Storage tanks with integral dispenser,

volume 1200, 2500, 3500, 5000, 9000 & 10000 litres

OPERATION MANUAL

FuelMaster®

EN

OPERATION MANUAL

PORTABLE FUEL OIL BATCHING MACHINES

VOLUME 1200, 2500, 3500, 5000, 9000 & 10000 L

FuelMaster ®

by TITAN ENVIRONMENTAL (rev. 4/2008)

CONTENTS

I. PURPOSE ............................................................................................................................................ 3

II. TECHNICAL PARAMETERS AND EQUIPMENT ............................................................................... 3

1. DIMENSIONS .................................................................................................................................. 3

2. EQUIPMENT ................................................................................................................................... 4

3. PUMP .............................................................................................................................................. 7

4. MECHANIC FLOWMETER. ............................................................................................................ 8

5. DIGITAL FLOWMETER ................................................................................................................ 10 A. GENERAL ................................................................................................................................. 10 B. OPERATING PRINCIPLE. ........................................................................................................ 13 C. CALIBRATION .......................................................................................................................... 15 D. MACHINE CONFIGURATION ................................................................................................... 19 E. MAINTENANCE ........................................................................................................................ 20

6. LEVEL INDICATOR – OIL WATCHMAN PLUS ............................................................................ 22 A. DESCRIPTION .......................................................................................................................... 22 B. ACTIVATION OF WATCHMAN PLUS ...................................................................................... 23

7. TANK OVERFILL PROTECTION .................................................................................................. 25

8. MACHINE’S LITRE CAPACITY CHART ....................................................................................... 26

III. TRANSPORT AND STORAGE .......................................................................................................... 27

IV. GENERAL SETUP REQUIREMENTS ............................................................................................... 28

V. ELECTRICAL SYSTEM ..................................................................................................................... 30

1. EARTHING .................................................................................................................................... 30

2. TEMPORARY POWER SUPPLY .................................................................................................. 30

3. PERMANENT POWER SUPPLY .................................................................................................. 31

VI. GENERAL SAFETY PRINCIPLES .................................................................................................... 33

VII. OPERATIONAL RECOMMENDATIONS ........................................................................................... 34

1. REFUELLING OF MACHINES ...................................................................................................... 34

2. REFUELLING OF VEHICLE ......................................................................................................... 35

VIII. MACHINE MAINTENANCE ............................................................................................................... 36

IX. TROUBLESHOOTING ....................................................................................................................... 37

X. GUARANTEE TERMS ....................................................................................................................... 38

3

FuelMaster ®

I. PURPOSE

FuelMaster® is a bunded fuel storage tank with transfer equipment double-jacket, overground tank with volume 1,200, 2,500, 3,500, 5,000 or 9,000l, equipped with fuel batching device.

Only fuel oil can be stored in FuelMaster® tanks. Storage of petrol and other fluids is prohibited.

II. TECHNICAL PARAMETERS AND EQUIPMENT

1. DIMENSIONS

Symbol BFM01200DG/* BFM02500DG/* BFM03500DG/* BFM05000DG/* BFM09000DG/*

Rated volume [litres] 1200 2500 3500 5000 9000

Length [m] 1,90 2,46 2,85 2,84 3,25

Width [m] 1,24 1,46 2,20 2,23 2,45

Height [m] 1,77 1,85 1,96 2,34 2,95

Weight [kg] 150 220 280 320 490

Dimensions can vary by +/- 1%.

* - Two last characters of the code indicate equipment options: AF – analogue meter, DF – digital meter, MU - multi-access distributor (only 3,500 , 5,000 and 9000 l), ZP – legalized distributor (only 5,000 and 9,000 l).

Rated volume is 95% of overflow volume.

Double-jacket tank (tank within a tank), with internal tank volume of 1,200 l, 2,500 l, 3,500 l, 5,000 l i 9,000 l is executed in UV stabilised medium density polyethylene.

4

2. EQUIPMENT

(open distributor enclosure of machines with volume 3,500 l and above)

(open inspection lid of machines with volume 3,500 l and above)

Pump venting line

Level sensor signal transmitter

Maximum level sensor terminal

Pump suction line Pump-mechanic flowmeter unit

Mechanic flowmeter zeroing handwheel

Level sensor probe connection

Refuelling line connection

Maximum level sensor probe

Inspection hole of internal tank 4”

Filler line 2” with mechanic overflow protection

Suction line 1”

Pump venting hose (tank inlet)

Earthing line

Distribution hose

Pump filter lid

Pump electric box

Filler nozzle

5

(open distributor enclosure of machines

with volume 1,200 l and 2,500 l with digital flowmeter)

1. Fuel distributor unit is equipped with:

− suction hose 1” with non-return valve and mesh filter on end;

− flowmeter indicating quantity (litres) of pumped oil from last zeroing, and total flow; there are two flowmeter variants available – mechanic and digital.

− a pump, supply 230V, max. output 56 l/min (1,200 and 2,500 l) or max. 72 l/min (3,500 and 5,000 l);

− filler nozzle with stop valve automatically cutting off fuel flow upon reaching maximum level in refuelled tank;

− distribution hose dia. ¾” and length 4 m (1,200 and 2,500 l) or 6 m (3,500, 5,000 and 9,000 l).

2. Current oil level sensor – Watchman Plus, with integrated jacket-to-jacket leak sensor.

Machine comprises:

− level probe installed inside of tank;

− leak sensor (signals leaks in internal tank);

− transmitter mated with probe and sensor;

− receiver with single-digit display (plug with antenna).

Digital flowmeter

Pump 230 V AC.

Automatic Filler nozzle

Level sensor

Maximum level sensor probe

Inlet 2” Inspection lid 4”.

Pump filter lid

Pump venting hose

6

3. Maximum level sensor. Appliance comprises a probe installed on top of internal tank, and a plug to be connected to circuit signalling exceeding of maximum level, or automatically switching off unloading pump on mobile cistern. Appliance protects the tank of portable distributor from overfill and overflow during unloading.

4. Vent in internal tank.

The vent is installed inside internal tank (invisible from the outside), and it compensates pressure level in the tank during refuelling and unloading.

5. Inspection lid dia. 4” in internal tank.

6. Two inspection lids 16” in tanks with volume over 3,500 l. One with a closure, in external tank, and one, invisible from the outside, in internal tank (access after disassembly of external tank).

7. Inlet in the form of two inch ferrule in distributor enclosure, allowing tight connection with mobile cistern. Machines with volume above 3,500 l are equipped with refueling line, comprising connection in distributor enclosure, hose and mechanic overfill protection – Spill Stop.

8. Distributor enclosure is locked with two locks, with keys.

9. Earthing going outside of distributor enclosure. *Equipment can vary depending on tank variant.

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3. PUMP

Pump unit comprises: PUMP: Self-priming pump, electric sliding-vane pump, with by-pass valve.

