TUFFA TANKS 30000VBFS Owner's manual

TUFFA
FUEL
STATIONS
Installation, Operation and Servicing Manual Version 3.0.0
Models:
1350SLBFS | 2500HBFS | 3500VBFS | 6000VBFS | 10000VBFS | 15000VBFS | 30000VBFS

1
1. Introduction 2
2. Conditions of use 2
3. Safety 3
4. Product description 4
4.1 Productidentication 4
4.2 Productspecication 5
4.3 Product dimensions 6
5. Transport & storage 13
6. Installation & commissioning 14
6.1 Installationguidelines 14
6.2 Systeminstallation 14
6.3 Systemlocation 14
6.4 Electricalrequirements 15
6.5 Electricalwiringdiagram 15
7. Operation of the system 17
7.1 Usingthesystem 17
7.2 Summaryofmainparts1350/1400/2500 17
7.3 Summaryofmainparts3500/6000/10000/15000/30000 19
7.4 Fillingdieselfuelstation 20
7.5 Dispensingdieselintovehicle 20
7.6 Equipmentcomponents 21
8. Maintenance of the TUFFA TANKS 44
8.1Systemmaintenancetasks 45
8.2 Inspection by competent person 45
8.3Internalexaminationandcleaning 45
8.4Troubleshooting 46
8.5Tankmaintenancerecord 52
8.6Fueldeliverylog 54
9. Warranty 56
10. Contact 57
11. Guarantee Registration 57
CONTENTS PAGE

23
3. Safety
PLEASE READ THIS MANUAL CAREFULLY BEFORE USE & COMPLY WITH ALL
INSTRUCTIONS BELOW.
THIS MANUAL SHOULD BE KEPT WITH THE EQUIPMENT AT ALL TIMES.
1.Themajorhazardinvolvedwithinstallingandoperatingtheunitiselectricalshock.
Thishazardcanbeavoidedifyouadheretotheproceduresinthismanualandexercise
allduecare.
2.Installationanduseofthisproductshouldonlybecarriedoutbyproperlytrainedand
approvedpersonnel.
3.PleaserefertostoragemediaMSDSwhichshouldbesuppliedbytheproprietorofthis
systemwhichwilldetailthePPErequiredforhandlingandemergencyprocedures.
4.Theuserofthisproductisresponsibleforthesafeandcorrectuseofthisproduct.
5.Thisproductisonlysuitableforstorageand/ordispensingoftheliquidmedia
referencedatthepointofsale.
1. Introduction
Thismanualcontainsspecicinstructionsandinformationrelatingtotheinstallation,
operationandmaintenanceofTu󰀨aTankssystems.
2. Conditions of use
• Readthismanualbeforeinstallingthissystem.
• Tu󰀨aTanksacceptsnoliabilityforpersonalinjuryorpropertydamageresultingfrom
workingonoradjustingtheequipmentincorrectlyorwithoutauthorisation.
• Tu󰀨aTanksacceptsnoliabilityfordirect,indirect,incidental,special,or
consequentialdamagesresultingfromfailuretofollowanywarnings,instructions,and
proceduressetoutinthismanual.
• Tu󰀨aTanksreservestherighttochangethespecicationsofitsproductsorthe
informationinthismanualwithoutnecessarilynotifyingitsusers.
• Variationsininstallationandoperatingconditionsmaya󰀨ecttheTu󰀨aTanksystems
performance.Tu󰀨aTanksmakesnorepresentationsorwarrantiesconcerningthe
performanceofthetanksystemundertheoperatingconditionsprevailingatthe
installation.
• OnlypartssuppliedbyorapprovedbyTu󰀨aTanksmustbeusedandno
unauthorisedmodicationstothehardwareorsoftwareshouldbemade.Theuseof
non-approvedpartsormodicationswillvoidallwarrantiesandapprovalsandcould
leadtohazardoussafetyconditions.
• Unlessotherwisenoted,referencestobrandnames,productnames,ortrademarks
constitutetheintellectualpropertyoftheownerthereof.
1. INTRODUCTION | 2. CONDITIONS OF USE 3. SAFETY

