Why have pneumatic tube dispensing systems failed

Measuring system GMVZ 1004 Operating and installation instructions

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1 measuring system Edition / Rev / JS / jp / December 2009 MNF08004 / DOK-461 Sening

2 Messanlage Sening Further documentation for this product: Designation None Order No. History: Revision date Processed by Status Description Rev July 2004 HO / US / as Approval of basic edition Rev July 2009 JS / jp Approval of format changes / new drawings Rev December 2009 / JS / jp / Approval Extension of the technical data in chapter 7 by a line Functional reliability Important note All explanations and technical information in this documentation were compiled and compiled by the author with the greatest care. Nevertheless, errors cannot be completely ruled out. F.A. Sening GmbH is grateful at any time. ii of iv Rev / JS / jp / December 2009 MNF08004 / DOK-461

3 Sening measuring system Contents 1 General Orientation aids for the manual Safety instructions Ex protection Particular attention should be paid to: Intended use Structure and mode of operation Schematic structure View from right View from front View from left Gas monitor Standard ventilation Additional ventilation (optional) Pressure switch (optional) Volume counter Valves Empty hose valve Full hose valve Bypass valve Elbow Pneumatic control Control by mechanical actuation blocks Control by electronic meter MultiFlow Order designations General installation Preventive measures Assembly Pneumatic installation Electrical installation Final inspection Commissioning Calibration Operation Mechanical control Delivery with overfill protection Delivery via the bypass Electronic control A Table of contents MNF08004 / DOK-461 Rev / JS / jp / December 2009 iii from iv

4 Sening measuring system Delivery with overfill protection Delivery via the bypass Maintenance Troubleshooting Technical data Warranty and service Address and contact lists Index of figures List of figures List of tables Appendix A. Drawings and approvals Offer drawings Stamp plans Pneumatic circuit diagrams Approvals 39 Drawings of measuring system L Measuring system L - Parts list for measuring system V, L Measuring system V, L - parts list measuring system U, V1, V2, L, B measuring system U, V1, V2, L, B - parts list measuring system U, V, B measuring system U, V, B - parts list measuring system U, V, L, B measuring system U, V, L, B - WM parts list Stamp plan for solenoid valves / connection diagrams & nomenclature Pneumatic circuit diagram / control measuring system with external overfill protection Pneum. Circuit diagram / control measuring system without overfill protection or with integrated overfill protection Pneumatic circuit diagram / unmeasured with 2 outlets Approvals EC - Declaration of Conformity iv by iv Rev / JS / jp / December 2009 MNF08004 / DOK-461

5 Sening measuring system 1 General 1.1 Orientation aids for the manual We have designed some orientation aids so that you can easily find the information you need in this manual. Pictograms The information in this manual ranges from mandatory protective measures and standardized specifications to specific steps and advice. For better differentiation in context, this information is marked by appropriate pictograms in front of the text. They are not only intended to increase awareness, but also to help you quickly find out the information you are looking for. The pictograms therefore represent the textual content behind them A The following pictograms are used in this manual: Warning. Here: Risk of explosion from highly flammable gases and liquids. Operational disruption is imminent. Actions that harm the device. Legal notices. Actions that have legal consequences. Work step. Specific job details, e.g. Press the key Positive feedback, e.g. The main menu Feedback negative now appears, e.g. If an error message now appears ... background information, short tip, e.g. More information can be found in Chapter XX General Options, Special Case Function / Function Description NOTE: refers to a special situation. ATTENTION: for special attention. - Keyword index at the end of the documentation makes it easier to find subject areas. MNF08004 / DOK-461 Rev / JS / jp / December

6 Sening measuring system 1.2 Safety instructions ATTENTION: Read through carefully before commissioning and observe Ex protection The type measuring system is designed for the flow measurement of highly flammable and flammable liquids (hazard class AI and AIII) on tank trucks. Sparks or open flames must be strictly avoided. Particular attention should be paid to the following: The type measuring system contains precise and high-quality components. Therefore, mechanical influences not resulting from operation (e.g. falling down) must be avoided. The measuring devices are subject to calibration. Any manipulation, intentional or unintentional, will break the calibration seal. Make sure that no fuel flows into the ground. Intended use The type measuring systems are built exclusively for dispensing low-viscosity mineral oils on tank trucks. The relevant applicable safety regulations (e.g. explosion protection) must be observed. Any use going beyond this is considered improper, the manufacturer is not liable for any damage resulting from this. Intended use also includes the operating, installation and maintenance conditions prescribed by the manufacturer. The type measuring systems may only be installed, operated, serviced and repaired by persons who are familiar with them and have been informed about the dangers. Unauthorized changes to the type of measuring system exclude the manufacturer from liability for any damage resulting therefrom. 6 Rev / JS / jp / December 2009 MNF08004 / DOK-461

