1. Manuals
  2. Brands
  3. TUFFA TANKS Manuals
  4. Industrial Equipment
  5. 30000VBFS
  6. Installation, operation and servicing manual

TUFFA TANKS 30000VBFS Installation, Operation And Servicing Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation, Operation and Servicing Manual Version 3.0.0
Models:
1350SLBFS | 2500HBFS | 3500VBFS | 6000VBFS | 10000VBFS | 15000VBFS | 30000VBFS
TUFFA
FUEL
STATIONS

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 30000VBFS and is the answer not in the manual?

Questions and answers

Related Manuals for TUFFA TANKS 30000VBFS

Summary of Contents for TUFFA TANKS 30000VBFS

  • Page 1 Installation, Operation and Servicing Manual Version 3.0.0 Models: 1350SLBFS | 2500HBFS | 3500VBFS | 6000VBFS | 10000VBFS | 15000VBFS | 30000VBFS TUFFA FUEL STATIONS...

  • Page 2: 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 / 30000 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 3: Introduction

    1. INTRODUCTION | 2. CONDITIONS OF USE 3. SAFETY 1. Introduction 3. Safety This manual contains specific instructions and information relating to the installation, PLEASE READ THIS MANUAL CAREFULLY BEFORE USE & COMPLY WITH ALL INSTRUCTIONS BELOW. operation and maintenance of Tuffa Tanks systems. 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 2.

  • Page 4: Product Description

    4. PRODUCT DESCRIPTION 4. PRODUCT DESCRIPTION 4. Product description 4.2 Product specification 1350SLBFS 2500HBFS 3500VBFS 6000VBFS 10000VBFS 15000VBFS 30000VBFS Tuffa Fuel Stations are designed solely for storage and dispensing of diesel. The static Capacity 1350 litres 2500 litres 3500 litres 6000 litres 10000 litres 15000 litres 30000 litres bunded systems enable safe diesel storage and dispensing in an outdoor environment and Length 2680 mm 2840 mm 6080 mm ensures you meet all stringent fuel storage regulations. The high standard of specification Width 870 mm 1520 mm 2890 mm ensures optimum safety and functionality. This product’s standard specification is not Diameter...

  • Page 5: Product Dimensions

    4. PRODUCT DESCRIPTION 4. PRODUCT DESCRIPTION Product dimensions 1350SLBFS 2500HBFS 2840 mm 2680 mm 870 mm 1520 mm DESIGNED BY CHECKED BY APPROVED BY DATE MATERIAL DATE DESIGNED BY CHECKED BY APPROVED BY DATE MATERIAL DATE J Shenton 11/06/2020 10/06/2020 Rob Smith J Shenton LLDPE...
  • Page 6 4. PRODUCT DESCRIPTION 4. PRODUCT DESCRIPTION 3500VBFS 6000VBFS 1200 mm 2613 mm 1200 mm 3150 mm DESIGNED BY CHECKED BY APPROVED BY DATE MATERIAL DATE DESIGNED BY CHECKED BY APPROVED BY DATE MATERIAL DATE Rob Smith J Shenton J Shenton 11/06/2020 LLDPE 10/06/2020 Rob Smith...
  • Page 7 4. PRODUCT DESCRIPTION 4. PRODUCT DESCRIPTION 10000VBFS 15000VBFS 1200 mm 3460 mm 1200 mm 3490 mm DESIGNED BY CHECKED BY APPROVED BY DATE MATERIAL DATE DESIGNED BY CHECKED BY APPROVED BY DATE MATERIAL DATE J Shenton 11/06/2020 10/06/2020 Rob Smith J Shenton LLDPE Rob Smith...

  • Page 8: Transport & Storage

    4. PRODUCT DESCRIPTION 5. TRANSPORT & STORAGE 5. Transport & storage 30000VBFS 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 1200 mm 600 mm below or forklift from the side. A ( 1 : 10 ) 300 mm...

