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