45
4.2 Product specication
1350SLBFS 2500HBFS 3500VBFS 6000VBFS 10000VBFS 15000VBFS 30000VBFS
Capacity 1350litres 2500litres 3500litres 6000litres 10000litres 15000litres 30000litres
Length 2680mm 2840mm - - - - 6080mm
Width 870mm 1520mm - - - - 2890mm
Diameter - - 2013mm 2550mm 2890mm 2890mm -
Height 1665 mm 1630mm 2520mm 2585 mm 2590mm 3500mm 3500mm
Cabinet depth - - 600mm 600mm 600mm 600mm 600mm
Weight (approx.) 190kgs 280kgs 350kgs 430kgs 500kgs 700kgs 1330kgs
Bund material LowerLinearDensityPolyethylene
Inner tank
material
LowerLinearDensityPolyethylene
Description Bundeddieselfuelstation
Fill point 2” BSP 2” BSP 2”BSPwithoverllpreventionvalve
Ventilation 1x3”vents 2x3”vents
Flow rate Standardowrate-52LPM(approx.)
Highowrate-72LPM(approx.)
Flowmeter Mechanicalowmeter(accuracy+/-1%)
Delivery hose 6 metres
Hose reel
(optional)
N/A Hosereelavailable
Nozzle Automaticshuto󰀨nozzle
Filtration 10micronwaterandparticulatelter
Gauge ClockGauge FMSgaugeandbundalarm(230V)
4. Product description
Tu󰀨aFuelStationsaredesignedsolelyforstorageanddispensingofdiesel.Thestatic
bundedsystemsenablesafedieselstorageanddispensinginanoutdoorenvironmentand
ensuresyoumeetallstringentfuelstorageregulations.Thehighstandardofspecication
ensuresoptimumsafetyandfunctionality.Thisproduct’sstandardspecicationisnot
approvedfortheresaleofdiesel.
4.1 Product identication
Theidenticationplateislocatedwithinthecabinetofeachsystemandwilldetailthe
capacity,serialnumber,modelnumberandyearofmanufacture.
4. PRODUCT DESCRIPTION 4. PRODUCT DESCRIPTION

67
4.3 Product dimensions
1350SLBFS
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
1350 BUNDED
DESIGNED BY CHECKED BY APPROVED BY DATE DATE
Rob Smith J Shenton J Shenton 11/06/2020 10/06/2020
ISSUE SHEET
D1 / 1
MATERIAL
LLDPE
1665 mm
870 mm
2680 mm
4. PRODUCT DESCRIPTION
2500HBFS
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
2500 BUNDED
DESIGNED BY CHECKED BY APPROVED BY DATE DATE
Rob Smith J Shenton J Shenton 11/06/2020 10/06/2020
ISSUE SHEET
D1 / 1
MATERIAL
LLDPE
2840 mm
1630 mm
1520 mm
4. PRODUCT DESCRIPTION

89
6000VBFS 3500VBFS
4. PRODUCT DESCRIPTION4. PRODUCT DESCRIPTION
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
3500 BUNDED WITH CABINET
DESIGNED BY CHECKED BY APPROVED BY DATE DATE
Rob Smith J Shenton J Shenton 11/06/2020 10/06/2020
ISSUE SHEET
D1 / 1
MATERIAL
LLDPE
2013mm
2613 mm
1200 mm
2520 mm
2000 mm
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
6000 BUNDED WITH CABINET
DESIGNED BY CHECKED BY APPROVED BY DATE DATE
Rob Smith J Shenton J Shenton 21/10/2020 21/10/2020
ISSUE SHEET
E1 / 1
MATERIAL
LLDPE
2550mm
1200 mm
2000 mm
3150 mm
2585 mm

10 11
15000VBFS
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
15000 BUNDED WITH CABINET
DESIGNED BY CHECKED BY APPROVED BY DATE DATE
Rob Smith J Shenton J Shenton 11/06/2020 10/06/2020
ISSUE SHEET
D1 / 1
MATERIAL
LLDPE
2890mm
1200 mm
3500 mm
2000 mm
3460 mm
10000VBFS
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
10000 BUNDED WITH CABINET
DESIGNED BY CHECKED BY APPROVED BY DATE DATE
Rob Smith J Shenton J Shenton 11/06/2020 10/06/2020
ISSUE SHEET
D1 / 1
MATERIAL
LLDPE
2890mm
2590 mm
1200 mm
2000 mm
3490 mm
4. PRODUCT DESCRIPTION
4. PRODUCT DESCRIPTION

12 13
4. PRODUCT DESCRIPTION
5. Transport & storage
DO NOT TRANSPORT WITH LIQUID INSIDE THE TANK
1. Duringtransportationtheiplidandcabinetdoorsaresecuredby1xRclip.TheR
clipmustbeinstalledpriortotransportation.
2. Loadingando󰀨-loadingmustbecarriedoutbyacompetentpersonusingsuitable
ratedandmaintainedequipment,eitheraforkliftwithextendedforks/tinesoracrane.Iflifting
slingsareused,theymustbeattachedtotheliftingpointsasshowninthepicturesbelow
usingasteelliftingeyeinsert.Ifliftingfrombelowuseasuitableratedforkliftwithextended
forks.Ifliftingfromaboveuseasuitableratingliftingslings/chains.
3. 1350SLBFS/2500HBFS-Liftwithmainliftingeyehighlightedinredintheimage
beloworforkliftfromtheside.
4. 3500VBFS/6000VBFS/10000VBFS/15000VBFS-Liftwithx4equalspacedlifting
bracketsashighlightedinredintheimagebeloworforkliftfromonesideusingaratchet
straptosecurethetanktotheforkliftmast.
5. Tu󰀨aFuelStationsmustneverbepushedorrolled.
6. Duringtransportandstorage,theiplidorcabinetdoorsmustbeclosedandsecured.
7. Loading,transportandstorageareasmustbesmoothandfreeofsharpedges.
5. TRANSPORT & STORAGE
30000VBFS
A ( 1 : 10 )
A
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
DESIGNED BY CHECKED BY MATERIAL DATE
Rob Smith J Shenton 01/06/2020
ISSUE SHEET
B1 / 1
WEIGH
T
30000VBFS
300 mm
2890mm
3500 mm
2000 mm
600 mm
1200 mm
6020 mm

