COMPACT AUTOMATIC FUEL PORT 1 TANK

COMPACT AUTOMATIC FUEL PORT 1 TANK

Last Revision Date: March 14, 2016 For the most up-to-date information for this product and others, please contact Simplex, Inc. at (800) 637-8603 or visit us on the web at http://www.simplexdirect.com.

Table of Contents 1 Warnings and Cautions... 1 Safety information symbols 1 Cautions 1 2 Nameplates and Placards... 3 3 Description and Specification... 4 4 Unpacking... 7 Included Components and Parts 7 Primary Inspection 7 5 Installation... 8 Welding FuelPort to Tank 8 Attaching FuelPort to Post 8 Attaching FuelPort to Stand 8 Installing Cable Access 9 Installing Control Power 9 Installing Float Assemblies 9 Setting up the meter 10 Entering the meter s setup menu 10 Changing the display from percentage to gallons 10 Calibrating the meter 10 6 Operating Instructions...12 7 Maintenance/Troubleshooting...13 General maintenance 13 Troubleshooting 13 Appendix A PRODUCT WARRANTY...14

Table of Figures Specifications...5 Compact Automatic FuelPort Dimensions...6 Compact Automatic FuelPort...7 Float Assembly...7 Weld Brackets...8 FuelPort Post...8 FuelPort Stand...8 Knock Outs...9 TB-A...9 Float Assembly Wiring...9 Meter... 10 Control Power... 12 Open Fill Valve... 12 High Fuel Alarm... 12 Troubleshooting... 13

1 WARNINGS AND CAUTIONS Safety information symbols The following images indicate important safety information: This General warning symbol points out important information that, if not followed, could endanger personal safety and/or property. This Explosion warning symbol points out potential explosion hazards. This Fire warning symbol points out potential fire hazards. This Electrical warning symbol points out potential electrical shock hazards. Cautions Improper operation of this equipment such as neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate, and/or maintain this equipment. Potentially lethal voltages and amperages are present in these machines. Ensure all steps are taken to render the machine safe before attempting to work on the equipment. All hardware covered by this manual have dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., on the hardware, if applicable. Ensure all appropriate covers, guards, grounds, and barriers are in place before operating the equipment. If work must be done around an operating unit, stand on an insulated dry surface to reduce shock hazard. Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DAN- GEROUS ELECTRICAL SHOCK MAY RESULT. If trained personnel must stand on metal or concrete while installing, servicing, adjusting, or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats. The National Electrical Code (NEC), Article 250 requires the frame of the equipment to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition or by static electricity. Never disconnect the ground wire. Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical current Warnings and Cautions 1

2 Warnings and Cautions (ampacity) to which they will be subjected. Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are completely turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock. In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and seek immediate medical attention. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury. Keep a fire extinguisher near the hardware at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, please consult the local fire department. The illustrations in this manual are examples only and may differ from your unit.

2 NAMEPLATES AND PLACARDS Nameplates and Placards 3

3 DESCRIPTION AND SPECIFICATION The Simplex Compact Automatic FuelPort is a compact, economical solution for simple filling and spill prevention for fuel-storage tanks. The CAFP includes all valves and fittings necessary for hose connection from a pumper truck to a fuel-storage tank. The FuelPort can be bolted to the tank, be attached to a stand, or attached via clamps to a 2 or 3 post. The CAFP is suitable for use with fuel oil. Includes: Weatherproof, lockable box with 7 gallon spill containment Tank mounting weld brackets (2) FuelPort mounting tabs to accept weld brackets or post clamps (2 or 3, optional) Quick disconnect hose coupling with dust plug Check valve Shutoff valve Hand pump for spill containment, with shutoff and check valve Ground stud 4 Description and Specification