MOTOR: Asynchronous, single-phase, 2 pole, totally-enclosed type motor (protection index IP 55, as per EN 60034-86), with integrated ventilation, connected via flange directly to body.

FILTER: Suction side filter, suitable for periodic inspection.

SPECIFICATIONS OF TECHNICAL PARAMETERS

1. Maximum flow rate:

− for machines with volume 1,200 and 2,500 – 56 l/min.

− for machines with volume 3,500 , 5,500 and 9,000 – 72 l/min.

2. Allowed working temperature: min -20oC / max +60oC.

3. Allowed viscosity of fuel oil from 2 to 5.35 cSt.

4. Allowed relative humidity max 90%.

5. Power supply voltage 230V AC ± 5% of rated value.

6. Power supply frequency 50 Hz ± 2% of rated value.

7. Power consumption 370 W (1200, 2500 l) and 500 W (3500, 5000, 9000 l).

8. Allowed by-pass working time (with inlet blocked): 2 – 3 minutes.

9. Lifting height max 2m.

10. Motor pump protection – automatic thermal circuit-breaker.

11. Protection index IP55.

Details of pump design and operation are included in operation manual by pump manufacturer.

Pump filter lid

8

4. MECHANIC FLOWMETER. Mechanic flowmeter is activated by flowing liquid, propelling gear installed in meter body lid. The meter is equipped with non-adjustable.

TECHNICAL DATA

Meter mechanism Nutanting disc

Flow rate (range) 20 - 120 litres/min.

Working flow (max.) 3.5 bar

Bursting pressure (min.) 28 bar

Storage temperature (range) - 20oC + 80oC

Storage humidity (max.) 95%

Working temperature (range) -10oC + 60oC

Pressure losses (flow rate in l/min.)

With fuel oil (Diesel) 30 - 60

Pressure loss (bar) 0.05 - 0.2

Accuracy following calibration +/-1%

Repeatability (typical) +/- 0.3%

Reading precision 0.1 litre

Connection (inlet/outlet) 1” (one inch) BSP

Calibration Flowmeter is pre-calibrated at the plant for application with fuel oil. Since specific working conditions (such as flow rate, properties and temperature of measured fluid) can affect accuracy of measuring device, recalibration is to be carried out periodically.

Brass screw - plug. When unscrewed it gives access to adjustment screw.

Current meter - zeroed.

Meter zeroing handwheel.

Total meter - non-zeroed.

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1. Unscrew the plug – brass screw.

2. Vent air out of the system by batching until solid, continuous flow.

3. Cut off the flow by switching off filler nozzle; leave the pump working.

4. Zero current meter using handwheel.

5. Batch at flow rate that requires the highest accuracy, using calibration tank, volume not less than 20 litres. Do not reduce flow to reach the scaled area of calibration tank. Recommended method is switching full flow on and off, for a couple of times, until required refill is reached.

6. Compare value indicated on calibration tank (actual value) with meter indication (indicated value).

− when indicated value is higher than actual value, loosen the screw; counter-clockwise.

− when indicated value is lower than actual value, tight the screw; clockwise.

7. Repeat operations in 4 – 6 until required accuracy is achieved.

8. Re-tighten the plug.

The purpose of self-sealinging o-ring set on calibration screw, is to prevent accidental loosening of adjustment screw – the ring performs no sealinging function whatsoever. Thus it is required to properly screw the plug with sealing every time.

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5. DIGITAL FLOWMETER

A. GENERAL

Measurement is based on oval gears, which ensure high accuracy in the broad range of flow rates, and low pressure loss. Fluid flowing through machine propels gears, which rotate and transport “units” of fluid. Precise measurement of batched fluid is carried out by counting rotations of gears (“units” passing gears). After each full rotation cycle magnets installed in gears send signals to magnetic sensor located in measurement chamber. Signals are received and processed by microchip.

Inlet is equipped with mesh filter in stainless steel, accessible after removing of flange installed on inlet side.

User can select one of two operating modes:

− Normal mode: Partial or total quantity of batched fluid is displayed. − Flow rate mode: Flow rate and partial quantity of batched fluid are displayed

Meter is equipped with non-volatile memory and stores quantitative flow data, also in the event of long power failures.

LCD display

Filter

CAL button

Battery chamber

Measurement

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Main components: Measuring electronics and LCD are installed on top of flowmeter, and they are isolated from fluid-filled measuring chamber and protected from effects of the environment by means of enclosure.

Flowmeter technical parameters.

Values for fuel oil

Meter

Resolution l/impulse 33.5

Flow rate range l/min. 100 –100

Working pressure bar 30

Bursting pressure bar 60

Measuring system Oval gears

Storage temperature °C -20 – +70

Storage humidity H.R. 95%

Maximum working temperature °C - 10 – +60

Pressure loss at maximum flow rate bar 0,3(Fuel oil in 20°C)

Measured fluids Fuel oil

Viscosity range cSt 2 – 5,35

Accuracy (regarding measured volume) ±0,5

Repeatability 0,2%

Threaded inlet and outlet connection point 1”

Batteries 2 x 1,5 V

Battery life (estimated) 18-36 months

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LCD screen Meter screen comprises two numeric records and various indicators displayed when given functionality requires so.

Explanation: 1. Subtotal register (partial register, 5 digits with moving colon: 0,000 ÷ 99999 ) indicating quantity

of fluid transferred since the last time RESET button was pressed.

2. Battery charging level indicator.

3. Calibration mode indicator.

4. Total and Reset Total register (6 digits with moving colon 0,0÷999999 x10 / x100).

4.1. Total, not zeroable (TOTAL).

4.2. Reset total (RESET TOTAL).

5. Total multiplier indicator ((x10 / x100).

6. Total type indicator (TOTAL / RESET TOTAL).

7. Total measurement unit indicator: L = litres, Gal=gallons.

8. Flow rate indicator.

9. Subtotal measurement unit indicator: Qts=quarts, Pts=pints, L=litres, Gal=gallons.

User buttons Meter is fitted with two buttons (RESET and CAL). Each of them has a primary functionality assigned. When pressed together they have a secondary functionality assigned.

Primary functions:

− RESET button: zeroes subtotal and reset total register,

− CAL button: sets the device in calibration mode.

Pressing of both buttons together sets the device sin configuration mode, where desired measurement unit can be set.

Battery chamber The device is powered by two standard 1,5V batteries (size N).

Battery chamber is sealinged with threaded water-proof plug, which can be easily removed for quick battery replacement.

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B. OPERATING PRINCIPLE.

Due to adoption of suitable calibration ratio (i.e. “weight” of a single impulse), integrated microchip (in executions with meter) or external microchip (in executions with pulse generator), translates impulses caused by fluid into measurement units displayed in subtotal and total register.

Flowmeters have factory coefficient K set to obtain optimum measurement conditions for fuel oil. Calibration settings can be changed in a way as described in this manual; restoring of factory settings is possible at any time.

