Polymaster DMDS5000 Self Bunded Bulk Diesel and Portable Instruction Manual

Polymaster DMDS5000 Self Bunded Bulk Diesel and Portable

Specifications

• Product Name: Polymaster Dieselmaster Station
• Intended Use: Static storage and dispensing of Diesel Fuel
• Construction: Bunded system (tank in tank)
• Designed for: Industrial, commercial, and public use
• Safety Features: High resistance against mechanical impact, protection against frost and heat

Product Usage Instructions

Installation

• Correct tank installation is crucial. Ensure the station is placed outdoors at a safe distance from buildings and hazard-zoned areas, following applicable codes or standards.

Operation

Read the operation manual thoroughly before use. Only trained personnel should install and operate the product. Do not alter components or make changes without consulting the manufacturer.

Safety Precautions

• Handle Diesel Fuel with care, keeping it away from skin, and eyes, and never consuming it. The control board contains electrical devices unsuitable for explosion-risk areas.

FAQ

• Q: Can this station be used for other fuels?
• A: No, the Dieselmaster Station is specifically designed for Diesel Fuel storage and dispensing only.
• Q: What should I do in case of an accident or spillage?
• A: Follow the procedures outlined in the operation manual for handling spills and accidents involving Diesel Fuel.
• Q: How often should maintenance be performed?
• A: Regular maintenance should be conducted as per the guidelines in the operation manual to ensure optimal performance and longevity of the station.

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 and New South Wales 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 on investing in a Polymaster Dieselmaster Station. Please ensure this product is correctly installed, operated and regularly maintained. By following the guidelines in this manual, your Dieselmaster will provide you with trouble-free service for years to come.
CORRECT TANK INSTALLATION IS THE SOLE RESPONSIBILITY OF THE PURCHASER
The following content is a guide only. Any vehicle/machinery affected negatively or positively is not covered by the Dieselmaster Tank warranty.
Dieselmaster® Brief
This Dieselmaster Station 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.
The station enables safe Diesel Fuel storage outdoors, at a safe distance from buildings and hazard zoned areas in line with applicable codes or standards requirements. High resistance against mechanical impact and protection against frost and heat due to the bunding system (tank in a tank) construction to suit most Australian temperature conditions. The high standard that your Dieselmaster Station has been made to ensure optimum safety and functionality.

Safety Guide

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, that 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 control board contains electrical devices that are not suited for use in areas where there may be risks of explosion.
• I. The Diesel Fuel must be kept away from skin, and eyes and never taken internally. Refer to Poisons Information for assistance.

Transport & Storage

• A. DO NOT TRANSPORT WITH LIQUID INSIDE
• B. The Dieselmaster Station must be protected against mechanical damage during transport and storage.
• C. Loading and off-loading must be carried out using only professional equipment, e.g. a forklift with extended forks. The covers, sockets or other protruding elements, which are not designed for lifting or moving the station must not be used to lift or move the station.
• D. The Dieselmaster Station must never be pushed, pulled, dragged or rolled.
• E. During transport and storage, the door must be tightly closed and secured. The dispensing nozzle must be placed in its holster and the control box shut.
• F. Loading and transport areas must be smooth and free of sharp edges. During transportation, the tank must be secured to prevent the tank from moving.
• G. The station must not be filled at a rate greater than 550 litres per Minute (LPM).

Installation & Handling

These instructions should be read in their entirety before commencing installation of the Dieselmaster Station.

• For all tank installation and maintenance, please take into consideration Health & Safety/Local Building Regulations and local fuel distributors policies.
• A solid minimum 75-100mm 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 station must be installed directly on a level, secure and non-combustible base. The base material is to be a 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 the station 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.
• Dieselmaster tanks are supplied with an electronic contents gauge and alarm as standard.
• 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 the warranty. This number is usually located on the outside tank by the access hole.
• Dieselmaster stations are supplied with an anti-static earth wire & probe. Ensure the probe is driven at least 600mm into the ground & securely attached before the initial fill.
• 240V Dieselmaster systems are earthed via the 3-pin power supply and earth probe. Electrical connections or works are to be completed by a qualified electrician.
• For further advice, contact the Dieselmaster helpline on 1800 062 064

AFTER INSTALLATION, PLEASE ENSURE THAT THIS INSTRUCTION BOOKLET IS LEFT WITH THE END USER FOR FUTURE REFERENCE
Custom design kits are available upon request.
This Dieselmaster Station tank 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):

• Piusi User System (MCBox) – 2yrs
• Pulse Meter, OCIO & Pump – 12mths
• Sensors, Nozzle and Hose – 3mths

