.2.1 Front View ...........................................................................................5-4

5.2.2 Back View ...........................................................................................5-6

5.2.3 Top View ...........................................................................................5-10

5.3 Maintenance Kits ...............................................................................................5-12

5.4 References of Specific Tools .............................................................................5-15

6 PROBLEM REPORT FORM FOR THE PAS V3 PUMP .................................... 6-2

4Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

Issue B

This page is intentionally blank

Document Ref 903647-001 Rev 3 Page 1-1

Component Technical Manual PAS V3 Pump for Fuel Dispensers

CONTENTS

1 GENERAL..................................................................................................................... 1-2

1.1 Definitions ............................................................................................................1-2

1.2 Configurations ......................................................................................................1-2

Issue B

Page 1-2 Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

1 GENERAL

1.1 Definitions

¤ PAS V3: Commercial name of the PAS version 3

There is one hydraulic block for both 80 l/min and 130 l/min flow

¤ PAS V3 80: Name used when the delivery is 80 l/min (4.8 m3/h)

The PAS is equipped with a 1kW 1400rpm motor

¤ PAS V3 130: Name used when the delivery is 130 l/min (7.8 m3/h)

The PAS is equipped with a 1.5kW 2800rpm motor

¤ Type plate:

IMPORTANT NOTE

When reporting a case of anomaly or malfunction, the name PAS V3 has to be mentioned

together with the serial number indicated on the type plate near the pump pulley (see

picture above). It is also possible to fill in a problem report (see Section 6) to report

malfunction or anomalies.

1.2 Configurations

Standard configurations of the PAS V3 80 l/min

Gas Separator PAS V3

for liquid fuel. Year:

Qmax 130 L/min Diesel Pmax 3,5 bar Pmin 2,3 bar

Qmax 80 L/min Gasoline/Diesel Pmax 3,5 bar Pmin 1,7 bar

Serial number:

OIML R117/1995-NL-01.04

Issue B

PAS V3 80

2.4 m3/h

40l/min 2.4 m3/h

40l/min

PAS V3 80

4.8m3/h

80l/min

Document Ref 903647-001 Rev 3 Page 1-3

Component Technical Manual PAS V3 Pump for Fuel Dispensers

Standard configurations of the PAS V3 130 l/min

Issue B

PAS V3 80

2.4 or 4.8m3/h

40 or 80 l/min

PAS V3 80 PAS V3 80

9.6m3/h

1680l/min

PAS V3 130

2.4 or 4.8m3/h

40 or 80 l/min 4.8m3/h

80l/min

2.4m3hr

40l/min

PAS V3 130

7.8m3/h

130l/min

Page 1-4 Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

This page is intentionally blank

Issue B

Document Ref 903647-001 Rev 3 Page 2-1

Component Technical Manual PAS V3 Pump for Fuel Dispensers

Issue B

CONTENTS

2 OPERATING DESCRIPTION................................................................................... 2-2

2.1 Technical Characteristics ..................................................................................... 2-2

2.2 Alignment of the Pump ........................................................................................ 2-3

2.3 Schematic Diagram of Operating Principles ........................................................ 2-4

2.4 Schematic Diagram References ..........................................................................2-4

2.5 Operating Description .......................................................................................... 2-5

2.5.1 Pumping, Filtration & By-Pass ............................................................ 2-5

2.5.2 Above Ground Tank Applications ........................................................2-5

2.5.3 Air Separation ......................................................................................2-5

2.5.4 Outlet Valve ......................................................................................... 2-6

2.5.5 Recovery Chamber .............................................................................. 2-6

2.5.6 Vent to Atmosphere ............................................................................. 2-6

2.5.7 Draining of the PAS............................................................................. 2-6

2.5.8 V-belt Transmission ............................................................................. 2-7

2.5.9 Motors.................................................................................................. 2-7

Page 2-2 Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

PAS type Motor power Ø of motor pulley Ø of pump pulley

PAS 80 1 kW / 1400rpm 95 mm 150 mm

PAS 130 1.5 kW / 2800rpm 71 mm 150 mm

HYDRAULIC PERFORMANCES

The hydraulic performances mentioned below are for a standard installation (one pump on

piping to the tank). The pump has a static lift of 4m, a pipe diameter of 2 inches and a

length of 40m. The fuel temperature is 20°C.