Illustrations below show two typical display indications. First of them shows subtotal register and reset total register. The second shows subtotal and total. Switching between reset total to total indication is automatic and depends on time intervals as set in factory, which cannot be changed by user.

− Subtotal register in the upper part of display indicates quantity of batched fluid since the last

time RESET button was pressed.

− Reset total register in the lower part of display indicates quantity of batched fluid since the last time reset total was zeroed. Reset total cannot be zeroed before subtotal is zeroed, and subtotal can be zeroed at any time without zeroing of reset total. Measurement unit of both totals can be identical as of subtotal or different, as per factory or user setting.

User cannot zero total register (TOTAL). Total reading increases throughout the whole flowmeter lifecycle.

Since reset total and total are displayed in the same area of LCD screen, they can only be seen alternately.

The device is programmed to display those values in regular time intervals.

TOTAL IS DISPLAYED WHEN DEVICE IS IN STAND-BY MODE.

RESET TOTAL IS DISPLAYED:

− some time following zeroing of subtotal (a few seconds), − always during batching, − some time following batching completion. In no time the device switches to stand-by mode

and lower register indicates total. NOTE: Totals are displayed using maximum of 6 digits and two symbols x10 / x100. Display switches to higher multiplier in the following sequence: 100000 x 10 ›? 999999 x 10 ›? 100000 x 100 ›? 999999 x 100. Batching in emergency mode It is a standard batching mode, when subtotal and reset total are displayed simultaneously during counting of units.

Accidental pressing of RESET or CAL button during counting of units should have no effect to meter reading.

SUBTOTAL REGISTER

RESET TOTAL

REGISTER

TOTAL REGISTER

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Within a few seconds following batching, reset total in lower register shall be replaced with reset total. RESET symbol above TOTAL symbol shall disappear, and reset total value shall be replaced with total value.

This is so-called standby mode (STANDBY) which lasts until device reactivation.

Zeroing subtotal. Subtotal is zeroed using RESET button in standby mode, i.e. when display indicates TOTAL symbol.

After RESET button is pressed the value is zeroed; display indicates all highlighted digits, and then all not highlighted digits.

When zeroing is complete display shows zeroed subtotal and reset total.

A moment later reset total is replaced with non-reset TOTAL.

Zeroing reset total. Reset total can be zeroed only after subtotal is zeroed. Reset total can be zeroed by pressing RESET button when display shows RESET TOTAL symbol, as illustrated below.

Follow the sequence below:

1. Wait until the device switches into standby mode (display shall indicate only TOTAL symbol).

2. Press RESET button shortly. 3. The device shall start zeroing of subtotal. 4. When display indicates RESET TOTAL press and hold RESET button for at

least 1 second. 5. Display shall indicate as per following sequence: all fields, off fields, and RESET

TOTAL screen. Batching in flow rate measuring mode. It is possible to batch and simultaneously display:

− currently batched quantity, − flow rate [subtotal unit / minute], as on display on the right.

To switch to this mode: − wait until the devices switches to standy mode, i.e. when display indicates

only TOTAL, − press CAL button shortly, − start batching.

Flow rate is updated every 0.7 second. Thus at low flow rates display indications can be unstable. The highest flow rate the more stable display readings.

NOTE: Flow rate is expressed in measurement units as selected for subtotal; when measurement units of subtotal and total differ, as in the example below, bear in mind that flow rate is expressed in subtotal units. In the example below flow rate is expressed in Qts (quarts) per minute.

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“Gal” symbol displayed next to flow rate refers to total or reset total register, which shall be displayed after leaving flow rate measurement mode. Press CAL button again to return to normal mode. Accidental pressing of RESET or CAL button during counting of units should have no effect to meter reading.

Note: Both reset total and total increase during batching in this mode, although they are not displayed. Their values can be checked after completion of batching and returning to normal mode by pressing CAL button shortly.

Zeroing subtotal. To zero subtotal after completion of batching wait until meter indicates flow rate equal to 0.0, as in the drawing on the right:

and then press RESET button shortly.

Contrary to normal mode in this case during zeroing the device does not follow the sequence of alternate highlighting and dimming of display fields – subtotal is zeroed immediately.

C. CALIBRATION

Calibration, or “K”, coefficient is a multiplier used by system to calculate received electric impulses to fluid measurement units.

Factory K coefficient: K coefficient with value set in the factory. Its value is 1.000 . Such coefficient ensures maximum accuracy in following conditions:

− Engine oil type SAE10W40 − Temperature: 20°C − Flow rate: 6-60 l/min

Factory K coefficient can be easily restored, regardless of changes introduced by user.

User defined K coefficient: Specially selected calibration coefficient, i.e. set by way of calibration.

Calibration procedure. Flowmeter allows fast and precise electronic calibration by modification of calibration coefficient (K).

Calibration coefficient can be modified as follows:

a) calibration through batching, b) direct calibration, by means of changing calibration coefficient.

Enter calibration mode (press and hold CAL button), and:

− display presently used calibration coefficient, − restore calibration coefficient to factory value to reverse modification by user, − modify calibration coefficient using one of the procedures above.

Quantities of batched fluid – subtotal and total – displayed in calibration mode differ in meaning at different stages of calibration procedure.

In calibration mode you cannot use meter for normal batching of fluid.

In calibration mode total/subtotal is not increasing.

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NOTE Device includes a non-volatile memory where calibration data and total batched quantity is stored. There is no need to repeat calibration even after long power outing or after battery replacement.

Displaying current calibration coefficient, restoring factory value. Current calibration coefficient is displayed after pressing CAL button in standby mode.

There are two possibilities:

a) When no calibration was carried out so far, or after previous calibrations factory value was restored, display shall indicate FACT (for Factory); it means that factory calibration coefficient is set.

b) Had the user carried out calibration, currently used calibration coefficient is displayed (in this case it is 0.998).

Symbol “User” indicates that calibration coefficient used was defined by user.

Attached block diagram shows the sequence with respective display indications.

In calibration mode RESET button allows switching from user’s coefficient to factory coefficient.

To confirm selection of calibration coefficient when USER or FACT symbols are displayed, press CAL button shortly.

After returning to normal mode the device shall use confirmed calibration coefficient.

IMPORTANT: Upon confirmation of factory calibration coefficient old user value is deleted from memory.

Calibration by batching Procedure requires batching of fluid to standard measurement tank in actual working conditions (flow rate, viscosity, etc.), requiring maximum accuracy.

CAUTION! Successful completion of calibration procedure requires that:

− prior to embarking calibration air is to be completely removed from the system; − carefully selected standard measurement tank is used, volume not less than 5 litres, fitted

with precision scale indicator; − batching is carried out at constant flow rate typical for standard operation, until the tank is

full; − flow rate is not reduced at the final stage of refuelling to achieve „to mark” refuelling of tank;

correct method of ending the refuelling is to batch small amounts, keeping normal flow rate); − upon completion of refuelling wait a few minutes to make sure that no air bubbles are

prezent in standard tank; read the value after fluid level settles.

