Diesel fuel transfer station FLW FLT 60-12V/24V

Diesel fuel transfer station FLW FLT 60-12V/24V

i

FLUID

Diesel Transfer Equipments

FLW 60-12

FLW 60-24

FLT 60-12

FLT 60-24

USE AND MAINTENANCE MANUAL 533004 GB Rev.0

INDEX

Safety Information _________________________________________________ pag. 2

Declaration of Conformity ___________________________________________ pag. 3

Technical Specifications ____________________________________________ pag. 3

Installation _______________________________________________________ pag. 4

Use ____________________________________________________________ pag. 6

Maintenance _____________________________________________________ pag. 6

Troubleshooting __________________________________________________ pag. 7

Parts - Accessories________________________________________________ pag. 7

Warranty ________________________________________________________ pag. 8

SAFETY INFORMATION

The following safety alert symbols are used in this manual. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER!

indicates an imminently hazardous situation which will result in

death or serious injury if not avoided.

WARNING!

indicates a potentially hazardous situation which will result in

death or serious injury if not avoided.

It is responsibility of the person that use the pump to:

-) Know and follow applicable national and local safety rules pertaining to installing and operating electrical equipment for use with petroleum fluids.

-) Know and follow adequate safety precautions when handling petroleum fluids.

-) Insure that all operators -must be adults only, children cannot use the pump- have access to adequate instructions concerning safe operating and maintenance procedures

DANGER!

pump is not explosion proof, do NOT USE the pump in ambient with flammable vapours. Do

NOT USE the pump whit gasoline, petrol or other flammable liquids with flash points less than 55°C (131°F), DO NOT use this pump to transfer Diesel fuel when ambient temperature exceeds the Diesel flash point temperature 55°C (131°F). DO NOT operate the pump in the presence of any source of ignition including running or hot engines, lighted cigarettes or gas or electric heaters. For safe operations, the diesel fuel transfer system must be properly grounded, this means a continuous metal to metal contact between components, supply tanks, pump, hose, metal nozzle and receiving tank. Failure to follow the above mentioned

WARNING!

in the way to get the best results and the maximum performance from the pump, please read carefully these operating instructions and store the manual in a safe place. Don’t leave the running pump unwatched, when the pump is not in use, store it in a safe place out of reach of children. When the pump is not in use and before of any maintenance, installation or inspection, disconnect the pump from the power supply. To disconnect the plug do not pull the cable, but remove directly the plug/clamps; don’t touch plug/clamps/switches with wet hands. It’s forbidden modify any part of the pump. Prevent any injury observing the basic safety rules. Use the pump for Diesel transferring only: a misuse of the pump can results dangerous for people, wares and/or animals. During the transferring operation, pay attention to avoid any splash of Diesel; avoid prolonged contact with Diesel fuel. It’s recommendet the use of protective glasses, gloves and aprons in case of splashing or spiling.

2

Before of use, chek always that the pump is in order: if any problem is found don’t use the pump and solve the problem and, if necessary, contact the service. Never point the Diesel jet at electrical equipment, cables, open flames, hot object, persons, animals, wares or other place different from the receiving tank.

DECLARATION OF CONFORMITY

We:

FLUID s.r.l.

via G. Fucà, 119

41100 Modena - ITALIA

herewith declare that the construction of the pumps

FLW 60-12 / FLW 60-24 / FLT 60-12 / FLT 60-24

complies with the following relevant regulations:

98/37 CEE - 73/23 CEE - 89/336 CEE

complies with the following relevant standards:

EN 292/1

EN 292/2

EN 294 EN 60204-1

complies with the following national standards:

DPR 547/55

Modena, lì 15/09/2008

EN 6100-6-1

EN 6100-6-3

EN 60335-1

Legal Rappresentative

Giovanni Bedoni

TECHNICAL SPECIFICATIONS

Diesel fuel dispenser with self- priming rotary vane pump, equipped with by-pass valve and filter integreted in the pump body, driven by a brush DC low tension motor, in protection class IP 55, designed for the transfer of Diesel fuel.

The pump is designed for an intermittent use, with a working cycle of 40 minutes (40 min

ON / 40 min OFF)

The Diesel fuel dispenserhas shell in painted steel, it’s available at 12 V or 24 V and it is equipped with 4 digit flow meter, nozzle holder, ON/OFF switch, cable with fuse and clamps suitable for a quick connection to the battery, 3/4” delivery rubber hose 4 mt. long and nozzle with swivle connector.

