Polymaster Single Skin Diesel Tank Installation Guide

Polymaster Single Skin Diesel Tank

Company Profile

ABOUT POLYMASTER

Polymaster manufactures an extensive range of quality products for industrial, residential and agricultural applications. Over the last two decades, Polymaster has been at the forefront of industry endorsed, product certified designs that have advanced the life-span and functional capabilities of process vessels, bulk storage, rainwater tanks and animal care products. As an Australian owned, quality assured company. Polymaster delivers every product to specification with confidence through our growing network of distributors.

PRODUCT DEVELOPMENT

We continue to extend our manufacturing operations to achieve market diversification and operational longevity. Our Design & Mould team offers custom design solutions and continual scope for new product development, product improvements and modifications. Coupled with our ability to customize colours to specification and apply brand identities on request, Polymaster delivers on quality and quantity, on time and within budget.

LOGISTICS CAPABILITIES

Polymaster’s distribution fleets are experienced in over dimensional loads, general freight and site handling, providing the flexibility and capability to deliver every Polymaster product. Our manufacturing locations in Victoria, New South Wales, and Queensland supported by warehouses in Melbourne and Adelaide supply direct freight lines to Melbourne, Adelaide and Sydney. To service deliveries nationwide. Over time we have established quality relations with proven logistics channels. Bulk storage capacity and warehouse pick-up capabilities are available from Metropolitan Melbourne and Adelaide.

QUALITY ASSURANCE

As a quality certified company, Polymaster’s quality assurance regimen is internationally recognised and certified to ISO9001 standards. Our exclusive use of UV stabilized premium resins to AS/ NZS 4766 standards, combined with FEA testing and engineering of our mould design assures quality in the manufacture of every Polymaster product. Every tank is independently certified to SAI Global’s AS/ NZS 4766:2006 standard and labelled to display manufacturing details and serial number for complete traceability.

Products in this Installation Guide have been manufactured to comply with the above standards.

Introduction

Congratulations for investing in a Polymaster Diesel Tank. This product is only to be used for the static storage and dispensing of Diesel Fuel. The range is designed and engineered to suit the needs of a vast coverage of industrial, commercial and public requirements from nationwide fleets to local users.

IMPORTANT

READ OPERATION MANUAL IN DETAIL BEFORE USE & COMPLY WITH ALL INSTRUCTIONS HEREIN. OPERATION MANUAL SHOULD BE KEPT WITH THE EQUIPMENT AT ALL TIMES.

A. This manual contains important information concerning the safe installation and use of this product. Read the manual carefully before installation and use. Pay attention to all safety warnings.
B. Installation and use of this product should only be carried out by properly trained and approved personnel.
C. Users of this product are responsible for the safe and correct use of this product.
D. Any changes to this product, which have been done without consulting the manufacturer, will invalidate all warranties and guarantees.
E. The components must not be altered or tampered with, due to potential risks to personnel.
F. The manufacturer will not be responsible for any accidents or damages caused by incorrect installation or use of this product.
G. This product is only suitable for storage and dispensing of Diesel Fuel.
H. The product contains electrical devices which are not suited for use in areas where there may be risks of explosion.

Installation & Handling

These instructions should be read in their entirety before commencing installation of the product. For all tank installation and maintenance, please take into consideration Health & Safety/ Local Building Regulations and local fuel distributors policies.

• A solid minimum 45mm thick base or Plinth extending 300mm on all sides made from Concrete/bitumen. This plinth is to be Engineered by the user.
• If this is not possible the product must be installed directly on a level, secure and non-combustible base. Base material is to be maximum 5mm particle size E.g. “Crusher Dust”. Where a non-concrete/bitumen base is used, Engineering of the restraint or tethering for local conditions is by the customer.
• Determine if product needs to be secured in place in exposed conditions. Do not drill holes in the tank.
• Restraint for site specific, latent or environmental conditions is by others.