All are from the date of purchase.
Provided that the following criteria is adhered to (applicable to all models):

• The enclosed warranty card is returned to Polymaster with evidence of the purchase date.
• The tank is installed and commissioned under the instructions outlined in the Installation and User Manual.
• The tank is installed and commissioned by a suitably qualified engineer.
• 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.
• The tank has been purchased by the end-user and is not for hire purposes.
• The tank has not been filled at a rate exceeding 550 litres per minute.
• The tank is installed above ground.
• The tank is inspected & serviced every 12 months or every 50,000 litres dispensed, depending on which occurs first, by a suitably qualified service Engineer or Technician.
• Immediately upon discovery of any defect in the tank, steps are taken to mitigate loss by contacting the fuel supplier and if necessary, arranging for a tank to be drained pending the supply of a new tank.
• 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

FILLING DIESELMASTER STATION
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 the dispensing nozzle is in the holster.
• D. Fit delivery hose to cam-lock coupling.
• E. Fill the tank in the normal manner.
• F. Stop filling when the desired amount has been dispensed into a tank or when a high-level alarm (90%) sounds.
• G. Disconnect delivery hose from the coupling.

DISPENSING FROM DIESELMASTER ESSENTIAL STATIONS

• A. Lift the dispensing nozzle from the holster. Ensure the nozzle is clean.
• Place the nozzle into the receiving tank fill point.
• B. Turn the pump on and open the pump suction gate valve.
• C. Pull the trigger on the nozzle handle to start fill delivery to the receiving tank.
• D. Dispense Diesel Fuel into the appropriate tank.
• E. When the vehicle or receiving tank is full, release the nozzle trigger.
• Turn off the pump immediately and close the suction gate valve.
• Ensure the nozzle is clean and place it back in the holster.

DISPENSING FROM DIESELMASTER QUANTUM & RANGER STATIONS

• A. Turn on the OCIO system via switch or fob system. Refer to the specific manual.
• B. Lift the dispensing nozzle from the holster. Ensure the nozzle is clean and there is no foreign material in the filter.
• C. Turn the pump on. Pull the trigger to start pumping immediately.
• D. Dispense Diesel Fuel into the appropriate tank.
• E. When a vehicle is full, turn off the pump immediately. Ensure the dispensing nozzle is clean before placing it back in the holster.
• F. When you have finished dispensing, ensure the isolation valve is closed.

POWERING YOUR PUMP

• The recommended way to power any 240V pump present in a Polymaster product is via mains power to ensure trouble-free operation.
• The use of generators is not recommended, however a minimum size of 5kVA should be used due to pump start-up requirements.

Service & Maintenance

• A. Keep all tank equipment in good working condition.
• B. Dieselmaster Station 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 on the visual condition of the tank, devices and power supply.
• E. Any faults or alarms should be reported to the tank supplier immediately.
• F. Protect against unauthorized access using the provided door lock.
• G. Dieselmaster Station should be serviced by qualified personnel every 12 months or every 50,000 litres dispensed, depending on which occurs first. Refer to the Care & Trouble-Shooting Guide for specific service intervals.
• H. Transport and store the tank so as not to damage the tank walls.
• I. The bunded tank: determine if any fluid is present in the bund, urgently determine the cause and rectify. Remove Fluid as soon as possible and dispose of it according to the required legislation.
• J. Do a check flow run and ensure devices are within tolerances.
• K. Ensure no foreign material is entering the Dieselmaster Station.
• L. If the station has not been used for an extended period, run contents through the dispenser for at least 10 seconds and dispose of them appropriately.
• M. Earth Cable & connections must be inspected at regular intervals to ensure their Electrical Continuity.

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

Self Bunded Tanks

Three models are available: Essential, Ranger or Quantum

Cabinet Details (Essential Model Shown)

Compare the Difference

Recommended Care Instructions

POLYMASTER DIESEL MASTER SELF-BUNDED STATIONS – MARCH 2020

Nozzle

| Check the action of the nozzle to ensure correct operation. Keep the unit clean and free of dust/dirt. Part Code: ATN90| As Used / 3 Months

Pump

| Visual / Aural check to ensure correct operation. Keep the unit clean and free of dust/dirt.

Part Code: ST Panther 72.

| As Used / 3 Months

Sensors

| Monitor sensors for large variations and unexpected alarms.

Quantum & Ranger Part Code: BMDMLI & BMDMBPR Essential Part Code: BMLI.

|

As Used

Filter

| Must be replaced every 12 months or every 50,000L dispensed. Whichever comes first

Part Code: DCF-100-CART

|

12 Months

Screw Lids

| Check that the screw lids (internal and external) are still tightly secured

Part Code: SL8-NV (ext.) & BCRF140L + BCRF140R (int.)

|

3 Months

Hoses

| Check the condition of the hoses to ensure there are no kinks or deterioration of the material. Keep clean and free of dust/dirt.

