TUFFA TANKS AdBlue 1350SLBFSAD Owner's manual

TUFFA
ADBLUE®
STATIONS
Installation, Operation and Servicing Manual Version 2.0.0
Models:
1350SLBFSAD | 2500HBFSAD | 3500VBFSAD | 6000VBFSAD | 10000VBFSAD | 15000VBFSAD

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 9
6. Installation & commissioning 10
6.1 Installationguidelines 10
6.2 Systeminstallation 10
6.3 Systemlocation 10
6.4 Electricalrequirements 11
6.5 Electricalwiringdiagram 11
7. Operation of the system 13
7.1 Usingthesystem 13
7.2 Summaryofmainparts1350/2500 13
7.3 Summaryofmainparts3500/6000/10000/ 15000 15
7.4 FillingAdBlue®Station 17
7.5 DispensingAdBlue®intovehicle 17
7.6 Equipmentcomponents 18
8. Maintenance of the TUFFA TANKS 35
8.1Systemmaintenancetasks 35
8.2 Inspection by competent person 36
8.3Internalexaminationandcleaning 36
8.4Troubleshooting 37
8.5Tankmaintenancerecord 41
8.4AdBlue®deliverylog 43
9. Warranty 45
10. Contact 46
11. Guarantee registration 46
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refer-
enced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
AdBlue®
2500HBFS
AdBlue®
3500VBFS
AdBlue®
6000VBFS
AdBlue®
10000VBFS
AdBlue®
15000VBFS
AdBlue®
Capacity 1350litres 2500litres 3500litres 6000litres 10000litres 15000litres
Length 2680mm 2840mm - - - -
Width 870mm 1520mm - - - -
Diameter - - 2013mm 2550mm 2890mm 2890mm
Height 1665mm 1630mm 2520mm 2585mm 2590mm 3500mm
Cabinet depth - - 600mm 600mm 600mm 600mm
Weight (approx.) 190kgs 280kgs 350kgs 430kgs 500kgs 700kgs
Bund material LowerLinearDensityPolyethylene
Inner tank
material LowerLinearDensityPolyethylene
Description BundedAdBlue®FuelStation
Fill point 2”stainlesssteeldrybreakcoupling
Ventilation 1x3”screenedvent
Flow rate 40lpm(approximately)
Flowmeter Digitalbatteryoperatedturbinemeter(accuracy+/-1%)
Delivery hose 6 metres
Hose reel
(optional) N/A Hosereelavailable 8 metres - 19mm bore
Nozzle Automaticshuto󰀨nozzle
Gauge Clockgauge FMSgaugeandbundalarm(230V)
4. Product description
Tu󰀨aAdBlue®StationsaredesignedsolelyforstorageanddispensingofAdBlue®.
ThestaticbundedsystemsenablesafeAdBlue®storageanddispensinginanoutdoor
environment.Thehighstandardofspecicationensuresoptimumsafetyandfunctionality.
Thisproduct’sstandardspecicationisnotapprovedfortheresaleofAdBlue®.
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
TUFFA TANK SERVICE HISTORY
Date Signature
Technical Details
If a spill occurs:
•Observe safety precautions (e.g. no smoking)
•Stop the liquid from entering drains or
watercourses by containing it with sand or
earth
•Do not spread the liquid by hosing it down. Do
not add detergents.
•Call the Environment Agency (24 hours)
EMERGENCY HOTLINE
0800 80 70 60
Model
Capacity
Date of manufacture
Serial number
Stored product
Weight
Material LLDPE
Minimum wall thickness 5.4 mm
Bunded Yes | No
Quality check
Tuffa UK Ltd
Doveelds Industrial Estate
Derby Road, Uttoxeter
Staffordshire, ST14 8SW
Tel: [phone]
www.tuffa.co.uk
SCAN
FOR
USER
MANUAL
If a spill occurs:
•Observe safety precautions (e.g. no smoking)
•Stop the liquid from entering drains or
watercourses by containing it with sand or
earth
•Do not spread the liquid by hosing it down. Do
not add detergents.
•Call the Environment Agency (24 hours)
EMERGENCY HOTLINE
0800 80 70 60
Model
Capacity
Date of manufacture
Serial number
Stored product
Weight
Material LLDPE
Minimum wall thickness 5.4 mm
Bunded Yes | No
Quality check

67
3500VBFS AdBlue®
6000VBFS AdBlue®
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
4.3 Product dimensions
1350SLBFS AdBlue®
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
2500HBFS AdBlue®
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 DESCRIPTION4. PRODUCT DESCRIPTION

89
10000VBFS AdBlue®
15000VBFS AdBlue®
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
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
5. TRANSPORT & STORAGE4. 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. 1350SLBFSAD/2500HBFSAD-Liftwithmainliftingeyehighlightedinredinthe
imagebeloworforkliftfromtheside.
4. 3500VBFSAD/6000VBFSAD/10000VBFSAD/15000VBFSAD-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AdBlue®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.

10 11
6. Installation & commissioning
6.1 Installation guidelines
TheproprietoroftheTu󰀨aAdBlue®Stationisresponsibleforcomplyingwithalllegalrequire-
ments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AdBlue®Stationhasbeenreceivedonsite,checkthatnodamagehasoc-
curredwhileintransit.Locatethetankinthedesiredlocationusingeither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AdBlue®.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vehi-
cles.
Provisionshouldbemadetoprotecttankfromimpactdamage.
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 (230V)
6.5.11350SLBFSAdBlue®/2500HBFSAdBlue®–KeySwitch
6. INSTALLATION & COMMISSIONING6. INSTALLATION & COMMISSIONING

12 13
6.5.2 3500VBFSAdBlue®/6000VBFSAdBlue®/10000VBFSAdBlue®/
15000VBFSAdBlue®–KeySwitch
6. INSTALLATION & COMMISSIONING
7. Operation of the system
ThesystemanditscomponentsareintendedforAdBlue®onlyandforthepurposesde-
scribed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
External
Pump
Clock Gauge
Delivery Hose
Dry Break
Fill Point Automatic Nozzle
With Built-In
Flowmeter
Suction Hose
Mains Power
Control Panel

14 15
(1” top suction)
7.3 Summary of main parts 3500 / 6000 / 10000 / 15000 (230V)
7. OPERATION OF THE SYSTEM
(230V, pulsemeter)
(12V/24V)
6. INSTALLATION & COMMISSIONING
Pulsemeter Pulsemeter
Remote Display
External
Pump
Clock Gauge
Delivery Hose
Dry Break
Fill Point
Automatic Nozzle
Suction Hose
Mains Power
Control Panel
Battery
Cable Clips
External
Pump
Clock Gauge
Delivery Hose
Dry Break
Fill Point Automatic Nozzle
With Built-In
Flowmeter
Suction Hose
Clock Gauge
Isolation
Valve
Fill Point
Outlet
Level Gauge &
Tank Alarm
Fill Point
Mains
Junction
Box
Fuel Management System (if selected)
Y-Filter
Flow Meter /
Pulse Meter
Isolation
Valve
Nozzle
Hose
Hosereel
(if selected)

