INSTALLATION AND OPERATION INSTRUCTIONS

BlueMaster®
PORTABLE TANKS FOR THE STORAGE
AND DISTRIBUTION OF ADBLUE®

EN
 INSTALLATION AND OPERATION MANUAL
Portable tanks for the storage and distribution of AdBlue®

BlueMaster®
SlimLine

BBM01300, BBM02500, BBM03500, BBM05000, BBM09000 SLB01333, SLB02666, SLB03999, SLB05332,

SLB02500, SLB05000, SLB07500, SLB10000,
SLB15000

BlueTruckMaster® BlueMaster® light

OTM00200BU, OTM00430BU, OTM00900BU OBLB1000, OBLB1300, OBLB1500, OBLB2500, OBLB3500, OBLB5000, OBLB9000
BBLB1200, BBLB2500, BBLB3500, BBLB5000, BBLB9000

This operation, installation and maintenance manual contains important notes and warnings. Before taking up
activities related to the installation and operation of the unit, read the instructions carefully and follow all
recommendations. The manual is ancillary and does not constitute a source of law. Compliance with instructions
does not exempt from the application of local laws, in particular Health and Safety, Fire Protection, Environmental
Protection and Construction Law. The manufacturer is not liable for any damage or loss caused by improper
selection, installation and use of the machine and non-compliance with existing regulations. Keep this document in a
safe place for further use. In case of the resale of the machine, the manual must be provided to the new owner.

Last update: 2012-09

1
Contents
I. TECHNICAL PARAMETERS AND EQUIPMENT ........................................................................................................................... 3
1. PURPOSE .................................................................................................................................................................................... 3
®
2. BLUEMASTER ........................................................................................................................................................................... 3
3. SLIMLINE ..................................................................................................................................................................................... 8
®
4. BLUETRUCKMASTER ............................................................................................................................................................. 13
II. EQUIPMENT .................................................................................................................................................................................... 18
1. PUMP.......................................................................................................................................................................................... 18
2. FLOWMETERS .......................................................................................................................................................................... 21
3. COOLING AND HEATING.......................................................................................................................................................... 23
4. INNER TANK VENTILATION ..................................................................................................................................................... 27
5. CONTROL UNIT (TANK MANAGEMENT SYSTEM) ................................................................................................................. 28
A) FUNCTIONS OF TMS CONTROL PANEL ....................................................................................................................... 28
B) PHYSICAL FEATURES .................................................................................................................................................... 28
C) FILLING TANK.................................................................................................................................................................. 29
D) DISPENSING FROM TANK .............................................................................................................................................. 29
E) TANK LEVEL .................................................................................................................................................................... 29
F) FLOW MODE .................................................................................................................................................................... 29
G) ALARMS ........................................................................................................................................................................... 30
H) MANAGEMENT MODE – PUMP ACCESS ....................................................................................................................... 32
I) POWER UP SCREEN ....................................................................................................................................................... 32
J) LIGHT................................................................................................................................................................................ 34
K) TMS CONTROL PANEL TECHNICAL SPECIFICATION ................................................................................................. 34
L) INPUTS/OUTPUTS SPECIFICATION .............................................................................................................................. 34
M) TROUBLE SHOOTING GUIDE ......................................................................................................................................... 37
N) CONTROL UNIT WIRE DIAGRAM. .................................................................................................................................. 38
6. LEVEL PROBE AND LEAK SENSOR ....................................................................................................................................... 39
7. NOZZLE...................................................................................................................................................................................... 41
8. IDENTIFICATION PLATE........................................................................................................................................................... 47
9. TANK LITRE CAPACITY TABLES ............................................................................................................................................ 47
III. OPTIONAL EQUIPMENT................................................................................................................................................................ 51
1. MANAGEMENT CONTROL SYSTEM........................................................................................................................................ 51
2. HEATING WIRE.......................................................................................................................................................................... 54
3. TELEMETRY - REMOTE MEASUREMENT ............................................................................................................................... 56
4. SEPARATE EQUIPMENT HOUSING......................................................................................................................................... 57
5. HOSE REEL ............................................................................................................................................................................... 58
6. ADDITIONAL LEAK SENSOR AND MAXIMUM LEVEL SENSOR ............................................................................................ 59
7. TUFFMASTER METAL PROTECTIVE REINFORCEMENT ...................................................................................................... 60
IV. TRANSPORT AND STORAGE ..................................................................................................................................................... 64
V. GENERAL SETUP REQUIREMENTS .......................................................................................................................................... 65
VI. ELECTRICAL SYSTEM................................................................................................................................................................. 67
VII. GENERAL SAFETY REQUIREMENTS ........................................................................................................................................ 70
VIII. OPERATION GUIDELINES .......................................................................................................................................................... 72
IX. DISPOSAL .................................................................................................................................................................................... 77
X. TROUBLESHOOTING - TYPICAL PROBLEMS AND SOLUTIONS ............................................................................................ 78
XI. MACHINE MAINTENANCE ........................................................................................................................................................... 79
XII. TERMS OF WARRANTY............................................................................................................................................................... 80
XIII. MANUAL PUMP SUZZARABLUE ............................................................................................................................................... 82
XIV. TURBINOX USE AND MAINTENANCE MANUAL ..................................................................................................................... 99
XV. FLOW METER USE AND MAINTENANCE MANUAL ............................................................................................................... 104
XVI. ELECTRONIC TURBINE METER K24 OPERATING MANUAL ............................................................................................... 125
XVII. OVAL GEAR METER COGEM-P OPERATING INSTRUCTION ............................................................................................. 144
VIII. CALIBRATABLE PANEL MANUAL .......................................................................................................................................... 149
XIX. GMS TELEMETRY INSTALLATION IN TMS ............................................................................................................................ 174
XX. TMS OPERATION MANUAL ...................................................................................................................................................... 183
XXI. TMS SOFTWARE INSTRUCTIONS .......................................................................................................................................... 209

2
I. TECHNICAL PARAMETERS AND EQUIPMENT

1. PURPOSE

The BlueStore® tank range has been designed for the storage and distribution of AdBlue®.
Storage of other fluids is prohibited.
AdBlue® is an aqueous solution of urea (32.5%) that meets the quality requirements specified in DIN
V 70070 and is used to reduce NOx emissions using SCR technology (Selective Catalytic
Reduction) in diesel engines.
The BlueStore® range of tanks has been designed to answer the requirements of both public and
private entities who have a need for the storage and distribution of AdBlue®.
The range includes three main model lines:
1. BlueMaster® - bunded tanks made of polyethylene with a distributor.
2. SlimLine – containers with tanks made of polyethylene with a distributor.
3. BlueTruckMaster® - single-walled, portable tanks with a simplified distributor.
4. BlueMaster® Light - single-walled and bunded tanks with a simplified distributor.

The tanks for the storage and distribution of AdBlue® exhibit excellent mechanical strength and
protect the contents from extremes of hot and cold weather. The construction, materials,
components and workmanship are of the highest quality. Each range includes several versions, both
in terms of volume, and equipment.

2. BLUEMASTER®

BlueMaster® is a range of bunded tanks made of polyethylene. The housing which is also made of
plastic contains a distributor and control/steering devices.

BlueMaster® tanks specification

®
BlueMaster BBM09000* BBM05000* BBM03500* BBM02500* BBM01300*
Height [m] 2.95 2.34 1.96 1.85 1.79
Width [m] 2.48 2.23 2.20 1.46 1.24
Technical
Length [m] 3.28 2.85 2.85 2.46 1.90
data
Capacity [l] 9,000 5,000 3,500 2,500 1,200
Weight [kg] 600 320 270 220 150
Control/steering console
Digital level indicator (pulse output 4-20 mA for telemetry connection)
Max. level and leakage alert > 90 dB
Leakage indicator
Tank and housing heating system - hot air blower
Tank cooling system Fan
Standard
Filling line 2" stainless steel hose with dry clutch
equipment
Suction line 3/4" stainless steel hose, strainer and anti-return valve
Automatic nozzle with integrated pump switch
Protection against improper storing of the nozzle
Dry-run shut-off feature to protect the pump
Current protection for all accessories
Cabinet lightning

3
 ®
Pump set 2 - with approval and for AdBlue distribution
Pump set 1 (Piusi) - for internal use:
(only 5000 and 9000 l tanks):

• Suzarra Blue pump, AC 230 V / 50 Hz, with thermal • Complies with the requirements of the MID Directive
motor protection (2004/22/EC)
• Power 370 W • Attractive stainless steel design
• Flow max. 40l/min. • Litre calculator with LCD display unit, unit price, total
• Max. pressure 5 bar price, sum counter and currency
• Max. lifting height 2 m • Hose drum, 6m dispensing hose
Pump sets
• Turbinox flow meter (accuracy +/-1 %) • Automatic dispensing nozzle with integrated pump
switch
• 4m delivery hose
• Single phase induction motor: 230 V, 50 Hz, 0,75
• Stainless steel OPW automatic nozzle
kW, IP 55 with running time limiter (set by default to
with switch-equipped holder
6 min.) and thermal protection
• Max. capacity 30 l/min.
• Pressure approximately 3 bar
• Compatible with ER 3/4 protocol equipped cash
registers system
Hose coiler with or without a brake
Microprocessor Control Box MC to record the quantities of fuel delivered to each of the max. 120 users. Each
user has an individual PIN code.
Optional equipment:
®
• Computer software for creating detailed reports on disbursement of AdBlue , data can be transferred to a
computer via an electronic key or by direct cable connection
• User electronic code keys (alternative for PIN codes)
Optional
XTrack Management System:
equipment for
- Supports up to 1,000 drivers and 1,000 vehicles (dual registration)
pump set 1
- Ability to define limits
- Constant control of the oil level in the tank
- Optional - the ability to manage the controller using SMS commands
- Optional PC application for complete control (i.e. controller configuration)
- Collecting and processing data
- Modular design allows further expansion of the system
- Computer software for creating detailed reports on disbursement of fuel
Dispenser housing suitable for mounting on the wall (away from the tank)- only for 3,500, 5,000 and 9,000 l tanks
Dispenser housing with a stand allowing its installation directly to the ground (away from the tank) - only for
Optional 3,500, 5,000 and 9,000 l tanks
equipment for Inner tank insulation with polyurethane foam
pump set 1
Electrical heating tape, mounted on the outer surface of the inner tank under a layer of insulation
and 2 ®
Telemetry unit for remote transmission of information about the AdBlue level in the tank
Elaflex automatic dispensing nozzle
* Code ending may vary depending on equipment. Dimensions variability may reach +/- 1%.

4
 a. BlueMaster® with a non-calibratable distributor

1. Mesh filter and non return valve.

2. Suction line.
3. Lifting point.
4. Tank ventilation.
5. Tank heater.
6. Inner tank vent.
7. 4” inspection lid on inner tank.
8. Level probe.
9. Suction line prepriming point.
10. 16” inspection lid on outer tank.
11. 16” inspection lid on inner tank.
12. Inner tank.
13. Filing line connection in tank.
14. Inner tank.
15. Suction line.
16. Equipment housing.
17. 2” filling line.
18. Control/Steering console.
19. Light.
20. Suction line shut off valve.
21. Pump with flowmeter.
22. Delivery hose.
23. Nozzle holder with pump switch.
24. Auto nozzle.
25. Spill free filling line connection.
26. Equipment housing door lock.
27. Equipment housing heater.
28. Leak detection probe.

®
CUTAWAY DRAWING OF BLUEMASTER BBM5000 (SET 1)

Main power junction box

"RESET" button
Lighting switch and alarm switch

Suction line and shut off valve

Flowmeter Flowmeter
TurbinoxC Turbinox

Main switch

2" filling line with spill free

connection

Control unit (TMS) Dispenser

Auto nozzle with switch-equipped

holder

Dispenser housing heater

Temperature probe in the

dispenser housing

Dispenser housing equipment BBM5000 (set 1)

5
Temperature sensor

8" inspection
hatch

Pressure level probe Suction hose with priming point on suction

pipe

Open inspection hatch BBM5000 (set 1)

Heating

Fan

Hose reel with 6m

hose (option)

Equipment BBM2500 Lighting

6
 b. BlueMaster® with a calibratable distributor

Distribution panels are compliant with the MID Directive and can be legally used for the sale of
AdBlue®. Panels can be connected to the POS systems using a standard ER3 protocol.
Detailed information on the use and maintenance of the system is contained in separate instructions.

Examples of BBM5000 with calibratable panels

BlueMaster® with a calibratable Adast panel

7
3. SLIMLINE

The SlimLine container range is made of sandwich elements with a set of cylindrical tanks installed
inside. Inside the container there is a separate space where distributor and control unit are mounted.
Optionally the distributor may be installed outside the container.

Technical parameters
Product Usable Overflow Height Width Length Number Volume Volume Weight
code volume** capacity*** [m] [m] [m] of tanks usable overflow [kg]
[l] [l] [l] [l]

SLB01333/* 1290 1290 2.40 1.20 2.02 1 1290 1290 400

SLB02500/* 2330 2330 2.40 1.53 2.35 2 2480 2580 500

SLB02666/* 2480 2580 2.40 1.20 3.02 3 3670 3870 550

SLB03999/* 3670 3870 2.40 1.20 4.03 4 4860 5160 750

SLB05332/* 4860 5160 2.40 1.20 5.03 2 4460 4660 900

SLB05000/* 4460 4660 2.40 1.53 3.72 1 2330 2330 850

SLB07500/* 6590 6990 2.40 1.53 5.07 3 6590 6990 1100

SLB10000/* 8720 9320 2.40 1.53 6.42 4 8720 9320 1400

SLB15000/* 12980 13980 2.40 1.53 9.26 6 12980 13980 2000

Dimensions variability may reach +/- 1%.
* Two last characters of the code indicate equipment options.
Usable volume ** - indicates the approximate amount of liquid which can be pumped from the full tank and
the overflow capacity *** is approximate, maximum amount of liquid that can fill the tank at the first stop.

Standard equipment:
- TMS control panel to control the functioning of the various elements of electrical equipment,
- Dispensing unit with delivery rate max. 30 l/min. can be implemented in two versions:
- calibratable, compliant with MID (Measuring Instruments Directive) with illuminated LCD display
indicating the total volume, the value and the unit price of the consumed AdBlue®, with ability to
connect dispenser with cash registers system in ER3 protocol,
- non-calibratable for the internal use indicating the current volume of the consumed AdBlue® on
the display,
- 230V AC pump,
- Current level indicator,
- 6 m dispensing hose, with a reel,
- Automatic nozzle with integrated pump switch,
- Leak sensor,
- Dry running pump protection,
- Maximum level indicator,
- 2” filling line with spill free coupling,
- Automatic heating and ventilation system to maintain the temperature of the liquid in the required
range,
- Impulse output signal for the flow of 100 pulses / litre,
- 4-20mA analogue signal for current level in the tank.

8
Optional equipment:
- free-standing distributor, separately from the container,
- GSM telemetry - remote sending data on the current level of AdBlue®,
- Elaflex nozzle - working with the magnetic ring which may be placed in the infusion of the vehicle
tank,
- Additional heating 950 W (blower),
- Multi-access device: MC BOX (supports up to 120 users) or XTrack Management System
(supports up to 1,500 drivers and 1,500 vehicles), with non-calibratable distributor only, indicating
the amount of the consumed AdBlue®, the software analyzes the data, such as the date of
refuelling, vehicle, amount of the consumed AdBlue®, etc,
- Location of the door to the technical section on different sides (on the short side of the container
or on the long, right or left side),
- Possibility to place any stickers on container walls,
- Ability to communicate in other formats, such as ER4, ER5, Logitron, etc. (calibratable version),
- Key switch protecting against unauthorized access (non-calibratable version).

9
 a. SlimLine with a calibratable distributor

Roof raised for service Set of tanks

Calibrated work
distribution panel
Level probe

2” filling line

Main power
junction box

Suction line and

priming point
Vent
Holes for inserting
Technical section lift truck forks during
door transport 16" inspection hatch

SlimLine with a calibratable container panel Open roof

Pump

Fine filter

6m reel

Fuel batching section

of the calibratable
panel with access to
displays and keyboard

Service section of the

calibratable panel
with access to TMS
and filling line
connection

Filling line connection

Technical section Calibratable panel

10
 Panel design enables its Technical section
easy removal lighting

Calibratable panel

Fan

Stand-alone
distributor - optional

11
b. SlimLine with a non-calibratable distributor

Flow meter display

Sliding cover

2" filling line with spill

Nozzle with holder free connection

Non-calibratable panel

12
 4. BLUETRUCKMASTER®

BlueTruckMaster® is used for the transport of AdBlue®. The design of the tank prevents the
movement of liquid during transport. Simplified equipment provides the necessary functionality.

Vent Inlet ferrule

Auto nozzle with

Suction line delivery hose

230 V AC pump
(optional)

BlueTruckMaster® with a capacity of 430 litres

Lockable lid lifted on

jacks

Flowmeter (optional)

230V AC pump (optional)

BlueTruckMaster® with a capacity of 900 litres

13
STANDARD EQUIPMENT:
- Self-priming pump with max flow of 35 l/min.,
- Suction hose with shut-off valve and non-return valve and mesh filter,
- 4m flexible delivery hose,
- Automatic nozzle with holder,
- Inlet with cup,
- Vent,
- Internal light for easy usage when dark,
- 4 metal shackles for easy transport of equipment,
- Lockable lid supported by a gas spring (9000 l tank).

OPTIONAL EQUIPMENT:
- 24V DC self-priming pump,
- 230V AC self-priming pump,
- Digital flow meter with acceptable deviation of +/-1%.
- Cordless LED light,
- Metal shackles to facilitate device lifting,
- Simple, non-automatic nozzle (no protection against overflowing petrol tank of the vehicle)

Product code Capacity** [l] Length [m] Width [m] Height [m]
OTM00200BU/* 200 1.18 0.86 0.50
OTM00430BU/* 430 1.18 0.86 0.91
OTM00900BU/* 900 1.41 1.05 1.21
Dimensions variability may reach +/- 1%.
* Code ending may vary depending on equipment.
** Usable capacity is 95% of max volume.

14
 5. BLUEMASTER® LIGHT

The BlueMaster® range of tanks is characterized by the simplest possible design. The equipment in
the standard version contains only the necessary accessories. The variety of optional accessories
available allows for the expansion and increasing the functionality of the device depending on the
user's needs.

16" revision hatch Clock level indicator

(option)

Suction line
Vent Submersible pump

Filling line connection 8" revision hatch

with dry coupling
(option)
Automatic nozzle
(option)

15
Maximum level sensor Maximum level sensor Power cable with Pump switch - standard
(option) (option) a length of 10m version

Available capacities and dimensions of single skin tanks:

Product code Capacity [ l ] Length [m] Width [m] Height [m]

OBLB1000* 1,000 1.95 0.62 1.23

OBLB1300* 1,300 diameter 1.20 1.40

OBLB1500* 1,500 2.10 0.75 1.40

OBLB2500* 2,500 diameter 1.65 1.50

OBLB3500* 3,500 diameter 1.90 1.80

OBLB5000* 5,000 diameter 2.01 2.30

OBLB9000* 9,000 diameter 2.30 2.85

Available capacities and dimensions of bunded tanks:

Product code Capacity [ l ] Length [m] Width [m] Height [m]

BBLB1200* 1,200 1.90 1.24 1.79

BBLB2500* 2,500 2.46 1.46 1.85

BBLB3500* 3,500 2.85 2.20 1.96

BBLB5000* 5,000 2.85 2.23 2.34

BBLB9000* 9,000 3.28 2.48 2.95

Dimensions variability may reach +/- 1%.
* Code ending may vary depending on equipment.

16
STANDARD EQUIPMENT OF SINGLE SKIN TANKS:
- white translucent single wall tank,
- 8" revision hatch,
- 16" revision hatch (from capacity of 3500l),
- vent,
- 2" BSP offset connection on the top of the tank,
- simplified distribution system consisting of:
- pump 230V (switch ON / OFF),
- manual, non-automatic nozzle (no overfill protection of the vehicle),
- 6 m distribution hose.

STANDARD EQUIPMENT OF BUNDED TANKS:

- double walled tank (blue outer tank),
- lockable distribution housing,
- 8" revision hatch in the inner tank,
- 16'' revision hatch in the inner and outer tank (from capacity of 3500l),
- vent,
- 2'' BSP offset connection on the top of the tank,
- simplified distribution system consisting of:
- pump 230V (switch ON / OFF),
- manual, non-automatic nozzle (no overfill protection of the vehicle),
- 6 m distribution hose,
- float type level indicator for 1200 and 2500 tanks, for tanks 3500, 5000 and 9000 pneumatic type
level indicator.

17
Optional tank equipment:
Single skin tanks Bunded tanks

Tank capacity 1000 1300 1500 2500 3500 5000 9000 1200 2500 3500 5000 9000

2'' filling line connection on the top

of the tank with dry coupling ● ● ● ● ● ● ●
2" filling line connection on the
working level (on the bottom)
with dry coupling
● ● ● ● ●

Digital flow meter ● ● ● ● ● ● ● ● ● ● ● ●

Automatic nozzle ● ● ● ● ● ● ● ● ● ● ● ●

Level indicator - clock type ● ● ● ● ● ●

Automatic heating of the tank ● ● ● ● ●

Exhaust fan ● ● ● ● ●

Electronic maximum level sensor ● ● ● ● ●

Electronic leak detector between
coats ● ● ● ● ●
Electronic level indicator with
pressure probe ● ● ● ● ●

Hose reel 6m ● ● ● ● ●

Thermal insulation of the inner tank ● ● ● ● ●

Electric heating tape and insulation
of the inner tank ● ● ● ● ●

II. EQUIPMENT

1. PUMP
a. Suzzara pump

18
Suzzara metal pump

Basic parameters:
Voltage: 230V AC, 50 Hz, +/-5%
Power: 550 W
Revolutions: 2900 r.p.m.
Maximum flow rate: 40 l/min
Maximum working temperature: +40°C
Maximum delivery pressure: 5 bar
Maximum suction pressure: 0.5 bar
Lifting height: 2m
Maximum sound level: 75 dB (A)
Protection class IP55

Suzzara diaphragm pump Suzzara diaphragm pump

powered by 230V AC
Basic parameters:
Voltage:
- 230V AC +/-5%, 50 Hz +/-2%
- 12V or 24V DC
Power: 370 W
Maximum flow rate: 30 l/min
Maximum working temperature: +40˚C
Maximum delivery pressure: 5 bar
Maximum suction pressure: 0.5 bar
powered by 12V or 24V DC
Maximum current: 1.5 A
Lifting height: 2m
Maximum sound level: 70 dB (A)
Maximum humidity: 90%
Operating temperature range:
min. + 5˚C … max. + 35˚C

ATTENTION:
1. The pump can be used with AdBlue® (AUS32) or water. The pump is not suitable for
flammable liquids.
2. Working “dry” shall cause damage to pump. The pump and delivery system are delivered
primed. The pump might need to be reprimed before first running.
3. After 20 minutes of operation stop the pump for 20 minutes to cool the engine.
4. Do not leave the pump in bypass mode for more than 3 minutes.
5. When the pump is not in use or is at risk of freezing, clean the pump and flowmeter with
clean water and dry. Prime the pump again before next running.
6. The motor is protected against overload by means of a thermal safety device.

19
b. Submersible pump

The BlueMaster® light tanks are equipped with submersible pumps. Optionally, submersible pumps
may be used for othe tank ranges with a capacity of over 3,500 liters. Their use is recommended
especially for tanks with a stand-alone distributor unit, where the distance from the tank is over 15
meters. The following are examples of parameters of submersible pumps.

20
The pump in plastic housing:
- Power supply 230V AC, 50Hz
- Protection index: IP68
- Power consumption: 750W, 900W or 1100W
- Compression stages: 2, 3 or 4
- Lifting height: 24m, 36m or 48m
- Maximum fIow rate: 80 l/min
- Motor pump protection – automatic thermal
circuit-breaker
- Connection: 1"
- Weight: 7.3 – 9kg
- Optional float switch
2. FLOWMETERS
a. Turbinox Flowmeter
The pump in stainless steel housing:
- Power supply 230V AC, 50Hz
(Optional three-phase)
- Protection index: IP68
- Power consumption: 750W to 1700W
- Lifting height: from 20m to 57m
- Maximum fIow rate: from 46 to 96 l/min
- Built-in reverse flow check valve
- Motor pump protection – automatic thermal circuit-
breaker
- Pump with liquid-cooled discs
- Connection 1 1 / 4 "
- Optional: float switch, pressure regulator
21
 Flowmeter
Flowmeter with display

Flowmeter technical parameters:

Measuring system: turbine / rotor
Resolution rate (l / impulse): 0.011 l/impulse
Flow rate range: min. 10 / max. 40 l/min.
Storage temperature: from -20°C to +70°C
Working temperature: -10°C to +60°C
Storage humidity (R.U.): 95%
Pressure loss at 40 l / min: 0.05 bar in line, 0.1 bar at 90°
Accuracy: +/- 1%
Repeatability: +/- 0.4%
Impulse type: reed relay
Current: 100 mA
Maximum power: 3W
Maximum voltage (AC / DC): 28 V
Impulses per litre: 92
Maximum working pressure: 20 bar
Maximum bursting pressure: 40 bar

The Turbinox is a single-channel impulse transmitter. The reed ampoule translates the magnetic-
field variations generated by the rotation of the turbine-impeller into electrical impulses which are
sent to the display unit.
The pulser does not need an independent electrical power supply because is powered directly from
the display. The type of impulse emitted is represented by a square wave generated by the voltage
variation.
The calibration of the instrument is made by means of the external impulse receiver.
The impulse from the flowmeter is received by the TMS control panel or a display (picture above).
The latter option is used in the SlimLine tank range with a non-calibratable distributor. The display
shows the current and the total quantity of the delivered liquid as well as the flow rate. It has a button
to reset the current value and to calibrate. It is powered by a 2x1,5V battery or by a 4-12V external
source. Optionally, the display might be fitted with an open-collector pulse output (1, 2, 5, 10, 20, 50,
100 impulses per liter) to other receivers.

b. K24 Flowmeter

22
 The BlueTruckMaster® machines may be optionally fitted
with a K24 flowmeter.

Parameters:
- Electronic digital meter featuring a turbine measurement
system, designed for precise measuring of low viscosity
fluids,
- Rotating display allows you to set input and output in any
position; it can be connected directly to the nozzle.

Technical data:
- Casing made of polyamide reinforced with glass fibres,
- Turbine made of polypropylene,
- Flow rate range 5 ÷ 120 l/min,
- Maximum working pressure 10 bar,
- Maximum bursting pressure 40 bar,
- Maximum humidity 85%,
- Working temperature range from -10 to +50 ºC,
- 4-digit partial register,
- 6-digit totaliser,
- Accuracy following calibration 1%,
- Repeatability (typical) 0.3%,
- Inlet / outlet 1 ",
- Weight 0.25 kg,
- 2x1.5 V alkaline batteries size AAA.

c. OGEM-P WGP 15 flowmeter

The flowmeter is suitable for calibratable distributors.

Basic parameters:
- Accuracy from +/-0.25% to +/-0.5% (depending on viscosity),
- Repeatability + / -0.025%,
- Flow from 2.5 l/min to 30 l /min.,
- Connection 1/2",
- Protection index IP67,
- Approval PTB 5.241.92.42.

Details on flowmeters and display are presented later in this manual.

3. COOLING AND HEATING

23
AdBlue® needs to be stored at a temperature between -11 ˚C and +35 ˚C. To meet this requirement
the BlueMaster® and SlimLine machines are equipped with heating and cooling systems. The TMS
control unit monitors the temperature according to settings, thus controlling the operation of the
systems.
The BlueTruckMaster and BlueMaster® light machines (in the standard version) are not equipped
with these systems and require additional protection from the adverse effects of ambient
temperature.
The BlueMaster® light machines may be optionally equipped with cooling-heating systems, the
control is carried out directly by thermocouples in the power supply circuit of each element.

a. Tank heating

In the space between the inner and outer tank a 250W heating element is installed. Tanks with a
capacity of 3,500 litres and above are equipped with an additional 950W heating element in the
distributor housing.
The heater consists of a heating element with an integrated fan. The complete unit is assembled in a
metal framework. The temperature of the heating element is
approximately 55°C. The heater will not work if the fan is broken.

Technical data:

Power supply 230V AC, 50/6-Hz

Heating capacity 250W

Approvals VDE + UL File No. E150057

Heating element Resistance - micanite

Overheat protection Built-in temperature limiter

Heater body Extruded aluminium, anodized

Surface temperature max. 75 °C (400 W)

Tank heating
Axial fan, ball bearing Service life 50.000h at 25°C
Air flow, free blowing
3 3
AC: 45 m /h (50 Hz) ; 54 m /h (60 Hz)
3
DC: 54 m /h
2
Connection Terminals 1,5 mm , clamping torque 0.8Nm max.

Connection housing Plastic, UL 94V-0, black

Mounting Clip for 35mm DIN rail, EN 60 715

Mounting position Vertical

Operating / Storage -45 to +70 °C

temperature

Protection type / Protection IP20 / II (double insulated)

class

Tank heating in the

bund

24
 Technical Data

Power supply 230V AC, 50/6-Hz

Heating capacity 950W

Approvals VDE + UL File No. E234324

Heating element High performance cartridge

Heater body Extruded aluminium profile

Axial fan, ball bearing Service life 50.000h at 25°C. Airflow 160m³/h,
free flow
Dispenser housing
Connection 2-pole max. 2.5mm²
heater
Casing Plastic, UL 94V-0, black

Mounting Screw fixing (M5)

Fitting position Horizontally

Operating / Storage 0 to +60 °C / -45 to +70 °C

temperature

Dimensions 168 x 145 x 100 mm

Weight approx. 1.4kg

Protection type / Protection IP20 / II (double insulated)

class

Further technical data Temperature sensor to protect against overheating

in case of fan failure

The heating system is activated in a temperature below 0°C.

b. Cooling equipment

Fans are installed in the wall of the outer tank or container. The fans start to work if the bund
temperature goes above +30°C.

