Installation and user manual for fuel dispensers Series UNI 60
Contents
1. K S ELEKTRONIK GmbH Page 31 eS V Installation And User Manual For Fuel Dispensers Series UNI 60 In addition to the grounding connection the following lines must be lay ed in the base below the fuel dispenser e Power supply of the calculator and switching circuits three wire cable NYYO I 3 x 2 5 e Data line shielded eight wire cable AYSTOE 8 x 0 75 e Additional data line for e g level monitoring 6 3 Wiring of the fuel dispenser IN A Page 32 Important The electr wiring of the K S fuel dispensers requires protection against electric shocks All fuel dispensers in the filling station must be interconnected to the grounding network via the grounding electrode The yellow and green conductor section of min 4 mm or a special cable can be used as grounding electrode The grounding electrode must be connected to the grounding terminal of the fuel dispenser placed on the foundation screw M 8 MARKED correspondingly All electr lines must resist to fuel vapours and have good insulating pro perties because they are subject to aggresive explosion hazardous en vironments for a long period All cable ends entering the fuel dispenser must be long enough to facili tate installation cable end in the pump head The cable ends must have a min length of 2 0 m above foundation K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 6 4 Supply of the pumps2. e Use of a mobile in the vicinity of the dispenser e Dispensing while the engine is running 7 2 Putting the fuel dispenser into operation ii Important Switching the fuel dispenser on and off is carried out in the master switch cabinet of the filling station where the fuel dispensers are connected Each fuel dispenser has three power supply outlets with protection switches in the master switch cabinet e Supply of the electr pumps e Supply of the electronic fuel dispenser calculator 230 VAC stabilized K S ELEKTRONIK GmbH Page 35 eS Installation And User Manual For Fuel Dispensers Series UNI 60 Recommendation Switch the fuel dispenser on as follows Page 36 Switch on the 230 V protection switch for stabilized supply of the elec tronic fuel dispenser calculator all display segments are tested automa tically and the values of the last fuelling operation are displayed K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 7 3 Operation of the fuel dispenser V Attention The owner of the filling station is liable for its operation He must supervize fuelling operations and instruct the customer regar ding correct use of the fuel dispenser in case of improper use The ow ner must mark the dangerous zone of the filling station by means of ap propriate symbols smoking prohibited no open fire driving direction etc The operating manual of the filling station
3. teed The ball valve must be installed at the lowest point in the line These valves must be closed by the fuelling station operator if the fuel dispenser is out of operation If these valves are not installed fuel leaks may be caused AL Te ee C uu Table legend for illustration underground tank and above ground tank Pos Description Pe Bep Fuel dispenser Not required 2 El power supply cable and T Inlet funnel without check data line valve Not required 8 Fuel tank Not required Not required K S ELEKTRONIK GmbH Page 29 eS Installation And User Manual For Fuel Dispensers Series UNI 60 5 5 Fuel cable wiring Cable wiring V Page 30 The company K S recommends laying the cables according to the standard i e a separate line leading into the fuel tank It is possible to connect several fuel dispensers pumps to the main line i e several fuel dispensers pumps can be connected to one sin gle supply line The company K S manufacturer of fuel dispensers does not recom mend this type of connection due to possible fluctuations when suc tioning fuel from the tank K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 6 Electr power supply 6 1 Overvoltage protection N Important An overvoltage caused by lightnings at a distance of several kilometers or by industrial activities can occur in all lines The pulses generated by lig
4. 34 Important To ensure correct operation of the fuel dispenser die signal lines of the fuel dispensers must be separated correctly from the power supply li nes Parallel connection of the power supply lines and signal lines wi thout separation results in disturbances and undesirable parasite phe nomena which may cause problems of the fuel dispenser control and or complete destruction of the electronics in the fuel dispenser and in the kiosk Therefore any crossing or parallel laying in a single bundle of the signal and power cables has to be avoided in any case Separate cable channels e g metal tubes for power and signal cables represent a suitable solution The manufacturer is not liable for damage caused by unsuitable laying and wiring of cables lines K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 7 Fuel dispenser operation 7 1 Instructions for safe fuel dispenser operation Important The fuel dispenser is a complex system which must fulfill a number of demanding functions Prior to putting the fuel dispenser into operation it is necessary to clean the tanks and lines and to check whether the fuel is pure For putting the fuel dispenser into operation the electr power supply and the correct wiring must be checked to prevent electric shock and to provide fire safety Prohibited e Smoking in the vicinity of the dispenser e Open fire in the filling station area
