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Whitmore OilSafe Advanced Bulk System, Owner'S Manual

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Whitmore OilSafe Advanced Bulk System Owner'S Manual Download Page 31

Advanced Bulk System

29

11. REPAIR AND REPLACEMENT PROCEDURES

The major components of the system were designed to be line replaceable.  Before attempting any repairs or replacement, contact OilSafe in the event 
your part is covered by warranty.

You may contact OS as follows: 

Telephone: 

(972) 771-1000

930 Whitmore Drive 

Fax: 

(972) 722-3252

Rockwall, TX 75087  USA 

Email: [email protected]
www.oilsafe.com

Do not disassemble any part of the system without authorization from OilSafe.  Failure to receive this authoriza-

tion will void your product warranty.

The following parts of your system are replaceable. Contact your supplier for ordering information.

•

 The Tank and Motor can be replaced.

Contact your supplier for specific instructions and have your system specification sheet at hand.

WARNING!

ALWAYS ensure the main power supply is first locked out and the system depressurized before any service 
is performed on this system.  NEVER connect or disconnect lines, change filter elements, or undertake any 
service work when this system is running or energized.  SEVERE injury or death may occur.

The Tank Isolation Valves (located on the underside of each tank) must be in the open position when operat-
ing the system and in the closed position when servicing the system.

Summary of Contents for OilSafe Advanced Bulk System

Page 1: ...Bulk System Owners Manual IMPORTANT Please read this Owners Manual carefully and thoroughly before installing and operating your Advanced Bulk System Please retain this owners manual for future reference after reading it thoroughly ...

Page 2: ......

Page 3: ... 12 Replacement Parts 30 13 Tank or Motor Replacement 34 14 Data Tables 35 FOR YOUR RECORDS Write the model and serial numbers here You can find them on the Serial Model No Plate mounted at the rear of your system on a lower tank frame rail Serial Model Supplier Name Date Purchased READ THIS MANUAL Inside you will find important information on how to use and maintain your OilSafe Advanced Bulk Sys...

Page 4: ...FAILURE TO FOLLOW this caution will void your product warranty IMPORTANT This text will be used before text that has been designated as important to the proper installation operation or maintenance of your system FAILURE TO READ and understand this text may result in improper installation operation or maintenance procedures and may void your warranty TIP This text will be used to highlight text th...

Page 5: ...tem ALWAYS ensure that all system hoses filters and fittings are securely fastened and in good working condition THE OIL DRUM MUST ALWAYS BE VENTED TO ATMOSPHERE preferably utilizing a Desiccant Air Breather When dispensing or recirculating ALWAYS ensure the grounding cable is connected to the drum or barrel before starting the pump ALWAYS ensure the system is appropriately grounded to earth utili...

Page 6: ... invalidate any other provision For products purchased in countries other than the United States please contact OS authorized representative i e the company or person who represented OS or brokered the sale in the country where the product was purchased Warranty Service Options For service under this warranty you must notify OS in writing Such notification must specify in writing the product in qu...

Page 7: ...s and color coding to prevent cross contamination and misapplication of fluids Your system was designed to store and dispense lubricants up to ISO 680 if specified at the time of order Throughout this document we will be referring to each individual frame set that houses a set of tanks motors pumps spill pan faucets etc as a Tank Pod or Pod 1 in the event you have purchased more than one Pod Each ...

Page 8: ...eight of system Please make sure operating valves are in Recirculation positions before start up and at shut down of units This provides the lowest amp draw and system pressure ensuring the safest conditions for operators during start up and shut down of the unit Each system section is referred to as a Pod in this manual Check that you have received the appropriate number of Pods for your order Oi...

Page 9: ...h a 100 ampere ground clamp and rubber covered bumper An instant acting lock and release provides operator convenience IMPORTANT CARE MUST BE TAKEN when reeling the cable back onto the reel DO NOT let go of the cable walk it back towards the reel keeping tension on the cable at all times The cable stop assembly may be adjusted to any position The mechanical locking device works positively at all t...