25
 The fan discharges warm air outside and brings cooler air inside. The air flow prevents formation of
spots of elevated temperature and thus prevents the liquid from overheating. Housing material
resistant to shock exhibits high resistance to weathering and UV radiation.

Technical Data

Service life min. 50.000h at 25°C (65% RH)

Axial fan, ball bearing
Fan body aluminium, rotor plastic
2
Connection 2 wires 100 mm with 2.5 mm terminals

Casing (filter fan and exit filter) Plastic according to UL94 V-0, light grey

Hood Plastic according to UL94 V-0, light grey; weather proof and UV light resistant according to
(filter fan and exit filter) UL746C (f1)

With double-sided industrial adhesive band for fixing to the outside of enclosure. Certain
Mounting frame operating circumstances can make the additional use of screws necessary (see drilling
template). Included in the delivery of the filter fans is a template for the enclosure cut-out

Filter mat G4 acc. to DIN EN 779, filtering degree 94%

Synthetic fibre with progressive construction, temperature resistant to 100°C, self-

Filter material extinguishing class F1. Moisture resistant to 100% RH, reusable – cleaning by washing or
vacuuming

Operating / Storage temperature -10 to +70 °C (+14 to +158 °F)/ -40 to +70°C (-40 to +158 °F)

Operating / Storage humidity Max. 90 % RH (non-condensing).

Protection type / Protection class IP55 / I (earthed)

Average
noise
Air volume
Operating Air volume, Current Power level Enclosure Weight
Art. No. with exit Depth Approvals
voltage free flow consumption consumption (DIN cut-out (approx.)
filter
EN ISO
4871)
FF018 VDE+UL
AC 230 V, 176 x 176 mm
(01802.0- 102 m³/h 68 m³/h 100 mA 15 W 39 db (A) 86mm 1.3 kg File No.
50 Hz + 0,4
00) E234324

NOTICE
The surface of the heater can be hot and may cause burns. The heater and
cooling fans must not be covered.
The TMS control box switch, must remain continuously "ON" in order to ensure
proper operation of heating and cooling systems.

26
4. INNER TANK VENTILATION

The BlueStore® tanks are pressureless. Installed ventilation equalizes the air pressure inside and
outside the inner tank.
Venting element with a diameter of 1 1/4" is equipped with a basket against the intrusion of major
pollutants.
Tank with volumes 3,500, 5,000 and 9,000 litres are equipped with a 16" revision hatch. The lid has
a ventilation unit. To keep the inside of the tank free from dust and insects the opening is protected
with a mesh. The lid provides access to the inside of the inner tank if necessary. Before using the lid
the top of the bund tank must be removed.

Vented inner tank.

The 16" inner tank hatch is equipped

with ventilation and a basket.

27
5. CONTROL UNIT (TANK MANAGEMENT SYSTEM)

The BlueMaster® and SlimLine machines are equipped with a specialised TMS control unit. The
Tank Management System is a bespoke design to control, monitor and manage efficient storage and
dispensing of AdBlue®.

A) FUNCTIONS OF TMS CONTROL PANEL

− Level Measurement: Ultrasonic or 4 – 20mA type identical transducer (accuracy +/-100 l),
− Overfill Alarm: Visual and audible,
− Variable Low Level Cut Off: Visual and audible,
− Bund Alarm: Active Conductive type sensor, 10mm from tank base,
− Equipment Alarms: Notification if level measurement, bund or capacitive sensors are damaged,
− Housing Light,
− Integrated Flow Meter: current flow and total. Auto display when pistol is lifted. Reverts back to
level after 1 minute or via button toggle facility,
− Flow Meter Conversion: 92 – 100 pulse converter for flow equipment. Additional signal output to
external devices,
− Automatic Pump Control: Cuts off after 5 minutes, if pump not used,
− Active 4-20 mA signal output to external control devices,
− Control the heating and ventilation equipment.

OPTIONAL FEATURES
− Remote Monitoring Facility: GSM/GPRS real time accessibility. Provision of Alarms. Web hosting
and integration of level / status information to SAP, Sage etc,
− RFID: Dispensing Measurement Solution.

B) PHYSICAL FEATURES
− Fire Resistant Cabling,
− Safety Cut Off Emergency Stop Button,
− Fuses for each current output,
− Fire Retardant Box,
− Tested for Humidity.

28
C) FILLING TANK
Do not exceed a maximum fill rate of 350 litres per minute.

1. Ensure pistol is in holder and control panel is switched on.

2. Fit delivery hose to valve.
3. Fill the tank with flow not greater than 350 l / min and pressure of not more than 0.8 bar.
4. Stop filling when Overfill Alarm sounds.
5. Disconnect delivery hose from valve.
6. Reset audible alarm with RESET button.

D) DISPENSING FROM TANK

1. Lift pistol from holder.
2. The LCD will automatically switch to the Pistol Screen.
3. Dispense contents.
4. Replace pistol in holder.
5. Pistol Screen will revert back to the Main Screen in 1 minute.

Note: If the pistol is not replaced correctly in the pistol holder the pump will run for 5 minutes before
automatically switching off.

E) TANK LEVEL
When the control panel is switched on, the LCD ‘Main Screen’ will appear. The numeric indicator
shows the volume of liquid remaining in the tank. The bar chart below the number is a visual
indication of the tank volume, each bar representing 1/10th of the volume.

Fig. 1: LCD – Main Screen

Accuracy +/-100 l
F) FLOW MODE
When the dispensing nozzle is removed from its holder, the LCD will automatically switch to the
‘Pistol Screen’, as shown in Figure 2 below. The large size numbers in the centre of the screen
indicate how many litres of Adblue have been dispensed in this operation. The small size numbers
beside “TOTAL” indicate the total volume (in litres) of Adblue dispensed to date.

Fig. 2: LCD – Pistol Screen

Accuracy +/- 1%

29
When the dispensing operation is complete and the dispensing nozzle is returned to its holder, the
‘Pistol Screen’ will revert back to the ‘Main Screen’ in approximately one minute.
There is still the ability to move between the two screens, by using the reset button. During filling do
not press the RESET because actual value will be lost.

If the unit is equipped with MC BOX system – the flow mode is not active. Flow is shown on MC
display.

G) ALARMS

This symbol will appear in the top left corner of display to indicate that there is at least 1
alarm mode present.

Low Level Alarm:

This indicates the level in the tank is low, and therefore it is not possible to dispense any Adblue.
The pump is switched off automatically, and cannot be switched on until the volume in the tank
exceeds the low level setting. The unit has to be refilled to enable the pump to operate.
Note: The first section of the bar chart will be flashing. No buzzer will sound and no Alarm LED will
light.

Fig. 3: LCD – Low Level Alarm

Level Alarm:

This indicates that a fault has occurred with the tank’s level detection device and that it cannot
measure the volume of Adblue remaining in the tank. The volume displayed is the last reliable level
received and will remain shown until a new level measurement is received. An Alarm LED will light
and a buzzer will also sound. It will not be possible to dispense AdBlue® while in this alarm mode, as
the pump will be automatically switched off.

Fig. 4: LCD – Level Alarm

30
Overfill Alarm:

Activation of this alarm indicates the BlueMaster® has reached full capacity and filling must be
stopped immediately. An Alarm LED will light and a buzzer will also sound.
Note: The tank volume will flash for five minutes. After five minutes the word ‘Stop’ will be replaced
with a bar graph, as per the normal screen.

Fig. 5: LCD – Overfill Alarm

Leak Alarm:

a leak from the tank has been detected the buzzer will sound and Alarm LED will light. The buzzer
will stop after 5 minutes, but the LED will remain lit. Check to see if bund cavity contains AdBlue®.
Once bund cavity is emptied, the LED will turn off and the LCD will revert back to the main screen.

Fig. 6: LCD – Leak Alarm

Leak Error Alarm:

A fault has been detected with the leak detector, the buzzer will sound and the alarm LED will light.

Fig. 7: LCD – Leak Error Alarm

31
H) MANAGEMENT MODE – PUMP ACCESS
The management mode must be activated in the TMS Tank Calibrator software. Refer to the “TMS
Tank Calibrator Manual” for more details. When management mode is ON the padlock symbol
appears on the top right of the screen. This mode works with the EXT IN input. The close circuit
between the EXT IN pins allows the pump for working. Management mode can be with dispensing
screen enabled or disabled.
That padlock informs about the access to the pump.
Padlock close – pump disable.

Padlock open – pump enable.

I) POWER UP SCREEN
From TMS firmware version 1.40 the following screen appears on the display after TMS for 10
seconds.

Power parameter description:

• Hei: tank height [cm]
• Cap: tank capacity [l]
• Ovr: overfill level [l]
• Low: low level [l]
• Exp and Man: are used to calculate the flow rate
Flow rate [l / imp] = Man / (EXP*10)
• Den: density of the liquid [g/cm3]. Only used for applications with pressure sensor.
• Tmp: high temperature [oC] and low temperature [oC] used for switching heaters and fans.
• Al: informs what alarms are active in TMS. Use the table below to decode the Alarm value:

32
Alarmoff value Low level Overfill Leak DIBT overfill DIBT leak
0
1 on
2 on
3 on on
4 on
5 on on
6 on on
7 on on on
8 on
9 on on
12 on on
13 on on on
16 on
17 on on
18 on on
19 on on on
24 on on
25 on on on

• Li: informs if the cabinet light option is enabled

0 – enable,
1 – disable.
• Sn: informs what type of level sensor is enabled
0 – ultrasonic,
1 – capacity probe,
2 – pressure sensor.
• Mg: informs about the management mode:
0 – management mode OFF,
1 – management mode ON but without the dispensing screen,
2 – management mode ON with the dispensing screen enabled.
• Hys: low level and overfill level hysteresis [%].
• Run: pump dry run time in [minutes]. When no pulses from the flow meter detected the pump
will switch off after predetermined time.
• Off: pressure offset after zero calibration of the pressure sensor.
• One: one time fill [L]. Pump protection – after predetermined value in [litres] the pump will
switch off.
0 - opcja wyłączona
• Rng: pressure sensor full scale range in [cmH2O].
• V1.40: TMS firmware version.

33
J) LIGHT

There is a light inside the housing which can be turned on and off by holding down the reset button
for five seconds.
This light will turn off automatically after five minutes if nothing is dispensed.

K) TMS CONTROL PANEL TECHNICAL SPECIFICATION

Ambient temperature -20°C to +40°C

Humidity Range 15%–95%

Altitude Range <2000m above sea level

Supply voltage 100 - 240 V AC, 50–60 Hz, 1.6 KVA

− High voltage: 6,4 and 3 way connectors 5.08 pitch,

− Low voltage: 2 way, 10-way and 20 way connector 3.5
Electrical connections pitch,
− Jack connector – 3 pole, 3.5mm, 1A jack socket.

Interface Jack connector – 3 pole, 3.5mm, 1A jack socket (RS232)

Operation − switch,

Buzzer 12 V DC

− 20 x 5mm, 1A fuse
− fans - 6A.
Circuit breakers − pump and MC Box - 6A.
− house heater - 10A.
− tank heater and lamp - 16A.

Relays 6 x 4031 - 12V DC, 10A

Unit meets the requirements of:

− Low Voltage Directive: EN 61010:2001,
Approvals − EMC Directive: EN55011:1999+A2:2001,
EN 61326:1998+A3:2003

L) INPUTS/OUTPUTS SPECIFICATION

1. High voltage connections:

- Two fans: max. current 6A, 230V AC,
- Pump + Ext out: max current 4A,
- Output to external devices: max. current 5A: 230 V AC,

34
- House Heater: max. current 5A, 230V AC,
- Tank Heater: max. current 5A, 230V AC,
- O/P 1: max. current 3 A, 230 V AC,
- Ext Out. to external devices 5A, 230 V AC.

2. Low voltage connections:

- Buzzer: 12V DC.
- 12V output: max. current 400mA.
- 20 way connector J1:
a) Ultrasonic: power supply 3V DC, this input is connected to level detection unit (Sensonic),
this unit uses ultrasonic wave to measure liquid level in the tank with 1 cm resolution.
- Pin1: yellow and shield (GND, shield)
- Pin2: blue (IN)
- Pin3: red (+)
b) 4-20 mA level probe: power supply 12VDC, this input can be connected to capacitance
level probe with 4-20 mA output.
- Pin4: yellow (GND, shield)
- Pin5: blue (-)
- Pin6: red (+)
c) Flow In: connection for pump flow meter, voltage 5V DC, this input is suitable for flow
meters with different resolution up to 100 impulse/litre.
- Pin7: blue and shield
- Pin8: red
d) Temp.: 10kOhm NTC thermistor, measures temperature in the dispenser housing in the
range between –40 °C and 80 °C, temperature is checked every second by the
microcontroller.
- Pin9: blue
- Pin10: red
e) Leak: voltage 5V DC, this is an input that works using a conductive circuit design to detect
when the resistance between two conductors on a detector has been reduced to give short
circuit. The resistance is poled every second by the micro controller. There is a third wire in
the line out and this is to enable a closed circuit for the connection alarm of the bund sensor.
Shield from the cable is connected to GND (pin 14) to lower the noise from the other cables.
- Pin11: blue
- Pin13: yellow
f) Temp.: 10kOhm NTC thermistor, measures temperature in the space between the tank in
the range between –40°C and 80°C, temperature is checked every second by the
microcontroller.
- Pin15: blue
- Pin16: red

10 pin connection for TELEMETRY

a) Output 4-20mA, max 30V DC, for connecting external devices
- Pin 1 (-)
- Pin 2 (+)
b) Output 12V DC 1,5A to connect telemetry
- Pin 8 (-)
- Pin 9 (+)

35
 c) Input for controlling the pump starting-up by external devices such as MC BOX or other
multi-access device. Shorting both inputs allows you to run the pump, opening prevents it
from starting.
- Pin 6 (-)
- Pin 7 (+)

d) Output 12V DC 1,5A to connect telemetry

- Pin 8 (-)
- Pin 9 (+)

10 pin connection for MANAGEMENT

a) Input to connect the leak probe Dibt, 12V DC
- Pin 1 (-)
- Pin 2 (+)
b) Input to connect the maximum level probe Dibt, 12V DC
- Pin 3 (-)
- Pin 4 (+)
c) Input for controlling the pump starting-up by external devices such as MC BOX or other
multi-access device. Shorting both inputs allows you to run the pump, opening prevents it
from starting.
- Pin 5 (-)
- Pin 6 (+)
d) Open collector output, 100 impulses/l for optional connection of external devices.
- Pin 7 (-)
- Pin 8 (+)
e) Output for the switch in the nozzle handle. Removing the nozzle from the handle make pin
9 and pin 10 short, placing the nozzle in the handle make them open.
- Pin 9
- Pin 10

Hysteresis:
This option works with the low level alarm and the overfill alarm. The diagram below shows how it
works:

OVERFILL ALARM ON

Overfill level
Hysteresis

OVERFILL ALARM OFF

Hysteresis can be set between 1% and 10% of the tank capacity. For example: in a 5,000 litre tank,
1% hysteresis is equal to 50 litres. If the overfill level is set to 4850 litres, the overfill alarm will switch
on above 4850 litres, and will switch off below 4800 litres (overfill level – hysteresis).

36
 High voltage outputs (fan, light, pump housing heater, tank heater)
are hazardous voltage (mains voltage).

If the equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.

Maintenance
F1 (Fuse) - 315mA Quick Blow Fuse

The equipment contains no other user serviceable parts and all maintenance
and repair must be carried out by the manufacturer or manufacturers, service
agents.

3. External circuit technical specifications

Circuit Max rated input/output

House Heater 230 V 50/60 Hz 250 W

Tank heater 230 V 50 Hz 250 W

Fan and pump 230 V 50 Hz 180 mA 15 W

Pump 230 V 50 Hz 520 W 2.4 A

M) TROUBLE SHOOTING GUIDE

Alarm Action/Solution

Low Level Alarm Fill tank.

Overfill Alarm Stop filling the tank and press ‘Reset’ button.
If the maximum level has not been not reached, and the
alarm is activated, remove the ultrasound probe level,
clean it and replace again.

Level Alarm Check connection to Level Device.

Leak Alarm Pump out bund area as soon as possible.

If the alarm is still active, alert the manufacturer.

Leak Error Alarm Check connection to the bund sensor.

37
N) CONTROL UNIT WIRE DIAGRAM.

38
6. LEVEL PROBE AND LEAK SENSOR

a) Pressure level probe

The tanks with TMS system are equipped with a pressure level probe JUMO MAERA S25
manufactured by Jumo, ranges from 2.50 m to 10 m H2O (head of water) with ambient pressure
compensation.

Permissible medium temperatures:

Measuring range (overload capacity)
Analog current output
Burden current output
Jump response
Supply voltage
Max. power consumption
0...0,25(0,75) / 0,4(1,4) / 0,6(1,8) / 1(2) bar (0 ... 50°C)
4 - 20 mA, 2- wires (Reverse polarity protection)
RL =< (UB - 10 V) / 0,02 A (W)
T90 =< 10 ms
10 - 30 V DC, nominal voltage 24 V DC
=< 25 mA

Permissible medium temperatures -5 ... +80°C

Principle of measurement
Enclosure protection
Interference emission
Material
Piezoresistive measuring sensor
IP68, immersible to 20 m
Class B
Process connection - stainless steel 316 Ti;
measuring membrane - stainless steel 316 L
housing - stainless steel 304
PVC cable, encased in a LD-PE

Optionally the tanks can be equipped with a pressure probe PR-26Y/81985 produced by Keller.

Permissible medium temperatures:

Measuring range (overload capacity)
Analog current output
Burden current output
Jump response
Supply voltage
Max. power consumption
0...0,25(0,75) / 0,4(1,4) / 0,6(1,8) / 1(2) bar (0 ... 50°C)
4 - 20 mA, 2- wires (Reverse polarity protection)
RL =< (UB - 10 V) / 0,02 A (W)
T90 =< 10 ms
10 - 30 V DC, nominal voltage 24 V DC
=< 25 mA

39
Accuracy:
Relative pressure
Measuring range 0,25 0,4 0,6 1 bar
a
Linearity 0,3 0,3 0,3 0,3 % of FS
Accuracy at 20 °C b 0,5 0,5 0,5 0,5 % of FS
Overall accuracy 1 1 1 1 % of FS
at temp. 0 ... 50°C c
Long-term stabilityd 0.3 % of FS per year
a.
linearity based on limit point setting
b.
includes: linearity, hysteresis, repeatability, deviation from initial (offset) and final values of measuring range
c.
includes: linearity, hysteresis, repeatability, deviation from initial (offset) and final values of measuring range, thermal effect on initial value
of measuring range and span.
d.
reference conditions as defined by EN 61298-1

Permissible medium temperatures -5 ... +80°C

Principle of measurement Piezoresistive measuring sensor
Enclosure protection IP68, immersible to 20 m
Interference emissiona Class B
Material Process connection
measuring membrane
housing
PVC cable, encased in a LD-PE

b) Leak sensor

Leak sensor with a piezo element is installed in the bund between the inner and outer tank (or
container wall).

40
7. NOZZLE

a) The BlueStore ® tanks are equipped with automatic OPW nozzles (blue cover). Maximum flow
40 l/min, maximum pressure of 3.4 bar. Below you will find the manufacturer's instructions.

AUTOMATIC NOZZLES
These instructions define the proper installation, operation, and
maintenance for OPW 7H, 7HB, 11A & 11B nozzles.

WARNINGS:
• High flow rates in excess of the regulatory allowable rates may result in splash
back or spillage. Damage or injury may result.
• Ensure nozzle is properly engaged in fill pipe prior to fuelling. (Figure 1) Some
fill pipe designs prohibit proper retention of the nozzle. In such case, nozzle
must be hand held to prevent it from falling out of the fill pipe. Failure may result
in a hazardous spill.
• For converting an OPW nozzle from full-serve to self-serve see back page,
otherwise do not alter the trigger or rack mechanisms. The nozzle shut off
mechanism could be impaired and result in property damage and/or personal
injury.
• Do not remove spout without OPW replacement kits and/or instructions.
Improper parts or assembly may result in leakage or a hazardous condition.
• If the spout is removed or replaced for any reason, the nozzle must be retested
in accordance with "Preparation and Test" section of these instructions.
• Never smoke, allow open flame, or sparking devices near the product
dispensers.
• Keep gasoline away from eyes and skin.
• Keep gasoline out of reach of children.
• Test can must be grounded at all times during tests.
• Nozzles are limited to applications consistent with NFPA Code 30A, OSHA
CFR1940.106, state and local fire codes or other local regulations. This nozzle
is designed for use with fuels normally dispensed at commercial service
stations.
• OPW products should be used in compliance with applicable Federal, State,
and Local laws and regulations. Product selection should be based on physical
specifications, limitations and compatibility with the materials to be handled.
OPW makes no warranty of fitness for a particular use.

41
INSTALLATION
• Apply suitable thread sealant on male threads of hose , or swivel. (OPW recommends Loctite
567).
• Do not use teflon tape. (Figure 3)
• Insert hose into inlet of nozzle. (Figure 4)
• Engage male thread Into nozzle body and tighten the hose nut. (Figure 5)
Do not over tighten.

PREPARATION AND TEST

• All 11A, 11B, 7H & 7HB nozzles are 100% flow, shutoff and leak tested prior to
shipment.
• Each nozzle should be tested for proper operation prior to being put into
service.
• 11A and 11B: Minimum dispensing flow rate is three (3) gallons per minute
(gpm) with the nozzle lever held in the full position.
• 7H and 7HB: Minimum dispensing flow rate is five (5) gallons per minute (gpm)
with the nozzle lever held in the full open position.
• Each nozzle hose point should be checked for minimum flow rate and shut off
in all clip positions.

FLOW TEST
• Equipment required: stop watch (Figure 6) 5 gallon vented test can.
• Start watch and initiate flow together.
• Test can should fill in under 60 seconds.
• If hose point does not comply, check system and repair prior to putting hose
point in service.

SHUT OFF CHECK

• Equipment: 5 gallon test can.
• Stan flow into test can, place nozzle in low clip position. (Figure 7).
• Immerse nozzle spout in test can with at least two inches of gas covering the
spout. (Figure 8) Do not place nozzle tip against bottom of container.
• Nozzle must shut off.
• Repeat procedure for medium and high clip positions. Nozzle must always
shut off. (Figure 9).
• Models without hold-open racks, test at full open position only.
• If shut off occurs prior to filling lank, reduce flow.
• Filling speed varies with style of fill pipe and vehicle.
• If no shut off occurs, verify flow rate is greater than 3 gpm for 11A/11B, and 5
gpm for 7H/7HB. Row rates below this will not allow the automatic shut off
feature to operate properly. If flow rate is above 3 and 5 gpm and there is no
shut off, replace nozzle.

42
NOZZLE CARE AND MAINTENANCE
• Monthly, apply a few drops of light oil (such as 3-in-1) where the main stem extends through the
nozzle body.
• Spare part kits available from your OPW distributor include:
• 5B series spout kits
• 6B, 6H, and 6S series hand insulators
• 18K series hold open rack kits

CONVERTING AN OPW NOZZLE FROM FULL SERVE TO SELF SERVE (Figure 10)
• All OPW 11 and 7HB sees nozzles come with a hold open lever and rack.
• If local codes require that the nozzle cannot have a hold open latch, please follow these
instructions to remove it: Place the nozzle on a flat surface, hold lever in open position and slide
screw driver along side hold-open rack. Pry the rack upward and pop off the rivets. CAUTION:
Protect your face and other exposed body pans-wear safety glasses. Make sure that broken
rivets are removed from the guard. Throw old parts away.

NOTICE TO INSTALLER
• Present these instructions to the station manager or other operational personnel.

IMPORTANT
For safety, OPW 11B and 7HB are designed to be non-operational unless hose Is pressurized;
therefore, should the customer attempt to open the lever before the pump is zeroed and switch
turned on, the customer will not receive fuel. A loose nozzle lever is normal until the hose is
pressurized.

WARNING
DO NOT USE FULL SERVICE NOZZLES WITH A HOLD-OPEN DEVICE ON PRE-PAY SELF-
SERVICE INSTALLATIONS.
The danger exists of flowing gasoline on yourself or others which can result in a fire with serious
personal injury or property damage. This hazardous condition occurs if a customer replaces the
nozzle in the pedestal rack with the hold-open device engaged after the pump mechanism has shut
off flow. The nozzle is latched open and flow will begin when the next customer turns on the pump
switch.
NOTICE TO INSTALLER: This warning card should be given to the station operator or attendant.

PLEASE NOTE: The OPW 11-B and 7-HB Nozzles are specially designed for pre-pay, self-service
application. It is designed to close automatically when the pump is turned off, and cannot be re-
opened until the pump is turned on, and the hose pressurized. Contact your OPW Distributor for
ordering information.

43
b) Optionally, the BlueMaster® and BlueMaster® machines can be equipped with integrated flow
meter.

c) If optionally Elaflex ZVA nozzle is used, it is required to install ELAFIX 40 magnet adapter in the
infusion of the vehicle. Below you will find the manufacturer's instructions.

44
 CONSTRUCTION DETAILS
HOSE PART
MATERIALS WEIGHT
INLET NUMBER
APPLICATION
Construction similar to standard Automatic nozzle ZVA DN 15 of nickel plated
®
type ZVA Slimline with automatic aluminium for "AdBlue " urea solution according DIN
shut-off and safety cut out ball 70070 . Flow rate up to 40 l/min, working pressure 0.5
valve, check valve, 3-speed lever – 3.5 bar.
latch with removable latch pin EB
280, and screen EK 172. ZVA AdBlue®
Available either with fixed hose Fixed ZVA4.0F-
inlet 'F' or special swivel 'EA 075 1" BSP male AdBlue®
®'
AdBlue of stainless steel.
Body of aluminium nickel plated,
spout aluminium, inner parts
stainless steel / plastic. Hose inlet
of aluminium nickel plated. Lever
rilsan plated (blue), scuffguard
and comfigrip PVC, seals NBR.
Spout with magnet opening. To
avoid misfuellings nozzle will only
open in combination with magnet
adapter ELAFIX 40 for the filler Swivel ZVA4.0-
neck. ® Swivel
1" BSP male AdBlue EA 075 AdBlue®
Weight of nozzle = 1.1 kg 'ELAFIX 40' magnet adapter Snivot

Other holders - on request

ELAFIX 40 is installed by the original equipment Magnet adapter ELAFIX 40 for installation in filler
manufacturer into a modified vehicle filler neck, (DN necks from DN 40. This adapter allows the refuelling
®
40 or larger). The delivery scope includes installation of urea solution with ZVA AdBlue , without the risk of
instructions. misfuellings.
®
Refuelling with the ZVA AdBlue nozzle is only ELAFIX 40
possible in combination with the ELAFIX 40 magnet
adapter. The fixed magnetic field within the filler neck
opens the magnet switch in the spout, so misfuelling
into petrol or Diesel tanks is made impossible. The ELAFIX 40
filling of the AdBlue tank with fuel is also excluded,
because petrol and Diesel spouts do not fit into the
ELAFIX 40 magnet adapter.
Materials: body of POM, capsulated ring magnet.
Weight = 60 g

Elastic
fastenings

45
 EK 145/495
Product badge
AdBlue®

ZVA AdBlue®

Magnet adapter - required

if ZVA AdBlue ® nozzle is
used

d) Manual nozzle without an automatic shut-off valve. Maximum flow 80 l/min; maximum pressure
3,4 bar.

46
8. IDENTIFICATION PLATE

Each BlueMaster® has an identification plate (shown below) attached:

9. TANK LITRE CAPACITY TABLES

The following tank litre capacity tables can be used to estimate the number and height of the liquid
column, measured with a measuring strip.

BlueMaster®

BBM01300 BBM02500 BBM03500 BBM05000 BBM09000

Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm]
158 --------------- 16 182 --------------- 13 250 --------------- 12 268 --------------- 9 500 --------------- 11
358 --------------- 30 363 --------------- 22 500 --------------- 20 500 --------------- 17 922 --------------- 23
558 --------------- 49 545 --------------- 31 750 --------------- 29 750 --------------- 26 1052 -------------- 27
758 --------------- 62 726 --------------- 38 1000 ------------- 39 1000 -------------- 34 1798 -------------- 46
958 --------------- 75 908 --------------- 45 1250 ------------- 49 1250 -------------- 42 1954 -------------- 50
1158 -------------- 91 1090 ------------- 52 1500 ------------- 60 1500 -------------- 51 3725 -------------- 97
1315 -------------- 100 1271 ------------- 60 1750 ------------- 70 1750 -------------- 60 3872 -------------- 101
1453 ------------- 67 2000 ------------- 80 2000 -------------- 68 5524 -------------- 147
1634 ------------- 74 2250 ------------- 90 2250 -------------- 77 5650 -------------- 151
1816 ------------- 81 2500 ------------- 101 2500 -------------- 86 7225 -------------- 196
1998 ------------- 89 2750 ------------- 112 2750 -------------- 95 7367 -------------- 200
2179 ------------- 97 3000 ------------- 122 3000 -------------- 104 8915 -------------- 246
2361 ------------- 107 3250 ------------- 135 3500 -------------- 124 9050 -------------- 250
2497 ------------- 112 3500 ------------- 145 4000 -------------- 143 9234 -------------- 257
2560 ------------- 122 3750 ------------- 159 4500 -------------- 163
5000 -------------- 183
5250 -------------- 195
5305 -------------- 199
5365 -------------- 204

* Approximate values.
NOTE:
- the data contained in the above tables are subject to errors caused by thermal expansion of polyethylene from which the tanks are
made;
- the litre measuring strip is not included in the equipment offered by the supplier.

