Bulletin M0092d EN_00
©PIUSI S.p.A.
EN
This document has been drawn with great care about the accuracy of the data
contained therein. However, PIUSI S.p.A. takes no responsibility for any mistakes
and omissions.
ENGLISH
(Translation of the original language)
ENGLISH
(Translation of the original language)
ENGLISH
(Translation of the original language)
ENGLISH
(Translation of the original language)
ENGLISH
(Translation of the original language)
ENGLISH
(Translation of the original language)
ENGLISH
(Translation of the original language)
1
INDEX
1
INDEX
2
CE DECLARATION OF CONFORMITY
3
GENERAL PRECAUTIONS
3.1
SAFETY WARNINGS
4
GETTING TO KNOW THE METER
4
DETAILED INFORMATION ON THE METER
4
MANUAL AND AUTO OPERATION
5
INSTALLING THE METER
5.1
SYSTEM REQUIREMENTS
5
LINE PRESSURE RELIEF
5.3
FLUSHING THE LINES
5.4
PRELIMINARY CHECKS ON THE METER
5.5
MOUNTING THE EXTENSION ON THE METER
5.6
ASSEMBLING THE METER
5.7
AIR PURGING FROM THE LINES
5.8
CHECKING THE FLOW-RATE
6
USING THE METER
6.1
DISPENSING IN MANUAL MODE
6.2
DISPENSING IN AUTO MODE
7
CUSTOMIZING THE METER
7.1
CUSTOMIZINGuMENU
7.2
FREQUENTLY USED PRESET VALUES
7.3
UNIT OF MEASUREMENT
7.4
DECIMAL DIGITS
7.5
AUTO RESET
7.6
STOP PRECISION IN AUTO MODE
7.7
CALIBRATION
8
MAINTENANCE OF THE METER
8.1
BATTERY REPLACEMENT
8.2
FILTER CLEANING
9
PRODUCT IDENTIFICATION
10
CONSTRUCTION DATA
10.1
TECHNICAL DATA
10.2
DIMENSIONS
10.3
SPARE PARTS EXPLODED VIEW
10.4
TROUBLESHOOTING
11
DISPOSAL
2
CE DECLARATION OF CONFORMITY
The undersigned:
PIUSI S.p.A
Via Pacinotti 16/A z.i. Rangavino
46029 Suzzara - Mantua - Italy
DECLARES
on its own responsibility, that the machine described below:
Description: Dispensing nozzle for oil.
Model:
K500
is in compliance with the legislative regulations which transpose directives:
- 2014/30/EEC (electromagnetic compatibility directive)
and subsequent amendments.
Documents are made available to the appropriate authority on request at Piusi S.p.A.
Alternatively, it can be requested writing to: e-mail: [email protected]
The person in charge of writing both the technical file and the conformity statement is Otto
Varini as the legal representative.
Suzzara 20/04/2016
Otto Varini
The legal representative
3
GENERAL PRECAUTIONS
Important
warnings
In order to protect workers' safety, to avoid damaging and before
performing any operation, please read and familiarize with the
whole instruction manual.
Symbols used
in the manual
In order to signal particularly important instructions or warnings,
the following symbols are used:
This symbol highlights important aspects as to
SAFETY
.
This symbol highlights important aspects as to the
CORRECT
USE
of the METER.
This symbol highlights important aspects as to avoid
POLLUTION HAZARDS
.
The instructions provided by this manual satisfy both the
Installer's and the Users' requirements (Manager and Operators)
of the METER.
In the Table of Contents a symbol alongside each paragraph
indicates the person this information is intended for.
Operator
All paragraphs marked with this symbol concern the Operator.
The operator is the person who uses the METER to carry out
dispensing operations.
Therefore the Operator is not expected to read paragraphs
other than those marked with this symbol.
Manager
All paragraphs marked with this symbol concern the Manager.
The METER offers several options (selection of the unit of
measurement, selection of the Number of Decimal Digits,
Calibration, etc.). At least one skilled Operator (hereinayer
referred to as the Manager) must know this data in order to allow
the Operators to use the METER correctly. The Manager must
read thoroughly all paragraphs concerning the Manager and the
Operator.
Installer
All paragraphs marked with this symbol concern the Installer
only.