  • Page 9: Installation & Commissioning

    6. INSTALLATION & COMMISSIONING 6. INSTALLATION & COMMISSIONING 6. Installation & commissioning 6.4 Electrical requirements 6.1 Installation guidelines Only a suitably qualified electrician according to applicable regulations may work on the electric wiring installation. The system components under service, maintenance, and repair The proprietor of the Tuffa Fuel Station is responsible for complying with all legal work must be disconnected from the power supply before any work in undertaken. requirements relating to the installation and use of this product, as well as the guidelines issued by local firefighting authorities and environmental authorities. System power requirements: 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. 230V 6.2 System installation • 220 - 240 Volts, 50 Hz +/- 10% • 20 amp circuit breaker recommended System foundation • Power cable recommendation: 3 Core 2.5mm flex cable • Duty cycle: 20 minutes The system must be installed and fully supported on a smooth levelled concrete base built in •...

  • Page 10: Operation Of The System

    6. INSTALLATION & COMMISSIONING 7. OPERATION OF THE SYSTEM Operation of the system 6.5.2 3500VBFS / 6000VBFS / 10000VBFS / 15000VBFS / 30000VBFS – Key Switch 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 (230V)

  • Page 11: Summary Of Main Parts 3500 / 6000 / 10000 / 15000 / 30000

    7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM (12V / 24V) 7.3 Summary of main parts 3500 / 6000 / 10000 / 15000 / 30000 (230V) Clock Gauge External Pump Mains Power Control Panel Watchman (if selected) Automatic Nozzle Water &...