7 Sening measuring system 2 Structure and mode of operation F.A. Sening measuring systems were developed for gravity and pump operation. The measuring systems are integrated in measuring systems in which the tried and tested technologies of the gas control device and the sliding valve meter have been combined in order to achieve optimal measuring results. The slide meter is equipped with an integrated pulse generator for direct connection to the MultiFlow electronic meter. Depending on national regulations, the electronic control of the measuring systems can be supplemented with an overfill prevention amplifier type ASE-E- .. or ASE-D- ... The measuring systems are volume counters with an integrated gas interceptor. The measuring systems are designed for the delivery of low-viscosity mineral oil products with a viscosity η <1 to 20 mpa s on road tankers A Advantages: Small, compact and lightweight measuring system Integrated pulse generator Electronic valve control Gas monitor with integrated filter Simple and inexpensive installation Cam track-controlled slide valve meter High flow rate in the pump and gravity operation Functional description: The material to be measured enters the gas monitor through the inlet nozzle. Due to the tangential position of the inlet nozzle, the material to be measured starts rotating. As a result, gases present in the liquid are separated out (principle of operation of the centrifuge). The gases rise and collect in the gas control hood, which is equipped with an automatic venting system. The degassed material to be measured is directed past the sight glass (below) into the volume counter. This is a sliding valve meter with internally guided rotor blades. The material to be measured leaves the measuring system through the shut-off valve mounted on the measuring chamber outlet. Structure and mode of operation MNF08004 / DOK-461 Rev / JS / jp / December

8 Sening measuring system 2.1 Schematic structure In the following figures, the measuring system is equipped with a shut-off valve for full and empty hose discharge, a double bend for two full hoses, additional ventilation on the hood and an outlet nozzle with throttle. The equipment of the measuring systems can be varied according to the requirements: Gas detection hoods with / without pressure switch with / without additional ventilation Discharge valves Full and empty hose Full hose valve Single or double full hose with / without bypass with / without throttle for full hose Unmeasured 6 Rev / JS / jp / December 2009 MNF08004 / DOK-461

9 Sening measuring system View from the right Flow switch connection for additional ventilation (optional) Sight glass Pneumatic connection for double elbow Pneumatic connection for full hose reversible elbow A Empty hose outlet connection Structure and mode of operation Figure 1: View from the right MNF08004 / DOK-461 Rev / JS / jp / December

10 Sening measuring system Front view Lever for throttle valve Additional vent valve with sight glass (optional) Connection for additional venting (optional) Pneumatic connection for empty hose valve Pneumatic connection for bypass valve Sight glasses GMV hood Temperature measuring pocket Mounting flange Connection lines Pulse generator Sight glass Bottom pump back connection for product hose emptying opening Connection option for the temperature sensor Figure 2: View from the front 8 Rev / JS / jp / December 2009 MNF08004 / DOK-461

11 Sening measuring system, view from the left 1 2 Pneumatic connection for flow switch Connections for full hoses Pneumatic connection of the hood (supply air) Pneumatic connection of the hood (control air) 4 Fastening nuts for gas monitor hood A Inlet nozzle Structure and mode of operation Fastening flange Figure 3: View from the left MNF08004 / DOK-461 Rev / JS / jp / December

12 Sening measuring system 2.2 Gas detection device If gases penetrate or are present in the measuring system, the measurement is automatically interrupted. The venting of the gas detector housing required after switching off and the subsequent continuation of the measuring process are also carried out automatically. Figure 4: Schematic structure of the gas detector hood with control head 10 Rev / JS / jp / December 2009 MNF08004 / DOK-461

13 Sening measuring system, standard ventilation If the gas control hood is filled with material to be measured up to the upper edge of the sight glass (switch-on level), the float raised by the material activates the 3/2-way valve in the control head. This closes the vent valve and the air pressure reaches the shut-off valve of the measuring system via output A. The material to be measured can now flow through the slide valve counter. If so much gas collects in the gas monitor hood that the liquid level drops to the switch-off level, the 3/2-way valve vents the shut-off valve, the shut-off valve is closed with spring force and the vent valve opens until the material to be measured in the gas monitor hood reaches the switch-on level again Has. Switch-on height Switch-off height A Figure 5: Switch-on and switch-off height (static) When gas is present, there is an automatic change between venting with the shut-off valve closed and measurement with the standard venting closed. The ventilation takes place via a shut-off valve to the outside. Structure and mode of operation Additional ventilation (optional) The additional ventilation reduces the number of switching operations of the shut-off valve during gravity discharge by continuously discharging the gases produced. The gases are introduced into the product line (empty hose) via a vent line bypassing the volume counter behind the shut-off valve. The vent line must be closed with a shut-off valve. At its end there is a non-return valve that closes automatically when dispensed with the pump. Additional venting is only required when the system is operated with gasoline in gravity. Pressure switch (optional) When dispensing with a pump, the liquid pressure on the pressure side collapses in the event of an ingress of air on the suction side. The control can be equipped with an additional pressure switch to avoid a possible incorrect measurement. This is a 3/2-way valve integrated in the control head. MNF08004 / DOK-461 Rev / JS / jp / December