Page 10: ... outlets have been installed at the rear of the system positioned behind where the motors will be located Each power outlet should be equally spaced along the wall and be placed approxi mately 12 up from floor level IMPORTANT It is important to note the effect of the ambient temperature in which the system is placed for operation System room temperature should be in the range of 60 F 15 C TO 80 F ...

Page 11: ... more information relating to service in cold environments STEP 1 The system is delivered pre assembled packaged and marked Pod 1 Pod 2 etc depending on the specific customized system This will indicate the respective Pod s position within the system from left to right when viewed from the front STEP 2 Locate Pod 1 and remove and appropriately dispose of the freight packaging STEP 3 Using a suitab...

Page 12: ... 6 Using a suitable hand pallet truck position Pod 2 to the right of Pod 1 so that the spill transport pallets are square and flush next to one another See Figure 5 and Figure 6 STEP 7 Using a level and the provided jacking bolts in the base frame adjust the Pod until it is level from front to back side to side and top to bottom and square with the adjacent Pod CAUTION ALWAYS keep hands and feet c...

Page 13: ...in a few minutes and is easily disconnected if it becomes necessary to move frames 5 INSTALLATION SPILL CONTAINMENT CONNECTOR KIT PART S 2 Pod Connector Kit SP CK 2 3 Pod Connector Kit SP CK 3 4 Pod Connector Kit SP CK 4 5 Pod Connector Kit SP CK 5 6 Pod Connector Kit SP CK 6 7 Pod Connector Kit SP CK 7 8 Pod Connector Kit SP CK 8 9 Pod Connector Kit SP CK 9 10 Pod Connector Kit SP CK 10 If connec...

Page 14: ... d Carefully insert the float assembly into the tank e Screw the aluminum bushing into the tank port until tight and ensure the arrow on the flat side of the hex bushing is pointing toward the rear of the tank f Gently lower red indicator to its resting position and then gently raise and lower it to ensure the float mechanism is free and clear inside the tank g Reinstall the calibration h Fasten t...

Page 15: ...the rod STEP 13 Once the clip is installed with the magnet on top of it you will then reinstall your red indicator Be sure to use the new red indicator provided with the alarm and discard the old indicator STEP 14 Install the 9 volt lithium battery into the alarm box STEP 15 Loosen the set screw located on the aluminum ring of your alarm Slide the ring over the calibration down to the center line ...

Page 16: ...all sealing surfaces are clean and free of damage b Apply a light film of clean oil to the sealing surfaces of the filter gasket NOTE never use grease to lubricate the gasket and then carefully insert the sealing gasket into the mating female annular seat in the filter head being sure to attain a firm flush seat with the gasket c Screw the new filter element on carefully avoiding cross threading A...

Page 17: ...nsing faucets supplied with your system into the threaded ports provided on the front face of the control panel Use of appropriate thread sealing paste is recommended on threaded joints 6 ELECTRICAL INSTALLATION WARNING Failure to follow system installation safety and operating instructions may result in severe injury or death damage to plant and equipment and void manufacturer warranties The foll...

Page 18: ...coming out of the lines and fluids to dispense normally before continuing If air continues to come out of the hoses after the initial use there may be a problem with a seal or a hose See the Troubleshooting section page 26 of this manual or contact your supplier for additional support Ensure that the Tank Isolation Valves located on the underside of each tank are in the open position before contin...

Page 19: ... Spin on Filter make sure you do so before proceeding FIGURE 10 Suction Hose Assembly FIGURE 11 Place Suction Tube STEP 1 Locate the Suction Hose Assembly Each tank will have its own individual Suction Hose Assembly See Figure 10 STEP 2 Place the tube end of the Suction Hose Assembly into the oil drum or container 55 gallon drum See Figure 11 ...

Page 20: ... ensure the Static Discharge Clip is connected to the drum or barrel before starting the pump 7 INITIAL OPERATION Filling the Tank s See Figure 12 for details STEP 3 Attach the Static Discharge Cable to the drum See Figure 12 FIGURE 12 Attach Static Discharge Cable ...

