Hytek ALPHA Manuel d'instructions

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Technical Data

ALPHA ATEX APPROVED TWIN

DIESEL PUMP WITH FUEL

CONTROL SYSTEM

Applies to ATEX Certified Alpha Twin diesel / gas oil pumps only.

Please read carefully before commencing installation

Registered Office: HYTEK (GB) LIMITED, Delta House, Green Street, Elsenham, Bishop’s Stortford

CM22 6DS UK. Registered in England No. 1915382

Tel: +44 (0) 1279 815 600 Fax: +44 (0) 1279 812 978 email: in[email protected]

Web: www.hytekgb.com

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ENVIRONMENTAL INFORMATION

European Directives 2012/19/EU requires that the equipment

bearing this symbol on the product an/or its packaging must not

be disposed of with unsorted municipal waste. The symbol

indicates that this product must be disposed of separately from

regular household waste streams. It is your responsibility to

dispose of this and other electric and electronic equipment via

designated collection facilities appointed by the government or

local authorities.

PRODUCT DESCRIPTION

This pump is ATEX certified to dispense diesel or other liquids

classed as category 3 in accordance with European Regulation

No. 1272/2008. It bears the following certification marking and

number:

IIII

2 G

MANUFACTURED TO: EN13617-1

CERTIFICATE NO: CML 15ATEX9183

2503

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IMPORTANT WARNING NOTES

1. On above ground storage tanks, an angle check valve fitted

with the appropriate spring or pressure regulating valve must

be fitted at the tank outlet to prevent loss of fuel under gravity

in the event of vandalism or accidental damage.

2. This pump must only be used to dispense diesel or other

liquids classed as category 3 in accordance with European

Regulation No. 1272/2008. It must not be used to dispense

petrol or any other liquid with a similar flash point.

3. Installation of this equipment and its associated tank, pipe

work and fittings should only be carried out by qualified fuel

installation engineers.

4. The installation must be carried out in accordance with the

requirements of EN 60079-14 and all relevant electrical and

local authority regulations and standards.

5. It must not be used with other liquids or for other applications.

We will accept no warranty claims or liability if it is used for

other liquids or applications.

CALIBRATION

The meter on this pump unit must be calibrated electronically to

ensure accuracy and reliability. Please see page 10 for further

details.

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INSTALLATION INSTRUCTIONS

1. Check you have the following items:

1 off Alpha twin pump

2 off delivery hoses

1 off front door key

2. Open the front panels using the key provided.

3. Remove the rear panels, if necessary, and store safely.

ALPHA TWIN EXTERNAL DIMENSIONS

MOUNTING

4. Bolt the pump to a firm level foundation by means of the four

14 mm diameter-mounting holes provided.

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ALPHA TWIN BASE AND SUCTION CONNECTION

PIPEWOR

5. Connect the 11/2” diameter pipe from the tank to the suction

inlet flexible connectors of the pump. The inlet threads of the

flexible connector flanges are 11/2” BSP taper female. Seal

the joints with a suitable thread-sealing compound. Alternative

pipe work entry points, for above ground pipe work, are

provided at the rear of the pump base. Push out the plastic

cover plates if required.

NB: On above ground tanks an angle check valve fitted

with the appropriate spring or an anti syphon valve must

be fitted in the suction line to prevent spillage or leakage

in the event of damage.

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6. Connect one end of the delivery hoses into the outlet elbow.

Ensure the nylon hose-sealing washers are in place on the

hose end. It should be hand tight plus a quarter turn.

7. Screw the nozzles onto the other ends of the hoses, again

ensuring the nylon washers are in place. No other sealing

compound is necessary. Hand tight plus a quarter turn.

ELECTRICAL

8. Remove the cover from the junction box.

9. Connect two constant 220/240V AC 50 Hz supplies, fused at

16 amps, to the terminal blocks in the junction box as shown

on the wiring details diagram.

NB:The Alpha pump must have a continual 220/240V AC

supply, even when not in use

10.If the Alpha is to be operated in conjunction with a key/card

system, remove the links in the junction box (shown on the

Alpha Installation Wiring Diagram) and connect so that the

control system makes and breaks the connections.