14 Sening measuring system If the pressure falls below a specified pressure (1.1 bar) during delivery with the pump, the shut-off valve closes. In the case of gravity discharge (pressure less than 0.2 bar), the pressure switch is automatically disabled and the shut-off valve is released. 2.3 Volume counter The volume counter is a cam track-controlled drive slide meter with an integrated pulse generator for connecting electrical counters. The leaves of the drive slide meter are guided by an internal cam track. This means that the blades of the slide meter run without contact in the measuring chamber housing. The robust volume counter is characterized by a low starting resistance and a long service life. The integrated pulse generator converts the rotation of the slide meter into electrical impulses. This takes place without contact in the measuring chamber. The pulse generator is connected directly to the MultiFlow electronic counter or a third-party computer. 2.4 Valves Empty hose valve A valve with a nominal width of 100 mm is used as an empty hose valve. The empty hose valve can optionally be equipped with a non-return valve on the connection side to the volume counter. To open the valve, compressed air is applied to a piston which is pressed into the end position against spring force. The valve cone is connected to the piston by a stem. This performs the same stroke and opens the valve outlet. So that the valve cannot be opened by the liquid pressure, the valve cone is designed as an annular piston in such a way that all surfaces exposed to the liquid do not give rise to any external forces (pressure-balanced). The empty hose valve can optionally be equipped with a manual throttle to reduce the flow. Full hose valve A valve with a nominal width of 80 mm is used as a full hose valve. To open the valve, compressed air is applied to a piston which is pressed into the end position against spring force. The valve cone is connected to the piston by a stem. This performs the same stroke and opens the valve outlet. So that the valve cannot be opened by the liquid pressure, the valve cone is designed as an annular piston in such a way that all surfaces exposed to the liquid do not give rise to any external forces (pressure-balanced). The wet hose valve can optionally be equipped with a manual throttle to reduce the flow. 12 Rev / JS / jp / December 2009 MNF08004 / DOK-461

15 Sening measuring system Bypass valve In the wet hose valves that have a B in the type designation, there is a bypass valve in addition to the wet hose main valve. The compressed air drives a piston against the valve stem of the bypass valve. When the bypass valve is open, the product enters the wet hose, bypassing the closed wet hose valve. A reed switch is cast in the cover of the bypass valve, the contacts of which are closed by a permanent magnet in the piston when the bypass valve is in the closed position. By operating the control device for the bypass, the magnet is moved out of the switching range of the reed switch. The contacts of the reed switch open. The electrical contact of the bypass valve is located in the electrical circuit of the limit switch. This fulfills the requirement that the green ready-light of the overfill protection switching amplifier does not light up when filling is carried out using the bypass, regardless of whether the switching amplifier is switched on. Elbow A With wet hose valves, a swiveling outlet elbow with a non-return valve must be installed on the wet hose side . The outlet elbow (type KR-2 / KR-3-ST) can be used to control a pump drive. For systems with 2 hose reels, a double bend type DKRSTD is used. This double elbow also has the control devices for a pump. Switching between hose reels 1 and 2 can take place under full pump pressure (8 bar). Both elbows can be swiveled through 360 through the threaded connection on the valve, steplessly, both around the longitudinal and the vertical axis. 2.5 Pneumatic control All shut-off valves of the measuring system are arranged behind the slide valve meter, viewed in the direction of flow. These are pneumatically operated shut-off valves that are closed by spring force when they are depressurized. Each delivery system (unmeasured, empty hose, wet hose and bypass) has its own shut-off valve. The shut-off valves are pneumatically controlled by solenoid valves, manual control valves, electronic computer systems and, if necessary, locking valves. Structure and mode of operation Control by mechanical actuation blocks The pneumatic shut-off valves of the measuring system are controlled by mechanical actuation blocks. All locking functions that are required for calibrating the measuring system and for dispensing with an overfill prevention device are performed by the mechanical actuation blocks in conjunction with pneumatically controlled locking valves. The overfill prevention amplifier is equipped with a solenoid valve as an actuator for the overfill prevention. An F.A. Sening overfill prevention amplifier with the type designation ASE-2, ASE-E-MV or ASE-D-MV is used. Alternatively, an F.A. Sening overfill prevention amplifier with MNF08004 / DOK-461 Rev / JS / jp / December