5. MPa 1 8 bar 0 25 MPa 2 5 bar for 50 70 and 90 liters Electric motor Single phase 230 V 370 W 1 5 A 2800 rpm Single phase 230 V 550 W 4 0 A 1400 rpm Single phase 230 V 1050 W 5 0 A 1400 rpm Liter counter Power supply 230 V 10 15 50 Hz x 5 Hz Power consumption max 50 VA Operating temperature 25 to 55 C LCD display with LED background illumination Display for quantity Character height quantity 2 54 mm 1 Separate description Liter counter VC1 Fuel terminal TDE 50 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 S 3 3 Functional description Housing casings Bearing parts Color Hydraulic unit Encoder Display Liter dispenser Fuel terminal Hoses nozzle The outer housing parts such as doors covers etc of the K S fuel dispensers of the UNI 60 series are made of zinc and powder coated steel which is permitted for fuel dispensing applications The bearing fuel dispenser parts are also made of powder coated hot galvanized steel with a thickness of 1 5 mm Standard colors of the K S fuel dispensers Combination of white aluminium RAL9006 blue RAL5005 and black RAL 9005 Each fuel dispenser is equipped with an hydraulic unit monoblock flow meter The pump used is a vane pump The flow meter is equipped with a reliably operating singlel channel encoder The display of the fuel dispenser with liter
6. The warning instructions on the information sheet included e The total weight and the dimensions of the dispenser e The vertical position of the dispenser A horizontal position may dama ge the outer casing e Sufficient fastening on the vehicle Fasten the dispenser so that it can not move or tilt over Important During transportation make sure that the environmental conditions e g storage temperature are complied with e f despite the proper packing a damage occurs the company K S must be contacted immediately K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 HS 4 2 Storage Important When storing the dispenser for an interim period K S recommends to store the dispenser in locations protected against fire and weather influences in order to protect the transport and packing material 4 3 Unpacking Important The transport and packing material can be used several times for rea sons of environmental protection Therefore it should be handled care fully and returned to K S K S ELEKTRONIK GmbH Page 19 c 5 Installation Installation And User Manual For Fuel Dispensers Series UNI 60 5 1 Safety instructions Important H During installation special attention must be paid to the safety symbols and their meaning described in chapter 2 3 Furthermore the following must be complied with Personnel o Smoking open fire Fuel diesel Leaks e Electr
7. connection Lightning protection e Fire extinguisher e Protective aids e Page 20 The regulation regarding inflammable liquids VbF The technical rules regarding inflammable liquids TRbF The Water Resources Act WHG EU and VDE directives The fuel dispensers may only be installed by staff qualified and autho rizued fuelling installation and fuelling station constructors pursuant to relevant standards regulations local regulations and the instructions in this manual omoking and open fire are prohibited in the complete vicinity of the dispenser Adhere to the handling instructions for fuel and diesel Check the fuel dispenser for leaks Should you establish fuel leaks di sconnect the power supply line and contact the technical service The electr connections must be carried out by qualified personnel A sufficient protection for the prevention of static charges and lightning strokes must correspond to the regulation TRbF Make sure that an operative fire extinguisher is available When handling the device use suitable protective aids K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 HS 5 2 Installation of the fuel dispenser First check the place of installation of the dispenser Place of installation e The so called range of action of the nozzle hose length plus one me ter must comply with the requirements given under Important e Installation below g
8. counter shows the quantity of dispensed fuel in liters The display of the fuel dispenser with fuel terminal shows the quanti ty dispensed and user information The hoses are made of high quality oil resistant rubber shunt resistance 100 M Ohm and are fitted standard equipment with an automatic nozzle K S ELEKTRONIK GmbH Page 13 FE Installation And User Manual For Fuel Dispensers Series UNI 60 Important A complete fuel dispenser always comprises a liter counter or a fuel terminal 3 4 Description of components Number of e The nozzle is the part of the fuel dispenser which allows the customer pump points to take the desired fuel The K S fuel dispensers of the Uni 60 series have one pump point Fuel dispenser e The fuel dispensers can be used as a single pump depending on the orientation orientation Number of productse With the series Uni 60 it is only possible to dispense 1 type of fuel Pump capacity e This is the max fuel quantity which can be dispensed via the nozzle It is indicated in liters per minute Display types e A display version for company fuelling stations liter display is availa ble The liter display shows only the dispensed quantity in centiliter and is used for fuel dispensers for e g company fuelling stations Page 14 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60 es 3 5 Designation of components ction meet A K S ELEKTR
9. of conformity EG Konformitatserklarung n EC Declaration of Conformity EC Declaration de Conformit Wir K S Elektronik GmbH We Nous Anschrift Heinrich Hertz StraBe 9 Address D 78052 VS Villingen erklaren dass das Produkt mit der Bezeichnung Typ Modell declare that the product with name type model d clarons que le produit nom type mod le Kraftstoffzapfsaule Serie Uni 60 mit den Anforderungen der Normen und Richtlinien fulfils the requirernents of the standards and regulations of the Directive satisfait aux exigences des normes et directives Maschinen Richtlinie 98 37 EG 1998 EN 292 1 2 Sicherheit von Maschinen EN 60204 1 Elektrische Ausr stung von Maschinen Niederspannungs Richtlinie 73 23 EWG EMV Richtlinie 89 336 EWG EN 55011 1998 A1 1999 A2 2002 Limit Class B EN 61000 3 2 2006 04 EN 61000 3 3 1995 01 A1 2001 06 A2 2005 11 EN 61000 4 2 2001 EN 61000 4 3 2001 EN 61000 4 4 2001 EN 61000 4 6 2001 EN 61000 4 11 2001 und den Prufberichten ubereinstimmt und damit den Bestimmungen entspricht and the test reports and therefore corresponds to the regulations of the Directive et les rapports d essais et ainsi correspond aux reglements de la Directive Ort und Datum der Ausstellung VS Villingen den 08 Februar 2009 Place and date of issue Lieu et date d etablissement Name und Unterschrift des Befugten Leitung Entwicklung Name and signature of the auth