14 15
6. Installation & commissioning
6.1 Installation guidelines
TheproprietoroftheTu󰀨aFuelStationisresponsibleforcomplyingwithalllegal
requirementsrelatingtotheinstallationanduseofthisproduct,aswellastheguidelines
issuedbylocalreghtingauthoritiesandenvironmentalauthorities.
OncetheTu󰀨aFuelStationhasbeenreceivedonsite,checkthatnodamagehasoccurred
whileintransit.Locatethetankinthedesiredlocationusingeitheracrane,forkliftorrollers.
6.2 System installation
Systemfoundation
Thesystemmustbeinstalledandfullysupportedonasmoothlevelledconcretebasebuiltin
accordancewithgoodbuildingstandardsandengineeringprinciples.Itisrecommendedthat
tanksbeinstalledonaconcretebaseatleast100mmthick.Pleaserefertodiagrambelow:
6.3 System location
Thelocationofthesystemshouldbepositionedbyaroadorpassingwithsu󰀩cientwidth,
andloadingcapacitytoaccommodateatankerdeliveringdiesel.ProvisionfortheU-turnof
atankershouldbeconsidered.Potentialobstaclesintheformoftreebranches,highvoltage
lines,orparkedvehiclesmustbeminimized.
Thespacearoundthesystemshouldallowfreeandcollision-freemovementofserved
vehicles.
Provisionshouldbemadetoprotecttankfromimpactdamage.
6. INSTALLATION & COMMISSIONING
6.4 Electrical requirements
Onlyasuitablyqualiedelectricianaccordingtoapplicableregulationsmayworkonthe
electricwiringinstallation.Thesystemcomponentsunderservice,maintenance,andrepair
workmustbedisconnectedfromthepowersupplybeforeanyworkinundertaken.
System power requirements:
230V
• 220-240Volts,50Hz+/-10%
• 20ampcircuitbreakerrecommended
• Powercablerecommendation:3Core2.5mmexcable
• Dutycycle:20minutes
• CAUTION: DO NOT RUN PUMP MOTOR WITH A CLOSED NOZZLE FOR MORE
THAN 2 MINUTES
12V/24V
• Cableclipscomepre-wired
• Dutycycle:20minutes
• CAUTION: DO NOT RUN PUMP MOTOR WITH A CLOSED NOZZLE FOR MORE
THAN 2 MINUTES
6.5 Electrical wiring diagram (230 V)
6.5.11350SLBFS/2500HBFS–KeySwitch
6. INSTALLATION & COMMISSIONING

16 17
6.5.2 3500VBFS/6000VBFS/10000VBFS/15000VBFS/30000VBFS–KeySwitch
6. INSTALLATION & COMMISSIONING
7. Operation of the system
Thesystemanditscomponentsareintendedfordieselfuelonlyandforthepurposes
describedbelow.Useofthissysteminameansotherthandescribedbelowisregardedas
mis-useofthesystem,theuserofthesystemwillbeliableforanydefectsthatoccurdueto
its unintended use.
7.1 Using the system
Theoperationandmaintenancepersonnelmustbesuitablytrainedtousethesystem,the
usermustmakesuretheyfullyunderstandtheoperationandmaintenancesectionsofthis
manual.
7.2 Summary of main parts 1350 / 2500
(230V)
7. OPERATION OF THE SYSTEM

18 19
(12V / 24V)
Clock Gauge
Water &
Particulate
Filter
Cartridge
Fill Point Mechanical
Flowmeter
Automatic Nozzle
External Pump
Quick
Disconnect
Camlocks
Delivery Hose
Suction Hose
Battery
Cable Clips
Watchman
(if selected)
7. OPERATION OF THE SYSTEM
7.3 Summary of main parts 3500 / 6000 / 10000 / 15000 / 30000
(230V)
(12V/24V)
Level Gauge &
Tank Alarm
External Pump
Mains Power
Control Panel
Water &
Particulate
Filter Cartridge
Fuel Management
System
Fill Point
Automatic Shut-Off
Nozzle
Delivery Hose
Hosereel
7. OPERATION OF THE SYSTEM
Hydrostatic Contents Gauge
External Pump
Battery Tank
Alarm
Water &
Particulate
Filter Cartridge
Mechanical
Flowmeter
Fill Point
Automatic Shut-Off
Nozzle
Delivery Hose
Quick Disconnect Camlocks
Suction Hose