He is responsible for installing the METER and is required to
read the manual thoroughly, no paragraph omihed.
Manual storage
This manual must be intact and completely readable. The
final users, as well as the qualified technicians authorised to
installation and maintenance must be able to view it at any time.
Reproduction
rights
Piusi S.p.A. is the exclusive owner of all rights envisaged by
applicable laws, including the rules concerning copyrights.
All rights arising from these standards are reserved to Piusi
S.p.A.: even partial reproduction of this manual, its publication,
edit, transcription, communication to the public, distribution,
marketing in any form, translation and/or processing, lending,
and any other activities are reserved by law to Piusi S.p.A..
This manual is and
essential and integral part of the product
and must be handed over to the personnel who carries out the
installation, uses and maintains the METER.
Read all indications given in this manual as they provide important
instructions as to safe installation, use and maintenance.
Keep this manual safe for future reference.
Do not remove, tear or modify any part of this manual for any
whatsoever reason.
In case of loss or damage, a new copy can be requested to the
manufacturer, provided the relevant code is indicated.
The manufacturer is not liable for any damage to persons, things
or the unit itself, if the latter is installed or used incorrectly.
rst
SAFETY.WARNINGS
ATTENTION
Mains -
preliminary
checks before
installation
You must avoid any contact between the electrical power supply
and the fluid that needs to be pumped.
Control and
maintenance
operations
Before any checks or maintenance work are carried out,
disconnect the power source.
FIRE AND EX-
PLOSION
When flammable
fluids are present
in the work area,
be aware that
flammable fumes
can ignite or
explode while the
station is oper-
ating.
To help prevent fire and explosion:
Use equipment only in will ventilated area.
Keep work area free of debris, including rags and spilled or open
containers of solvent and gasoline.
Do not plug or unplug power cords or turn lights on or off when
flammable fumes are present.
Ground all equipment in the work area.
Stop operation immediately if static sparking occurs or if you feel
a shock. Do not use
equipment until you identify and correct the
problem.
Keep a working fire extinguisher in the work area.
EQUIPMENT
MISUSE
Misuse can
cause death or
serious injury
!
Do not operate the unit when fatigued or under the influence
of drugs or alcohol.
Do not leave the work area while equipment is energized or in op-
eration.
Turn off the equipment when not in use.
Do not alter or modify the equipment. Alterations or modifica-
tions may void agency approvals and create safety hazards.
Route hoses and cables away from traffic areas, sharp edges,
moving parts, and hot surfaces.
Keep children and animals away from the working area.
Respect all safety norms in force.
TOXIC FLUID
OR FUMES
HAZARD
For issues arising from the treated product with eyes, skin, inhalation
and ingestion refer to the safety data sheet of the fluid used.
Store hazardous fluid in approved containers, and dispose of it
according to applicable guidelines.
Prolonged contact with the product may cause skin irritation; during
delivery phases, always wear protective gloves.
4
GETTING TO KNOW THE METER
The METER is a dispensing nozzle for oils and other fluids, to
be installed as a final shutoff device at the end of pressurized
flexible hoses.
Besides guaranteeing an exact measurement and display of the
fluid amount dispensed, when used as a normal nozzle.
The METER also allows the user to PRESELECT the quantity
to be supplied and automatically stops dispensing when the
preset amount has been reached.
The METER integrates:
"
(
#
%
&
!
'
$
A.
An ergonomic handle.
B.
A swivel, with a rubber cover, which allows the user to rotate the handle
independently from the connected flexible hose.
C.
A flow control valve, activated by a trigger, which is equipped with a protection
against accidental starts.
D.
A meter with oval gears, controlled by an electronic board and equipped with a
battery-powered microprocessor.
E.
A large liquid-crystal display, integrated in the 5-key keypad, for the communication
between the K500 and the Operator.
F.
A motorized valve shutting system, automatically activated by a microprocessor
when dispensing a PRESELECTED amount (AUTO mode).
G.
A multi-position extension to adjust the angle of the valve with respect to the handle.
H.
An automatic no-drip valve, adjustable with respect to the end, to further facilitate
dispensing in confined spaces.
4.1
DETAILED.INFORMATION.ON.THE.METER
The handle
An external shock-resistant plastic cover contains all the
components of the METER and provides an ergonomic handle.