10. 33 34 34 35 35 35 36 37 of 38 38 38 39 40 40 41 42 42 43 43 45 46 46 47 48 Installation And User Manual For Fuel Dispensers Series UNI 60 12 Troubleshooting 12 1 Safety instructions 12 2 Malfunctions 12 2 1 Pump does not dispense fuel 12 2 2 Reduced or no fuel dispensing 12 3 After troubleshooting 13 Test certificates and other certificates 13 1 EC declaration of conformity 13 2 QMS certificate K S ELEKTRONIK GmbH 49 50 50 51 52 53 53 54 Page 3 Kes 2 Introduction 2 1 For the user About this manual Intended use Page 4 Installation And User Manual For Fuel Dispensers Series UNI 60 This installation and user manual serves for providing the user with the necessary information and instructions facilitating complete and effecti ve installation parameter setting operation and maintenance of the fuel dispenser series Uni 60 Therefore read the corresponding chapters prior to proceeding with the installation or operation of the fuel dispen ser Observe all danger warnings and general instructions set out in this ma nual This manual has been carefully worked out by the manufacturer and is an integral part of any fuel dispenser delivery according to the CE direc tive The manual is arranged in individual topic related chapters and sections and has a logical structure learn prepare use maintain The manual and any attached documents must be kept in a saf
11. Installation And User Manual For Fuel Dispensers Series UNI 60 as Installation and user manual for fuel dispensers Series UNI 60 Responsable for the contents K S ELEKTRONIK GmbH Heinrich Hertz Stra e 9 D 78052 VS Villingen Phone 49 0 77 21 99 8460 Fax 49 0 77 21 99 846 66 kronenbitter k s elektronik de www k s elektronik de This documentation is protected by copyright Neither the manual in full nor any part of it may be extended reproduced nor modified without the explicit written approval of K S ELEKTRONIK GmbH Development Version 14 12 2007 Copyright K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 1 Contents 2 Introduction 2 1 2 2 2 3 2 4 2 5 2 6 2 1 2 8 For the user Safety instructions Safety symbols Additional important symbols at the fuelling station site Basic safety instructions Obligations of the operator Compliance with instructions and regulations Warranty 3 General product information 3 1 3 2 3 3 3 4 3 5 3 6 3 7 Overview Technical data Functional description Description of components Designation of components Rating plates fuel dispenser Explanations regarding the fuel dispenser rating plate 4 Transport storage and unpacking 4 1 4 2 4 3 Transport Storage Unpacking 5 Installation 9 1 5 2 Ss SN De 5 4 5 4 1 5 4 2 5 4 3 5 4 4 5 4 5 DO Safety instructions Installation of the fue
12. L ww PRECARIATO p SEL SESTO a GUAI AU ATL ARAM TENTH ATA DEDE CART AACA NATE LATER ATEO Dorm a ca re N MOS EU MONDE M i zi S A 2 Mia tell li Dre RINT ja Paus Tr iu SOC a MUTO Se dyno gigia ea Pn PRE DR EUN e EU Et OX eie Era i ag S S a d i OC RR OR E OR RO OR D A NI d Hd m ate nena TY ma ta gg RS ALL eT Ze mn MI en A EL HEH EU EL EE HL OL EL HE HOS UE HL DH AH HE UR UL HL O AL DL A OL cb HEH m SLE waters z Lille pL NEL NE LR a mm Ill drawing assignment of explosion protected zones according to EN 13617 1 c O Q o o o e O Q o o o e lt r LO O C O N o o x O uc O D O C O O fs nf I 2 V T O C D C O N i o zoez Vertical division type 1 detail Explosion protected cable connection EEx e II IP67 Zone 0 Page 47 K S ELEKTRONIK GmbH aes Installation And User Manual For Fuel Dispensers Series UNI 60 11 1 Wiring diagram Terminal designation Liter counter Izialaisioirio ow ET y Pump head Data line Page 48 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 12 Troubleshooting 12 1 Safety instructions Before starting the elimination of any failures of a defective fuel dispenser the following safe ty instructions must be complied with Warning Any inter
13. LEHF CLLANTIT T 1 FFOHTSCHEEE 295 Nzi m 3000 1 2 RESET TASTE fi 302000000 1 3 SCHWARZE E 140061000005 1 SCHEALBE M4X 10 Bon 419100 b 5 MATAREL 3 STELUG fi 20200000 1 FE GELGE THERE 61 407 000000 1 i SCHFALBE ME X 12 BC BT 4100 g 8 ECKEL 155005000000 1 a ANG 2515 11010040200 1 10 SCHFAUBE 9 5 X 35 Ben E1E 100 d 11 HULSE 34x 912 i 634000000 1 12 DHHRATEPRER 245 61304000000 1 13 ZAHKRAD 2 5 61406000000 1 14 KALIBFIERDECKELT 8 Et DOO BOOOO DO 1 16 Sf UNCER THERE 99 ME MALE CET 1 16 DABECKSELAMMEA Et Bot DODODD 1 17 BOLZEH MIT HEBEL 60616000000 1 18 ARE 108 11010100200 1 18 FEDER EE es 4 A ANG B 20x 1 11020500000 1 zi OBEREMESSEAMMEE i 2x DODOOD 1 22 CAEHSCHEBE 140200000008 1 UNTEFE MEIC NER i 302000000 1 2 RING 4400 11010480500 1 zh ALUHR FPER DO 000000 1 zh ARE 201 B 11010050200 1 2 KALIBFIERSCHEAUBE 1 8 ft DOO BOO X 1 zB BOLEH 8 2X 17 5 60619000000 1 24 HFFEL 1 M X IM 23006 2200000 1 A ROHRYEFRENG KE 17M X FO 250172000200 1 K S ELEKTRONIK GmbH Page 45 les Installation And User Manual For Fuel Dispensers Series UNI 60 10 Fuel dispenser dimensions 10 1 Single pump 13 4 Page 46 K S ELEKTRONIK GmbH Kes Installation And User Manual For Fuel Dispensers Series UNI 60 11 Hazardous areas DR Me Ac CX Es B ah I gt gt rer ah NUR NO Mar ze hie E Ur in A wh i Lu m Ss L4 LE Ps S na a
