Piusi K33 Atex Use And Maintenance Manual

ENGLISH (Translated from Italian) ENGLISH (Translated from Italian)
A TABLE OF CONTENTS
C1 DEFINITION OF CLASSIFIED ZONES
FOREWORD
Definition of zones as shown in directive 99/92/CE
A TABLE OF CONTENTS ZONE 0 Place where an explosive atmosphere made up of a mix of air and inflam-
mable substances in the form of gas, vapour or mist is continuously pres-
B CONFORMITY
ent, either for long periods or frequently.
B1 DECLARATION OF
Note: Generally speaking, said conditions, when they occur, involve the
CONFORMITY (94/9/CE, Annex X, lett. B) inside of tanks, pipes and containers, etc.
ZONE 1 Place where it is probable that an explosive atmosphere, made up of a
C MACHINE DESCRIPTION
mix of air and inflammable substances in the form of gas, vapour or mist,
C1 DEFINITION OF CLASSIFIED ZONES can occur occasionally during normal operation.
Note: Said zone can also include:
C2 INTENDED USE
- places in the immediate vicinity of zone 0;
C3 HANDLING AND TRANSPORT
- places in the immediate vicinity of supply openings;
D GENERAL WARNINGS - places in the immediate vicinity of filling and and emptying openings;
- places in the immediate vicinity of appliances, protection systems and fragile
E FIRST AID RULES
glass and ceramic components, or components made of other similar materials;
F GENERAL SAFETY RULES
- places in the immediate vicinity of inadequately sealed stuffing boxes,
G TECHNICAL DATA e.g., on pumps and valves with stuffing box.
ZONE 2 Place where it is improbable that an explosive atmosphere, made up of a
H OPERATING CONDITIONS
mix of air and inflammable substances in the form of gas, vapour or mist,
H1 ENVIRONMENTAL CONDITIONS can occur during normal operation, but which, if it does occurs, only per-
sists for a short time.
H2 FLUIDS PERMITTED
Note: Said zone can include, among others, places surrounding the zones 0 or 1.
I INSTALLATION ZONE 20 Place where an explosive atmosphere in the form of a cloud of combus-
tible powders in the air is continuously present, either for long periods
L CALIBRATION
or frequently.
M EVERY DAY USE
Note: Generally speaking, said conditions, when they occur, involve the
N MAINTENANCE
inside of tanks, pipes and containers, etc.
O DISASSEMBLING REASSEMBLING
ZONE 21 Place where it is probable that an explosive atmosphere, in the form of a cloud of
P PROBLEMS, CAUSES AND SOLUTIONS
combustible powders in the air, can occur occasionally during normal operation.
Note: Said zone can include, for example, among others, places in the im-
Q DEMOLITION AND DISPOSAL
mediate vicinity of powder loading and emptying points and places where
R EXPLODED VIEW
powder layers form or which, during normal operation, could produce an
explosive concentration of combustible powders mixed with the air.
ZONE 22 Place where it is improbable that an explosive atmosphere, in the form of
B CONFORMITY
a cloud of combustible powders in the air, occur during normal operation
but which, if it does occur, only persists for a short time.
B1 DECLARATION OF
Note: This zone can comprise, among others, places near appliances, pro-
CONFORMITY
(94/9/CE, Annex X, lett. B) tections systems and components containing powder, out of which the
The manufacturer: PIUSI S.p.A. powder can come out due to leaks with the formation of powder deposits
Via Pacinotti, 16/A
(e.g., milling salt, where the powder comes out of the mills and deposits).
46029 Suzzara (MN) Italy
ZONE 1
Declares under its own responsibility that the machine:
Type: Meter
Model: K33 ATEX
ZONE 2
Year of manufacture: refer to the year of production shown on the CE plate affixed to the prod-
uct.
