Earthsafe M500 User manual
earth safe
Fuel Systems for Critical Power
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
Earthsafe M 00
Generator Day Tank
T: (630) 794-5 00
F: (630) 794-5 06
www.earthsafe.com
Earthsafe Systems, Inc.
7320 S. Madison
Willowbrook, IL 60527
Updated: October 20 2
The information contained herein is proprietary and is provided for the sole purpose of the owner’s installation,
operation, and maintenance of the system. Reproduction of this information for other purposes is prohibited
without the prior consent of Earthsafe Systems, Inc.
EMERGENCY POWER FUEL SYSTEMS
Notice
Earthsaf mak s no warranty of any kind with r gard to this publication, including but not
limit d to, th impli d warranti s of m rchantability and fitn ss for a particular purpos .
Earthsaf shall not b liabl for rrors contain d h r in or for incid ntal or cons qu ntial
damag s in conn ction with th furnishing, p rformanc or us of this publication. Earthsaf
r s rv s th right to chang syst m options or f atur s, or th information contain d in this
publication. This publication contains propri tary information which is prot ct d by
copyright. All rights r s rv d. No part of this publication may by photocopi d, r produc d,
or translat d to anoth r languag without th prior writt n cons nt of Earthsaf .
Damage Claims
Thoroughly xamin all compon nts and units as soon as th y ar r c iv d. If damag d,
writ a compl t and d tail d d scription of th damag on th fac of th fr ight bill.
Th carri rs ag nt must v rify th insp ction and sign th d scription. Imm diat ly notify
th d liv ring carri r of damag or loss. This notification may b giv n ith r in p rson or
by t l phon . Writt n confirmation must b mail d within 48 hours. Risk of loss, or damag
to m rchandis b longs with th buy r. It is th buy rs r sponsibility to fil a claim with th
carri r involv d. Imm diat ly advis Earthsaf of th probl m so that w may assist you.
Safety Information
UL List d. Th Earthsaf C ntraPl x Control Modul is UL list d.
Int nd d Us . Th Earthsaf C ntraPl x Control Modul is int nd d for us with di s l fu l
syst ms for m rg ncy pow r g n rators. Th control modul and any conn ct d s nsors or
d vic s ar int nd d for op ration only within ordinary l ctrical ar as. Us of th modul
and conn ct d s nsors or d vic s within hazardous l ctrical ar as is prohibit d.
Intellectual Property
Th quipm nt and softwar d scrib d h r in ar th prop rty of Earthsaf Syst ms, Inc.
and ar prot ct d by various trad marks and pat nts.
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Fuel Systems for Critical Power
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Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Fuel Systems for Critical Power
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Saf ty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
G n ral D scription . . . . . . . . . . . . . . . . . . . . . . . . .5
Planning th Installation . . . . . . . . . . . . . . . . . . . . . . .7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
T sting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Op ration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Maint nanc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubl shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Spar Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Warranty and S rvic . . . . . . . . . . . . . . . . . . . . . . . .15
App ndix: Viking Pump Manual . . . . . . . . . . . . . . .15
Table of Contents
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
earth safe
Fuel Systems for Critical Power
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EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
Safety notices – General Safety Rules – Symbols (danger-warning-caution)
SAFETY INFORMATION AND INSTRUCTIONS
Danger — Failur to follow th indicat d instruction may r sult in s rious injury or d ath.
Warning — In addition to possibl s rious injury or d ath, failur to follow th indicat d
instruction may caus damag to pump and/or oth r quipm nt.
IMPROPER INSTALLATION, OPERATION OR MAINTENANCE MAY CAUSE SERIOUS INJURY
OR DEATH AND/OR RESULT IN DAMAGE TO UNIT AND/OR OTHER EQUIPMENT.
EARTHSAFE’S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION,
OPERATION OR MAINTENANCE.
THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION,
OPERATION OR MAINTENANCE OF EQUIPMENT AND MUST BE KEPT WITH EQUIPMENT.
EQUIPMENT MUST BE INSTALLED, OPERATED AND MAINTAINED ONLY BY SUITABLY
TRAINED AND QUALIFIED PERSONS.
THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO
AT ALL TIMES.
Sy bol Legend:
Danger — Failur to follow th indicat d instruction may r sult in s rious injury or d ath
Warning — In addition to possibl s rious injury or d ath, failur to follow th indicat d
instruction may caus damag to pump and/or oth r quipm nt.