14. ONIK GmbH Page 15 HS Installation And User Manual For Fuel Dispensers Series UNI 60 3 6 Fuel dispenser rating plate Hersteller Umgebungs Temp 25 C 55 C Medium Temp lt 20 C K S Elektronik GmbH Genauigkeitsklasse 0 5 Medium Mineralol Heinrich Hertz Str 9 5 D 78052 VS Villingen Mechanische nasse M1 Elektromechanische Klasse E1 Type Uni 60 Serial No Year XXXX XX W amp M Approval No Q max Q min P max V min L min L min bar L C 5004310 Page 16 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series N HS 3 Explanations regarding the fuel dispenser rating plate Important The rating plate provides information about the manufacturer serial numbers and dispensing quantity of the fuel dispensers K S Elektronik GmbH Name and address of the manufacturer Heinrich Hertz Str 9 D 78052 VS Villingen IM 07 0103 Fuel dispenser for diesel of use of the dispenser biodiesel and fuel oil TYPE UNI 60 Designation of the fuel dispenser type Qmax 50 70 90 l min Versions of hydraulic parameters Ex II 2G HA T3 Marking of explosion protected el equipment e Min pump capacity Il 2 equipment for rooms subject to explosion ha zard other than mines probability of creation of ex plosive atmosphere danger zone 1 e G risk of explosion caused by gases or vapour e IIA gas group lowest group of risk e T3 max temperature of th
15. V 6 5 Data lines V Important The supply of the electr pump motors of all fuel dispenser models is re alized via a five wire cable NYYO I 3 x 2 5 In the switch cabinet the ca ble is connected to fuses and switches The individual pump motors are controlled via switches in the fuel dispenser The data line serves for remote fuel dispenser control in the so called automatic mode i e the fuel dispenser is controlled remotely by the console or the computer The line is not required if the dispenser is operated in the manual mode only For the data line at least a shielded eight wire data line with a min sec tion of 0 75 mm must be used The cable sheath must be made of fla me resistant and fuel vapour resistant material The shielded eight wire cable AYSTOE 8 x 0 75 can be used as data line The cable is led from the operator s workplace in the kiosk into the fuel dispenser K S ELEKTRONIK GmbH Page 33 eS 6 6 Service lines V Installation And User Manual For Fuel Dispensers Series UNI 60 Service lines serve for special purposes These lines are not required for the operation of the fuel dispenser They are used in order to remo tely control certain fuel dispenser functions or to send certain signals from the fuel dispenser In order to decide whether a service line is re quired you must always contact the personnel of the company K S Elektronik GmbH 6 7 Trouble free cable installation AN Page
16. and or information about the general obligations must be accessible to the customer 7 4 Fuel dispensing ii Data storage V Note The fuel dispenser is activated by removing the nozzle from the nozzle boot The integrated contact releases the liter counter price calculator which is automatically reset to zero The pump motor starts and the fuelling operation begins The fuel flows by pressing the nozzle and stops by releasing the nozzle The user must place the nozzle back into the nozzle boot Thus the valve contact interrupts the power supply of the pump motor The dispensed quantity remains displayed on the liter counter until the nozzle is operated again With the autofuel terminal the quantity and the unit price are saved for a period of 90 days for fiscal reasons In the case of self service filling stations nozzles with locking are used The flow is controlled via the locking lever In the basic version the nozzle is supplied with lever locking To activate the lever locking it must be pressed during the fuelling operation When releasing the lever or the nozzle drops out of the filler neck the flow is stopped The stop function is activated as soon as the tank is full overlow sensor The fuelling opera tion is stopped even if the locking lever is still pressed The safety function is also activated in case of improper use of the nozzle e g if the nozzle deviates by more than 15 degrees from the horizontal plane the
17. charge and thus to destruction of the components or circuit boards e Therefore this energy must be reduced by touching the protective earth metallic housing parts before proceeding with any work in the interior of the pump head The fuel dispensers are designed for use in business and industrial areas and fulfill the requirements of the e EMC directive 89 336 EEC e Low voltage directive 73 23 EEC e Machinery directive 98 37 EC e En DIN 13617 1 2004 To ensure compliance with the above mentioned directives during fuel dispenser installation you must observe the installation instructions described in this manual and make sure that the metallic housing parts of the fuel dispenser and the earthing conductor are connected to the same potential and no compensation current may flow K S ELEKTRONIK GmbH Page 9 c 2 8 Warranty i Exclusion of warranty Personnel Original spare parts Delivery Page 10 Installation And User Manual For Fuel Dispensers Series UNI 60 Important The company K S grants a warranty for the fuel dispenser within the scope of the General Terms and Conditions AGB Warranty claims are void if one of the following points is not observed and complied with e Any work as well as any interventions on the fuel dispenser require special knowledge and may only be carried out by authorized companies The company K S is not liable for any damage resulting from incorrect maintenance o