  • Page 12: Dispensing Diesel Into Vehicle

    7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM 7.4 Filling a Tuffa Fuel Station 7.6 Equipment components 1. FMS gauge level (3500 litres models and above) 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. 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 3. On 3500 / 6000 / 10000 / 15000 models before filling the tank with diesel, please predetermined level in a storage tank is reached. The FMS gives a content readout in both check the level of the tank and make note of the tank level before filling and ensure the litres and a percentage. high-level alarm indicator functions correctly. 4. Fit tanker delivery hose to 2” BSP fill coupling on tank.
  • Page 13 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM c. Low level alarm 2. Flowmeter (fitted to all systems) 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 1.1 GENERAL INFORMATION checked and drained as soon as practicable.
  • Page 14 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM 2. Purge the system (pump, pipelines, meter) of air by dispensing until the flow stream is full Pressure loss with diesel oil Flow rate (l/min) 30 60 90 and steady. Pressure loss (bar) 0.005 0.2 0.4 3. Stop the flow by shutting off the nozzle, but let the pump running. Accuracy after calibration +/- 1% 4. Reset the batch register by means of the reset knob (pos. “2”). Repeatability (typical) +/- 0.3% 5. Dispense at the flow rate which the best accuracy is required at, by using a calibration Batch total readout 3 digits height 18mm container having a capacity not lower than 20 litres. Do not reduce the flow in order to reach Totaliser readout 6 digits height 6mm the graduated zone of the calibration container. The right method is to start and stop the full Readout resolution 0.1 litri flow repeatedly until the required filling is obtained. Connections (inlet/outlet) 1” BSP 6. Compare the indication of the calibration container (real value) with the one of the meter Weight (approximate) 1.8 Kg (indicated value).
  • Page 15 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM WARNING: b. Loosen the eight screws (see diagram 1, pos. “7”). Before disassembling alwaysmake sure that all fluid is drained from the meter and pipes connected to it. c. Remove the body cover (pos. “8”) together with the gear unit. During this operation be careful not to damage the gasket (pos. “10”). Necessary cleaning can be carried out by means of a soft brush or small tool (i.e. a screwdriver). d. Remove the whole measuring chamber (pos. “11”) by lifting it from the meter body and at the During cleaning be careful not to damage the chamber or the disk. Carefully check the meter and same time pulling it back towards the inlet in order to remove the O ring (pos. “16”) from its seat replace the parts which have suffered any possible damage. Only use the original spare part kits at the outlet. To check the inside of the measuring chamber (pos. “15”), remove the O ring and shown in diagram 1 “Exploded view and spare part list”. A new calibration is always necessary divide the two half chambers containing the nutating disk. after cleaning or replacing the meter parts. 3) The meter resets the present total already. 1.11 GEAR UNIT 1.7 DISASSEMBLING REASSEMBLING To reach the gear unit components:...
  • Page 16 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM 3. MC Box Fuel Management Operation Specifications Panel with dual display, keyboard and i-button reader. MC BOX Electronic Panels are designed for the private distribution of fuel (or other liquids). The electric box can be opened, allowing easy access to the wiring. Maximum power supply: 6.5 amps. All of the models in the series are characterised by the same form for which the MC BOX is known: a solid metal structure, high-accuracy measurements in the dispensed product and PC Optional software that is designed for simplicity. • PC Software with dedicated RS converter or i-button reader to export data. • I-button keys for users. This electronic panel allows you to control and monitor private use fuel consumption via a fuel • High-accuracy oval gear flow meters. dispenser with pump and flow meter. Performance The MC system consists of a multi-user panel, dedicated software and the option to connect to a • 80 or 120-user capacity (depending on model), managed via password or i-button key. • Total consumption calculation for defined periods for each user. • Local memory that can store data until the last 255 dispenses. • Vehicle identification and mileage tracking option. • Dispensing date and time control. • Dedicated software that allows you to print dispense data for each user. • Ability to manage up to 16 control panels with one single software. • Key reader with USB plug for exporting data. • RS converter with USB plug for direct connection to the PC via cable (up to 1000 m) MC Box Installation General...
  • Page 17 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM The MC BOX is equipped with 3 junction boxes. These can easily be accessed by opening the DC Versions: door to where the screw terminals for the external cable connections are located. Inputs Outputs Note DC Power Supply DC motor power is the Voltage: 12Vdc or WARNING same as the supply 24Vac, depending on the Before accessing the electrical parts, be sure that you have disconnected all of the general voltage maximum power of the switches that power off the device. pluggable motors: • 12Vdc version = 600 W The connections that need to be made vary according to the model (AC or DC): • 24Vdc version = 600 W AC Versions: Power input WITH IGNITION ON. By removing a jumper and Given the DC systems’ high power inserting the “in ignition” Inputs Outputs Note absorption, the motor should be...
  • Page 18 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM...