Page 21: ...the Fill position up and up and also ensure the dispensing faucets are in the closed position STEP 7 Press the START button above the corresponding Dispensing Faucet to begin loading the Bulk Tank STEP 8 Monitor the Bulk Tank Fluid Level Gauge to avoid over flow situations STEP 9 When the tank is full raise the suction tube vertically out of the oil drum and allow the pump to pull through any resi...

Page 22: ...figuration left DOWN right UP STEP 13 Run each filled Bulk Tank for the approximate times set out in the Re Circulation Kidney Loop Cycle Time Guide table in the Data Tables section page 35 Dispenser Faucets STEP 1 Press START to start the pump STEP 2 Place a clean fluid transfer or storage container under the tap approximately 5 Gallon 10 Liter capacity STEP 3 Lift up on the handle See Figure 15 ...

Page 23: ...lem with the System provided the pump pressure bypass relief valves on each pump have first been set to suit the particular oil viscosity and ambient room temperature as the fluid will bypass back to the corresponding Bulk Tank via the pump bypass pressure return hose Normal System operating pressure should be less than 240 PSI when pumping against a closed faucet and should never exceed 300 PSI R...

Page 24: ...solate the system with the normal T Ball Valve simply move the handle of the valve such that it finishes perpendicular 90 to the valve body The valves are located on the underside of the tank See Figure 16 for a normal T Ball Tank Isolation Valve that is in the open position CAUTION Personal Protective Equipment PPE should be worn when installing and operating this system WARNING ALWAYS ensure the...

Page 25: ...r is used 4 Check the batteries on any installed over fill alarms Batteries should be changed once per year 4 Inspections Inspect all hoses for cracks or kinks Inspect all hose fittings for cracks or leaks Inspect and tighten all bolts 4 Clean external surfaces Use an environmentally friendly cleaning degreasing fluid and warm water Rinse completely before replacing Remove drip pans from beneath t...

Page 26: ...n on Static Discharge Reel If additional tension is needed apply a wrench to the flats on the mainspring shaft rotating counter clockwise until the desired tension is reached If mainspring tension is too high it may be decreased by depressing tension lock spring on the opposite side of the reel DO NOT remove more tension than desired If too much tension is removed increase tension as described abo...

Page 27: ...r from any upper tanks d Place the hoses and cords in the spill pan at the bottom of the Pod STEP 7 Repeat all steps until each pod is isolated similar to how it was delivered initially STEP 8 Using a hand pallet truck position the Tank Pod Pod 1 into its new service position ensuring that there is at least 18 of free clear space at the rear and each end of the system STEP 9 Continue to follow the...

Page 28: ...heck all fittings for cracks or leaks 3 Check all hydraulic hoses for cracks or leaks 4 Check the motor to ensure it is rotating in the correct direction If not contact your authorized Electrician 5 Check the Tank Isolation Valves and ensure they are in the OPEN position 6 Check the Pressure Gauge to make sure that the pressure level is registering when the motor is running 7 If the Pressure Gauge...

Page 29: ...e Dispensing Faucet to remove dirt debris or clogs 9 Check the o ring on the Dispensing Faucet Replace if necessary The motor stops working The Stop or Start Buttons do not light up correctly 1 Check electrical enclosure to ensure power is applied to the pump 2 Check all circuit breakers to ensure power is available Check the power cord from the electrical enclosure to the motor for cracks or prob...

Page 30: ...monitors the pressure gauge This pres sure setting re adjustment will likely take 1 5 to 2 5 turns of the valve spindle depending on oil viscosity and operating temperature 7 Once the desired pressure has been achieved re tighten the valve spindle lock nut by turning the nut clock wise 1 Ambient room temperature where the system is installed should be in the range of 60 F 15 C TO 80 F 26 C with op...

Page 31: ...r product warranty The following parts of your system are replaceable Contact your supplier for ordering information The Tank and Motor can be replaced Contact your supplier for specific instructions and have your system specification sheet at hand WARNING ALWAYS ensure the main power supply is first locked out and the system depressurized before any service is performed on this system NEVER conne...