BEFORE op ning any pip syst m, pump, or valv b sur that:
• Any pr ssur in th chamb r has b n compl t ly v nt d through th suction or
discharg lin s or oth r appropriat op nings or conn ctions.
• Th l ctrical syst m syst m m ans has b n “lock d out” or oth rwis b n mad
non-op rational so that it cannot b start d whil work is b ing don on th quipm nt.
• You hav obtain d appropriat mat rial saf ty data sh t (MSDS) and und rstand and
follow all pr cautions appropriat for th saf handling of th mat rial.
INSTALL pr ssur gaug s/s nsors at piping and pump conn ctions to th quipm nt to
monitor pr ssur s.
USE xtr m caution wh n lifting th pump. Suitabl lifting d vic s should b us d wh n
appropriat .
DO NOT att mpt to dismantl a pr ssur r li f valv that has not had th spring pr ssur
r li v d or is mount d on a pump that is op rating.
AVOID contact with hot ar as of th pump or quipm nt. C rtain op rating conditions,
t mp ratur control d vic s, improp r installation, improp r op ration, and improp r
maint nanc can all caus high t mp ratur s on th pump or quipm nt.
Pu ps and piping syste s must b provid d with pr ssur prot ction.
THE equip ent must b install d in a matt r that allows saf acc ss for routin maint nanc
and for insp ction during op ration to ch ck for l akag and monitor op ration.
General Description
Safe Fuel Storage Inside Buildings.
Earthsaf day tanks saf ly stor fu l for g n rator ngin consumption within th building.
Day tanks ar d sign d with int gral s condary containm nt. Fu l transf r quipm nt and
controls ar d sign d for saf and r liabl r -filling.
Reliable Refill Syste s.
Day Tanks ar d sign d and furnish d with pr -ass mbl d and t st d fu l transf r quipm nt and
controls. Inl t control valv s, transf r pumps, l v l s nsors, l ak s nsors, and oth r quipm nt ar
all monitor d and controll d by th Earthsaf OmniPl x or C ntraPl x control pan ls.
Integrated Building Manage ent Syste s.
Earthsaf advanc d controll rs allow for th communication of vital day tank op rating information
to oth r building syst ms. Th s syst ms may includ Building Automation Syst ms, g n rator
controls, switchg ar and oth r pow r controls, s curity and fir alarm syst ms.
Readily Adaptable for Special Operation.
Earthsaf day tanks can b r adily adapat d for sp cial op ration charact ristics such as: dual
inl t valv s, monitor d valv positions, high l v l / ov rflow pumping, m rg ncy vacuation,
auto-commissioning, fluid m t ring, high t mp ratur control.
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Fuel Systems for Critical Power
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EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Physical Description
1. Primary Fu l Tank: UL 142 St l Tank
2. Containm nt: Rat d w ld d st l containm nt
basin – doubl wall tank
3. Control pan l support: Support for OmniPl x
Controll r and pump motor start r pan ls
4. Control Pan l: PLC bas d control pan l
5. Motor Start r: Motor start r for r turn flow pump
6. Inl t Valv Ass mbly: Inl t sol noid valv s,
manual valv s, and strain rs.
7. Pump and Motor for R turn Flow:
Viking positiv displac m nt pump
8. Engin Inl t and Outl t: Suction pip on
ngin supply
9. Standard V nt: 2” tank op ning
10. Em rg ncy V nt: 4-6” tank op ning
11. Dir ct R ad Gaug
12. Insp ction Port
13. L ak S nsor
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
7RETURN FLOW PUMP
4
CONTROL PANEL
5PUMP MOTOR
STARTER
1PRIMARY STEEL TANK
2CONTAINMENT TANK
3
PANEL BRACKET
NOT SHOWN IN
PHOTO PERSPECTIVE
6. Inl t Valv Ass mbly
8. Engin Inl t and Outl t
9. Standard V nt
10. Em rg ncy V nt
11. Dir ct R ad Gaug
12. Insp ction Port
13. L ak S nsor
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Planning the Installation
Location
1. Location — locat th day tank as clos as practical to th ngin g n rator.
2. Acc ssibility — th day tank should b locat d wh r it is acc ssibl for insp ction,
maint nanc , and r pair.