16 17
7.4 Filling AdBlue® 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drybreakcoupling.
3. On3500/6000/10000/15000modelsbeforellingthetankwithAdBlue®,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”drybreak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 AdBlue® 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clip.
3. RemovenozzlefromnozzleholsterandinsertthenozzlecompletelyintotheAdBlue®
tankllerneck.
4. PulltriggeronthenozzletoallowAdBlue®toowintothevehicleAdBlue®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AdBlue®tankisfull.
6. WhentheAdBlue®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
(Terminating in cabinet)
6. INSTALLATION & COMMISSIONING
Level Gauge &
Tank Alarm
Fill Point
Mains
Junction
Box
Y-Filter
Isolation
Valve

18 19
7.6 EQUIPMENT COMPONENTS
1. FMS GAUGE LEVEL (3500 | 6000 | 10000 | 15000)
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.
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us-
ing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us-
ing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. NOZZLE & INTEGRATED FLOWMETER (1350 | 2500)
A. INSTALLATION
Theautomaticnozzlesaresuppliedreadyforuse.
ThenozzlefeaturesaSWIVELhose-endtting(completewithO-ring)
usefulforconnectingtothesupplyhose.
TOENSUREPERFECTOPERATION,THEDEVICEMUSTBEUSED
TODISPENSEFLUIDSWITHCHARACTERISTICSFALLINGWITHIN
THEFOLLOWINGPARAMETERS:
-Qmin.:15l/min-Qmax:45l/min
-Pmin.:1,5bar-Pmax:3,5bar
Attention
During installation, use adequate sealants, being careful no residues
remain inside the hose.
Soasnottonegativelya󰀨ectproductoperation,couplethehose-end
ttingwiththehosewithoutusingtoolssuchaspliers,etc
Assemblywillbeeasieriftheswivelhose-endttingisalreadyttedon
thenozzle.
Makesurethehosesandthesuctiontankarewithoutthreadingscaleor
residueswhichcoulddamagethenozzleandtheaccessories
Warning
Apply adequate sealants on the male threads of the connections and
swivels
Do not use Teon tape
B. USE MODALITY
B1. MECHANICAL CHARACTERISTICS
Themainfeatureofthesenozzlesisthattheyareeasytouse.
Twooperatingmodesareavailable:
1 - Assisted Mode
Dispensebyoperatingthenozzlelever.Tointerruptdispensingmanually,
releasethelever.
2 - Automatic Mode
Usetheopeningleverlockdeviceforautomaticdispensing.
Tocontinuedispensingafterautomaticstop,thelevermustbefully
releasedbeforeproceedingtooperateitagain.
Tointerruptdispensinginmanualmode,presstheleveragain,thereby
releasingthedevice,andthenrelease.
Attention
DO NOT USE THE NOZZLE OUTSIDE THE PARAMETERS INDICATED
ON THE ”TECHNICAL SPECIFICATIONS” CHART
Dispensing is automatically interrupted thanks to the shut-o󰀨
device, which operates when the level of the liquid reaches the end
of the spout.
B2. ELECTRONIC CHARACTERISTICS
Attention
The user can choose between two di󰀨erent operating modes:
1 - Normal Mode
ModewithdisplayofPartialandTotaldispensedquantities
2 - Flow rate Mode
ModewithdisplayofFlowRate,aswellasPartialdispensedquantity.
Note:Themeterfeaturesanon-volatilememoryforstoringthedispensing
data,evenintheeventofacompletepowerbreakforlongperiods.The
measurementelectronicsandtheLCDdisplayarettedinthetoppart
ofthemeterwhichremainsisolatedfromtheuidbythemeasurement
chamberandsealedfromtheoutsidebymeansofacover.
C. MISFILLING
Premise
ModewithdisplayofPartialandTotaldispensedquantities
Operation
The“magnetswitch”isamagneticeldwithinthellernecksofthe
nozzle.Thisopensthemagnetswitchinthespout,soitisonlypossibleto
dispensefromthetankwherethemagnetadaptorisinstalled.
Attention
Nozzlesequippedwith“magnetswitch”workonlyincombinationwith
the“magnetadapter”.The“magnetadapter”isanoptiontobebought
separately.
D. PRELIMINARY CHECK
Warning
Checkthecorrectoperationofthelockdevice,accordingtothefollowing
procedure:
1.Takeagraduatedreceptaclewithacapacityof20
litres(5gal)
2.Begindispensingintothereceptacle,setting
theleverintheminimumowposition,untilthe
receptacleisfull.
3.Keepingtheleveropen,makesurethespoutis
submergedbyabout5cm(2inches).
4.Thenozzlemuststop,withaclickofthelever
5.Repeatthesameoperationswiththeleverin
medium-owand
maximum-owposition.Checkthecorrectoperation
ofthestopdeviceasdescribedabove.
6.Ifthenozzlestopsduringdispensing,checkand
reducetheow.
7.Iftheshut-o󰀨devicedoesnotbegintooperate,
checktheminimumowrateofthesystemor
replacethenozzle.
E. INITIAL START UP
Onlystartdispensingaftermakingsurethatassemblyandinstallationhave
beencorrectlyperformed.
Attention
Itisgoodpracticetoonlyoperatethenozzleleveraftermakingsurethe
spouthasbeenproperlyinsertedinthemouthofthetanktobelled.
Note
Whenusingforthersttimeandeverytimethenozzleisused,following
theconnectionofthesupplyhose,gentlyoperatethelevertoenabletheair
toescapefromthecircuit,untilnormaloperationisachieved.
Attention
Checkthecorrectoperationoftheautomaticstopdeviceoncethetankis
full.
THE FAULTY OPERATION OF THIS DEVICE COULD CAUSE THE
SPILL OF LIQUIDS THAT ARE HAZARDOUS FOR PEOPLE AND THE
ENVIRONMENT.
F. WHAT IT LOOKS LIKE
The“LCD”oftheMETERfeaturestwonumericalregistersandvarious
indicationsdisplayedtotheuseronlywhentheapplicablefunctionso
requires.
1.Partialregister(5gureswithmovingcommaFROM0.1to99999)
indicatingthevolumedispensedsincetheresetbuttonwaslastpressed
2.Indicationofbatterycharge
3.Indicationofcalibrationmode
4.Totalsregister(6gureswithmovingcommaFROM0.1to999999),that
canindicatetwotypesofTotal:
7. OPERATION OF THE SYSTEM