The baSeries
The baheries are housed in the upper compartment. The cover
is fixed by means of four cross-head screws. The user can easily
access this compartment to replace the baheries.
Filter
The swivel and filter
The METER is equipped with a swivel to be connected to the
flexible hose.
The swivel is equipped with a 1/2" female thread (BPS or NPT)
and houses the filter.
The large filtering surface guarantees a reduced pressure loss.
The rubber cover of the swivel
During installation the swivel may be equipped with a rubber
cover to prevent the swivel itself or the metal end of the flexible
hose from damaging the vehicle body.
This cover is available in different colours, which can be used as
a "colour code" to identify the dispensed product easily.
The trigger
The METER is equipped with a balanced valve, controlled by a
trigger, which can be activated using just one finger.
The trigger, protected against accidental starting, can be:
Released
The valve is in
closed position
.
Fully pressed
The valve is in
maximum open position
.
Locked in open position
The valve is in open position for
automatic operation
.
The liquid-
crystal display
“LCD”
The METER uses an LCD with the following numeric registers
and indications:
1.
Batch total
(4 digits, floating point)
2.
Totals
(7 digits).
3.
Indication
of the Total type (TOTAL / Resettable TOTAL).
4.
Indication
of the Unit of Measurement:
QTS = Quarts
PTS = Pints
LIT = Liters
GAL = Gallons
5.
Indication
of operation in AUTO mode.
The LCD automatically turns off if the METER is not used for a
certain period.
To reactivate the LCD press the RESET key.
Keypad
The keypad is of membrane type and is equipped with 5 keys.
Numeric keys
to be used
to set the PRESET value
(automatic dispense stop
value).
AUTO key
to be used to
select and confirm the PRESET value.
RESET key
to be used to reset the Batch Total and to display the
Resehable TOTAL.
Liter-counter
meter
To guarantee an accurate measurement of the dispensed amount
the METER uses the principle of the oval gears.
Multi-position
extension
To guarantee an easy use, the METER is equipped with a multi-
position extension. It can be positioned by the operator within
a 75° range.
75°
The dripless valve can be rotated by 240°
4.2
MANUAL.AND.AUTO.OPERATION
The METER is a PRESETTABLE dispensing nozzle which can be
used in two operating modes:
MANUAL Mode
In MANUAL mode, dispensing starts as soon as the Operator
operates the trigger.
The only preliminary operation to be carried out by means of
the METER keys is the possible resehing (RESET) of the value
previously indicated on the Batch total.
The operator must check the dispensing operation personally
and stop it by releasing the trigger when the desired amount is
reached.
The METER has been designed to ensure maximum safety during
use an avoid oil spillage due to an improper use or operator's
carelessness.
In particolar the METER does not allow
the valve to be locked in
open position during MANUAL mode
. This avoids a continuous
dispensing, should the operator be absent or has not preset an
automatic stop value (AUTO mode).
AUTO Mode
To dispense using the PRESELECTION option, before starting
dispensing the operator must:
Select
the desired amount by means of the METER keys as
explained in paragraph 6.2.
Confirm
the selected value thus entering the AUTO mode:
The METER displays the
AUTO
message and is ready to
dispense automatically without requiring the presence of the
operator.
Start dispensing
, by pulling the trigger and sehing it to the
locked position.
The operator's presence is no longer needed and he can wait
until the METER automatically stops once the selected amount
has been dispensed.
In any case the operator must attend to the METER while
dispensing in AUTO mode in order to avoid any oil spillage due
to external factors.
Carefully read the instructions given in paragraph 6.2 before
dispensing in AUTO mode.
The METER allows the user to lock the trigger in open position
only when the display shows the message
AUTO
.
To lock the trigger in open position:
pull it completely;
then release it.
If the message AUTO blinks, automatic dispensing cannot
be started;
if the trigger is completely pulled and afterwards
released, it does not remain locked in position, but it closes again
thus interrupting the dispensing operation.
The blinking message
AUTO
indicates that
the selecting phase
of the desired value is still in progress
, but the AUTO mode has
not yet been entered by confirming the displayed value.
The METER automatically unlocks the trigger thus stopping the
dispensing when the predetermined value has been reached.
