Related Manuals for TUFFA TANKS 1350SLBFS
Summary of Contents for TUFFA TANKS 1350SLBFS
- Page 1 Installation, Operation and Servicing Manual Version 2.0.0 Models: 1350SLBFS | 2500HBFS | 3500VBFS | 6000VBFS | 10000VBFS | 15000VBFS TUFFA FUEL STATIONS...
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Page 3: Table Of Contents
System location 6.4 Electrical requirements 6.5 Electrical wiring diagram Operation of the system 7.1 Using the system 7.2 Summary of main parts 1350 / 1400 / 2500 7.3 Summary of main parts 3500 / 6000 / 10000 / 15000 7.4 Filling diesel fuel station 7.5 Dispensing diesel into vehicle 7.6 Equipment components Maintenance of the TUFFA TANKS 8.1 System maintenance tasks 8.2 Inspection by competent person 8.3 Internal examination and cleaning 8.4 Troubleshooting 8.5 Tank maintenance record 8.6 Fuel delivery log Warranty Contact Guarantee Registration... -
Page 4: Introduction
1. INTRODUCTION | 2. CONDITIONS OF USE 1. Introduction This manual contains specific instructions and information relating to the installation, operation and maintenance of Tuffa Tanks systems. 2. Conditions of use • Read this manual before installing this system. • Tuffa Tanks accepts no liability for personal injury or property damage resulting from working on or adjusting the equipment incorrectly or without authorisation. • Tuffa Tanks accepts no liability for direct, indirect, incidental, special, or consequential damages resulting from failure to follow any warnings, instructions, and procedures set out in this manual. • Tuffa Tanks reserves the right to change the specifications of its products or the information in this manual without necessarily notifying its users. • Variations in installation and operating conditions may affect the Tuffa Tank systems performance. Tuffa Tanks makes no representations or warranties concerning the performance of the tank system under the operating conditions prevailing at the installation. • Only parts supplied by or approved by Tuffa Tanks must be used and no unauthorised modifications to the hardware or software should be made. The use of non-approved parts or modifications will void all warranties and approvals and could lead to hazardous safety conditions. • Unless otherwise noted, references to brand names, product names, or trademarks constitute the intellectual property of the owner thereof. -
Page 5: Safety
3. SAFETY 3. Safety PLEASE READ THIS MANUAL CAREFULLY BEFORE USE & COMPLY WITH ALL INSTRUCTIONS BELOW. THIS MANUAL SHOULD BE KEPT WITH THE EQUIPMENT AT ALL TIMES. 1. The major hazard involved with installing and operating the unit is electrical shock. This hazard can be avoided if you adhere to the procedures in this manual and exercise all due care. 2. Installation and use of this product should only be carried out by properly trained and approved personnel. 3. Please refer to storage media MSDS which should be supplied by the proprietor of this system which will detail the PPE required for handling and emergency procedures. 4. The user of this product is responsible for the safe and correct use of this product. 5. This product is only suitable for storage and/or dispensing of the liquid media referenced at the point of sale. -
Page 6: Product Description
4. PRODUCT DESCRIPTION 4. Product description Tuffa Fuel Stations are designed solely for storage and dispensing of diesel. The static bunded systems enable safe diesel storage and dispensing in an outdoor environment and ensures you meet all stringent fuel storage regulations. The high standard of specification ensures optimum safety and functionality. This product’s standard specification is not approved for the resale of diesel. 4.1 Product identification The identification plate is located within the cabinet of each system and will detail the capacity, serial number, model number and year of manufacture. -
Page 7: Product Specification
4. PRODUCT DESCRIPTION 4.2 Product specification 1350SLBFS 2500HBFS 3500VBFS 6000VBFS 10000VBFS 15000VBFS Capacity 1350 litres 2500 litres 3500 litres 6000 litres 10000 litres 15000 litres Length 2680mm 2840mm Width 870mm 1520mm Diameter 2034mm 2580mm 2890mm 2860mm Height 1665mm 1630mm 2520mm 2610mm 2600mm 3500mm Cabinet depth 600mm 600mm 600mm 600mm Weight (approx.) -
Page 8: Product Footprint
4. PRODUCT DESCRIPTION Product Footprint 1350SLBFS... - Page 9 4. PRODUCT DESCRIPTION 2500HBFS...
- Page 10 4. PRODUCT DESCRIPTION 3500VBFS...