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Follow the procedure below. Calibration by batching:

ACTION DISPLAY SCREEN

1 NO ACTION

Device in normal mode (not counting).

2

PRESSING AND HOLDING CAL BUTTON

Devices enters calibration mode, CAL symbol is displayed and calibration coefficient indication replaces subtotal indication. Symbols FACT and USER indicate which coefficient (user’s or factory) is presently selected.

3 PRESSING AND HOLDING RESET BUTTON

CAL symbol is displayed and subtotal zeroed. The device is ready for calibration by batching.

4

BATCHING TO STANDARD TANK

Do not press any button, start refuelling the standard tank.

You can stop and restore refuelling the tank at any time. Fluid level in tank is to reach the marked area. There is no need to fill the tank with any specific quantity of fluid.

Indicated value Actual value

5

PRESSING RESET BUTTON

Device is notified on completion of batching procedure. Prior to performing this action make sure that batching is completed successfully. To calibrate the device replace the value indicated in subtotal register (e.g. 9,800) with actual value taken from the scale of standard tank. In bottom left corner of display an arrow appears (up or down arrow) pointing direction (increase or decrease) in the change of user K value during action 6 and 7.

6 PRESSING RESET BUTTON

Changes arrow direction. This action can be repeated a number of times.

7

PRESSING/PRESSING AND HOLDING CAL BUTTON

Indicated value changes in direction indicated by arrow, one unit per each pressing of CAL button, or continuously when CAL button is pressed and held (slowly for first 5 seconds and then fast).

When desired value is exceeded repeat procedure, starting from point (6).

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8

PRESSING AND HOLDING RESET BUTTON

Device is notified on completion of batching procedure. Prior to performing this action make sure that INDICATED value equals ACTUAL value.

Indicated value Actual value

9

NO ACTION

Upon completion of calculations a new user K coefficient is displayed for a few seconds, and then the activation cycle continues until the devices switches to standby mode. IMPORTANT: From this moment on the device shall use indicated calibration coefficient, even after battery replacement.

10 NO ACTION

The device keeps the new calibration coefficient and is ready for batching fluid using newly defined K coefficient.

Direct modification of K coefficient Below described procedure is particularly useful when correcting “average error” determined based on a few batchings. When meter indicates specific average per cent value of error it can be modified by correcting currently used calibration coefficient by this per cent value. In this case correction of user K coefficient can be calculated as follows:

New calibration coefficient = old calibration coefficient x (100 - E%) / 100.

Example:

When the device underrates the quantity of batched fluid (negative error), new calibration coefficient is to be higher than the old one, as in example below: When the device overrates the quantity of batched fluid (positive error) new calibration coefficient is to be lower than the old one.

ACTION DISPLAY SCREEN

1

NO ACTION

Device in normal mode (not counting).

2

PRESSING AND HOLDING CAL BUTTON

Devices enters calibration mode, CAL symbol is displayed and calibration coefficient indication replaces subtotal indication. Symbols FACT and USER indicate which coefficient (user’s or factory) is presently selected.

3

PRESSING AND HOLDING RESET BUTTON

CAL symbol is displayed and subtotal zeroed. The device is ready for calibration by batching – see previous section.

Value of observed error E%. : - 0.9 % PRESENT calibration coefficient : 1,000 New coefficient : 1,000 * [(100 - (-0,9))/100] = 1,000 * [(100+0,9)/100] = 1,009 User calibration

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4

PRESSING AND HOLDING RESET BUTTON

You can start direct modification of calibration coefficient. DIRECT symbol is displayed, along with presently used calibration coefficient. In bottom left corner of display an arrow appears (up or down arrow) pointing direction (increase or decrease) in the change of displayed value during action 5 and 6.

5

PRESSING RESET BUTTON

Changes arrow direction. This action can be repeated a number of times.

6

PRESSING/PRESSING AND HOLDING CAL BUTTON Displayed value changes in direction indicated by arrow, one unit per each pressing of CAL button, or continuously when CAL button is pressed and held (the faster the longer the button is held).

When desired value is exceeded repeat procedure, starting from point (5).

7

PRESSING AND HOLDING RESET BUTTON The device is notified on completion of calibration procedure. Prior to performing this action make sure that indicated value equals actual value.

8

NO ACTION

After completion of calculation a new user K coefficient is displayed for a few seconds, and then activation cycle is repeated until the devices switches to standby mode. IMPORTANT: From this moment on the device shall use indicated calibration coefficient, even after battery replacement.

9

NO ACTION

The device keeps the new calibration coefficient and is ready for batching fluid using newly defined K coefficient.

D. MACHINE CONFIGURATION

User can select the following measurement unit from flowmeter counter’s menu: Quarts (Qts), pints (Pts), litres (Lit) or gallon (Gal). Relation between subtotal and total register unit is described in table below.

Combination No. Subtotal register unit Total and reset total unit

1 Litres (Lit) Litres (Lit)

2 Gallons (Gal) Gallons (Gal)

3 Quarts (Qts) Gallons (Gal)

4 Pints (Pts) Gallons (Gal)

To select from 4 available combinations:

− Wait until meter switches to standby mode.

− Press and hold CAL and RESET buttons until UNIT symbol is displayed, along with currently selected measurement unit (in this example litres / litres).

Each pressing of RESET button causes displaying subsequent combination of units, as in drawing below.

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Holding of CAL button causes saving of newly selected setting; meter performs activation cycle and is ready for batching in selected units.

NOTE

Values in reset total and total registers are displayed with new measurement unit.

The device does NOT require calibration after changing of measurement unit.

E. MAINTENANCE

The machine is designed and manufactured in a way requiring minimum maintenance.

The only maintenance operations required are:

− Changing batteries when they expire.

− Cleaning measurement chamber. Cleaning might be required due to properties of batched fluids or the presence of fine solids due to bad filtering.

Changing batteries The meter is delivered with two standard 1,5V alkali batteries (size N).

Meter can display two types of low battery warnings:

1) When battery charging level displayed In LCD drops below level 1, battery symbol appears.

Meter operates normally, battery symbol reminds operator to change batteries.

2) If the meter is operated without changing batteries, the second warning shall appear and meter function is blocked. Battery symbol starts to pulse and it is the only symbol displayed.

NOTE Expired batteries are to be disposed of in accordance with regulations in force.

To change batteries follow the sequence below (items as per diagram on page 11):

− Press RESET button to update the totals.

− Unscrew battery compartment cover (item 4).

− Remove used batteries.

− Insert new batteries into battery compartment, mind orientation (see instructions on compartment cover - item 3). Screw in battery compartment cover; make sure sealinging (item 4) is placed correctly.

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The meter switches on automatically and it is ready for operation.

The values of reset total, total and subtotal displayed by meter should be the same as before.