Essential & Ranger Part Code: DH25ES. Quantum Part Code: DHR10M25 Hose Reel.

|

As Used / 3 Months

MC-Box (Quantum Range Only)

| Monitor sensors for large variations and unexpected alarms. Keep the unit clean and free of dust/dirt.

Java script on your PC needs to be regularly updated. Java script is Windows and not part of the MC box.

Quantum Part Code: BMCB-D.

|

As used / 3 Months

OCIO Settings (Quantum & Ranger)| Monitor sensors for large variations and unexpected alarms. Keep the unit clean and free of dust/dirt.

Quantum & Ranger Part Code: PB240V-BS

| As used / 3 Months
ITEM/AREA OF INTEREST| ACTION RECOMMENDED| FREQUENCY
---|---|---
OCIO Instrument (Essential)| Monitor sensors for large variations and unexpected alarms. Keep the unit clean and free of dust/dirt.

Essential Part Code: BMLI

| As Used / 3 Months

Flow Meter

| Check the operation of the meter to ensure that the correct litre age is being dispensed. Replace the battery on the LCD unit as required.

Quantum Part Code: DPM (Pulse Meter) Ranger Part Code: DMDT

Essential Part Code: K33 Type.

|

As Used / 3 Months

Hose Reel (Quantum Range Only)| Check the operation of the reel regularly and the condition of the attached hose.

Quantum Part Code: DHR10M25 Hose Reel.

| As Used / 3 Months

Valves

| Check the condition of the fill line ball valve when filling the unit. Check the suction line ball valve at regular intervals.

Part Code: BV2 (fill) & BV1MF (suction)

| As Used / 3 Months
Moving| ONLY MOVE UNIT WHEN COMPLETELY EMPTY|

Foundation/Base

| Check the condition of the tank foundation for any erosion, cracking or subsidence. Repair as required. Ensure any repair materials meet the Installation Guide requirements.|

3 Months

12Volt Range – 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

12Volt Range – Power| Ensure that the Solar Panel is oriented in a manner to maximises energy production based on the site-specific environment and conditions.|

3 Months

Troubleshooting

Bund alarm activated

|

Over filling

| Check high-level alarm. Shut off the filling pump before the high level is reached.| Contact Polymaster

Leaking internal tank

| Review both the Cabinet (is supplied) and tank to determine the location of any leak.| Contact Supplier/ Polymaster
Faulting bund alarm or alarm parameters| Check parameters on the OCIO controller (Quantum & Ranger).| Contact Polymaster

Faulting bund alarm

| Check connections in OCIO (Essential).

Check bund sensor is located at a low level in the bund.

|

Contact Polymaster

Water ingress

| Check manhole cover is fitted correctly and sealed.

Check for damage to any vents or connected pipework.

|

Contact Polymaster

Hoses or fill line issue

| Check all hoses (fill lines) are connected and haven’t come off.| Contact Polymaster

High-level alarm

| Overfill| Dispense diesel until below alarm level.|
Faulty alarm or parameters| Check parameters on OCIO controller (Quantum & Ranger), if correct contact the supplier.| Contact Polymaster

Faulting bund alarm or Parameters

| Check connections in OCIO (Essential).

Check bund sensor is located at a low level in the bund.

|

Contact Polymaster

Tank overfilled

| Check mechanical overfill protection device is operating as intended. Must open the access hatch and visually inspect.| Contact Polymaster for direction

Low-level alarm

| Faulty alarm parameters / low diesel level| Check tank levels if enough diesel is in the tank.

Check alarm parameters on the OCIO controller.

|
TOPIC| POSSIBLE CAUSE| ACTION| CONTACT
---|---|---|---

Tank Level Indicator reading is not accurate

| Settings in OCIO have been changed| Contact Polymaster to get factory settings| Contact Polymaster
No digital display of tank volume – Sensor has malfunctioned| Replacement sensors are available from Polymaster. Please replace.| Contact Polymaster

Little or no diesel is being dispensed while the pump is running

|

Build-up of dirt in a nozzle

| Clean nozzle, use a clean damp cloth.