16 Sening measuring system of type designation ASE-M, which is connected to a solenoid valve via a NoMix system.The electronic meter MultiFlow (for temperature conversion) activates the supply air to the measuring system with a solenoid valve. If necessary, the control switch is unlocked when the counter is reset. Pneumatic circuit diagrams / control by mechanical actuation blocks Control by electronic MultiFlow counter The pneumatic shut-off valves of the measuring system are controlled by the MultiFlow electronic counter. The MultiFlow takes on all locking functions that are required for calibrating the measuring system and for dispensing with an overfill prevention device. A solenoid valve is assigned to each shut-off valve in the measuring system and the hose path is selected using the. Two variants are possible for this electronic control by the MultiFlow, depending on the overfill prevention amplifier. AS amplifier with solenoid valve Integrated AS amplifier from F.A. Sening (without solenoid valve) Input S4 of the MultiFlow electronic index may only be used with an AS amplifier from F.A. Sening (ASE-E-MF, ASE-D-MF or ASE-M) or with a pressure switch (see electrical circuit diagrams). Electrical connection plans / version AI version AIII Rev / JS / jp / December 2009 MNF08004 / DOK-461

17 Sening measuring system Electronic counter MultiFlow and AS amplifier with solenoid valve The overfill prevention amplifier is equipped with a solenoid valve as an actuator for the overfill prevention. An F.A. Sening overfill prevention amplifier with the type designation ASE-2, ASE-E-MV or ASE-D-MV is used. Alternatively, an F.A. Sening overfill prevention amplifier with the type designation ASE-M, which is connected to a solenoid valve via a NoMix system. A pressure switch connected to input S4 of the MultiFlow electronic meter monitors the activation of the AS solenoid valve. This pressure switch takes over the self-holding function (mechanical actuation block). As an alternative to the pressure switch, a type STB control block can be used (see circuit diagrams). Pneumatic circuit diagrams / control by electronic counter and AS amplifier with solenoid valve (MultiFlow) A Electronic meter MultiFlow with integrated AS amplifier The overfill prevention amplifier is connected to input S4 of the electronic meter MultiFlow with an intrinsically safe open collector output. The solenoid valves of the electronic meter are considered to be the final control element of the overfill prevention system. An F.A. Sening overfill prevention amplifier with the type designation ASE-E-MF or ASE-D-MF is used. Alternatively, an F.A. Sening overfill prevention amplifiers with the type designation ASE-M can be used in connection with the NoMix system. A type STB control block can be used as an option (see circuit diagrams). Structure and mode of operation Pneumatic circuit diagrams / control by electronic counter integrated AS amplifier (MutiFlow + AS) MNF08004 / DOK-461 Rev / JS / jp / December

18 Sening 2 measuring system.

19 Sening measuring system 3 Installation 3.1 General The installation of the measuring system on road tankers may only be carried out by specialist companies. [A specialist company is a company according to TRbF 20 No. 15.4] Preventive measures To avoid accidents: The type measuring system is built exclusively for the delivery of low-viscosity mineral oils on road tankers. The relevant applicable safety regulations (e.g. explosion protection) must be observed. All regulations and instructions in the manuals for the electronic devices connected to the measuring system must be observed. (e.g. MultiFlow, AS amplifier) ​​Notes on all signs must be observed. In the event of a malfunction, only the relevant assembly may be completely replaced. In order to meet standard requirements: All regulations, requirements and guidelines for the calibration of volumetric instruments must be observed. (See type approvals) The overfill prevention system must meet the requirements of TRbF 512. The electrical installation is carried out in accordance with EN; VDE 0165 from A Installation To ensure trouble-free operation: The hoses, pipes and vehicle chambers must be carefully cleaned before assembly. The lines are to be screwed tension-free to the measuring system. The measuring system must be carefully filled with the material to be measured using the throttle (open the bottom valve). This prevents damage to the measuring chamber. After the measuring system has been pressed with water, the measuring system must be filled with product (e.g. heating oil). This prevents the measuring chamber from being damaged by corrosion. During welding work on the vehicle, interrupt the power supply (plus 24V and minus 24V) to all electronic components. MNF08004 / DOK-461 Rev / JS / jp / December