20 21
7.4 Filling a Tu󰀨a Fuel Station
1. Fillingshouldbeperformedonlyunderconstantsupervisionofanauthorisedperson.
2. Thistankcanonlybelledbyatankerequippedwitha2”femaleBSPcoupling.
3. On3500/6000/10000/15000modelsbeforellingthetankwithdiesel,please
checkthelevelofthetankandmakenoteofthetanklevelbeforellingandensurethe
high-levelalarmindicatorfunctionscorrectly.
4. Fittankerdeliveryhoseto2”BSPllcouplingontank.
5. Engagetankerpumpandbegintoll.Stopllingwhendesiredamounthasbeen
dispensedintotank,orwhenhigh-levelalarmsounds.
6. Duringthetankerllalwaysobservetanklevelgaugethroughoutthedurationofthe
llingprocess.Thetankerdrivermustobservethetankbeinglledatalltimesduringthis
process.
7. Oncecompletedisconnectdeliveryhosefromtankcoupling.
7.5 Dispensing diesel into vehicle
1. Resettheowmetertotalizerto0.
2. Activatepumpusingoneofthefollowing:rockerswitch/keyswitch/auto-
operationalnozzleholster/batterycableclips.
3. Removenozzlefromnozzleholsterandinsertthenozzlecompletelyintothediesel
tankllerneck.
4. Pulltriggeronthenozzletoallowdieseltoowintothevehicledieseltank.
5. Atthistimetheowmetercounterwillstartrecordingtheow,continuerefuelinguntil
thedesiredamountisreachedorwhenthevehicledieseltankisfull.
6. Whenthefueltankisfullthenozzlewillautomaticallyswitcho󰀨.
7. Releasethetriggerofthenozzleandreplacebackintotheholster.
8. Deactivatepumpwithrockerswitch/keyswitch/autooperationalnozzleholster/
removalofbatterycableclips.
7. OPERATION OF THE SYSTEM
7.6 Equipment components
1. FMS gauge level (3500 litres models and above)
TheFuelLevelMonitoringSystemisa240vcombineddigitaltanklevelindicatorandbund
andhigh-levelalarmthatisdesignedtoprovidebothvisualandaudiblealarmswhenevera
predeterminedlevelinastoragetankisreached.TheFMSgivesacontentreadoutinboth
litresandapercentage.
a. Full alarm
Activationofthisalarmindicatesthatthetankisfull.Thisalarmisshownthroughvisual
LED’sandaudiblesiren.Note:Thisaudibleandvisualalarmwillremaintriggeredfora
shortperiodoftimeafteritsounds.Theaudiblecanbemutedusingthemutebuttononthe
keypad.THEPUMPWILLCONTINUETODISPENSEINTHISALARMMODE.
b. High level alarm
Activationofthisalarmindicatesthetankhasreachedahighcapacityandcloseattention
mustbepaidtothedieselinsidethetank.ThisalarmisshownthroughvisualLED’sand
audiblesiren.Note:Thisaudibleandvisualalarmwillremaintriggeredforashortperiodof
timeafteritsounds.Theaudiblecanbemutedusingthemutebuttononthekeypad.THE
PUMPWILLCONTINUETODISPENSEINTHISALARMMODE.
7. OPERATION OF THE SYSTEM

22 23
c. Low level alarm
Activationofthisalarmindicatesthetankhasreachedalowlevel.Thisalarmisshown
throughvisualLED’sandaudiblesiren.Note:Thisaudibleandvisualalarmwillremain
triggeredforashortperiodoftimeafteritsounds.Theaudiblecanbemutedusingthemute
buttononthekeypad.THEPUMPWILLCONTINUETODISPENSEINTHISALARMMODE.
d. Empty alarm
Activationofthisalarmindicatesthetankisemptyandneedslling.Thisalarmisshown
throughvisualLED’sandaudiblesiren.Note:Thisaudibleandvisualalarmwillremain
triggeredforashortperiodoftimeafteritsounds.Theaudiblecanbemutedusingthemute
buttononthekeypad.THEPUMPWILLCONTINUETODISPENSEINTHISALARMMODE.
e. Bund alarm
Activationofthisalarmindicatesthatthereisproductinthebundcavity.Thisalarmisshown
throughvisualLED’sandaudiblesiren.Note:Thisaudibleandvisualalarmwillremain
triggeredconstantlyuntilmutedoruntiltheproductisremoved.Theaudiblecanbemuted
usingthemutebuttononthekeypad.Intheeventofthisitisadvisedthebundcavityis
checkedanddrainedassoonaspracticable.
f. FMS Wiring diagram
7. OPERATION OF THE SYSTEM
2. Flowmeter (tted to all systems)
1.1 GENERAL INFORMATION
TheK33meterisamechanicalowmeterwithnutatingdisk,designedtoallowaprecise
measurementofDieseloilorotheruidscompatiblewiththemanufacturingmaterial.The
nutatingdiskofthemeteringchamber(seediagram1,drawing“15”),whichissetinmotion
bytheuiditself,drivesthegeartrainlocatedinthecoverofthemeterbody(drawing“8”)
whichtransmitsthemotiontothemeter(pos.“6”).Themeterisequippedwithanon-
resettablelitretotaliserandabatchregisterwhichcanberesetbymeansofaknob(Pos.“2”)
whoseunitdigitisprovidedwithmarksforthereadoutofthetenthsofalitre.
To ensure a proper and safe use of the meter it is necessary to read and follow the instructions and warnings
contained in this manual. An improper installation or use of the meter may cause damage to objects and people.
1.2 TECHNICAL DATA
MeterMechanism Nutatingdisk
FlowRate (range) 20-120litres/min
Operatingpressure (max) 3.5bar
Burst pressure (min) 28bar
Storagetemperature (range) -20+80°C
Storagehumidity (max) 95%RU
Operatingtemperature (range) -10+60°C
7. OPERATION OF THE SYSTEM