CERTIFIES THAT
comply with all relevant provisions of the following directives:
- 94/9/CE
and the following harmonized standards, applied standards and/or technical specifications:
C2 INTENDED USE
UNI EN 1127-1:2011; UNI EN 13463-1:2009; UNI EN 13463-5:2011
WARNING APPLIANCE FOR THE MEASUREMENT OF FUEL SUITABLE FOR
This equipment is classified as follows:
INTENDED OPERATING IN ZONES CLASSIFIED"1"AND "2", ACCORDING TO
Group II, category 2 G c IIB T=85° C (T6)
USE DIRECTIVE 99/92/CE
THE DETERMINATION OF THE AREAS (ZONES) IS TO BE
Read the Use and Maintenance manual before using the pump.. CARRIED OUT BY THE USER
FORBIDDEN Using the appliance for fluids other than those listed at para-
USE graph "H2 – Fluids permitted" and for uses other than those
described at the item "authorised use" is forbidden.
Place: Suzzara (Mn)
PLANT OPERATION RESTRICTIONS
Date: 01/03/2014
IT IS FORBIDDEN:
Legal Representative
1 To use the appliance in a construction configuration other than
that contemplated by the manufacturer
2 To use the appliance with fixed guards tampered with or re-
moved.
C MACHINE DESCRIPTION
3 To use the appliance in places where there is risk of explosion
and/or fires classified in the following zones:
K33 atex is mechanical flowmeter with nutating disk, designed
0; 20; 21; 22
toallow a precise measurement of Diesel oil or other fluids
4 To integrate other systems and/or equipment not considered
compatible with the manufacturing material. The nutating disk by the manufacturer in the executive project.
5 To connect the appliance up to energy sources other than
of the metering chamber (seediagram 1, drawing "15"), which
those contemplated by the manufacturer
is setin motion by the fluid itself, drives thegear train located in
6 To use the commercial devices for purposes other than those
the cover of themeter body (drawing "8") which transmitsthe indicated by the manufacturer.
7 Don't use in presence of lightnings
motion to the meter (pos. "6"). The meter is equipped with a
non-resettable litre totaliser and a batch register which can be
C3 HANDLING AND TRANSPORT
reset by means of a knob (Pos. "2") whose unit digit is provided
Due to the limited weight and dimensions of the METERS, special lifting equipment is not
with marks for the readout ofthe tenths of a litre.
required to handle them. THE APPLIANCES ARE CAREFULLY PACKED before dispatch. Check
WARNING To ensure a proper and safe use of the meter it is neces-
the packing when receiving the material and store in a dry place.
sary to read and follow the instructions and warnings
contained in this manual. An improper installation
or use of the meter may cause damage to objects and
people.
ENGLISH (Translated from Italian)
D
GENERAL WARNINGS
Important to ensure operator safety and to protect instrument from
precautions potential damage, workers must be fully acquainted with
this instruction manual before performing any operation.
Symbols used in The following symbols will be used throughout the manual to
the manual highlight safety information and precautions of particular im-
portance:
WARNING
Important note for guaranteed safety in classified zones
WARNING indicates a hazardous situation which, if not
WARNING avoided, could result in death or serious injury
NOTICE is used to address pratices not related to personal
injury
NOTICE
Manual preser- This manual should be complete and legible throughout.
vation It should remain available to end users and specialist instal-
lation and maintenance technicians for consultation at any
time.
All reproduction rights are reserved by Piusi S.p.A. The text
Reproduction cannot be reprinted without the written permission of Piusi
rights S.p.A.
© Piusi S.p.A.
THIS MANUAL IS THE PROPERTY OF Piusi S.p.A.
ANY REPRODUCTION, EVEN PARTIAL, IS FORBIDDEN.
This manual belongs to Piusi S.p.A., which is the sole propri-
etor of all rights indicated by applicable laws, including, by
way of example, laws on copyrights. All the rights deriving
from such laws are reserved to Piusi S.p.A.: the reproduction,
including partial, of this manual, its publication, change,
transcription and notification to the public, transmission,
including using remote communication media, placing at
disposal of the public, distri¬bution, marketing in any form,
translation and/or processing, loan and any other activity
reserved by the law to Piusi S.p.A..
NOTE THIS MANUAL IS VALID ONLY FOR K33 ATEX METER
WARNING BEFORE PROCEEDING WITH THE REFUELLING OF THE
AIRCRAFT, ENSURE THAT THE SYSTEM INTENDED FOR
SUCH ACTION COMPLIES WITH THE REGULATIONS IN
FORCE IN THE COUNTRY OF USE
WARNING USE THE METER ONLY WITH FLUIDS PERMITTED.