However, while dispensing in
AUTO mode,
it is possible to stop
dispensing manually before the desired value is reached by
unlocking the trigger.
To unlock the trigger and set it in closed position again:
pull it completely;
then release it.
When the dispensing has been manually stopped, as soon as
the AUTO message is displayed, it is possible to restart the
automatic operation as the trigger can still be locked in open
position.
The METER automatically exits the AUTO mode after a given
period of time (TIME OUT) without dispensing.
5
INSTALLING THE METER
This paragraph describes the necessary operations to be
carried out when the METER is installed for the first time on a
new system or to replace an existing nozzle with the METER.
5.1
SYSTEM.REQUIREMENTS
1
2
4
3
5
6
The METER has been designed to be used as a component of
a
centralized system for oil distribution
and other industrial
fluids, which must be
manufactured and installed by specialized
personnel in compliance with the standards
relevant to such a
pressurized system.
To explain the installation and maintenance operations relevant
to the METER, refer to the following diagram which shows
a
typical installation
, as regards to the components located
directly upstream any
“dispensing outlet”
of the METER.
1.
Distribution system lines.
2.
Shut-off valve.
3.
Flexible hose for reel entry.
4.
Reel.
5.
Flexible hose.
6.
Nozzle.
The presence of the
shut-off valve
in the system is necessary
to ensure a safe and correct installation and maintenance
of the METER without requiring to make the whole system
unserviceable.
The structure and complexity of the system upstream the above-
mentioned shut-off valve (rigid or flexible feeding lines, pumps,
tanks, valves, etc.) as well as the possible presence of the flexible
hose reel can be freely chosen by the installer. In fact they do not
affect the maintenance operations of the METER.
5.2
LINE.PRESSURE.RELIEF
This operation is to be carried out when replacing a pre-existing
nozzle with the METER nozzle or when dismounting the METER
for maintenance purposes.
Failure to carry out the line pressure relief procedure may
cause damage to persons or things.
Close the shut-off valve.
Otherwise
stop the feeding pump
and make it unserviceable to avoid an accidental re-start
during maintenance operations.
Operate the valve of the nozzle to be replaced (or of the
METER to be disassembled for maintenance purposes)
dispensing into a suitable container in order to release the
line pressure.
If a
dripless valve
is installed at the end of the nozzle, the
pressure inside the line will not drop to zero, but it may remain
around 0.2 - 0.5 bar, according to the dripless valve used.
Only for METER dismounting: remove the rubber cover from
its coupling on the swivel and move it along the flexible hose
in order to gain an easy access to the swivel.
By means of two wrenches, unscrew the threaded end of the
flexible hose from the swivel.
Be careful to collect any oil leakage into a suitable container.
5.3
FLUSHING.THE.LINES
Flushing the lines means to let a given amount of oil flow inside
them, so as to ensure a proper
“washing”
of the whole system,
a correct cleaning
and the absence of dirt, contaminated
material or processed waste inside the lines before installing
the nozzle.
The flushing operation must be carried out on
all lines upstream
the nozzle
and, in case the system is equipped with more than
one nozzle, flush the lines which supply the nozzles farthest away
from the supply pump, then continue with the nozzles situated
near the pump.
The flushing procedure depends on the type and features of
the system and must be carried out by trained and qualified
personnel in compliance with the procedures set down by the
installer.
This operation is absolutely necessary with NEW
INSTALLATIONS or if the lines used are contaminated.
Consequently it may not be necessary to carry out this
procedure when replacing a nozzle already in use.
5.4
PRELIMINARY.CHECKS.ON.THE.METER
Make sure that the threaded end fihed on the flexible hose is
suitable for the swivel of the METER equipped with:
Female
thread 1/2” BSP
or
Female thread 1/2” NPT.
Filter
Check that the METER nozzle to be installed is complete and
in good condition, making sure that the
filter
is
clean
and
correctly installed
(see paragraph 8.2).
The METER filter
, characterized by a large filtering surface,
has been designed to guarantee a correct filtering and a low
pressure loss.
To remove and re-install the filter, refer to paragraph 8.2.
The absence or improper installation of the filter may
block the
METER valve o the liter-counter
if dirt is present in the tubes.