24 25
Pressurelosswithdieseloil Flowrate(l/min) 306090
Pressureloss(bar) 0.0050.20.4
Accuracyaftercalibration +/-1%
Repeatability (typical) +/-0.3%
Batchtotalreadout 3digitsheight18mm
Totaliserreadout 6digitsheight6mm
Readoutresolution 0.1litri
Connections (inlet/outlet) 1” BSP
Weight (approximate) 1.8Kg
Packagedimensions 185x185x170mm
Optionalfeatures RegistrationinUSgallonsfemale
threadedinlet/outlet1”NPT
1.3 INSTALLATION
TheK33canbeinstalledinanyposition,onrigidpipelines
orexiblehoses,directlyonpumpsortanks.Themeter
owdirectionisxedandindicatedbyanarrow.The
meterissuppliedinthestandardconguration(A).
Themeterandthecovercanberotatedby90°to90°
inrespecttothebodyinordertocarryoutthedi󰀨erent
congurationsshown(B,C,D).Theresetknobcanbe
installedeitherontherightsideorontheleftsideof
themeter.Inordertomodifythestandardconguration
followtheinstructionsgiveninsection“Disassembling
/Reassembling”.Themeterbodyisequippedwith4
blindholeswhichcanbethreaded(M5)forapossible
fastening.Ifsolidparticlesenterthemeasuringchamber
thecorrectworkingofthenutatingdiskmaybea󰀨ected.
Alwaysltertheuidbyinstallingalteronthemeterinlet
(recommendedlter400µ).
1.4 CALIBRATION
TheK33ispre-calibratedinfactorytobeusedwithDieseloil.Asspecicoperatingconditions
(suchasrealowrate,natureandtemperatureofthemeasureduid)maya󰀨ectthemeter
accuracy,are-calibrationshouldbecarriedoutaftertheinstallationhasbeencompleted.A
newcalibrationisnecessaryeachtimethemeterisdisassembledformaintenanceoperations
orwhenitisusedtomeasureuidsthatdi󰀨erfromDieseloil.
1.4 CALIBRATION PROCEDURE
1.Unscrewtheplug(seediagram1,pos.“14”).
7. OPERATION OF THE SYSTEM
2.Purgethesystem(pump,pipelines,meter)ofairbydispensinguntiltheowstreamisfull
andsteady.
3.Stoptheowbyshuttingo󰀨thenozzle,butletthepumprunning.
4.Resetthebatchregisterbymeansoftheresetknob(pos.“2”).
5.Dispenseattheowratewhichthebestaccuracyisrequiredat,byusingacalibration
containerhavingacapacitynotlowerthan20litres.Donotreducetheowinordertoreach
thegraduatedzoneofthecalibrationcontainer.Therightmethodistostartandstopthefull
owrepeatedlyuntiltherequiredllingisobtained.
6.Comparetheindicationofthecalibrationcontainer(realvalue)withtheoneofthemeter
(indicatedvalue).
-Iftheindicatedvalueishigherthantherealvalue,loosenthescrew(pos.“12”);
-Iftheindicatedvalueislowerthantherealvalue,tightenthescrew(pos.“12”).
7.Repeattheoperations4to6untilaccuracyissatisfactory.
8.Tightentheplug(pos.“14”)again.TheOringwhichthecalibrationscrewisprovidedwith,
hasthefunctiontoavoidaccidentallooseningoftheadjustmentscrewbutdoesnothaveany
sealingfunctions.Thereforeitisalwaysnecessarytoproperlyxtheplugwiththesealing
gasket(pos.“12”).
1.5 USE
AfterinstallationandcalibrationtheK33isreadytowork.Turntheresetknob(seediagram
1,pos.“12”)(clockwiseifitismountedontheleftofthemeterandanticlockwiseifitismounted
ontheright)untilthebatchregisteriscompletelyreset.Thetotalisercannotberesetinany
way.Makesurethatduringusepressuredoesnotexceedthevalueindicatedinsection
“Technicaldata”.
1.6 USE BY GRAVITY
K33canalsobeusedinfuelunitswhicharenotequippedwithpumpsandwheretheowis
generatedbythedi󰀨erenceinfuellevelbetweenthetankandthenozzleoutlet.Asareference,
asystemcomposedofatanko󰀨theground,withthemeterinstalledrightatthebottomofthe
tank,a3-mlong1’’exiblepipeandamanualnozzletypeSelf2000,guaranteesaowrate
ofapproximately30litres/minuteifthedi󰀨erenceinlevelishigherthan1.5metres.Longer
pipesornozzlesproducinghigherpressurelossesreducetheowinrespecttotheexisting
di󰀨erenceinlevel.Usebygravityisnotrecommendedwithdi󰀨erencesinlevellowerthan1
metre,astheconsequentreducedowratecausesthemetertoworkoutsideitsguaranteed
accuracyrange.Oneldcalibrationisalwaysadvisableincaseofgravityinstallations.
1.6 MAINTENANCE
NoordinarymaintenanceisrequiredprovidedthatthemeterK33isproperlyinstalledand
used.Anincorrectlteringonthemeterinletmayblockorwearoutthemeasuringchamber,
thusa󰀨ectingthemeteraccuracy.Shouldthisproblemoccur(seesection“Problem,Causes
andSolutions”)disassemblethemeasuringchamber,asshowninsection“Disassembling/
Reassembling”.
7. OPERATION OF THE SYSTEM