Following changing of batteries, and after power failure, the meter reactivates and uses the same calibration coefficient that was used before power failure. Thus no recalibration is required.

Cleaning measurement chamber. Flowmeter measurement chamber can be cleaned without disconnecting the machine from pipeline. Prior to closing the lid make sure that gears rotate freely.

CAUTION!

Prior to cleaning make sure that no liquid is present in the machine. To change batteries follow the sequence below (items as per diagram on page 11):

− Loosen four bolts of bottom lid (item 7).

− Remove the lid (item 7) and sealing (item 6).

− Remove oval gears.

− Clean the chamber, if necessary. Use a brush or pointed object, such as screwdriver. Avoid damaging enclosure or gears.

− Reassemble the machine following above sequence In reverse.

CAUTION

Replace gears as per diagram included. CAUTION

Magnets are included with only one of two coupled gears, as in the drawing. Mind orientation of gears with magnets, see included drawing. Replace second gear (one without magnets), with axis at angle not exceeding 90° as related to first gear.

Cleaning filter Filter is to be cleaned in intervals depending on content of impurities in fluid. To clean filter disconnect the machine from pipeline, since filter is installed between enclosure and connection flange.

CAUTION! Prior to cleaning make sure that no fluid is present in the machine. Filter cleaning procedure (items as per drawing on page 11):

− To Access filter ring in digital flowmeter loosen 2 bolts of flange connecting flowmeter and pump at machine inlet.

− Remove flowmeter, carefully remove flange sealing.

− Remove filter (item 9).

− Clean filter using compressed air.

− Reassemble the machine following above sequence in reverse.

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6. LEVEL INDICATOR – OIL WATCHMAN PLUS

A. DESCRIPTION

OIL WATCHMAN PLUS is an electronic measuring device designed for continuous monitoring of fuel or engine oil level in tank. The device comprises three elements:

− Transmitter, installed on the tank. In the case of tanks with volume 3,500 l and more it comprises two parts, connected with black wire. One part, with transmitter antenna and threaded battery connection, is installed in distributor box, whereas the second, a probe, is installed on the top of internal tank. In the case of tanks with volume 2,500 l and 1,200 l transmitter is made as a single piece, probe and transmitter antenna integrated, and installed inside distributor box, on the top of internal tank.

− Level probe (black plastic pipe inside the tank).

− Leak sensor (located at the tank bottom, in the space between internal and external tank; it is connected with white wire to one of transmitter parts).

Transmitter and receiver are one set and they are not interchangeable, i.e. this transmitter works only with specific receiver. In the event of permanent damage or loss of one of the parts remaining parts cannot be used with parts from different sets. Probes can work with various transmitter-receiver sets.

Probe length is adjusted to height of given tank. Transmitter and probe measure the level of fuel in the tank and check for possible leaks. Information is then sent to receiver of OIL WATCHMAN PLUS. Receiver, in the form of plug with antenna and display, can be placed in any 230V power socket within 100 m distance from the tank. This distance can be much shorter if there are barriers, such as earth embankments, buildings, and electrical cables and appliances.

Oil level data is sent to receiver over radio frequency and displayed on receiver screen.

Measurement is updated ca. every 15 minutes.

battery transmitter

leak sensor probe

receiver

level sensor probe

23

Oil level (regardless of tank volume) is shown in the form of digits:

„0”- from 0% to 10% of total volume,

…

„9”- from 90% to 100% of total volume.

Indicated oil level is laden with material error.(up to 10%) and provides only approximation on oil quantity in tank.

B. ACTIVATION OF WATCHMAN PLUS

OIL WATCHMAN PLUS sensors are installed in double-jacket tanks by TITAN EKO as a standard. Sensor activation procedure:

− Place the receiver in 230V socket, possibly close to the tank. Best choose a single socket, where receiver can stay permanently. Avoid placing receiver near electrical appliances, such as microwave ovens, refrigerators or washing machines, since that may aggravate reception. Place antenna in possibly vertical position, at location free from obstructions. Display shows sensor serial number and then “r” or “L” which means that receiver is waiting for signal from transmitter.

− After two minutes carefully screw in the battery (copper tube with threaded connection) to the transmitter in tank.

− After few minutes more the receiver shall display current oil level in tank.

Battery consumption depends on distance between the tank and the socket with Oil Watchman Plus receiver connected, as well as on type of materials between transmitter and receiver.

WATCHMAN READING SPECIFICATION

„L“ Receiver waits for signal from transmitter in tank.

RED DIODE BLINKING and “0” and ”1” digits are displayed

Low oil level, place order for new supply.

RED DIODE BLINKING and “r” is displayed every 5 sec.

Blinking diode along with “r” symbol means that following last activation receiver does not receive signal from transmitter in tank. Power failure or electrical appliance is used nearby (radio, hairdryer, blender) can cause such reading. Receiver starts showing oil level after another update from transmitter. If that persists reset the system. 1. Remove receiver from socket. 2. Unscrew the battery from transmitter in tank. 3. Check the cable connecting both transmitter parts in tank (clean and tighten concentric cable ends). 4. Place receiver in 230 V socket. 5. Wait 2 minutes. Carefully insert battery to transmitter. If nothing changes call the service.

RED DIODE LIGHTS CONTINUOUSLY

Leak – oil (or other fluid) in external tank. Check if the fluid is oil and fluid level (e.g. using flexible measuring tape) and then call the service.

BAT LOW This information is displayed in place of level reading. It means reduction in voltage level of battery in transmitter occurred. Battery voltage shall be dropping at low temperatures. When battery temperature rises so will battery voltage and information shall no longer be displayed. Oil Watchman Plus shall continue to work normally at low battery voltage for weeks, without need for changing the battery.

24

Displayed oil level blinking Battery used up – change battery.

“F”

Tank is full. When “F” symbol is displayed and tank is not full it means there is some fluid in the upper part of the probe. Dismantle transmitter, remove and clean the probe thoroughly.

Capital “C”

This symbol indicates transmitter – probe connection error. Check connection between transmitter and probe – if correct the probe is to be replaced.

Small “c” and level displayed alternately

Leak sensor defective. Check the sensor at the end of white cable leading from probe end.

25

7. TANK OVERFILL PROTECTION In FuelMaster® machines (with volume over 3,500 l) mechanic and electronic overfill protections are used. Mechanical protection is a Spill Stop device installed on machine inlet. When oil level in device reaches ca. half of the float height the inlet is almost completely cut-off. It shall allow only the flow rate of maximum 2,5 litre/min. The system works only with pressure refuelling of tank; required refuelling parameters:

Minimum pressure: 150mbar (15kPa) Maximum pressure: 3 bar (0.3Mpa)

Minimum flow: 35 litres/min. Maximum flow: 350 litres/min.

Spill Stop – mechanic overfill protection

Electronic protection is a probe installed on top of the tabk. Level of installed sensor determines where the maximum level is signalled. When the end of the probe is in the fluid rapid change in electric resistance occurs. That rapid change in resistance is used for generation of voltage surge for controlling the process of shutting down the tank valve.