- Page 11 4. PRODUCT DESCRIPTION 6000VBFS...
- Page 12 4. PRODUCT DESCRIPTION 10000VBFS...
- Page 13 4. PRODUCT DESCRIPTION 15000VBFS...
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Page 14: Transport & Storage
5. TRANSPORT & STORAGE 5. Transport & storage DO NOT TRANSPORT WITH LIQUID INSIDE THE TANK During transportation the flip lid and cabinet doors are secured by 1 x R clip. The R clip must be installed prior to transportation. Loading and off-loading must be carried out by a competent person using suitable rated and maintained equipment, either a forklift with extended forks/tines or a crane. If lifting slings are used, they must be attached to the lifting points as shown in the pictures below using a steel lifting eye insert. If lifting from below use a suitable rated forklift with extended forks. If lifting from above use a suitable rating lifting slings / chains. 1350SLBFS / 2500HBFS - Lift with main lifting eye highlighted in red in the image below or forklift from the side. 3500VBFS / 6000VBFS / 10000VBFS / 15000VBFS - Lift with x4 equal spaced lifting brackets as highlighted in red in the image below or forklift from one side using a ratchet strap to secure the tank to the forklift mast. Tuffa Fuel Stations must never be pushed or rolled. During transport and storage, the flip lid or cabinet doors must be closed and secured. Loading, transport and storage areas must be smooth and free of sharp edges. -
Page 15: Installation & Commissioning
6. INSTALLATION & COMMISSIONING 6. Installation & commissioning 6.1 Installation guidelines The proprietor of the Tuffa Fuel Station is responsible for complying with all legal requirements relating to the installation and use of this product, as well as the guidelines issued by local firefighting authorities and environmental authorities. Once the Tuffa Fuel Station has been received on site, check that no damage has occurred while in transit. Locate the tank in the desired location using either a crane, forklift or rollers. 6.2 System installation System foundation The system must be installed and fully supported on a smooth levelled concrete base built in accordance with good building standards and engineering principles. It is recommended that tanks be installed on a concrete base at least 100mm thick.Please refer to diagram below: 6.3 System location The location of the system should be positioned by a road or passing with sufficient width, and loading capacity to accommodate a tanker delivering diesel. Provision for the U-turn of a tanker should be considered. Potential obstacles in the form of tree branches, high voltage lines, or parked vehicles must be minimized. The space around the system should allow free and collision-free movement of served vehicles. Provision should be made to protect tank from impact damage. -
Page 16: Electrical Requirements
6. INSTALLATION & COMMISSIONING 6.4 Electrical requirements Only a suitably qualified electrician according to applicable regulations may work on the elec- tric wiring installation. The system components under service, maintenance, and repair work must be disconnected from the power supply before any work in undertaken. System power requirements: • 220 - 240 Volts, 50 Hz +/- 10% • 20 amp circuit breaker recommended • Power cable recommendation: 3 Core 2.5mm flex cable 6.5 Electrical wiring diagram 6.5.1 1350SLBFS / 2500HBFS – Key Switch PUMP SWITCH MCB1 6A PUMP Dunford & Pearson SCHEMATIC 2 13/05/2019 ISOLATOR REMOVED MB SDN TUFFA TANKS 14/12/2016 NTS... - Page 17 6. INSTALLATION & COMMISSIONING 6.5.2 3500VBFS / 6000VBFS / 10000VBFS / 15000VBFS – Key Switch PUMP SWITCH MCB1 6A PUMP MCB2 2A GAUGE 3C X 0.5 @ 1MTR LONG Dunford & Pearson PANEL LAYOUT XX/XX/XX XXXX MB SDN TUFFA TANKS 14/12/2016 NTS LT/WPS 1 of 1 XXXXXXXX...
