User manual | Titan Bluestore Manual :: Commercial Fuel Solutions Ltd

Installation and Operation
Manual
AdBlue Storage and Dispensing
Above Ground Polyethylene Tanks
Issue 2 August 2011
1
Index
1.
2.
3.
4.
5.
6.
7.
8.
Safety Instructions
Product Description
Transport & Storage
Installation & Commissioning
User Guide
Maintenance & Service Schedule Information
Warranty
Trouble shooting Guide
Appendix A – Further Details of Main Parts
Appendix B – Tank Monitoring System Information
2
1. Safety Instructions
PLEASE READ OPERATION MANUAL CAREFULLY BEFORE USE & COMPLY WITH
ALL INSTRUCTIONS HEREIN
OPERATION MANUAL SHOULD BE KEPT WITH THE EQUIPMENT AT ALL TIMES
1. This manual contains important information concerning the safe installation and use
of this product. Read the manual carefully before installation and use. Pay attention to
all safety warnings.
2. Installation and use of this product should only be carried out by properly trained and
approved personnel.
3. The user of this product is responsible for the safe and correct use of this product.
4. Any changes to this product, which have been done without consulting the
manufacturer, may invalidate all warranties and guarantees.
5. The manufacturer will not be responsible for any accidents or damages caused by
incorrect installation or use of this product.
6. This product is only suitable for storage and dispensing of AdBlue to DIN70070.
2. Product Description
The BlueMaster range of tanks are designed to answer the needs of commercial companies
as well as public depots with truck fleets for storage and dispensing of 32.5% urea, trade
mark AdBlue. The tank enables safe AdBlue storage outdoors, at a safe distance from
buildings and Atex hazardous zoned areas. High resistance against mechanical impact and
protection against frost and heat due the "tank in tank" construction and optional inbuilt
heating and cooling to suit UK and ROI temperature conditions can be shown. The high
standard of specification ensures optimum safety and functionality. The product is not Atex
approved.
Capacity
Length/Diameter
Width
Height
BMH2500
2500 litres/550 gallons
2460mm
1430mm
1855mm
BMV5000
5000 litres/1100 gallons
2230mm
2800mm
2420mm
BMV9000
9000 litres/ 1980 gallons
3280mm
2480mm
2950mm
3. Transport & Storage
1. DO NOT TRANSPORT WITH LIQUID INSIDE
2. On the BlueMaster 5000 and 9000 litre tanks, a plastic strap is used to secure the
housing to the tank for transportation and off loading. Do not remove until tank is in
final location.
3. The BlueMaster tanks must be protected against mechanical damage during
transport and storage.
4. Loading and off-loading must be carried out using only professional equipment, either
a forklift with extended forks/tines or a crane. If lifting slings are used they must be
attached to the lifting points on the external tank. The covers, sockets or other
protruding elements, which are not designed for lifting or moving the tank, must not
be used to lift or move the tank.
5. The BlueMaster tanks must never be pushed or rolled.
6. During transport and storage, the door must be tightly closed and secured. The
dispensing nozzle must be placed in its holster and the control box shut.
7. Loading and transport areas must be smooth and free of sharp edges. During
transportation the tank must be secured to prevent the tank from moving.
3
4. Installation & Commissioning
When installing a BlueMaster tank, the following guidelines must be observed:
1. The area on which the tank sits on should be solid (eg. concrete), smooth and free of
sharp edges.
2. The tank should be placed at a minimum distance of 0.5m from all devices with
surface temperatures > 100 ° C.
3. The tank should be protected against direct sunlight in hot regions with ambient
temperatures > 40° C.
4. The user shall ensure safe urea supply (tank filling) and free space around the tank
for periodic inspections and reviews.
5. Tank is delivered without power supply line. A qualified engineer should connect a
suitable 230V power line to junction box in the pump housing with a dedicated fused
spur rated at 13amps. The individual cores of the power supply cable should be
2
minimum 2.5mm .