DO NOT USE WITH FLUIDS NOT PERMITTED TO AVOID
DAMAGING THE INSTRUMENT. THE GUARANTEE
LAPSES IN CASE OF MISUSE OF THE FLUID.
DO NOT USE THE METER WITH LIQUID FOOD PROD-
UCTS AND/OR WATER-BASED FLUIDS.
Before connection, make sure that the piping and the suction
tank are free of dirt and solid residue that could damage the ME-
TER and its accessories. NEVER COLLECT THE FLUID FROM THE
ZONE 0
BOTTOM OF THE TANK SINCE IT MAY CONTAIN IMPURITIES
BEFORE USING THE PUMP SWITCH OFF ALL THE ELEC-
ZONE 20
TRONIC DEVICES ( I.E. MOBILE PHONES, BEEPERS ETC.)
ZONE 21
E FIRST AID RULES
Contact with In the event of problems developing following EYE/SKIN CON-
the product TACT, INHALATION or INGESTION of the treated product, please
refer to the SAFETY DATA SHEET of the fluid handled.
NOTE Please refer to the safety data sheet for the product
SMOKING DO NOT SMOKE NEAR THE METER AND DO NOT USE
PROHIBITED THE INSTRUMENT NEAR FLAMES.
F GENERAL SAFETY RULES
WARNING IT IS ESSENTIAL TO GET TO KNOW AND UNDERSTAND
USER'S THE INFORMATION CONTAINED IN THIS MANUAL.
RESPONSIBILITY IT IS ESSENTIAL TO GET TO KNOW AND OBSERVE THE
SAFETY SPECIFICATIONS FOR FLAMMABLE LIQUIDS.
BEFORE USING THE METER IT'S IMPORTANT TO TRAIN
OPERATORS, INSTALLERS AND MAINTENANCE STAFF
TO LET THEM WORK IN A PARTICULAR AREA NO. 1 AS
MENTIONED BY DIRECTIVE 94/9/EC
Essential IN CASE OF CONTACT WITH THE PRODUCT AND FOR GOOD
protective STANDARD OF BEHAVIOUR, wear protective equipment which
equipment is:
characteristics • suited to the operations that need to be performed;
• resistant to products used
TO DO SO, PLEASE REFER TO THE RELEVANT TECHCNICAL
DATASHEETS OF THE FLUID USED.
Personal
protective
equipment
close-fitting clothing
safety shoes
that must be
worn
protection gloves
safety goggles
Necessary
safety
devices instructions manual
Protective Prolonged contact with the treated product may cause skin
gloves irritation; always wear protective gloves during dispensing.
NOTE TO PREVENT ELECTRIC SHOCK AND DETONATION OF
SPARKS, ALL PUMPING SYSTEM MUST HAVE PROPER
GROUNDING, INCLUDING TANK AND ANY ACCESSORIES.
WARNING FAILURE TO OBSERVE THE ABOVE MENTIONED RULES
CAN CAUSE SERIOUS ACCIDENTS
ENGLISH (Translated from Italian) ENGLISH (Translated from Italian)
G TECHNICAL DATA L CALIBRATION
Technical data Mod. K33 ATEX FOREWORD K33 ATEX are pre-calibrated in factory to be used with Diesel
Meter Mechanism Nutating disk oil. As specific operating conditions (suchas real flow rate,
Flow rate (range) 20 ÷ 120 litres/min
nature andtemperature of the measured fluid) may affect
Operating pressure (max) 3,5 bar
the meter accuracy, a re-calibration should be carried out
Burst pressure (min) 28 bar
afterthe installation has been completed. A new calibration
Storage temperature (range) -20 +80 °C
Storage humidity (max) 95 % RU is necessary eachtime the meter is disassembled formain-
Operating temperature (range) -20 +60 °C
tenance operations or when it isused to measure fluids that
Pressuer loss with diesel oil Flow rate (l/min) 30 60 90
differ fromDiesel oil.
Pressuer loss (bar) 0.005 0.2 0.4
CALIBRATION 1 Unscrew the plug (see diagram 1,pos. "14").