18. e el equipment which might cause ignition of the ambient atmospheree 200 C K S ELEKTRONIK GmbH Page 17 c Installation And User Manual For Fuel Dispensers Series UNI 60 4 Transport storage and unpackin 4 1 Transport Safety instructions N Dispatch method transport Storage case of damage N Page 18 The fuel dispenser and its individual components have been tested in the manufacturer s premises using a medium e g spindle oil which is not classified as a hazardous material Therefore the fuel dispenser is not subject to the strict regulations for hazardous materials transportation when being delivered The customer shall agree the method of dispatch with the manufacturer If the company K S is responsible for dispatch the product will be delivered to the corresponding place of destination place of installation The manufacturer has adequate knowledge of proper packing loading and transportation Therefore the fuel dispenser is bolted to a special transport pallet and protected against external influences by its eco friendly packing Should the customer desire another method of dispatch the manufacturer shall provide professional loading but is not liable for the method of transportation Warning When transporting the dispenser only lift trucks may be used K S is not liable for possible damage if other handling devices are used Observe the following for transportation e
19. e place within reach during the whole service life of the fuel dispenser Thus it also constitutes an information source for operation settings and error elimination with regard to the fuel dispenser This manual reflects the technical state of the art at the date of fuel di spenser sale or delivery This manual is subject to modifications and updates resulting from furt her developments The fuel dispensers of the series UNI 60 are designed to meet only the requirements of an end user and for a maximum fueling capacity of 10 000 liters per month These fuel dispensers are only intended for the dispensing of the following liquids other than water e Diesel biodiesel and fuel oil K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 HS 2 2 Safety instructions General i The user is liable for the observance of the contents of this manual Any use contrary to the designated use described in this manual is not per mitted The user is solely responsible for any damage resulting from such use The safety instructions are not only intended for assuring the own safety but also for the protection of persons not involved against damage to property and body Safe operation of the fuel dispenser is hereby garan teed The safety instructions must be attached in the required size accor ding to the regulations for hazardous substances GefStoffV The symbol shown left hand side is used in this
20. el monitoring K S ELEKTRONIK GmbH Page 25 K S Installation And User Manual For Fuel Dispensers Series UNI 60 5 4 2 Connection of the hydraulic unit Connection e The corrugated pipe is connected to the suction line hydr unit to e Observe the correct position of the gasket seals suction line e All recesses and outlets at the foundation frame must be sealed Page 26 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 5 4 3 Electr installation wiring eS p Pump head 230 V Motor K S ELEKTRONIK GmbH Page 2 K S Installation And User Manual For Fuel Dispensers Series UNI 60 5 4 4 Underground tank Connection to an When connecting the fuel dispenser to an underground tank the underground tank check valve must be installed in the suction line It is intended to prevent an interruption when refuelling and the air inlet when starting the refuelling operation The separate check valve must not be instal led if a check valve is already installed in the inlet funnel Fuel dispenser installation underground tank Page 28 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 las 5 4 5 Above ground tank Connection above When connecting the fuel dispenser to an above ground tank the ground tank ball valve must be installed in the suction line for safety reasons Thus a negative pressure of approx 0 03 Mpa of the pump is guaran
21. er to prevent electric shocks and to ensure explosion protection fuels are combu stibles of class I Even in case of minor leakage in the fuel dispenser measures must be taken to minimize the generation of vapours and to prevent escaping fuel from entering into the soil Leakage in the interior of the fuel di spenser must be checked via the exit hole located in the middle of the front base Ensure sufficient illumination of the refuelling area When not operated the fuel dispenser must be protected against unauthorized use 2 7 Compliance with instructions and regulations Overview i Page 8 UVV Accident prevention regulation VdTUV bulletin 651 Electric equipment of fuelling stations TRbF Technical rules for inflammable liquids GefStoffV Regulations for hazardous substances VbF Regulations for inflammable liquids VAwS Regulations for installations used for storage filling and handling of substances hazardous to water VLwF Regulations for the storage of liquids hazardous to water VDE regulations 21 BimSchV Regulations regarding the Federal Immission Control Law K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS ESD Directives Installation instructions N e Electro Static Discharge Under daily conditions persons and tools may be electrostatically char ged by friction When touching electronic components this charge may lead to dis
22. ertical incl drive pulley 197 mm Durchmesser Antriebswelle 14 93 mm Stroke pistons 2 and 4 29 86 mm Stroke pistons 1 and 4 adjustable from 28 35 mm 31 39 mm Minimum mechanical adjusting device increment 0 05 96 Flow rate capacity 0 3 Q min Q max objective Page 42 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 9 1 2 Vane pump PA 1 PA 2 illustration K S ELEKTRONIK GmbH eS Page 43 KS Installation And User Manual For Fuel Dispensers Series UNI 60 9 1 3 Flow meter KME Calibration Liter counter VC 1 Software version 30 35 Tuthill single channel encoder Parameter number 31 in service mode The number of pulses per liter can be entered here Min 2 pulses per liter Max 36 pulses per liter Fuel terminal TDE 50 Software version 40 35 Tuthill single channel encoder Parameter number 21 in service mode The pulse factor correction value can be entered here The pulse factor is 0 034480 which corresponds to 29 pulses per liter The factor can be changed between 0 025000 and 0 039000 Example 1 liter 30 pulses 1 30 0 033333 Reason for the number input Since the fuel terminal is fitted with a keypad direct input is possible without the need for complicated conversions Page 44 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 9 2 Flow meter KME LEE BESCHREIBUHG TEI