BMV5000
Junction Box
Location
BMH2500
6. The BlueMaster user is responsible for complying with all legal requirements related
to the installation and use of this product, as well as the guidelines issued by local fire
fighting authorities and environmental authorities.
7. Provision should be made to protect tank from impact damage.
5. User Guide
(a) Summary of Main Parts
1. Bunded tank - inner storage tank with capacity equal to 95% of nominal volume &
outer bund with capacity equal to 110% of inner tank.
2. 2" filling line and dry break coupling
3. Stainless steel ¾" suction pipe with filter, check valve & shut-off valve (not available
on 2500litre).
4. Lockable equipment housing
5. Inner tank ventilation
6. Tank Monitoring System (TMS). To connect TMS with and without software please
refer to Appendix B: TMS Management Interface.
- level & flow displays
- overfill, leak and equipment alarms
- low level & time cut-offs
- remote monitoring telemetry (optional)
7. Pump – in cabinet or submersible
8. Dispensing hose and autonozzle - Standard or ZVA
9. Nozzle holster and switch
4
BMH2500
6
3
7
2
8
1
9
BMV5000
3
6
7
9
2
8
For further details on main parts see Appendix A and B
5
(b) Filling BlueMaster Tank
Do not exceed a maximum fill rate of 350 litres per minute.
During the first fill of the tank the level indicator shows less volume than that filled.
The level indicator minimum read point is placed several centimetres above the base of
the tank, which creates a dead zone in the bottom of the tank.
o
o
o
o
o
o
o
Filling should be performed only under constant supervision of an authorised person
This tank can only be filled by a tanker equipped with a female dry-break coupling.
Ensure dispensing nozzle is in the holster.
Fit delivery hose to dry-break coupling
Fill tank in normal manner.
Stop filling when desired amount has been dispensed into tank or when overfill alarm
sounds.
Disconnect delivery hose from dry-break coupling.
(c) Dispensing From BlueMaster Tanks
o
o
o
o
o
Lift dispensing nozzle from holster.
The TMS display will automatically switch to the Dispensing Screen and pump will
start.
Dispense AdBlue.
Replace dispensing nozzle in holster.
Dispensing Screen will revert back to the Main Screen in 1 minute.
Note: If the dispensing nozzle is not replaced into the holster correctly, the pump will run
for 5 minutes before automatically switching off. If this occurs press the reset button on
the TMS or lift and replace the dispensing nozzle in the holster.
(d) General Operation (via TMS)
Main Screen
When the control panel is switched on, the TMS ‘Main Screen’ will appear, as shown in Figure
1 below. The numeric indicator shows the volume of liquid remaining in the tank, in litres. The
bar chart below the number is a visual indication of the tank’s volume; each bar represents
1/10th of the volume (ullage).
Figure 1 LCD – Main Screen
6
Flow Mode
When the dispensing nozzle is removed from its holder, the TMS will automatically switch to
the ‘Dispensing Screen’, as shown in Figure 2 below. The large size numbers in the centre of
the screen indicate how many litres have been dispensed at present. The small size numbers
beside “TOTAL” indicates the total volume of liquid dispensed in litres.
Figure 2 LCD – Dispensing Screen
When the dispensing operation is complete and the dispensing nozzle is returned to its
holster, the ‘Dispensing Screen’ will revert back to the ‘Main Screen’ in approximately one
minute. There is still the ability to move between the 2 screens, by using the reset button.
If the dispensing nozzle is lifted off its holster or not positioned back correctly, the pump turns
off after 5 minutes if nothing is dispensed.
Pushing the reset button in the middle of dispensing will reset the flow meter to 0.
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
liquid. The pump is switched off automatically, and cannot be switched on until the volume in
the tank exceeds the low level setting, i.e. tank has to be filled to enable pump to operate.
Note: The first section of the bar chart will be flashing. There will be no buzzer sound and no
Alarm LED light.