47
SlimLine
SLB01333
Capacity* Level [cm]
26 ----------------- 5
54 ----------------- 10
89 ----------------- 15
126 --------------- 20
162 --------------- 25
197 --------------- 30
232 --------------- 35
331 --------------- 50
477 --------------- 70
614 --------------- 90
757 --------------- 110
895 --------------- 130
1033 -------------- 150
1138 -------------- 165
1171 -------------- 170
1203 -------------- 175
1231 -------------- 180
1258 -------------- 185
1279 -------------- 190
SLB02500
Capacity* Level [cm]
64 ----------------- 5
127 --------------- 10
190 --------------- 15
251 --------------- 20
307 --------------- 25
365 --------------- 30
428 --------------- 35
615 --------------- 50
860 --------------- 70
1107 -------------- 90
1362 -------------- 110
1603 -------------- 130
1853 -------------- 150
2040 -------------- 165
2096 -------------- 170
2151 -------------- 175
2207 -------------- 180
2267 -------------- 185
2336 -------------- 190
* Approximate values.
NOTE:
- the data contained in the above tables are subject to errors caused by thermal expansion of polyethylene from which the
tanks are made;
- the litre measuring strip is not included in the equipment offered by the supplier.
SLB02666
Capacity* Level [cm]
53 ----------------- 5
107 --------------- 10
179 --------------- 15
252 --------------- 20
324 --------------- 25
393 --------------- 30
464 --------------- 35
661 --------------- 50
954 --------------- 70
1229-------------- 90
1514-------------- 110
1789-------------- 130
2067-------------- 150
2276-------------- 165
2342-------------- 170
2406-------------- 175
2463-------------- 180
2515-------------- 185
2558-------------- 190
SLB05000
Capacity* Level [cm]
127 --------------- 5
255 --------------- 10
380 --------------- 15
502 --------------- 20
613 --------------- 25
730 --------------- 30
855 --------------- 35
1230-------------- 50
1720-------------- 70
2213-------------- 90
2724-------------- 110
3205-------------- 130
3705-------------- 150
4080-------------- 165
4191-------------- 170
4302-------------- 175
4413-------------- 180
4535-------------- 185
4672-------------- 190
SLB03999
Capacity* Level [cm]
79 ----------------- 5
161 --------------- 10
268 --------------- 15
378 --------------- 20
486 --------------- 25
590 --------------- 30
696 --------------- 35
992 --------------- 50
1430 -------------- 70
1843 -------------- 90
2271 -------------- 110
2684 -------------- 130
3100 -------------- 150
3414 -------------- 165
3513 -------------- 170
3609 -------------- 175
3694 -------------- 180
3773 -------------- 185
3838 -------------- 190
SLB07500
Capacity* Level [cm]
191 --------------- 5
382 --------------- 10
570 --------------- 15
753 --------------- 20
920 --------------- 25
1095 -------------- 30
1283 -------------- 35
1845 -------------- 50
2580 -------------- 70
3320 -------------- 90
4087 -------------- 110
4808 -------------- 130
5558 -------------- 150
6120 -------------- 165
6287 -------------- 170
6453 -------------- 175
6620 -------------- 180
6802 -------------- 185
7008 -------------- 190
SLB05332
Capacity* Level [cm]
105 --------------- 5
214 --------------- 10
357 --------------- 15
504 --------------- 20
648 --------------- 25
786 --------------- 30
929 --------------- 35
1323 -------------- 50
1907 -------------- 70
2457 -------------- 90
3028 -------------- 110
3579 -------------- 130
4133 -------------- 150
4552 -------------- 165
4684 -------------- 170
4811 -------------- 175
4926 -------------- 180
5030 -------------- 185
5117 -------------- 190
SLB10000 SLB15000
Capacity* Level [cm] Capacity* Level [cm]
255 --------------- 5 382---------------- 5
509 --------------- 10 764---------------- 10
760 --------------- 15 1140 -------------- 15
1004 -------------- 20 1507 -------------- 20
1227 -------------- 25 1840 -------------- 25
1460 -------------- 30 2190 -------------- 30
1710 -------------- 35 2565 -------------- 35
2460 -------------- 50 3690 -------------- 50
3440 -------------- 70 5160 -------------- 70
4427 -------------- 90 6640 -------------- 90
5449 -------------- 110 8173 -------------- 110
6410 -------------- 130 9615 -------------- 130
7410 -------------- 150 11115 ------------ 150
8160 -------------- 165 12240 ------------ 165
8382 -------------- 170 12573 ------------ 170
8604 -------------- 175 12907 ------------ 175
8827 -------------- 180 13240 ------------ 180
9070 -------------- 185 13605 ------------ 185
9344 -------------- 190 14016 ------------ 190
48
BlueMaster® light

Single skin tanks

OBLB1000 OBLB1300 OBLB1500 OBLB2500

Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm]
100-----------13 96--------------9 150-------------13 100 --------------- 8
200-----------24 196------------18 300-------------25 200 --------------- 12
300-----------34 296------------27 445-------------35 300 --------------- 17
400-----------45 398------------36 595-------------48 400 --------------- 21
500-----------58 499------------45 740-------------62 500 --------------- 26
600-----------71 601------------54 890-------------77 600 --------------- 30
700-----------82 702------------63 1035-----------89 700 --------------- 35
800-----------92 804------------72 1185-----------100 800 --------------- 40
900-----------102 904------------81 1330-----------111 900 --------------- 45
1000---------113 1005----------90 1480-----------124 1000 ------------- 50
1060---------123 110------------99 1565-----------134 1100 ------------- 54
1208----------108 1200 ------------- 59
1310----------117 1300 ------------- 63
1407----------126 1400 ------------- 68
1500 ------------- 73
1600 ------------- 77
1700 ------------- 82
1800 ------------- 86
1900 ------------- 91
2000 ------------- 96
2100 ------------- 101
2200 ------------- 105
2300 ------------- 110
2400 ------------- 115
2500 ------------- 120
2600 ------------- 124
2700 ------------- 129
2775 ------------- 134

OBLB3500 OBLB5000 OBLB9000

Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm]

250 --------------- 12 268 ---------------- 9 500 ----------------11
500 --------------- 20 500 ---------------- 17 922 ----------------23
750 --------------- 29 750 ---------------- 26 1052 --------------27
1000 -------------- 39 1000 -------------- 34 1798 --------------46
1250 -------------- 49 1250 -------------- 42 1954 --------------50
1500 -------------- 60 1500 -------------- 51 3725 --------------97
1750 -------------- 70 1750 -------------- 60 3872 --------------101
2000 -------------- 80 2000 -------------- 68 5524 --------------147
2250 -------------- 90 2250 -------------- 77 5650 --------------151
2500 -------------- 101 2500 -------------- 86 7225 --------------196
2750 -------------- 112 2750 -------------- 95 7367 --------------200
3000 -------------- 122 3000 -------------- 104 8915 --------------246
3250 -------------- 135 3500 -------------- 124 9050 --------------250
3500 -------------- 145 4000 -------------- 143 9234 --------------257
3750 -------------- 159 4500 -------------- 163
5000 -------------- 183
5250 -------------- 195
5305 -------------- 199
5365 -------------- 204

* Approximate values.
NOTE:
- the data contained in the above tables are subject to errors caused by thermal expansion of polyethylene from which the
tanks are made;
- the litre measuring strip is not included in the equipment offered by the supplier.

49
Bunded tanks:

BBLB1200 BBLB2500 BBLB3500 BBLB5000 BBLB9000

Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm] Capacity* Level [cm]
158 --------------- 16 182 --------------- 13 250 --------------- 12 268 --------------- 9 500 --------------- 11
358 --------------- 30 363 --------------- 22 500 --------------- 20 500 --------------- 17 922 --------------- 23
558 --------------- 49 545 --------------- 31 750 --------------- 29 750 --------------- 26 1052 -------------- 27
758 --------------- 62 726 --------------- 38 1000 ------------- 39 1000 -------------- 34 1798 -------------- 46
958 --------------- 75 908 --------------- 45 1250 ------------- 49 1250 -------------- 42 1954 -------------- 50
1158 -------------- 91 1090 ------------- 52 1500 ------------- 60 1500 -------------- 51 3725 -------------- 97
1315 -------------- 100 1271 ------------- 60 1750 ------------- 70 1750 -------------- 60 3872 -------------- 101
1453 ------------- 67 2000 ------------- 80 2000 -------------- 68 5524 -------------- 147
1634 ------------- 74 2250 ------------- 90 2250 -------------- 77 5650 -------------- 151
1816 ------------- 81 2500 ------------- 101 2500 -------------- 86 7225 -------------- 196
1998 ------------- 89 2750 ------------- 112 2750 -------------- 95 7367 -------------- 200
2179 ------------- 97 3000 ------------- 122 3000 -------------- 104 8915 -------------- 246
2361 ------------- 107 3250 ------------- 135 3500 -------------- 124 9050 -------------- 250
2497 ------------- 112 3500 ------------- 145 4000 -------------- 143 9234 -------------- 257
2560 ------------- 122 3750 ------------- 159 4500 -------------- 163
5000 -------------- 183
5250 -------------- 195
5305 -------------- 199
5365 -------------- 204

* Approximate values.
NOTE:
- the data contained in the above tables are subject to errors caused by thermal expansion of polyethylene from which the tanks are
made;
- the litre measuring strip is not included in the equipment offered by the supplier.

50
III. OPTIONAL EQUIPMENT

1. MANAGEMENT CONTROL SYSTEM

The BlueMaster® tanks with capacities from 3,500 to 9,000 litres and all Slimline containers can be
equipped with multi-user devices. The following are the two most popular solutions.
a) MC BOX - control unit for 120 users

Multi-user control panel

The MC Box fuel management panel has the capability to control and
manage the consumption of AdBlue® for the private and commercial
user sector. The MC system consists of a dedicated multi-user panel with
the option to connect to a PC.

The control panel has the ability to:

- Switch a pump on/off.
- Recognize authorised users by means of i-button key or pin code.
- Preset a quantity to dispense.
- Manage a pulse meter to measure quantity dispensed.
- Manage an external level switch to control pump operation on low level.
- Operate an external nozzle switch.
to 120 users - Connect to a PC for exporting data files.
- Connect to an external printer.

The system is easy to install and has excellent weather resistance. The
wiring connections are located in an easy to access electric box.

Options:
Software for PC with dedicated RS converter or PC i-button key reader.
User i-button keys.

Features:
- Ability to handle up to 120 users.
- Measure total consumption per user in a defined period.
- Local memory capable of storing data for last 255 dispenses.
- Accepts vehicle registration numbers and odometer readings.
- Records date and time of re-fuelling.
- Exports data to PC by means of direct cable or memory key.
- Dedicated software for dispensing reports.
- Electronic i-button key for user or vehicle identification.
- Ability to manage up to 16 control panels with single software.
- Key reader with USB plug available for exporting to the PC.
- RS converter with USB plug available for direct connection to the PC up
to 1000 mtr.

b) XTrack - multiple access control system

51
Terminal parameters:
- Registration of fuel quantity delivered to each user or vehicle - microprocessor control system.
- Built-in database for up to 1500 users and vehicles.
- Identification with unique code RFID cards.
- Remote and immediate user database update with GPRS modem – tank can be situated in any
location.
- Two-level authentication-login (eg. driver/vehicle, manager/employee) allows to start filling.
- Location control – thanks to the built-in GPS module-anti-theft protection.
- Measurement of the amount of fuel in the tank-fuel theft, leakage, drop, replacement detection.
- Terminal supports input of kilometer counter readout before starting to fill.

Data analysis
The terminal is part of a comprehensive vehicle and machinery
fleet management system consisting of:
- XTrack GPS vehicle and machine monitoring system.
- Logistics and dispatcher modules including wholesaler software for managing deliveries to service
stations and fuel tanks.
- OptiTrax – route planning and optimization software.
- Road card and driver settlement module.

tank operation report

fuel consumption graph

52
Fuel management with the XTrack system
The XTrack system supports comprehensive fuel management activities in the company. By
metering intracompany fuel stations or tanks distributing fuel to eg. construction sites, the system
provides complete control over distributed fuel. The use of proprietary flow meters allows you to
install the system on any tank or station or tank used for fuel distribution.
The use of XTrack GPS monitoring system in vehicles and machinery allows to verify whether all
distributed fuel went into the tank of a vehicle or machine. XTrack GPS also allows you to detect any
drop or other fuel-related abuse. The XTrack system provides comprehensive control of fuel
management activities starting from the filling station tank up to the usage of fuel by a vehicle or
machine.

Key characteristics of the distribution terminal for fuel station/tank:

- user identification via unique RFID card which can be used by a number of other systems (RCP,
door systems, access to facilities) and to identify drivers of vehicles equipped with XTrack.
- two-step refueling authentication (eg, manager / driver, vehicle / driver, contractor / employee,
etc..).
- complete and up-to-date user database is stored in the memory of the device - this allows you
remotely lock/activate the card with immediate effect (for example, a lost card), and assign
appropriate rights to users.
- communication with management software for GPRS (GSM) module – the system is remotely
manageable even in mobile stations or tanks.
- the system has a relay output, allowing you to control the fuel pump. Only after authorization is it
possible to start the pump and begin fuel distribution.
- optional measurement of fuel level in the tank (probe) - detection of fuel leakage, theft, drop and
other events (eg. substitution with low quality fuel).
- detector to monitor tank hatch opening for filling purposes.
- sustain power for control and measurement system.

Software
Communication between the XTrack software server and recorders in vehicles, machinery and tanks
is performed using packet data transmission (GPRS). The system administrator can modify
parameters and access rights for individual employees by specifying days and times of week in
which they can collect fuel, daily refueling limits and other parameters. The system allows you to
efficiently manage multiple tanks visualizing on the map the filling level of each tank, in order to
place an order/delivery when needed. Full integration with the XTrack GPS monitoring system allows
to capture in one system all events related to the operation of both vehicles and machines, the
drivers working hours, the tasks performed and fuel management. Dispatcher modules, as well as
routes planning and optimization modules complete the XTrack offer making it the most
comprehensive solution for companies active in transportation, agriculture, construction, municipal
services or distribution of goods and services.

53
2. HEATING WIRE

If the BlueMaster® should be operated at low temperatures it is recommended to equip the inner
tank with additional heating wire and foam insulation.
The heating wire is attached to the outside of the inner tank and is covered by aluminum foil for
better heat distribution.
It is controlled by a thermocouple installed on the top part of inner tank and automatically adjusts
heat output in response to increasing or decreasing tank temperature (reduces power consumption).
The wire is protected from overheating or burnout and is approved for use in hazardous, non-
hazardous and corrosive environments

54
 Low temperatures: High temperatures:
More charge carriers, more Fewer charge carriers, less
heat output. heat output.

Volume of the Maximum power

Wire length [m]
bunded tank [L] consumption [W]

1200 9.5 295

2500 11.0 341
3500 11.0 341
5000 13.0 403
9000 15.0 465

Overall power consumption depends on the length of the wire and the ambient temperature, but
shall not exceed 31W per meter tape. Heating wire is turned on and off directly by the TMS.

Internal tanks may be covered with a layer of approximately 20mm polyurethane foam insulation,
which will reduce electricity consumption by the wire, as well as stabilize oil temperature in the
summer.

Only the manufacturer or his authorized service can install and repair the
wire.

55
3. TELEMETRY - REMOTE MEASUREMENT

The TMS control box is equipped with a signal output for the current level in the tank. This signal can
be used to connect the system to a wireless data transmission (telemetry). The system can be
installed directly in the distributor housing.

After installing and buying an annual subscription, the device every 10 minutes will transfer data via
GSM to the server.
The current level of liquid in the tank will be presented on www.connectsensor.com. Collected data
can also be presented in a graph.

The exact description of the telemetry system is presented further in this manual.

56
4. SEPARATE EQUIPMENT HOUSING

The equipment housing can be installed separately from the tank (“stand
alone”). Connections for filling, emptying and sensors are installed on the
tank.

2" filling line connection

Connection tank on external tank

1" suction line

Electrical connections (level probe, leak probe, temperature

probe, conditioning or heating supply)

There are two versions of the stand alone distributor housing available:

- housing for wall mounting - housing with rack to mount directly

to the ground

In these locations drill holes to At the bottom of the frame there are holes for mounting View after removing back
attach the enclosure to the the frame to the wall with screws. Access after plate. Access to filling
wall with screws. removing the cover. line,suction line and wiring
connections.

A smaller distributor housing is possible as an

option.

All pipework connecting tank to housing must be from a material that is compatible
with AdBlue® eg. stainless steel, PVC, PE and must be protected against very low
temperatures (insulation, heating wire as an option.)
The maximum recommended distance between tank and distributor housing is 15 m
where the pump is located in the distributor housing. If greater distances are required,
it is necessary to use a submersible pump of sufficient capacity.

All electrical work should be done by a qualified electrician.

57
5. HOSE REEL

The SlimLine and BlueMaster® machines with a calibratable

panel are equipped with a hose reel.
The BlueMaster® tanks can be equipped with 6m hose reels
(capacities to 3,500 litres and 7.5 m for larger capacities).
Two versions are available: with and without bracket. Drum
spring must be properly spanned to ensure proper functioning
of the reel.

58
6. ADDITIONAL LEAK SENSOR AND MAXIMUM LEVEL SENSOR

You can use the TMS system as a maximum level detector and a leak sensor, or install independent
equipment. In such cases, the TMS functions get deactivated. The devices are powered from the
control box (see wiring diagram of the TMS).

Detailed information on the operation and construction of equipment is contained in separate

manuals.

Leak
sensor

Maximum level
sensor

Leak Maximum level

probe sensor

BlueMaster® tanks with additional equipment

59
7. TUFFMASTER METAL PROTECTIVE REINFORCEMENT

Where there is an increased risk of mechanical damage, use the TuffMaster machine in a protective
metal reinforcement. Protective reinforcement is also adapted for handling by forklift and lifting with a
crane and slings.

60
8. LEVEL INDICATOR

a) Electronic level indicator - Smart Box

SmartBox 1 - provides an accurate measurement of liquid level in the tank using a pressure probe.
It also allows further extension of the system with optional functions such as:
- telemetry data transmission,
- output signal for connection to external monitoring systems,
- temperature measurement,
- adaptation to special requirements (such as Ex zone).

Detailed instructions are contained in a separate document.

61
b) Pneumatic tank contents gauge

1. Slot for opening the front glass

2. Basic dial

3. Reference pointer for consumption

monitoring

4. Adjustment screw for tank height

5. Support for additional slide-in scale

6. Adjustment scale for tank height

7. Date indicator for marking the most

recent tank filling

8. Capillary tube connection

9. Fixing lug

10. Adjustment pin for date indicator

11. Pump knob

12. Adjustment screw for zero correction

Accuracy measurement: +/- 2% of full scale value

Operating temperature range: -5° C to 55° C

62
Construction
The pneumatic tank contents gauge Unitop consists of a plastic, impact-resistant casing, inside
which there is a capsule pressure gauge with a valve to prevent excess pressure build-up, spring
bellow, pressure module with pointer and scale of measurement, adjustment screw used to set the
zero level, set screw used to set up the tank, reference pointer used to control consumption, pointer
for easy control of the storage medium, connection to the pneumatic connection with the supervised
tank.
Pressure in the pressure pipe is increased with the spring bellow until it reaches a value of
hydrostatic pressure prevailing at the end of the cable. The pneumatic tank contents gauge Unitop
measures the hydrostatic pressure at the bottom of the tank. Measurements are made with a
capsule pressure gauge with a valve to prevent excess pressure build-up. The pointer of the
pressure gauge shows the measured liquid level. The liquid level is indicated in%, regardless of the
shape of the tank. The manufacturer shall provide additional scales in litres for horizontal, cylindrical,
non-standard tanks, such as oval, cubic tanks.
UNITOP allows accurate determination of fuel consumption.
Additionally, the indications of Unitop can be used for the tank vehicle to control filling accuracy of
the tank.

Principle of operation
UNITOP is a versatile, pneumatic device used to measure the filling level in the tank. It has a
measuring mechanism with a spring bellow. In order to control the level of liquid in the tank you
should pump air with bellow through a pneumatic hose at the bottom of the tank. This pressure in the
pressure pipe pushes away the liquid present in the pipe. You should pump air in the pipe and
increase its pressure until all the liquid is removed and the air comes out of the pipe. The pointer of
the device stops moving despite the continuous pumping of air.
The pressure in the pipe will then be equal to the pressure at the bottom of the tank. The indication
of the device depends on the hydrostatic pressure at the bottom of the tank. Pressure in the
pressure pipe is measured with a capsule pressure gauge and is indicated as a percentage of the
tank height with a black pointer on the 270 ° scale. Due to additional scales for cylindrical, cubic and
spherical tanks UNITOP is suitable for all tanks in accordance with DIN. The fill level indications can
also be read in litres. Tank height is set by means of a special screw, which is accessible after
removing the transparent front cover. The other screw is used to set the zero level of liquid in the
tank. With the red pointer you can set the reference level of liquid in the tank. The black pointer is
used to control the consumption of liquid.

Operation
The pneumatic tank contents gauge UNITOP is maintenance-free. The device can be checked for
correct indication at any time. Where possible, equipment should be checked at each filling of the
tank in terms of accuracy of its readings.
Since the gauge UNITOP is usually the only device that allows you to read the level of liquid in the
tank, even at the time of filling the tank from the tank vehicle, it is advisable to check and adjust the
machine during each maintenance of the tank.

63
IV. TRANSPORT AND STORAGE

1. Transport and storage of

BlueStore® machines is to ensure
protection from mechanical
damage. Machines can be
transported only with their tanks
emptied.
2. Loading and unloading must be
carried out with the use of
specialized equipment, such as
forklift or a crane, slings and belts.
To anchor slings you can use
special fastening points. For
loading and unloading the SlimLine
containers with a forklift use
specials openings for the forks.
3. Transport of machines can be carried out with specially prepared Push the forklift
vehicles, i.e. vehicles equipped with at least fixing points suitable for forks in the
transport of tanks, allowing fixing the tank and protecting it from openings
sliding during transport. Loading space is to be smooth, with no
sharp edges.
4. Sliding or rolling the machines is prohibited. Never use projecting
parts when lifting or sliding the machines. Do not place any burdens
on walls and roof.

5. Machines can be stored outdoors, without specific limitations. Storage space is to be paved,
even and without sharp edges.
6. Lid and ferrule are to be tightly closed and secured during storage and transport. Electric cables
and hose are to be coiled, filler nozzle placed in holder, distributor enclosure closed.

64
V. GENERAL SETUP REQUIREMENTS

Users of BlueStoreMaster® machines are obliged to follow domestic regulations concerning

installation and operation of this machine, as well as recommendations by local fire-safety and
environmental protection services.
1. The assembly is allowed only when the tank is empty.
2. Please observe the statutory provisions relating to installation of refuelling equipment.
3. Installation and refuelling of machines displaying defects due to e.g. transport or storage, with
visible signs of damages to ferrules, cracks to tank jacket, or with incomplete equipment, is
forbidden.
4. Machine is to be placed on flat (levelled), even and stable surface executed in non-flammable,
load bearing, washable material not absorbing spilled substance, such as B35 WU concrete.
Base is to be at least 30 cm wider and longer than machine itself. Base thickness is to be at
least 5 cm. Loading space is to be smooth, with no sharp edges.
5. Electric wiring is to be carried out in accordance with pump manufacturer’s instructions and
regulations in force.
6. It is not allowed to place BlueStore® in explosion hazard areas, as well as on sidewalks and
pedestrian passages.
7. Space around the machine is to enable free and unobstructed traffic of vehicles.
8. Machine is to be placed by access road with required width, with enough space for U-turn, and
suitable for the load of AdBlue® supplier mobile cistern. Potential obstructions, in the form of
parked vehicles, overhead power lines, tree trunks, etc. are to be monitored and reduced on a
day-to-day basis by machine operator. Operator is to ensure safety of oil supply, as well as free
space around the machine for the purpose of periodic inspections and overhauls.
9. Machine location is to meet minimum distance requirements as in table below:

REQUIRED MINIMUM DISTANCES

OBJECT DISTANCE

Individual houses, apartment buildings, public buildings > 15 m

Other buildings, plot border, roads >5m

Sewers or heating system ducts >5m

Not applicable where the yard is equipped with linear drainage and oil separators >5m

Forest border > 10 m

Power line up to 1kV >3m

Power line 15kV to 30kV >5m

Power line 30kV to 110kV >10 m

Power line above 110kV > 30 m

Devices with surface heating up to temperatures exceeding 100°C > 0.5 m

65
10. While positioning and operating the machine never exceed below threshold noise values,
expressed in equivalent level of sound for residential development areas:
− 67 dB – during the day,
− 57 dB – during the night.
11. No explosion hazard areas are specified for BlueStore® machines.
12. Protect the machine from direct sunlight, especially when temperatures exceed 35º C, snow and
rain. It is recommended that the machine is placed under suitable roofing. Roofing shall be of
such height that it does not hamper the performance of service work. Around the machine there
should be free space with a minimum width of 0.5 m and a minimum of 1.0 m above the
machines.
13. BlueTruckMaster and BlueMaster® light both single-walled and double-wall tanks (in the
standard equipment version) do not have protection systems from the adverse effects of ambient
temperature. Therefore, they should be mixed on a permanent basis or at least during the winter
and summer on the premises with the temperature above -11° C and under +35° C. Failure to do
so may lead to the fact that the AdBlue® freezes and damages the equipment of the unit, while
too high temperatures will lead to its degradation (presence of ammonia).
14. Adjacent to the machines it is prohibited to use open flames, smoke and use other substances
that could cause ignition. Operator (owner) is obliged to provide a powder extinguisher 12 kg
near the machine, and mark it in accordance with safety regulations - (“Fire Extinguisher”), and
attach the sign “Using open fire and smoking prohibited”.

66
VI. ELECTRICAL SYSTEM
Electrical system for BlueMaster® and SlimLine machines is outside the scope of delivery and is to
be provided by Customer. Electrical system is to be carried out in accordance with below
instructions:

1. EARTHING
To successfully neutralize electrostatic charges on machines executed in
plastic, as well as on connected equipment, and to ensure effective shock
protection:
a) Place an earth electrode of copper or galvanized wire, cross-section
16 mm2, near the machine, to bring electrostatic charges to earth.
Connect the following to earth electrode:
− AdBlue® unloading system when refuelling the machine,
− earthing screw outside distributor enclosure (photo).
b) Connection to be executed with earthing cable with resistance below
10Ω.
c) PE protection cable (yellow and green) of pump power supply to be connected to the existing
power mains.

2. TEMPORARY POWER SUPPLY

When the machine is often moved it is allowed to use extensions with the following parameters:
− oil resistant cable, minimum cross-section 3x1.5 mm2 (copper wire),
− thermo-breaker for overload protection,
− socket with PE earthing and cover of current paths,
− protection index: at least IP44,
− fully functional; with no signs of wear, no damage to isolation, no loose contacts, no signs of rep
air, etc.
− extension feeder line cut-out value is to be C16A (value of trip current: 16 A with C type
characteristics).
When connecting and disconnecting the extension cable make sure that TMS switch is in OFF
position.

Make sure that the extension is not exposed to mechanical damage or

moisture.

67
3. PERMANENT POWER SUPPLY
The Blue TruckMaster® and BlueMaster® light are equipped with the power cord. When the machine
is not going to be moved it is recommended that permanent power
cord is installed, going directly to pump electrical box. The following One phase
requirements are to be met:

1. Power mains 230V is to be connected to control box in

accordance with wiring diagram, by qualified electrician. Mains is
to meet the requirements specified by pump (and possibly a
heating wire) manufacturer and provisions of regulations in force.
2. Power mains should be protected with C16A over-current fuse. In
addition, it is advisable to install a residual current device with trip
current of max 30mA.

Condenser
3. Use 3 x 2.5mm2 YKY power cord. For longer distances, use
cables with larger cross section, that there is no voltage drop over
5% of the nominal value. Cable must be protected against To engine
mechanical damage by hanging it on the height or placement in
the ground.
Diagram of the electrical box
4. If the cord is placed in the ground, the following requirements of the Suzzara pump
must be observed:
a) the cord should not be extended if the connection is to be in
the ground. If necessary, replace the entire cable with a
longer one or if it is not possible, the connection should be
made with a specialized sleeve that ensures adequate
durability and tightness.
b) the cord should be placed in the following depths:
- min. 0.5 m for lines arranged in the sidewalk
- min. 0.7 m for lines on the ground without surface
- min. 1 m for lines arranged under roads
Cables should be installed at least 1m from the road and
at least 2m from the tree trunks. Power junction box of the
®
BlueMaster
c) Cables should be arranged in such a way as to prevent
a SlimLine machines
their damage or damage to other cables or devices that
are built on the route of the line. Ambient temperature during
the installation of cables shall not be less than 0°C.
d) The cable should be placed in a casing pipe, which should
be placed in a dense layer of non-cohesive soil with a
thickness of 10 cm above and below the pipe. On a layer of
non-cohesive soil lay a subsoil layer with a thickness of 15
cm and cover it with blue warning foil. The rest of the trench
fill with subsoil and thicken.
e) Casing pipe should be sealed so as to prevent the ingress
of ground water, rain or rodents. All piping should be done
with a decline of 0.1% to allow drainage of water resulting
from a possible condensation. Power junction box of the
BlueMaster® light machines

68
5. Power supply box connection
a) In the event of power network TN-C, type, with only two power wires available – phase
(black or brown wire) and working zero (blue wire), it is recommended that PE wire (yellow
and green) is connected to power supply working zero terminal (blue wire).

Power supply box, type TN-C

Tank electrical box

Terminals

Power supply box

black or brown

blue

Electrical connection between the machine

and main switching station with power supply system TN-C

b) If the supply network is TN-S type, which means three power cables – phase (black or
brown cable), working zero (blue cable) and a safety cable (yellow and green), it is
recommended to connect the PE cable of the device (yellow and green) to the PE supply
cable (yellow and green).