Electronic overfill protection

220mm Cut-off level:

26

8. MACHINE’S LITRE CAPACITY CHART

BFM09000DG Litres* Level [mm] 350 ---------------- 100 710 ---------------- 200 1100 -------------- 300 1480 -------------- 400 1890 -------------- 500 2250 -------------- 600 2600 -------------- 700

BFM09000DG Litres* Level [mm] 2970 --------------- 800 3350 --------------- 900 3740 --------------- 1000 4100 --------------- 1100 4490 --------------- 1200 4850 --------------- 1300 5210 --------------- 1400

BFM09000DG Litres* Level [mm] 5570 ---------------1500 5930 ---------------1600 6300 ---------------1700 6650 ---------------1800 7000 ---------------1900 7340 ---------------2000 7700 ---------------2100

BFM09000DG Litres* Level [mm] 8040 -------------- 2200 8390 -------------- 2300 8740 -------------- 2400 9000 -------------- 2530 9450 -------------- 2750 9560 -------------- 2800

BFM05000DG Litres* Level [mm] 180 --------------- 80 360 --------------- 150 540 --------------- 215 725 --------------- 280 900 --------------- 340 1090 -------------- 410 1270 -------------- 475

BFM05000DG Litres* Level [mm] 1450 -------------- 530 1635 -------------- 590 1815 -------------- 660 2000 -------------- 720 2180 -------------- 805 2360 -------------- 880 2545 -------------- 945

BFM05000DG Litres* Level [mm] 2725 --------------1010 2905 --------------1090 3090 --------------1160 3270 --------------1220 3450 --------------1300 3630 --------------1370 3810 --------------1440

BFM05000DG Litres* Level [mm] 3995 ------------- 1510 4175 ------------- 1595 4360 ------------- 1675 4540 ------------- 1750 4720 ------------- 1830 4905 ------------- 1905 5000 ------------- 1940

BFM03500DG Litres* Level [mm] 250 --------------- 125 500 --------------- 205 750 --------------- 295 1000 -------------- 395 1250 -------------- 495 1500 -------------- 600 1750 -------------- 700

BFM03500DG Litres* Level [mm] 2000 -------------- 800 2250 -------------- 905 2500 -------------- 1010 2750 -------------- 1125 3000 -------------- 1225 3250 -------------- 1350 3500 -------------- 1450 3750 -------------- 1590

BFM02500DG Litres* Level [mm] 182 ----------------135 363 ----------------225 545 ----------------310 726 ----------------385 908 ----------------455 1090 --------------520 1271 --------------605

BFM02500DG Litres* Level [mm] 1453 ------------- 670 1634 ------------- 740 1816 ------------- 810 1998 ------------- 890 2179 ------------- 970 2361 ------------- 1070 2497 ------------- 1125

BFM01200DG Litres* Level [mm] 158 ----------------160 258 ----------------235 358 ----------------305 458 ----------------435 558 ----------------495 658 ----------------555 758 ----------------620

BFM01200DG Litres* Level [mm] 858 --------------- 680 958 --------------- 750 1058 ------------- 825 1158 ------------- 910

* Approximate values

Notes:

− Data included in above charts are laden with error due to thermal expansion of polyethylene – material used for tank.

− The end of suction hose is located a few centimetres above tank bottom, which causes occurrence of so-called “dead zone”, with volume of ca. 30% of nominal tank value. In the event of BFM05000DG tank it is ca. 150 litres. This way pump system of the machine is protected from sucking the oil from the very bottom, where sludge and other contaminants tend to settle.

− Litre capacity measurement strip is not included with FuelMaster® accessories offered by manufacturer.

27

III. TRANSPORT AND STORAGE

1. Transport and storage of machines is to ensure protection from mechanical damage. Machines can be transported only with their tanks emptied.

2. Loading and unloading of machines is to be carried out using specialised equipment, such as forklift or crane, slings and belts.

3. Transport of machines can be carried out with specially prepared vehicles, i.e. vehicles equipped with at least fixing points suitable for transport of tanks, allowing fixing the tank and protecting it from sliding during transport.

4. Sliding or rolling the machines is prohibited. Never use projecting parts when lifting or sliding the machines.

5. Loading space is to be smooth, with no sharp edges. Machines are to be secured against movement during transport.

6. Machines can be stored outdoors, without specific limitations. Storage space is to be paved, even and without sharp edges.

7. 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.

8. Machine can be stored temporarily only when its tank is emptied.

28

IV. GENERAL SETUP REQUIREMENTS

Users of FuelMaster® 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. 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.

2. Machine is to be placed on flat (levelled), even and stable surface executed in non-flammable material. Base is to be at least 30 cm wider and longer than machine itself. Base thickness is to be at least 5 cm.

3. Verify if parameters of power supply network are the same as required by pump motor. Connection to supply is to be carried out only by means of suitable, fully functional extensions, or permanent connection.

4. Cables exposed to mechanic damages are to be secured by suspending them, placing them in protective pipe, or covering with protective strip.

5. It is not allowed to place FuelMaster® machines in garages, storage spaces adn other buildings, as well as on sidewalks and pedestrian passages.

6. Space around the machine is to enable free and unobstructed traffic of vehicles.

7. Machine is to be placed by access road with required width, with enough space for U-turn, and suitable for the load of fuel oil 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.

8. It is forbidden to use open fire and smoke near the machine, as well as to use other media which might initiate combustion of fuel oil. A fire-safety sign “Using open fire and smoking forbidden” is to be placed at machine location.

9. When using distributor with a pump powered with 230V AC voltage, electric wiring is to be carried out in accordance with pump manufacturer’s instructions and regulations in force.

10. 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 > 5 m

Sewers or heating system ducts; not applicable where the yard is equipped with linear drainage and oil separators

> 5 m

Water intakes, heating chambers, openings to premises with floor below adjacent ground level > 5 m

Forrest border >10m

29

Power line up to 1kV >3m

Power line 15 kV to 30 kV >5m

Power line 30kV to 110 kV >10m

Power line above 110KV. >30m

Devices with surface heating up to temperatures exceeding 100°C >0,5m

11. When positioning and operating the machine never exceed below threshold noise values, expressed in equivalent level of A sound, for residential development areas:

− 67 dB – during the day,

− 57 dB – during the night.

12. No explosion hazard areas are specified for FuelMaster® machines designated for storage and distribution of petroleum products cat. III.

13. Protect the machine from direct sunlight, snow and rain. It is recommended that the machine is placed under suitable roofing.

14. In the event of machines which are to be often moved or exposed to mechanic damages we recommend ordering protection frame (optional).

15. 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”.

30

V. ELECTRICAL SYSTEM

Electrical system for FuelMastera® 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) W 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:

− oil unloading system when refuelling the machine,

− earthing screw outside distributor enclosure.