Determine if a fuel de-activator should be used depending on storage conditions and duration. Refer to the fuel supplier for further information.

Prior to installing inspect for damage, if damaged do not install.

The warranty card in this booklet should be returned to the supplier at Locked Bag 4001, Swan Hill Vic. 3585 or aftersales@polymaster.com.au

The tank serial number must be recorded on the warranty card to validate warranty. This number is usually located on outside tank by the access hole.

This product is supplied with an anti-static earth wire & probe. Ensure the probe is driven at least 600mm into ground & securely attached before initial fill.

For further advice, contact the helpline on 1800 062 064

AFTER INSTALLATION, PLEASE ENSURE THAT THIS INSTRUCTION BOOKLET IS LEFT WITH THE END USER FOR FUTURE REFERENCE.

This product is warranted for 5 years from the date of purchase against faulty materials or manufacture of the tanks.

Equipment and accessories are warranted as follows (where fitted):

• Pump – 12mths
• Nozzle and Hose – 3mths

All are from date of purchase.

Provided that the following criteria is adhered to (applicable to all models):

1. The enclosed warranty card is returned to Polymaster with evidence of the purchase date.
2. The tank is installed and commissioned in accordance with the instructions outlined in the Installation and User Manual.
3. The tank is installed and commissioned by a suitably qualified engineer.
4. The tank has not been subject to misuse, careless handling or faulty installation. Any repairs have not been attempted or carried out other than by authorized, competent service staff.
5. The tank has been purchased by the end user and is not for hire purposes.
6. The tank has not been filled at a rate exceeding 400 litres per minute.
7. The tank is installed above ground.
8. The tank is inspected every 6 months or every 50,000 litres dispensed, depending on which occurs first, by a suitably qualified service Engineer or Technician.
9. Immediately upon discovery of any defect in the tank, steps are taken to mitigate loss by contacting the fuel supplier and if necessary, arrange for tank to be drained pending the supply of a new tank.
10. Immediately upon discovery of any defect you contact Polymaster and allow a representative to inspect the tank and its surroundings and where necessary carry out any repairs (before any attempts are made to move the tank).

This warranty excludes ancillary fittings such as contents measuring gauges or mechanical pumps. Further warranty information on ancillary fittings and pumps is provided within the manual.

Filling & Dispensing

During the first fill of the tank the level indicator may show less volume than that filled. The level indicator minimum read point is placed at the base of the tank. The maximum level must NOT be exceeded.

A. Filling should be performed only under constant supervision of an authorized person as required by law.
B. This tank can only be filled by a tanker equipped with a female camlock coupling.
C. Ensure dispensing nozzle is in the holster.
D. Fit delivery hose to cam-lock coupling.
E. Fill tank in normal manner.
F. Stop filling when the desired amount has been dispensed into tank.
G. Disconnect delivery hose from the coupling.

Service & Maintenance

A. Keep all tank equipment in good working condition.
B. This product should only be serviced by Polymaster approved qualified personnel. Please contact Polymaster for further details.
C. Spare parts must comply with the requirements of the manufacturer.
D. A daily check should be carried out in the visual condition of the tank, devices and power supply.
E. Any faults should be reported to the tank supplier immediately.
F. Protect against unauthorized access.
G. This product should be serviced by qualified personnel every 6 months or every 50,000 litres dispensed, depending on which occurs first.
REFER TO THE CARE & TROUBLESHOOTING GUIDE FOR SPECIFIC SERVICE INTERVALS.
H. Transport and store the tank so as not to damage the tank walls.
I. Do a check flow run and ensure devices are within tolerances.
J. Ensure no foreign material is entering the product.
K. If the station has not been used for an extended period, run contents through the dispenser for at least 10 seconds and dispose of appropriately.
L. Earth Cable & connections must be inspected at regular intervals to ensure their Electrical Continuity.