69
VII. GENERAL SAFETY REQUIREMENTS

1. Material in store.
The basic source of information concerning hazardous material is Material Safety Data Sheet. Refer
to AdBlue® supplier to obtain MSDS.
AdBlue® is an aqueous urea solution obtained from technically pure urea (without contaminants) and
deionised water containing 32.5% urea. It is nontoxic, odourless, safe to handle and environmentally
friendly. High quality is required not only at the production stage but also during transport and
storage.
2. AdBlue® in accordance with applicable regulations is not classified as dangerous substance.
When handling this product, please note the following aspects:
− prolonged skin contact may cause skin irritation,
− eye contact may cause irritation, wear safety glasses with side shields,
− ingestion of larger quantities (more than 141cm³ of solution) causes gastrointestinal symptoms,
− use work clothing and gloves when refuelling the machine,
− when storing in closed tanks, ammonia at low concentrations may occur above the surface of the
solution.
3. Maintain order at the machine workplace. Provide suitable lighting. Supervision of the tank is the
responsibility of owner (or hirer, if the machine is rented). The machine can be operated by person
18 years old, who familiarized himself/herself with operation manual and operational safety
principles. Children and third persons are to stay away from the machine workplace.
4. Owner and operator of the machine is to take appropriate safety measures, with regard to nature and
reasonably predictable risks, to prevent damages/injuries, and, if necessary, to reduce their
consequences. Obligations are specified by relevant domestic regulations.
5. In the event of machine failure (leaks from tank, electric shock), person who observed such failure is
obliged to:
− stop work in hazardous area,
− switch off distributor power supply,
− immediately assist injured persons – having made sure that entrance to hazard zone is safe,
− remove from the hazardous area all persons not involved in the emergency and, if necessary,
order the evacuation; notify the supervisor,
− person with management capacity responsible for storage or hazard area , or person assigned by
such person, has to manage rescue activities, and, if necessary, notifies fire-brigade, ambulance
or other appropriate emergency services and provides them with necessary information,
− in the event of leak to pump its content to another machine,
− notify authorised service,
− prevent product from entering drains, water or soil, in the event of a release of large quantities of
the product notify appropriate authorities,
− cover small amounts of spilled liquid with non-combustible absorbent material such as sand,
sawdust, then gather in closed container for disposal, dispose of in accordance with applicable
regulations or hire a company entitled to transportation and disposal of waste,
− tanks exposed to fire or high temperature cool with water from a safe distance. If possible and
safe, remove them from the hazardous area.
The exact procedures in the event of failure should be included in safety instructions that should be
developed and placed in a conspicuous place near the unit.

70
6. In the case of injured persons first aid must be taken, depending on how the exposure occurred:
- by inhalation - remove victim from the contaminated area,
- ingestion - if swallowed, do not induce vomiting, give water to drink,
- skin contact - wash immediately with plenty of soap and water, remove contaminated clothing,
- eye contact - flush eyes with plenty of water for at least 10 minutes, if irritation persists get medical
attention.
If any irritation or discomfort, contact your doctor. In the workplace, skin contact - wash immediately
with plenty of soap and water, remove contaminated clothing,where employees are in contact with
AdBlue ®, provide easy access to running water. It is recommended to use protective equipment.
7. In the event of machine utilization it is to be disassembled to basic parts and then recycled in
accordance with European Directive 2002/96/EC.
8. Do not discharge contaminated fluid into drains. Prevent pollution of surface water and groundwater.
Recovery or disposal should be carried out in accordance with the principles of waste management,
environmental protection requirements and waste management plans, only in the place designated in
accordance with regulations and with systems or devices that meet certain requirements. It is
possible to use the polluted AdBlue® as a fertilizer.
9. Installation of equipment, particularly electrical wiring must be carried out very carefully, according to
applicable regulations. All maintenance work associated with the machine, performed by internal
services or third parties must be in accordance with the provisions of health and safety and fire
protection.

71
VIII. OPERATION GUIDELINES

The BlueStore® machines are designed and executed for durability, reliability and low maintenance
during operation. Heeding the following recommendations will help to keep the BlueStore® in best
operating condition:

1. REFUELLING OF MACHINES.
a. Refuelling can only be carried out by a trained person. In the situation where the tank is located
at a considerable distance from the tanker one person should observe the tanker while a second
person should observe the unit while filling is in progress.
b. In justified cases it is also required that person supervising refuelling of the machine wear bright
coloured clothing and hardhats. In addition, depending on situation, mobile tank driver is to wear
personal protective equipment, such as boots, goggles, gloves, ear protection, raincoats, etc. as
provided for this type of activities.
c. Fuel oil delivery place is to be secured for the period of refuelling with safety signs, warning lights,
etc.. Safety measures are to be used particularly when mobile tank occupies the whole street
width and obstructs normal traffic.
d. Prior to refuelling check the condition of inlet ferrule, oil level in the machine, and cleanness of
machine interior. Check if the machine is stable on the ground of adequate bearing capacity.
Damages and other irregularities make the machine unfit for refuelling.
e. The BlueStore® machines should only be refilled from delivery tankers specifically intended for
the transport and delivery of AdBlue®. If the BlueMaster®, SlimLine and BlueMaster® light
machines are equipped with the optional dry coupling, the refilling can only be done through a
leak proof connection and with the TMS control panel switched. Check the technical condition of
connections. Any damage make them unfit for using. If the connection items are contaminated
with crystallized AdBlue®, flush them with warm water.
Align and bring both connections (housing and hose) together. Turn the hose connection
15°clockwise until the connections lock.
To close the valves and to unlock the units, reverse the procedure.

Male filling line connection on right (in housing)

Female filling line connection on left (on hose end)

72
f. The machine can be filled up only to its rated capacity, which is 95% maximum capacity. Never
allow overfilling! After the beep signalling that the maximum level is achieved you should
immediately stop refuelling. Reset the alarm with "RESET" button.
g. Both loading and unloading of AdBlue® is to be carried out under strict supervision of properly
trained person.
h. Maximum allowed speed of refuelling the tank is 350 l / min., maximum filling pressure is 0.8
bar. For BlueTruckMaster® machines maximum allowed speed of refuelling is 150 l / min.
i. The delivery tanker must be leak proof and while refuelling the machine connected via
a suitable grounding wire to grounding stub.
j. Refuelling of BlueTruckMaster® and BlueMaster® light machines (standard versions without dry-
coupling) should be done using an automatic nozzle via 2" Eurofitting. During the refuelling level
indicator should be monitored.
k. The machines can store only pure AdBlue®. When refuelling use caution to avoid contamination
of the product.
l. The BlueMaster® SlimLine and Bluemaster® light machines (equipped with optional electronic
accessories) must be supplied with 230V AC during refuelling and operation, excluding
performance of service work, and the TMS control box and optional control devices must be
enabled.
This will ensure proper functioning of heating / cooling equipment. At temperatures below -
11.5°C the urea solution gets crystallized, leading to blockages and damages to parts of the
distribution system, and at temperatures above 35°C the urea is slowly decomposed (ammonia
excretion). Do not cover the fan and heating elements, periodically monitor their performance
and keep them clean.
Active TMS will also provide operation of level indicator, leak detector, maximum level alarm,
flow meter, lighting and telemetry.
m. It is not recommended to store AdBlue® longer than 6 months, because it is biodegradable
under the influence of bacteria and fungi. If the planned outage in operation is longer than 6
months, it is recommended to completely empty the tank and remove the AdBlue® from the
distribution system. Then thoroughly rinse pipe and pump with clean water, pumping a minimum
of 50 l. During the winter months the whole system should be emptied because freezing water
may cause damages to its elements. Before using again, the system requires repriming via
nozzle in suction pipe.
n. The TMS Control Panel allows you to reset to zero the current level indications. The procedure
is as follows:

73
 Pressure probe zeroing procedure
in TMS 1.40

Note: If the tank is not empty, remove the probe from the tank

Press and hold You will hear a

the reset button single beep Release the Press and hold You will hear a Release the Press and hold You will hear a Release the
for 10 seconds reset button the reset single beep reset button the reset double beep reset button
button for button for
10seconds 10seconds

The pressure probe has been zeroed.

The display shows 0

2. PROCEDURE BEFORE FIRST REFUELLING.

The BlueMaster® machines with a volume of 3,500 litres and above, and the SlimLine machines are
supplied with distribution system primed (except winter).
BEFORE STARTING THE PUMP CONTROL AND IF NECESSARY REFILL AdBlue® IN THE
DISTRIBUTION SYSTEM. WORKING DRY WITH DISTRIBUTION SYSTEM NOT PRIMED SHALL
CAUSE DAMAGE TO PUMP.

Proceed according to the following instructions:

a. Fill up the tank.

b. Open the valve located before the pump in the housing distributor.

74
c. Unscrew the lid for priming (located on the top of the inner container).

d. Remove the element of non-return valve.

e. Carefully prime or refill AdBlue® if the line is not completely primed.

f. Insert the element of non-return valve and screw the lid.

g. Switch on the TMS control system.
h. Lift the nozzle from the holder and push the clutch halfway.
i. When fluid appears fill first 20 litres to a separate can and dispose of.
j. If there is no flow in 1 minute, put the nozzle back and repeat priming.
Check the tightness of the suction line. Priming is a one-off activity carried out only during the
first run, after longer periods of operation, or some service work. During normal operation the
TMS system will prevent air from getting into suction line.

75
3. REFUELLING OF VEHICLE
1. Never operate the machine at temperatures below - 20°C and above +40°C, nor in bad weather
conditions such as strong wind, etc..
2. It is forbidden to park more than one vehicle near the machine. Park your vehicle at a proper
distance from the machine to ensure smooth distribution. Turn off the engine of refuelled
vehicle.
3. It is forbidden to park vehicle in a way obstructing possible emergency evacuation from fire
hazard area.
4. Before operation make sure that the machine contains the minimum necessary volume of
AdBlue®. The TMS will indicate an alarm and the pump will not start if the level in the tank is
below the minimum as running the pump dry will damage it. The minimum levels are 75 l for
1,200 l, 100 l for 2,500 l, 150 l for 3,500 l, 200 l for 5,000 l and 280 l for 9,000 l. In
BlueTruckMaster®, BlueMaster® light machines the current level is visible through the tank wall
or can be determined using indicators such as SmartBox pneumatic indicator.
5. Perform visual inspection of the machine condition. Check that the delivery system is in good
condition without visible signs of external damage.
6. After long periods of non-operation nozzle may be blocked by crystallized AdBlue®. Rinse it with
warm water (40˚C), pouring it directly into nozzle.
7. At the pump inlet open the ball valve. Place nozzle in vehicle tank inlet and hit the clutch to start
filling. If the distribution system is partially filled with air (after a longer period of non-operation)
push nozzle clutch for about 50% of the maximum opening, until complete venting.
8. After refuelling remove nozzle from the inlet of the vehicle and place in the holder. The TMS
display will automatically go from flow indication mode to current level indication mode.Close the
ball valve on the inlet of the pump. BlueMaster® and SlimLine machines must remain powered,
the TMS must be "ON". Only than all ventilation systems, heating and alarm systems will remain
active.
9. The BlueMaster ® light machines have simplified design (especially in the standard version) and
you should proceed with caution. In particular:
- observe the current level in the tank, submersible pump is not protected against dry running,
- in machines with manual taps use caution because they are not protected against overfilling
the tank of the vehicle.
10. In the event of spilling AdBlue® onto or near the machine immediately remove the spill and rinse
with plenty of water.
11. If there is a tank leak immediately pump the contents over to another container and inform the
supplier of the machine.
12. Never cover the venting ferrule, clean it regularly.
13. If you have different fauIts pIease contact the authorized service center.

76
IX. DISPOSAL

In order to protect the environment machine excluded from the operation must not be disposed of
together with unsorted household waste. After operation period the machine must be disposed of in
accordance with European Directive 2002/96/EC.

Recycling should be carried out by a specialist company. Tanks must be cleaned of

residual oil, cut up, divided into different components - from plastic, rubber, metal
and electronic components. Each of the materials should be recycled or disposed of
in accordance with current regulations. The resulting waste can not be mixed with
other waste, if it endangers the environment.

77
X. TROUBLESHOOTING - TYPICAL PROBLEMS AND SOLUTIONS

No. Problem Cause Advice

Using hand-operated hot air blower, heat

the connection carefully and dismantle it.
1 Leaking Damage to seals. Thoroughly clean threads and put
connection together. If damaged, replace
the faulty component.

Not enough Flowmeter miscalibration Perform recalibration.

measurement precision
2 Contaminated flowmeter chamber. Dismantle and clean flowmeter chamber.
(options with MC BOX
or calibratable panel). ®
Air content in AdBlue . Find and remedy leak in pump/suction line.

Filter clogged at end of suction line or blockage in

Remove and unblock the suction Line.
another part of suction Line.

3 Reduced flow rate.

Vent pumping system, check tightness of
Air in pump, air in AdBlue®.
suction line.

Incorrect pump power supply. Ensure proper power supply.

®
Air content in AdBlue . Find and remove leaks.
Increase in noise level
4 during pump operation.
Pump bearing broken, foreign body in engine fan. Fix the pump.

No power or wrong power supplied. Ensure proper power supply.

Dismount and check for damage and

Rotor jammed.
obstructions than remount.
Pump motor not
5 working
Fuse burned out. Check fuses in control box.

Switch OFF the pump and wait until engine

Pump thermal protection working.
cools down.

Remove liquid from bund. If leakage alarm

6 Leakage alarm. Tank was overfilled, rain water in bund, inner tank leak. sounds again, contact the Service
Department.

Leakage probe error Leakage probe broken or probe cable connection Check leakage probe and cable
7 alarm. broken. connection.

Prime suction system at the top of inner

Lack of fluid in pump and suction pipe.
container.
No flow during pump
8 operation. Nozzle blocked with crystallized AdBlue ®. Rinse nozzles with warm water.

Leak in suction system. Find and remove leaks.

Maximum level alarm is Contaminated or damaged level probe.

Reset audible alarm with RESET button,
9 not activated during
dismantle and check level probe.
refuelling.
Incorrect programmed TMS.

If above listed suggestions do not solve the problem please contact Kingspan Environmental service department. During the
warranty period repairs of the machine should be performed only by authorized personnel by the manufacturer.

78
XI. MACHINE MAINTENANCE

Item Activity Frequency

Check if machine accessories are complete. Replace or tighten all

1 damaged or loose parts. before operation

2 Check condition of electrical system and connections. before operation

3 Earthing condition, shock-protection effectiveness, continuity of PE wire. •

4 Check functionality of the level sensor. •
5 Check functioning of max level indicator. •
6 Check functioning of leakage sensor. •
7 Check and clean filter at the end of suction hose. •
8 Check cooling and heating system. •
9
Check condition and efficiency of distribution system.
Check for leaking joints. •
10
Check and tighten, if necessary, all joining elements, e.g. screws, bolts,
nuts, etc. Check all wires and electrical connections. •
11 Check and clean the equipment, outer tank and distributor housing. •
Proof metallic elements against corrosion.
12 Rubber parts (distribution hose, filler nozzle guard) to be protected with
rubber protection agents.
•
13 Check machine marking. •
• means every 6 months or every 50,000 litres of consumed fluid.
In order to maintain the machine in good working condition perform the above actions according to
the assigned time intervals.

79
XII. TERMS OF WARRANTY

1. The manufacturer issues warranty for:

10 years for tank leakproofness,
2 years for distribution system and other equipment.
2. When reporting failure the first step is to send Service Order (Defect Report Sheet) in writing
(e.g. by fax), to Kinsgpan Environmental Sp. z o.o..
3. Defects revealed within guarantee period shall be remedied within two weeks following the date
of report in writing. Guaranteed response time to notification is 48 hours on business days.
Defect reports are received 24/7. Report acceptance time for reports sent on 4 p.m. to 8 a.m.,
and on holidays and weekends, is 8 a.m. the following business day.
4. If within the warranty period the defect resulted from improper use, supervision or installation, or
if the fault took place after the expiry of the warranty, the reporting party shall be charged with
service costs.
5. The warranty does not include damages or malfunctions resulting from incorrect operation of the
machine, not compliant with the manufacturers' manual. Therefore, we recommend that you read
all manufacturer's manuals of the machine and additional manuals of pump, flowmeter or other
electronic accessories.
6. By placing order for service Purchaser agrees to be charged for services outside the scope of
guarantee offered by Service Centre authorized by manufacturer. Kingspan Environmental Sp. z
o.o. verifies reports, supports purchaser of service, and authorized service centre, to ensure
most effective performance of order company is not however the party in settlements between
Purchaser and service Contractor.
7. The warranty does not cover the following services:
− services required during the periodic reviews (recommended: every six months or after
50.000 litres delivered, or as needed),
− first start-up by an authorized service,
− calibration (flow meter, TMS, level sensors),
− cleaning / replacement of filters (recommended: every six months or as needed),
− pump chamber cleaning (recommended: every six months or as needed),
− replacement of damaged mechanical components of the pump,
− replacement of damaged rotor in the pump Flaco as a result of seizure,
− replacement of o-rings in pumps in case of leakage,
− repair / replacement of damaged pump as a result of seizure,
− repair of damages caused by contamination, e.g. rust in pumps, flowmeters and other items
of equipment,
− modifications by the owner / unauthorized repairs of parts,
− mechanical damage - broken housing, broken handle, etc., that indicate improper use,
− contamination of the nozzle sensor,
− mechanical damage of the nozzle, evidence of improper use or vandalism,
− programming of MC box settings,
− replacement of fuses (for pumps, TMS, MC Box)
− electrical short-circuit: TMS, MC Box, Flaco panel, pumps, caused by improper electrical
connection,

80
− replacement of batteries (for digital flow meter, oil level indicators, etc.),
− cleaning of the tank and equipment such as flow meter, nozzle of the crystallized AdBlue®,
− replacement of pump shaft seal, seals on joints.

You can find serial

number of machine in
these locations

Kingspan Environmental is not liable for any damage resulting from

product use at variance with the supplier’s instruction or with applicable
legal regulations.

81
XIII. MANUAL PUMP SUZZARABLUE

A. TABLE OF CONTENTS
A TABLE OF CONTENTS
B MACHINE AND MANUFACTURER IDENTIFICATION
C DECLARATION OF INCORPORATION OF THE PARTLY-COMPLETED MACHINERY
D MACHINE DESCRIPTION
D1 HANDLING AND TRANSPORT
E GENERAL WARNINGS
F FIRST AID RULES
G GENERAL SAFETY RULES
H TECHNICAL DATA
H1 PERFORMANCE SPECIFICATIONS
I ELECTRICAL DATA
L OPERATING CONDITIONS
L1 ENVIRONMENTAL CONDITIONS
L2 ELECTRICAL POWER SUPPLY
L3 DUTY CYCLE
L4 PERMITTED AND NON-PERMITTED F
M INSTALLATION
M1 POSITIONING, CONFIGURATIONS AND ACCESSORIES
M2 NOTES ON SUCTION AND DELIVERY LINES
N CONNECTIONS
N1 ELECTRICAL CONNECTIONS
N2 PIPING CONNECTIONS
O INITIAL START-UP
P EVERY DAY USE
Q MAINTENANCE
R NOISE LEVEL
S PROBLEMS AND SOLUTIONS
T DEMOLITION AND DISPOSAL
U VISTE ESPLOSE / EXPLODED VIEWS
V INGOMBRI / OVERALL DIMENSIONS

82
B. MACHINE AND MANUFACTURER IDENTIFICATION

C. DECLARATION OF INCORPORATION
OF THE PARTLY-COMPLETED MACHINERY

The undersigned
PIUSI S.p.A
Via Pacinotti c.m.- z.i.Rangavino
46029 Suzzara - Mantova – Italy

HEREBY STATES under its own responsibility, that the partly-completed machinery:
Description: Pump for the transfer of AUS32 - WATER
Model: Diaphragm pump
Serial No.: refer to Lot Number shown on CE plate a&xed to product
Year of manufacture: refer to the year of production shown on the CE plate a&xed to the
product.

Is intended to be incorporated in a machine (or to be with other machines) so as to

create a machine to which applies Machine Directive 2006/42/EC, may not be brought
into service before the machine into which it is to be incorporated has been declared in
conformity with the provisions of the directive 2006/42/EC.
Is in conformity with the legal provisions indicated in the directives:
- Machine Directive 2006/42/EC
- Electromagnetic Compatibility Directive 2004/108/EC

To which the essential safety requirements have been applied and complied with
what indicated on annex I of the machine directive applicable to the product and shown
below: 1.1.3 - 1.1.5 - 1.3.1 - 1.3.2 - 1.3.3 - 1.3.4 - 1.3.7 - 1.3.8 - 1.4.1 - 1.4.2.1 - 1.5.1 - 1.5.2 - 1.5.4
- 1.5.5 - 1.5.8 - 1.5.9 - 1.5.11 - 1.5.13 - 1.5.15 - 1.6.1 - 1.6.3 - 1.6.4 - 1.7.1 - 1.7.2 - 1.7.3 - 1.7.4.

The documentation is at the disposal of the competent authority following motivated

request at Piusi S.p.A. or following request sent to the email address:
doc_tec@piusi.com

The person authorised to compile the technical "le and draw up the declaration is Otto
Varini as legal representative.

Suzzara, 29/12/2009 Legal Representative

83
D. MACHINE DESCRIPTION

PUMP: Five-chamber positive-displacement diaphragm pump.

MOTOR: Asynchronous motor, single-phase, 2 pole, closed type, protection class IP55 according to
CEI-EN 60034-5.

Handling and transport

Due to the limited weight and dimensions of the pumps, special lifting equipment is not required to
handle them. The pumps are carefully packed before dispatch. Check the packing when receiving
the material and store in a dry place.

E. GENERAL WARNINGS

Important precautions
To ensure operator safety and to protect the pump from potential damage, workers must be fully
acquainted with this instruction manual before performing any operation.

Symbols used in the manual

The following symbols will be used throughout the manual to highlight safety information and
precautions of particular importance:

ATTENTION
This symbol indicates safe working practices for operators and/or potentially exposed
persons.

WARNING
This symbol indicates that there is risk of damage to the equipment and/or its
components.

NOTE
This symbol indicates useful information.

Manual preservation
This manual should be complete and legible throughout. It should remain available to end users and
specialist installation and maintenance technicians for consultation at any time.

Reproduction rights
All reproduction rights are reserved by Piusi S.p.A. The text cannot be reprinted without the written
permission of Piusi S.p.A.

84
F. FIRST AID RULES

Contact with the product

In the event of problems developing following EYE/SKIN CONTACT, INHALATION or INGESTION
of the treated product, please refer to the SAFETY DATA SHEET AUS32/DEF/AD-BLUE.

Persons who have suffered electric shock

Disconnect the power source, or use a dry insulator to protect yourself while you move the injured
person away from any electrical conductor. Avoid touching the injured person with your bare hands
until he is far away from any conductor. Immediately call for help from qualified and trained
personnel. Do not operate switches with wet hands.

NOTE
Please refer to the safety data sheet for the product

G. GENERAL SAFETY RULES

Essential protective equipment characteristics

Wear protective equipment that is:
- Suited to the operations that need to be performed;
- Resistant to cleaning products,

Personal protective equipment that must be worn

safety shoes;

close-fitting clothing;

protection gloves;

safety goggles;

instructions manual

Protective gloves

Prolonged contact with the treated product may cause skin irritation; always wear
protective gloves during dispensing.

85
 DANGER
Never touch the electric plug or socket with wet hands.
Do not switch the dispensing system on if the network connection cable or important parts
of the apparatus are damaged, such as the inlet/outlet pipe, nozzle or safety devices. Replace the
damaged pipe immediately.
Before each use, check that the network connection cable and power plug are not damaged. Have
the
network connection cable replaced immediately by a qualified electrician.

ATTENTION
The electrical connection between the plug and socket must be kept well away from
water.
Unsuitable extension leads can be dangerous. In accordance with current regulations, only
extension cords that are labelled for outdoor use and have a sufient conduction path should be used
outdoors.
For safety reasons, we recommend that, in principle, the equipment be used only with a earth-
leakage circuit breaker (max 30 mA).

H. TECHNICAL DATA

1. PERFORMANCE SPECIFICATIONS
The performance diagram shows flow rate as a function of back pressure.

Typical Delivery Configuration

No. 4 metres of ¾”

Manual nozzle

Functioning
Absorption (A)

Point
Voltage (V)

Dispensing
K24 Meter
Flow Rate

Automatic

Nozzle
pipe

A 28 120 3.1
● ●
(Maximum fow rate) 32 230 1.2
B 27 120 3.2
● ● ●
(High fow rate) 31 230 1.3
C 25 120 3.3
● ● ●
(Normal conditions) 29 230 1.3
D 120 3.3
0 Delivery closed
(By pass) 230 1.3

86
ATTENTION

The curve refers to the following operating conditions:

Fluid: AUS32 - DEF - ADBLUE®
Temperature: 20°C
Suction conditions: The pipe and the pump position relative to the fluid level is such that a low
pressure of 0.3 bar is generated at the nominal flow rate. Under diferent suction conditions higher
low pressure values can be created that reduce the flow rate compared to the same back pressure
values. To obtain the best performance, it is very important to reduce loss of suction pressure as
much as possible by following these instructions:
- Shorten the suction pipe as much as possible,
- Avoid useless elbows or throttling in the pipes,
- Keep the suction filter clean,
- Use o pipe with a diameter equal to, or greater than, indicated (see Installation).

I. TECHNICAL DATA

POWER SUPPLY CURRENT

PUMP MODEL
Current Voltage (V) Frequency (Hz) Max (*) (A)
120V version AC 120 60 3.5
230V version AC 230 50 1.5
(*) Refers to functioning in by-pass mode.

87
J. OPERATING CONDITIONS

1. ENVIRONMENTAL CONDITIONS

TEMPERATURE
min. +23 °F / max +104 °F
min. -5 °C / max +40 °C

RELATIVE HUMIDITY
max. 90%

LIGHTING
The environment must conform to directive 89/654/EEC on work environments.
In case of non-EU countries, refer to directive EN ISO 12100-2 § 4.8.6.

ATTENTION
The temperature limits shown apply to the pump components and must be
respected to avoid possible damage or malfunction.

2. ELECTRICAL POWER SUPPLY

NOTE
The pump must be powered by AC single-phase line, the nominal values of which are
indicated on the table in the paragraph "G - ELECTRICAL DATA".
The maximum acceptable variations from the electrical parameters are:
Voltage: +/- 5% of the nominal value
Frequency: +/- 2% of the nominal value

ATTENTION
Power supply from lines with values that do not fall within the indicated limits
could cause damage to the electrical components.

3. DUTY CYCLE

NOTE

The pumps have been designed for intermittent use and a 20-minute duty cycle under
conditions of maximum back pressure.

ATTENTION
Functioning under by-pass conditions is only allowed for short periods of time
(max. 3 minutes).

88
4. PERMITTED AND NON-PERMITTED FLUIDS

FLUIDS PERMITTED

- AUS32 (DEF, AD-Blue);

- WATER
- LIQUID FOOD PRODUCTS

FLUIDS NON PERMITTED AND RELATED DANGERS

- DIESEL FUEL - OXIDATION OF PUMP
- PETROL - FIRE
- INFLAMMABLE LIQUIDS - EXPLOSION
- CORROSIVE CHEMICAL PRODUCTS - CORROSION AND INJURY TO PERSONS
- SOLVENTS - DAMAGE TO GASKET SEALS
- LIQUIDS WITH VISCOSITY >20 cst - MOTOR OVERLOAD

K. INSTALLATION

ATTENTION
The pump must never be operated before the delivery and suction lines have been
connected.

PRELIMINARY INSPECTION
- Verify that all components are present. Request any missing parts from the manufacturer.
- Check that the pump has not su$ered any damage during transport or storage.
- Carefully clean the suction and delivery inlets and outlets, removing any dust or other packaging
material that may be present.
- Check that the electrical data corresponds to those indicated on the data plate.
- Always install in an illuminated area.
- Install the pump at a height of min. 80 cm.

1. POSITIONING, CONFIGURATIONS AND ACCESSORIES

NOTE
In the case of installation in the open air, proceed to protect the pump by providing a
protection roof.
The pump can be installed in any position (pump axis vertical or horizontal).
The pump must be secured in a stable way using the holes on the bed of the motor and
vibration damping devices.

ATTENTION
THE MOTORS ARE NOT OF THE ANTI-EXPLOSIVE-TYPE. DO NOT install them
where inflammable vapours could be present.

NOTE
The broad range of pump accessories make it suitable for many di$erent uses,
installations and applications. The supporting base can be positioned in di$erent ways.

89
 NOTE
The pump can be installed in any position (pump axis vertical or horizontal)

ATTENTION
It is the responsibility of the installer to provide the necessary line accessories to ensure
the correct and safe operation of the pump. The accessories that are not suitable to be
used with the previously indicated material could damage the pump and/ or cause injury to
persons, as well as causing pollution.

ATTENTION
To maximise performance and prevent damage that could affect pump operation, always
demand original accessories.

2. NOTES ON SUCTION AND DELIVERY LINES

DELIVERY
EFFECTS ON FLOW RATE
Length and diameter of pipe, flow rate of dispensed liquid, accessories fitted, can create back
pressures above those allowed.
In this case, the pump mechanical control (bypass) will trip to reduce the flow rate.

HOW TO REDUCE EFFECTS ON FLOW RATE

To avoid these problems, system flow resistances must be reduced using shorter and/or larger
diameter pipes, as well as line accessories with low resistances (e.g., automatic nozzle for higher
flow rates).

CHARACTERISTICS OF DELIVERY PIPES

The delivery pipe must have the following technical characteristics:

- recommended minimum nominal diameter: ¾”

- recommended nominal pressure: 10 bar

90
SUCTION

FOREWORD
Diaphragm positive-displacement pumps are self-priming and feature good suction capacity.
During the start-up phase, when the suction pipe is empty and the pump is wet, the electric pump
unit is able to suck liquid from a maximum vertical distance of 2 mt.

IMPORTANT NOTE
Priming time can last a few minutes. We suggest performing priming operations without
automatic nozzle and making sure the pump is properly wet.

WARNING
Always install a foot valve to prevent the suction pipe from being emptied and to keep the
pump wet at all times. In this way, the pump will always start up immediately the next
times it is used.

CAVITATION
The pump is able to work with vacuums of up to 0.5 bar at the suction mouth. Over this value,
CAVITATION can occur that causes a fall in flow rate and increase in noise levels.

HOW TO PREVENT CAVITATION

It is important to ensure low vacuums at suction mouth by using:
- short pipes with larger or identical diameter to that recommended
- reduce bends to the utmost
- use large-section suction filters
- use foot valves with minimum possible resistance
- keep the suction filters clean because, when they become clogged, they increase the resistance of
the system.