20 21
7. OPERATION OF THE SYSTEM
1.GeneralTotalthatcannotbereset(TOTAL)
2.Resettabletotal(ResetTOTAL)
5.Indicationoftotalmultiplicationfactor(x10/x100)
6.Indicationoftypeoftotal,(TOTAL/ResetTOTAL);
7.IndicationofunitofmeasurementofTotals:
L=LitresGal=Gallons
8.IndicationofFlowRatemode
9.IndicationofunitofmeasurementofPartial:
Qts=QuartsPts=Pints
L=LitresGal=Gallons
F1. USER BUTTONS
TheMETERfeaturestwobuttons(RESETandCAL)whichindividually
performtwo
mainfunctionsand,together,othersecondaryfunctions.
Main functions performed
-fortheRESETkey,resettingthepartialregisterandResetTotal
-fortheCALkey,enteringinstrumentcalibrationmode
Secondary functions
Usedtogether,thetwokeyspermitenteringcongurationmodewhere
thedesiredunitofmeasurementcanbeset.
Legend
CALIBRATEMEANSPERFORMINGACTIONSONTHEMETERKEYS.
BELOWISTHELEGENDOFTHESYMBOLSUSEDTODESCRIBE
THEACTIONSTOBEPERFORMED
F2. BATTERY HOUSING
K24ispoweredbytwo1.5Vstandardtypebatteries(sizeAAA).The
batteryhousingiseasilyaccessibleandisclosedbyacoverwithseal.
Everythingiseasilyremovablebytakingo󰀨therubberprotectionaround
thenozzleandlooseningthescrewswhichsecurethecover.
G. DAILY USE
Theonlyoperationsthatneedtobedonefordailyusearepartialand/
orresettabletotalregisterresetting.Theusershoulduseonlythe
dispensingsystemofK24.Occasionallythemetermayneedtobe
conguredorcalibrated.Todoso,pleaserefertotherelevantchapters
Belowarethetwotypicalnormaloperationdisplays.Onedisplaypage
showsthepartialandresettotalregisters.Theothershowsthepartial
andgeneraltotal.Switchoverfromresettabletotaltogeneraltotal
displayisautomaticandtiedtophasesandtimesthatareinfactoryset
andcannotbechanged.
Note:
6digitsareavailableforTotals,plustwoiconsx10/x100.The
incrementsequenceisthefollowing:
0.0->99999.9->999999->100000x10->999999x10->100000x
100->999999x100
G1. DISPENSING IN NORMAL MODE
Normalmodeisthestandarddispensing.Whilethecountismade,the
partialandresettabletotalaredisplayedatthesametime(resettotal).
Warning: Shouldoneofthekeysbeaccidentallypressedduring
dispensing,thiswillhavenoe󰀨ect.
Standby
Afewsecondsafterdispensinghasended,onthelowerregister,the
displayswitchesfromresettabletotaltogeneraltotal:thewordreset
abovethewordtotaldisappears,andtheresettotalisreplacedbythe
generaltotal.Thissituationiscalledstandbyandremainsstableuntilthe
useroperatestheK24again.
G1.1 PARTIAL RESET (NORMAL MODE)
Thepartialregistercanberesetbypressingthe
resetkeywhenthemeterisinstandby,meaning
whenthedisplayscreenshowstheword“TOTAL”.
Afterpressingtheresetkey,duringreset,the
displayscreenrstofallshowsallthelit-updigits
andthenallthedigitsthatarenotlitup.
Attheendoftheprocess,adisplaypageisrstof
allshownwiththeresetpartialandtheresettotal
and,afterafewmoments,theresettotalis
replacedbythenonresettableTotal.
G1.2 RESETTING THE RESET TOTAL
Theresettotalresettingoperationcanonlybe
performedafterresettingthepartialregister.The
resettotalcaninfactberesetbypressingthereset
keyatlengthwhilethedisplayscreenshowsreset
totalasonthefollowingdisplaypage:
Schematically,thestepstobetakenare:
1.Waitforthedisplaytoshownormalstandby
displaypage(withtotalonlydisplayed)
2.Presstheresetkeyquickly
3.Themeterstartstoresetthepartial
4.Whilethedisplaypageshowingtheresettotalis
displayed
Presstheresetkeyagainforatleast1second
5.Thedisplayscreenagainshowsallthesegments
ofthedisplayfollowedbyalltheswitched-o󰀨
segmentsandnallyshowsthedisplaypagewhere
theresetResetTotalisshown.
G2. DISPENSING WITH FLOW RATE MODE
DISPLAY
Itispossibletodispenseuid,displayingatthesame
time:
1.Thedispensedpartial
2.TheFlowRatein[PartialUnit/minute]asshownon
thefollowingdisplaypage:
Procedure for entering this mode:
1.WaitfortheRemoteDisplaytogotoStandby,meaningthedisplay
screenshowsTotalonly
2.QuicklypresstheCALkey.
3.Startdispensing
Theowrateisupdatedevery0.7seconds.Consequently,thedisplay
couldberelativelyunstableatlowerowrates.Thehighertheowrate,
themorestablethedisplayedvalue.
ATTENTION
Theowrateismeasuredwithreferencetotheunitofmeasurementof
thePartial.Forthisreason,incaseoftheunitofmeasurementofthe