Table 1 Specifications Delivery Type Pumper truck to one tank Shutoff Automatic Product Class II Liquid, > 100 F Flash Point Inlet Fitting Size 2, 3 or 4 (3 internals and 3 outlet) Spill Containment 7 gallons Paint UL Listed powder-coat process Hand Pump Capacity 1 GPM Dimensions 24 W x 35 H x 25 D Weight 229 lbs. Description and Specification 5

Figure 1 Compact Automatic FuelPort Dimensions 6 Description and Specification

4 UNPACKING Included Components and Parts The following items are included with your FuelPort. If any of the following are not included, please contact Simplex Direct, Inc., at 800-637-8603. 1. Compact Automatic FuelPort 2. Float assembly 3. Drawing package 4. Manual Figure 2 Compact Automatic FuelPort Figure 3 Float Assembly Primary Inspection If any problems are observed during Primary Inspection, call Simplex 24 hours a day at 800-637-8603 Preventative visual inspection of the shipping crate and the fuel port is advised. Mechanical problems due to handling and vibration may occur. Never pump fuel through a Compact Automatic FuelPort before performing this procedure. The following inspection is recommended before installation and as part of a 6-month maintenance schedule or as the fuel port is relocated: 1. If the crate shows any signs of damage, examine the fuel port in the corresponding areas for signs of initial problems. 2. Check the entire outside of the cabinet for any visual damage, which could cause internal mechanical problems due to reduced clearance. Unpacking 7

5 INSTALLATION The Compact Automatic FuelPort can be installed in three ways: 1. Welded to a fuel tank 2. Attached to a post 3. Placed in a stand Figure 4 Weld Brackets Welding FuelPort to Tank Attaching FuelPort to Post You can mount the Compact Automatic FuelPort directly to a storage tank by welding two mounting brackets (Figure 4) to the tank and bolting the CAFP to them. With the post mounting option, the Compact Automatic FuelPort can be attached to a free-standing post. To do so, attach the post to a concrete pad and use the supplied U-bolt post brackets to attach the FuelPort to it. Figure 5 FuelPort Post Attaching FuelPort to Stand To affix the Compact Automatic FuelPort to a stand, simply attach the stand to a Figure 6 FuelPort Stand concrete pad using the predrilled holes in the stand s feet, then affix the FuelPort to the stand via the mounting holes on the front. 8 Installation

Installing Cable Access Installing Control Power Installing Float Assemblies To bring cabling into the CAFP, remove one of the six knock outs located along the right and left vertical sides of the back of the controller housing (see Figure 7). Install a 1/2 3R-rated conduit connector for access. To install control power, connect a 120VAC, 60Hz, 15-amp power source to the CAFP s TB-A-1-2, with TB-A-GND connecting to an earth ground (See Figure 8.) To install the float assemblies, push the latch handles on the assembly down and slide the coupler off. Apply an appropriate threadlocker to the threads on the coupler and screw it into the appropriate fitting. Figure 7 Knock Outs Figure 8 TB-A Figure 9 Float Assembly Wiring Slide the assembly into the coupler and lift the latching arms until the assembly is locked into place.make the following wiring connections: Check your electrical drawing package to confirm wire assignments. 1. Common wire (white) to TB-A-10 2. Full Level Float wire (green) to TB-A-11 3. High Level Float wire (yellow) to TB-A-12 4. Tank Leak Float wire to TB-A-14-15. 5. Level transducer positive wire (red) to TB-B-1 Installation 9