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Page 18: Operation Of The System
7. OPERATION OF THE SYSTEM Operation of the system The system and its components are intended for diesel fuel only and for the purposes described below. Use of this system in a means other than described below is regarded as mis-use of the system, the user of the system will be liable for any defects that occur due to its unintended use. 7.1 Using the system The operation and maintenance personnel must be suitably trained to use the system, the user must make sure they fully understand the operation and maintenance sections of this manual. 7.2 Summary of main parts 1350 / 2500... -
Page 19: Summary Of Main Parts 3500 / 6000 / 10000 / 15000
7. OPERATION OF THE SYSTEM 7.3 Summary of main parts 3500 / 6000 / 10000 / 15000... -
Page 20: Filling Diesel Fuel Station
7. OPERATION OF THE SYSTEM 7.4 Filling a Tuffa Fuel Station 1. Filling should be performed only under constant supervision of an authorised person. 2. This tank can only be filled by a tanker equipped with a 2” female BSP coupling. 3. On 3500 / 6000 / 10000 / 15000 models before filling the tank with diesel, please check the levek of the tank and make note of the tank level before filling and ensure the high-level alarm indicator functions correctly. 4. Fit tanker delivery hose to 2” BSP fill coupling on tank. 5. Engage tanker pump and begin to fill. Stop filling when desired amount has been dispensed into tank, or when high-level alarm sounds. 6. During the tanker fill always observe tank level gauge throughout the duration of the filling process. The tanker driver must observe the tank being filled at all times during this process. 7. Once complete disconnect delivery hose from tank coupling. 7.5 Dispensing diesel into vehicle 1. Reset the flowmeter totalizer to 0 2. Activate pump using one of the following: rocker switch, key switch, auto - operational nozzle holster 3. Remove nozzle from nozzle holster and insert the nozzle completely into the diesel tank filler neck 4. Pull trigger on the nozzle to allow diesel to flow into the vehicle diesel tank 5. At this time the flowmeter counter will start recording the flow, continue refueling until the desired amount is reached or when the vehicle diesel tank is full 6. When the fuel tank is full the nozzle will automatically switch off... -
Page 21: Equipment Components
7. OPERATION OF THE SYSTEM 7.6 Equipment components 7.6.1 FMS gauge level (3500 litres models and above) The Fuel Level Monitoring System is a 240v combined digital tank level indicator and bund and high-level alarm that is designed to provide both visual and audible alarms whenever a predetermined level in a storage tank is reached. The FMS gives a content readout in both litres and a percentage. a. Full alarm Activation of this alarm indicates that the tank is full. This alarm is shown through visual LED’s and audible siren. Note: This audible and visual alarm will remain triggered for a short period of time after it sounds. The audible can be muted using the mute button on the keypad. THE PUMP WILL CONTINUE TO DISPENSE IN THIS ALARM MODE. b. High level alarm Activation of this alarm indicates the tank has reached a high capacity and close attention must be paid to the diesel inside the tank. This alarm is shown through visual LED’s and audible siren. Note: This audible and visual alarm will remain triggered for a short period of time after it sounds. The audible can be muted using the mute button on the keypad. THE PUMP WILL CONTINUE TO DISPENSE IN THIS ALARM MODE. - Page 22 7. OPERATION OF THE SYSTEM c. Low level alarm Activation of this alarm indicates the tank has reached a low level. This alarm is shown through visual LED’s and audible siren. Note: This audible and visual alarm will remain triggered for a short period of time after it sounds. The audible can be muted using the mute button on the keypad. THE PUMP WILL CONTINUE TO DISPENSE IN THIS ALARM MODE. d. Empty alarm Activation of this alarm indicates the tank is empty and needs filling. This alarm is shown through visual LED’s and audible siren. Note: This audible and visual alarm will remain triggered for a short period of time after it sounds. The audible can be muted using the mute button on the keypad. THE PUMP WILL CONTINUE TO DISPENSE IN THIS ALARM MODE. e. Bund alarm Activation of this alarm indicates that there is product in the bund cavity. This alarm is shown through visual LED’s and audible siren. Note: This audible and visual alarm will remain triggered constantly until muted or until the product is removed. The audible can be muted using the mute button on the keypad. In the event of this it is advised the bund cavity is checked and drained as soon as practicable. f. FMS Wiring diagram...