Figure 3 LCD – Low Level Alarm
7
Level Alarm:
This indicates a fault has occurred with the tank’s level detection device and therefore cannot
measure the volume of liquid remaining in the 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 will not be possible to dispense liquid while in this alarm mode, as the pump
will be automatically switched off.
Figure 4 LCD – Level Alarm
Overfill Alarm:
Activation of this alarm indicates the tank has reached full capacity and filling must be
stopped immediately. An Alarm LED will light and a buzzer will also sound for 5 minutes.
Note: It will remain like this until the level falls below the Overfill Level.
Figure 5 LCD – Overfill Alarm
Factory Programmed Level Settings
BMH2500
BMV5000
BMV9000
Low Level
Overfill
Low Level
Overfill
Low Level
Overfill
250 litres
2325 litres
485 litres
4700 litres
600 litres
8500 litres
8
Bund Alarm:
If fluid in the bund area has been detected the buzzer will sound and an Alarm LED will light.
The buzzer will stop after 5 minutes, but the LED will remain lit. Check to see if bund area is
wet. Once bund area is emptied, the LED will turn off and the LCD will revert back to the main
screen.
Repetitive occurrences of this alarm should be investigated to determine cause of fluid in
bund.
Figure 6 LCD – Bund Alarm
Bund Sensor Error Alarm:
If a fault has been detected with the bund sensor, the buzzer will sound and Alarm LED will
light. Check the connection between the TMS and the bund sensor.
Figure 7 LCD – Bund Sensor Error Alarm
9
6. Maintenance & Service Schedule
o
o
o
o
o
o
o
o
o
Transport and store the tank so as not to damage the tank walls.
Keep all tank equipment in good working condition.
A daily check should be carried out in the visual condition of the tank, devices and
power line.
Any faults or alarms should be reported to the tank supplier immediately.
If fluid is found in the bund, contact the tank supplier immediately.
Spare parts must comply with the requirements of the manufacturer.
Protect against unauthorised access.
BlueMaster tanks should be serviced every 6 months or every 50,000 litres
dispensed, depending on which occurs first.
BlueMaster tanks should only be serviced by Kingspan Environmental approved
qualified personnel. Please contact Commercial Fuel Solutions Ltd for further details.
7. Warranty
Within the warranty period Commercial Fuel Solutions will repair or replace, at their discretion,
any tanks found faulty due to incorrect material or workmanship.
Kingspan Environmental products are guaranteed against material or manufacturing defect
and have the following guarantee period commencing from the date of invoice:
For polyethylene tanks: 5 years
For accessories/components: 12 months
This guarantee is not valid for the following defects:
Mechanical damage caused by the user, dealer or improper maintenance.
Faults, damage or premature wear caused by improper use.
Damage caused by third parties.
Repairs carried out by unauthorised service personnel.
Claims:
If a problem develops during the guarantee period, please call Commercial Fuel Solutions
Customer Care with the serial number and model type on +44 (0) 2380 231 007
Commercial Fuel Solutions Ltd
City West, Millbrook Road East
Southampton,
SO15 1AH
Tel: +44 (0) 2380 231 007
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8. Trouble Shooting Guide
Fault
Nozzle fails to operate
Pump fails to operate
TMS Alarms
Low Level Alarm
Overfill Alarm
Level Alarm
Bund Alarm
Bund Sensor Error Alarm
Action/Solution
1. If nozzle is ZVA ensure magnetic collar is fitted to
receiving tank
2. Check TMS for alarms - See below.
3. If no alarm is displayed check if nozzle is blocked by
adblue. If so, submerge nozzle in bucket of water for
approx. 20 minutes to dissolve AdBlue.
4. Internal parts may be damaged if nozzle has been
dropped or damaged. New nozzle required.
If problem not resolved please contact Customer Care
1. Check power supply to tank.
2. Check TMS for alarms – see below.
3. If tank is fitted with nozzle holder into which nozzle is
pointed downwards check the nozzle switch area has
no adblue crystals surrounding it. Hot wash away any
crystallisation.