FOR FURTHER INFORMATION PLEASE CONTACT POLYMASTER ON 1800 062 064 OR REFER TO ADDITIONAL EQUIPMENT MANUALS

Recommended Care Instructions

cracking or subsidence. Repair as required. Ensure any repair materials meet the Installation Guide requirements.| 3 Months
Earth Rod| Ensure the earth rod is installed as per the Installation Guide.
Ensure that the ground around the earth rod is moist.
Contact Polymaster if further information is required.| 3 Months

Troubleshooting

Use a pipe cleaner for hose internal if required. In This case, safely dispose of contaminated fuel in line with environmental requirements.|
Pump valve turned off| Turn pump valve on to fully open.|
Pump blocked| Turn off Pump. Remove filter strainer, thoroughly clean & replace.|

Not Required

Insufficient tank level| Refill tank to desired level| Not Required
Excessive tank vacuum| Check 2-way tank breather and

clean if required.

| Polymaster for replacement
Delivery hose too long| Confirm hose is Polymaster supplied part.
If changed or extended, replace with correct Polymaster part.| Polymaster for replacement part.
Pipe/Vacuum leak| Inspect all pipework/fittings and replace any that are damaged.| Polymaster
By-base valve| Release nozzle rapidly, re-start pump, inspect if required| Polymaster
TOPIC| POSSIBLE CAUSE| ACTION| CONTACT
---|---|---|---
Pump not running or working.| Water Capture blocked| Replace the water capture filter and ensure there is no blockage. Part code DCF25F|

Polymaster

No power supply| Check there is power to station.|

Power to pump not on

| Check that the switch on the physical pump is turned on. Check power supply to complete unit is correctly connected.|
Electrical fault| Check power to pump, if no power contact supplier.| Power Supplier
Pump making squealing/ scratching or grinding sound.| Dirt or debris may have entered the pump| Cease use of the system. Inspect tank level and quality of fuel.| Polymaster
Water present in diesel when dispensed| Water ingress to internal tank| Check the man hole cover is fitted correctly and sealed, replace water filter cartridge.| Polymaster
Review age of diesel fuel. Perform flush operation into approved container to remove any water contaminated fuel. Dispose of fuel in line with environmental requirements.
Static shock felt when pumping diesel| Static electricity build-up in the hose| Check that all earth connections comply to installation guidelines.| If static electricity remains contact Polymaster

Dispensing Kit

SETUP

Note: Setup instruction for the tank itself must be observed/action prior to using your new dispenser kit.

Your new dispenser kit will be ready to use from delivery. Please follow the below steps:

• Remove any packaging used to protect the dispenser kit during transport.
• Prior to connecting to power, ensure cables are in good/serviceable condition.
• Connect power to your dispenser (12V DC, or 240V AC depending on variant.
• Ensure all fittings/items are secured and have not become loose/free during transport
• Ensure filter is present/secured

USAGE

Note: Prior to usage, ensure that power cable is in serviceable condition

• Open the dispenser kits isolation valve.
• Remove nozzle from holster.
• Lift metal tab the resides under the nozzle when holstered, to start the pump.
• Dispense required volume of diesel.
• Holster nozzle, which will automatically cut pump.
• Ensure valve is isolated when dispenser is not in use.

MAINTENANCE NOTES

The dispenser kit is supplied with a water captor filter. If the fuel delivery performance of the dispenser unit begins to deteriorate, cease usage, and investigate potential water contamination in filter/tank. The captor filter contains water absorbent beads, which will swell and cause flow rate reduction if water is present to warn the user.

Warranty Card

Please send this back to Polymaster Pty Ltd within 30 days of installation to confirm acceptance of terms in the warranty and we will formally register your warranty for you. This does not affect your statutory rights.

Failure to do this will make all warranty’s invalid.
Postal address: Locked bag 4001, Swan Hill VIC 3585
Email: aftersales@polymaster.com.au

We value your feedback – please share your experiences with us at feedback@polymaster.com.au

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