Accuracy after calibration +/- 1%
2 Purge the system (pump, pipelines, meter) of air by dispens-
Repeatability (typical) +/- 0.3% PROCEDURE
Batch total readout 3 digits height 18 mm ing until the flow stream is full and steady.
Totaliser readout 6 digits height 6mm 3 Stop the flow by shutting off the nozzle, but let the pump
Readout resolution 0.1 litri
running
Connections (inlet/outlet) 1" BSP
4 Reset the batch register by means of the reset knob (pos. "2").
Weight (approximate) 1.8 Kg 1.9 Kg
Package dimensions 185x185x170 mm 5 Dispense at the flow rate which thebest accuracy is required
Optional features Registration in US gallons female
at, by using a calibration container having a capacity not
threaded inlet/outlet 1"NPT
lower than 20 litres. Do not reducethe flow in order to reach
the graduated zone of the calibration container. Theright
H OPERATING CONDITIONS
method is to start and stop the fullflow repeatedly until the
required fillingis obtained.
H1 ENVIRONMENTAL CONDITIONS
6 Compare the indication of the calibration container (real
AMBIENT min. +23 °F / max +140 °F value) withthe one of the meter (indicated value).
TEMPERATURE min. -20 °C / max +60°C - If the indicated value is higher than the real value, loosen
FLUID
min. +23 °F / max +140 °F the screw (pos. "12");
TEMPERATURE
min. -20 °C / max +60 °C - If the indicated value is lower than the real value, tighten
RELATIVE HU- max. 90%
the screw (pos. "12").
7
MIDITY Repeat the operations 4 to 6 until accuracy is satisfactory
LIGHTING The environment must conform to directive 89/654/EEC on 8 Tighten the plug (pos. "14") again. The O ring which the
work environments. calibration screwis provided with, has the function to avoid
In case of non-EU countries, refer to directive EN ISO 12100-2 accidental loosening of the adjustment screw but does not
§ 4.8.6. haveany sealing functions. Therefore it is always necessary
WARNING The temperature limits shown apply to the METER compo-
toproperly fix the plug with the sealinggasket (pos.
nents and must be respected to avoid possible damage or
malfunction. M EVERY DAY USE
WARNING THE WORKING OPERATIONS MUST ALWAYS BE
H2 FLUIDS PERMITTED
GUARDED BY THE OPERATOR.
WARNING THE PUMP CAN BE USED ONLY WITH THE FOLLOWING
Should any sealants be used on the suction and deliv-
FLUIDS:
ery circuit of the pump, make sure that these products
- DIESEL - KEROSENE
are not released inside the meter.
- PETROL - PETROL ALCOHOL MIXED MAX 20% (E20) Foreign bodies in the suction and delivery circuit of
- AVGAS 100/100LL - JET A / A1 the pump could cause malfunctioning and breakage
- ASPEN 2 / 4
of themeter components.
While dispensing, do not inhale the pumped product
I INSTALLATION
IF ANY TREATED FLUID LEAKS OUT DURING DISPENS-
FOREWORD The meters K33 ATEX can be installedin any position, on
ING, TAKE ALL STEPS NECESSARY TO ENSURE THE
rigid pipelines or flexible hoses, directly on pumps ortanks.
LEAKED FLUID IS CLEANED UP AND SAFE AS SPECI-
The meter flow direction is fixed and indicated by an arrow.
FIED ON THE PRODUCT TECHNICAL SHEET.
USE
The meteris supplied in the standard configuration (A). The After installation and calibration K33 ATEX is ready to work.