Setting up the meter 6. Level transducer Figure 10 Meter neutral wire (blue) to TB-B-7 7. Level transducer ground wire (pink) to TB-B-6.Before you calibrate your meter, fill your tank with a known quantity of fuel. We strongly suggest you fill the tank to 90 percent of its capacity, which will ensure the greatest accuracy. Entering the meter s setup menu Changing the display from percentage to gallons There are a number of options for configuring the meter, but only two concern us: dsp 2, which allows you to see approximately how many gallons remain in your tank, rather than a percentage; and OFSEt, which calibrates the meter for greater accuracy. To enter the meter s setup menu, press and hold the SEL button for one second. The screen will begin alternating between Pro and NO. Press RST while it shows Pro and you will be in the setup menu. From here, pressing RST will cycle through five options, but all of the settings you might need to change are in the first, 1-INP. Press SEL to enter this category, and the meter will display range. If you want the meter to display the number of remaining gallons rather than a percentage, you need to change the dsp 2 setting. This setting determines what the meter will display when the level transducer tells the fill controller it is reading a full tank. To change the display, enter the meter s setup menu as outlined above. When the meter displays range, press SEL nine times. The meter should now read dsp 2. Press RST to change the value, which should initially be 100. Press RST to increase the flashing digit and RST to move one digit to the left. Change the value to the maximum capacity of your tank, measured in gallons. Press and hold SEL to return to the menu, then press SEL three more times until No is displayed. The meter should exit the menu on its own after about a second. 10 Installation

Calibrating the meter The meter will be most accurate at the level of fuel you used to calibrate it When you have filled the tank with a known quantity of fuel, you may need to calibrate the meter. To do so, you need to enter the meter s setup menu and change the offset value. Enter the meter s setup menu as detailed above. When the meter displays range, press SEL twice until it displays OFSEt. Press RST to change the setting to the value that will adjust the reading to match the amount of fuel in your tank. Press RST to increase the flashing digit and SEL to move one digit to the left. If you need to enter a negative value, press SEL until the left-most digit is flashing, then press RST until a negative sign appears. When you have entered a value, press and hold SEL to return to the menu, then press SEL ten more times until No is displayed. The meter should exit the menu on its own after about a second. If the meter is not displaying the correct value, repeat the process to enter a new offset until the meter is accurate. Installation 11

6 OPERATING INSTRUCTIONS If 95% fuel level is reached, audible and visual alarms are activated. The Compact Automatic Fuel Port valve closes completely and cannot be reopened until the fuel level falls below 95% level. 12 Operating Instructions 1. Connect a ground Figure 11 Control Power cable from the truck to trucker s ground stud provided on the Compact Automatic FuelPort. 2. Unlock the fill box. 3. Connect a delivery hose to the hose coupling in the CAFP. 4. Open the valve on truck. Figure 12 Open Fill Valve 5. Turn the Control Power switch to the On position and press the Fill Valve Open pushbutton. 6. The valve opens. 7. Start the delivery pump on the truck. 8. Fuel is delivered to the tank. 9. Delivery may be Figure 13 High Fuel Alarm stopped at any time by pressing the Close Fill Valve button and proceeding to step #13. 10. At about 90% fuel level, audible and visual alarms are activated and the valve will close partially to restrict flow. 11. Stop the delivery pump on the truck. 12. Close the valve on the truck. 13. Drain the delivery hose. 14. Disconnect the delivery hose from the CAFP. 15. Turn the Control Power switch to the Off position. 16. Close and lock the fill box. 17. Fuel delivery is complete, disconnect the ground cable from the trucker s grounding stud.

7 MAINTENANCE/TROUBLESHOOTING General maintenance Trouble shooting All electrical connections should be tightened every 6 months. Although Compact Automatic Fuel Ports are designed with trouble-free operation in mind, some problems can arise. Please consult the following table for solutions to the most common issues before contacting a Simplex service representative. Table 2 Troubleshooting Remove all power before servicing the CAFP. Never operate or service a CAFP that is not grounded. Problem Solution Controller reporting wrong fuel level Ensure float assembly is wired correctly (see page 9). Ensure float assembly is fully installed in tank receptacle. Adjust offset (see page 11). If your tank is rectangular, check setting for tank capacity (see page 10). Ball valve not opening and/ or closing correctly Check fuel port piping for obstructions. Checking drawing package to ensure valve is wired correctly. Controller not operating Ensure controller is supplied with power (see page 9). Remove controller cover and ensure relays are seated securely. Check tightness of electrical connections. Maintenance/Troubleshooting 13