26 27
7. OPERATION OF THE SYSTEM
WARNING:
Before disassembling alwaysmake sure that all uid is drained from the meter and pipes connected to it.
Necessarycleaningcanbecarriedoutbymeansofasoftbrushorsmalltool(i.e.ascrewdriver).
Duringcleaningbecarefulnottodamagethechamberorthedisk.Carefullycheckthemeterand
replacethepartswhichhavesu󰀨eredanypossibledamage.Onlyusetheoriginalsparepartkits
shownindiagram1“Explodedviewandsparepartlist”.Anewcalibrationisalwaysnecessary
aftercleaningorreplacingthemeterparts.3)Themeterresetsthepresenttotalalready.
1.7DISASSEMBLINGREASSEMBLING
K33canbeeasilydisassembledintoitsmainpartswithoutremovingthebodyfromthepipes.
1.8METERUNIT
Todisassemblethemeterunitoperateasfollows:
a.Removetheresetknobbyrmlypullingitaxially.
b.Loosenthe4retainingscrews(seediagram1,pos.“7”).
c.Loosenthe2screws(pos.“5”).
Toreassembletheunitreversetheproceduredescribedabove.
1.9RESETKNOB
Tomodifytheresetknobposition:
a.Performonlytheoperationsa)andb)describedabove.
b.Takeouttheplug(seediagram1,pos.“4”)bypushingitfromtheinsidetowardstheoutsideof
thecover.
c.Fixagaintheplugontheoppositeholebyplacingitinsidethecoverandpushingitoutwards.
d.Fixagainthemetercoverandresetknob.
1.10MEASURINGCHAMBER
Toenterthemeasuringchamberoperateasfollows:
a.Disassemblethemeterunit.
b.Loosentheeightscrews(seediagram1,pos.“7”).
c.Removethebodycover(pos.“8”)togetherwiththegearunit.Duringthisoperationbecareful
nottodamagethegasket(pos.“10”).
d.Removethewholemeasuringchamber(pos.“11”)byliftingitfromthemeterbodyandatthe
sametimepullingitbacktowardstheinletinordertoremovetheOring(pos.“16”)fromitsseat
attheoutlet.Tochecktheinsideofthemeasuringchamber(pos.“15”),removetheOringand
dividethetwohalfchamberscontainingthenutatingdisk.Measuringchamber.
Toenterthemeasuringchamberoperateasfollows:
a.Disassemblethemeterunit.
7. OPERATION OF THE SYSTEM
b.Loosentheeightscrews(seediagram1,pos.“7”).
c.Removethebodycover(pos.“8”)togetherwiththegearunit.Duringthisoperationbecareful
nottodamagethegasket(pos.“10”).
d.Removethewholemeasuringchamber(pos.“11”)byliftingitfromthemeterbodyandatthe
sametimepullingitbacktowardstheinletinordertoremovetheOring(pos.“16”)fromitsseat
attheoutlet.Tochecktheinsideofthemeasuringchamber(pos.“15”),removetheOringand
dividethetwohalfchamberscontainingthenutatingdisk.
1.11GEARUNIT
Toreachthegearunitcomponents:
a.Removethecover.
b.Loosenthescrews.
c.Removetheplate.Nowallgearscanbereachedforinspection.Shouldthegasketbereplaced,
removethebevelgearfromtheshaftbypullingaxially,thenremovethegeartogetherwith
theshaft.Thegasketreplacementalwaysrequiresthereplacementofthebushprovidedwith
thesparepartkit.Toreassemblereversetheabovedescribedprocedurepayingparticular
attentionto:
•LubricatetheOringbeforeinstallation.
•Checkthatthegearunitcanrotatefreelybeforexingthecover
1.12PROBLEMS,CAUSESANDSOLUTIONS
Problem Possible cause Corrective action
Leakfromthe
shaftgasket
-Damagedgasket Remove(seesection“Gearunit”)
andreplacetheOringandthebush
Insu󰀩cient
accuracy
-Wrongcalibration Repeatcalibrationfollowingtheinstructions
insection“Measuringchamber”
-Soiledorblockedmeasuringchamber Cleanthemeasuringchamberfollowingthe
instructionsinsection“Meterunit”
-Airintheuid Locateandeliminateleaksininletlines
Reducedowrate -Cloggedorblockedmeasuringchamber Cleanthemeasuringchamberfollowingthe
instructionsinsection“Measuringchamber”
-Blockedorsoiledlter Cleanthelter