Turn the reset knob (see diagram 1,pos. "12") (clockwise if it
meter and the cover (see diagram1, pos. "3") can be rotated
is mounted on the left of the meter and anticlockwiseif it is
by 90° to 90° in respect to the body in order to carry out
mounted on the right) until the batch register is completely
the different configurations shown (B, C, D). The reset knob
reset. The totaliser cannot be reset in any way. Make sure that
can be installed either on the right side or on the left side during use pressure does not exceed the value indicated in-
section "Technical data".
of the meter. In order to modify the standard configuration
USE BY GRAVITY K33 ATEX can also be used in fuel units which are not
follow the instructions given in section "Disassembling / Re-
equipped with pump sand where the flow is generated by
assembling". The meter body is equipped with 4 blind holes
the difference in fuel level between the tank and the nozzle
(see diagram 2) which can be threaded (M5) for a possible outlet. As a reference, a system composed ofa tank off the
fastening.If solid particles enter the measuring chamber the ground, with the meter installed right at the bottom of the
tank,a 3-m long 1'' flexible pipe and a manual nozzle type Self
correct working of the nutating disk may be affected.Always
2000, guarantees aflow rate of approximately 30 litres/min-
filter the fluid by installing a filter on the meter inlet (recom-
ute if the difference in level is higherthan 1.5 metres. Longer
mended filter 400 μ).
pipes or nozzles producing higher pressure losses reduce the
A flowin respect to the existing difference inlevel. Use by grav-
ity is not recommended with differences in level lower than
1metre, as the consequent reduced flowrate causes the me-
ter to work outside its guaranteed accuracy range. On field
calibration is always advisable in case of gravity installations.
B C
N MAINTENANCE
FOREWORD No ordinary maintenance is required provided that the meter K33 ATEX
is properly installed and used. An incorrect filtering on the meter inlet
may block or wear out the measuring chamber, thus affecting the me-
D
ter accuracy. Should this problem occur (see section"Problem, Causes
and Solutions") disassemble the measuring chamber, as shown in
section"Disassembling/Reassembling".
Necessary cleaning can be carried out by means of a soft brush or small
tool (i.e. a screwdriver). During cleaning be careful not to damage the
WARNING BEFORE ANY OPERATION, ENSURE TO BE OUT OF
chamber or the disk. Carefully check the meter and replace the parts
POTENTIALLY EXPLOSIVE AREAS
which have suffered any possible damage. Only use the original spare
The meter must never be operated before the delivery and
part kits shown in diagram 1 "Exploded view and spare part list". A new
suction lines have been connected. calibration is always necessary after cleaning or replacing the meter
parts.
PRELIMINARY
- Verify that all components are present. Request any missing parts
WARNING TO MAINTAIN THE SAFETY OF THE APPLIANCE, IT IS
CHECK from the manufacturer.
MANDATORY TO REPLACE THE DAMAGED PARTS.
- Check that the meter has not suffered any damage during transport FOR SAFETY PURPOSES, YOU MUST USE ONLY GENU-
INE SPARE PARTS.
or storage.
Safety instruc-
WARNING IF VALVES IN THE CIRCUIT ARE TO BE INSTALLED, MAKE During maintenance, the use of personal protective equipment (PPE) is
tions
compulsory.
SURE THEY ARE EQUIPPED WITH OVERPRESSURE SYSTEM.
In any case always bear in mind the following basic recommendations for
CLEAN THE TANK AND MAKE SURE IT IS WELL-VENTILATED
a good functioning of the METER
(RECOMMENDED OPENING PRESSURE: 3 psi)
WARNING BEFORE ANY OPERATION, ENSURE TO BE OUT OF
APPLY THE QUICK COUPLING TO THE TANK CORRECTLY
POTENTIALLY EXPLOSIVE AREAS
AND SAFELY
Authorised
All maintenance must be performed by qualified personnel. Tampering
maintenance
can lead to performance degradation, danger to persons and/or prop-
personnel erty and may result in the warranty and UL/ATEX CERTIFICATION being
voided.
Measures to be Check that the labels and plates found on the dispensing system do not
taken deteriorate or become detached over time.
ONCE A WEEK:
- Check that the pipe connections are not loose to prevent any leaks;
ENGLISH (Translated from Italian)
O DISASSEMBLING REASSEMBLING
FOREWORD K33 ATEX METER can be easily disassembled into its main
parts without removing thebody from the pipes.
METER UNIT To disassemble the meter unit operate as follows:
A Remove the reset knob by firmly pulling it axially
B Loosen the 4 retaining screws (see diagram 1, pos. "7")
C Loosen the 2 screws (pos. "5").
To reassemble the unit reverse the procedure described
above.