Type

FLW 60-12

Tension

V

(+/-5%)

12

Power max

W

336

Current nom.

A

19

Current max. A

(by-pass)

28

Fuse

Port

1”

Weight

Kg

14,5

FLW 60-24

FLT 60-12

FLT 60-24

24

12

24

432

336

432

11

19

11

28

28

28

1”

1”

1”

14,5

27,8

27,8

Noise level

Under normal working conditions, the noise emission pression do not exceed the value of

70 dB at the distance of 1 meter from pump.

3

Diesel fuel flow rate

Autom Nozzle

Autom. Nozzle

+

Meter

Delivery hose lenght (meters)

To get the maximun pump flow rate it’s necessary:

-) Minimize lenght of suction and discharge lines;

-) Avoid, if possible, elbow and throttling along the line;

-) Use tubing with diameter equal or grater than 3/4”;

-) Keep clean the strainer regularly;

-) Use extension cable only if necessary (5 mt. lenght , minimum section 2x4 mmq).

Product identification

Serial Number

Date of Production

Product Code

Product Description

Technical Data

Dimensions

Delivery

Port

360

~200

527

25

211

Suction

Port

INSTALLATION

506

DANGER!

sion-proof product, DO NOT INSTALL THIS ELECTRIC PUMP.

4

202

527

25

211

506

202

Preliminary operations:

-) Check that the product has not suffered any damage during transport or storage, in case of damages or missing parts, please contact immediately the dealer.

-) Remove the protection plugs on inlet and outlet of the pump;

-) Fix the pump on a firm, level and no slithery wall surface, by the holes provided on the

FLW shell and through the holes on the rear FLT box rib.

Tubing connection

Before connection make sure that the tubing, the inlet - outlet of the pump and the suction tank are not clogged and free of dirt, rust, etc. that could damage the pump and/or clog the retainer. The threaded connections must be 1” BSP type (do not use conical threaded joints that could damage the threaded pump bores), the pipes connections must be leakage-proof, to avoid air or fuel leakage and pump trouble.

When the hoses are not supplied, it is consiled minimize the lenght of both suction and discharge hoses, use hoses with adequate characteristics for diesel fuel, antistatic, with diameter equal or greater than ¾” and working pressure equal or grater than10 bar, in addition the suction hose shall be suitable for functioning under suction pressure. Connect the pump, observing the right fuel flow, like indicated by the arrows on the pump body.

WARNING!

pump, injury persons and produce pollution, because of diesel fuel splashing/spilling.

WARNING!

grounded (to dissipate the electrostatic currents), alternatively the hoses must be of antistatic type). It is installer responsability to use tubing with adequate characteristics.

Electrical connections

WARNING!

with respect for the applicable local or national regulations. Check that the suppling electrical specifications correspond to those shown on the plate.Failure in the electrical specifications respect could damage the electrical pump. Check the fuse efficency on the supply cable.

WARNING!

edges. Inspect always the supply cable against damages: in case of damage replace immediatly the supply cable with an original one. Avoid that cables, electrical receptacle, clamps and switches have contact with water or flammable fluids and avoid high moisture ambient for the pump. If necessary, use extension cable 5 meters lenght with minimum section 2x4 mmq, unwinding completely the extension cable.

All metal parts must be always grounded.

Before of electrical connection of the pump, be sure that the swicht is in OFF position, than wire the 2 clamps: red clamp at positive pole (+) and black clamp at negative pole (-) of the battery.

USE

DANGER!

explosion when dispensing fuel. Do not operate switch with wet hands. Do not operate the pump in presence of any source of ignition including running or hot engines, lighted cigarettes or gas or electric heater.

Start the diesel fuel dispensing turning ON the switch on the pump and opening the delivery valve (the lever of the nozzle) solidly grasping the end of the hose; at the end of the diesel

fuel dispensing turn OFF the switch on the pump and disconnect the main power supply.

5

WARNING!

+40°C. Serious or fatal shock can result from operating electrical equipment in dump or wet

WARNING!

gloves and aprons in case of splashing or spills. Change saturated clothing and wash skin promptly with soap and water.

This pump is designed for the transfer of diesel fuel with flash point at or above 55 °C

(131°F). DO NOT USE this pump for other types of fluid. Use of this pump with other types of fluid may damage components and will void the warranty. The pump in not suitable with alimentary or food fluids.

Operation without fluid

WARNING!

few minutes only) can damage the pump.