PartialandTotalbeingdi󰀨erent,asintheexampleshownbelow,it
shouldberememberedthattheindicatedowraterelatestotheunit
ofmeasurementofthepartial.Intheexampleshown,theowrateis
expressedinQts/min.
Theword“Gal”remainingalongsidetheowratereferstotheregisterof
7. OPERATION OF THE SYSTEM
theTotals(ResetorNONReset)whichareagaindisplayedwhenexiting
fromtheowratereadingmode.
Toreturnto“Normal”mode,presstheCALkeyagain.Ifoneofthetwo
keysRESETorCALisaccidentallypressedduringthecount,thiswill
havenoe󰀨ect.
ATTENTION
Eventhoughinthismodetheyarenotdisplayed,boththeResetTotal
andtheGeneralTotal(Total)increase.Theirvaluecanbechecked
afterdispensinghasterminated,returningto“Normal”mode,by
quicklypressingCAL.
G2.1 PARTIAL RESET (FLOW RATE MODE)
ToresetthePartialRegister,nishdispensingand
waitfortheRemoteDisplaytoshowaFlowRateof
0.0asindicatedintheillustrationthenquicklypress
RESET
H. CALIBRATION
H1. WHY CALIBRATE?
Whenworkinginextremeoperatingorowconditions,(closeto
minimumormaximumacceptablerangevalues),itmaybeagoodidea
tocalibrateintheeld,intherealconditionsinwhichtheproducthasto
work.
H2. DEFINITIONS
CALIBRATION FACTOR OR “K-FACTOR”:
Multiplicationfactorappliedbythesystemtotheelectricalpulses
received,totransformtheseintomeasureduidunit.
Factory-setdefaultfactor.Itisequalto1,000.Thiscalibrationfactor
ensuresutmostprecisioninthefollowingoperatingconditions:
Fluidwater/ureasolutionorliquidfoodproductsTemperature:20°C
Flowrate:10-30ltr/min
Evenafteranychangeshavebeenmadebytheuser,thefactorykfactor
canberestoredbymeansofasimpleprocedure
USER K FACTOR:
Customizedcalibrationfactor,meaningmodiedycalibration.
H3. KEY
LEGEND:CALIBRATEMEANSPERFORMINGACTIONSONTHE
METERKEYS.BELOWISTHELEGENDOFTHESYMBOLSUSEDTO
DESCRIBETHEACTIONSTOBEPERFORMED.
H4. CALIBRATION MODE
Why calibrate?
1 Displaythecurrentlyusedcalibrationfactor:
2 Returntofactorycalibration(FactoryKFactor)afteraprevious
 calibrationbytheuser
3 Changethecalibrationfactorusingoneofthetwopreviously
 indicatedprocedures
TwoproceduresareavailableforchangingtheCalibrationFactor:
1 In-FieldCalibration,performedbymeansofadispensing 
 operation
2 DirectCalibration,performedbydirectlychangingthe 
 calibrationfactor
Incalibrationmode,thepartialandtotaldispensedquantitiesindicatedon
thedisplayscreentakeondi󰀨erentmeaningsaccordingtothecalibration
procedurephase.
H4.1 DISPLAY OF CURRENT CALIBRATION FACTOR AND
RESTORING FACTORY FACTOR
BypressingtheCALkeywhiletheapplianceisin.
Standby,thedisplaypageappearsshowingthe
currentcalibrationfactorused.Ifnocalibrationhas
everbeenperformed,orthefactorysettinghas
beenrestoredafterpreviouscalibrations,the
followingdisplaypagewillappear:Theword“Fact”
abbreviationfor“factory”showsthatthefactory
calibrationfactorisbeingused.
If,ontheotherhand,calibrationshavebeenmade
bytheuser,thedisplaypagewillappearshowing
thecurrentlyusedcalibrationfactor(inourexample
0,998).Theword“user”indicatesacalibration
factorsetbytheuserisbeingused.
Theowchartalongsideshowstheswitchoverlogicfromonedisplaypage
toanother.Inthiscondition,theResetkeypermitsswitchingfromUser
factortoFactoryfactor.
Toconrmthechoiceofcalibrationfactor,quicklypressCALwhile“User”or
“Fact”aredisplayed.
Aftertherestartcycle,theK24usesthecalibrationfactorthathasjustbeen
conrmed.
ATTENTION
WhentheFactoryFactorisconrmd,theoldUserfactorisdeletedfrom
thememory.
H4.2 IN FIELD CALIBRATION
Thisprocedurecallsfortheuidtobedispensedintoagraduatedsample
containerinrealoperatingconditions(owrate,viscosity,etc.)requiring
maximumprecision.
ATTENTION
ForcorrectK24calibration,itismostimportantto:
1.WhentheFactoryFactorisconmed,theoldUserfactorisdeletedfrom
thememory
2.UseapreciseSampleContainerwithacapacityofnotlessthan5litres,
featuringanaccurategraduatedindicator.
3.Ensurecalibrationdispensingisdoneataconstantwrateequivalentto
thatofnormaluse,untilthecontainerisfull;
4.Notreducethewratetoreachthegraduatedareaofthecontainer
duringthenaldispensingstage(thecorrectmethodduringthenal
stagesofsamplecontainerllingonsistsinmakingshorttop-upsatnormal
operationowrate);

