Operating manual BlueMobil 60 Item no: Z-3285 Original operating manual Illustration shows item no Z-3285
Important Copyright It is essential that you read this manual thoroughly before the initial operation of the device. Warranty claims for malfunctions and damage to the device resulting from an insufficient knowledge of the content of this manual will be deemed null and void. HORN GmbH & Co. KG. All rights reserved. The text, images and layout of this publication are protected by copyright law. Reproductions and copies, including reproductions and copies of parts of this publication, are only permitted with express written consent. Subject to technical changes. Service hotline +49 1805 900 301 Repair service +49 1805 900 302 ( 0.14/min: when calling from a German landline, max 0.42/min when calling from a mobile phone) service@tecalemit.de Document no: 44 1719 101-A Updated on: 2016-06-06 2 44 1719 101-A BlueMobil 60
Contents 1. Safety instructions... 4 1. Technical description... 6 1.1. Description... 6 1.2. Intended use... 6 1.3. Permitted media... 6 1.4. Technical data... 7 1.4.1. Dimension sheet... 8 2. Assembly instructions... 9 2.1. Initial operation... 9 2.2. Initial and subsequent priming... 9 2.2.1. Filling the storage tank... 9 2.2.2. Filling the suction line... 9 2.3. Electrical connection... 10 3. Operation... 11 3.1. Safety instructions... 11 3.2. Operation... 11 4. What should I do if?... 11 5. Maintenance... 11 5.1. Leak inspections... 12 5.2. Dirt trap... 12 5.3. Wheels12 5.4. Cleaning the unit... 12 6. Disposal... 12 7. Declaration of Conformity... 13 8. Notes... 14 441719 101-A BlueMobil 60 3
1. Safety instructions The device is a state of the art piece of equipment and has been constructed according to recognised safety specifications. It is nevertheless possible that use of the device will present hazards to the operator or to third parties, or may damage the device or other property. It is therefore essential to act in accordance with these safety instructions, and in particular with those sections identified as warnings. Warning notices and symbols In the operating manual, the following signs are used for highlighting important information. Special information for economical use of the equipment. Special information or dos and don'ts for damage prevention. Information or dos and don'ts for the prevention of damage to persons or equipment. Appropriate use The device may only be used if it is in perfect condition, and then only for its intended purpose, in compliance with all safety regulations, with an awareness of the potential risks, and according to the operating manual. Any faults that may impair the safety must be rectified immediately. The device and its components are only to be used for handling the liquids listed and the purpose described. Using the machine for any other purpose would constitute inappropriate use. The manufacturer is not responsible for any loss arising as a result of this, the risk for this is borne only by the operating company. Organisational measures This operating manual should always be kept readily available at the site of operation! Each person concerned with the assembly, commissioning, maintenance and operation of the equipment must have read and understood the entire operating manual. It is essential that the type plate and the warning notices attached to the device are observed, and are maintained in a fully readable condition. Qualified personnel The operating, maintenance and assembly personnel must be appropriately qualified for their work. The areas of responsibility, competences and supervision of the personnel must be precisely regulated by the operating company. If the personnel do not have the required knowledge, they must be trained and instructed. The operating company must also ensure that the contents of the operating manual are properly understood by the personnel. Waters protection The device has been designed to handle water hazardous substances. The regulations on the operating place must be adhered to. 4 44 1719 101-A BlueMobil 60
Hydraulics Only persons with special knowledge and experience with hydraulic systems may carry out work on hydraulic parts and equipment. All lines, hoses and screw joints should regularly be checked for leaks and visible external damage. Any damage must be rectified immediately. Any oil spurting out can cause injuries and fire. The relevant safety regulations for the product must be followed when handling oils, greases or other chemical substances! Maintenance and Service According to the regulations of the water resources law only authorized services may work on devices for flammable and/or water endangering substances. During such works, appropriate tools are to be used (avoid sparking). Before any kind of work on the device, all fuel lines are to be completely emptied and aerated. Do not make any changes. Modifications or additions to the device which may affect the safety cannot be carried out without consent of the manufacturer. Exclusively genuine spare parts made by the manufacturer may be used. Electric power Work on the electrical equipment may only be carried out by a qualified electrician or by trained persons under the guidance and supervision of a qualified electrician according to electro-technical guidelines. Machine or system components, on which inspection, maintenance or repair work is to be carried out, must be de-energised. 441719 101-A BlueMobil 60 5
1. Technical description 1.1. Description The BlueMobil 60 is a portable, electrically operated device for dispensing urea solution AUS32 in accordance with ISO 22241-1. Dispensing is via a standardscompliant filler neck complying with ISO 22241-5. The equipment comprises a trolley with an electric membrane pump, volume meter, dispensing hose, automatic nozzle, suction line, charger and connection cable. The storage tank has a capacity of approx 60 litres. 1.2. Intended use The device is intended for use in industrial environments, workshops, petrol stations and similar facilities. The equipment may only be operated when supervised! The BlueMobil 60 tap system must only be operated with urea solution AUS32 in accordance with 22241-1. In particular, it must not be used to convey any flammable liquids! 1.3. Permitted media Urea solution AUS32 complying with 22241-1. No other media may be conveyed using this equipment! Please observe the information in your medium s safety data sheet. 6 44 1719 101-A BlueMobil 60