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 suitable parameters.

The machine is delivered with power cord and plug with earthing pin, which can be connected to extension cable. Alternatively the plug can be replaced with permanent plug (with suitable IP), installed on distributor enclosure.

Extension is to have the following parameters:

− minimum cross-section 3x2.5 mm2,

− copper wire - line,

− PE pin (earthing),

− protection index: at least IP65,

− extension feeder line cut-out value is to be C16A (value of trip current: 16 A with C type characteristics),

− fully functional; with no signs of wear, no damage to isolation, no loose contacts, no signs of rep air, etc.

When connecting extension make sure that pump switch is in OFF position.

NOTE: Protect extension connection from humidity. When the machine is in a standstill or not operating (at night) power cord is to be disconnected, unless the machine is working.

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3. PERMANENT POWER SUPPLY 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 requirements are to be met:

− 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 manufacturer and provisions of regulations in force.

− Use power cord 3 x 2.5mm2.

− Mains connection is to be protected with suitable cut-out.

Pump electrical box diagram

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).

Schemat podłączenia elektrycznego urządzenia z rozdzielnią główną w układzie zasilania TN-C

SINGLE PHASE

TO MOTOR

CA

PAC

ITOR

Power supply box, type TN-C

Tank electrical box

Power supply box

Terminals

Black or Brown

Electrical connection between the machineand main switching station with power supply system TN-C

Blue

32

In the event of power network TN-S type, with three power wires available – phase (black or brown wire) and working zero (blue wire), and protection wire (yellow and green), it is recommended that PE wire (yellow and green) is connected to powers supply PE wire (yellow and green).

Electrical connection between the machine

and main switching station with power supply system TN-S

Machine overcurrent protection In addition to protection in pump electrical box also overcurrent protection in power supply box is to be employed. Cut-out value is to be C16A (value of trip current: 16 A with C type characteristics).

NOTE: Permanent connection between the machine and power supply box is to be carried out by electrician with valid license, issued by relevant organisation, for the scope of operations performed.

Blue

Power supply box, type TN-C

Tank electrical box

Power supply box Black or Brown

Yellow and green

Terminals

33

VI. GENERAL SAFETY PRINCIPLES 1. Material in store.

The basic source of information concerning hazardous material is Material Safety Data Sheet. Refer to fuel oil supplier to obtain MSDS concerning purchased oil. Fuel oil is a mixture of petroleum hydrocarbons, with carbon atoms content 9 to 25, and additives.

2. Major hazards caused by stored material (fuel oil) and methods of their reduction: − avoid repeated or long exposure of skin to fuel oil, − always wear protective gloves when refuelling the machine, − follow the general hygiene principles; wash contaminated body parts immediately using

water and soap, − do not eat/drink when operating the machine, − do not use open fire and do not smoke when operating the machine, − oil fumes are harmful when inhaled, and are likely to cause irreversible damage to health;

exercise extreme caution when using fuel oil, − avoid contact with eyes, if possible wear protective goggles with lateral screens; exposure is

likely to cause health risk, − fuel oil has toxic effect to aquatic and land animals; it is likely to cause long-term adverse

effects to natural environment, − increases fire hazard; fumes create explosive mixture with air; since they are heavier than air

they tend to accumulate near premises floors. 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. In the event of direct hazard to public safety, owner and operator are to notify emergency services immediately, and provide them with information required by such services to perform their functions. 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, − notify his/her superior, − person with management capacity responsible for storage or hazard area , or person

assigned by such person, is managing rescue activities, and, if necessary, notifies fire-brigade,

− in the event of leak to pump its content to another machine, − notified authorised service.

6. In the event of machine utilization it is to be disassembled to basic parts and then recycled. 7. Beware of electric shock. Strictly follow the instructions included in this manual. 8. Follow plant’s fire-safety and H&S regulations.

34

VII. OPERATIONAL RECOMMENDATIONS Portable fuel oil distribution machine is designed and executed for durability, reliability and low-maintenance during operation. Due to the type of fluid stored and potential hazards to environment, the following recommendations are to be followed:

1. REFUELLING OF MACHINES Oil is to be fed from mobile tanks or other means of transport of hazardous materials class III. Unloading is to be carried out only via tight connection!

Feeder lines of machines with volume from 3,500 litres can be have the following fittings: 1. The machine can be refilled only to half of its rated volume, which is 95% of maximum volume.

Never allow overfilling! 2. Both loading and unloading of oil is to be carried out under strict supervision of properly trained

person. 3. Do not store contaminated fuel oil, or other oil, e.g. biodiesel, hydraulic oil, etc., as it may lead to

contamination of the machine and damage to pumping system. Operator is to be able to document origin and ignition temperature of stored fuel oil.

4. 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.

5. 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. The same safety measures are to be used when mobile tank hoses occupy the sidewalk.

6. 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 and if it is not damaged. Damages and other irregularities make the machine unfit for refuelling.

7. It is recommended that mobile tanks with maximum level sensor are used. 8. When the tank is situated in a large distance from mobile tank, there should be one more person

supervising refuelling. 9. Maximum allowed speed of refuelling the tank is 350 l/min.

Dry fitting 2” (no ball valve requried prevents leakage)

Eurofitting 2” Camlock 2”

35

2. REFUELLING OF VEHICLE − During first refuelling the whole suction line contains

air. Start the pump, place filler nozzle in vehicle tank inlet, and keep it open all the time to allow venting of air. Fuel can appear after maximum 2 minutes. Upon completion of refuelling first stop the pump, and then, when flow stops, release the handle of filler nozzle valve. Another sequence shall cause pressurized oil to stay in distribution hose, which is not desired.

− Prior to starting operation read operations manual of pump and flowmeter.

− Never operate the machine at temperatures below -20°C and above +40°C, nor in bad weather conditions, such as rain, strong wind, etc.

− !!! Prior to starting operation make sure there is fuel in the machine. !!! Working “dry” shall cause damage to pump.

− Maximum allowed time of pump operations with distributor filler nozzle closed is very short (2 – 3 minutes). After the use make sure the pump is shut off.

− Perform visual inspection of the machine condition.

− Make sure that distribution filler nozzle with automatic cut-off valve and flexible hose is in good condition, without visible signs of external damage.

− Drive the vehicle to be refuelled near the machine, to the distance which allows effective refuelling operation. Turn off the engine of refuelled vehicle.

− It is forbidden to stay inside the vehicle being refuelled; leave the vehicle.

− Drive the vehicle away immediately after refuelling. It is forbidden to park vehicles near the distributor.

− It is forbidden to park more than one vehicle near the machine. Driver of vehicle is obliged to keep safe distance (min. 5 metres).

− It is forbidden to park vehicle in a way obstructing possible emergency evacuation from fire-hazard area.

− In the event of spilling fuel onto or near the machine immediately remove the spill, before the machine is restarted.

− In the event of observing leak in machine tank immediately pump the oil to another tank; notify machine manufacturer.