WARNING
The vertical distance between the pump and the fluid must fall within the 2 mt. maximum
required for priming. If the distance is greater, a foot valve must be installed to allow the
suction pipes to "ll up and the diameter pipes must be larger. It is recommended that the
pump not be installed at a vertical distance greater than 2 meters.

ATTENTION
If the suction tank is higher than the pump, an antisiphon valve should be installed
to prevent accidental product leaks. Size the installation to contain the back
pressures caused by water hammering.

ATTENTION
It is a good system practice to immediately install vacuum and air pressure gauges
at the inlets and outlets of the pump which allow verification that operating
conditions are within anticipated limits. To prevent the suction pipes from being
emptied when the pump stops, a foot valve should be installed.

CHARACTERISTICS OF THE SUCTION PIPES

The suction pipe must have the following technical specifications:
- recommended minimum nominal diameter: ¾”;
- recommended nominal pressure: 10 bar;
- use pipes suitable for low pressure operation (e.g. with metal core)

91
L. CONNECTIONS

a. ELECTRICAL CONNECTIONS

ATTENTION
IT IS THE INSTALLER'S RESPONSIBILITY TO CARRY OUT THE ELECTRICAL
CONNECTIONS IN COMPLIANCE WITH THE RELEVANT STANDARDS.

WARNING
Comply with the following (not exhaustive) instructions to ensure a proper electrical
connection:

- During installation and maintenance make sure that power supply to the electric lines has been
turned off.
- Use cables with minimum sections, rated voltages and installation type that are suitable for the
characteristics indicated in paragraph "I - ELECTRICAL DATA" and the installation environment.
- Always make sure that the cover of the terminal strip box is closed before switching on the power
supply, after having checked the integrity of the seal gaskets that ensure the IP55 protection grade.
- All motors are equipped with a grounding terminal that is to be connected to the ground line of the
electrical system.

PUMP FITTINGS
The pump is "fitted with:
- single-phase motor with 2-mt. power cord,
- bipolar switch,
- capacitor.
Wired and installed inside the terminal strip box (see chart).

NOTE
The capacitor characteristics are those indicated on the pump label. The switch has the
only function of starting/ stopping the pump and cannot in any way replace the main
power switch required by the relevant standards.

SWITCH

92
b. PIPING CONNECTIONS

FOREWORD
- Before carrying out any connection, refer to the visual indications i.e. arrow on the pump head, to
identify suction and delivery.

ATTENTION
Wrong connection can cause serious pump damage.

PRELIMINARY INSPECTION
- Before connection, make sure that the piping and the suction tank are free of dirt and solid residue
that could damage the pump and its accessories.
- Before connecting the delivery pipe, partially fill the pump body, from delivery side, with the liquid
that needs to be pumped in order to facilitate priming.
- Do not use conical threaded fittings, which could damage the threaded inlet or outlet openings of
the pump if excessively tightened.

NOTE
If not already fitted, fit a suction filter.

93
M. INITIAL START-UP

FOREWORD
- Check that the quantity of fluid in the suction tank is greater than the amount you wish to transfer.
- Make sure that the residual capacity of the delivery tank is greater than the quantity you wish to
transfer.
- Make sure that the piping and line accessories are in good condition.

ATTENTION
Do not run the pump dry for more than 20 minutes. This can cause serious damage
to its components.
Fluid leaks can damage objects and injure persons.

NOTE
- Never start or stop the pump by connecting or cutting out the power supply.
- Prolonged contact with some fluids can damage the skin. The use of goggles and
gloves is recommended.

ATTENTION
Extreme operating conditions with duty cycles longer than 20 minutes can cause
the motor temperature to rise thus damaging the engine. For each duty cycle of 20
minutes, allow for a rest phase of 20 minutes with motor switched off.

NOTE
During the priming phase, the pump must discharge all the air that is initially
present from the delivery line. Therefore it is necessary to keep the outlet open to
permit the evacuation of the air.

WARNING
If an automatic type dispensing nozzle is installed on the end of the delivery line,
the evacuation of the air will be difficult because of the automatic stopping device
that keeps the valve closed. It is recommended that the automatic nozzle be
temporarily removed during initial start-up.

IF THE PUMP DOES NOT PRIME

Depending on the system characteristics, the priming phase can last from several seconds to a few
minutes. If this phase is prolonged, stop the pump and verify:
- that the pump is not running completely dry (fill with fluid from the delivery line);
- that the suction pipe guarantees against air infiltration;
- that the suction filter is not clogged;
- that the suction height is not higher than 2 mt.
- that all air has been released from the delivery pipe.
AT THE END OF THE INITIAL START-UP
When priming has occurred, verify that the pump is operating within the anticipated range, in
particular:
- that under conditions of maximum back pressure, the power absorption of the motor stays within
the values shown on the identification plate;
- that the suction pressure is not greater than 0.5 bar;
- that the delivery back pressure does not exceed the maximum back pressure for the pump.

94
N. EVERY DAY USE

USE PROCEDURE
1. If flexible pipes are used, attach the ends of the piping to the tanks. In the absence of an
appropriate slot, solidly grasp the delivery pipe before beginning dispensing.
2. Before starting the pump make sure that the delivery valve is closed (dispensing nozzle or line
valve).
3. Turn the ON/OFF switch on.
4. Open the delivery valve, solidly grasping the pipe.
5. While dispensing, do not inhale the pumped product
6. Should you spill any fluid while dispensing, bank it with earth or sand to absorb it and limit its
spreading.
7. Close the delivery valve to stop dispensing.
8. When dispensing is finished, turn o$ the pump.

ATTENTION
The by-pass valve allows functioning with delivery closed only for short periods
(max. 3 minutes)
To avoid damaging the pump, after use, make sure the pump is off.
In case of a power break, switch the pump off straight away.
Should any sealants be used on the suction and delivery circuit of the pump, make sure that
these products are not released inside the pump.
Foreign bodies in the suction and delivery circuit of the pump could cause malfunctioning
and breakage of the pump components.
In case of prolonged dry-running of the pump, the suction circuit may be empty and suction
may become di&cult. If so, !ll the suction circuit with demineralised water.

O. MAINTENANCE

Safety instructions
The dispensing system was designed and built to require a minimal amount of maintenance.
Before carrying out any maintenance work, disconnect the dispensing system from any electrical
and hydraulic power source.
During maintenance, the use of personal protective equipment (PPE) is compulsory.
In any case always bear in mind the following basic recommendations for a good functioning of the
pump.

Authorised maintenance personnel

All maintenance must be performed by qualified personnel.
Tampering can lead to performance degradation, danger to persons and/or property and may result
in the warranty being voided.

Measures to be taken
Whenever there is risk of frost, empty the circuit and the pump, taking care to place the pump in an
environment where the temperature is no lower than 0°C/32°F.
Check that the labels and plates found on the dispensing system do not deteriorate or become
detached over time.

95
ONCE A WEEK:
- Check that the pipe connections are not loose to prevent any leaks;
- Check and keep the "lter installed on the suction line clean.

ONCE A MONTH:
- Check the pump body and keep it clean and free of any impurities;
- Check that the electrical supply cables are in good condition.

Long periods without the pump being used

Whenever it is thought that the system will remain unused for at least 15 days, it must be emptied in
order to prevent the product from crystallising inside. This shall be followed by a washing cycle.

P. NOISE LEVEL

In normal operating conditions, noise emissions of all models do not exceed 70 dB at a distance of 1
metre from the electric pump.

96
R. PROBLEMS AND SOLUTIONS
For any problems contact the authorised dealer nearest to you.
PROBLEM POSSIBLE CAUSE
Lack of electric power.
THE MOTOR IS NOT
TURNING Rotor jammed.
Motor problems.
THE MOTOR TURNS Low voltage in the electric
SLOWLY WHEN STARTING power line.
Low level in the suction tank.
Foot valve blocked.
Filter clogged.
Excessive suction pressure.
High loss of head in the
delivery circuit (working with
the by-pass open).
LOW OR NO FLOW RATE
By-pass valve blocked.
Air entering the pump or the
suction piping.
A narrowing in the suction
piping.
Low rotation speed.
The suction piping is resting
on the bottom of the tank.
Cavitation occurring.
Irregular functioning of the by-
INCREASED PUMP NOISE
pass.
Presence of air in the fluid.
LEAKAGE FROM THE
Seal damaged.
PUMP BODY
Suction circuit blocked.
Malfunction of foot valve
THE PUMP DOES NOT fitted on suction circuit.
PRIME THE LIQUID
The suction chambers are dry.
The pump chambers are dirty
or blocked.
CORRECTIVE ACTION
Check the electrical
connections and the safety
systems.
Check for possible damage
or obstruction of the rotating
components.
Contact the Service
Department.
Bring the voltage back within
the anticipated limits.
Refill the tank.
Clean and/or replace the valve.
Clean the filter.
Lower the pump with respect
to the level of the tank or
increase the cross-section of
the piping.
Use shorter piping or of
greater diameter.
Dismantle the valve, clean
and/or replace it.
Check the seals of the
connections.
Use piping suitable for
working under suction pressure.
Check the voltage at the
pump. Adjust the voltage and/
or use cables of greater
crosssection.
Raise the piping.
Reduce suction pressure.
Dispense until the air is purged
from the by-pass system.
Verify the suction connections.
Check and replace the seal.
Remove the blockage from
the suction circuit.
Replace foot valve.
Add liquid from pump delivery
side.
Remove the blockages from
the suction and delivery valves.
97
S. DEMOLITION AND DISPOSAL

Foreword
If the system needs to be disposed, the parts which make it up must be delivered to companies that
specialize in the recycling and disposal of industrial waste and, in particular:
DISPOSAL OF OTHER PARTS:

Disposal of packing materials

The packaging consists of biodegradable cardboard which can be
delivered to companies for normal recycling of cellulose.

Disposal of metal parts

Metal parts, whether paint-finished or in stainless steel, can be consigned to scrap metal collectors.

Disposal of electric and electronic components

These must be disposed of by companies that specialize in the disposal of electronic components, in
accordance with the indications of directive 2002/96/CE (see text of directive below).

Information regarding the environment for clients residing within the

European Union
European Directive 2002/96/EC requires that all equipment marked with this
symbol on the product and/or packaging not be disposed of together with
non-differentiated urban waste. The symbol indicates that this product must
not be disposed of together with normal household waste. It is the
responsibility of the owner to dispose of these products as well as other
electric or electronic equipment by means of the specific refuse collection structures indicated by the
government or the local governing authorities.

Disposal of miscellaneous parts

Other components, such as pipes, rubber gaskets, plastic parts and wires, must be disposed of by
companies specialising in the disposal of industrial waste.

98
XIV. TURBINOX USE AND MAINTENANCE MANUAL

A. TABLE OF CONTENTS

A. TABLE OF CONTENTS
B. DETAILS
C. MEASUREMENT PRINCIPLES
D. FLOW METER
D1 90° HOSE-END FITTING
D2 IN LINE
D3 HOW IT WORKS
E. TECHNICAL DATA
F. INSTALLATION
G. DAILY USE
H. MAINTENANCE
I. DISPOSAL

99
B. DETAILS

The turbine flow meter (Turbinox) represents a range of flow meters developed to meet the different
control and measurement requirements during the transfer of liquids.

In accordance with the materials used for its construction (Stainless steel AISI 316I and A2 for body
and components, samarium-cobalt for magnets, Viton for seals and polypropylene for the impeller),
Turbinox can be used with different kinds of liquids such as acetone, alcohol, aniline, mineral oils,
vegetable oils, petrol, diesel fuel, water, urea/water solution.

The turbine/impeller measurement principle Allowi you to obtain a high degree of accuracy (for the
flow rate indicated) together with reduced load loss.

C. MEASURING PRINCIPLE

As it moves through the instrument, the fluid causes the turbine/impeller to start rotating; during
rotation, the turbine/impeller transfers “units of fluid” of a constant volume.

The exact measurement of the fluid dispensed is calculated by counting the revolutions of the
turbine/impeller and therefore the units of fluid transferred. The magnetic coupling, with the magnets
installed In the turbine/impeller and a magnetic switch located outside the measuring chamber,
guarantee the seal of the measuring chamber and ensure that the impulses generated by the
rotation of the turbine/ impeller are transmitted to a microprocessor.

D. THE FLOW METER

D1 WITH 90° HOSE-END FITTING

The body of the flow meter is made of turned stainless steel, with 1-inch thread and hose-end fitting
at the outlet for ease of installation on piping (fixed system). The hose-end fitting, which is part of the
flow meter, has a 90° angle compared to the body of the flow meter and allows direct dispensing of
the measured liquid.

D2 IN LINE

The body is made of turned stainless steel. It Has two 1”-inch male threaded connectors. This
version is to be installed in line between the pipes and fixe systems. It is easy to install, but does not
allow for direct dispensing, except at the end of the system line in which the Turbinox is installed.

100
D3 HOW IT WORKS

Turbinox Pulser is a single-channel impulse transmitter. The Reed ampoule translates the magnetic-
field variations generated by the rotation of the turbine/impeller into electrical impulses to be sent to
an external receiver. The connection should be made in accordance with the diagram found in the
chapter “Installation”.

The pulser does not need an independent electrical power supply because it is powered directly by
the connection with the receiver. The type of impulse emitted is represented by a square wave
generated by the voltage variation, in accordance with the following diagram:

The calibration of the instrument is made by means of the external impulse receiver.

E. TECHNICAL DATA

DATUM U. of M. VALUE
Measurement System Turbine / impeller
Resolution L/impulse 0,011
Flow rate field * L/min. min. 10 - max 40
Storage Temperature °C -20 / +70
Storage Humidity R.U. 95%
Operating Temperature °C -10° / +60°
Head loss (at 40 lit) bar 0,05 in line - 0,1 a 90°
Compatible Fluids cetone, alcohol,
aniline, mineral oils,
vegetable oils, petrol,
diesel fuel, water,
water/urea solution
Precision % +/- 1
Repeatability % +/- 0,4
Peso G 380
Type of Impulse clean contact (reed switch)
Max Current mA 100
Max Voltage Volt ac/dc 28
Impulse / Litre no. 92
Max. operating pressure bar 20
Max. bursting pressure bar 40

* NOTA BENE:
Do not use Turbinox at a flow rate that exceeds 40 litres/minute. Using it at higher flow rates
causes excessive wear of components.

101
F. INSTALLATION

The turbine flow meter (Turbinox) is designed to be installed as a fixed installation on a distribution
line. The hydraulic connections during the installation phase must be carried out by qualified
personnel.

The Turbinox pulser must be connected by means of two cables, in compliance with the electrical
characteristics shown on the diagram:

G. DAILY USE

Turbinox is supplied ready-to-use. Even after long periods of storage, commissioning operations are
not required. Once the flow meter has been correctly connected to the impulse receiver, there is no
Reed to switch it on or off.

H. MAINTENANCE

The turbine flow meter (Turbinox) has been designer so that it does not require maintenance.

The only work that may be necessary is the replacement of the o-ring seal (X on the exploded
diagram).

If there are serious impeller blockage problems caused by excess dirt, it is possible to replace the
entire measuring unit.

I. DISPOSAL

The components must be given to companies that specialise in the disposal and recycling of
industrial waste and, in particular, the

DISPOSAL OF PACKAGING.
The packaging consists of biodegradable cardboard which can be delivered to companies for normal
recycling of cellulose.

DISPOSAL OF METAL COMPONENTS

The metal components, both painted and stainless steel, are usually recycled by companies that are
specialised in the metal-scrapping industry.

102
DISPOSAL OF ELECTRIC AND ELECTRONIC COMPONENTS:
these have to be disposed by companies that are specialised in the disposal of electronic
components, in accordance with the instructions of 2002/96/EC (see text of Directive below).

ENVIRONMENTAL INFORMATION FOR CUSTOMERS IN THE EUROPEAN UNION

European Directive 2002/96/EC requires that the equipement Bering this symbol
on the product and/or its packaging must not be disposed of with unsorted
municipal waste. The symbol indicates that this product should be disposed of
separately from regular household waste streams. It is your responsibility to
dispose of this and other electric and electronic equipment via designated
collection facilities appointed by the government or local authorities.

DISPOSAL OF OTHER PARTS:

DECLARATION OF CONFORMITY
In accordance with directive:
89/336/CEE (electromagnetic compatibility) and subsequent amendments
PIUSI S.p.A. - 46029 Suzzara (Mantova) Italy declares that the following flow meter model
TURBINOX to which this declaration makes reference, complies with the following
applicable norms:
European norms: EN 61000-6-1; EN 61000-6-3; EN 55014-1-2000;EN55014-2-97

Suzzara, 29/12/2009 Podpis

103
XV. FLOW METER USE AND MAINTENANCE MANUAL

INDEX

A. Becoming acquainted with Remote Display: General

B. Installation
C. Daily use
C1. Dispensing in Normal mode
C.1.1 Azzeramento del Parziale
C.1.2 Resetting the Reset Total
C2. Dispensing with Flow Rate Mode display
C.2.1. Partial reset
D. Calibration
D1. Definitions
D2. Why calibrate
D3. Calibtation Procedure
D.3.1. Display of Current Calibration Factor and Restoring Factory Factor
D.3.2. In Field Calibration
D.3.2.1. Sequence of operations to be performed for correct in-field calibration
D.3.3. Direct Modification of K Factor
E. Pulse Transmitter (Puls OUT)
F. Maintenance
G. Malfunctions
H. Technical Details
I. Remote Display maintenance

104
A. BECOMING ACQUAINTED WITH REMOTE DISPLAY:
GENERAL

Remote Display is a digital remote display system of the amount of fluid dispensed and measured by an
electronic meter featuring an oval-gear measurement system or a turbine/impeller.
The transmission of electric pulses from meter to Remote Display is carried out through a simple 2-wire
cable.

Below is the logic connection diagram:

The user can choose between two different operating modes:

- Normal Mode: Mode with display of Partial and Total dispensed quantities
- Flow Rate Mode: Mode with display of Flow Rate as well as Partial dispensed
quantity.
The Remote Display features a non-volatile memory for storing the dispensing data, even in the
event of a complete power break for long periods.

Main components:

1) LCD display

105
The “LCD” of the RD features two numerical registers and various indications displayed to the user only
when the applicable function so requires

Legend:
1. Partial register (5 figures with moving comma: 0.000 ÷ 99999 ),
indicating volume dispensed from when the RESET button was last pressed;
2. Indication of battery charge;
3. Indication of calibration mode;
4. Totals register (6 figures with moving comma 0.0÷999999 x10 / x100),
that can indicate two types of Total:
4.1. General Total that cannot be reset ( TOTAL )
4.2. 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

2) User Buttons

and, together, other secondary functions.

The main functions performed are:

- for the RESET key, resetting the partial register and Reset Total
- for the CAL key, entering instrument calibration mode
Used together, the two keys permit entering configuration mode where the desired unit of
measurement can be set.

106
3) Battery Housing

The Remote Display is powered by two standard 1,5 V (size AA) batteries.
The batteries are inside the Remote Display (see photo chapter L).

B. INSTALLATION

The Remote Display has been specifically designed for stationary installation. The display is fitted with
a bracket that allows its rotation for best reading inclination.
To connect the pulser, loosen the 4 fixing screws of the rear lid, open the lid and insert the cable into
the cable gland. The two electrical wires of the cable must be connected to a terminal (see photo) with
two screws. Close the lid, ensuring that the o-ring is placed properly to guarantee a perfect seal.
Below are the connection diagrams, models without Pulse Transmitter and with Pulse Transmitter,
featuring the two power options by means of battery or external power supply.

REMOTE DISPLAY CONNECTION DIAGRAM WITHOUT PULSE

TRANSMITTER (Pulse Out) - EXTERNAL / INTERNAL POWER

107
 REMOTE DISPLAY CONNECTION DIAGRAM WITH PULSE
TRANSMITTER (Pulse Out) - EXTERNAL / INTERNAL POWER

C. DAILY USE

METER is delivered ready for use. No commissioning operations are required even after long
storage periods. The only operations that need to be done for daily use are Partial and/or Reset Total
register resetting. 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.
The PARTIAL REGISTER positioned in the top part of the display indicates the quantity dispensed
since the RESET key 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 different 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.

108
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
- For a few seconds after the end of dispensing. Once this short time has expired. Meter switches
to standby and lower register display switches to General Total.

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

C1. DISPENSING IN NORMAL MODE

This is default dispensing during which, while the count is made, the Partial and Reset Total are
displayed at the same time.

Should one of the two keys RESET or CAL be accidentally pressed during counting, this will have no
effect.

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

109
C.1.1 Resetting the Partial Register

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 first 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 first 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
(Total).

C.1.2 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-off segments and finally shows the display page where the reset Reset
Total is shown.

110
C2. DISPENSING WITH FLOW RATE MODE DISPLAY

It is possible to dispense fluids, displaying at the same time:

* the dispensed partial
* the Flow Rate in [Partial Unit / minute] as shown on the following display page:
Procedure for entering this mode:

- wait for the Remote Display to go to Standby, meaning the display screen shows Total only
- quickly press the CAL key.
- Start dispensing
The flow rate is updated every 0.7 seconds. Consequently, the display could be relatively unstable at
lower flow rates. The higher the flow rate, the more stable the displayed value.

IMPORTANT: The flow rate is measured with reference to the unit of measurement of the Partial.

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
effect.

IMPORTANT!
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.

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C.2.1. Partial reset

To reset the Partial Register, finish dispensing and wait for the Remote Display to show a Flow Rate of
0.0 as indicated in the illustration

then quickly press RESET

Unlike Normal mode, in this case during reset, you do not pass through the stages where the display
segments are first lit up and then switched off, but rather the reset partial register is immediately
displayed.

D. CALIBRATION

D1. DEFINITIONS

pulses received, to transform these into measured fluid units - Factory K Factor: Factory-set default
factor. It is equal to 1,000.

This calibration factor ensures utmost precision in the following operating conditions:
Fluid_______________motor oil type 10W40
Temperature:________20°C
Flow rate:___________5-25 litres/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 modified by calibration.

D2. WHY CALIBRATE

METER is supplied with a factory calibration that ensures precise measuring in most operating
conditions.
Nevertheless, when operating close to extreme conditions, such as for instance:
• with fluids close to acceptable range extremes (such as low-viscosity antifreeze or high-viscosity oils
for gearboxes )
• in extreme flow rate conditions (close to minimum or maximum acceptable values) on-the-spot
calibration may be required to suit the real conditions in which the meter is required to operate.

112
D3. WHY CALIBRATE

METER permits making quick and precise electronic calibration by changing the Calibration
Factor (K FACTOR).
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

The calibration phases can be entered ( by keeping the CAL key pressed for a long time) to
display the currently used calibration factor
- Return to factory calibration (Factory K Factor) after a previous calibration by the user
- Change the calibration factor using one of the two previously indicated procedures.

In calibration mode, the partial and total dispensed quantities indicated on the display screen take
on different meanings according to the calibration procedure phase.

In calibration mode, the METER can not be used for normal dispensing operations.
In “Calibration” mode, the totals are not increased.

IMPORTANT
The METER features a non-volatile memory that keeps the data concerning calibration and total
dispensed quantity stored for an indefinite time, even in the case of a long power break; after
changing the batteries, calibration need not be repeated.

D. 3.1 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.
Two cases can occur:
a) 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

113
 b) 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 flow 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 confirm the choice of calibration factor, quickly press

CAL while “User” or “Fact” are displayed.

After the restart cycle, the meter uses the calibration

factor that has just been confirmed

IMPORTANT:
When the Factory Factor is confirmed, the old User
factor is deleted from the memory

D.3.2 In Field Calibration

This procedure calls for the fluid to be dispensed into a graduated sample container in real operating
conditions ( flow rate, viscosity, etc.) requiring maximum precision.

IMPORTANT
For correct METER calibration, it is most important to:
• completely eliminate air from the system before calibrating;
• use a precise Sample Container with a capacity of not less than 5 litres, featuring an accurate
graduated indicator.
• ensure calibration dispensing is done at a constant flow rate equivalent to that of normal use, until
the container is full;
• not reduce the flow rate to reach the graduated area of the container during the final dispensing
stage (the correct method during the final stages of sample container filling consists in making short
top-ups at normal operation flow rate) ;
• 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.
Carefully follow the procedure indicated below.

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D.3.2.1 Sequence of operations to be performed for correct in-field calibration:

Action Display

NONE
1
METER in Standby.

LONG CAL key keying

The METER enters calibration mode, shows <<CAL>> and displays the
calibration factor in use instead of partial. The words “Fact” and “USER”
2
indicate which of the two factors (factory or user) is currently in use.
Important: This factor is that which the instrument also uses for field
calibration measurement operations

LONG RESET key keying

3 The METER shows “CAL” and the partial at zero. The meter is ready to
perform in-field calibration.

DISPENSING INTO SAMPLE CONTAINER

Without pressing any key, start dispensing
into the sample container.

Dispensing can be interrupted and started again at will. Continue dispensing

4 until the level of the fluid in the sample container has reached the graduated
area. There is no need to reach a preset quantity.

Indicated value Real value

SHORT RESET key keying

The METER is informed that the calibration dispensing operation is finished.
Make sure dispensing is correctly finished before performing this operation. To
5 calibrate the METER, the value indicated 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 direction (increase or decrease) of the value
change displayed when the following operations 6 or 7 are performed.

SHORT RESET key keying

6 The arrow changes direction. The operation can be repeated to alternate the
direction of the arrow.

SHORT/LONG CAL key keying

The indicated value changes in the direction indicated by the arrow
- one unit for every short CAL key keying
7
- 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).

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 LONG RESET key keying
The METER is informed that the calibration procedure is finished.
Before performing this operation, make sure the INDICATED value is the
same as the REAL value.

Indicated value Real value

The METER calculates the new USER K FACTOR ; this calculation could
require a few seconds, depending on the correction to be made.

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 finally achieve standby
9 condition.
IMPORTANT: From now on, the indicated factor will become the
calibration factor used by the meter and will continue to remain such
even after a battery change

NO OPERATION
10 The METER stores the new work calibration factor and is ready to begin
dispensing, using the USER K FACTOR that has just been calculated.

D4. DIRECT MODIFICATION OF K FACTOR

This procedure is especially useful to correct a “mean error” obtainable on the basis of several
performed dispensing operations. If normal METER 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 *

Example:
Error percentage found E% - 0.9 %
CURRENT calibration factor
New USER K FACTOR

1.000
1.000 * [(100 – ( - 0.9))/100] =
1.000 * [(100 + 0.9)/100] =
1.009

116
If the meter 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 meter shows
more than the real dispensed value (positive error).
Direct procedure calibration:

Action Display

NONE
1
METER in Standby.

LONG CAL KEY KEYING

2 METER 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.

LONG RESET KEY KEYING

The METER shows “CAL” and the zero partial total.
3
METER is ready to perform in-field calibration by dispensing – see previous
paragraph.

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.
4
In the bottom left part of the display, an arrow appears (upwards or
downwards) defining the direction (increase or decrease) of change of the
displayed value when subsequent operations 5 or 6 are performed.

SHORT RESET KEY KEYING

5 Changes the direction of the arrow. The operation can be repeated to
alternate the direction of the arrow.

SHORT/LONG CAL KEY KEYING

The indicated value changes in the direction indicated by the arrow
- one unit for every short CAL key keying
6
- 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).

LONG RESET KEY KEYING

The METER is informed that the calibration procedure is finished.
7
Before performing this operation, make sure the INDICATED value is that
required.

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 finally achieve standby
8 condition.
IMPORTANT: From now on, the indicated factor will become the
calibration factor used by the meter and will continue to remain such
even after a battery change

NO OPERATION
9 The METER stores the new work calibration factor and is ready to begin
dispensing, using the USER K FACTOR that has just been changed.

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E. CONFIGURATION OF UNIT OF MEASUREMENT
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 predefined
according to the following table:

Combination Unit of Measurement Unit of Measurement

no. Partial Register Totals Register
1 Litres (L) Litres (L)
2 Gallons (Gal) Gallons (Gal)
3 Quarts (Qts) Gallons (Gal)
4 Pints (Pts) Gallons (Gal)

To choose between the 4 available combinations:

* Wait for the METER to go to Standby

* 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 )

Every short press of the RESET key, the various combinations of the units of measurements are
scrolled as shown below:

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.

IMPORTANT
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

118
F. PULSE TRANSMITTER (PULS OUT)

In some models an outlet of “NPN-Open Collector” type is available. This outlet issues a certain number
of pulses by Unit of measurement of the partial quantity dispensed. The Number of pulses can be
selected amongst 7 proposed options (1, 2, 5, 10, 20, 50, 100)

This outlet can be connected to a remote receiver having the following characteristics:
- at software level it shall have a “pulse weight” according to the transmission of the Remote Display
- at hardware level the receiver connection shall have an input circuit of “Pull-up” type with the
following features
- Vdc max = 12 V
- I max = 0,5 A
Below is the logic connection diagram of the outlet with the remote receiver:

The procedure for entering the selection menu of the number of pulses emitted by each unite of
measurement of the dispensed partial quantity is the same used to change the unite of measurement:

Wait for the Remote Display to go to Standby,

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):

119
By quickly pressing CAL (only for models with Pulser Out) you will pass to a new configuration menu.

It will be displayed the definition page of the pulse number that the Remote Display supplies on the
outlet by each counted unit of measurement of Partial; by quickly pressing RESET, the available [pulse
number / Unite of Measurement of Partial] is scrolled down:

By pressing the CAL key at length, the new settings will be stored, the Remote Display will pass
through the start cycle and will then be ready to dispense.

ATTENTION:
Only for the turbine/impeller model, the Pulse Out 100 option does not work with flow
rates above 150 Pt/min (70 Lt/min.)

G. MAINTENANCE

The only maintenance operation required on the Remote Display is the battery change, necessary only
when the batteries have run down
Changing the batteries
The Remote Display is complete with 2 x 1.5 V. alkaline batteries SIZE 1N.
The Remote Display features two low-battery alarm levels:
1) When the battery charge falls below the first level on the LCD, the fixed battery symbol appears. In
this condition, the Remote Display continues to operate correctly, but the fixed icon warns the user
that it is time to change the batteries.