20 Sening measuring system To make work easier for service: Install the measuring system so that the hood can be removed to clean the filter and the manifold or double bend can be replaced without dismantling the measuring system. For vehicles with a pump, screw a pressure gauge into the supply line to the gas control device. Attach the electronics housing so that it is easily accessible. Lightly grease the fastening screws of the cover before putting them on (copper paste, graphite grease). This is to prevent the screws from corroding after prolonged use and thus no longer loosening. 3.2 Installation The measuring system is to be installed horizontally. There are two options for fastening in the fittings cabinet: fastening from below (through-holes in the base of the fittings cabinet) fastening from the side. For both types of mounting, there are 3 through holes for M12 on the one hand and 3 threaded holes for M10 on the other. The hoses and pipes must be carefully cleaned before assembly. They are to be screwed tension-free to the system. When arranging the measuring system, it should be ensured that the switch-on point of the gas monitor hood is below the valve seat in the distribution channel of the tanker. The switch-on points can be found in the offer drawings. (see Appendix). The supply line to the inlet to the gas detector should be laid with a slight gradient and with as few diversions (pipe bends) as possible. This increases the gravity output of the measuring system. Pneumatic installation The pneumatic lines must be connected in the system in accordance with the circuit diagrams. The connections marked with a cross (X) in the pneumatic circuit diagrams must be tamper-proof. This is ensured by the use of corrosion-resistant steel pipes 6x1, which are provided with connection locks (type VS) at both ends. If, for example, a flexible air line is required for the gas monitor hood, then a corrugated stainless steel hose with an inside diameter of 4 mm with connection locks at both ends must be used. The line lengths specified in the pneumatic circuit diagrams must not be exceeded. Lines without length specifications may not exceed 0.2 m behind the solenoid valves marked AS. 18 Rev / JS / jp / December 2009 MNF08004 / DOK-461

21 Sening measuring system Electrical installation All electronic devices and terminal boxes must be fixed in the armature cabinet in a stable and vibration-free manner. All screws that are used to fasten all housings must be marked with e.g. Molikote (graphite paste) or similar can be used. During assembly, a reliable electrical connection must be established between each metal housing and the vehicle chassis. Corrosion-resistant screws (V2A) are to be used for this. All cables used must be fuel-resistant. Ex cables must be used for cabling in the non-intrinsically safe area. All cables must be laid (protected) in such a way that they are not damaged during the activities (working methods) of the operator. Wire end sleeves, cable lugs, etc. must be used to clamp the cables. The cable glands must be carefully tightened. Unused cable glands must be sealed watertight with suitable blind screw connections or suitable locking pins. Unused clamping screws must be tightened. After the connection work, the cover of the housing must be carefully tightened again. A With bypass The electrical contact (blue cable) of the bypass valve must be connected to the circuit of the limit indicator. This fulfills the requirement that the green ready-light of the overfill prevention switch amplifier does not light up when filling is carried out using the bypass, regardless of whether the switch amplifier is switched on Final test The specialist company checks the entire system in accordance with the test criteria listed in the associated workshop and installation manuals . The correct installation, specifying the schematic of the pneumatic control circuit and the connection diagrams of the electronic systems, must be certified. The following tests should be carried out on the vehicle: Installation test Leak test of the entire measuring system, e.g. Pressure test with water Function and leak test of the pneumatic installation. Functional test of the electrical installation. (See relevant manuals) Note Completely remove water from the measuring system after the test. MNF08004 / DOK-461 Rev / JS / jp / December

22 Sening measuring system 3.3 Commissioning After switching on the compressed air supply and releasing the electronic counter, open the shut-off valve on the control head of the hood. In the case of a system with additional ventilation, the associated shut-off valve must also be opened. The material to be measured must then be fed to the system (open the bottom valve). The system now vents until the material to be measured is on the upper edge of the sight glass of the gas control hood. Then the vent valve closes, the shut-off valve opens and the filling of the measuring chamber, the dispensing valve and possibly the full hoses begins. The measuring chamber must be filled with a low flow rate (low pump output / throttle closed). If there are two full hoses, both hoses must be filled before the first measurement. 3.4 Calibration The measuring system type can only be operated with an electronic counter (e.g. MultiFlow). The calibration of the measuring system is thus carried out by the electronic counter. The calibration is carried out by changing the so-called K-factor. The new K-factor is calculated as follows: K K NEW display calibration standard = display electr. ALT counter Further information can be found in the associated operating instructions. There is a measuring pocket for the calibration thermometer on the cover of the lower inspection glass of the gas monitor. The calibration test must be carried out in accordance with the regulations or construction and test regulations of the type approvals. The stamp points of the measuring system can be found in the attached stamp plans. 20 Rev / JS / jp / December 2009 MNF08004 / DOK-461