Use a pipe cleaner for the hose if required. In This case, safely dispose of contaminated fuel in line with environmental requirements.

|
Pump valve was turned off| Turn the pump valve on to fully open.|

Pump blocked

| Turn off the Pump. Remove the filter strainer, thoroughly clean & replace.|
Insufficient tank level| Refill tank to the desired level|
Foot valve blocked| Check & clean the foot valve (where installed)|

Excessive tank vacuum

| Check the 2-way tank breather and clean if required.| Contact Polymaster for replacement

Delivery hose too long

| Confirm hose is a Polymaster-supplied part.

If changed or extended, replace with the correct Polymaster part.

| Polymaster for a replacement part.

Pipe/Vacuum leak

|

Inspect all pipework/fittings and replace any that are damaged.

|

Contact Polymaster

By-base valve

|

Release the nozzle rapidly, re-start pump, and inspect if required

|
TOPIC| POSSIBLE CAUSE| ACTION| CONTACT
---|---|---|---

Little or no diesel is being dispensed while the pump is running

| Water filter blocked| Replace the water filter cartridge, part code DCF-100-CART.| Contact Polymaster

Water Capture blocked

| Replace the water capture filter and ensure there is no blockage.|

The pump not running or working.

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

Power to the pump not on

| Check that the switch on the physical pump is turned on. Check the power supply to ensure that the unit is correctly connected.|
Electrical fault| Check the power to the pump, if no power contact supplier.| Power Supplier
Dispensing locked out by MC box if fitted| Check MC box settings, if settings are lost re-calibrate.|

Incorrect dispensing volume. Or, Diesel is not dispensing at the desired flow rate.

|

Faulty flow meter or flow meter calibration incorrect

|

Check flow meter operation and/ or re-calibrate. Refer to the OCIO manual.

|
The amount recorded while dispensing is different on the User Manager System (MCBOX)|

Dispensing calibration out of specification.

|

Refer to the “Quick Reference Guide” and follow the Dispensing Calibration steps.

|
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.

|

Contact Polymaster

The cabinet door not shutting

|

The tank is not level on the base

| Re-level the base so the cabinet door will shut. Confirm not damaged and handle/latch is operable.|
TOPIC| POSSIBLE CAUSE| ACTION| CONTACT
---|---|---|---
Water present in diesel when dispensed|

Water ingress to the internal tank

| Check the manhole cover is fitted correctly and sealed, and replace the water filter cartridge.

Product Code DCF-100-CART. Check the condition of all connected pipework.

|

Contact Polymaster

Water present in diesel when dispensed

|

Water ingress to the internal tank

| Review the age of diesel fuel. Perform flush operation into an approved container to remove any water-contaminated fuel.

Dispose of fuel in line with environmental requirements.

|

Contact Polymaster

Static shock felt when pumping diesel

|

Static electricity build-up in the hose

|

Check that all earth connections comply with installation guidelines.

| If static electricity remains contact Polymaster

12 Volt (Solar)

Specific

|

Low Power

| Check for any damage to the Solar system.

Review solar Panel Orientation relative to the site-specific environment and conditions.

E.g. Shading, ambient temperature, Orientation, and cleanliness of the panel.

|

Contact Polymaster

No Power

| Check for any damage to the Solar system.

Review solar Panel Orientation relative to the site-specific environment and conditions.

E.g. Shading, ambient temperature, Orientation, and cleanliness of the panel.

|

Contact Polymaster

No Power

| Carefully and Safely visually inspect the condition of all cabinet internal electrical wiring for any signs of heat, damage or lack of connection.

Any Electrical work must be performed by a

suitable qualified Electrician.

|

Contact Polymaster

Earth Rod Function

| Ensure that the Earth Rod is installed in line with the Installation Guide.

Ensure that the earth/soil around the Earth Rod is moist to aid conduction.

|

Contact Polymaster

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.
• All tanks must be serviced every 12 months or 50,000 litres dispensed (whichever comes first) to ensure the tank is covered by the manufacturers warranty.
• Postal address: Locked bag 4001, Swan Hill VIC 3585
• Email: aftersales@polymaster.com.au
• Serial number of Dieselmaster tank : __ (located around lid area or rib)
• Dieselmaster tank capacity (Ltr) : ____

Warranty

This warranty is not valid for the following defects:

• Mechanical damage caused by the user, dealer or improper maintenance.
• Faults, damage or premature wear caused by improper use.
• Damage caused by third parties.
• Repairs carried out by unauthorized service personnel.
• Within the warranty period, Polymaster will repair or replace, at their discretion, any tank found faulty due to incorrect material or workmanship.
• Polymaster products are guaranteed against material or manufacturing defect and have the following guarantee period commencing from the date of the invoice:
• For polyethylene tanks: 5 years
• For accessories/components: up to 12 months

CONTACT

• 1300 062 064
• polymaster.com.au/enginereed-solutions

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