- Page 23 7. OPERATION OF THE SYSTEM 7.6.2 Flowmeter (fitted to all systems) 1.1 GENERAL INFORMATION The K33 meter is a mechanical flowmeter with nutating disk, designed toallow a precise measurement of Diesel oil or other fluids compatible with the manufacturing material. The nutating disk of the metering chamber (see diagram 1, drawing “15”), which is set in motion by the fluid itself, drives thegear train located in the cover of themeter body (drawing “8”) which transmits the motion to the meter (pos. “6”). The meter is equipped with a non- resettable litre totaliser and a batch register which can be reset by means of a knob (Pos. “2”) whose unit digit is provided with marks for the readout of the tenths of a litre. To ensure a proper and safe use of the meter it is 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 objects and people. 1.2 TECHNICAL DATA Meter Mechanism Nutating disk...
- Page 24 7. OPERATION OF THE SYSTEM Pressure loss with diesel oil Flow rate (l/min) 30 60 90 Pressure loss (bar) 0.005 0.2 0.4 Accuracy after calibration +/- 1% Repeatability (typical) +/- 0.3% Batch total readout 3 digits height 18mm Totaliser readout 6 digits height 6mm Readout resolution 0.1 litri Connections (inlet/outlet) 1” BSP Weight (approximate) 1.8 Kg Package dimensions 185 x 185 x 170 mm Optional features Registration in US gallons female threaded inlet/outlet 1” NPT 1.3 INSTALLATION The K33 can be installed in any position, on rigid pipelines or flexible hoses, directly on pumps or tanks. The meter flow direction is fixed and indicated by an arrow. The meter is supplied in the standard configuration (A). The meter and the cover can be rotated by 90° to 90° in respect to the body in order to carry out the different configurations shown (B, C, D). The reset knob can be installed either on the right side or on the left side of...
- Page 25 7. OPERATION OF THE SYSTEM 2. Purge the system (pump, pipelines, meter) of air by dispensing until the flow stream is full and steady. 3. Stop the flow by shutting off the nozzle, but let the pump running. 4. Reset the batch register by means of the reset knob (pos. “2”). 5. 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. Do not reduce the flow in order to reach the graduated zone of the calibration container. The right method is to start and stop the full flow repeatedly until the required filling is obtained. 6. Compare the indication of the calibration container (real value) with the one of the meter (indicated value). - If the indicated value is higher than the real value, loosen the screw (pos. “12”); - If the indicated value is lower than the real value, tighten the screw (pos. “12”). 7. Repeat the operations 4 to 6 until accuracy is satisfactory. 8. Tighten the plug (pos. “14”) again. The O ring which the calibration screw is provided with, has the function to avoid accidental loosening of the adjustment screw but does not have any sealing functions. Therefore it is always necessary to properly fix the plug with the sealing gasket (pos.“12”). 1.5 USE After installation and calibration the K33 is ready to work. Turn the reset knob (see diagram 1,pos. “12”) (clockwise if it is mounted on the left of the meter and anticlockwise if it is mounted on the right) until the batch register is completely reset. The totaliser cannot be reset in any way. Make sure that during use pressure does not exceed the value indicated insection “Technical data”. 1.6 USE BY GRAVITY K33 can also be used in fuel units which are not equipped with pump sand where the flow is generated by the difference in fuel level between the tank and the nozzle outlet. As a reference, a system composed of a tank off the ground, with the meter installed right at the bottom of the tank,a 3-m long 1’’ flexible pipe and a manual nozzle type Self 2000, guarantees a flow rate of approximately 30 litres/minute if the difference in level is higher than 1.5 metres. Longer pipes or nozzles producing higher pressure losses reduce the flow in respect to the existing difference in level. Use by gravity is not recommended with differences in level lower than 1 metre, as the consequent reduced flowrate causes the meter to work outside its guaranteed accuracy range. On field calibration is always advisable in case of gravity installations.
- Page 26 7. OPERATION OF THE SYSTEM WARNING: Before disassembling alwaysmake sure that all fluid is drained from the meter and pipes connected to it. Necessary cleaning can be carried out by means of a soft brush or small tool (i.e. a screwdriver). During cleaning be careful not to damage the chamber or the disk. Carefully check the meter and replace the parts which have suffered any possible damage. Only use the original spare part kits shown in diagram 1 “Exploded view and spare part list”. A new calibration is always necessary after cleaning or replacing the meter parts. 3) The meter resets the present total already. 1.7 DISASSEMBLING REASSEMBLING K33 can be easily disassembled into its main parts without removing the body from the pipes. 1.8 METER UNIT To disassemble the meter unit operate as follows: a. Remove the reset knob by firmly pulling it axially. b. Loosen the 4 retaining screws (see diagram 1, pos. “7”). c. Loosen the 2 screws (pos. “5”). To reassemble the unit reverse the procedure described above. 1.9 RESET KNOB To modify the reset knob position: a. Perform only the operations a) and b) described above. b. Take out the plug (see diagram 1,pos. “4”) by pushing it from the inside towards the outside of the cover.
