DIESEL SMARTPUMP TANK FILLING SYSTEM 1-16 TANKS

DIESEL SMARTPUMP TANK FILLING SYSTEM 1-16 TANKS

Last Revision Date: March 10, 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. Many of the illustrations and instructions in this manual refer to the standard configuration for this product. If you have requested customizations, the drawings provided with your order take precedence; please refer to them for details specific to your order. If you have any questions, please contact Simplex at 800-637-8603.

Table of Contents 1 Warnings and Cautions... 1 Safety information symbols 1 Cautions 1 2 Nameplates and Placards... 3 3 Description and Specification... 9 Overview of Use 9 Capabilities 9 Safety 9 4 Unpacking...11 Included Components and Parts 11 Primary Inspection 11 5 Installation...13 Initial Start-up Test Procedure 13 Testing Leak Sensor 13 Checking Pump Rotation 14 6 Operating Instructions...15 Draining the Spill Containment Basin 16 Purging the Pump 16 7 Maintenance/Troubleshooting...17 Preventative Maintenance 17 Troubleshooting 17 8 Supplemental Equipment...19 Valves 19 Level Transmitters 20 Appendix A PRODUCT WARRANTY...21

Table of Figures Specifications... 10 SmartPump... 11 Valve... 11 Float Assembly... 11 Ground stud... 13 TB-T1... 13 AX1... 13 Shaft Coupler Guard... 14 Overload Relay... 14 Pump Inlet Valve... 16 Pump Outlet Valve... 16 Air Purge Valve... 16 Troubleshooting... 17 Dimensions... 18 Valves... 19 Level Transducers... 20

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

(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 Warnings and Cautions

2 NAMEPLATES AND PLACARDS Please see fill controller manual for additional nameplates and placards Nameplates and Placards 3

4 Nameplates and Placards

Nameplates and Placards 5

6 Nameplates and Placards

Nameplates and Placards 7

Did you know? Michael Debrey got the idea for his Simplex s first product, the Automatic Voltage Regulator, while working as an electrician at a furniture factory on the night shift. Part of his job was to regulate the output voltage of a steam turbine generator by hand. Being a skilled tinkerer, he developed a device to do it for him.

3 DESCRIPTION AND SPECIFICATION Overview of Use Capabilities Please refer to your fill controller manual for instructions for setting up and filling tanks Safety Due to variances in tank design, the values are approximate. The SmartPump controls and monitors fuel delivery and storage. The SmartPump consists of three components: a fuel port, which makes it easier to fill storage tanks by providing ground-level access; a fill controller, which monitors and controls filling and delivery of up to 16 tanks (with optional expansions); and a fuel pump, which accommodates gravity fuel trucks by delivering up to 300 GPM. The fill controller, which acts as the brains of the Smart- Pump, allows for remote filling of up to 16 tanks while monitoring their fuel level. After an established limit is reached, the filling is stopped and the operator is alerted. The fill controller allows for multi-tank filling and monitoring, and through sensors in the tanks, displays the fuel level in real time. The SmartPump can fill, monitor, and control up to sixteen tanks. A touch screen provides control and monitoring, while communication options allow for central monitoring from a building management system (BMS/BAS). The SmartPump can be equipped with one of two fill controllers, depending on your needs: 1. The Compact Automatic Fill Controller, which can control one or two tanks 2. The Automatic Fill Controller, which can control one to four tanks and up to 16 tanks with the addition of separately mounted slave panels. The SmartPump is capable of controlling round or rectangular tanks containing Class II liquids, such as diesel fuel. The Smart- Pump s fill controller uses a single motorized ball valve per tank to ensure accurate filling. The SmartPump s fill controller monitors the fuel level in each tank and displays the levels in gallons or percentage. Each tank can be programmed independently for shape, volume, and height as well as low level alarm (%) and refill (%) alert. The default value for the full level is approximately 90%, the default value for the high level is approximately 95%, and the default critical high level is approximately 98%. Description and Specification 9