  • Page 19 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM Commissioning To correctly commission the MC BOX the sequence of operations indicated below must be followed and the MC control system functions must be known. Electrical power supply Once the power connections have been made, the MC BOX can be energised by means of the master switch to be fitted by the installer on the upstream line. Switching on of the MC system will be indicated by the lighting up of the two backlit LCDs fitted on the front. NOTE: In the event of continuous current power supply (DC), a fuse size that is appropriate to the DC motor’s absorption level should be introduced to the motor power line. For example: • If the connected motor is one that absorbs 10A max then a 12A delay fuse should be inserted. • If, however, the motor absorbs 50A max, then a 60A delay fuse should be inserted. • If the fuse is small, it can be fitted along the cable inside the junction box, in position (1) (see illustration) • If, however, the fuse is very big (e.g. 60A) and cannot physically fit inside the box, then it can be inserted along the motor’s power supply cable in position (2) (see illustration) Station configuration Every MC BOX station can be adapted to the specific requirements of the station manager. To do this the MC control system must be CONFIGURED. WARNING MC configuration is crucial and must be done by skilled personnel. To perform this operation, the MC manual must be carefully and thoroughly read. After completing configuration, user PIN CODES can be assigned to the persons charged with using MC BOX, in accordance with the detailed information in the MC manual.
  • Page 20 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM Disengaging the “MC” system Meter calibration All the MC BOX functions are controlled by the MC control system. Before using the MC BOX station, check the METER ACCURACY. For this purpose, proceed as follows: The MC system can nevertheless be disengaged for any startup or maintenance activities • Enter a previously enabled USER PIN code; requiring repeated pump starting. • Run the fuel into a calibrated container; • Compare the quantity of dispensed diesel fuel using a calibrated container. In these case, it is often convenient to simplify pump startup by not having to enter any code and record any dispensing data. If accuracy is NOT satisfactory, proceed to CALIBRATE THE METER according to the instructions in the specific manual. To do this, a JUMPER has been fitted on the card that permits switching from AUTOMATIC mode WARNING (code request to access dispensing) to MANUAL mode (no code request). To correctly check accuracy, always keep to the following instructions: WARNING •...
  • Page 21 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM 4. Watchman Sonic The configuration of the MC system permits requiring the User to enter further optional data (vehicle licence plate, mileage, quantity to be dispensed). 1. CHECK LEVEL, DISTANCE AND HEIGHT For details, see the MC control system manual. Ensure before you start your install that the tank the WatchmanSonic is to be fitted to is: In the event that these options are not set, MC will recognise an activated PIN CODE and, once the nozzle contact (if applicable) has been closed, the pump is enabled, allowing it to dispense. 1. On a flat level base. 2. Within a 200 metre range from receiver position. The pump will start (if previously enabled) just as soon as the control lever is moved to ON 3. A maximum actual tank height of 3 metres. 50 metre effective range (200 metre clear line of position, while it switches off as soon as the control lever is moved to OFF position. sight). 4. Tank must be fitted in accordance with manufacturers guidelines & instructions. WARNING Such enabling does not result in immediate pump startup. The pump is in fact NB: Any radio frequency signal may be seriously inhibited if positioned underground. Please check controlled by a switch (positioned in the nozzle seat) operated by the user.
  • Page 22 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM The Transmitter can’t sit at an angle as this gives an 4. DEFINE THE SONIC HEIGHT incorrect level reading on the receiver. Take care not to choose an area on which water could gather i.e. a dent/ Accurately measure the sonic height making depression or a position directly above any restricted area note of this measurement. The permissible inside the tank. (See Picture 4) maximum tank height is 3 metres from the base of your tank to the position of the WatchmanSonic (which should be no lower than the fill point). (Seen in Picture 10). • Height does not include the base/piers NB: For tanks with window corrugations or internal braces which tank sits on. please ensure that the WatchmanSonic is not positioned above or within 15 cm of the area of the WINDOW or the edge of the tank. (See Picture 5). Ensure that the sonic path 5. SETTING THE SWITCHES ON THE RECEIVER is clear to the bottom of the tank as per pic 2. Using the tank height chart (see section 9), read across to the relevant multi switch setting using tank measurements you took down earlier. The...
  • Page 23 7. OPERATION OF THE SYSTEM 7. OPERATION OF THE SYSTEM Hold the transmitter against the receiver right hand side, as shown (Picture 13), so that the white 9. WATCHMANSONIC RECEIVER MULTI SWITCH SETTING CHART dot on the transmitter is touching the black dot on the receiver (important!) for about 20 seconds to allow unique code to be transferred. Bars will increase up the display screen and you will hear a clicking sound. When all 10 bars are shown they will flash to indicate that the unique code is transferred. When matched the transmitter must immediately be placed on the tank. • If you are installing more than one WatchmanSonic unit please wait 15 minutes between each matching. 7.