Flow rate: 40 and 80 l/min (motor of 1 kW) or

130 l/min (motor of 1.5 kW)

Pressure: 1.7 ≤P ≤3.5 bar for PAS V3 80 l/min

2.3 ≤P ≤3.5 bar for PAS V3 130 l/min

Suction capacity: vacuum pressure dry pump is 400 mbar,

vacuum pressure wet pump (with oil) is 900 mbar

Pump intake depth 0.5 to 4.5 meters

Air separator fulfils the EEC regularisation for systems without sight glass

Filters 12 or 25 μm paper mesh and 90 μm plastic mesh (can be cleaned

and re-used). The filter can easily be replaced without spillage,

and without losing the priming on the suction line due to the foot

valve in the bottom of the filter box.

Liquids fuels with a viscosity lower than 10-4 m2/s

Minimum inlet vacuum 100mB @ 80 l/min

for correct operation 150mB @ 130 l/min

2 OPERATING DESCRIPTION

2.1 Technical Characteristics

DIMENSIONS

Width x height x length 225 x 450 x 490 mm including motor, filter and mounting

bracket

Weight 37 kg

Suction pipe Ø 1.5 or 2 inches (40 l/min)

Ø2 inch (80 and 130 l/min)

Inlet of the filter housing DN Ø 40/49 mm (1.5”)

Issue C

Document Ref 903647-001 Rev 3 Page 2-3

Component Technical Manual PAS V3 Pump for Fuel Dispensers

If a tensioning roller (optional) is used, the v-belt should run in the middle of this roller. This

has to be checked during running of the pump.

ENVIRONMENTAL CONDITIONS

Climate Marine, tropical, industrial and polar

Ambient temperature range -40 °C to +55 °C

Temperature of liquid -25°C to +25°C

Relative humidity 5% to 95% non condensing

Altitude Sea level up to 2000 m

2.2 Alignment of the Pump

When installing the PAS V3 the following measures have to be taken concerning the V-

belt.

Adjust the pulleys of the motor and pump in such a way that they are positioned in one

plane. A flat plate can be used to position the pulleys correctly. In this case the plate has

to touch the pulleys at 4 points (see picture).

Issue B

Page 2-4 Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

2.3 Schematic Diagram of Operating Principles

2.4 Schematic Diagram References

1) Inlet pipe

2) Foot valve

3) Filter

4) Gear pump

5) Drain

6) Float system

7) Vent float (non overflow device)

8) Vent

9) Top vent plug

10) Recovery chamber

11) Permanent air separation leak

12) Vortex regulating valve

13) Low pressure air separation leak

14) Low pressure vortex valve

15) Outlet valve reference to atmosphere

16) By-pass

17) Vortex centrifugal inlet

Issue B

Document Ref 903647-001 Rev 3 Page 2-5

Component Technical Manual PAS V3 Pump for Fuel Dispensers

18) Air separation channel

19) High-pressure chamber

20) Drain and pressure plug

21) Outlet valve seat

22) Outlet valve

23) Outlet valve spring

24) Aeration valve

2.5 Operating Description

2.5.1 PUMPING, FILTRATION& BY-PASS

The fuel held in the tank underground is raised by the gear pump [4] and passes

through the filter [3] and the foot valve [2].

The gear pump forces the product through the vortex system [17] into the high-

pressure chamber [19].

When the flow pressure exceeds the reference pressure, adjusted by the by-

pass screw, the by-pass valve [16] opens and the excess fuel in the high-pressure

chamber [19] is channelled back to the intake. Thus, the outlet pressure is kept

constant regardless of the flow drawn off by the fuel distribution hose(s).

2.5.2 ABOVEGROUNDTANKAPPLICATIONS

The PAS V3 pump has been specifically designed to work in conjuction with

underground tanks where the fuel level inside varies between 0.5 and 4 meters

below the pump shaft.

If the fuel in the tank can rise above this level, then we do not recommend you

use the PAS V3 pump.

Should there be no other option available, then the following precautions must be

taken:

1) Install a special “Tokheim 52 Valve” between the tank and the inlet of the

pump.

For VHS applications, you are required to use 2 of these valves in parallel.

2) Install a 1 in. solenoid valve between the tank and the inlet of theTokheim 52

Valve.

For VHS applications, you are required to use 2 of these valves in parallel

The valve(s) should only be opened when the pump is running.

Note: This installation must be done in accordance with all local safety

legislation.

Issue C

Page 2-6 Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

2.5.3 AIRSEPARATION

The flow is channelled tangentially into the vortex where the shape of the inlet

[17] imparts a helical movement to the flow producing a centrifugal effect.

the heavier liquid product molecules in the flow forced by the centrifugal pressure

towards the outside walls of the vortex channel and then directed away to the

high-pressure chamber. The lighter air/vapour molecules remain trapped in the

centre of the vortex channel and are then directed away through the vortex

tube, the vortex valves into the recovery chamber.