The fill controller can also alert the user when the tank reaches adjustable refill and low fuel levels. The controller also monitors a leak sensor for each tank. When a leak is detected, filling of that tank is prohibited. The fill controller is also equipped with a sump leak detector. Table 1 Specifications Delivery Type Gravity truck to one or more tanks Shutoff Automatic Product Class II liquids, 100 F - 140 F flash point (Diesel fuel) Inlet Fitting Size 1.5, 2, 3, or 4 Motor and Pump 2 HP / 150 GPM (1.5 and 2 inlet fitting) 5 HP / 300 GPM (3 and 4 inlet fitting) Spill Containment 7 gallons Paint UL-listed powder-coat process Dimensions (Approximate) SmartPump: 66" W x 44" H x 26" D SmartPump with Full Lockable Enclosure: 72 W x 69.75 H x 24 D Weight SmartPump (Oil): approximately 617 lbs. SmartPump with Full Lockable Enclosure: approximately 875 lbs 10 Description and Specification

4 UNPACKING Included Components and Parts The following items are included with your SmartPump. If any of the following are Figure 1 SmartPump not included, please contact the Simplex Direct, Inc., service department at 800-637- 8603 ext. 4. 1. SmartPump 2. Valve(s) 3. Float Assembly(s) 4. SmartPump manual 5. Fill Controller manual 6. Drawings package Figure 2 Valve 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 Smart- Pump is advised. Never apply power to a Smart- Pump before performing this procedure. The following four-point inspection is recommended before installation and as part of a 6-month maintenance schedule: Figure 3 Float Assembly 1. If the crate shows any signs of damage, examine the SmartPump 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 electrical or mechanical problems due to reduced clearance. 3. Check electrical connections for tightness. 4. Examine all accessible internal electrical components. Unpacking 11

Did you know? Simplex founder Michael Debrey got his first experience with power generation when he worked as an electrician for the Ringling Bros. Circus.

5 INSTALLATION 1. Anchor the Smart- Figure 4 Ground stud Pump to a concrete pad using the mounting holes in the base of the unit. 2. Connect the cabinet to an earth ground via the 1/2 ground stud on the left-hand side of the assembly. (See Figure 4.) 3. Follow the instructions in your fill controller manual for information regarding installing control power, float assemblies, etc. Initial Start-up Test Procedure Before connecting the SmartPump to your fuel tank(s), ensure it will operate correctly by testing the leak sensor (if ordered) and checking the rotation of the fuel pump. Testing Leak Sensor To test the optional leak sensor: 1. Ensure the control power circuit breaker is off. 2. Open the control panel s inner door to access the control compartment. 3. For the first tank, install a wire jumper from TB-T1-7 to TB- T1-11 (see Figure 5). 4. Close the inner door. 5. Turn on the control power circuit breaker. 6. The Tank Leak indicator should come on and the tank leak relay AX1 should energize (see Figure 6). Figure 5 TB-T1 Figure 6 AX1 Installation 13

7. Turn off the control power circuit breaker. 8. Open the control panel inner door to access the control compartment. 9. Remove the wire jumpers. 10. Repeat the procedure for the remaining tanks. Checking Pump Rotation 1. Turn off the control power circuit breaker. 2. Remove the shaft coupler guard from the pump (see Figure 7). 3. Turn on the control power circuit breaker. 4. Press the Start Fill button. The pump should start and run. 5. The shaft should rotate in the direction indicated on the sticker on the motor (see Figure 7). 6. If rotation is incorrect: Figure 7 Shaft Coupler Guard a. Press the Stop Fill button. b. Turn off the control power circuit breaker. c. Open the Control Panel inner door to access the control compartment. d. Locate the overload relay (see Fig- Figure 8 Overload Relay ure 8). e. On either side of the relay, reverse the black and red wires: connect the red wire to line one and the black wire to line two. f. Close the Control Panel inner door and repeat steps 3 through 5. 7. Turn the control power circuit breaker off. 8. Reinstall the shaft guard. 9. Connect the outlet of the SmartPump to the storage tank(s) using 3-inch steel or black iron pipe. 14 Installation