  • Page 24: Maintenance Of The Tuffa Tanks

    8. MAINTENANCE OF THE TUFFA TANKS 8. MAINTENANCE OF THE TUFFA TANKS 8. Maintenance of the TUFFA TANKS 8.1 System maintenance tasks Activity Frequency of Keep this manual stored in a place of use so it can be obtained for future reference. All Task persons who install, commission, maintain, and operate the system must be deemed Keep equipment in good working order by returning to its original position After every use competent by their employers and have the adequate knowledge and training required to Visually inspect operation of gauge equipment Weekly 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 Visually inspect exterior condition of tank Monthly set out by this manual. Visually inspect condition of delivery hose Monthly Physically check bund alarm by activating the float switch in bund cavity...

  • Page 25: Troubleshooting

    8. MAINTENANCE OF THE TUFFA TANKS 8. MAINTENANCE OF THE TUFFA TANKS 8.4 Troubleshooting 8.4 Troubleshooting Symptom Possible Causes Solutions Symptom Possible Causes Solutions No power 1. Local distribution board fuse 1. Check local distribution board RCD Bund alarm not 1. Bund float switch not postioned 1. Alter position of float switch to hang 2. Power cable damaged 2. Check condition of power cables working correctly approximately 1” off bund floor 3. Power cable connection broken 3. Check power cable connections 2. Bund float not able to move freely 2. Check float switch for blockage or replace if necessary 4. System control panel circuit breakers 4. Open system control panel and check circuit breakers 3. Damage to bund cable...
  • Page 26 8. MAINTENANCE OF THE TUFFA TANKS 8. MAINTENANCE OF THE TUFFA TANKS 8.4 Troubleshooting 8.4 Troubleshooting Symptom Possible Causes Solutions Symptom Possible Causes Solutions The MC BOX does not 1. Power supply has failed due to: 1. • Check connections DOES NOT COUNT when 1. The Pulser that emits the count 1. Check connections switch on • The power leads being connected • Ensure disconnect switch is in dispensing signals has not been connected properly incorrectly the ON position 2. The Pulser that emits the count 2. An incoming electronic signal, • The upstream circuit switch being in the • Check fuse signals is NOT compatible with the namely “clean contact” or...
  • Page 27 8. MAINTENANCE OF THE TUFFA TANKS 8. MAINTENANCE OF THE TUFFA TANKS 8.4 Troubleshooting 8.4 Troubleshooting Watchman Sonic - Technical Information TRANSMISSION If the receiver detects a transmission not heard for a long time the symbol NOT HEARD outlined in Pic 16 is displayed on the LCD. This starts approximately 12 hours The WatchmanSonic is suitable for use in tanks for the storage of diesel, water, fuel, kerosene, and from the last received good signal. (Shown in picture 16). To rectify this re-site gas oil types A2, C1, C2 and D as defined by BS 2869. Check with the manufacturer and/or supplier the receiver in a location where the transmission is heard. Rematch receiver before using with any other fluids. and transmitter as per point 6. In the event of a power failure or if the receiver is switched off or moved to a new socket: When power NO ECHO If the receiver detects a No Echo Condition the following message is displayed returns again or unit is switched on, the receiver display screen will show the top bar flashing. There is CONDITION on the LCD. Warning triangle constantly flashing plus indication bar 5 on. no need to repeat the matching instruction. The top bar will continue to flash for 2 minutes, after which (Shown in picture 17). To rectify this situation check that the transmitter unit is time the last valid signal is displayed. It may take up to two hours for the next transmission from the correctly positioned on the tank and no interference is present from a tank wall, transmitter. corrugation or window.

  • Page 28: Tank Maintenance Record

    8. MAINTENANCE OF THE TUFFA TANKS 8. MAINTENANCE OF THE TUFFA TANKS 8.5 Tank maintenance record 8.5 Tank maintenance record Date Description of works Comments Site representative / Date Description of works Comments Site representative / contractor details contractor details...

  • Page 29: Fuel Delivery Log

    8. MAINTENANCE OF THE TUFFA TANKS 8. MAINTENANCE OF THE TUFFA TANKS 8.6 Fuel delivery log 8.6 Fuel delivery log Date Description of works Comments Site representative / Date Description of works Comments Site representative / contractor details contractor details...

  • Page 30: Warranty

    9. WARRANTY 10. CONTACT 11. GUARANTEE REGISTRATION 9. Warranty • 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 Subject to the conditions below, your product is supplied with a warranty against material instructions contained in the installation and operating instructions appropriate to your defects in workmanship or materials from the date of delivery or invoice Tax point date, product, and in this respect, we would draw particular attention to the fact that your product whichever is earliest for the following warranty period: 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. PRODUCT WARRANTY PERIOD IF WARRANTY PERIOD IF REGISTERED NOT REGISTERED Your product has been used only for the purpose for which it is designed, and that any terms Bunded fuel station tanks 10 years 5 years and conditions held with your installer have also been adhered to. To the maximum extent permitted by UK law: ACCESSORIES WARRANTY PERIOD Fuel station suction / delivery hoses 3 months • the warranty is given in lieu of all other warranties, express or implied by statute or common All other ancillary equipment 1 year 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 The warranty is subject to the following conditions: 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 To qualify for the extended warranty period this product must be registered and installed by a...

This manual is also suitable for:

2500hbfs3500vbfs6000vbfs10000vbfs15000vbfs1350slbfs

Table of Contents