Page 32: ...removed and replaced by screwing it on or off Direct Mount Overfill Alarm Part s 921100 921101 or 921102 This is optional equipment which signals if your tank is overfilling There is an audible only alarm a flashing light only alarm and an alarm which combines the audible alarm and a flashing light These alarms are fitted to the Tank Level Gauge located on the top of every tank The alarm has a 9 V...

Page 33: ...lacing for any reason it can be removed by unscrewing it from the handle and replacing it with a new knob Be sure to keep the color coded system in place to allow users to easily recognize which Dispensing Faucet goes with each tank Steel Auto Shut off Faucet with Black Ball Knob The Steel Auto Shut off Faucet can be removed and replaced as needed There are also spare parts available for the Steel...

Page 34: ...tion Static Discharge Grounding Reel Retractable 25 ft The Static Discharge Grounding Reel can be removed and replaced Disassembly of the reel will void any warranty Contact your supplier for additional information Suction Hose Assembly Stainless Steel Tube with Reinforced PVC Hose The Suction Hose Assembly used to load fluid from 55 gallon drums can be replaced Contact your supplier for additiona...

Page 35: ... Colored Ball Knob for Steel Faucet Shut Off Valve Red Ball Knob 921008 Colored Ball Knob for Steel Faucet Shut Off Valve Yellow Ball Knob 921009 Tank Desiccant Air Breather Breather 46Z134 Steel Auto Shut Off Faucet with Black Ball Knob Faucet 921020 Brass Faucet Fire Upgrade Option Faucet 921110 Brass Faucet Fire Upgrade Option 2 Faucet 921111 Spin on Filter 3um β200 Micro Glass Filter 469903 Sp...

Page 36: ...g Screws No 10 24 Cap Screws Hex Key 1 8 Dispensing Console Pressure Gauge Face Mounting Screws No 6 Cap Screws Hex Key 5 64 Dispensing Console Stainless Splash Plate Mounting Screws 5 16 UNC Cap Screws Hex Key 3 16 Dispensing Console Steel Mounting Plate Screws 5 16 UNC Cap Screws Hex Key 3 16 Hose Connections all discharge hydraulic hose connections 3 4 JIC Hose Coupler Wrench 1 1 4 Hose Connect...

Page 37: ...rated full tank not brimful capacity Flow rate values are approximate For oils ISO 220 motor pump set was 1HP 115V 60Hz 14A 1750 RPM positive displacement direct coupled gear pump For oils ISO 320 motor pump set was 0 75HP 115V 60Hz 10A 1170 RPM positive displacement direct coupled gear pump Factory supplied Micro glass β200 spin on filters STANDARD TANK SIZE APPROX BRIM FULL CAPACITY 30 Gallons 3...

Page 38: ...disconnect 7 Suction 3 way ball valve 8 1HP 1200rpm motor 3gpm 11 4lpm 150psi 10 3bar pump or Pneumatic diaphragm pump 9 Pressure gauge 10 Oil filter with condition indicator 11 Dispense or recirculate 3 way ball valve 12 Dispensing tap for container filling 13 Optional hose reel and dispensing gun OilSafe Advanced Bulk System Plumbing Schematic Rev2 6 Hose Reel 1 7 8 10 11 13 12 2 3 5 4 9 ...

Page 39: ...tomer service ordering requests or warranty issues please contact your authorized supplier or OilSafe You may contact OS as follows Telephone 972 771 1000 930 Whitmore Drive Fax 972 722 3252 Rockwall TX 75087 USA Email sales oilsafe com www oilsafe com ...

Page 40: ...Advanced Bulk System 37 NOTES ...

Page 41: ...38 NOTES ...

Page 42: ......

Page 43: ...Telephone 972 771 1000 930 Whitmore Drive Fax 972 722 3252 Rockwall TX USA Email sales oilsafe com www oilsafe com 2016 Whitmore 100245 1BSADV ...

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