Piping
Before starting layout and installation of your piping system, consider the following points:
1. Siz th fu l supply piping to minimiz frictional h ad loss bas d on th d sign flow.
2. Siz gravity ov rflow piping to assur ad quat flow capacity. It should b at l ast on siz
larg r than th inl t piping of th day tank – for a singl day tank installation. Wh r
multipl day tanks shar a r turn flow lin , th lin should b ad quat ly siz d and slop d
to assur r quir d capacity.
3. Install gravity ov rflow pip so that it slop s continuously from th day tank back to th
main storag tank.
4. B sur th insid of th pip is cl an b for conn cting to th day tank.
5. B sur allowanc is mad for xpansion and contraction of th piping so th day tank
conn ctions ar not str ss d by th piping.
6. Th day tank should not b us d to support th piping. Th w ight of th pip should b
carri d by hang rs and supports.
7. Wh n fast ning th piping to th day tank it should not b n c ssary to impos any
strain on th day tank fittings. Do not us th day tank to corr ct rrors in piping layout
or ass mbly.
8. All joints of th piping syst m should b tight; pip s al r will h lp assur l ak-fr
thr ad d joints.
9. Provid a pr ssur r li f d vic in any part of a pump and piping syst m that can b valv d
off and, thus, compl t ly isolat d. Th ris in t mp ratur caus s th liquid to xpand; if
th r is no provision for pr ssur r li f in th clos d off s ction, th r is a chanc that th
pump or piping will ruptur .
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Fuel Systems for Critical Power
Installation
1. R mov packaging and insp ct for shipping damag . Not any shipping damag on th
shipping tick t and notify Earthsaf within 24 hours of r c ipt.
2. S t unit at installation location. Us prop r handling proc dur s to avoid damag to
th unit.
3. Install anchor bolts at 4 corn rs. Us ½” diam t r xpansion anchors with 3” mb dm nt or
as r quir d for local cod complianc .
4. Conn ct pow r to motor start rs and controll r. R f r nc sp cific installation instructions
and wiring diagrams for th controll r and motor start r pan ls.
5. Ch ck tightn ss of all bolts, which may hav loos d during shipm nt. Tight n 4 bolt flang s
by gradually tight ning across th bolt patt rn.
6. Pr ssur t st th pump s t to 50 PSI or in accordanc with proj ct d sign r quir m nts.
Corr ct any loos bolts or thr ad d joints if r quir d. Th day tank is not rat d for
pr ssur ov r 5 PSI, so piping to b t st d must b isolat d from th tank using valv s or
oth r m ans.
7. Cl an fi ld install d piping. Cl an all dirt and d bris from fi ld install d piping prior to
conn cting to th day tank.
8. Conn ct piping to inl t and outl t (inl t piping consid rations). Confirm that fi ld piping
is ind p nd ntly support d to avoid str ss on th pump s t piping.
9. Ch ck pump rotation. En rgiz th pump mom ntarily to obs rv dir ction of motor fan
rotation. Th pump inl t and outl t ar offs t from th c nt rlin of th pump h ad, so that
th r is a long arc or short arc from th inl t to th outl t. Th pump rotation should b
that it progr ss s along th long arc from th inl t to th outl t.
10. Engin supply and r turn piping should includ rat d hos s or fl xibl conn ctors to isolat
vibration from th day tank.
11. V nt piping shall b install d to t rminat to th building xt rior. Th v nt piping should
slop continuously from th t rmination point back to th day tank.
12. Wh r a r turn flow pump is us d, and th main fu l tank is b low th day tank, an
anti-siphon valv must b install d on th r turn flow pump discharg .
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Startup
Remote Fuel Supply Pumps
1. Clos th inl t piping valv to th day tank.
2. Ch ck that th ov rflow pip (or ov rflow pump discharg piping) is op n to provid a
r turn flow path back to th day tank.
3. Ch ck that th r mot fu l supply pump is prim d with fu l and r ady for op ration in th
automatic mod .
4. En rgiz th fu l syst m controll r. Confirm that th r mot fu l pump is n rgiz d to
d liv r fu l to th day tank. Confirm that th day tank inl t sol noid valv is n rgiz d
to op n.