− Never cover the venting ferrule, clean it regularly.

− Disconnect the machine form power supply when not in use.

− In the event of incorrect operation order have the machine repaired.

36

VIII. MACHINE MAINTENANCE

Maintenance activities and schedule is to be carried out as per table below:

Item Activity Frequency

1 Check if machine accessories are complete.

Replace or tighten all 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 functioning of level sensor.

5 Check and clean mesh filter in pump and at the end of suction hose.

6 In the event of contamination clean flowmeter measuring chamber. In the event of digital flowmeter, clean also filter.

7 Calibrate flowmeter.

8 Check for leaking joints.

9 Check pump venting duct.

10 Check condition and efficiency of distribution system.

11 Clean the accessories.

12 Check and tighten, if necessary, all joining elements, e.g. screws, bolts, nuts, etc.

13 Check and if necessary clean the interior of tank.

Clean the machine from the outside.

14 Proof metallic elements against corrosion.

Rubber parts (distribution hose, filler nozzle guard) to be protected with rubber protection agents.

periodic

15 Check machine marking.

„” means every 6 months or every 50,000 litres of fuel, depending which date is earlier.

37

IX. TROUBLESHOOTING

Item DEFECT CAUSE ADVICE

1 Leak Damaged sealing. Dismantle connection, install new sealing.

2 Insufficient accuracy.

Flowmeter miscalibration. Perform recalibration.

Contaminated flowmeter chamber. Dismantle and clean flowmeter

chamber.

Air content in oil. Find and remedy leak in

pump/suction line.

3 Reduced flow rate.

Blocked or contaminated filter at the end of suction hose or other part of suction line. Locate and remove contamination.

Air in pump, air in oil. Vent pumping system, check

tightness of suction line. Check supply voltage.

Irregular pump operation. Check voltage of power.

Blocked gears or contaminated filter in digital flowmeter. Clean measuring chamber, filter.

Obstructed or blocked measuring chamber in analogue flowmeter. Clean measuring chamber.

4 Increase in noise level during pump operation. Air in oil. Find and remedy leak.

5 Motor is not rotating.

No power supply. Ensure proper power supply.

Rotor jammed. Check rotating parts of pump and motor.

Pump thermal protection tripped.

Wait until motor cools down.

6

Digital flowmeter counter does not count units despite displaying

correct flow rate value.

Gears incorrectly installed after cleaning. Reinstall gears correctly.

7

Digital flowmeter counter does not count units.

Incorrect installation of gears. Reinstall gears correctly.

Defective reed relay. Replace reed relay.

8 Defective level indicator. See section “Level indicator”.

9 Vibrations in refuelling line during refuelling.

Too high flow rate. Reduce flow rate.

Line incorrectly mounted. Mount the line correctly.

Strong throttling due to defective connection or Spill Stop. Replace defective part.

38

X. GUARANTEE TERMS 1. Firma Titan Eko Sp. z o.o. issues the following guarantees for FuelMaster® machine:

- 10 years for tightness of double-jacket tank, - 1 year for distribution system (pump, flowmeter, hoses, etc.), - 1 year for sensors: Watchman Plus oil level and leak sensor, maximum level sensor, and other\ accessories installed in tnaks.

2. In the event of failure please contact Titan Eko Service Department , phone no. +61 814 44 28. Notifications to be sent to fax no. +61 814 54 99 or to e-mail: serwis@titan-eko.pl .

3. When reporting failure the first step is to send Service Order (Defect Report Sheet) in writing (e.g. by fax), using the form included in Operation Manual attached with each machine (we recommend to photocopy the form so that it could be reused).

4. Guarantee and post-guarantee servicing of FuelMaster® machines is provided by authorized Titan Eko service Centre – Rohe Polska Sp. z o.o.

5. For details of servicing contact directly ROHE Service Centre, mobile 507 130 912, fax no. +32 250 54 62.\ 6. Defects revealed within guarantee period shall be remedied within two weeks following the date of report in

writing. 7. Guaranteed response time to notification is 48 hours on business days. 8. 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. 9. Aiming at improvement of mechanic parts of tanks we suggest periodic inspection after first 6 months of

usage, or after 50,000 litres of fuel is pumped through the tank (whichever comes first). 10. Inspection is voluntary, however failure to perform such inspection may in extreme cases lead to revoking

guarantee for mechanic components of tank. Inspection order is to be placed directly with company ROHE Polska (mobile 507 130 912, fax no. +32 250 54 62).

11. If defect disclosed during guarantee period is due to improper operation or installation of the machine (see clauses 6 and 7 of this Manual), or if defect is disclosed after expiration of guarantee period, reporting party shall be charged with servicing costs.

12. By placing order for service Purchaser agrees to be charged for services outside the scope of guarantee offered by Service Centre authorized by manufacturer. Titan Eko 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.

13. Guarantee is exclusive of standard maintenance, such as cleaning of filters, changing of batteries, calibration (accuracy adjustment) of flowmeters. When observing inaccuracies in flowmeter indications, perform calibration in accordance with included instruction.

14. Purchaser forfeits guarantee rights in following cases: - damages due to improper installation and operation, - failure to ensure maintenance, mechanic damages, acts of vandalism, - defects due to unauthorized repairs or modifications, - changing product purpose.

15. Company Titak Eko Sp. z o.o. is not responsible for damages due to operation of the machine in a way contrary to manufacturer’s instructions and regulations in force.

You can find serial number of machine in

these locations

39

DEFECT REPORT SHEET SERVICE ORDER

Serial no.: Date of purchase: Guarantee card no.:

* 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.

Immediate remedies: Responsible person: Date of closure: Signature:

Preventive measures: Responsible person: Date of closure: Signature:

DECISION (Sales Administration Dept.): Name .................................................................... Signature …………..................................................

Attn: Commercial Fuel Solutions LtdUnit 22 Badgers Way Buckingham, MK18 7EQ tel.:+44 (0)845 688 9755 fax:+44 (0)845 688 9744

Titan Eko Client: COMPANY: ADDRESS: CONTACT:

phone: ………………………………. fax: ............................................ Detailed address of product location:

COMPANY: ……...………………………………………........................

ADDRESS: …..…………………………………………........................

CONTACT ……………………………......................

phone: ………………………………. fax: ............................................ Date and time when the product can be services/collected:

......................................................................................................

Fuel-Mastera type* BFM09000DG BFM05000DG BFM03500DG BFM02500DG BFM01200DG Flowmeter type* K33

(analogue) K600

(digital) MC CUBE (PIN codes)

PETROSOLO (GUM verification)

“R” DOCUMENT NUMBER ........................................... DATE ............................................... ADJUSTMENT NOTE NUMBER ........................................... DATE ............................................... “D” DOCUMENT NUMBER ........................................... DATE ............................................... SENT BY: ........................ NUMBER ........................................... DATE ..............................................

Date: ...........................