23. flow is stopped even if the operating lever is pressed After activation of the stop and safety function the locking lever must be released K S ELEKTRONIK GmbH Page 37 aes Installation And User Manual For Fuel Dispensers Series UNI 60 7 4 1 Position of the nozzle Correct position of the nozzle during fuelling The nozzle is in a vertical position the valve does not block the air sup ply and the fuel can flow Incorrect position of the nozzle The nozzle swivels and is no longer in a horizontal position The valve blocks the air supply and the fuel supply 7 4 2 Operating mode of the fuel dispenser Attention Before switching the automatic mode to the manual mode the service technician must be contacted 7 5 Switching the fuel dispenser off Remark Switch the fuel dispenser off as follows 1 Switch off the 230 V protective switch for the stabilized supply of the electronic fuel dispenser calculator 2 Switch off the uninterruptible power supply UPS in the kiosk via the switch located on the console the yellow indicator lamp of the USP goes off Page 38 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 8 Maintenance and service V n Attention Prior to starting any maintenance work on mechanical hydraulic or electric parts components it is always necessary to disconnect the fuel dispenser from the power supply source and to protect it from re con nec
24. htnings may destroy the complete electronics For this reasons an overvoltage protection is used in most countries leading the overvoltage energy to the grounding connection thus protecting the electronics Therefore the fuel dispenser manufacturer recommends protecting the main switch cabinet and or the secondary switch cabinet supplying the fuel dispenser and the electronics PC POS etc by means of an overvoltage protection and lightning arresters 6 2 Uninterruptible power supply UPS V Important In order to ensure trouble free operation of fuel dispensers it is neces sary to secure the stabilized fuel dispenser feeding by an uninterruptible power supply UPS Current interruptions heavy disturbances or voltage drops in peak hours particularly during winter time are very frequent phenomena in the po wer supply network All these phenomena can be eliminated by the use of a correct uninterruptible power supply UPS There are two types of UPS available and suitable for the fuel dispenser UPS offline and UPS online UPS offline is sufficient for the stabilization in the filling stations conb nected to a very stable power supply network without any voltage drop and any disturbances In other cases the online version of UPS must be used Disturbances voltage drops or failures can result in frequent blok king of the dispensers problems in the computer dispenser communica tion failures of computers data loss etc
25. installation and user manual in order to draw special attention to important information and remarks K S ELEKTRONIK GmbH Page 5 c 2 3 Safety symbols Installation And User Manual For Fuel Dispensers Series UNI 60 The following symbols draw the attention to important special notes Page 6 Attention This pictogram draws attention to legal regulations which must be com plied with regarding assembly commissioning and use of fuel dispen Sers Warning Non observance of these requirements can lead to injury of persons and or damage to the fuel dispenser Caution electric voltage Warning against touching electric lines and contacts Non observance of these requirements can cause electric shock and lead to injury of persons and damage to property Explosion hazard opecial care is required in the case of spilled fuel Inflammable vapours may easily lead to explosion or deflagration Therefore such fuel must be removed immediately by means of suitable absorbent means Electrostatically endangered components ESD This means that any contact with the contact surfaces or electr components may lead to the destruction of the electronic control unit and put the fuel dispenser out of service K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60 HS 2 4 Additional important symbols at the fuelling station site AN i Explosion hazard No smoking No mobile phones No
26. l dispenser Foundation Foundation plan single pump Foundation frame single pump Mechanical fuel dispenser mounting Electric cables Connection of the hydraulic unit Electr installation wiring Underground tank Above ground tank Fuel cable wiring K S ELEKTRONIK GmbH e wn o ON NOORA A 11 12 13 14 15 16 17 18 18 19 19 20 20 21 21 22 23 24 25 26 27 28 29 30 Page 1 HS Installation And User Manual For Fuel Dispensers Series UNI 60 6 Electr power supply 6 1 Overvoltage protection 6 2 Uninterruptible power supply 6 3 Wiring of the fuel dispenser 6 4 Supply of the pumps 6 5 Data lines 6 6 Service lines 6 7 Trouble free cable installation 7 Fuel dispenser operation 7 1 Instructions for safe fuel dispenser operation 7 2 Putting the fuel dispenser into operation 1 3 Checking changing the direction of rotation of the motor 7 4 Operation of the fuel dispenser 7 4 1 Fuel dispensing 7 4 2 Position of the nozzle 7 4 3 Operating mode of the fuel dispenser 1 9 Switching the fuel dispenser off 8 Maintenance and service 8 1 Instructions for maintenance 8 2 Maintenance of the housing 9 Technical specifications 9 1 Hydraulic components 9 1 1 Flow meter KME 9 1 2 Vane pumps PA 1 PA 2 illustration 9 1 3 Flow meter KME 9 2 Flow meter KME 10 Fuel dispenser dimensions 10 1 Single pump 11 Hazardous areas 11 1 Wiring diagram Page 2 K S ELEKTRONIK GmbH 21 31 31 32 33