4. Check that nozzle switch is operating by using a pencil
to push down inside the tube – click/click should be
heard.
If problem not resolved please contact Customer Care
Action/Solution
Fill Tank
Stop Filling the Tank
Check connection to Level Device
Pump out bund area as soon as possible. Dispose of fluid
safely and according to the requisite legislation
Check connection to the Bund Sensor
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Appendix A
Pumps
Suzzara Blue Membrane Pump
Name and producer: Suzzara Blue, PIUSI
Voltage: 230 V, 50 Hz
Power: 370 Watt;
Maximum flow: 35 litres/min
Weight: 5kg
Working pressure: 1.3 bar
Self-priming height: 2metre when pump is
wet
Maximum sound level: 70dB at 1metre
Attention:
1. Before use carefully read the instructions provided by the pump manufacturer.
2. The pump is only suitable for dispensing AdBlue.
3. Ensure the pump is wet if re-priming for any reason.
4. Do not run the pump dry for more than 20 minutes. This can cause serious damage
to its components.
5. Do not leave the pump filled with liquid when there is a risk of freezing.
Submersible Pump
Name and producer: Ecodiver, Leader
Voltage: 230V, 50Hz
Maximum flow: 80 litres/min
Weight: 7.3 – 8.8kg
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Inner Tank Ventilation
The inner tank is ventilated by two means:
A). The plastic 16” lid in the centre top of the inner tank is equipped with a built-in vent unit.
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.
B). Plastic 2” vent, with protection mesh,
varying in number depending on tank size
Filling Line
The filling line consists of 2" EPDM pipe or stainless steel elbow (on 2500) and stainless steel
fittings. The fill line is attached to the tank. The other end of the filling line is in the pump
housing. It is connected to a spill free, male 2” dry break valve (shown on right below). Filling
lines to this must be equipped with a female 2” dry break connection (shown on left below).
Suction line, Nozzle and Nozzle Holster (In-cabinet pump)
The suction line is made entirely from stainless steel. The mesh filter prevents dirt from
entering the line. A shut off ball valve (not available on 2500litre) enables easy pump
maintenance. The pump outlet is connected to Turbinox flowmeter and from there to a
dispensing hose and automatic nozzle. The nozzle holster contains an on/off switch for the
pump.
13
Identification Plate
Each BlueMaster has an identification plate (shown below) attached:
Sectional image of a BlueMaster 5000 litre tank BMV5000
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Vent fan
2” Inner tank vent
Ultrasonic level sensor
4” Screw lid
16” vented lid
2” Fill hose
Housing heater
Nozzle holster
Dispensing nozzle
Tank Management System (TMS)
Pump unit
2” Dry break coupling
Hose reel
Equipment housing
Stainless steel suction line
Inner tank
Bund
Please note: Equipment shown is not standard on all tanks and positions of equipment
may vary depending on BlueMaster model.
14
Appendix B
ADBLUE TMS
General
The AdBlue TMS is a bespoke design to control, monitor and accommodate efficient storage
and dispensing of AdBlue.