23 Sening measuring system 4 Operation 4.1 Mechanical control The pneumatically controlled shut-off valves of the measuring system are controlled by electromechanical pneumatic valves. The operating air pressure can be between 3 bar and 8 bar. Only the control output of the gas monitor acts directly on the control air of the shut-off valves and thus ensures quick shutdown. The pneumatic shut-off valves of the measuring system are controlled by mechanical actuation blocks (such as control switch, control unit, control blocks) and a bypass delivery is provided as an option. The AS amplifier is equipped with a solenoid valve as the final control element for the overfill prevention device. An electronic temperature volume conversion is available. The pneumatically operated actuators of the overfill prevention device and the gas detection device for measured and unmeasured delivery and also the bypass valve can only be opened when the pneumatic working pressure is at least 3 bar. If the pressure falls to less than 2.5 bar, the self-holding force of the pneumatic control devices (such as the control switch, control unit, control blocks) in the on position is no longer large enough and previously opened shut-off valves close A Discharge with overfill protection Establish the hose connection from the selected discharge nozzle of the tanker to the filler neck of the customer's storage tank in question. Determining the amount of liquid in the storage tank. Switching on the switching amplifier (yellow lamp lights up) and the electronic counter. Establish the line connection from the switching amplifier to the limit indicator of the storage tank in question. After approx. 10 seconds to a maximum of 3 minutes, the green lamp on the switching amplifier lights up (AS ready for operation). Enter the preselection data according to the operating instructions for the electronic index. Open the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch on the tank truck's pump. Operation of the control switch Set the dial of the control switch to the dispensing nozzle that is to be used. It is only possible to change the setting of the dial when it is unlocked. It is unlocked by the solenoid valve for zeroing the electronic counter. The dispensing begins when the pull button on the control switch is pressed, whereby it is assumed that the automatic gas control device has been activated when the liquid is sufficiently filled. The locking of the dial against an alteration- MNF08004 / DOK-461 Rev / JS / jp / December

24 Measuring system Sening of the setting during or after the measured delivery occurs automatically when the pull button on the control switch is pressed. Control unit or control block To initiate the dispensing process, the pull button on the relevant control unit or control block must be actuated. The occurrence of air or gas inclusions in the gas control device leads to the automatic interruption of the delivery process, with the gas control device being vented at the same time and delivery being continued automatically. If necessary, set the required flow rate with the throttle on the shut-off valves. When the permissible filling level in the tank is reached, the dispensing stops automatically (green lamp goes out). The dispensing process can also be interrupted at any time by pressing the pull button or by the electronic counter without waiting for the overfill prevention device to respond. Close the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch off the tank truck pump. Remove the line connection between the switching amplifier and the limit switch and the hose connection from the road tanker to the filled storage tank. Set the electronic counter to zero by printing a receipt. Switching off the switching amplifier (yellow lamp goes out) and the electronic counter. Delivery via the bypass Via the bypass of the overfill protection in the full hose system, only tanks with a capacity of up to 1000 l with heating oil EL or diesel fuel or mobile machines outdoors with diesel or petrol without a permanent connection to a Filler necks are filled, whereby the delivery volume flow must be limited to a maximum of 200 l / min. In the case of a delivery via the bypass, this is only possible using the wet hose. For vehicles with 2 full hoses, you can choose between the two. Determining the amount of liquid in the customer's container to be filled. Connect the self-closing nozzle to the closed nozzle at the end of the wet hose with TW coupling. Enter the preselection data according to the operating instructions for the electronic index. Open the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch on the tank truck's pump. Set the dial of the control switch to the dispensing nozzle B or B1 or B2. It is only possible to change the setting of the dial on the control switch to a different delivery nozzle if it is unlocked. It is unlocked by the solenoid valve for zeroing the electronic counter. By pressing the pull button on the control switch, the bypass valve is opened and at the same time the dial is locked in the existing setting. For dispensing, both the nozzle valve at the end of the wet hose must be brought into the open position with the locking of the operating lever and the self-closing nozzle upstream must be opened, whereby the latter does not lock in the open position. 22 Rev / JS / jp / December 2009 MNF08004 / DOK -461

25 Sening measuring system, but must be kept open by hand (dead man's safety) during the entire dispensing process. The overfill prevention is not in operation. The filling process must be closely monitored. The occurrence of air or gas inclusions in the gas control device leads to the automatic interruption of the delivery process, with the gas control device being vented at the same time and delivery being continued automatically. The dispensing is ended by closing the nozzle, which is held in the open position by hand. Press the pull button on the control switch on the vehicle, the bypass valve closes. Release the operating lever of the nozzle at the end of the wet hose from the lock and close the nozzle. Briefly open the upstream self-closing nozzle again so that a small amount of residue can still be added to the container to be filled. Remove the self-closing nozzle by releasing the TW coupling before the wet hose is wound up.Close the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch off the tank truck pump. Set the electronic counter to zero by printing a receipt. Switching off the switching amplifier (yellow lamp goes out) and the electronic counter A Control units Instead of a control switch, there are control units and the pull button labeled "B" must be operated to open the bypass valve and to close it again later after the delivery is complete. Operation MNF08004 / DOK-461 Rev / JS / jp / December