This situation may occur especially during new installations. To
solve these problems,
consult a qualified Service Centre.
usu
MOUNTING.THE.EXTENSION.ON.THE.METER
D
E
B
C
A
Three different types of extensions
can be installed on the
METER nozzle:
SWIVELLING extension;
RIGID extension;
FLEXIBLE extension;
All of them are equipped with an
automatic dripless valve.
All extensions on the nozzle side are equipped with a rigid
ending part (external Ø 12 mm, 3/8"G nut) suitable for a quick
connection to the METER without using any sealant.
Remove the plug from outlet
A
(3/8”G).
Make sure that gasket
B
on the swivel is correctly seated.
Lubricate the gasket and its seat.
Tighten end
D
on METER by means of two wrenches; while
the first one on outlet
A
locks the METER, the second one
tightens nut
C
on end
D
. Before locking nut
C
orientate valve
E
.
An improper tightening of the extension may cause it to
become loose thus endangering persons or things
. Tighten the
ring nut with a torque wrench setting of 3.5 Kgm
5.6
MOUNTING.THE.METER
Fit the rubber cover of the swivel into the flexible hose, in
the direction indicated in figure, making it slide over the male
thread of the hose.
Apply a thread sealant to the male thread of the hose.
Tighten the swivel completely by means of two wrenches.
Slide the rubber cover towards the valve until it fits into the
seat, located on the swivel.
5.7
AIR.PURGING.FROM.THE.LINES
After the installation of the nozzle, a certain quantity of air will
be inevitably present both inside the flexible hose downline the
shut-off valve and in the other system lines. To purge the air
and guarantee a
steady flow and a correct calculation of the
amount dispensed,
two operators should proceed as follows:
With the shut-off valve still closed, insert the METER
extension into the opening of a container of suitable capacity,
to avoid spraying or spillage which may occur during the initial
irregular flow.
While the first operator acts on the METER trigger, the
second must open the shut-off valve; when the flow starts
being steady, the second operator shall set the valve to the
fully open position.
Continue line purging while keeping the METER valve
completely open, till reaching a steady flow. At this point
release the trigger thus stopping dispensing.
5.8
CHECKING.THE.FLOW-RATE.
Once carried out the installation and purging operations, it is
advisable to check the dispensing flow-rate which must comply
with the range indicated in paragraph 10.1, to ensure a correct
operation of the valve.
The METER allows the user to check easily and directly the
dispensing flow-rate:
During the operation in MANUAL mode,
press and keep
pressed the AUTO key
.
The METER will display the current flow-rate in units per minute.
Batch total dispensed
Current flow-rate
If the flow-rate exceeds the range limits, adjust the system
components (pumps or balancing valves) to comply with them.
6
USING THE METER
The METER has been designed for professional use and
must be
utilized by adult personnel properly trained for the
intended purpose.
The METER must not be used outside the operating ranges
(see Technical Data in paragraph 10.1) or for fluids other than
lubricants and anti-freeze mixtures.
Do not tamper with or modify the METER.
Regularly check the good condition of the METER.
The METER dispenses high-pressure fluids; do not point the
nozzle to any part of the body.
Use the personal protection equipment recommended by the
national standards relevant to the dispensed products.
Do not carry out any maintenance operation on the METER
without previously relieving the pressure from the system
lines.
The METER is designed for indoor use only.
Is used outdoors, make sure it will not be exposed to rain, snow
or direct sunrays.
In case of manual dripless valve, after a daily use it is important
to discharge the overpressure between the chamber
(1)
and
the manual valve
(2)
of the spout. Carry out this operation with
the pump switched off. Then unscrew the valve
(2)
. During this
discharging operation, do NOT push the trigger
(3)
.
6.1
DISPENSING.IN.MANUAL.MODE
The METER can be used as a normal dispensing nozzle if the
operator does not preset an automatic stop value.
If the METER is off, press RESET to restart it.
The METER displays:
Last amount
dispensed
Non-resettable
Total
The METER can be programmed to display the last amount
dispensed until the RESET button is pressed or to automatically
reset the Batch Total a few minutes after a dispensing operation
in MANUAL mode (see “Auto RESET” at paragraph 7.5).
If the last dispensing operation has been carried out in AUTO
mode, the dispensed amount is never reset, independently from
the selection of the Auto RESET.