Operation in by-pass mode

Pump is equipped with an automatic by-pass valve. Pump wil go into by-pass mode when the discharge line is close. To prolong the life of the pump, minimize time spent in by-pass

..

DANGER!

maximum 3 minutes only. Longer pump running in by-pass mode produce abnormal diesel fuel temperature raising, with all the diesel fuel spilling, fire or explosion risks connected.

MAINTENANCE

WARNING!

Always disconnect power before attempting any service. Never apply electrical power to the pump when any of the cover plates are removed. The mobile dispenser is designed for minimal maintenance, it is recommended observe the following indications:

Daily:

Keep pump and pipes clean to help identify leaks, check the connection/joints sealing and repair immediatly any leakage, if necessary. Check the electrical cable conditions: if damages/cuts or other defects are recognized, it is necessary replace the cable with an original one, this operation must be performed by an expert technician, accordingly with local regulations.

Check the conditions of suction and discharge hoses: if fissures, cuts, bulges or other damages are recognized, it is necessary replace the hose with an original one.

Weekly or every 5 hours of work:

Inspect and/or clean the strainer integrated in the body pump: a clogged retainer reduce the fuel flow delivery and the pump lifetime; to disassemble the retainer unscrew the plug on the pump body (2, pag. 7) and remove the strainer from its seat, clean it by air-blast spray, then reassemble the strainer and the plug and chek about leakage.

Every 2 years it’s recommended replace the discharge rubber hoses.

Transport

Switch off the pump, disconnect the electrical wiring, disconnect the lines and flush the pump. Package properly the dispenser unit and be care to avoid shocks during the transportation.

Disposing of contamined materials

Don’t disperse contamined parts into the environment. Refer to local regulations for proper disposal of the product.

6

TROUBLESHOOTING

Troubles

Motor does not run

Possible Cause

No electrical power to pump

Motor runs slowly and low fuel flow

Motor runs, but no fuel delivery

Low voltage in the electric line

Tank level low

Clogged suction line

Air leak in system

Corrective Action

Check electrical connections, extension cable and fuse.

Chek for possible locking of rotating shaft

Bring the voltage in the corrrcts limits

IUsing extension cable, cable sections shall be at least 2x4 mmq, max. 5mt long

Add fuel to tank

Clean suction line

Check all joints

PARTS - ACCESSORIES

G H

B

A

I

F

E

D C

11

9

9

9

8

2

2

6

5

1 1 2 3 3 3 2

10

4 5 5 7

14

15

16

12

13

Pos.

A

B

C

D

E

F

G

H

I

2

1

1

1

1

1

1

1

Q.ty

1

FLW 60-12/24 - FLT 60-12/24

Description

FLW steel shell

Nozzle seat

Nozzle holder

FLW hose + connectors

FLC 60-12/24 DC pump

Flow meter

Elbow 90° 1 "

S shape holder

FLT painted steel box

P/N

200014

200011

200012

-----

-----

320701

-----

200023

------

12

13

13

9

10

11

14

15

15

16

5

6

7

7

8

Pos.

1

2

3

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Q.ty

1

1

1

1

FLC 60 12/24 DC PARTS

Description

Bracket + screws kit

Gaskets kit

Rotor + vanes kit

Pump body 60lt.

60 lt. by-pass valve kit

Strainer

24Vcc motor

12Vcc motor

Cover FLC 60 DC kit

Electrical box kit

FLC 60 DC holder kit

ON/OFF switch

Cord 2x4 4mt + clamps

25A fuse (12Vcc motor)

15A fuse (24Vcc motor)

Suction hose

Autom. nozzle 60 Lt/min

Man. nozzle 80 Lt/min

Delivery hose 1"-4 mt

P/N

695005

695001

695002

210002

695016

217001

460102

460101

695017

695006

695018

425001

400003

450001

450002

990201

320601

321601

990104

7

METER - FM4

ATTENTION! To ensure a proper and safe use of the meter it’s necessary to read and follow the instructions and warnings contained in this manual. An improper installation or use of the meter may cause damage to object or people. This meter has been designed for diesel only use: don’t use it for other chemical or inflammable substance or food. Be aware that this device is not suitable to measure product for resale.

GENERAL INFORMATION

FM4 is mechanical flow meter with nutating disk, designed to allow a precise measurement of Diesel oil. The nutating disk of the metering chamber, which is set in motion by the fluid itself, drives the gear train located in the cover of the meter body, which tranfer the motion to the 4 digits meter. The meter is equipped with a no-resettable litre totaliser and a batch register which can be reset by means of a knob, whose unit digit is provided with marks of the readout of the tenths of a litre.