5. Confirm that th day tank insp ction port is availabl to obs rv fu l l v ls in th day tank.
6. Op n th manual valv at th day tank inl t to allow fu l flow into th tank.
7. R cord th tank l v l at which th critical low l v l alarm c as s. R cord th tank l v l at
which th low l v l alarm c as s.
8. Monitor th fu l flow into th day tank, until th fill stop l v l is r ach d. R cord th tank
l v l for fill stop. Confirm that th inl t sol noid valv clos s, and th r mot fu l supply
pumps ar stopp d.
9. P rform additional r quir m nts und r t sting.
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Fuel Systems for Critical Power
Startup
Day Tank Pumps as Suction Supply Method or Overflow Pump
1. Prim th suction lin . R mov th thr ad d plug on th pump inl t piping and plac
di s l fu l into th piping until full. R install th thr ad d plug. Op rat th pump for
60 s conds maximum. Obs rv th inl t and outl t gaug s to confirm pump rotation and
progr ss of liminating any r maining air from th suction piping. A fully prim d suction
pip will b d monstrat d by a st ady vacuum gaug r ading on th pump inl t.
2. Op n all inl t and outl t valv s and confirm that th r is a cl ar flow path from th fu l
sourc to th d stination.
3. Manually start pump to confirm pump prim . Op rat th pump for 60 s conds maximum.
Obs rv th inl t and outl t gaug s to confirm pump rotation and progr ss of liminating
any r maining air from th suction piping. A fully prim d suction pip will b d monstrat d
by a st ady vacuum gaug r ading on th pump inl t.
4. If th pump still do s not d liv r, th caus may b on or mor of th following:
a. Suction lin air l aks
b. Suction lin obstructions
c. Suction tub or foot valv in tank is not install d.
d. Suction lift is too gr at or th suction piping is too small.
. Anti-siphon or ch ck valv s tting in suction lin is xc ssiv .
5. Adjust pr ssur r li f valv to r quir d s tting. Adjust th pump pr ssur r li f valv to th
maximum d sign pr ssur of th syst m. This is don by r moving th cap from th valv
and adjusting th spring bolt. Th valv adjustm nt should r sult in th pump b ing abl to
op rat against clos d discharg valv s, without ov rload trip to th motor.
6. Ch ck pr ssur and vacuum op rating rang s. Confirm that th vacuum and pr ssur
gaug r adings ar in conformanc with th d sign r quir m nts.
7. Ch ck for l aks and corr ct any loos flang s or thr ad d fittings.
8. Ch ck motor start r ov rload s ttings. Confirm that th motor start r ov rload s ttings
match th full load amps indicat d on th pump motor.
9. Cl an inl t strain r. Clos th inl t valv to isolat th strain r. R mov th thr ad d plug.
Cl an any d bris from th strain r scr n.
Fuel Supply to Engine
1. Us a vacuum pump to prim th fu l piping and r mov all air from th day tank to th
ngin conn ction.
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
Th day tank t sting r quir s fu l transf r to low r th day tank l v l to ch ck op rating points.
Day tanks quipp d with r turn flow pumps, may us th on-board pump for this fu l transf r.
Day Tanks without r turn flow pumps should b op rat d with a t mporary pump to low r fu l
l v ls for t sting.
Perform the testing procedure in accordance with the startup checklist.
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Day Tank Startup and Test Checklist
It m D scription Ch ck Dat Comm nts
1 Pow r to control pan l
2 Pow r to r turn flow pump
3 Initial display is accurat
4 Critical low s nsor input and display
5 Low l v l input and display
6 Pump start l v l input and display
7 Pump stop l v l input and display
8 High l v l input and display
9 L ak input and display
10 Manual mod fill inl t sol noid n rgiz
11 Manual mod fill pump start
12 Manual mod fill disabl on high l v l
13 Manual mod fill disabl on stop
14 Manual mod r turn flow pump n rgiz
15 Manual mod pump flow confirm d
16 Manual mod pump disabl on stop
17 Auto mod fill start l v l inl t sol noid n rgiz
18 Auto mod fill start l v l pump start
19 Auto mod fill start l v l disabl on stop
20 Auto mod fill start l v l disabl on high l v l
21 Auto mod fill start l v l disabl on l ak
22 Auto mod fill stop l v l inl t valv d - n rgiz
23 Auto mod fill stop l v l pump stop
24 High l v l r turn pump start
25 High l v l r turn pump tim out aft r cl ar
26 Confirm Output r lay and horn on Alarm
27 Alarm mod s: L ak, Low, Clow, High
Testing
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Operation
1. Day Tank controll r op ration.
Refer to Controller manual for details of day tank operations.