27. lation of the fuel dispensers on islands to make sure that the moving direction of the vehicles is not important The dispenser orientation depends on the moving direction of the vehcile e A maximum distance of 3 0 meters between the dispensers and the fuel tanks is recommended Non observance of this reguirement may cause that the fuelling operation is hindered and the pump capa city flow is reduced All technical requirements for fuelling stations must be complied with by the manufacturer of the fuel dispensers e To ensure free access during cleaning and repair work a distance of at least 1m between the wall or building must be observed e Dispensers can be connected to both underground and above ground tanks The steel housing must be placed on the base aligned in concrete There the lines leading from the tanks to the dispensers must be connected The supply lines leading to the dispenser must have good insulating properties to prevent inflammable liguids or vapours from entering into the fuel dispenser K SELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60 _ 2 es 5 4 1 Electric cables In addition to the grounding connection the following lines must be con nected in the base below the fuel dispenser e Power supply of the calculator and the switching circuits three wire cable NYYO I 3 x 2 5 e Data line shielded eight wire cable AYSTOE 8 x 0 75 e Additional data line e g lev
28. open fire The No mobile phones sign is especially important if one uses the mo bile phone while refuelling motor gasoline at the same time Deflagration may occur when activating the buttons 2 5 Basic safety instructions Protection and safety devices Any protection and safety devices must be checked regularly but at the latest when carrying our maintenance work They may never be bypassed or ignored Any removed safety and proection devices must be e mounted again before putting into operation e checked for correct functioning Make sure that the safety devices at the installation site e g Emergency Stop button fire fighting devices are visible and easily accessible K S ELEKTRONIK GmbH Page Kes Installation And User Manual For Fuel Dispensers Series UNI 60 2 6 Obligations of the operator V Soiling Power supply Leakage Lighting Out of operation Attention The fuel dispenser is a complex unit and must fulfill high requirements Therefore the operator is obliged to carry out the following protection measures and to observe the safety instructions It is required to clean the tanks and pipes and to check whether the fuel is pure soiled filters in the fuel dispenser do not justify any repair under warranty before putting the fuel dispenser into operation Before putting the fuel dispenser into operation the electric power supply and the correct wiring must be checked in ord
29. orised persons Nom et signature des personnes autoris es K S ELEKTRONIK GmbH Page 53 S 13 2 QMS certificate rile Dir Page 54 E E3 a j x Li Li miir CS L s Ll TE EE Lid LL 7 Su n cL LL Lal E 441 Tal pa CERTIFICATE ZERTIFIKAT Installation And User Manual For Fuel Dispensers Series UNI 60 Suz Wingren Srnazr ZERTIFIKAT _ Dia Zertifizierunguatelle der TUV SUD Management Service GmbH bescheinigi dass des Uniernehmen K 5 Elektronik GmbH Hain ri amp h Hertz 34r 8 D 78052 Villingen Schwerrningen f r den Zeltungsbereich Entwicklung Herstellung und Vartriab von Tanksnlagan mil alakironischer Anzeige cin ya lfatsmanagementsy slam eingef hrt nat urd ammende Durch cin Audit Barichi iNr TOT 29553 wurde der Nachweis erbracht daas dm Forderungen der ISO 8001 2000 artullt sind Dieses Zerlfikat ist gulig b 2016 10 15 Zerthkat Regisinier Nr 12 106 22328 TMS Pa res est I ZA Hed uh ca Pa PU SLO nas em den cp arnbll gta nesil Him erst be uad EDGE Mu clian Tuin o K S ELEKTRONIK GmbH
30. r incorrect intervention e Any modifications of the fuel dispenser carried out without the explicit approval of the manufacturer lead to the exclusion of all liability claims towards the manufacturer This also applies to the use of spare parts which are not produced or released by the company K S The correct functioning safety and accuracy of each fuel dispenser are checked in the factory The fuel dispenser is delivered together with the required approval certificates K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI 60 aes 3 General product information 3 1 Overview Manufacturer K S ELEKTRONIK GmbH Fuel dispensers oystem engineering Pump electronics Fuel data acquisition Heinrich Hertz Stra e 9 D 78052 VS Villingen Phone 49 0 77 21 99 846 0 Fax 49 0 77 21 99 846 66 Product Fuel dispenser with liter counter or fuel terminal Tankautomat not calibratable Product Fuel dispenser series Uni 60 designation K S ELEKTRONIK GmbH Page 11 eS 3 2 Technical data Hydraulic system Electronic liter counter Fuel terminal Displays Page 12 Installation And User Manual For Fuel Dispensers Series UNI 60 Capacity e Min capacity 50 l min e Average capacity 70 l min e Max capacity 90 l min depending on the temperature and quality of the medium Dispens tolerance 0 50 with min dispensing of 2 0 Max oper pressure 0 18
31. roducts for the regular maintenance of the fuel dispenser housing K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS Note The company K S Elektronik GmbH offers annual inspections of the fil ling stations carried out by its dealers 9 Technical specifications Min capacity 50 l min Pump capacity Average capacity 70 l min MEE Max capacity 90 l min Min capacity 0 25 with min dispensing of 2 0 Pumping tolerance mM Max capacity 0 5 with min dispensing of 3 0 I Max Min capacity 0 18 MPa 1 8 bar operating pressure Max capacity 0 25 MPa 2 5 bar Viscosity of the Max 21 mm s fuel Recommended 1 0 m to achieve the nom capacity Suction height Max Max 2 0 m Single channel 5 VDC Encoder 1 x 35 imp rev per liter Electr motors Tuthill type MEC80 230 V 0 37 kW 2800 rpm 2 5 A fuel pump Tuthill type PA 1 PA 2 Displays Quantity From 0000 00 to 9999 99 I min K S ELEKTRONIK GmbH Page 41 HS _____ Installation And User Manual For Fuel Dispensers Series UNI 60 9 1 Hydraulic components Note H Vane pump hydraulic pump type PA 1 PA2 9 1 1 Flow meter KME The KME flow meter is compatible with the PA 1 PA 2 pumps It is used as a measuring in strument for accurate and reliable measurement of liquids other than water Rotation direction connection shafte encoder top Clockwise view Dimensions Horizontal 200x220 mm V