26 Sening measuring system 4.2 Electronic control The pneumatic shut-off valves of the measuring system are controlled by the MultiFlow electronic counter. A bypass delivery is optional. The AS amplifier is equipped with a solenoid valve (or NoMix solenoid valve) as the control element for the overfill prevention device or the AS amplifier is connected to the MultiFlow electronic counter via an open collector output. The pneumatically operated shut-off valves for measured and unmeasured dispensing and also the bypass valve are opened by the MultiFlow when the switching amplifier of the overfill prevention device releases it Dispensing with overfill prevention Establishing the hose connection from the selected dispensing nozzle of the tanker to the filling nozzle of the customer's storage tank. Determining the amount of liquid in the storage tank. Switch on the switching amplifier (yellow lamp lights up) and the electronic MultiFlow counter, if necessary also switch on the NoMix system. Establish the line connection from the switching amplifier to the limit indicator of the storage tank in question. After approx. 10 seconds to a maximum of 3 minutes, the green lamp on the switching amplifier lights up (AS ready for operation). Open the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch on the tank truck's pump. Select the delivery nozzle to be used according to the operating instructions for the MultiFlow electronic index. The selected dispensing nozzle can only be changed if the liter display of the MultiFlow is still showing zero liters (zero position). After the preselection data have been entered on the electronic counter (see MultiFlow operating instructions), delivery begins by pressing the start button. If the delivery is measured, it is assumed that the automatic gas control device has been activated when the liquid is sufficiently filled. A new selection of the hose route is not possible during or after the delivery. The occurrence of air or gas inclusions in the gas control device leads to the automatic interruption of the delivery process, with the gas control device being vented at the same time and delivery being continued automatically. If necessary, set the required flow rate with the throttle on the shut-off valves. When the permissible filling level in the tank is reached, the dispensing stops automatically (green lamp goes out). The dispensing process can also be interrupted at any time by pressing the stop button without waiting for the overfill prevention device to respond. Close the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch off the tank truck pump. Remove the line connection between the switching amplifier and the limit switch and the hose connection from the road tanker to the filled storage tank. Set the counter to zero by printing a receipt on the MultiFlow electronic counter. Switching off the switching amplifier (yellow lamp goes out) and the MultiFlow, if necessary also switching off the NoMix system. 24 Rev / JS / jp / December 2009 MNF08004 / DOK-461

27 Sening measuring system Delivery via the bypass Via the bypass of the overfill protection in the full hose system, only tanks up to 1000 l content may be filled with heating oil EL or diesel fuel or mobile machines outdoors with diesel or petrol without a fixed connection to a filler neck, whereby the delivery volume flow is limited to a maximum 200 l / min must be limited. In the case of a delivery via the bypass, this is only possible using the wet hose. For vehicles with 2 full hoses, you can choose between the two. Determining the amount of liquid in the customer's container to be filled. Connect the self-closing nozzle to the closed nozzle at the end of the wet hose with TW coupling. Open the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch on the tank truck's pump. According to the operating instructions for the electronic MultiFlow index, select the delivery nozzle B, B1 or B2. The selected dispensing nozzle can only be changed if the liter display of the MultiFlow is still showing zero liters (zero position). After the preselection data have been entered on the MultiFlow (see operating instructions), delivery begins by pressing the start button. It is assumed that the automatic gas control device has been activated when there is sufficient liquid filling. A new selection of the hose route is not possible during or after the delivery. For the dispensing, both the nozzle valve at the end of the wet hose must be brought into the open position with the locking of the operating lever and the self-closing nozzle upstream must be opened, whereby the latter cannot be locked in the open position, but open by hand during the entire delivery process (dead man's safety) must be kept. The overfill prevention is not in operation. The filling process must be closely monitored. The occurrence of air or gas inclusions in the gas control device leads to the automatic interruption of the delivery process, with the gas control device being vented at the same time and delivery being continued automatically. The dispensing is ended by closing the nozzle, which is held in the open position by hand. The bypass valve closes by pressing the stop button on the MultiFlow. Release the operating lever of the nozzle at the end of the wet hose from the lock and close the nozzle. Briefly open the upstream self-closing nozzle again so that a small amount of residue can still be added to the container to be filled. Remove the self-closing nozzle by releasing the TW coupling before the wet hose is wound up. Close the bottom valve and the distribution valves of the corresponding chamber of the tanker. If necessary, switch off the tank truck pump. Set the counter to zero by printing a receipt on the MultiFlow. Switching off the switching amplifier (yellow lamp goes out) and the MultiFlow, if necessary also switching off the NoMix system A Operation MNF08004 / DOK-461 Rev / JS / jp / December