- Page 27 7. OPERATION OF THE SYSTEM b. Loosen the eight screws (see diagram 1, pos. “7”). c. Remove the body cover (pos. “8”) together with the gear unit. During this operation be careful not to damage the gasket (pos. “10”). d. Remove the whole measuring chamber (pos. “11”) by lifting it from the meter body and at the same time pulling it back towards the inlet in order to remove the O ring (pos. “16”) from its seat at the outlet. To check the inside of the measuring chamber (pos. “15”), remove the O ring and divide the two half chambers containing the nutating disk. 1.11 GEAR UNIT To reach the gear unit components: a. Remove the cover. b. Loosen the screws. c. Remove the plate. Now all gears can be reached for inspection. Should the gasket be replaced, remove the bevel gear from the shaft by pulling axially, then remove the gear together with the shaft. The gasket replacement always requires the replacement of the bush provided with the spare part kit. Tor eassemble reverse the above described procedure paying particular attention to: • Lubricate the O ring before installation. • Check that the gear unit can rotate freely before fixing the cover 1.12 PROBLEMS, CAUSES AND SOLUTIONS Problem Possible cause Corrective action Leak from the - Damaged gasket Remove (see section “Gear unit”) shaft gasket and replace the O ring and the bush Insufficient - Wrong calibration Repeat calibration following the instructions accuracy in section “Measuring chamber” - Soiled or blocked measuring chamber Clean the measuring chamber following the instructions in section “Meter unit”...
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Page 28: Maintenance Of The Tuffa Tanks
8. MAINTENANCE OF THE TUFFA TANKS 8. Maintenance of the TUFFA TANKS Keep this manual stored in a place of use so it can be obtained for future reference. All persons who install, commission, maintain, and operate the system must be deemed competent by their employers and have the adequate knowledge and training required to carry out any required tasks which are recommended by this manual, it is recommended that any persons carrying out work on the system have fully read and understood the instructions set out by this manual. It is advised that no changes nor conversions with potential impact on safety may be performed on this system, any spare parts which are used must comply with the technical requirements which are defined in this manual or directly by the manufacturer. ATTENTION Please make sure prior to any maintenance work that power supply is turned OFF and that there is not an inadvertent chance to reconnect the system to power supply. WARNING System warranty will become void if any repairs are made by technicians not authorised by the manufacturer, the same applies to works with hazardous or potentially hazardous equipment. ATTENTION Do not use jet cleaners to clean the system. You can clean the system with water and household cleaners. Do not use an excessive amount of water when cleaning near any electrical items as this can cause a short circuit to occur potentially permanently damaging the equipment. -
Page 29: System Maintenance Tasks
8. MAINTENANCE OF THE TUFFA TANKS 8.1 System maintenance tasks Activity Frequency of Task Keep equipment in good working order by returning to its original position After every use Visually inspect operation of gauge equipment Weekly Visually inspect exterior condition of tank Monthly Visually inspect condition of delivery hose Monthly Physically check bund alarm by activating the float switch in bund cavity 3 Months (audible alarm) Check electrical cables and cable connection points 3 Months Visually inspect and if required maintain the tank id plate and warning labels 3 Months Check and replace filter if necessary 3-6 Months Physically check fixings and bracket stability 6 Months Visually inspect inner tank and bund cavity 6 Months 8.2 Inspection by competent person Inspections should be undertaken by a competent person that is receiving a delivery of product on every fill prior to and whilst filling. -
Page 30: Troubleshooting
8. MAINTENANCE OF THE TUFFA TANKS 8.4 Troubleshooting Symptom Possible Causes Solutions No power 1. Local distribution board fuse 1. Check local distribution board RCD 2. Power cable damaged 2. Check condition of power cables 3. Power cable connection broken 3. Check power cable connections 4. - Page 31 8. MAINTENANCE OF THE TUFFA TANKS 8.4 Troubleshooting Symptom Possible Causes Solutions Bund alarm not 1. Bund float switch not postioned correctly 1. Alter position of float switch to hang working approximately 1” off bund floor 2. Bund float not able to move freely 2.