Maintenance
1. Insp ct for l aks at r gular int rvals, w kly as a minimum.
2. Op rat pump manually to confirm prim at r gular int rvals, monthly as a minimum.
3. Ch ck strain rs aft r initial us and cl an if r quir d.
4. P riodically ch ck th day tank r fill function by low ring th day tank fu l l v l and
obs rving th r -fill function.
5. On annual basis also ch ck th day tank high, low, and l ak alarms.
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Fuel Systems for Critical Power
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Fuel Systems for Critical Power
Troubleshooting — General
1. Low Level Alarm
Ch ck controll r m rg ncy stop
Ch ck that manual inl t valv s ar op n
Ch ck that r mot fu l supply pump is op rating prop rly
Ch ck that inl t sol noid valv is n rgiz d. If not ch ck for loos wir s or fus issu .
Ch ck that l v l s nsor pump start signal is activ on controll r.
Ch ck inl t strain r for d bris.
Ch ck main tank fu l l v ls
Ch ck PLC normal op rating status.
2. High Level
Ch ck that th inl t sol noid valv is d - n rgiz d
Ch ck that th l v l s nsor pump stop signal is n rgiz d
Ch ck th sol noid valv for l akag
3. High Level Return Flow Pump does not start:
Ch ck pow r to motor start rs and controll rs,
ch ck m rg ncy stop,
ch ck motor ov rloads
4. High Level Return Flow Pump Low Flow rate:
Ch ck discharg piping b tw n pump and main tank
Ch ck pump prim and tightn ss of suction sid conn ctions.
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Fuel Systems for Critical Power
Spare Parts:
1. Inlet / Outlet Gauges
Comm rcially availabl 2.5” diam t r, liquid fill d gaug , ¼” MNPT bottom conn ction
2. Pump Parts
Viking pump parts ar r f r nc d in th app ndix.
3. Motors
Baldor motors ar availabl from local distribut rs worldwid .
4. Controllers / Motor Starters
S Earthsaf Controll r manuals for sp cific information.
. Solenoid Valves
ASCO sol noid valv s ar availabl from local distribut rs worldwid .
6. Level Sensors
G ms l v l s nsors ar availabl from G ms worldwid .
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
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Fuel Systems for Critical Power
Technical Support
Contact Earthsaf at
(630) 794-5100
(630) 794-5106 Fax
www. arthsaf .com
7320 S. Madison
Willowbrook, IL 60527
Warranty Statement
Earthsaf Syst ms, Inc. warrants th tank l v l controls to b th kind and quality d scrib d in
sp cification provid d h r in and to b fr from d f cts in mat rial or workmanship und r normal
s rvic for a p riod of 1 y ar aft r shipm nt. Earthsaf obligations und r this warranty shall b
limit d to r pair or r plac m nt, at th option of Earthsaf , of parts d m d to b d f ctiv upon
insp ction by Earthsaf . Us r is r sponsibl for transportation of parts or ass mbli s to Earthsaf
or its authoriz d r pair location wh r th r pairs ar to b p rform d.
Th provisions of th warranty shall not apply to any quipm nt, part, or acc ssory which
(a) has b n improp rly sp cifi d by buy r, (b) has b n improp rly stor d or handl d prior to
placing in s rvic , (c) has b n damag d or loos n d during shipm nt, (d) has b n improp rly
mount d or conn ct d, ( ) has not b n op rat d within th quipm nt sp cifications, or (f) has
b n improp rly maintain d.
Earthsaf r s rv s th right to r j ct warranty claims of any kind for quipm nt for which it has not
r c iv d full paym nt.
This warranty is in li u of all oth r warranti s, xpr ss or impli d, and all oth r obligations or
liabiliti s on th part of Earthsaf . Earthsaf assum s no r sponsibility or liability for any sp cial,
incid ntal, or cons qu ntial damag .
Appendix
1. Viking Pump Manual
Technical Support / Warranty Service
EMERGENCY POWER FUEL SYSTEMS
Earthsafe M 00
Generator Day Tank
INSTALLATION, OPERATION, AND MAINTENANCE
Table of contents