2) If the Remote Display 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 flash and
is the only one to remain visible on the LCD.

120
ATTENTION
Do not discard the old batteries into the environment. Refer to local disposal regulations.

To change the batteries, with reference to the spare parts list positions, proceed as follows:
• Press RESET to update all the totals
• Loosen the 4 screws of the battery cover (pos.1); remove the cover (pos.2) and the gasket (pos.3)
• Remove the battery compartment (pos.4)
• Remove the old batteries
• Place the new batteries in the same position as the old ones, making sure the positive pole is
positioned as indicated on the battery compartment.
• Place the battery compartment in its seat and apply the gasket and cover with the relevant screws,
by performing the previously described operations in reverse order.
• The Remote Display will switch on automatically and normal operation can be resumed.

The Remote Display will display the same Reset Total, the same Total and the same Partial indicated
before the batteries were changed.
After changing the batteries and, subsequently, every time there is a power break, the Remote Display
will start again and use the same calibration factor used when the break occurred. The meter does not
therefore need calibrating again.

H. MALFUNCTIONS

Problem Possible cause Remedial Action

LCD: indications dull
Not enough measurement
precision
Reduced or zero flow rate
The meter does not count,
but the flow rate is correct
See paragraph
Battery low
HMaintenance-replace battery
With reference to paragraph F,
Wrong K FACTOR
check the calibration factor
The meter works out of flow rate Reenter at flow rate nominal
nominal range. range
Clean the measurement
Gears blocked
chamber
Incorrect installation of gears after Repeat the reassembly
cleaning procedure
Possible electronic board
Contact your dealer
problems

121
I. TECHNICAL DATA

Model K600/3 K600/4 K700 TURBINE

liters - rising/falling edge 0.015 0,02 0,035 0,011
Nominal Gal / rising/falling edge 0.003963 0,005284 0,009247 0,0029
Resolution Qt / rising/falling edge 0.01585 0,02113 0,0369 0,0116
Pt / rising/falling edge 0.0317 0,0422 0,0739 0,023
Measurement system pulse reading Open Collector type
External Power 4 ÷ 12 Vdc
Pulse Transmitter (Pulse Out) Electrical input Open Collector type
Flow Rate
Pulser Model K600/3 K600/4 K700 TURBINE
Lt / min 10 ÷ 100 15 ÷ 150 25 ÷ 250 15 ÷ 120
Pt / min. 21 ÷ 210 32 ÷ 320 53 ÷ 530 32 ÷ 249
Qt / min. 10 ÷ 106 16 ÷ 160 26 ÷ 260 16 ÷ 125
Gal / min. 2.6 ÷ 26 4 ÷ 40 6.6 ÷ 66 4 ÷ 31,2
Storage Temperature -20 ÷ + 70 (°C)
Storage Humidity (Max) 95 (% RU)
Operating Temperature (Max) 60 (°C)
Humidity Resistance IP54
LCD - lyquid crystal
with:
Display - Partial 5 digit
- Reset Total 6 digit + x10 / x100
No reset total 6 cifre + x10 / x100
Power Supply alkaline batteries 2x1,5V size 1N
Battery Life 18 - 36 months
Weight 1 Kg (incliding batteries)

J. REMOTE DISPLAY MAINTENANCE

There are no spare parts for the Remote Display.

Below are diagrams showing the battery-replacement procedure.
To replace the batteries, open the rear lid by loosening the 4 screws indicated by the arrows and
replace them.

rear lid

122
 remote display without pulse out remote display with pulse out

Use cable gland “1” to connect to the flowmeter.

Should additional connections be required (e.g.
external power), cable glands “2” and “3” may be
used (see photo).
If cable gland “1” is used, the nut must be
unscrewed.
If cable glands “2” and “3” are used, the hole
must be “opened” using an appropriate tool (e.g.
screwdriver), as shown in the photo.

123
K. DISPOSAL

The components must be given to companies that specialise in the disposal and recycling of industrial
waste and, in particular, the

DISPOSAL OF PACKAGING.

The packaging consists of biodegradable cardboard which can be delivered to companies for normal
recycling of cellulose.

DISPOSAL OF METAL COMPONENTS

The metal components, both painted and stainless steel, are usually recycled by companies that are
specialised in the metal-scrapping industry.

DISPOSAL OF ELECTRIC AND ELECTRONIC COMPONENTS:

these have to be disposed by companies that are specialised in the disposal of electronic components,
in accordance with the instructions of 2002/96/EC (see text of Directive below).

European Directive 2002/96/EC requires that the equipement bearing this symbol
on the product and/or its packaging must not be disposed of with unsorted
municipal waste. The symbol indicates that this product should be disposed of
separately from regular household waste streams. It is your responsibility to
dispose of this and other electric and electronic equipment via designated
collection facilities appointed by the government or local authorities.

DISPOSAL OF OTHER PARTS:

The disposal of other parts such as pipes, rubber seals, plastic components and cables should be
entrusted to companies that special in the disposal of industrial waste.

DECLARATION OF CONFORMITY
In accordance with directive:
89/336/EEC (electromagnetic compatibility) and subsequent amendments

PIUSI S.p.A. - 46029 Suzzara (Mantova) Italy

declares that the following flowmeter model

REMOTE DISPLAY

which this declaration refers to, complies with the following applicable norms:
European norms: EN 61000-6-1; EN 61000-6-3; EN 55014-1-2000; EN55014-2-97

Suzzara, 01/10/2006 the President. Otto Varini

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XVI. ELECTRONIC TURBINE METER K24 OPERATING MANUAL

A. TABLE OF CONTENTS
A. Table of contents
B. BECOMING ACQUAINTED WITH K24
B1. Measurement System
B2. Display Positioning
B3. Operating modes
B4. LCD Display
B5. User Buttons
B6. Battery Housing
C. Installation
D. DAILY USE
D1. Dispensing in Normal mode
D1.1 Partial reset
D1.2 Resetting the Reset Total
D2. Dispensing with Flow Rate Mode display
D2.1 Partial reset
E. CALIBRATION
E1. Definitions
E2. Why Calibrate
E3. Calibration procedure:
E3.1 Display Of Current “K Factor” And Restoring “Factory K Factor”
E3.2 In-field calibration
E3.2.1 Calibration procedure:
E3.3 Direct modification of K factor
F. METERS CONFIGURATION
G. MAINTENANCE
H. MALFUNCTIONS
I. TECHNICAL SPECIFICATIONS
J. DISPOSAL
K. EXPLODED DIAGRAM AND DIMENSIONS

125
B. BECOMING ACQUAINTED WITH K24

Electronic digital meter featuring a turbine measurement system, designed for precise measuring
of low viscosity fluids.

It is divided into two using macrogroups:

1. With body made of inconductive plastic material of light colour, designed to be used with water /
urea solution.
2. 2. With body made of conductive plastic material of dark colour (assessed resistance: 50
ohm), designed to be used with DIESEL FUEL, WATER and windscreen fluids. The card can be
rotated with respect to its housing, thus allowing easy display readings in any position. The card
housing, easily accessible, is closed by a plastic cover sealed through a rubber protection acting
as a gasket as well. The whole unit can be easily removed by unscrewing the 4 screws fixing the
card and the cover.

B1 MEASUREMENT SYSTEM

The turbine is placed inside a hole through the body of k24, fitted with threaded inlet and outlet.
The body of k24 is made of a plastic material that allows several types of threads with relevant
combinations. K24 has 2 rubber protections, designed to act as gaskets, too, and thus reducing
the number of its components. The liquids compatible with k24 must be at low viscosity, namely:
• Diesel fuel.
• Water.
• Water/urea solution.
• Kerosene.
• Windscreen.
• Petrol.

Main components:

B2 DISPLAY POSITIONING

The square shape of the k24 body allows the card to be rotated in its housing, thus ensuring great
versatility in positioning.

126
NOTICE
While fixing the K24 card, make sure the battery contact cable is not placed above the circular
housing of the bulb.

B3 OPERATING MODES

The user can choose between two different operating modes:

• Normal mode: Mode with display of Partial and Total dispensed quantities.
• Flow rate mode: Mode with display of Flow Rate, as well as Partial dispensed quantity.

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
fitted in the top part of the K24 which remains isolated from the fluid-bath measurement chamber
and sealed from the outside by means of a cover.

B4 LCD DISPLAY

The “LCD” of the METER features two numerical registers and various indications displayed to the
user only when the applicable function so requires.

Key:
1. Partial register (5 figures 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 figures with moving comma
FROM 0.1 to 999999), that can indicate two types of
Total:
4.1. General Total that cannot be reset (TOTAL)
4.2. 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
8. Indication of Flow Rate mode Gal= Gallons
9. 9. Indication of unit of measurement of Partial: Qts= Quarts
Pts= Pints
L= Litres
Gal= Gallons

B5 USER BUTTONS

The k24 features two buttons (reset and cal) 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 resettable total (reset total)
• For the cal key, entering instrument calibration mode.
Used together, the two keys permit entering configuration mode, useful for changing the units of
measurements and calibration factor.

127
B6 BATTERY HOUSING

The k24 is powered by two standard type 1.5 V batteries (size AAA). The battery housing, easily
accessible, is closed by a metal cover sealed through a rubber protection acting as a gasket as
well. The whole unit can be easily removed by unscrewing the 4 screws fixing the cover and the
protection to the body.

C. INSTALLATION

K24 features a threaded, perpendicular inlet and outlet (1” gas or ntp male and female that can be
combined together). It has been designed to be easily installed in any position:
fixed in-line or mobile on a dispensing nozzle. In order to improve the life of the turbine, it is
recommended to fit a strainer before the meter itself.

NOTICE
At the female inlets, tighten the couplings at a max. torque of 55N/m.

D. 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 configured 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.

NOTICE
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

128
D1 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).
Should one of the keys be accidentally pressed during
dispensing, this will have no effect.

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.

D1.1 PARTIAL RESET

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 first of all shows all the lit-up digits and
then all the digits that are not lit up.

129
At the end of the process, a display page is first of all shown with the reset partial and the reset
total.

and, after a few moments, the reset total is replaced by the non resettableTotal.

D1.2 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),

130
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-off
segments and finally shows the display page where the reset Reset Total is shown.

D2 DISPENSING WITH FLOW RATE MODE DISPLAY

It is possible to dispense fluids, displaying at the same time:

• the dispensed partial,
• the Flow Rate in [Partial Unit / minute] as shown on the following display page.

Procedure for entering this mode:

• wait for the Remote Display to go to Standby, meaning the display screen shows Total
only,
• quickly press the CAL key.
• Start dispensing.
The flow rate is updated every 0.7 seconds. Consequently, the display could be relatively unstable
at lower flow rates. The higher the flow rate, the more stable the displayed value.

NOTICE
The flow 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 different, as in the
example show below, it should be remembered that the indicated flow rate relates to the
unit of measurement of the partial. In the example shown, the flow rate is expressed in
Qts/min.

The word “Gal” remaining alongside the flow rate refers to the register of the Totals (Reset
or NON Reset) which are again displayed when exiting from the flow rate reading mode.

131
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 effect.

NOTICE
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.

D2.1 PARTIAL RESET

To reset the Partial Register, finish dispensing and wait for the Remote Display to show a Flow
Rate of 0.0 as indicated in the illustration then quickly press RESET.

E. CALIBRATION

E1 DEFINITIONS

Calibration factor or “k factor” : Multiplication factor applied by the system to the electrical pulses
received, to transform these into measured fluid units.
FACTORY K FACTOR: Factory-set default factor.
It is equal 1,000. This calibration factor ensures utmost precision in the following operating
conditions:
Fluid diesel fuel,
Temperature: 20°C,
Flow rate: 10-120 litres/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 modified by calibration.

E2 WHY CALIBRATE

When operating close to extreme conditions, such as for instance with fluids close to acceptable
range extremes (like diesel fuel at low temperatures) or in extreme flow rate conditions (close to
minimum or maximum acceptable values), an on-site calibration may be required to suit the real
conditions in which the k24 is required to operate.

132
E3 CALIBRATION PROCEDURE

K24 permits making quick and precise electronic calibration by changing the calibration factor
(k factor).
There are 2 different ways of calibration:
1. On-site calibration, performed by means of a dispensing operation.
2. Direct calibration, performed by directly changing the k factor.

To enter the calibration phases it is necessary to press and hold down the “cal” button.

Why enter the calibration phases?

• Display the currently used calibration factor
• Return to factory k factor after a previous calibration with user k factor
• Change the calibration factor using one of the two previously indicated procedures.

In calibration mode, the partial and total dispensed quantities indicated on the display screen take
on different meanings according to the calibration procedure phase. During the calibration, the k24
cannot perform any normal dispensing operations. In calibration mode, the totals are not
increased.

WARNING:
The k24 features a non-volatile memory.
It keeps the calibration and dispensing data stored even after replacing new batteries or
long periods of inactivity.

E3.1 DISPLAY OF CURRENT “K FACTOR” AND RESTORING “FACTORY K FACTOR”

By pressing the cal key while the appliance is in standby, the display page appears showing the
current calibration factor used.

If you are using k24 with “factory k factor”, the display page shown in the diagram will be
displayed, with the word “fact”.

If one “user k factor” has been set, the calibration factor set by the user (in our example 0.998) will
be displayed. The word “user” indicates a calibration factor set by the user is being used.

The flow chart alongside shows the switchover logic from one display page to another.

133
In this condition, the Reset key permits switching from User factor to Factory factor. To confirm the
choice of calibration factor, quickly press CAL while “User” or “Fact” are displayed. After the restart
cycle, the meter uses the calibration factor that has just been confirmed.

NOTICE
When the Factory Factor is confirmed, the old User factor is deleted from the memory.

E3.2 IN-FIELD CALIBRATION

This procedure calls for the fluid to be dispensed into a graduated sample container in real
operating conditions (flow rate, viscosity, etc.) requiring maximum precision.

WARNING:
For correct K24 calibration, it is most important to:
• completely eliminate air from the system before calibrating;
• use a precise Sample Container with a capacity of not less than 5 litres, featuring an
accurate graduated indicator.
• ensure calibration dispensing is done at a constant flow rate equivalent to that of
normal use, until the container is full;
• not reduce the flow rate to reach the graduated area of the container during the final
dispensing stage (the correct method during the final stages of sample container
filling consists in making short topups at normal operation flow rate);
• 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.
• if necessary, carefully follow the procedure indicated below.

134
 OPERATION DISPLAY

NONE
1
K24 in STAND BY.

LONG CAL KEY KEYING

2 K24 enters calibration mode, shows ”CAL” and displays the calibration factor
in use instead of total. The words “Fact” and “USER” indicate which of the two
factors (factory or user) is currently being used.

LONG RESET KEY KEYING

3 K24 shows “CAL” and the partial at zero. K24 is ready to perform on-site
calibration. K24 is ready to perform on-site calibration.

DISPENSING INTO SAMPLE CONTAINER

Without pressing any KEY, start dispensing into the sample container.

Dispensing can be interrupted and started again at will. Continue dispensing

4 until the level of the fluid in the sample container has reached the graduated
area. There is no need to reach a preset quantity.

Indicated value Real value

SHORT RESET KEY KEYING

K24 is informed that the calibration dispensing operation is finished.
Make sure dispensing is correctly finished before performing this operation.
To calibrate the K24, the value indicated by the partial totaliser (example
5
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 direction (increase or decrease) of the USER
K FACTOR value change when the operations 6 or 7 are performer.

SHORT RESET KEY KEYING

6
Arrow direction changes. The operation can be repeated IF NECESSARY

SHORT/LONG CAL KEY KEYING

The indicated value changes in the direction indicated by the arrow
7 - one unit for every short CAL key keying
- continually if the CAL key is kept pressed (for the first 5 units slowly and then
quickly).
If the desired value is exceeded, repeat the operations from point (6).

LONG RESET KEY KEYING

K24 is informed that the calibration procedure is finished. Before doing this,
make sure the DISPLAYED factor is the ACTUAL factor.
Indicated value Real value K24 calculates the new USER K FACTOR. This
calculation could require a few seconds, depending on the correction to be
8
made.
During this operation the arrow disappears but the CAL indication remains.
If this operation is performed after operation (5), without changing the
indicated value, the USER K FACTOR would be the same as the FACTORY K
FACTOR, thus it is ignored.

135
 Indicated value Real value

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 finally achieve standby
9 condition.
Note: From now on, the indicated factor will become the calibration
factor used by the meter and will continue to remain such even after a
battery change.

NO OPERATION
10 K24 stores the new calibration factor and is ready for dispensing, applying the
newly defined USER K FACTOR.

E3.3 DIRECT MODIFICATION OF K FACTOR

This procedure is especially useful to correct a “mean error” obtainable on the basis of several
performed dispensing operations. If normal K24 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:

⎛ 100 – E% ⎞
K factor new = K factor old ∗ ⎜ ⎟
⎝ 100 ⎠

Example:

Error percentage found E% - 0,9 %

CURRENT calibration factor 1.000
New USER K FACTOR
1,000 * [(100 – ( - 0,9))/100] = 1.0 * [(100 + 0,9)/100] = 1.009

If the meter 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 meter shows
more than the real dispensed value (positive error).

136
 OPERATION DISPLAY

NONE
1 K24 in STAND BY: not in counting mode.

LONG CAL KEY KEYING

K24 enters calibration mode, shows “CAL” and displays the calibration factor
2 being used instead of the partial. The words “Fact” and “USER” indicate which
of the two factors (factory or user) is currently being used.

LONG RESET KEY KEYING

K24 shows “CAL” and the partial at zero. K24 is ready to perform on-site
3
calibration by dispensing.

LONG RESET KEY KEYING

We now go on to Direct change of the calibration factor: the word “Direct”
4 appears together with the Currently Used calibration factor. In the bottom left
part of the display, an arrow appears (upwards or downwards) defining the
direction (increase or decrease) of change of the displayed value when
subsequent operations 5 or 6 are performed.

SHORT RESET KEY KEYING

5 Arrow direction changes. The operation can be repeated to alternate the
direction of the arrow.

SHORT/LONG CAL KEY KEYING

The indicated value changes in the direction indicated by the arrow
6 - 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).
LONG RESET KEY KEYING
K24 is informed that the calibration procedure is finished. Before performing
7
this operation, make sure the indicated value is that required.

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 finally achieve standby
8 condition.
ATTENTION: From now on, the indicated factor will become the
calibration factor used by the meter and will continue to remain such
even after a battery change.
NO OPERATION
The K24 stores the new work calibration factor and is ready to begin
9
dispensing, using the USER K FACTOR that has just been calculated.

137
F. METERS CONFIGURATION

Some models of 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
predefined according to the following table:

Combination Unit of Measurement of the Register Unit of Measurement

no. Partial Register of the Totals Register
1 Litres (L) Litres (L)

2 Gallons (Gal) Gallons (Gal)

3 Quarts (Qts) Gallons (Gal)

4 Pints (Pts) Gallons (Gal)

To choose between the 4 available combinations:

• wait for K24 to go to Standby,
• 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)
• Press the reset key to select the desired combination of unit of measurement, amongst
those shown below.
• Save the new combination by pressing the cal key at length. K24 will pass through the
start cycle and will then be ready to dispense in the set units.

WARNING:
The Resettable 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.

138
G. MAINTENANCE

K24 has been designed to require a minimum amount of maintenance. The only types of
maintenance required are the following:
1. Battery change – necessary when the batteries have run down
2. Cleaning of the turbine with washing or mechanically-handling

1 Battery Replacement
K24 is complete with 2 x 1.5 V. alkaline batteries SIZE AAA.
K24 features two low-battery alarm levels:

1) When the battery charge falls below the first level on the LCD, the fixed battery symbol appears.

In this condition, K24 continues to operate correctly, but the fixed icon warns the user that it is
ADVISABLE to change the batteries.

2) 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 flash and is the
only one to remain visible on the LCD.

WARNING
Do not discard the old batteries in the environment. Refer to local disposal regulations.

To change the batteries, with reference to the exploded diagram positions, proceed as follows:
• Press RESET to update all the totals
• Loosen the 4 fixing screws of the lower cover
• Remove the old batteries
• Place the new batteries in the same position as the old ones
• close the cover again, by positioning the rubber protection as a gasket
• K24 will switch on automatically and normal operation can be resumed.

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.

2. 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.

WARNING
Do not use compressed air onto the turbine in order to avoid its damage because of an
excessive rotation.

139
H. MALFUNCTIONS
PROBLEM:
LCD: no indication
Not enough measurement
precision
Reduced or zero flow rate
The meter does not count,
but the flow rate is correct
POSSIBLE CAUSE: CORRECTIVE ACTION:
Bad battery contact. Check battery contacts.
With reference to paragraph H, check
Wrong K FACTOR.
the K FACTOR.
The meter works below Increase the flow rate until an
minimum acceptable flow acceptable flow rate range has been
rate. achieved.
TURBINE blocked. Clean the TURBINE.
Incorrect installation of gears
Repeat the reassembly procedure.
after clearing.
Possible electronic card
Contact your dealer.
problems.
140
I. TECHNICAL SPECIFICATIONS

Measurement System TURBINE

0.010 lit/pulse
Hi Flow
Resolution (nominal)
0.005 lit/pulse
Low Flow
K24 COL. BLACK Flow-rates: 5 ÷ 120 (Litres/minute) FOR
DIESELFUEL, WATER,.

Flow Rate (Range)

K24 COL. BLACK Flow-rates: 5 ÷ 100 (Litres/minute) FOR

WATER/UREA SOLUTION.
Operating pressure (Max) 10 (Bar) 145 (psi)

Bursting pressure (Min) 40 (Bar)

Storage temperature (Range) -20 ÷ + 70 (°C)

Storage humidity (Max) 95 %

Operating temperature (Range) -10 ÷ + 50 (°C)

Flow resistance 0.30 Bar at 100 lit/min.

Viscosity (Range) 2 ÷ 5,35 cSt

Accuracy ±1% after calibration within10÷90

(litres/min) 2.65÷23.8 (gallons/min) range
Reproducibility (Typical) ±0.3 (%)

DISPLAY Liquid crystals LCD. Features:

- 5-figure partial
- 6-figure Reset Total plus x10 / x100
- 6-figure non reset Total plus x10 / x100
Supply voltage 2x1.5 V alkaline batteries size AAA

Battery life 18 ÷ 36 months

Wright 0.25 Kg (included batteries)

Protection IP65

141
J. DISPOSAL

The components must be given to companies that specialise in the disposal and recycling of
industrial waste and, in particular, the DISPOSAL OF PACKAGING
The packaging consists of biodegradable cardboard which can be delivered to companies for
normal recycling of cellulose.

DISPOSAL OF METAL COMPONENTS

The metal components, both painted and stainless steel, are usually recycled by companies that
are specialised in the metal-scrapping industry.

DISPOSAL OF ELECTRIC AND ELECTRONIC COMPONENTS

these have to be disposed by companies that are specialised in the disposal of electronic
components, in accordance with the instructions of 2002/96/EC (see text of Directive below).

ENVIRONMENTAL INFORMATION FOR CUSTOMERS IN THE EUROPEAN UNION

European Directive 2002/96/EC requires that the equipment bearing this symbol on
the product and/or its packaging must not be disposed of with unsorted municipal
waste. The symbol indicates that this product should be disposed of separately from
regular household waste streams. It is your responsibility to dispose of this and other
electric and electronic equipment via designated collection facilities appointed by the
government or local authorities.

DISPOSAL OF OTHER PARTS:

The disposal of other parts such as pipes, rubber seals, plastic components and cables should be
entrusted to companies that special in the disposal of industrial waste.

DECLARATION OF INCORPORATION
In accordance with directive:
89/336/EEC (electromagnetic compatibility) and subsequent amendments PIUSI S.p.A. - 46029
Suzzara (Mantova) Italy declares that the following flowmeter model

K24
which this declaration refers to, complies with the following applicable norms:
European norms: EN 61000-6-1; EN 61000-6-3; EN 55014-1-2000; EN55014-2-97
Suzzara, 01/10/2007

142
K. EXPLODED DIAGRAM AND DIMENSIONS

143
XVII. OVAL GEAR METER COGEM-P
OPERATING INSTRUCTION

Operating and maintenance instruction

1. Measuring principle and destination

Oval gear meters are measuring and control instruments used for acquiring and processing
measured volume and flow values. They form the basis for realizing system solutions in
automation tasks of liq-uids flowing in pipelines.
Oval gear meters are volume and flow measuring instruments that work according to the principle
of positive displacement. Two meshing, involute toothed oval gears are caused to rotate by the
flowing liquid and transport an exactly defined measuring chamber volume with each rotation of
the oval gear. This rotation of the oval gear is transformed into pulses by means of magnets and
can then be ac-quired electronically.
Oval gear meters are optimally tailored to the respective conditions of application by the vemm tec
company, whereas later optimization for other applications is possible as well.

2. Oval gear meters for industrial measurements

Oval gear meters can be used as industrial measuring instruments for liquid mediums to be
measured with a viscosity of between 0.3mPas and 300,000mPas. The exact conditions of use for
your oval gear meter are given on the type plate of the oval gear meter or the specification sheet
attached to each oval gear meter. All data, such as viscosity and temperature ranges, flow etc. are
indicated here as well. Before delivery each oval gear meter is checked on our test stand and
adjusted in accordance with the envisaged application.

144
 3. Oval gear meters for measuring equipment for custody transfer

Oval gear meters are approved by the Physikalisch-Technische Bundesanstalt (PTB) for use in
meas-uring equipment for custody transfer. Before installation they must be checked preliminarily
on a test stand approved for these purposes by a Gauging office. The preliminary test error limits
are taken down in a preliminary test certificate which is allocated to the instrument and attached to
it when it is supplied. The temperature and viscosity ranges required by the PTB have to be
complied with. Open-ing the instruments by persons not having the permission for repair and prior
to calibration of the whole system by the respective Gauging office leads to the expiration of the
preliminary test certificate of the Gauging office.

4. Environmental and operating conditions

admissible temperature range (standard):

grey cast iron design: -20 +80 °C
cast steel design: -25 +80 °C
stainless steel design: -40 +80 °C
Generally, the data given on the type plate or on the specification sheet are valid!
admissible relative humidity: 100 % at +30°C
(in case of oval gear meter completely filled with liquid)
Degree of protection: IP67
admissible mechanic vibrations and shocks:
Medium mechanic vibrations are admissible.
The following applies
amplitude of vibration 75um
acceleration 1g
shocks 6 ms at 10g
The use on movable objects is admitted.

5. Installation hints for installation of measuring equipment

In installations where the fluid to be metered is pumped, the suction line should be kept as short as
pos¬sible. The pumps should be located below the liquid level. Oval gear meters shall not be used
imme¬diately after reciprocating pumps, dosing machines etc. or in applications where the flow is
sud-denly interrupted by cut-off devices (e. g. undamped solenoid valves)! In order to prevent
pressure shocks in the line steady flow of the liquid has to be ensured. The oval gear meter must
be installed in such a way that the fluid does not drain from the meter under no-flow conditions.
The fluid to be metered must pass through the meter without bubbles. The measurement result will
be affected by air or gas in the fluid and the oval gear meter can be damaged. By installing a gas
separator closely upstream the meter it is possible to reduce air and gas in the fluid to an
admissible minimum. In installations where the measured medium is supplied to the meter under
natural flow or by gas or liquid pressure a gas separa¬tor is not necessary since the danger of gas
in the fluid does not exist here. It has to be taken into ac¬count that there is a pressure loss across
the oval gear meter depending on flowrate and viscosity of the measured medium. The oval gear
meters are designed by vemm tec in such a way that the pressure loss is below 1 bar in case all
technical data indicated on the type plate are complied with. The exact value is given on the
specification sheet that is attached to each oval gear meter.
If you do not know the value, vemm tec will be pleased to inform you considering your equipment
data. Oval gear meters can be damaged by solids in the fluid. That is why basket type meter-
protection strainers should be fitted directly upstream the meter. High-viscosity fluids often have to
be heated in order to reach the low viscosity required for processing and measurement. In this
case not only the pipeline, but also the oval gear meter has to be heated.
145
Before measurement begins the measured media in the oval gear meter must be raised to the
required temperature.

6. Important hints for installation of oval gear meters

Before installing the meter, the pipeline and the whole plant should be thoroughly cleaned from
dirt, impuri¬ties as weld spatters, chips, dust etc. For this, instead of the meter a fitting piece must
be installed in the pipeline and the plant must be rinsed several times. The sealing caps in the
connecting flanges of the meter must be removed just immediately before installation.
Oval gear meters must be installed such that the head flange or body cover is vertical, irrespective
of whether the pipe axis is horizontal, vertical or inclined. Thus it is reached that the horizontal
position of the oval gear axis required for faultless function and accuracy of the meter is
guaranteed. The flow direction indicated on the measuring unit casing has to be observed in any
case. The meter has to be fitted tightly in the line and fixed with few stress. Support of the dead
weight is recommended!
If the oval gear meters are used outside, they must be protected from rain and snow by a
respective cover. For the electric connection attention has to be paid that an equipotential bonding
conductor of at least 4 sq.mm CU is connected between the oval gear meter and the respective
equipment (NAMUR switch amplifier).

Safety characteristics:

NAMUR signalling circuits for channel 1 and channel 2:

Ui: 12,5 V Pi: 160 mW
Ii: 60 mA
Qi: 1,12 μF Li: 4 μH

Only NAMUR switch amplifiers with the following characteristics may be used for connection
Uo<Ui Po<Pi lk<li
Lo > Li Co > Ci
Capacitance per unit length Ck and inductance per unit length Lk of the connecting cable have to
be taken into consideration here.

The capacitance and inductance of the cable have to be added to

Ci and Li. Co - Ci > I ' Ck; Lo - Li > I ' Lk l = cable length
The switch amplifiers must provide a common supply voltage for channel 1 and channel 2.