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Page 32: Tank Maintenance Record
8. MAINTENANCE OF THE TUFFA TANKS 8.5 Tank maintenance record Date Description of works Comments Site representative / contractor details... - Page 33 8. MAINTENANCE OF THE TUFFA TANKS 8.5 Tank maintenance record Date Description of works Comments Site representative / contractor details...
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Page 34: Fuel Delivery Log
8. MAINTENANCE OF THE TUFFA TANKS 8.6 Fuel delivery log Date Description of works Comments Site representative / contractor details... - Page 35 8. MAINTENANCE OF THE TUFFA TANKS 8.6 Fuel delivery log Date Description of works Comments Site representative / contractor details...
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Page 36: Warranty
9. WARRANTY 9. Warranty Subject to the conditions below, your product is supplied with a warranty against material defects in workmanship or materials from the date of delivery or invoice Tax point date, whichever is earliest for the following warranty period: PRODUCT WARRANTY PERIOD IF WARRANTY PERIOD IF REGISTERED NOT REGISTERED Bunded fuel station tanks 10 years 5 years ACCESSORIES WARRANTY PERIOD Fuel station suction / delivery hoses 3 months All other ancillary equipment 1 year The warranty is subject to the following conditions: To qualify for the extended warranty period this product must be registered and installed by a registered competent person in accordance with prevailing statutory requirements. The period of the warranty will commence from the date of delivery or invoice Tax point date, whichever is earliest. The warranty is provided to the original purchaser only. Proof of purchase and evidence of annual inspection by a registered competent person will be required in the event of a claim. To obtain the extended warranty period for your product, you must register the purchase and installation of your product with us within 21 days from date of purchase. To register, please complete and submit our registration form. Registration forms can be obtained and submitted online at www.tuffa.co.uk. Failure to register the purchase and installation of your product (or incomplete registration) within the 21 day period will mean that the shorter warranty period (above) only will apply to your product. During the warranty period, any component of your product which is proved to contain any material defect in workmanship or materials will be exchanged or repaired, at our sole discretion, by us free of charge for material or labour. In respect of your product, the warranty does not cover (and we will not accept responsibility for) any consumable items, any component which has not been manufactured by us (please refer to the manufacturer’s warranty supplied with the relevant component), fair wear and tear, or any fault: • in respect of any component not forming part of your product; or... -
Page 37: Contact
10. CONTACT 11. GUARANTEE REGISTRATION • caused by alteration or repair by you or by a third party who is not one of our authorised repairers; or • caused by non-observance of either any applicable statutory requirement or any of the instructions contained in the installation and operating instructions appropriate to your product, and in this respect, we would draw particular attention to the fact that your product must not be used in conditions which are either below -17°C or which are above 35°C without protection from exposure to direct sunlight. Your product has been used only for the purpose for which it is designed, and that any terms and conditions held with your installer have also been adhered to. To the maximum extent permitted by UK law: • the warranty is given in lieu of all other warranties, express or implied by statute or common law, including implied warranties or conditions of satisfactory quality and fitness for a particular purpose, provided that this warranty is in addition to your legal rights in relation to goods that are faulty or not as described; and • we shall not in any circumstances be liable to you or any other party, whether in contract, tort (including for negligence and breach of statutory duty howsoever arising), misrepresentation (whether innocent or negligent), restitution or otherwise, for any special, indirect or consequential loss or damage. 10. Contact Tuffa UK Limited Tel: +44 (0) 1889 567700 Dovefields Industrial Estate Web: www.tuffa.co.uk Derby Road Email: sales@tuffa.co.uk Uttoxeter Staffordshire ST14 8SW 11. Guarantee registration To register your tank warranty please visit the link to our website as below. The guarantee card must be completed online within 21 days of the date of the tank delivery to the first purchaser (namely the person or entity buying direct from Tuffa UK Limited). https://www.tuffa.co.uk/services/support/guarantee-registration/... - Page 38 NOTES...
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