Appendix A PRODUCT WARRANTY SIMPLEX, Inc., warrants the industrial electrical control, test and accessory equipment and parts and accessories thereof to be the kind and quality described in SIMPLEX s specifications and to be free from defects in material or workmanship under normal service, its obligations under this warranty being limited to repairing or replacing, at its option, any part or parts which shall, within twelve (12) months from date of shipment from its factory, as indicated by serial date code on the nameplate or sales records, be returned to SIMPLEX or an authorized SIMPLEX repair station, with transportation costs prepaid, and which its examination shall disclose to its satisfaction to have been thus defective. The provisions of this warranty shall not apply to any equipment, part or accessory which (a) has been improperly specified by buyer; (b) has been improperly stored or handled prior to placing in service; (c) has been improperly mounted or connected; (d) has not been operated within specifications stated on its nameplate, label or placard; (e) has not been properly maintained; (f) parts supplied by buyer for inclusion in finished equipment are not covered by this warranty; (g) components or assemblies specified by buyer with no substitution permissible that are not normally used by SIMPLEX. SIMPLEX reserves the right to reject warranty claims of any kind against assembled equipment, parts or material for which SIMPLEX has not received payment in full. Should buyer, at his own risk, elect to replace defective equipment or parts in the field rather than return equipment to SIMPLEX s factory or authorized repair station, SIM- PLEX will supply and invoice parts at normal prices upon receipt of buyer s bona-fide purchase order. Defective equipment or parts returned for in-warranty crediting in exchange for replacement parts must be returned within 45 days from date of shipment of replacement in order to qualify for warranty consideration. Defective equipment or parts returned after 45 days may be subject to a restocking charge of 20% or a minimum charge of $50.00, whichever is greater. This warranty is in lieu of all other warranties, express or implied, and all other obligations or liabilities on the part of SIMPLEX, and SIMPLEX neither assumes nor authorizes any other person to assume for it any other liability in connection with any such electrical control, test or accessory equipment or accessories or parts. 14 - Product Warranty

WE WELCOME YOUR FEEDBACK! Simplex designs and manufactures Load Banks and Fuel Supply systems for power generation and liquid automation. Simplex is certified to ISO 9001:2008. Used world-wide for mission critical environments in manufacturing, technology, transportation, hospitals, schools, public utilities and the U.S. military, Simplex products provide solutions meeting exact requirements, from the simplest testing and proving equipment for backup generators to custom-designed and engineered mission-critical fuel systems. At Simplex, we are experts at building products that meet our customers exact requirements. For a complete listing of Simplex products visit www.simplexdirect.com. Simplex welcomes your questions, comments, suggestions, compliments, and complaints as a way to continuously improve our service to you. Please call us at 800-637-8603 (24 hours a day) or visit www.simplexdirect.com.

LOAD BANK RENTAL AND SERVICE CENTERS Simplex Onsite can place Load Banks, Cables, Transformers, and Fuel Polishers rentals as well as service technicians at your fingertips anywhere in the United States quickly and cost effectively. For information call 855-767-5483 or visit www.simplexonsite.com. COLORADO Serving Colorado, Idaho, Montana, Nevada, Utah and Wyoming GEORGIA Serving Alabama, Florida, Georgia, North Carolina and South Carolina ILLINOIS Serving Illinois, Indiana, Kentucky, Michigan, Missouri and Tennessee MASSACHUSETTS Serving Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania and Vermont MINNESOTA Serving Iowa, Minnesota, North Dakota, South Dakota and Wisconsin OHIO Serving Indiana, Michigan, Ohio, Pennsylvania (western) and West Virginia TEXAS Serving Arkansas, Louisiana, New Mexico, Oklahoma and Texas

5300 Rising Moon Road Springfield, IL 62711-6228 Simplex, Inc. 2100 Boggs Road Duluth, GA 30096-4691 (800) 637-8603 www.simplexdirect.com