22 23
7. OPERATION OF THE SYSTEM
5.Afterdispensing,waitafewminutestomakesureanyairbubblesare
eliminatedfromthesamplecontainer;onlyreadtheRealvalueatthe
endofthisstage,duringwhichthelevelinthecontainercoulddrop.
6.Carefullyfollowtheprocedureindicatedbelow
H4.2.1 IN FIELD CALIBRATION PROCEDURE
ACTION DISPLAY
1 NONE
NEXTinStandby
2 LONG CAL key keying
TheNEXTenterscalibrationmode,
shows<<CAL>>anddisplaysthecali-
brationfactorinuseinsteadofpartial.
Thewords“Fact”and“USER”indicate
whichofthetwofactors(factoryor
user)iscurrently
in use.
Important:Thisfactoristhatwhichthe
instrumentalsousesforeld
calibrationmeasurementoperations.
3 LONG RESET key keying
TheNEXTshows“CAL”andthepartial
atzero.TheNEXTisreadyto
performin-eldcalibration.
4 DISPENSING INTO SAMPLE
CONTAINER
Withoutpressinganykey,startdis-
pensingintothesamplecontainer.
Dispensingcanbeinterruptedand
startedagainatwill.Continuedis-
pensinguntiltheleveloftheuidin
thesamplecontainerhasreachedthe
graduatedarea.Thereisnoneedto
reachapresetquantity.
5 SHORT RESET key keying
TheNEXTisinformedthatthecalibra-
tiondispensingoperationisnished.
Makesuredispensingiscorrectlyn-
ishedbeforeperformingthisoperation.
TocalibratetheNEXT,thevalueindi-
catedbythepartialtotaliser(example
9.800)mustbeforcedtotherealvalue
markedonthegraduatedsample
container.Inthebottomleftpartofthe
displayanarrowappears(upwards
anddownwards),thatshowsthedirec-
tion(increaseordecrease)ofthevalue
changedisplayedwhenthefollowing
operations6or7areperformed.
ACTION DISPLAY
6 SHORT RESET key keying
Thearrowchangesdirection.The
operationcanberepeatedtoalternate
thedirectionofthearrow.
7 SHORT/LONG CAL key keying
Theindicatedvaluechangesinthe
directionindicatedbythearrow
-oneunitforeveryshortCALkey
keying
-continuallyiftheCALkeyiskept
pressed.Thespeedincreaserises
bykeepingthekeypressed.Ifthe
desiredvalueisexceeded,repeatthe
operationsfrompoint(6).
8LONG RESET key keying
TheNEXTisinformedthatthe
calibrationprocedureisnished.
Beforeperformingthisoperation,make
suretheINDICATEDvalueisthesame
astheREALvalue.
TheNEXTcalculatesthenewUSERK
FACTOR;thiscalculationcould
requireafewseconds,dependingon
thecorrectiontobemade
ATTENTION:Ifthisoperationis
performedafteraction(5),without
changingtheindicatedvalue,the
USERKFACTORwouldbethesame
astheFACTORYKFACTOR,thusit
isignored.
9 NO OPERATION
Attheendofthecalculation,thenew
USERKFACTORisshownforafew
seconds,afterwhichtherestartcycle
isrepeatedtonallyachievestandby
condition.
IMPORTANT:Fromnowon,the
indicatedfactorwillbecomethe
calibrationfactorusedbytheNEXT
andwillcontinuetoremainsucheven
afterabatterychange.
10 NO OPERATION
TheNEXTstoresthenewwork
calibrationfactorandisreadyto
begindispensing,usingtheUSERK
FACTORthathasjustbeencalculated.
H4.3 DIRECT MODIFICATION OF K FACTOR
IfnormalNEXToperationshowsameanpercentageerror,thiscanbe
correctedbyapplyingtothecurrentlyusedcalibrationfactoracorrection
ofthesamepercentage.Inthiscase,thepercentagecorrectionofthe
USERKFACTORmustbecalculatedbytheoperatorinthefollowingway:
New cal. Factor = Old Cal Factor * (100-E%)
100
Example:
Errorpercentagefound:E%-0.9%
CURRENTcalibrationfactor:1.000
NewUSERKFACTOR:
1.000*[(100–(-0.9))/100]=1.000*[(100+0.9)/100]=1.009
IftheNEXTindicateslessthantherealdispensedvalue(negativeerror)
thenewcalibrationfactormustbehigherthantheoldoneasshownin
theexample.TheoppositeappliesiftheNEXTshowsmorethanthereal
dispensedvalue(positiveerror).
7. OPERATION OF THE SYSTEM
ACTION DISPLAY
1 NONE
METERinStandby
2 LONG CAL KEY KEYING
NEXTenterscalibrationmode,shows
“CAL”anddisplaysthecalibration
factorbeingusedinsteadofthepartial.
Thewords“Fact”and“User”indicate
whichofthetwofactors(factoryor
user)iscurrentlybeingused.
3 LONG RESET KEY KEYING
TheNEXTshows“CAL”andthezero
partialtotal.NEXTisreadytoperform
in-eldcalibationbydispensing–see
previousparagraph.
4 LONG RESET KEY KEYING
WenowgoontoDirectchangeofthe
calibrationfactor:theword“Direct”
appearstogetherwiththeCurrently
Usedcalibrationfactor.
Inthebottomleftpartofthediplay,
anarrowappears(upwardsor
downwards)deningthediection
(increaseordecrease)ofchangeof
thedisplayedvaluewhensubsequent
operations5or6areperformed.
5 SHORT RESET KEY KEYING
Changesthedirectionofthearrow.
Theoperationcanberepeatedto
alternatethedirectionofthearrow.
6 SHORT/LONG CAL KEY KEYING
Theindicatedvaluechangesinthe
directionindicatedbythearrow-one
unitforeveryshortCALkeykeying
-continuallyiftheCALkeyiskept
pressed.Thespeedincreaserises
bykeepingthekeypressed.Ifthe
desiredvalueisexceeded,repeat
theoperationsfrompoint(5).
7 LONG RESET KEY KEYING
TheNEXTisinformedthatthecali-
brationprocedureisnished.Before
performingthisoperation,makesure
theINDICATEDvalueisthatrequired.
8 NO OPERATION
Attheendofthecalculation,thenew
USERKFACTORisshownforafew
seconds,afterwhichtherestartcycle
isrepeatedtonallyachievestandby
condition.
IMPORTANT:Fromnowon,theindi-
catedfactorwillbecomethecalibration
factorusedbytheNEXTandwill
continuetoremainsuchevenaftera
batterychange
9 NO OPERATION
TheNEXTstoresthenewworkcali-
brationfactorandisreadytobegindis-
pensing,usingtheUSERKFACTOR
thathasjustbeenchanged.
I. METER CONFIGURATION
TheMETERfeatureamenuwithwhichtheusercanselectthemain
measurementunit,Quarts(Qts),Pints(Pts),Litres(Lit),Gallons(Gal);
ThecombinationoftheunitofmeasurementofthePartialregisterand
thatoftheTotalsispredenedacordingtothefollowingtable:
Combination
no.
Unit of Measurement
Partial Register
Unit of Measurement
Totals Register
1Litres(L) Litres(L)
2Gallons(Gal) Gallons(Gal)
3Quarts(Qts) Gallons(Gal)
4Pints(Pts) Gallons(Gal)
Tochoosebetweenthe4availablecombinations:
1.WaitfortheMETERtogotoStandby
2.ThenpresstheCALandRESETkeystogether.
Keepthesepresseduntiltheword“UNIT”appearson
thescreentogetherwiththeunitofmeasurementset
atthattime(inthisexampleLitres/Litres)
3.EveryshortpressoftheRESETkey,thevarious
combinationsoftheunitsofmeasurementsare
scrolledasshownbelow:
4.BypressingtheCALkeyatlength,thenewsettings
willbestored,theMETERwillpassthroughthestart
cycleandwillthenbereadytodispenseintheset
units.
ATTENTION
TheResetTotalandTotalregisterswillbeautomaticallychangedtothe
newunitofmeasurement.
NOnewcalibrationisrequiredafterchangingtheUnitofMeasurement.
J. MAINTENANCE
Battery Use2x1.5ValkalinebatteriessizeAAA
Replacement
WARNING K24shouldbeinstalledinapositionallowingthe 
  batteriestobereplacedwithoutremovingitfromthe
system.
K24featurestwolow-batteryalarmlevels:
Whenthebatterychargefallsbelowtherstlevel
ontheLCD,thexedbatterysymbolappears.In
thiscondition,K24continuestooperatecorrectly,
butthexediconwarnstheuserthatitis
ADVISABLEtochangethebatteries.
IfK24operationcontinueswithoutchanging
thebatteries,thesecondbatteryalarmlevelwill
bereachedwhichwillpreventoperation.Inthis
conditionthebatteryiconstartstoashandisthe
onlyonetoremainvisibleontheLCD.