Technical Data

Flow rate (range)

Meter mechanism

Read out system: subtotal / total

Operating pressure

Accuracy after calibration / Repeatibility

Treathed connectors

Body material

Dimensions (bxhxp) / Weight

20 - 120 l/min.

Nutating disk

4 digits (9999) / 8 digits (99999999) max. 3.5 bar

+/- 1% / +/- 0.2%

1” BSP/NPT

Aluminium

240x165x170 mm / 1.8 Kg

CALIBRATION

FM 4 is pre-calibrated in factory to be used with Diesel oil. As specific operating conditions may affect the meter accuracy, a recalibration should be carried out after the installation has been completed. A new calibration is necessary each time the meter is disassembled for maintenance operations.

Meter Calibration Procedure (see picture 1, page 9)

1) Unscrew the plug (P) and purge the system from air, shutting off the nozzle and let the pump running;

2) Reset the batch register by means of the knob;

3) Dispense at the flow rate which the best accuracy is required at, by using a calibration container having a capacity not lower than 20 litres.

4) Compare the indication of the calibration container (real value) with the one of the meter

(indicated value): a) if the indicated value is higher than the real value, turn counterclockwise the screw (H), using a screwdriver (S); b) if the indicated value is lower than the real value, turn clockwise the screw (H), using a screwdriver (S);

5) Repeat the operation 3 and 4 until accuracy is satisfactory.

6) At the end of the procedures, screw the plug (P).

8

USE

Turn the reset knob clockwise until the batch register is completely reset (0000). The totaliser cannot be reset in any way. Make sure that during the use the pressure and flow rate do not exceed the values indicated in “Technical Data” section.

MAINTENANCE - SPARE PARTS

No ordinary maintenance is required when the FM4 meter is properly intalled and used.

Anyway, an incorrect filtering on the meter inlet may block or wear out the meausiring chamber, thus affecting the the meter accuracy. Should this problem occour, disassemble the measuring chamber as indicated below.

WARNING! Before disassembling the meter always make sure that all fluid is drained from the meter and pipes connections.

The FM4 meter can be disassembled without remove the main body from the pipes.

To disassemble the meter unit, follow this steps:

1) Remove the reset knob by firmly pulling it axially (see pos. 4, page 4);

2) Loosen the 4 retaining screws and remove the plastic cover (see pos. 3, page 4);

3) Loosen the 4 retaining screws and remove the counter (see pos. 2, page 4)

4) If is necessary replace the measuring chamber and /or the gear box, disconnect the pipes line and remove the complete hydraulics group (see pos. 1, page 4).

To reassemble the unit, reverse the above described procedure.

Exploded view

3 4 2 1

Picture 1

P

S

H

Pos.

1

2

3

4

Q.ty

1

1

1

1

POS. Q.TY

1 1

2

3

1

1

1

FM4 Spare Parts

DESCRIPTION

FM4 Hydraulic group

FM4 Counter group

FM4 Cover (black)

FM4 Knob (black)

P/N

695008

695009

695010

695011

Description

FM4 Hydraulic group

FM4 Counter group

FM4 Cover (black)

FM4 Knob (black)

P/N

695008

695009

695010

695011

9

WARRANTY

The product is guaranteed in accordance with statutory/country-specific regulations, only when it is used for the designed purpose. The warranty period shall begin on the date of purchase with an original sales receipt. The warranty is limited to demostrable defects that can be attributed to workmanship and/or material; the buyer will pay for any transport costs and will bear any transporting risks responsibilty. Failure/defects resulting from normal wear, incorrect and/or improper use, erroneus connections of the device, manomissions or modifications (without our written authorization) are not covered by the warranty. The manufacturer exclude any additional liability, in particular for subsequent ware or persons damages arising from the use of the product.

Timbro Rivenditore - Dealer’s stamp

FLUID

s.r.l.

Fuel Transfer Equipments

via G. Fucà, 119 ZI Torrazzi Sud

41100 Modena (MO) Italy

Tel. +39 059 250307

Fax +39 059 250307 e-mail: [email protected]fluiditalia.it

www.fluiditalia.it

Pictures and descriptions are FLUID srl properties. Technical datas and characteriscs indicated are intended not binding and FLUID srl could change them without any advanced notice.

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