ReseSing the
Batch Total
To reset the batch total, press RESET. The METER will display:
Resettable Batch total
Non-resettable
Total
ReseSing the
Total
To reset the resettable Total, press and keep pressed the RESET
key. The METER will display:
Non-resettable
total
Dispensing
Pull the trigger to dispense.
Release the trigger to stop dispensing.
6.2
DISPENSING.IN.AUTO.MODE
The METER allows the user to select the automatic stop value -
“PRESET value”
- with different procedures:
Direct seSing
of a new
PRESET value
The METER allows the user to directly set the PRESET value
by means of the numeric keys.
If the METER is off, press RESET to restart it.
The METER will display:
Non-resettable
Total
To select a new PRESET value (for example 12.3) use the numeric
keys.
The METER will display:
Selected value
AUTO message
Blinking
As long as the AUTO message blinks, it is not yet possible to
start a new automatic dispensing
; if the trigger is completely
pulled, when released, it does not remain locked in open position
but closes again thus interrupting the dispensing.
The blinking message
AUTO
indicates that
the selecting phase
of the desired value is still in progress
, but the AUTO mode has
not yet been selected by confirming the displayed value.
To confirm the PRESET value,
press and keep pressed the
AUTO key
until the METER displays:
Resettable Batch total
Selected value
Indication
AUTO not
Blinking
Selecting a
PRESET value
The METER allows the operator to use the most frequently
used PRESET values without having to set them by means of
the numeric keys.
In particular, the METER stores:
The last PRESET value
“AUTO LAST”
;
Five different PRESET frequent values
“AUTO 1 ... AUTO 5”
.
The
AUTO LAST
value is automatically updated each time a new
PRESET value is set by means of the keypad; the last value used
replaces the previous one in memory.
The
“AUTO 1 ... AUTO 5”
values can be freely set and modified
according to the procedure indicated in paragraph 7.2.
If the METER is off, press RESET to restart it. The METER will
display:
Last amount
dispensed
Non-resettable
Total
Press AUTO. The METER displays the PRESET value stored in
AUTO LAST.
PRESET value
AUTO LAST indication
Blinking
Pressing AUTO again, the METER displays the PRESET
value stored in AUTO 1:
PRESET value
AUTO 1 indication
Blinking
To display the other stored values, press AUTO as many times as
necessary to reach the desired value.
The blinking message will be:
As long as the AUTO message blinks, it is not yet possible to
start a new automatic dispensing
; if the trigger is completely
pulled, when released, it does not remain locked in open position
but closes again thus interrupting the dispensing.
The blinking message
AUTO
indicates that
the selecting phase
of the desired value is still in progress
, but the AUTO mode has
not yet been selected by confirming the displayed value.
In this phase it is possible to modify the displayed AUTO value
by means of the numeric keys. The modification of the displayed
AUTO value, however, does not change the stored AUTO value;
to modify the latter, it is necessary to follow the procedure
indicated in paragraph 7.2.
To confirm the PRESET value,
press and keep pressed the
AUTO key
until the METER displays:
Batch total zeroed
Selected value
Indication
AUTO
not
Blinking
Dispensing in
AUTO mode
To start dispensing:
Pull the trigger
fully down
and then release it.
The trigger thus remains locked in open position. Now dispensing
can continue even if the Operator is not attending.
To stop manually the dispensing in progress:
Pull again the trigger fully down and then release it.
The dispensing operation can be resumed in AUTO mode
within a given time (TIME OUT) from the stop. Within this
TIME OUT the METER still allows the locking of the trigger
in open position.
Once expired this TIME OUT, the METER still allows the user
to continue the dispensing but only in MANUAL mode.
Dispensing automatic stop:
The supply automatically stops when the preset value is reached.
The AUTO message disappears from the LCD.
Manual resumption of the dispensing (TOPPING UP):
Once dispensing has been carried out in AUTO mode, the
METER allows the user to continue the dispensing operation, if
necessary.
To carry out the TOPPING UP,
DO NOT press RESET
and pull
the trigger.
The dispensed amount is added to the previous one in AUTO
mode. The
PRESET value
previously set, displayed in the Total,
starts blinking to indicate that the preset value has been
exceeded.
Blinking value