24 25
7. OPERATION OF THE SYSTEM
To change the
batteries, with
reference to the
exploded diagram
positions, proceed
as follows:
UNSCREW THE NUT
REMOVETHECOVER(1)
LOOSENTHESCREW(2)
REMOVETHECOVER(3)RIGHTSIDE
CHANGETHEBATTERIES
ASSEMBLEEVERYTHINGBACKON
THESEALAROUNDTHECOVER
HOUSINGANDTAKECARETOPLACE
ATTENTION DO NOT OVER-TIGHTEN THE SCREW
TheK24willdisplaythesameResetTotal,thesameTotalandthesame
Partialindicatedbeforethebatterieswerechanged.Afterchangingthe
batteries,themeterdoesnotneedcalibratingagain.
CLEANING
OnlyoneoperationisnecessarytocleantheK24.
AfterremovingK24fromtheplantwhereitwasbuiltin,anyresidual
elementscanberemovedbywashingormechanically-handling.
Ifthisoperationdoesnotrestoreasmoothrotationoftheturbine,itwill
havetobereplaced.
ATTENTION
Do not discard the old batteries in the environment. Refer to local
disposal regulations.
Do not use compressed air onto the turbine in order to avoid its
damage because of an excessive rotation.
PERIODICALLY CHECK THE CORRECT OPERATION OF THE
AUTOMATIC STOP DEVICE.
IF FITTED, IT IS BEST TO PERIODICALLY CHECK THE FILTER AND
CLEAN IT EVERY 1000 LITRES OF TRANSFER.
PERIODICALLY CHECK THE TIGHTNESS OF THE CONNECTIONS.
K. MALFUNCTIONS
K1. MECHANICAL MALFUNCTIONS
THEPOSSIBLECAUSESOFMALFUNCTIONAREMAINLY
ATTRIBUTABLETOTHREEFACTORS:
1.NOZZLEDIRTYININNERHOLEOFLIPATENDOFSPOUT
2.OPERATINGPRESSUREOFLIQUIDTOBEDISPENSED 
BELOW0.5BARORABOVE3.5BAR
3.FLOWRATETOOLOWORTOOHIGH
NOTE: CORRECT AND REGULAR MAINTENANCE OF THE
NOZZLE AND OF THE SYSTEM TO WHICH IT IS CONNECTED
PREVENTS MALFUNCTIONS AND POSSIBLE ACCIDENTAL
SPILLS OF HAZARDOUS LIQUIDS.
REFER TO 8.4 TROUBLESHOOTING FOR FURTHER
ELECTRONIC MALFUNCTIONS.
3 FLOWMETER (FITTED TO 3500 | 6000 | 10000 | 15000)
A. INTRODUCTION
NotsuitablewhenusedinaretailsaleofAdBlue®.
A1. LCD DISPLAY
The“LCD”ofthemeterfeaturestwonumericalRegistersandvarious
indicationsdisplayedtotheuseronlywhentheapplicablefunctionis
selected.
A2. USER BUTTONS
Theturbinedigitalmeterfeaturestwobuttons(MENUandRESET)which
individuallyperformtwomainfunctionsandtogether,othersecondary
functions.Themainfunctionsperformedare:
Fortheresetkey,resettingthepartialRegisterandresettabletotal
(resettotal)
Forthemovekey,enteringinstrumentcalibrationmode.
Usedtogether,thetwokeyspermitenteringcongurationmode.
A3. BATTERY REPLACEMENT
Whenreplacingthebattery,pleaseopenthecover,removetheplugand
replacethebattery.
B. DAILY USE
B1. BUTTON USAGE, CALIBRATION AND
MEASUREMENT UNIT CHANGE
• Reset the present total
1)Whenthemeterisonstandby,presstheRESETkey.
2)Thedisplayshowsallthesegments.
3)Themeterresetsthepresenttotalalready.
• Show current correction factor and
general total
PressMENUandRESETtogetherandholdfortwo
seconds.
Value“1.4000”isthecorrectionfactorwhichcanbereset;
“1234567”isthegeneraltotalwhichcannotbereset.
• Measurement unit change
PressMENUandRESETtogetherandholdforveseconds.
Zone7onthedisplayisthecurrentunit.PressRESETtochoseadi󰀨er-
entmeasurementunitandthenpressMENUtoconrm.
B2. RESET THE RESETTABLE TOTAL (SEE FIG. 5)
Whenthemeterisonstandby,presstheRESETkeyfor2secondsto
resetthepresenttotalrst.
B3. PROCEDURE TO ENTER THE CORRECTION FACTOR DIRECTLY
Carefullyfollowtheprocedureindicatedbelow:
FORMULA
Propercorrectionfactor=
currentcorrectionfactor×(actualvalue/displayvalue)
Example:
Actual value 20.75
Display value 18.96
Current correction factor 1.000
Proper correction factor 1.000×(20.75/18.96)=1.000×1.094=1.094
B4. MODIFY THE CORRECTION FACTOR IN FIELD
Carefullyfollowtheprocedureindicatedbelow:
1)Waitforthemetertogotostandby.
2)Resettheresettabletotal.
3)Startdispensingintoameasuringglass.
Stopdispensingwhenover5Litresofvolumeis
reached,readouttheactualvalue.Thevolume
thatisdisplayedontheLCDistheDisplayValue,
nottheActualValuewhichmaybeslightlyhigher.
Forexample,inthegureontheright,theDisplay
Valueis18.96whiletheActualValueis20.75.
4)PresstheMENUkey.Keepitpresseduntlthe
rstdigit‘0’ashes.
PresstheRESETkeytochoosetherightdigit
from0to9.PresstheMENUkeytogothethe
nextdigitsothattheActualValuecanbeinput.
5)Makesurethecorrectionfactorisrightand
thenpresstheMENUkey.Keepitpresseduntil
calibrationisnishedandthefactorissaved.The
meterwillthenreturntostandby.
4. PULSED OUTPUT FLOWMETER OPERATION
Themeterisdeliveredreadytouse.Nocommissioningoperationsare
requiredevenafterlongstorageperiods.Theonlyoperationsthatneedto
bedonefordailyuseareresettingthePartialand/orResetTotalregister.
Belowarethetwotypicalnormaloperationdisplays.
OnedisplaypageshowsthePartialandResetTotalregisters.Theother
showsthePartialandGeneralTotal.SwitchoverfromResetTotalto
GeneralTotaldisplayisautomaticandtiedtophasesandtimesthatare
factorysetandcannotbechangedbytheuser.
7. OPERATION OF THE SYSTEM
ThePartialregisterpositionedinthetoppartofthedisplayindicatesthe
quantitydispensedsincetheRESETbuttonwaslastpressed.
-TheResetTotalregister,positionedinthelowerpartofthedisplay,
indicatesthequantitydispensedsincethelastResetTotalresetting.
TheResetTotalcannotberesetuntilthePartialhasbeenreset,while
viceversa,thePartialcanalwaysberesetwithoutresettingtheReset
Total.TheunitofmeasurementofthetwoTotalscanbethesameasthe
Partialorelsedi󰀨erentaccordingtothefactoryorusersettings.
-TheGeneralTotalregister(Total)canneverberesetbytheuser.It
continuestorisefortheentireoperatinglifeofthemeter.Theregister
ofthetwototals(ResetTotalandTotal)sharethesameareaanddigits
ofthedisplay.Forthisreason,thetwototalswillneverbevisibleatthe
sametime,butwillalwaysbedisplayedalternately.
Themeterisprogrammedtoshowoneortheotherofthetwototalsat
veryprecisetimes:
-TheGeneralTotal(Total)isshownduringMeterstandby
-TheResetTotalisshown:
-AttheendofaPartialresetforacertaintime(afewseconds)
-Duringtheentiredispensingstage
A. USER BUTTONS
Remotedisplayhastwobuttons(RESETandCAL)whichcanbeused
individuallyortogether.Ifusedindividually,theRESETbuttonresetsthe
PartialregisterandthatoftheResetTotal.
Usedtogether,thetwobuttonspermitenteringcongurationmodewhere
youcansetthedesiredunitofmeasurementandthenumberofpulses
byunitofmeasurementofthepartialarrivingatthePulseIninlet.
B. DISPENSING IN NORMAL MODE
Thisisthedefaultdispensing.Duringthistimethecountismade.The
PartialandResetTotalaredisplayedatthesametime.Shouldoneofthe
twobuttonsRESETorCALbeaccidentallypressedduringcounting,this
willhavenoe󰀨ect.
Afewsecondsafterdispensinghasended,onthelowerregister,the
displayswitchesfrom
ResetTotaltoGeneralTotal:theword“Reset”abovetheword“Total”
disappears,andthe
ResetTotalisreplacedbytheGeneralTotal.
ThissituationiscalledSTANDBYandremainsstableuntiltheuser
operatesthemeteragain.
C1. RESETTING THE PARTIAL REGISTER
ThePartialRegistercanberesetbypressingtheRESETbuttonwhen
themeterisinStandby,meaningwhenthedisplayscreenshowsthe
word“Total”.