RESET KNOB To modify the reset knob position:
A Perform only the operations a) and b) described above.
B Take out the plug (see diagram 1,pos. "4") by pushing it from
the inside towards the outside of the cover
C Fix again the plug on the opposite hole by placing it inside
the cover and pushing it outwards.
D Fix again the meter cover and resetknob
MEASURING
To enter the measuring chamber operate as follows:
CHAMBER A Disassemble the meter unit.
B Loosen the eight screws (see diagram 1, pos. "7").
C Remove the body cover (pos. "8") together with the gear unit.
During this operation be careful not to damage the gasket
(pos. "10").
D Remove the whole measuring chamber (pos. "11") by lifting it
from themeter body and at the same time pulling it back to-
wards the inlet in order toremove the O ring (pos. "16") from
its seat at the outlet.
To check the inside of the measuring chamber (pos. "15"), remove the O ring and divide the
two half chambers containing the nutating disk. Measuring chamberTo enter the measuring
chamber operate as follows:
A Check that the nutating-disk rotates freely in the ASSEMBLED
measuring chamber;;
B Install the gasket seals correctly after having checked and
lubricated them;
C During the assembly of the lid on the body prevent the
needle of the nutating-disk from jamming on the gear that
"12")..
should be free to be able to be correctly drawn from the disk
needle;
D
Properly tighten the screws (position. "7")
GEAR UNIT To reach the gear unit components:
A Remove the cover
B
Loosen the screws
C Remove the plate. Now all gears canbe reached for inspec-
tion. Should the gasket be replaced, remove the bevel
gear from the shaft by pulling axially,then remove the gear
together with theshaft. The gasket replacement always re-
quires the replacement of the bush provided with the spare
part kit. Toreassemble reverse the above described proce-
dure paying particular attention to:
• Lubricate the O ring before installation.
• Check that the gear unit can rotate freely before fixing the
MANUALE D'USO E MANUTENZIONE
cover
USE AND MAINTENANCE MANUAL
P PROBLEMS, CAUSES AND SOLUTIONS
For any problems contact the authorised dealer nearest to you.
Problem Possible cause Corrective action
Leak from the- •Damaged gasket Remove (see section "Gear unit") an-
shaft gasket dreplace the O ring and the bush
Insufficient ac- •Wrong calibration Repeat calibration following the in-
curacy structions in section "Measuring cham-
ber"
•Soiled or blocked mea- Clean the measuring chamber follow-
suring chamber. ing the instructions in section "Meter
unit"
• Air in the fluid Locate and eliminate leaks in inlet lines
Reduced flow- • Clogged or blocked Clean the measuring chamber follow-
rate measuring chamber ing the instructions in section "Measur-
ingchamber"
• Blocked or soiled filter Clean the filter
Q DEMOLITION AND DISPOSAL
Foreword If the system needs to be disposed, the parts which make it up must be
delivered to companies that specialize in the recycling and disposal of
industrial waste and, in particular:
Disposal of pack-
The packaging consists of biodegradable cardboard which can be deliv-
ing material
ered to companies for normal recycling of cellulose.
Disposal of metal
Metal parts, whether paint-finished or in stainless steel, can be consigned
parts to scrap metal collectors.
Disposal of electric These must be disposed of by companies that specialize in the disposal
and electronic of electronic components, in accordance with the indications of directive
components 2002/96/CE (see text of directive below).
European Directive 2002/96/EC requires that all equipment marked
with this symbol on the product and/or packaging not be disposed of
together with non-differentiated urban waste. The symbol indicates that
this product must not be disposed of together with normal household
Information
waste. It is the responsibility of the owner to dispose of these products
regarding the envi-
as well as other electric or electronic equipment by means of the spe-
ronment for clients
cific refuse collection structures indicated by the government or the local
residing within the
governing authorities.
European Union
Disposal of miscel- Other components, such as pipes, rubber gaskets, plastic parts and wires,
laneous parts must be disposed of by companies specialising in the disposal of indus-
trial waste.
K33
Atex
IT
EN
Bulletin M0268 ITEN _ 00
PIUSI S.p.A.
Suzzara (MN) Italy
Bulletin M0268 ITEN _ 00