28 Sening measuring system 26 Rev / JS / jp / December 2009 MNF08004 / DOK-461

29 Sening measuring system 5 Maintenance The sieve basket, which is located before the material to be measured enters the volume counter, must be cleaned regularly (in normal operation at least once a year, more frequently with heavily soiled material to be measured). Proceed as follows: Pay particular attention to contamination on the sieve edge! T-screw for securing the sieve A Maintenance Disassemble the gas detector hood (to do this, loosen the four M16 hex nuts) Remove contamination from the sieve edge with a brush. ATTENTION: No dirt may get into the space below the sieve. Dirt inevitably damages the meter! Dismantle and clean the strainer (to do this, loosen the T-screw). Clean the gas detector hood and housing base. During assembly, ensure that the flange surfaces are clean and that the O-ring is correctly positioned. A dirty sieve leads to a reduced flow rate when dispensing by gravity; when dispensing with a pump, it can be damaged. MNF08004 / DOK-461 Rev / JS / jp / December

30 Sening measuring system 28 Rev / JS / jp / December 2009 MNF08004 / DOK-461

31 Sening measuring system 6 Troubleshooting The exchange or repair of components of the measuring system on road tankers may only be carried out by specialist companies. [A specialist company is a company according to TRbF 20 No. 15.4] Malfunction Possible cause Measure No flow too low flow No control air or air pressure too low Pressure switch in gas monitor has not activated (GMV D only) Solenoid valve defective / electronic device not switched Liquid level in the hood too low vent valve closed strainer in the GMV filter bowl clogged dirty float of the gas monitor defective / stuck control head defective The shut-off valve (V, L or B) does not open rotor of the volume counter stuck strainer in the GMV filter bowl dirty throttle on shut-off valve closed pressure before measuring system too low (only pump operation ) Check the compressed air supply Increase the pressure of the pump / close the throttle on the shut-off valve a little Check the solenoid valve / replace if necessary / check the electronic device Check the flow Open the vent valve Clean the sieve (see Maintenance) Replace the float with the control head (only replace both parts together) Replace valve Replace measuring chamber Make rotor passable (remove impurities) *) Clean sieve (see maintenance) Open throttle Check inlet to measuring system (pump) / pump draws air on suction side A Troubleshooting MNF08004 / DOK-461 Rev / JS / jp / December

32 Sening measuring system Fault Possible cause Measure Output valve does not open Flow switch in the manifold does not switch Mineral oil escapes Control switch or solenoid valve venting Electronic counter shows incorrectly Additional venting (optional) does not vent Additional venting (optional) A large amount of mineral oil is sucked through the hose, no control air or Air pressure too low Valve insert defective No control air or air pressure too low Flow switch defective In the case of a shut-off valve, the seal on the compressed air side is leaking Calibration incorrect The rotor of the volume counter is stiff Venting valve closed Non-return valve on the empty hose connector is defective Discharge with the pump Venting valve is defective Table 2: Malfunctions and possible causes Check the compressed air supply If compressed air is available, replace the corresponding valve *) only by factory-trained specialist companies. Check the compressed air supply. If compressed air is available, replace the manifold. Identify the defective valve and swap (e.g. Connect the clear PA air hose and deliver with the pump) *) Recalibrate / recalibrate (see associated operating instructions) Replace the measuring chamber Make the rotor passable (remove impurities) *) Open the vent valve Replace the non-return valve Close the vent valve Replace the additional vent *) only by factory-trained specialist companies 30 Rev / JS / jp / December 2009 MNF08004 / DOK-461

33 Sening measuring system 7 Technical data Nominal diameter: DN 100 empty hose: DN 100 full hose: DN 80 Materials: Housing: Aluminum Rotor: Gray cast iron also glass, POM, Viton, NBR, brass, stainless steel Weight: approx kg, depending on the equipment, nominal pressure: 10 bar (PN 10) Pneumatics: Working pressure p = 3-7.5 bar (45 to 110 psi) Nominal flow rate: 1000 l / min Minimum flow rate: 100 l / min Smallest delivery quantity: 200 liters Meter accuracy: ± 0.15% rel. Measuring chamber volume: 3.437 liters Discharge temperature: -10 C to +50 C (material temperature) Measured material: Mineral oils and mineral oil products with a viscosity A Technical data η <1 mpa * s to 20 mpa * s Connection dimensions: Approvals: Functional reliability: See appendix, drawing number and the following PTB Gas measuring device: approval mark / slide valve meter: approval mark / TÜV-Nord Overfill protection: certificate from / 2543 ru All requirements are created to meet the DIN. The supplier is responsible for the standard-compliant installation of the measuring system. DIN secured measurement technology on tank vehicles for the delivery of heating oil EL, diesel fuel and biodiesel to end users Table 3: Technical data MNF08004 / DOK-461 Rev / JS / jp / December