28 29
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM
3. MC Box Fuel Management Operation
MCBOXElectronicPanelsaredesignedfortheprivatedistributionoffuel(orotherliquids).
AllofthemodelsintheseriesarecharacterisedbythesameformforwhichtheMCBOXis
known:asolidmetalstructure,high-accuracymeasurementsinthedispensedproductandPC
softwarethatisdesignedforsimplicity.
Thiselectronicpanelallowsyoutocontrolandmonitorprivateusefuelconsumptionviaafuel
dispenserwithpumpandowmeter.
TheMCsystemconsistsofamulti-userpanel,dedicatedsoftwareandtheoptiontoconnecttoa
PC
The MC BOX System has the ability to:
•Switchthepumpon;
•Recogniseauthorisedusers;
•Presetthedispensequantity;
•Managethepulsemeter;
•Manageanexternallevelswitchthatturnso󰀨thepumpintheeventofminimumowlevel;
•Operateanexternalnozzleswitch;
•ConnectdirectlytoaPC;
•Connecttoanexternalprinter
Thepaneliseasytoinstallandisadequatelyprotected.Thewiringconnectionscanbeeasily
accessed.Thegroupcanalsobesuppliedwithameter,tobeinstalledtogetherwiththepump.
Specications
Panelwithdualdisplay,keyboardandi-buttonreader.
Theelectricboxcanbeopened,allowingeasyaccesstothewiring.
Maximumpowersupply:6.5amps.
Optional
•PCSoftwarewithdedicatedRSconverterori-buttonreadertoexportdata.
•I-buttonkeysforusers.
•High-accuracyovalgearowmeters.
Performance
•80or120-usercapacity(dependingonmodel),managedviapasswordori-buttonkey.
•Totalconsumptioncalculationfordenedperiodsforeachuser.
•Localmemorythatcanstoredatauntilthelast255dispenses.
•Vehicleidenticationandmileagetrackingoption.
•Dispensingdateandtimecontrol.
•Dedicatedsoftwarethatallowsyoutoprintdispensedataforeachuser.
•Abilitytomanageupto16controlpanelswithonesinglesoftware.
•KeyreaderwithUSBplugforexportingdata.
•RSconverterwithUSBplugfordirectconnectiontothePCviacable(upto1000m)
MC Box Installation
General
TheMCBOXcanbeinstalledoutdoors.Nevertheless,itisadvisabletolocateitundertheshelter
ofarooftoensurethedispenser’slongevityandprovidegreatercomfortduringrefuelinginthe
eventofbadweather.Theinstallationofthedispensermustbecarriedoutbyskilledpersonnel
andperformedaccordingtotheinstructionsprovidedinthischapter.
Electrical connections
Thepowerconnectionsmustbeworkmanlikeperformedbyskilledpersonnel,instrictcompliance
withthelawsapplicableinthecountryofinstallationandwiththeinstructionsonthewiring
diagramsinthismanual.

30 31
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM
TheMCBOXisequippedwith3junctionboxes.Thesecaneasilybeaccessedbyopeningthe
doortowherethescrewterminalsfortheexternalcableconnectionsarelocated.
Theconnectionsthatneedtobemadevaryaccordingtothemodel(ACorDC):
AC Versions:
Inputs Outputs Note
ACmainssupply ACmotorpowerthesame
voltageasthemains-
Voltage:230Vacor110Vac,
dependingonthemaximum
powerofthepluggablemotors:
•230Vacversion
=1400W
•110Vacversion
=750W
Nozzlecontact:
cleancontact:Openwith
nozzlereplacedandClosed
whennozzledispensing
Levelcontact:
cleancontact:Openwith
nozzleinnormalconditions
andClosedbelowthe
minimumowlevel
Pulsemeterinput:
cleancontactorOpen
Collectoroutputsignal,with60
Hzmaximumfrequencyand
between20%and80%duty
cycle
TheRS485datalinetothePC
(optional)
WARNING
Beforeaccessingtheelectricalparts,besurethatyouhavedisconnectedallofthegeneral
switchesthatpowero󰀨thedevice.
DC Versions:
Inputs Outputs Note
DCPowerSupply DCmotorpoweristhe
sameasthesupply
voltage
Voltage:12Vdcor
24Vac,dependingonthe
maximumpowerofthe
pluggablemotors:
•12Vdcversion
=600W
•24Vdcversion
=600W
PowerinputWITHIGNITIONON.
GiventheDCsystems’highpower
absorption,themotorshouldbe
poweredwhilethebatteryisbeing
recharged
Byremovingajumperand
insertingthe“inignition”
contactinitsplace,
theelectronicscanbe
poweredonlywhenthe
vehicleis
switchedon
Nozzlecontact:
cleancontact:Openwithnozzle
replacedandClosedwhennozzle
dispensing
Levelcontact:
cleancontact:Openwithnozzlein
normalconditionsandClosedbelow
theminimumowlevel
Pulsemeterinput:
cleancontactorOpenCollector
outputsignal,with60Hzmaximum
frequencyandbetween20%and
80%dutycycle
TheRS485datalineto
thePC(optional)