6 OPERATING INSTRUCTIONS These are abstracted instructions. Please refer to your fill controller manual for details 1. Connect a ground cable from the truck to the provided ground stud. 2. Unlock the fill box. 3. Connect the delivery hose from the fueling truck to the hose coupling. 4. Turn on the control power switch on the fill controller. 5. If the digital display is blank, tap the screen to wake it up. 6. Choose the desired tank to fill by tapping its readout on the display. 7. Press the Start Fill button to open the fill valve for the selected tank. Only one fill valve may be open at a time. 8. Open the valve on the truck. 9. Fuel is delivered from the truck to the tank. 10. You can stop the fuel delivery at any time by pressing the Stop Fill button. 11. When the Tank Full level is reached, an indication will be displayed, the alarm horn will sound, and the fill valve will close. 12. When the tank reaches the Tank Full level, you can only open the valve in 30-second increments. To reopen the valve, press the Start Fill button to drain the hose. 13. If the Tank High level is reached, an indication will be displayed, the alarm horn will sound, and the fill valve will close. You cannot reopen it until the fuel level has dropped below the Tank High level. 14. If any tank in the system reaches the Critical High level, an indication will be displayed, the alarm horn will sound, and all fill valves will close. They will not be allowed to reopen until the condition clears. 15. If the tank fill valve is open, press the Stop Fill button to close the fill valve. 16. Disconnect the delivery hose. 17. Press the Back button to return to the main screen. 18. Turn off the control power. 19. Fuel delivery is complete. 20. Close and lock the fill box. 21. Disconnect the ground cable from the truckers grounding stud. Operating Instructions 15

Draining the Spill Containment Basin Purging the Pump 1. Start the pump by pressing the Start Fill button. 2. The pump will start and empty the spill basin. A full basin should take about 20 seconds to empty. 3. Stop the pump when the basin is empty by pressing the Stop Fill button. You must purge the pump of air on initial start-up or whenever air has entered the pump system. Open the SmartPump inlet and outlet valves (Figure 9 and Figure 10) to flood the system. Open the air purge valve (Figure 11) located at the pump discharge, then close the valve. The pump should now be purged of air. Figure 9 Pump Inlet Valve Figure 10 Pump Outlet Valve Figure 11 Air Purge Valve 16 Operating Instructions

7 MAINTENANCE/TROUBLESHOOTING Preventative Maintenance Trouble shooting Remove all power before servicing the SmartPump. The SmartPump is designed to require minimal maintenance. On a yearly schedule, the unit should be fully opened and cleaned out. At this time, it would be a good idea to disconnect power and tighten all connections to ensure proper operation. To troubleshoot the SmartPump, a full set of drawings is required. Any electrical work should be performed by trained personnel. Simplex, Inc. is not liable for any damage or bodily harm. If additional help is required, contact Simplex or your local Simplex Onsite branch for troubleshooting and onsite assistance. The following table (Table 2) contains some common scenarios which you may face while operating the SmartPump. If you experience any other problems, consult the troubleshooting section in the fill controller s manual. Table 2 Troubleshooting Problem Cause Resolution Pump turning in wrong direction Wiring reversed at overload relay Reverse wiring at overload relay. See page 14 No fuel pumping Air trapped in line Purge pump system. See page 16 Pump not operating Motor Overload Relay tripped Investigate why relay and tripped and reactivate relay Motor contactor connections loose Tighten contactor connections Maintenance/Troubleshooting 17

Figure 12 Dimensions 18 Maintenance/Troubleshooting

8 SUPPLEMENTAL EQUIPMENT The SmartPump is designed to interface with several other pieces of hardware. Without this additional hardware, the SmartPump will not function properly. Consult your sales representative to order equipment. Valves Valves, which are required for each tank in the system, can be either motorized ball valves or actuated butterfly valves. Table 3 Valves Stock Number Pipe Size Cv Flow Factor Ball Valves High Voltage: 85-240v AC or DC Max. PSI 22919240 1 50 600 22919255 2 307 600 22919280 3 1012 300 Butterfly Valves Lug Body VITON Seals: 85-240v AC or DC 562742 1 (2-inch orifice) 50 230 562743 2-1/2 307 230 562744 3 1012 230 562745 4 1012 230 562747 6 1012 230 Supplemental Equipment 19

Level Transmitters Level transducers are used to determine the fluid level in the tanks. Any 4-20mA sensor can be used as long as it is properly calibrated to the particular tank in which it is used. Due to the variation in tank sizes, particularly height, it is important to select the appropriate sensor. Consult your sales representative for transducer selection. Table 4 Level Transducers Stock Number Type Max PSI* Range 20 ma High Voltage: 85-240v AC or DC 25328255 Submersible Pressure 0-7.5 0-255 Fuel Oil 255 25328251 Submersible Pressure 0-1 0-34 Fuel Oil 34 Call Ultrasonic N/A 0-49.2 * Call Ultrasonic N/A 0-117 * Call Ultrasonic N/A 0-216 * Call Magnetostrictive N/A Call * *Calibrated to Tank Height in inches 20 Supplemental Equipment

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. Product Warranty - 21

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.

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