146
 7. Putting into service and operation

Before putting into service an oval gear meter, its operation data (flowrate, viscosity, temperature,
pressure, material qualities) have to be compared with those of the equipment. Application beyond
the parameters determined for the meter is not permitted. In case of doubt get in touch with
vemmtec. The equipment has to be deaerated slowly and thoroughly, flooded and started
throttledly. As soon as the function of the meter is shown on the indicator unit, the equipment has
to be run throttledly until complete deairing of the pipeline is reached. Care should be taken to
ensure that there will be no pressure shocks, strong pulsations and vibrations. Such irregularities
have a negative effect on the result of measurement and might cause damage to the oval gear
meter.
During putting into service attention has to be paid to a faultless operation of the meter (indication,
running noise).
If clear irregularities occur, the flow has to be throttled. If the meter fails to operate (blocking of
oval gears), the flow must be interrupted immediately, since otherwise the excessively rising feed
pressure can cause damage to the meter.
Only after eliminating the cause of the fault (e. g. solids in the pipeline) and the damages possibly
caused putting into operation may be repeated. If a bypass is existing, the equipment has to be put
into operation via this. The flow should be released slowly via the meter. After this the liquid flow in
the bypass should be gradually interrupted. When putting into operation oval gear meters with
volume presetting unit, the measuring equipment has to be started without using the control
function of the volume presetting unit. For this the equipment must be cut off by an additional
actuator and the actuator controlled by the volume presetting unit must be opened by presetting a
respectively big volume. After that, the equipment has to be started via the additional actuator
observing all abovementioned hints. Only in case of faultless and normal operation of the
equipment, the control function of the volume presetting unit may be used.

8. Pulse output
The pulse output is connected to a socket. NAMUR, PNP or NPN outputs are available.
For application in hazardous areas a blue data line (NAMUR) has to be used generally. The
insulation check shall be carried out in the plant. When a two-channel pulse generator is used,
only one connection to two-channel devices with a common Plus (+) is admissible. The two-
channel pulse generator with connector must not be used at two connections physically separated
from each other.

Pin assignment (8-pole flange socket):

1) Pulse generator according to DIN EN60947-5/-6 (NAMUR)
Operating voltage range: 5 12.5 VDC
Switching points on/off: <1.2 mA />2.1 mA
Application in hazardous area: Ex II2G EEx ib II C T4 X
EU prototype test certificate: I BExU 04 AT EX 1067
Contact assignment:

NAMUR: contact 5 (1+) contact 7 (1 -)

contact 4 (2+) contact 6 (2 -)

2) Pulse generator three-wire - PNP /NPN

Switching voltage: 5 20V DC +/-10%
Switched current: 50 mA
Degree of protection: IEC 60529 IP 67
147
 Application in hazardous area: No application in hazardous areas!
Contact assignment:
PNP/NPN; contact 1 signal 2 contact 2 +Ub 1
contact 3 signal 1 contact 6 GND 2
contact 7 GND 1 contact 8 +Ub 2

9. Service Maintenance

Maintenance shall be carried out only by sufficiently trained personnel only. ATTENTION! When
releasing the casing cover or measuring chamber lid liquid drains from the meter. In case of
aggressive or harmful as well as very hot or very cold measured media there is danger of
cauterization, poisoning or burn.
If an oval gear meter is taken out of service for a longer time the meter has to be removed,
cleaned thoroughly and in case of types of steel casting or gray cast iron to be conserved with
non-corroding oil. Inlet and outlet boreholes must be closed by sealing caps.

10. Repair instructions

The user is not able to correct failures. The personnel should be duly instructed. Occurring failures
have to be cor¬rected by the after-sales service of the manufacturer or by the contractual
workshops. In most cases the oval gear meter has to be readjusted (calibrated) after repair. In
case of repair orders the failure has to be described (e.g. error limits not observed, oval gears
blocked etc.).
Attention!
Before dispatching the meters to be repaired must be rinsed and cleaned thoroughly by the user in
order to exclude damage by drainage of aggressive media.

11. Warranty

The warranty period depends on the "General conditions for business" of the company vemm tec
Messtechnik GmbH Babelsberg. It is 24 months. The place of execution is D-14482 Potsdam.
Observe storage and transport rules!

12. Storage and transport

The following instructions have to be observed: Oval gear meters should be transported in rigid
cardboard boxes or other cases. Transport must be carried out with the care necessary for
sensitive measuring instruments. The fitted transport instructions have to be observed. During
transport and storage inlet and outlet openings of the measuring units have to be kept closed by
sealing caps.
Non-corrosion-resistant measuring units are preserved before packing up by spraying the inside of
the measuring unit with an anticorrosive agent. If it is stored for a period longer than 6 months,
preservation has to be repeated. After that, connecting flanges have to be closed by sealing caps.
In case of outdoor storage roofing has to be pro-vided.

148
VIII. CALIBRATABLE PANEL MANUAL

Price Calculator FLAZAEP Operating Instructions

Single Counter with Price Calculation Functions - Calibratable

149
Table of contents

1. General description
1.1 Operating Instructions for a Tank Filling
2. Boot sequence
3. Changing the Litre Price
4. The device Menu
4.1 Daily totals
4.2 Total Amounts
4.3 Quantity Available
4.4 Minimum quantity
4.5 Set time
4.6 Set date
4.7 Time of Dispensal
4.8 Pulses Pause
4.9 Start time
4.10 Follow-up Time
4.11 Decimal Points
4.12 Zp Option
4.13 Button Pause
4.14 Zero Fuellings
4.15 Com parameter
4.16 Er3 Protocol
4.17 Receipt Number
4.18 User Code
4.19 Mechanic Code
4.20 Price Code
4.21 Pulses Value (K Factor)
4.22 False Pulses:
4.23 Hose Strain
4.24 Min. Dispensal
4.25 Max. Dispensal
4.26 Options
4.27 Currency
4.28 Unit Price
5. Calibration Instructions Calibration Switch
6. Error Codes
6.1 ERR11
6.2 ERR12
6.3 ERR13
6.4 ERR14
6.5 ERR15
6.6 Minimum quantity
7. LED Functions
7.1 The LED lights yellow
7.2 The LED lights green
7.3 The LED lights red
7.4 The LED flashes red
7.5 LED is off
8. Technical Details
9. Layout Main Circuit Board
9.1 Wiring Diagram Pulse Transmitter / Pump Motor
9.2 Wiring Diagram Pulse Interface (TASS)
9.3 Wiring Diagram Data Interface (ER-3 Slave)
9.4 Wiring Diagram Twin Display
9.5 Marking
10. Calibration procedure
11. Index
12. Notes

150
 1. General description

EZPr is designed as a fuel pump price calculator. The setup and operating concept is designed for a
universal application and to be set and operated as easy as possible. EZPr may optionally be used
for calibrated fuel pumps, if the device has been tested in advance by the Bureau of Weights and
Measures.

EZPr's mode of operation is quite simple. You take out the fuel nozzle, the mini-counter switches the
pump on and you can begin fuelling.

The following connections are needed to operate the fuel pumps:

Pulser Fuelling valve deposit switch Pump motor

Already integrated in the electronics of the EZPr is the 3-phase protection used to trigger the pump
motor so that externally, along with the 3-phase fuses, only a motor protection switch will need to be
installed.

The device is delivered pre-configured with all of the necessary settings. This allows it to be operated
immediately after being assembled. In the upper large display, the dispensed amount can be seen in
litres.

The smaller display shows in the upper line the total price, in the lower line it shows the unit price per
litre.

With optional additional modules, the device can be connected to automated fuelling and point of sale
systems. Two modules are available to choose from: TASS is an Pulses interface, ER3-Slave is a data
interface. With these additional modules, EZPr can be connected to almost any automated fuelling
system or to any point of sale system. You can receive a list of devices, which we have tested in
combination EZPr upon request.

The add-on data interface ER-3 also allows for a possible Pulses interface, which will make it possible
to exclude any gas recalculation control within the fuel pump. EZPr can be used at exterior
temperatures of down to -20°C.

1.1 Operating Instructions for a Tank Filling

The device is set to counting mode as soon as the fuelling nozzle is pulled out. A display test is carried
out during which all segments flash. After that the feed pump is switched on.

! Note: If the add-on module for an impulse interface has been installed, the fuelling system must
first have given a release signal.

The same applies for the optional add-on module for the data interface ER-3.

151
2. Boot sequence

Once launched, the device displays the boot devices, such as hardware and software. If the device
was already enabled, you can repeat the boot sequence with the ↑ button. Settings will be
displayed in the following way:

1. Unit type
i. Dohmann
MiZae

2. Software version

i. Dohmann or i. Dohmann
MiZae MiZae

Calibratable unit (E) Non-Calibratable Unit

3. Date and Time

We 21.11.01
10:00

4. Mode
Mode
02589000

5. Serial number

Serial number:
02271125

6. Check sum
Check sum:
9562

152
3. Changing the Litre Price

Price display:

57,58 EUR Total price

1,129 €/c Unit price

In order to change the litre price, you take the following steps:

1. Press the OK button. Enter the code:

Access code
999999

2. The default setting for the code is 999999. Once you approve the properly entered code with
the OK button, the device will display the current unit price:

Changing price 1:
1,129

3. To change the price delete the digits by using the C button:

Changing price 1:
0,000

4. The new price should be entered via the keyboard:

Changing price 1:
1,159

5. Press the OK button. The device will jump back to its original settings. The new total price
and unit price are shown:

57,58 EUR
1,159 €/c

Note: The default setting for the access code is 999999. The code may be modified individually in the
device menu.

153
4. The Device Menu

With the ↑ and ↓

buttons, you navigate
through the menu.
You select a point by
pressing the OK button.
This area can be
accessed by the
operator of the
system with a
respective code

Menu points marked In

gray have no function in
this version of the
device.

This area is
reserved for
mechanics with the
appropriate code.

154
 This area is
reserved for
mechanics with the
appropriate code.

4.1 Daily Totals

This is where the daily totals counter is displayed.
The counter can be reset by pressing the C button.

Daily totals: 1
20,00

4.2 Total Amounts

The total amounts counter is the device's lifelong counter. This
counter cannot be reset.

Total Amounts: 1
20,00

4.3 Quantity Available

If you have entered the quantity of fuel dispensed, you can display the remaining quantity available. To
make it possible, after first filling of the storage tank you should enter in this menu item the quantity
delivered. After each filling the fuel delivered is subtracted from the amount in the tank. You can view the
available quantity in this item. After each filling of the storage tank the dispensed quantity should be
entered manually.
Example: After filling the storage tank with 10 thousand litres of rapeseed oil, this quantity shall be entered
under the menu item "Quantity Available". After delivering 900 litres to the client the device will
automatically calculate the remaining quantity (9,100 litres).

Quantity Available:
10000,00

The amount of fuel is displayed in litres:

Range: 0-100 000.00 (0 = Function not active)

155
4.4 Minimum quantity
In this menu item the minimum amount of fuel in the tank is set. This is a control function.

Minimum quantity
30,00

Minimum quantity is displayed in litres.

Range: 0-100 000.00 (0 = Function not active)

After reaching the minimum quantity, the device displays the following warning:

Minimum quantity
1

Number 1 on the display indicates that the container no. 1 reached the minimum quantity.

NOTE: The warning disappears after the refuelling of the tank above the minimum value or when
you deactivate it by hand. The warning does not affect the filling of the tank.

4.5 Set time

In this menu item you can set the time using the keyboard.

Change the time

9:20:00

4.6 Set date

In this menu item you can set the date using the keyboard.

Set date
9.11.2007

NOTE: The date can not be changed after calibration (if the calibration switch is on).

4.7 Time of dispensal

The time of dispensal determines the maximum duration of the fuelling process. If the maximum
amount of time has been reached, the device is set back to release mode.

Time of dispensal
300

The time is measured in seconds.

Input range: 1–60000
(0 = Function not active)

4.8 Pulses Pause

The entry Pulses Pause determines the maximum amount of time which can pass between two pulses
before a release is interrupted.

Pulses Pause 90
156
The time is measured in seconds. (0 = Function not active)
Input range: 0–1000

4.9 Start time

This is where the time is shown, which can pass by after a release has been given before the device
interrupts the release. The Start Time is active until more than five quantity Pulses have been counted.
Start time 2000

The time is measured in seconds.

Input range: 0–2000 (0 = Function not active)

4.10 Follow-up Time

The Follow-up Time determines the time period after the pump has been switched off in
which any possible remaining flow of product quantities are being counted.

Follow-up Time: 3.0

The time is measured in seconds.

Input range: 0.0–200.0 (0 - Function not active)

4.11 Decimal Points

The number of decimal points to be used In the quantity display can be entered here. The decimal
point is moved to match in the display.

Decimal Points: 2

Note: Any change here effects the display value. If, for example, the number displayed is reduced
by a decimal point, the value in the display is increased ten-fold.

Input range: 0–5

4.12 Zp Option

The Zp option is to turn on the pre-selection for a refuelling point. This function can be enabled
by setting the first digit on the left (1-on, 0-off). If the pre-selected quantity is sent through the
ER3, the refuelling point is cut off at the selected value. If the function is disabled (set to 0), the
pre-selection is ignored, and the device selects the default value. In this version the second digit
of the device is devoid of function.

4.13 Button Pause

The function Button Pause determines the period of time, which can pass between pushing two
buttons, before the device is automatically switched back from the menu to its default settings.
Button Pause: 100
The time is measured in seconds.

Input range: 1-100

157
4.14 Zero Fuellings

This area defined how many Fuellings can he performed without a quantity (e.g. it the tank is empty)
consecutively before the device locks up.

Zero Fuellings: 3

Input range: 1–100 (0 = Function not active)

Once this values has been reached, the device will read out an error code Error 12.

Error: 12
Zero Fuellings

Note: The error code can be reset by activating the Menu once.

4.15 Com parameter

In this menu item you can set up optional interfaces. It has two sub-items: the first is the customer
interface, and the other the internal interface.

Com parameter: 1

After entering 1 you can set selected parameters.

Com parameter: 1k2 8 n 1

With the ↑ and ↓ buttons, you navigate through the menu. After approval of the selected item
with the OK button the cursor moves to the next.

Possible values:
300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 38400, 57600, 115000

The default value in this version is 1200 bauds, 8 bits, no parity, 1 transmission stop bit (protocol
ER3). The ER3 protocol allows only these values - the other values are ignored.

After setting the parameters, you can set the com function. The ER3 function starts with setting 1 on
the button 7. The number in the upper right corner is the value currently being edited. Also here it is
the only acceptable value, the other values must be 0. In this menu item you can also set other com
functions, but they do not operate in this version of the device.

Function Com 1:000001000

158
4.16 ER3 Protocol
If the price calculator is attached to an ER3 system, the protocol has to be activated here.

ER3 Protocol: 0

The ER 3 protocol is switched off by entering 0. The correct ER3 operation type for your device can
be found in the table below.
For the following point of sale systems, communication through ER3 was tested using the Lohmann
price calculator:

Manufacturer Type Device version Operating type

Lohmann GmbH Fuelling System TAU 6 from V2.12 2

Point of sale system Type

Huth V5.02/008 2
T400/450

Point of sale
Huth 6
system/Fuelling system

Point of sale system with

Kienzle Hectronic 2
ZK converter

Point of sale system /

Kienzle Hectronic Fuelling device with 4
coupler electronics

Point of sale system RCT

Ratio V1.40 2
3000 with SSW 2000 ER3

Lumatic 630 / II / E V3.26 1502.02 2

TS 50 / X with console PC100 V.1.0.0.12

DOSTASK 1
PC100 Software V3.24

NOVOTEC SV10 1

MFP SCP2-ER3 Converter V.3.15 3

TMS20 FC-V11
Schmidt & Bachmann Bridges ICT/KI-S Art. 05 V.7.4.9 5
75081

Although the ER3 operation type allows the device to be adjusted to systems by different
manufacturers, depending on the software configuration and the installed (possibly additional)
hardware, there may be some incompatibility issues. Even the partially limited test options for the
devices and the point of sale systems could not cover all of the special exceptions for operation and
service. If you have problems we ask that you contact your calculator’s manufacturer.

Note: Not until after the system restarts, will the ER3 protocol again be enabled!

1
Since the combination of a converter and a point of sale system / device generally impacts the functions, we cannot give a guarantee that the
converter will function correctly. To date we nave only tested the device with Huth T450 and T2010.
159
4.16 Receipt Number

The receipt number is a consecutive number for each fuelling process with which the ER3 protocol is
transmitted.

Receipt Number: 1

4.17 User Code

A new user code can be defined. The code is set at 123 at the factory.

User Code: 123

4.18 Mechanic Code

A new mechanic code can be defined. The code is set at 123456 at the factory.

Mechanic Code: 123456

4.19 Price Code

A new price code can be defined.

The code is set at 999999 at the factory.
It serves to access the price set-up area quickly.

Price code 999999

4.21 Pulses Value (K Factor)

The incoming Pulses can be evaluated in order to correctly display the quantity. The entry
made depends on the Pulses transmitter.

Pulses Value: 1,0000

Pulses Transmitter Pulses/Litre Pulses Value*

20 (K Factor) 5,0000
50 2.0000
100 1.0000
200 0.5000

*The value is displayed in centilitres if the device was set to read two positions after the decimal
point.

Example:
- Metering Chamber:
- Pulse transmitter:
- Display accuracy
0.356 litres/revolution
100 Imp./revolution
= 10 at one position after the decimal point (0.0)
100 at two positions after the decimal point (0.00)

100 / 0.356 = 280.9 Imp./litre 100 / 280.9 = 0.356 K factor

100 / 0.356 = 280.9 Imp./litre 100 / 280.9 = 0.356 K factor

0.3560 (for two positions after the decimal point)
0.0356 (for one position after the decimal point)

160
Pulses/Revolution
Litre/Revolution = Pulses/Litre

Display Accuracy
Pulses/Litre = K factor

For variations In the measurements the Pulses values must be re-defined. The following applies:

Quantity Bell Prover

Display quantity * K factor old = K factor new

You can find further information in the chapter "Calibration Instructions"

! Note: The K factor (Pulses value) can no longer be revised after it has been calibrated
switch - ON).

4.22 False Pulses

In the calibrated version, this is were the maximum amount of allowable false Pulses is entered.
After the device has been calibrated, this value can no longer be revised.

False Pulses: 3

Input range: 1–100 (0 = Function not active)

! Note: After calibration, the false pulses can no longer be adjusted.

4.23 Hose Strain

The hose strain function serves to suppress the initial pulses in the display. The amounts are
counted, but not displayed. The function is often used for fuel pumps with long fuelling hoses, since
the hose at the connection point at the pump is slightly strained and a small amount is measured,
but not dispensed.

Hose Strain: 0.10

Input range: 0.00–1.27 (0 = Function not active)

4.24 Min. Dispensal

The minimum quantity that can be dispensed is important for calibrated operation. All dispensals
lower than the amount defined here are as per legal definition no longer to be considered calibrated
measurements.

Min. Dispensal: 3.00

Input range: 1-100

Note: For uncallibrated systems. 0 can be entered here.

161
4.25 Max. Dispensal
This is where the maximum dispensal amount of a fuelling is defined. If during dispensal the maximum
value is reached, the fuelling process will automatically be stopped. This function is often used for position
limitations.

Max. Dispensal 980.00

Input range: 0–9999.99

Note: If 0 is entered here, the function is switched off.

The maximum dispensal can no longer be revised after the device has been
calibrated.

4.26 Options
Using the eighth digit (from the left) you can start the calibration (1 = on, 0 = off). The seventh digit
from the left allows you to run the second refuelling point. In this version of the device other digits
are not active.

Options 1
0000011

4.27 Currency

In this menu item you can set up the currency. The default value is 00455552 and it stands for euro. The
currency can be marked with up to three characters. Example: Swiss Franc is SF (in English). The code
for S is 53, for F - 46 (see table). There are only two characters in the abbreviation, so we describe the first
position with the code 20 (space). The whole code is as follows: 00205346. With the ↑ and ↓ buttons, you
navigate through the menu.

Currency abbreviations
00205346
Hexadecimal Character Hexadecimal Character
number number
01 c 4F O
06 € 50 P
20 space 51 Q
2F / 52 R
41 A 53 S
42 B 54 T
43 C 55 U
44 D 56 V
45 E 57 W
46 F 58 X
47 G 59 Y
48 H 5A Z
49 I 5B [
4A J 5C \
4B K 5D ]
4C L 5E ^
4D M 5F _
4E N

4.28 Unit Price

In this menu item, using the above tables, you can set the unit price. Default value is 00062F01, for
which the currency is euro. The unit price can be marked with up to three characters. With the ↑ and
↓ buttons, you navigate through the menu.

Unit Price 00062F01

162
5 Calibration Instructions
To start calibration, the calibration switch is to be set at OFF (see illustration 2) so that the device is
not In calibration mode. The following points must be considered:
Determine the pulse values or the K factor of the metering chamber and use these as the settings in
the menu item "Pulse Value".

Example:
- Metering Chamber: 0.356 litres / revolution
- Pulse transmiter: 100 Pulses/ revolution
- Display accuracy = 10 for one position after the decimal point (0.0)
100 for two positions after the decimal point (0.00)

100 / 0.356 = 280.9 Pulses/L 100 / 280.9 = 0.356 K factor

- 100 / 0.356 = 280.9 Pulses/L 100 / 280.9 = 0.356 K factor

0.3560 (for two positions after the decimal point)

0.0356 (for one position after the decimal point)

Pulses/Revolution
Litre/Revolution = Pulses/Litre

Display Accuracy = K factor

Pulses/Litre

For variations in measurements the pulse value must be re-defined. The following applies:

Quantity bell prover

Quantity display * K Factor old = K factor new

Example, display too low:

- Quantity Bell Prover = 500 litres
- Quantity display =497.45 litres (500 / 497.45) * 0.356 = 0.3578 K factor new

Example, display too high:

- Quantity Bell Prover = 500 litres
- Quantity display =503.12 litres (500 / 503.12) * 0.356 = 0.3538 K factor new

For these measurements, determining the exact calibration of the volumes at loading temperature is
monitored. This device does not have a calibrated thermometer and is not designed to compensate
for variations in temperature.
After completing the calibration, power to the device is to be switched off and the calibration switch is
to be set to ON. After that, the appropriate technical calibration fuses are to be attached.
The calibration parameters that were entered are recorded on a copy of the last page of these
instructions and are added to the documents for the next time the device is checked.

163
5.1 Calibration Switch

The unit Is in calibration mode when the calibration

switch is switched on

calibration switch

Circuit board with display and

calculator in the lid

Processor

This is only the case if the device has the option "calibratable”. This option must be specified when
the order is placed. A board of weights and measures pre-examination is performed at the factory
and the device is certified with an appropriate seal of approval.
You can verify it your device is a calibratable design by what is shown on the nameplate. Information
on pre-legalization is shown on the stamp.

The PTB approval number

The PTB approval number is only printed on the nameplate of calibratable version.

! Note: If the device is in calibration mode (calibration switch = ON), parameters, which must be
calibrated cannot be revised.

6. Error Codes

6.1 ERR11

The pulse transmitter monitor signals an error.

Possible causes:
1. The pulse transmitter is not connected or connected improperly.
-> Check the pulse transmitter.
2. The pulse transmitter is not getting any power or not enough.
-> Set the jumper to by-pass the current monitor.

! Note: The error will be reset at the next release.

164
6.2 ERR12

The maximum number of consecutive tank fillings without a quantity was reached (zero fuellings).
Possible causes could be improper operation or defective readings. Check if the quantity pulse
LED's (yellow light indicator) flash while the product is flowing. If this is not the case, the pulse
transmitter may be defective or its connection / wire.
! Note: This error is reset by pulling up the Menu once.

6.3 ERR13

Double pulse error. Too many false pulses were recognized.

Possible causes:
- Defective pulse transmitter
- One of the two pulse channels is defective or a wire has been pulled off.

6.4 ERR14

One of the two pulse channels is defective or a wire has been pulled off.

It may be caused by an external release by the service station or the level cut off.

! Note: The TASS interface LED is active when the TF is closed.

The error will be reset at the next release.

6.5 ERR15

Interrupted communication at the ER3 data interface.

Possible causes:
- POS system failure
- faulty channel
- baud rate is wrong

! Note: The error will be reset after it is corrected and after the first
communication via ER3 protocol.

6.6 Minimum quantity

This warning is displayed if the amount of fuel in the first or second storage tank reaches the
minimum quantity entered.

! Note: The error will be reset after refilling the fuel to a level above the minimum quantity
or turning off this function.

165
7. LED Functions

Underneath the large display there are 2 LEDs, which may be green, yellow and red. The left LED
shows the first filling station, the right LED the other.

! Note: The error will be reset after refilling the fuel to a level above the minimum quantity
or after Turing off this function.

7.1 The LED lights yellow

If there was a release, the LED lights up until the start of refuelling, or its completion.
When closed, the LED lights up until the remaining fuel runs off (delay time).

7.2 The LED lights green

The machine is ready to refuel.

7.3 The LED lights red

The minimum delivery level has not been reached. LED goes out after the level has been reached.

7.4 The LED flashes red

- ERR11 or 21: The impulse monitor reports an error. The LED goes out when the pulser error is
corrected or when The minimum delivery level has not been reached is set. LED goes out after it
has been reached or after setting the jumper to by-pass the current monitor.
- ERR 12 or 22: The maximum number of zero fuellings has been reached. The LED goes out after
pulling up the Menu once.
- ERR 13 or 23: Double impulse error. The LED goes out after the error reset by the next release,
- ERR14: External release or level cut-off. The LED flashes until the TF on the pulse interface
closes and the error is reset by the next release.
- ERR 15: Interrupted communication at the ER3 data interface. The LED is off once the error is
repaired and reset after the resumption of communication via ER3.

7.5 LED is off

No errors, the device is ready for use.

166
 8. Technical Details

Supply voltage: 230 V AC, 50-60 Hz, from 190 V up to 250 V

Power input: approx. 14VA
Construction form: Steel housing RAL 7032 (grey)
Film applied to the front providing a high level of resistance against mineral oils and mechanical stress.
Cable glands M20. M25
Ventilation membrane M12
Touch memory reader
Keypad with 16 keys
Alphanumeric display 2 lines @ 16 characters each
Protection type IP54
(as per EN60529):
Dimensions: 300 mm x 150 mm x 126 mm (width x height x depth. Dimensions each not including cable glands)
Weight: approx. 3.3 kg
o o
Ambient operating -20 C to + 60 C
temperature:
Humidity: up to 95% relative humidity, non-condensing
2
Electrical connections: screw terminals up to 2.5 mm
Cable feedthroughs: 3 x M20, 2 x M25 (standard for all versions)
Control elements: 16 key keyboard
Display elements: - Status illuminated diode red/green/orange
- LCD number display 6-digits 26mm number height.
- LCD text display 2x16 characters
Twin display: Twin display is connected with two cables to the central unit plate. Twin display cables should be placed so that
no interference occurs. Maximum length 0.5 m.
2
Connection cable: Power line / motor connection: 5x1.5mm
Low-voltage: shielded stranded twin cable.
Low voltage cables must be connected separately from the cables leading to the main power supply!
Pulse output: Electronically triggered pulse proportionately to the smallest display pitch, passive, open collector
5 V < Uce < 25 V, 5 mA < Ice < 30mA
max. output frequency: 250Hz; min. pulse duration: 2ms; phase offset:
o o
90 +/- 10 , from this information, a maximum output speed of 150 L / minute at 2 decimal point positions is the
result.
Pulse Input: 12V-Pulses: connection to an active 12V pulse transmitter. Supply current max. 80mA. Passive pulse
transmitters are also possible.
The minimumiInput pulse width Is 50% of the cycle time of the maximum input frequency.
o o
Pulse Input: 90 Phase shift, +/- 60
Pulse Input frequency Max. 400 Hz
Interfaces:
Interfaces: For all interface variations, a pairwise twisted data cable is recommended
ER3-Slave: Device side passive. Data interface with ER-3 protocol
TASS: Device side passive. Pulse interface to the connection to the fuelling system with a double pulse output;
release input; nozzle valve switch output
Release output:
Protection: towards the direct switching of the 3-phases of the pump motor
Switched power max. 8A AC
Switched voltage max. 300V AC
Relay: Potential-free mechanical relay, is locked during release.
Switched power max. 20mA AC or DC
Switched voltage max. 30V AC or DC
This data refers to resistive loads
Approvals: PTB calibration approval 5.631.96.19
Explosion hazardous area: The device is not approved for explosion hazardous areas.

167
7. DRAWINGS / ASSEMBLY DIAGRAMS

7.1 Layout Main Circuit Board

168
7.2 Wiring Diagram Pulse Transmitter / Pump Motor

169
7.3 Wiring Diagram Pulse Interface (TASS)

170
7.4 Wiring Diagram Data Interface (ER-3 Slave)

171
7.5 MARKING

172
8. Calibration Protocol

Date of calibration: ...........................

Device factory no. ...........................
Pulse transmitter factory no. ...........................
Metering chamber factory no. ...........................
Device name: FlaZaeP

Pulses Value: __ __ , __ __ __ __ (Menu item: Pulse value)

Metered values:
1. Measurement: Bell prover: __________ Display: ________ Variance: ________
2. Measurement: Bell prover: __________ Display: ________ Variance: ________
3. Measurement: Bell prover: __________ Display: ________ Variance: ________

min. dispensal quantity: ...........................

max. false pulses: ...........................
Medium being measured: ...........................
(Product name)

Next scheduled calibration: ...........................

(Month/Year)

173
XIX. GMS TELEMETRY INSTALLATION IN TMS

Blue GSM Operation and Installation Manual

1. Ensure Power is disconnected from the TMS Box before you open the door or carry out any
work on the unit.

2. Place Blue GSM board in the left bottom corner of TMS and screw down the board ensuring
not to over tighten. Ensure orientation is such that the two capacitors are positioned in the
centre at the top of the board as per picture.

3. Connect 12V from the TMS 12v power socket board to Blue GSM board.

Ensure red wire connects positive poles and black wire connects negative poles (GND)

174
4. Connect the blue gsm antenna cable assembly to the top right hand corner of the box
base in the hole provided. Use sealant to ensure against ingress. Connect the other end
of the blue gsm cable assembly to the Blue GSM board by hand tightening the brass
screw fully onto the socket. Do not put pressure on the board or over tighten.