26 27
7. OPERATION OF THE SYSTEM
AfterpressingtheRESETbutton,duringreset,thedisplayscreenrst
showsallthelit-updigitsandthenallthedigitsthatarenotlitup.
Attheendoftheprocess,adisplaypageisrstshownwiththeReset
PartialandtheResetTotal.
Afterafewmoments,theResetTotalisreplacedbytheNONresettable.
C2. RESETTING THE RESET TOTAL
TheResetTotalresettingoperationcanonlybeperformedafterresetting
thePartialregister.TheResetTotalcaninfactberesetbypressingthe
RESETbuttonatlengthwhilethedisplayscreenshows“ResetTotal”as
onthefollowingdisplaypage:
Schematically,thestepstobetakenare:
1.Waitforthedisplaytoshownormalstandbydisplaypage(withTotal
onlydisplayed).
2.PresstheRESETbuttonquickly.
3.ThemeterstartstoResetPartial.
4.WhilethedisplaypageshowingtheResetTotalisdisplayed,pressthe
RESETbuttonagainforatleast1second.
5.Thedisplayscreenagainshowsallthesegmentsofthedisplay
followedbyalltheswitched-o󰀨segments.Finallyitshowsthedisplay
pagewheretheresettotalisshown.
C3. DISPENSING WITH THE FLOW RATE MODE DISPLAY
Itispossibletodispenseuids,displayingatthesametime:
•ThedispensedPartial
•Theowratein[PartialUnit/minute]asshownonthefollowing 
displaypage:
Procedureforenteringthismode:
1.WaitfortheRemoteDisplaytogotoStandby,meaningthedisplay
screenshows“Totalonly”
2.QuicklypresstheCALbutton.
3.Startdispensing
Theowrateisupdatedevery0.7seconds.Consequently,thedisplay
couldberelativelyunstableatlowerowrates.Thehighertheowrate,
themorestablethedisplayedvalue.
WARNING
The ow rate is measured with reference to the unit of measurement
of the Partial. For this reason, in case of the unit of measurement of
the Partial and Total being dierent, as in the example shown below,
remember that the indicated ow rate relates to the unit of measurement
of the partial. In the example shown, the ow rate is expressed in Qts/
min.
The word “Gal” remaining alongside the ow rate refers to the register of
the Totals (Reset or NON Reset) which are again displayed when exiting
from the ow rate reading mode.
Toreturnto“Normal”mode,presstheCALbuttonagain.Ifoneofthetwo
buttonsRESETorCALisaccidentallypressedduringthecount,thiswill
havenoe󰀨ect.
WARNING
Even though in this mode they are not displayed, both the Reset Total
and the General Total (Total) increase. Their value can be checked after
dispensing has terminated, by returning to “Normal” mode, and quickly
pressing CAL.
C4. PARTIAL RESET
ToresetthePartialRegister,nishdispensingandwaitfortheRemote
DisplaytoshowaFlowRateof0.0as
indicatedintheillustrationthenquicklypressRESET
D1. CONFIGURATION
UsethemenuintheRemoteDisplaytocongurethemachinein
accordancewiththeirrequirements.Thecongurationmenuconsistsof
twosubmenus:
1.Congurationmenuforthemainunitofmeasurement
2.Congurationmenuforthenumberofimpulsesperunitof
measurementthatthemachinecanreceiveonthePulse-Ininlet.
7. OPERATION OF THE SYSTEM
Toenterthecongurationmenu,proceedasfollows:
1.WaitfortheRemoteDisplaytogoonStand-by;
2.PresstheCALandRESETbuttonsatthesametimeandholdthem
downuntiltheword“Unit”andthepreviously-setunitofmeasurement
appearonthedisplay(Litre/Litreinthisexample);
3.TomovebetweensubmenuspresstheCALbuttononcequickly.
D2. CONFIGURATION OF THE UNITS OF MEASUREMENT
Thecongurationmenufortheunitsofmeasurementallowstheuserto
selectthepartialunitofmeasurementbetweenfouravailableunits:Quarts
(Qt),Pints(Pt),Litres(L)andGallons(Gal).
ThecombinationbetweenthePartialregisterandtheTotalregisterunitsis
presetaccordingtothefollowingtable:
WARNING
The partial unit of measurement of the Universal Remote Display Pulse In
must be the same as that of the Universal Remote Display Pulse Out to
which it is connected.
Enterthecongurationsubmenuasshownpreviously.
EachtimetheRESETbuttonispressedquickly,thevariousunitsof
measurementwillappearasshown:
Ifyouwanttoexitthecongurationmenu,pressandholddowntheCAL
button.Thenewsettingswillbesaved,theRemoteDisplaywillstartup
andbereadyformeasurement.However,ifyouwanttomovetothe
nextsubmenu,presstheCALbuttonquickly.Thenewsettingswillstill
besaved.Ifnooperationiscarriedoutforacertainperiodoftime,the
RemoteDisplaywillstartupandbereadyformeasurement,butany
congurationmodicationsthathadbeenmadewillnotbesaved.
E. PULSER INPUT (PULSE IN)
TheREMOTEDISPLAYmaybeusedwithmostofthePulserowmeters
and,asanoptional,itcanhavethePulseOUToutlettotransmit
impulsestoadisplayrepeaterknownasthe“PulseINRemoteDisplay”.
Forthe“RemoteDisplayPulseIn”toshowthecorrectquantityofuid,it
mustbeconguredwithan“impulseweight”thatisconsistentwithwhat
isbeingreceivedfromtheUniversalRemoteDisplayPulsein.Todo
this,theRemoteDisplaymustbeconguredinaccordancewithimpulse
numbersbypartialunitofmeasurementissuedbytheUniversalRemote
DisplaywithPulseOut.
Enterthecongurationmenuasshownpreviously.PresstheCALbutton
togotothePulserinletcongurationsubmenu:thescript“P_in”andthe
previouslysetnumberofimpulsesbyunitofmeasurementwillappearon
thedisplay.
“10”onthedisplayindicatesthat10impulsesbypartialunitof
measurementmustenterontheinlet.
PresstheRESETbuttonquicklytoscrollthroughalltheavailable
owmetermodels.
Thenumberthatappearsonthedisplayimmediatelymatchesthemodel
asshowninthetablebelow:
PressRESETquicklytoscrollthroughallthepossiblePulse-Ins:
Selecttheappropriateowmetermodel.Ifyouwanttoexitthe
congurationmenu,pressandholddowntheCALbutton.Thenew
settingswillbesaved,theRemoteDisplaywillstartupandbereadyfor
measurement.However,ifyouwanttomovetothenextsubmenu,press
theCALbuttonquickly.Thenewsettingswillstillbesaved.
Ifnooperationiscarriedoutforacertainperiodoftime,theRemote
Displaywillstartupandbereadyformeasurement,butanyconguration
modicationsthathadbeenmadewillnotbesaved.