The purpose of the vortex valves is regulating the flow at different pressures.

The pressure depends on the amount of air in the flow. From the vortex valves

the particles move into the recovery chamber [10].

The vortex body exists of two valves in parallel:

•The vortex regulating valve [12]

A piston spring loaded valve, which gives a constant headloss between the air

separation channel and the recovery chamber. This valve stays open to keep the

air separation system working at any pressure or flow.

•Low-pressure vortex valve [14]

A piston spring loaded valve, which opens when the pressure is less than 1 bar.

2.5.4 OUTLETVALVE

Once the liquid has had the air/vapour extracted, it enters the high-pressure

chamber located on the down-stream circuit after the vortex. Here a spring

loaded non-return outlet valve [22] performs the dual function of:

•An authorisation valve (opening when the pressure is sufficient),

•A non-return valve which will keep pressure on the measuring system. This is

necessary to avoid start up errors at the next pumping cycle. In the valve a

pressure overload vent limits this pressure.

An aeration valve is placed on the other side of the outlet-channel. This valve is

open on low pressure (up to 0.7 bar) and closes on higher pressure. This means

it is open on high air intakes, which will keep the pressure low and the outlet

valve closed. On lower air intakes it closes which will close the internal leakage

and increases the maximum flow. The PAS is then ready to distribute fuel when

the nozzle is opened.

2.5.5 RECOVERY CHAMBER

In the recovery chamber [10] the following flows are collected back:

- the vapour/ liquid flow from the central canal of the vortex [18]

- the flow through the aeration valve in the outlet channel [24] (only when the

pressure is < 0.7 bar)

Issue B

Document Ref 903647-001 Rev 3 Page 2-7

Component Technical Manual PAS V3 Pump for Fuel Dispensers

Together these flows, necessary for the functioning of the system, are about 8 l/

min. These flows are brought back to the pump inlet by the recovery float valve

[6].The specially designed recovery float valve maintains the liquid at a constant

level.

2.5.6 VENT TOATMOSPHERE

A vent [8], located at the highest point on the cover, maintains the recovery

chamber at atmospheric pressure.

The gas that is extracted from the central channel of the vortex is released into

the atmosphere by this vent. According to some local regulations, a pipe or hose

must be connected to this vent.

A non-overflow device [7], made by a floating valve is put in the vent channel.

NOTE:- If this vent (internal thread R 3/8”) is connected to an

atmospheric pressure equalising pipe, the pipe has to have a minimum

internal diameter of 12mm.

2.5.7 DRAININGOFTHE PAS

The PAS V3 is provided with a double drain [5] located at the lowest point of

the housing. The pump can easily be drained without spillage. Therefore the

following actions must be carried out:

•open the filter box

•remove the foot valve (to let the fuel go back to the tank underground)

•unscrew the drain [5] and pull it one level down to empty the recovery chamber

[10] in the filter box

If the fuel can not go back to the tank underground (e.g. non-return valve in the

pipeline, ground tank higher than pump), the draining is still possible by unscrewing

the drain screw [5] completely and catch the fuel in a tank.

2.5.8 V-BELTTRANSMISSION

In the new range of dispensers, Quantium T range, the motor is fixed on the

PAS support which can be adjusted in order to get the right tension. A spring

roller (optional) is also available to get the correct tension.

For the Quantium T-range the following V-belts are used:

- For 80 l/min pumps (is with a SPA 95 pulley) the V-belt has Tokheim code

number 900028-004.

- For 130 l/min pumps (is with a SPA 71 pulley) the V-belt has Tokheim code

number 900028-005.

- For all other dispenser models check the code on the old V-belt before ordering,

different V-belts may be used.

Issue B

Page 2-8 Document Ref 903647-001 Rev 3

PAS V3 Pump for Fuel Dispensers Component Technical Manual

Issue B

2.5.9 MOTORS

The power that is required is proportional to the flow rate and pressure:

•For the 80 l/min version: 1 kW at 1400 rpm

•For the 130 l/min version: 1.5 kW at 2800 rpm

The motors correspond to European safety regulations: EExd

The body of the motor must always be earthed. The motors supplied are D 230

V/50 Hz and Y 400 V/50 Hz; other specifications can be delivered on demand.

Document Ref 903647-001 Rev 3 Page 3-1