Make connection - Pump on

Break connection - Pump off

Alternatively remove the links and connect a switched live

supply (230V AC 16A max.) to each terminal 4 (shown on the

Alpha Installation Wiring Diagram)

Live supply switched on - Pump on

Live supply switched off - Pump off

11. A pulse output for connection to key/card systems is available

from the separate terminals located in the junction box. This is

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a passive contact giving 10 or 100 pulses per litre. Contact

ratings are as follows:

Maximum current - 0.25 amps

Maximum voltage - 50 volts

Maximum power - 5 VA

12. Ensure all the terminal screws are tight and replace the

junction box cover.

ALPHA JUNCTION BOX WIRING DIAGRAM

PUMP 1 FC10 DISPLAY CONNECTIONS DETAILS

PUMP 1 – FC10 PUMP 2

240V AC

POWER INPUT

CONNECTOR

2345678910

BLUE

YELLOW

12V DC - RED

PULSE - GREEN

0V - BLACK

SCREEN

DATA 1 - BROWN

DATA 2 - BLUE

NOZZLE SWITCH

INPUT

PUMP PULSER

CONNS (& NOZ

SWITCH +12VDC)

RS485 DATA

CONNECTIONS

MOTOR RELAY

CONNECTIONS

0V - BLUE

12V DC - BROWN

12 3 4 5 6 7 8 9 10

12V DC - BROWN

PULSE - GREEN

0V - BLUE

SCREEN

DATA 1 - BROWN

DATA 2 - BLUE

PUMP PULSER

CONNECTIONS

RS485 DATA

CONNECTIONS

MOTOR RELAY

CONNECTIONS

0V - BLUE

12V DC - BROWN

INTERNAL WIRING

CONNECTIONS

SECOND PUMP CONNECTIONS

TO PUMP 2 JUNCTION BOX

(ONLY USED IF SECOND PUMP

CONNECTED)

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SOLENOIDP/OUT

COM GND

12V

PULSE IN

REED OPT +12V

CH1CH2 GND

GND IN 12V

NOZZLE SWITCHES

GND SW GND SW GND SW

TANK LEAK EXT GND + -

COMMS

56 421 3

0V - BLACK (W&M BROWN)

AND SCRN

10:1 /

100:1

PULSE

OUTPUT

PULSE

TRANSMITTER

INPUT

NOZZLE

SWITCH

INPUT

OPTO ISOLATED - GRN/YEL

REED RELAY - BLUE

COMMON - BROWN

GREEN/BLUE

YELLOW

+12VDC - RED (W&M GREEN)

CH 1 - YELLOW (W&M WHITE)

CH 2 - GREEN (W&M YELLOW)

12V DC SOL.

OUTPUT

(WEIGHTS &

MEASURES

VERSION

ONLY)

0V - BLUE

+12VDC - BROWN

RED

21 3 21 21 321 3421 3

LIVE

220/240 VAC

MOTOR RELAY

OUTPUT

1 1 232

220/240 VAC

POWER

INPUT

EARTH

LIVE - BLACK

NEUTRAL - GREY

NEUTRAL

AC INPUT

PUMP

DISPLAY /

CALCULATOR

VIEWED FROM

REAR

CALIBRATION

BUTTON

PUMP 2 DISPLAY CONNECTION DIAGRAM

INSTRUCTIONS FOR USE

1. See additional document for using the FC10 fuel control unit.

2. Remove the nozzle from the holster.

3. Place the nozzle spout in the fuel tank.

4. Squeeze the nozzle trigger to dispense fuel.

5. On completion of the delivery release the trigger and replace

the nozzle in the holster.

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MAINTENANCE

The Alpha should require minimum maintenance in normal regular

use, but as with all mechanical apparatus regular servicing will

prolong its life and ensure maximum efficiency & reliability.

The following should be carried out every 12 months or 1 million

litres which ever comes first.

Isolate power supply

Inspect & clean or replace pump filters

Inspect & clean or replace nozzle filters

Inspect & replace if necessary the V-belts

Check motor pulley grub screws are tight

Re-calibrate electronic displays

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ALPHA PUMP UNIT FILTER LOCATION

ALPHA SIDE ACCESS PANEL VIEW

20 34

PUMP UNIT

FILTER LOCATION

AS VIEWED FROM

THE FRONT

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