32 33
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM

34 35
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM
Commissioning
TocorrectlycommissiontheMCBOXthesequenceofoperationsindicatedbelowmustbe
followedandtheMCcontrolsystemfunctionsmustbeknown.
Electrical power supply
Oncethepowerconnectionshavebeenmade,theMCBOXcanbeenergisedbymeansofthe
masterswitchtobettedbytheinstallerontheupstreamline.SwitchingonoftheMCsystemwill
beindicatedbythelightingupofthetwobacklitLCDsttedonthefront.
NOTE:
Intheeventofcontinuouscurrentpowersupply(DC),afusesizethatisappropriatetotheDC
motor’sabsorptionlevelshouldbeintroducedtothemotorpowerline.
Forexample:
•Iftheconnectedmotorisonethatabsorbs10Amaxthena
12Adelayfuseshouldbeinserted.
•If,however,themotorabsorbs50Amax,thena60Adelay
fuseshouldbeinserted.
•Ifthefuseissmall,itcanbettedalongthecableinsidethe
junctionbox,inposition(1)(seeillustration)
•If,however,thefuseisverybig(e.g.60A)andcannot
physicallytinsidethebox,thenitcanbeinsertedalongthe
motor’spowersupplycableinposition(2)(seeillustration)
Station conguration
EveryMCBOXstationcanbeadaptedtothespecicrequirementsofthestationmanager.Todo
thistheMCcontrolsystemmustbeCONFIGURED.
WARNING
MCcongurationiscrucialandmustbedonebyskilledpersonnel.
Toperformthisoperation,theMCmanualmustbecarefullyandthoroughlyread.
Aftercompletingconguration,userPINCODEScanbeassignedtothepersonschargedwith
usingMCBOX,inaccordancewiththedetailedinformationintheMCmanual.

36 37
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM
Disengaging the “MC” system
AlltheMCBOXfunctionsarecontrolledbytheMCcontrolsystem.
TheMCsystemcanneverthelessbedisengagedforanystartupormaintenanceactivities
requiringrepeatedpumpstarting.
Inthesecase,itisoftenconvenienttosimplifypumpstartupbynothavingtoenteranycodeand
recordanydispensingdata.
Todothis,aJUMPERhasbeenttedonthecardthatpermitsswitchingfromAUTOMATICmode
(coderequesttoaccessdispensing)toMANUALmode(nocoderequest).
In MANUALmode:
•TheMC’sLCDmaybeswitchedo󰀨(onlythebacklightis
clearlyvisible)oryoumaycontinuetoseetheindicationthat
waspresentatthetimeoftransitionfromAUTOtoMAN.
•NoPINCODEisrequiredtoactivatethepump;thepump
startswhenthedispensernozzleisremovedfromitslodging
andstopswhenitisputback(naturallythisisintheevent
thatthe“nozzlecontact”functionisused).
•Theamountdispensedisnotshowninanyway.
WARNING
Before accessing the electrical parts, be sure that you have disconnected all of
the general switches that power the device.
WARNING
Thejumperisonlyaccessiblebyopeningthefrontpanelandispositionedasshowninthe
photo.Inthisoperatingmode,MCdoesnotrecordanydatarelatingtoperformeddispensing
operations.Before accessing this jumper, the voltage must be removed.
Meter calibration
BeforeusingtheMCBOXstation,checktheMETERACCURACY.
Forthispurpose,proceedasfollows:
•EnterapreviouslyenabledUSERPINcode;
•Runthefuelintoacalibratedcontainer;
•Comparethequantityofdispenseddieselfuelusingacalibratedcontainer.
IfaccuracyisNOTsatisfactory,proceedtoCALIBRATETHEMETERaccordingtothe
instructionsinthespecicmanual.
Every day use
ThankstotheMCcontrolsystem,alltheMCBOXmodelsprovideaccesstoauthorisedusersonly.
MCacknowledgesUserauthorisationbymeansoftwoalternativesystems:
•Theenteringofa4-gureSECRETCODE(PINCODE)
•Thettingofanelectronickey(OPTIONAL)
WARNING
To correctly check accuracy, always keep to the following instructions:
• Use a precision sample container, featuring a graduated scale, with a capacity of at
least 20 litres.
• Before making the check, always make sure you have eliminated all the air from the
system and then run the fuel until a full and regular ow is achieved.
• Dispense continuously at MC BOX maximum ow rate.
• Stop the ow by quickly closing the nozzle.
• Reach the graduated area of the sample container, avoiding prolonged dispensing
at low ow rate, but rather performing short dispensing operations at maximum ow
rate.
• Compare the reading provided by the container, with that provided by MC BOX, after
waiting for all the froth to disappear
WARNING
Di󰀨erences of up to 1/10 of a litre a󰀨ecting the dispensing of 20 litres of uid fall
within the guaranteed precision of +/- 0,5%.
WARNING
All the users to whom a PIN CODE is assigned must be adequately instructed and
be at least acquainted with the contents of this chapter.