175
5. Connect I2C cable between Blue GSM and TMS PsoC board. Double check that the
SDA, SCL and GND are connected to each other.

6. Switch on TMS box.

176
 7. Observe the LED’s.

There are 4 LED’s on the left side of the Blue GSM Board – SIGNAL, GPRS, ACTIVE,
SDCARD

• SIGNAL – LED ON means that is good GSM signal strength

• GPRS – LED ON means that is GPRS signal
• ACTIVE – LED ON means that Blue GSM is ready to work
LED FLASHING ( 1 second ON, 1 second OFF) – SIM card fail (not inserted,
not inserted correctly, broken or pin code enabled).
• SD CARD – No operation. (disregard this LED)

After power on all 4 LED’s should flash 3 times. Note if this does not occur It takes up to 2
minutes for the capacitors to fully charge. In this state the LED’s will illuminate one after
another.

When the capacitors are fully charged LED’s are switched off for about 20 seconds (until
GSM modem initializes).

After that SIGNAL LED and ACTIVE LED should switch ON. That means the modem is
working properly and GSM signal strength is good.

GPRS LED can also switch ON, but it’s not necessary for correct functionality.

8. Close the TMS box and ensure that the seals are intact and the glands are fully closed.

9. If there is any concern about ingress use a sealant to bond the box.

177
Troubleshooting

1. Properly working GSM unit

2. Where I can find the GSM serial number?

GSM serial number (don’t mix up with TMS serial number) is placed on the back of the GSM
board.

178
 3. Power LED off

No power
- Check the 12V DC connection

4. LED’s sequent flashing

GSM capacitors charging

- wait approx. 2 minutes to fully charge capacitors
-

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 5. Signal LED off

No network coverage
- check the network coverage on site

Aerial fault
- replace the aerial or aerial cable

6. Active LED off

Modem fault
- reset the GSM unit (power off, wait 30s and power on)
- if no changes after reset replace the unit

7. Active LED flashing (1s on, 1s off)

No SIM card
- install SIM card

PIN number enabled

- disable the pin number on the SIM card

SIM card fault

- replace the SIM card

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 8. All 4 LEDs flashing together three times

Power up (if appears once)

- normal modem initializing sequence

Modem reseting (if repeats constantly)

- check the aerial connection to the modem
- replace the aerial and aerial cable
- replace the unit

9. GSM unit sends wrong data on the website

Broken connection between GSM and TMS

- check the connection
- replace the cable

Missing jumper (only for TMS rev.2)

- place the jumper

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 10. GSM unit not sending the data

Roaming disabled (abroad only)

- enable the roaming on the SIM card

Sleep mode
- contact service

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XX. TMS OPERATION MANUAL

1. Introduction 19. Buzzer

2. Technical specification 20. Level – ultrasonic
3. Schematics 21. Level – 4-20mA sensor
4. TMS types descriptions 22. Flow In
5. TMS functions 23. Thermistor 1 (TH1)
6. Safety switch 24. Leak detector
7. Display, reset button and LEDs 25. Thermistor 2 (TH2)
8. Communication with computer 26. Pistol
9. Overload and residual current protection 27. 4-20mA OUT
10. Fuse 28. I˛C.
11. Power supply 29. EXT IN
12. Pump 30. 12V
13. Fans 31. TH3, TH4
14. House heater (HH) 32. Flow Out
15. Tank heater (TH) 33. Relay 6
16. O/P 1 34. Display screens and alarm indications
17. EXT OUT 35. TMS dimensions
18. J19 terminal

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1. Introduction

The TMS (Tank Monitoring System) is a device that is used to control, monitor and
accommodate efficient storage and dispensing of liquid.

This instruction covers all the functions of TMS revision2.

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2. Technical specification

Dimensions Height: 310mm, Width: 358.5mm, Depth: 114.7mm

Material Flame Retardant ABS
Ambient temperature -20°C to +40°C
Humidity Range 15% - 95%
Altitude Range <2000m above sea level
Supply voltage 100 – 240 V AC, 50-60Hz, 1.6kVA
Fuse 20 x 5mm, 1A Slow Blow Fuse
Relays 6 x 4031 – 12V DC, 10A
High voltage: 6, 4 and 3 way connectors 5.08 pitch
Electrical connections Low voltage: 2, 10 and 20 way connector 3.5 pitch,
Jack connector – 3 pole, 3.5mm, 1A jack socket
High voltage:
- 1 – Circuit breakers input
- 2 – Safety switch input
- 3 – 230V, power supply input
- 4 – Pump, output, max current 4A
- 5 – Fan1, output, max current 2A
- 6 – Fan2, output, max current 2A
- 7 – HH, house heater output, max current 5A
- 8 – TH, tank heater output, max current 5A
- 9 – O/P1, lamp output, max current 3A
- 10 – Ext Out, external output, max current 5A
Low voltage:
Main:
- Level - Ultra – ultrasonic device input (3 V)
- Level 4-20mA – pressure sensor input (4-20mA)
- Flow In – input from flowmeter
Inputs / Outputs - TH1 – house thermistor input
- Leak – leak detector input
- TH2 – tank thermistor input
- Pistol – pistol switch input
- I/O – input/output, not used
Buzzer:
- Input for 12V buzzer
Management:
- TH3 – input for calorimetric thermistor, not used
- TH4 – input for calorimetric thermistor, not used
- Ext In – tank management input
- Flow Out – 100imp/litre output, open collector
- Relay6 – additional relay normally open output Telemetry:
- 4-20mA Out – output for telemetry unit with standard 4-20mA signal
- I2C – communication with GSM
- Ext In – tank management input
- 12V – DC power supply for GSM or other external units, max current 1.5A
Interface Jack connector – 3 pole, 3.5mm, 1A jack socket (RS232)
Display 128x64 graphic LCD, blue
LEDs Green – power, Red – alarm
- Reset Switch
Operation
- On/Off Switch
Buzzer 12 V dc, 80dB
- RCD – 30mA, 25A residual current device for 230V power supply
- Pump – 6A, D type
Circuit breakers - Fans – 6A, D type
- Tank and house heater – 16A, D type
- External output and O/P1 – 10A, D type
Unit meets the requirements of;
● Low Voltage Directive: EN 61010:2001
Approvals ● EMC Directive: EN55011: 1999+A2: 2001, EN 61326:1998+A3: 2003
● EN61010-1:2001
● WEEE Compliant

185
3. Schematics

186
4. TMS descriptions

TMS contains all functionality that TMS rev2 have:

- circuit breakers and residual current device protection

- pump, fans, heaters and lamp driving
- level measurement (ultrasonic device or 4-20mA sensor)
- leak detection (piezo leak detector)
- flowmeter input
- pistol switch input to drive the pump
- thermistors to drive the heaters and fans
- 100imp/litre output
- Ext In (input for management control)
- 4-20mA output
(standard current representation of tank volume for external telemetrydevices)
- Relay6 – relay output indicating pistol switch state
- GSM unit (optional) – wireless tank monitoring

5. TMS functions

Below are described all the functions that TMS have. It is important to note that not all
TMS units are equipped with all the features outlined below. Please note each unit may only
have some of the outlined features active at any time.

All the external wires are connected to the power board. Display board is screwed to the TMS door
and connected internally with power board by ribbon cable as shown on the picture below.

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6. Safety switch

Safety switch is located on the front door and switching power on/off to the TMS. It is connected
through the RCD to the terminal ”2” named SW on the power board.

7. Display, reset button and LEDs

Display, reset button and LEDs are located at the front of the TMS box as shown below.

Display indicates fluid level in litres, dispensing volume, indicates when alarms appear.
All the display screens and alarms are described at the end of this manual.

Reset switch is used to cancel the audible alarm, to change display screen from main screen to
dispensing screen. The light inside the cabinet can be turned on and off by holding down the reset
button for 5 seconds. Pushing the reset button in the middle of dispensing will reset the dispensing
meter to 0.

Power LED (green) indicates that the TMS is powered.

Alarm LED (red) indicates that there is at least one alarm present.

188
8. Communication with computer

There is possibility to calibrate the TMS for certain type of tank, change his parameters
or switch off/on the alarms. To communicate with the computer we need a special calibration
cable, spare COM port on the computer and special software called TMS Tank Calibrator.

Refer to the “TMS Calibrator Manual” about more details. At the side of the TMS box
there is a jack port to connect the TMS box to the computer (see picture below).

9. Overload and residual current protection

There are 4 MCB (miniature circuit breakers) and 1 RCD (residual current device) to protect TMS
and external devices from electrical damage (see picture below).

- RCD – 25A, 30mA residual current device, connecting to 230V power supply,
protecting TMS with all the external devices
- D6 MCB – 6A, D type pump circuit breaker
- D6 MCB – 6A, D type fans circuit breaker
- D10 MCB – 10A, D type EXT OUT and O/P1 circuit breaker
- D16 MCB – 16A, D type tank and house heaters circuit breaker

Circuit breakers are connected to the “1” terminal on the power board.

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10. Fuse

There is a fuse located on the top left corner of the power board. This fuse is protecting
low voltage components and devices connected to the TMS.

The fuse will blow up if there is a short circuit between the low voltage pins (especially between 12V
DC and GND).
This fuse is 20x5mm, 1A slow blow glass fuse.
To replace the fuse switch off the power supply.

11. Power supply

230V AC connection.
Power supply is connected to the power board terminal “3” named 230V. The other end is connected
to the junction box located at the end of the loom as shown on the pictures below.

12. Pump

230V AC connection.

Pump is connected to the terminal “4” named PUMP on the power board. TMS is driving the pump
by a 10A relay 1. There is an overload protection for pump inside the TMS – 6A, D type circuit
breaker. The pump comes on when the pistol is lifted (pistol switch change his state) and there is no
low level or level disconnection alarms. Refer to the alarms at the end of the manual.

190
13. Fans

230V AC connection.
One or two fans are connected either to the power board terminal “5” named FAN1 or
terminal “6” named FAN2.

TMS is driving the fans by a 10A relay 2. There is an overload protection for fans inside
the TMS – 6A, D type circuit breaker.
The temperature when the fans come on can be set by TMS Tank Calibrator Software.
The default temperature is +35ºC. Temperature is measured by the 2 thermistors connected to the
MAIN low voltage terminal on the power board.

14. House heater (HH)

230V AC connection.
House heater is connected to the power board terminal “7” named HH.

191
TMS is driving the house heater by a 10A relay 3. There is an overload protection for
house and tank heater inside the TMS – 16A, D type circuit breaker.
The temperature when the house heater come on can be set by TMS Tank Calibrator
Software. The default temperature is -8ºC. Temperature is measured by the thermistor TH1
connected to the MAIN low voltage terminal on the power board.

15. Tank heater (TH)

230V AC connection.
Tank heater is connected to the power board terminal “8” named TH.

TMS is driving the tank heater by a 10A relay 4. There is an overload protection for tank
and house heater inside the TMS – 16A, D type circuit breaker.

The temperature when the tank heater come on can be set by TMS Tank Calibrator
Software. The default temperature is -8ºC. Temperature is measured by the thermistor TH2
connected to the MAIN low voltage terminal on the power board.

16. O/P 1.

230V AC connection.

This is the output for external 230V lamp. The cable is connected to the power board
terminal “9” named O/P 1.

TMS is driving this output by a 10A relay 5. There is an overload protection for O/P 1 and EXT OUT
inside the TMS – 10A, D type circuit breaker.

The light inside the cabinet can be turned on and off by holding down the reset button for 5 seconds.

192
17. EXT OUT

230V AC connection.

For TMS EKO this output is used for supplying the external devices such as MC Box,
Flaco panel, GOK devices. The cable is connected to the power board terminal “10” named EXT
OUT.

There is an overload protection for EXT OUT and O/P 1 inside the TMS – 10A, D type circuit
breaker.

18. J19 terminal

Non potential normally open relay outputs to indicate when overfill alarm (relay2), low level alarm
(relay3) or leak alarm (relay6) appears. The terminal is located at the top left corner of the power
board.

19. Buzzer

12V DC connection.

Buzzer is connected to the BUZZER terminal on the power board and is switching on when alarm
appears.

193
20. Level – ultrasonic

3V DC connection.
Ultrasonic level sensor is connected to the MAIN terminal on the power board.
Connection is named LEVEL-ULTRA.
Pin 1 (GND)
Pin 2 (IN)
Pin 3 ( + )

Ultrasonic unit (picture below) detects the level in the tank and send digital data to the TMS.

194
21. Level – 4-20mA sensor

12V DC connection.
4-20mA level sensor is connected to the MAIN terminal on the power board. Connection
is named LEVEL 4-20mA.
Pin 4 (GND)
Pin 5 ( - )
Pin 6 ( + )

The 4-20mA level sensor like in the picture below send current from 4 to 20mA
depending on the measuring level.

TMS measuring level from the ultrasonic device as a default. TMS Tank Calibrator
software can change sensor type from ultrasonic to 4-20mA.

195
22. Flow In

5V DC connection.
MAIN terminal.
Pin 7
Pin 8
Flow In is an input for pump flowmeter. This input is suitable for flow meters with
different resolution

23. Thermistor 1 (TH1)

5V DC connection.
MAIN terminal.
Pin 9
Pin 10

TH1 is an input for 10kK thermistor. TMS measuring temperature in the house using that
thermistor and then driving the house heater and fans.

Temperatures for switching on/off heaters and fans can be set by TMS Tank Calibrator
softwar

196
Thermistor is shown on the picture below.

24. Leak detector

5V DC connection.
MAIN terminal.
Pin 11
Pin 13

This input is for piezo leak detector. It can be used in leak detection for conductive fluids
(Adblue) as well as for non-conductive fluids (Diesel).

Leak detector is shown on the picture below.

197
25. Thermistor 2 (TH2)

5V DC connection.
MAIN terminal.
Pin 15
Pin 16

TH2 is an input for 10kK thermistor. TMS measuring temperature in the tank using that
thermistor and then driving the tank heater and fans.

Temperatures for switching on/off heaters and fans can be set by TMS Tank Calibrator software.

26. Pistol.

5V DC connection.
MAIN terminal.
Pin 17
Pin 18

This input is for pistol switch. When the dispensing pistol is lifted from the pistol holder, the pump
turns on, and the screen on the TMS unit reverts into dispensing mode. When the pistol is replaced
to the holder, the pump turns off.

198
27. 4-20mA OUT

Max. 30V DC.

TELEMETRY terminal.
Pin 1 ( - )
Pin 2 ( + )

This is 4-20mA output used for external telemetry systems. It gives current from 4mA to
20mA proportional to the actual tank volume.
4mA – 0 litres.
20mA – nominal tank capacity.

This output is a passive output. It needs to be supply from the external device to give a
properly readings. Maximum supply voltage is 30V DC.

28. I²C

TELEMETRY terminal.
Pin 3 (GND)
Pin 4 (SCL)
Pin 5 (SDA)

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These are communication pins with a GSM unit. If the GSM unit is used, these pins have
to be connected with the pins on the GSM board terminal as shown on the picture below.

29. EXT IN

5V DC connection.

TELEMETRY terminal.
Pin 6 ( - )
Pin 7 ( + )

MANAGEMENT terminal.
Pin 5 ( - )
Pin 6 ( + )

This input is for pump management control. The close circuit between that pins allow the
pump for working. TMS must be calibrated for management mode using TMS Tank Calibrator.
Refer to the “TMS Calibrator Manual” about more details. After calibration on the top right
corner of the display a padlock should appear. That padlock informs about the access to the
pump.

Padlock open – pump enable.

Padlock close – pump disable.

200
They are the same inputs on the TELEMETRY and MANAGEMENT terminals. It
doesn’t matter what terminal the cable is connected to.

30. 12V

12V DC, 1.5A max.

TELEMETRY terminal.
26
Pin 8 ( - )
Pin 9 ( + )

This is 12V DC power supply for GSM or other external telemetry units. Maximum
current is 1.5A.

If the GSM unit is used, these pins have to be connected with the pins on the GSM board
terminal as shown on the picture below.

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31. TH3, TH4

Not available at this moment.

32. Flow Out

Open collector output, max 30V DC.

MANAGEMENT terminal.
Pin 7 ( - )
Pin 8 ( + )

This open collector output converts impulses from pump flow meter and creates 100
impulses per litre. This output works similar to reed switch. The external device which will read
the pulses must have the pull-up input (input with a pull-up resistor).

The schematic below shows how to connect the Flow Out to external device.

202
33. Relay 6

MANAGEMENT terminal.
Pin 9
Pin 10

This relay output indicates the pistol switch state. When the pistol is lifted this relay closes, when the
pistol is replaced to the holder this relay opens.

34. Display screens and alarm indications

a) Main screen
This screen is a default TMS screen. It appears after power up. The numeric indicator
shows the volume of the liquid remaining in the tank in litres. The bar chart below the
number is a visual indication of the tanks volume.

If the triangle with exclamation mark inside appears on the top left corner of the screen
that means there is at least one alarm in the system. The meaning of alarms are explain
below.

203
b) Dispensing screen
This screen appears when the pistol is lifted (TMS EKO) or first pulse from flowmeter arrives.

The large number indicates how many litres have been dispensed at present. The small size number
beside “TOTAL” indicates the total volume of liquid dispensed in litres for the lifetime of the TMS unit
to date.

For TMS EKO: when the dispensing operation is complete and the dispensing nozzle is returned to
its holder, the “Dispensing Screen” will revert to the “Main Screen” in approximately 1 minute.

For TMS 100 and 200: when no pulses come from the flowmeter in approximately 1 minute the
“Dispensing Screen” will revert to the “Main Screen”.

c) Low level alarm

This indicates that the level in the tank is low, and so it is not possible to dispense any liquid. The
purpose of the alarm is to ensure that pre determined level of fluid is left in the 31 bottom of the tank
to avoid pump dry run. During this alarm the pump is switched off automatically and cannot be
switched on until the volume in the tank exceeds the low level setting, e.g. tank has to be filled to
enable the pump to operate.

The first section of the bar graph will flash. There will be no buzzer and no Alarm LED light.

d) Overfill alarm
Activation of this alarm indicates the tank has reached a predetermined high capacity and filling must
be stopped immediately. An alarm LED will light and a buzzer will also sound. The buzzer can be
silenced by pushing the reset button but the screen remain the same until the level falls below the
overfill level.

204
e) Leak alarm
If a leak from the tank is detected the screen below will appear, the buzzer will sound and the Alarm
LED will light.

Check to see if bund area is wet. Once bund area is emptied, the LED will turn off and the alarm will
disappear.

f) Level disconnection alarm

This indicates that a fault has occurred with the tank level detection device (ultrasonic or 4-20mA
sensor) and therefore cannot measure the volume of the liquid remaining in tank. The volume
displayed is the last good level received and will remain until new level is received. An alarm LED
will light and a buzzer will also sound. It is not possible to dispense liquid while in this alarm mode,
as the pump will be automatically switched off.

g) Leak disconnection alarm

If a fault has been detected with the leak detector the screen below will appear, the buzzer will
sound and Alarm LED will light. The condition will remain on the screen until the connection issue is
resolved.

h) Management mode – pump access

The management mode must be activate in the TMS Tank Calibrator software. Refer to the “TMS
Calibrator Manual” about more details. After that a padlock symbol appears on the top right of the
screen. This mode working with the EXT IN input. The close circuit between the EXT IN pins allow
the pump for working. That padlock informs about the access to the pump.

Padlock close – pump disable.

205
Padlock open – pump enable.

35. TMS dimensions

206
36. TMS cable schematic

Wiring diagram for TMS programming

207
TMS supply wiring diagram

TMS signal wiring diagram

208
XXI. TMS SOFTWARE INSTRUCTIONS

13. Introduction

TMS calibrator is a software to use with the TMS Box. The latest version of calibrator
covering all the TMS versions.

14. Starting with the TMS Calibrator

TMS Calibrator zip file contains a directory “STables” with the strapping tables and a TMS Calibrator
exe file. When you extract a zip file make sure that the “STables” and the exe file are in the same
directory.

Open the exe file to start working with the calibrator.

15. Working with the different TMS versions

From the version 1.35b TMS box start to use the Strapping Table to make a volume measurements
more accurate. Strapping table is a table with the heights and volumes which describe the specified
type of the tank. There is one strapping table for one type of tank. The versions below 1.35b uses
the linear function to calculate volume.

TMS Calibrator automatically recognise the TMS version and choose the correct procedure to
calibrate. Calibrator also deactivates some functions not used in the old versions.

16. Connecting to the TMS

Use a special cable to connect TMS with the COM port in your computer. Choose the
COM port from the list and click “Connect to TMS” button.

209
 Picture2. Choose the COM port.

If you are not sure what COM port you are using in your computer check that in the
Control Panel.

When you successfully connect TMS to the computer you will see a message below the
button and the button change the name to “Connected”.

Picture3. TMS connected.

17. Calibrating a Standard Tank

Choose the tank from the list and click “Calibrate” button.

Picture4. Standard Tank.

210
Depend on version of the TMS the calibrator will choose whether send strapping table or
use a linear function.

“Detected” value beside the Height box showing an actual height measured by Ultrasonic
device. This is very useful parameter when calibrating the TMS with ultrasonic device.
Sometimes “detected” value could be a little different than the default height for a tank. But the
“detected” value shows a real height of the tank and should be used rather than a default
“Height” value.

After you click “Calibrate” program will ask you whether use Height or Detected value.

Picture5. Choosing the height.

By clicking the “Edit value” button we will be able to change the tank parameters
manually for a specified type of tank. The password is: changeme.

“Const” value is only true for the TMS versions 1.35a and lower and shows the
coefficient [litres/cm] for the linear function calculations.

18. Creating a New Tank

To calibrate the tank which is not in the standard tanks you have to go to “Advanced” tab
and use Create New Tank. To activate this tab click File in the pop-up menu and then Advanced.
Password is: bigson.

Depend on the TMS version this field could be different:

• Version 1.35a and lower

Picture6. Create New Tank – old TMS versions.

To Calibrate New Tank you must choose the tank shape, put the height, capacity, overfill and low
level values. Then click “Calibrate” button.

211
• Version 1.35b and higher

Picture7. Create New Tank – new TMS versions.

You can choose one from the three tank shapes: Cubic, Cylindrical or Irregular. For first
two there is fixed strapping table. For Irregular you have to create a strapping table by clicking
“Strapping Table” button.

Click “Go” beside the “Max Capacity” to send Height, Max Capacity and Tank Shape to the TMS.

Click “Go” beside the “Low Level” to send High Level and Low Level to the TMS. For Irregular tank
you can edit the strapping table. Click “Strapping Table” button to open edit window.

Picture8. Strapping table edit window.

212
First values in the Level Table and Volume Table are fixed (0,0). In the Level Table
column enter the height in centimetres. In the Volume Table column enter the volume in litres.
You can save the tables to the text files using “Save as” button, or load the tables from
files using “Browse” button. If the table is ready click “Send” to calibrate the TMS with that
table. Remember that the table should contains at least 2 level and 2 volume elements. The
quantity of level element should equal the quantity of volume element. Do not use values with
decimal point.

19. Alarm Controls

Alarm Controls change some of the TMS parameters. To send parameter to TMS just
click “Go” button beside it.

Picture9. Alarm Controls.

• Flow rate: you can choose one from the three types, depends what flowmeter is used (AdBlue –
0.011 litre/imp, FuelMaster® – 0.02985 litre/imp, Biodiesel – 0.02857)
• Custom Flow Rate: enter manually the flow rate in [litres/imp]
• Management Mode: switching on/off the automatic pump control.
Panel ON – enables driving the pump from the external panel, there is no dispensing screen on
the TMS display, flowmeter is connected to the external panel.
RFID ON – enables driving the pump from the RFID module.
Mgmt Mode OFF – switches off management mode.
• Low Level Alarm: switches on/off low level alarm indication.
• High Level Alarm: switches on/off overfill alarm indication.
• Leak Alarm: switches on/off leak alarm indication.
• Light: switches on/off light control.
• Dry Run Pump Time: set the maximum pump running time when no pulses coming from
flowmeter (no dispensing)
• Hysteresis [%]: alarms on/off difference (refer to the TMS manual)

213
• High Temperature, Low Temperature: changing the temperature levels for heaters and fans,
available only for versions 1.38 and higher.
• Manual Command: sending a command straight to the COM port.

20. Diagnostics

We can do here a functionality test, 4-20mA output test and read status report.

Picture10. Diagnostics tab.

• Functionality test: click “Begin” to start, it takes 30 seconds, during the test TMS switches on light
and buzzer, displays measured height in centimetres on the display and when you lift the pistol it
switches on the pump.
• 4-20mA Calibration Test: available only for versions 1.38 and higher. 4 – sets 4mA on the output
20 – sets 20mA on the output End – ends a test. Click “Send” button to set the value.
• TMS Status Report: reads status report from the TMS, you can see here most of the TMS
parameters and check the TMS version. Click “Update (Allow 10 seconds)” button to update the
fields.

21. Sensor Type

We can change the type of the sensor TMS is using for level measurement and do adjustments for
pressure sensor.

Picture11. Sensor Type.

214
• Selecting the sensor: choose sensor type from the list and click “Send>” button.
• Pressure sensor zero adjustment: take the pressure sensor out of the liquid, if the TMS reading
value different than zero you can set zero by choosing the pressure sensor from the list and
clicking “Send 0 Level” button.
• Set liquid density: only for pressure sensors. Select the pressure sensor from the Choose Sensor
list, then choose the density of the liquid you storage in the tank. Choose density from the list. If
you select Custom, then write manually value in the Custom Density box. Values with decimal
point are acceptable. Click “Send>” button to set the density in TMS.

215
 DEFECT REPORT SHEET Date: …………………..
SERVICE ORDER

Attn: Client: Customer code:

Kingspan Environmental Sp. z o.o. COMPANY: ………………………………………………………………..
62-090 Rokietnica
ul. Topolowa 5, Poland ADDRESS: ………………………………………………………………..
tel.:+48 61 814 44 00 CONTACT: ……………………………………………………………………………..
fax:+48 61 814 54 99
phone. ……………………………………..fax ......................................................

“R” DOCUMENT Detailed address of product location:

NUMBER ........................................... COMPANY: …………………………………………………………………………….
DATE ...............................................
ADDRESS: ……………………………………………………………………………..
ADJUSTMENT NOTE
NUMER ...........................................
CONTACT: ……………………………………………………………………………..
DATE ............................................... phone. ……………………………………….fax ....................................................
Date and time when the product can be services/collected:
“D” DOCUMENT
NUMBER ........................................... ....................................................................................................
DATE ...............................................
Serial no.:
SENT BY: ........................
NUMBER ........................................... Date of purchase: Guarantee card no.:
DATE ..............................................

BlueMaster* BBM01300* BBM02500* BBM03500* BBM05000* BBM09000*

SlimLine* SLB01333 SLB02666 SLB03999 SLB05332 SLB02500 SLB05000 SLB07500 SLB10000 SLB15000

BlueTruckMaster* OTM00200BU OTM00430BU OTM00900BU

* Select correct

REASON OF REPORT/DESCRIPTION OF DEFECT:

Name .................................................................... Signature…................................................

NOTE: If it is determined that defect disclosed during guarantee period is due to improper use or installation of the product, or defect
occurred after expiration of guarantee period, reporting party shall be charged with service-related costs.

DECISION (Sales Administration Dept.):

Name .................................................................... Signature…................................................

216
Kingspan Environmental
Ter Reigerie 11, 8800 Roeselare
Belgium
Tel.: +32 51 48 51 42
Fax: +32 51 48 51 53
info@kingspan-env.be
www.kingspanenviro.be
Kingspan Environmental
– organizacní složka
Pražské Předměstí, Habrmanova 166/26
500 02 Hradec Králové
Czech Republic
Tel.: +420 725 114 555
Fax: +420 491 619 006
info@kingspan-env.cz
www.kingspanenviro.cz
www.klargester.cz
Kingspan Miljøcontainere A/S
Strandvejen 44, 2900 Hellerup
Denmark
Tel.: +45 9626 5620
Fax: +45 9626 5628
salg@kingspanmiljo.dk
www.kingspanenviro.dk
www.klargester.nu
Kingspan Environmental
36 rue du Louvre, 75001 Paris
France
Tel.: +33 (0) 474 99 04 56
Fax: +33 (0) 474 94 50 49
bureau@kingspan-env.fr
www.kingspanenviro.fr
www.klargester.fr
Kingspan Environmental GmbH
Siemensstr. 12a, 63263 Neu-Isenburg
Germany
Tel.: +49 (0) 6102 3686700
Fax: +49 (0) 6102 3686720
info-deutchland@kingspan.com
www.kingspanenviro.de
www.klargester.de
Kingspan Environmental
Lingewei 8, 4004 LL Tiel
The Netherlands
Tel.: +31 (0)344 760050
Fax: +31 (0)344 760052
info@kingspan-env.nl
www.kingspanenviro.nl
www.klargester.nl
Correspondence address:
Ter Reigerie 11,
8800 Roeselare
Belgium
Kingspan Miljø AS
Skiveien 42, 1410 Kolbotn
Norway
Tel.: +47 22 02 19 20
Fax: +47 22 02 19 21
post@kingspanmiljo.no
www.kingspanenviro.no
www.klargester.no
Kingspan Environmental Sp. z o.o.
Topolowa 5, 62-090 Rokietnica
Poland
Tel.: +48 61 814 44 00
Fax: +48 61 814 54 99
biuro@kingspan-env.pl
www.kingspanenviro.pl
www.klargester.pl
Kingspan Environmental
180 Gilford Road Portadown, Co. Armagh
Northern Ireland BT63 5LE
Tel: +44 (0) 28 3836 4400
Fax: +44 (0) 28 3836 4445
Dundalk Road, Carrickmacross, Co. Monaghan
Ireland
Tel: +353 (0) 42 969 0022
Fax: +353 (0) 42 969 0030
Dunmore Road, Glenamaddy, Co. Galway
Ireland
Tel: +353 (0) 94 965 9110
Kingspan Environmental
College Road North, Aston Clinton
Aylesbury, Buckinghamshire, HP22 5EW
United Kingdom
Tel: +44 (0) 1296 633000
Fax: +44 (0) 1296 633001