Functions of AdBlue TMS
•
•
•
•
•
•
•
•
Level Measurement
Ultrasonic or 4 – 20mA type identical transducer
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
Integrated Flow Meter
Flow in litres and cumulative amount
Auto display when pistol is lifted
Reverts back to level after 1 minute or via button toggle facility
Flow Meter Conversion
91 – 100 pulses converter for flow equipment
Automatic Pump Control
Cuts off after 5 minutes if not used
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
Physical Features
•
•
•
•
•
•
Fire Resistant Cabling
Safety Cut Off Emergency Stop Button
Fire Retardant Box
IP65 Rated Box
Tested for Humidity, (see Technical Specification)
Fits full range of BlueMaster AdBlue tanks
15
AdBlue Control Panel Technical Specification
Dimensions
Height: 310mm, Width: 358.5mm, Depth: 114.7mm
Material
ABS
Ambient temperature
-20°C to +40°C
Supply voltage
230 V ac
High voltage: 2 and 3 way connectors 5.08 pitch
Low voltage: 2 way and 20 way connector 3.5 pitch,
Jack connector – 3 pole, 3.5mm, 1A jack socket
Electrical connections
Inputs
High voltage:
- power supply 230 V
- thermostat 35 C
- thermostat –8 C
Low voltage:
- ultrasonic input (3 V)
- 4 - 20 mA
- flowmeter input (91 impulses/ litre)
- thermistor 10k
- bund sensor
- pistol
Outputs
High voltage (230 V):
- fan 1
- fan 2
- pump
- house heater
- tank heater
- management interface
- light
Low voltage:
- impulses out (100 impulses/litre), open collector,
12 V dc
Interface
Jack connector – 3 pole, 3.5mm, 1A jack socket (RS232)
Display
128x64 graphic LCD, blue
LEDs
Green – power
Red – alarm
Operation
Buzzer
Circuit breakers
Approvals
-
switch
emergency button
12 V dc
-
fans - 6A
pump and MC Box - 6A
house heater - 10A
tank heater and lamp - 16A
Unit meets the requirements of;
● Low Voltage Directive: EN 61010:2001
● EMC Directive: EN55011:1999+A2:2001,
EN 61326:1998+A3:2003
16
!
High Voltage Outputs (Fan 1, Fan 2, Light, Pump House 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.
F1 (Fuse) - 315mA Slow Blow Fuse
The equipment contains no other user serviceable parts and all maintenance and
repair must be carried out by the manufacturer.
TMS Management Interface
This should only be undertaken by trained personnel
Pistol:
Pin14: blue
Pin15: red
a) In normal mode and management mode, when the pistol is lifted and the pump is switched
on and the screen switches to dispensing mode. In normal mode and management mode,
when the pistol is lifted the third relay closes until the pistol is returned to park position. To
use this relay output, ensure that the third relay is inserted. To connect to the output of the
relay use the red and blue wire outlined in the figure below. If the board has no relay please
call Commercial Fuel Solutions Ltd and we can send a kit for easy installation of this relay.
b)
Ext In:
Note: This input will only work when the jumper on the Display board is connected to both
pins as per picture on the next page.
This is an active low control signal that is used by external management systems to over ride
the local control of the pump. Creating a short circuit between the two pins of EXT In will
enable the pump. Creating an open circuit between the two pins on EXT in will disable the
pump.
Pin16: black
Pin17: red
17
Note: Ext In only works when the Mode jumper is as show in the picture below. You must also
configure the Panel setting in software to be turned on.
c)
Flow Out: open collector output, max. 30V DC, 20mA, 100 impulses/litre,
microprocessor convert impulses from pump flow meter and creates 100 impulses per litre.
This output is present in normal mode and management mode.
Pin18: green
Pin19: yellow
3. Jumpers on the PSoC board:
At the back of the PSoC board (board with blue LCD) there are two places for jumpers:
18
• LEVEL MODE - J4:
J4 is a 3 pin connector. If we put the jumper (red) on the top two pins that means the TMS
box will read the tank level from ultrasonic unit. If the jumper is on the bottom two pins the
TMS box will read level from 4..20 mA level probe.
• MODE – J5:
J5 is a 2 pin connector. J5 without the jumper means that TMS is in “normal mode”.
If there is a jumper on the J5 connector the TMS is in “access mode”. In this mode we can
see the pad lock symbol on blue LCD in the top-right corner. If the pad lock is closed this
th
means the pump is disable. A short circuit on EXT IN input enables the pump. EXT IN it is 4
th
(positive) and 5 (negative) pin from the left side in the 20 way connector J1. This input has
an internal pull-up resistor to work with any switch, relay or open collector output device. The
active low signal (short circuit) should remain for as long as pump control is required.
Commercial Fuel Solutions Ltd
City West, Millbrook Road East
Southampton, SO15 1AH
Tel: 0845 688 9755
[email protected]
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