32. round level is prohibited e All water drains must be provided with oil separators according to DIN e Hazardous zones around the fuel dispenser are specified according to EN 60079 10 5 3 Foundation Local Important requirements A foundation is required for the installation of the fuel dispenser The lo cal conditions determine the installation height and the required founda tion If necessary this must be clarified on the site by an architect and the owner of the fuelling station K S ELEKTRONIK GmbH Page 21 KS Installation And User Manual For Fuel Dispensers Series UNI 60 5 3 1 Foundation plan o 8 SEE 5 3 Page 22 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 5 3 2 Foundation frame single pump Order no for The foundation frame is not included in the standard delivery and must single pump therefore be ordered separately See price list K S ELEKTRONIK GmbH Page 23 c Installation And User Manual For Fuel Dispensers Series UNI 60 5 4 Mechanical fuel dispenser mounting Mounting i Distance dispenser and tank Distance dispenser and wall Fuel tanks Page 24 The foundation frame is seated into concrete The front and rear fuel di spenser casings must be removed in order to fasten the fuel dispenser The fuel dispenser is placed on the foundation frame and fixed by the screws included in the delivery Important K S recommends instal
33. tion Note e Do not remove the casings of the fuel dispenser during operation K S ELEKTRONIK GmbH Page 39 Kes Installation And User Manual For Fuel Dispensers Series UNI 60 8 1 Instructions for maintenance i Instructions for fuel dispenser maintenance Maintain all fuel dispenser components clean so that possible unfore seeable faults can be dientified easily and removed quickly Check all connection elements systematically and in case of fuel le aks retighten the connection elements and or seal them Check and tighten the screws by means of which the electr motor and the pump are fastened on the console Check the condition of the nozzles and decide its repair or replacement depending on the revealed defect Check the correct functioning of the door locks and the nozzle boot Regularly check the tank for oil residues mud water residues and other impurities and clean 8 2 Maintenance of the housing Housing Page 40 Note Parts of the fuel dispenser housing are made of powder and zinc coa ted steel or stainless steel These parts need regular maintenance par ticularly during the winter season because aerosols of chloride prepa rations arisen from the salts used for road maintenance can result in permanent damage to lacquers of untreated body parts and or to inter crystalline corrosion Pay attention to the corrosion of guards Use water and or solutions of detergents and available car care p
34. tions for tightness retighten if necessary If required replace defective seals Motor drive Uneven running genera Remove oil deposits tion of noise Pump Sluggish pump drive Check for wear and excessive backlash Contact technical service Dispensed fuel volume _ Soiled filter Clean all suction and outlet filter too low strainers replace if necessary Flow meter Sluggish When the pump operates at high Capacity replace the flow meter Contact technical service Nozzle Restrainer soiled etc Replace nozzle The fuel does not flow valve cone and seat Contact technical service while the nozzle is relea blocked due to fuel sed deposits K S ELEKTRONIK GmbH Page 51 eS Installation And User Manual For Fuel Dispensers Series UNI 60 12 3 After troubleshooting i V Page 52 Important Mount again all casing covers after maintenance and repair work and close the pump head Check all loosened screw connections for tight seat Carry out recommissioning only according to the relevant instructions Take the necessary measures to ensure that the fuel dispenser is only operated in a safe and functional state Carry out a test run Attention After any intervention on the hydraulic installation the volume rate must be checked K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ WS 13 Test certificates and other certificates 13 1 EC declaration
35. vention regarding the elimination of errors and repair of a de fective fuel dispenser requires special knowledge This work may be carried out only by trained pesonnel and authorized companies Dangerous voltage Prior to starting any work on the electr supply of fuel dispenser compo nents it is always necessary to disconnect the fuel dispenser from the power supply source and to protect it against re connection ESD A When carrying out any work on electronic components e g replacing a the control electronics first touch grounded metal parts Thus any pos sible charges are discharged K S ELEKTRONIK GmbH Page 49 HS Installation And User Manual For Fuel Dispensers Series UNI 60 12 2 Malfunctions 12 2 1 Pump does not dispense fuel Motor not running Power supply failure First check all fuses switches and motor protection switches in the switch cabinet as well as the connec tion cables for e the fuel dispenser motor nozzle contact cable connection junction box e the price calculator check fuses check for short circuit check contactor Motor Motor defective Motor defective Replace the defective motor the Replace the defective motor motor Page 50 K S ELEKTRONIK GmbH Installation And User Manual For Fuel Dispensers Series UNI60_ HS 12 2 2 Reduced or no fuel dispensing Pipings Suction line not tight Seal suction lines hydraulic connections Check screw connec
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