1.4. Technical data Dimensions: (WxHxD) 460 x 1330 x 730 mm Dirt trap 630 μm Ambient temperature -10 C to +50 C Pressure port 3/4" Medium temperature -7 C to +30 C Suction port 3/4" Motor Direct current motor Power 0.15 kw Rated current 15 A Voltage 12 V Duty cycle 100% Protection class IP 54 Pump type Membrane pump Delivery volume* approx Max 8 l/min Delivery pressure Max 5.0 bar* Min 4.5 l/min Pressure relief valve 5.5 bar Sound pressure level Max 71 db(a) Weight (without medium) Approx 70 kg Connecting cable Approx 2 m long Dispensing hose DN 19 Wide range charger Battery 100 V 240 V, 50/60 Hz, 60W 12V VRLA, 36Ah *Depending on viscosity and system 441719 101-A BlueMobil 60 7
1.4.1. Dimension sheet Nozzle Charger Dispensing hose approx 3 m Filling connection Fill level indicator Pump Drum Battery Dirt trap Hose holder Swivel castor Swivel castor with locking device Power plug Set down compartme nt FMT3 meter High flow/low flow switch On/Off switch 8 44 1719 101-A BlueMobil 60
2. Assembly instructions 2.1. Initial operation Pay attention to the content of this operating manual before first using and operating this equipment. Before using with urea solution AUS32 for the first time, the entire conveying system must be rinsed out with demineralised water. This is the only way to guarantee the required system purity. It may be necessary to analyse the rinse water for impurities. Do not use mains tap water! The system was rinsed with demineralised water at the factory. Therefore, the storage temperature must not fall below 0 C. Before initial operation, the system must be brought to a temperature of over 5 C. 2.2. Initial and subsequent priming 2.2.1. Filling the storage tank To fill, remove the plug on the storage tank s fill connection and fill using a funnel or nozzle. The BlueMobil 60 does not have overfill protection! Max filling quantity is 60 litres. Observe the fill level indicator! 2.2.2. Filling the suction line The system was rinsed with demineralised water at the factory. Therefore, the storage temperature must not fall below 0 C. Before initial operation, the system must be brought to a temperature of over 5 C. Always avoid running the pump dry for prolonged periods (>1 min), as this can cause irreparable damage to important components. Ensure that the pump does not run dry for longer than necessary. A normal priming process should not take longer than 5 minutes. If priming with the medium is still not complete after this time, check the suction line for leaks. 441719 101-A BlueMobil 60 9
To prime with the medium, loosen the nozzle s vent screw then open the nozzle. In order to avoid the medium accidentally escaping, place a cloth around the vent screw. Now switch on the feed pump. The pump begins to draw in the medium. After about three litres, close the vent screw. The pump can also be turned off. Another 3 5 litres should now be drawn in, in order to close any air pockets in the suction system. The equipment is now ready for operation. We recommend that you keep the storage tank topped up during daily use, and do not allow it to empty completely. This avoids having to repeatedly fill the suction line. Venting: Vent screw M6 open Nozzle open 2.3. Electrical connection The pump is powered with 12 V direct current from a battery. The battery s charger is fitted with a Europlug. The battery s charging status is shown on the display (optional). We recommend charging the battery regularly (eg overnight), but at the very latest when the battery charge level falls below around 25%. 10 44 1719 101-A BlueMobil 60
3. Operation 3.1. Safety instructions Moving and parking Pay careful attention when moving the trolley, especially when its storage tank is full. Adhere to safety clearances. Please pay special attention when moving it on sloping surfaces! When parking it, activate both locking brakes on the rear swivel castors. Then gently push the trolley to test that the brakes are working! 3.2. Operation Press the On/Off switch. The pump starts up for a little while, before switching off via the integrated pressure switch. Use the select button to choose between High flow/low flow, and if required, reset the meter via the Reset button. Remove the nozzle and begin the filling process by pressing the nozzle s shift lever. Once the fuelling process has completed, and when the nozzle is closed, the pump automatically switches itself off. Turn the machine off again via the On/Off switch. 4. What should I do if? the device issues a Battery empty! message? - The battery must be recharged for at least 6 hours using the built-in charger. the delivery rate is too low? - Check the dirt traps for dirt and clean if required. the pump is not drawing in any medium? (eg first use, longer periods out of use)? - Ensure that the vent screw on the nozzle has been opened (2.2.2). - Check the suction line and screws on the suction side for leaks, and replace seals if necessary.! If there is excessive emission of noise, further operation is only permissible after the reason for the noise has been eliminated! 5. Maintenance! Works on the equipment may only be carried out by factory trained technicians. 441719 101-A BlueMobil 60 11
The pump and all components must be cleaned at regular intervals (at least once a year). 5.1. Leak inspections The device and all other components of the unit are to be inspected regularly for leaks and damage; any leaks are to be sealed. 5.2. Dirt trap 5.3. Wheels Clean the sieve insert in the dirt trap. To do so, remove the sieve insert, wash it, blow it out with compressed air and then reinstall it. Replace damaged sieve inserts. The locking brakes on the castors must be checked regularly to ensure that they are in working order. Wheels that can no longer be properly braked by the locking brakes must be replaced immediately. 5.4. Cleaning the unit Wash the device with cold or lukewarm water. Do not use any aggressive cleaning agents or soap. If water alone is not sufficient to remove dirt, use a washing shampoo. When using a water hose, do not aim the water jet at the paintwork with full pressure. Do not clean using steam jets or similar equipment. 6. Disposal Upon being decommissioned, the equipment must be completely emptied and the fluid disposed of correctly. Upon being taken out of service permanently, the device must also be disposed of properly: Dispose of metal parts at a metal recycling site. Take plastic parts to a recycling facility. Dispose of electrical waste in a recycling facility. The legal regulations concerning water protection must be observed. 12 44 1719 101-A BlueMobil 60
7. Declaration of Conformity 441719 101-A BlueMobil 60 13
8. Notes 14 44 1719 101-A BlueMobil 60
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Horn GmbH & Co. KG Munketoft 42 24937 Flensburg Germany T +49 461-8696-0 T +49 461-8696-66 www.tecalemit.de info@tecalemit.de 16 44 1719 101-A BlueMobil 60