28 29
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM
4. MC BOX FUEL MANAGEMENT OPTION
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.
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
samevoltage
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)
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)
WARNING
Beforeaccessingtheelectricalparts,besurethatyouhave
disconnectedallofthegeneralswitchesthatpowero󰀨thedevice.

30 31
7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM

32 33
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.
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.
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.
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
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.
WARNING
Before accessing the electrical parts, be sure that you
have disconnected all of the general switches that power
the device.

34 35
7. OPERATION OF THE SYSTEM
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)
ThecongurationoftheMCsystempermitsrequiringtheUsertoenter
furtheroptionaldata(vehiclelicenceplate,mileage,quantitytobe
dispensed).
Fordetails,seetheMCcontrolsystemmanual.
Intheeventthattheseoptionsarenotset,MCwillrecogniseanactivated
PINCODEand,oncethenozzlecontact(ifapplicable)hasbeenclosed,
thepumpisenabled,allowingittodispense.
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
Thepumpwillstart(ifpreviouslyenabled)justassoonasthecontrol
leverismovedtoONposition,whileitswitcheso󰀨assoonasthecontrol
leverismovedtoOFFposition.
Nofurthermanualoperationisrequiredtostartorstopthepump.
Fuel dispensing
Inthecaseofthesimplestconguration(nooptionaldatarequired),the
fueldispensingprocedureisthefollowing:
•InsertPINCODE(orapplytheelectronickey)
IftheMCrecognisestheactivatedPIN(orkey),a“GOODMORNING
MANAGER/USER”messageisdisplayedandthepumpenabled.
WARNING
Such enabling does not result in immediate pump startup.
The pump is in fact controlled by a switch (positioned in the
nozzle seat) operated by the user.
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.
WARNING
Fuel must ONLY be dispensed under the careful control of the
user.
8. Maintenance of the TUFFA TANKS
Keepthismanualstoredinaplaceofusesoitcanbeobtainedforfuturereference.All
personswhoinstall,commission,maintain,andoperatethesystemmustbedeemed
competentbytheiremployersandhavetheadequateknowledgeandtrainingrequiredto
carryoutanyrequiredtaskswhicharerecommendedbythismanual,itisrecommendedthat
anypersonscarryingoutworkonthesystemhavefullyreadandunderstoodtheinstructions
setoutbythismanual.
Itisadvisedthatnochangesnorconversionswithpotentialimpactonsafetymaybe
performedonthissystem,anysparepartswhichareusedmustcomplywiththetechnical
requirementswhicharedenedinthismanualordirectlybythemanufacturer.
ATTENTION
PleasemakesurepriortoanymaintenanceworkthatpowersupplyisturnedOFFandthat
thereisnotaninadvertentchancetoreconnectthesystemtopowersupply.
WARNING
Systemwarrantywillbecomevoidifanyrepairsaremadebytechniciansnotauthorised
bythemanufacturer,thesameappliestoworkswithhazardousorpotentiallyhazardous
equipment.
ATTENTION
Donotusejetcleanerstocleanthesystem.Youcancleanthesystemwithwaterand
householdcleaners.Donotuseanexcessiveamountofwaterwhencleaningnearany
electricalitemsasthiscancauseashortcircuittooccurpotentiallypermanentlydamaging
theequipment.
8.1 System maintenance tasks
Activity Frequencyof
Task
KeepEquipmentingoodworkingorderbyreturningtoitsoriginalposition Aftereveryuse
Visuallyinspectoperationofgaugeequipment Weekly
Visuallyinspectexteriorconditionoftank Monthly
Visuallyinspectconditionofdeliveryhose Monthly
Physicallycheckbundalarmbyactivatingtheoatswitchinbundcavity
(audiblealarm)
3Months
Checkelectricalcablesandcableconnectionpoints 3Months
Visuallyinspectandifrequiredmaintainthetankidplateandwarninglabels 3Months
Physicallycheckxingsandbracketstability 6Months
Visuallyinspectinnertankandbundcavity 6Months
8. MAINTENANCE OF THE TUFFA TANKS

36 37
8.2 System maintenance tasks
Inspection by Competent Person
Inspectionsshouldbeundertakenbyacompetentpersonthatisreceivingadeliveryof
productoneveryllpriortoandwhilstlling.
Thisinspectionshouldinclude:
• Thellpointarrangementforsoundnessandleaks
• Anyoutletvalvesshouldbecheckedforleaksandoperation(openandclose 
successfully)
• Thetestingofcontentsgauge,anyhighlevel/overllalarmandbundalarm.
• Ifventscanbeseenthattheyareclearandunblockedandfreeofdebris.
• Avisualinspectionaroundthetankwithemphasisonthebaseofthetank.The
inspectionforplastictanksshouldincludeanydeformationofthesurfaceofthetanki.e.
excessivebulging,changeincolourduetochemicalattack,crazingorstressfractures.
Theinspectionofsteeltanksshouldincludelookingforevidenceofrustandheavy
corrosion,damppatchesonseams&seamfractures.
• Bundtobevisuallyinspectedforsoundnessandintegrity,water,spiltproduct,orother
debris.
8.3 Internal examination and cleaning
Internalexaminationsshouldbeundertakenbyacompetentpersonatappropriateintervals,
asdeterminedbytheproductused,anditscleanlinessi.e.solidsorwaterfallingout
ofsuspension.Entryintoconnedspacesshouldbecarefullyplannedandsupervised
andshouldbesubjecttoastrictproceduresdependentonthesubstancestored,andin
accordancewithHSErequirements.
8. MAINTENANCE OF THE TUFFA TANKS
8.4 Troubleshooting
Symptom PossibleCauses Solutions
No power 1. Local distribution board fuse 1. Check local distribution board RCD
2. Power cable damaged 2. Check condition of power cables
3. Power cable connection broken 3. Check power cable connections
4. System control panel circuit breakers 4. Open system control panel and check
circuit breakers
5. System control panel connections loose 5. Check cable connections inside of system
control panel
6. Low battery / poor battery clip connection 6. Check battery level / check clip connection
Pump not operating 1. Potential air lock in pipeline caused by tank ll
after running dry
1. Remove nozzle allowing air to pass
through pipeline
2. No AdBlue®in the system 2. Request AdBlue®delivery
3. Pump circuit breaker in control panel tripped 3. Engage pump circuit breaker or replace if
necessary
4. Pump relay fuse in system control panel blown 4. Replace relay / fuse
5. Pump failure 5. Replace pump
6. No power to system 6. Check power supply
Slow ow rate 1. Blockage in the system 1. Clean Y lter
Auto nozzle not
operating
1. Spring mechanism inside nozzle valve failed 1. Replace nozzle
2. Trigger plunger failed 2. Replace nozzle
Nozzle holster not
switching pump
correctly (auto
operation nozzle
holster versions only)
1. Micro switch failure 1. Replace micro switch
2. Micro switch lever not contacting correctly 2. Adjust position of micro switch or switch
lever
Level gauge does not
show reading
1. Power failure to gauge 1. Check power supply and cable
connections
2. Sensor cable connection loose 2. Check sensor cable connections inside
gauge unit
3. Sensor failure 3. Refer to manufacturer
4. Gauge unit failure 4. Refer to manufacturer
Level gauge shows
incorrect reading
1. Pressure sensor not positioned at base of tank 1. Lower pressure sensor down until it
touches base of tank
2. Incorrect gauge parameters 2. Refer to manufacturer to alter gauge
parameters
3. Sensor failure 3. Refer to manufacturer
4. Gauge unit failure 4. Refer to manufacturer
Bund alarm not
working
1. Bund oat switch not postioned correctly 1. Alter position of oat switch to hang
approximately 1” o bund oor
2. Bund oat not able to move freely 2. Check oat switch for blockage or replace
if necessary
3. Damage to bund cable 3. Refer to manufacturer
4. Float switch cable 4. Refer to manufacturer
8. MAINTENANCE OF THE TUFFA TANKS