Earthsafe M20 User manual

earth safe
Fuel Systems for Critical Power
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
Model M20
Duplex Fuel Pump
T: [phone]
[email protected]
www.earthsafe.com
Earthsafe Systems,Inc.
1000 W. Crossroads Pkwy
Bolingbrook, IL 60490
Updated: October 20 9
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
Earthsafe makes no warranty of any kin with regar to this publication, inclu ing but not
limite to, the implie warranties of merchantability an fitness for a particular purpose.
Earthsafe shall not be liable for errors containe herein or for inci ental or consequential
amages in connection with the furnishing, performance or use of this publication. Earthsafe
reserves the right to change system options or features, or the information containe in this
publication. This publication contains proprietary information which is protecte by
copyright. All rights reserve . No part of this publication may by photocopie , repro uce ,
or translate to another language without the prior written consent of Earthsafe.
Dama e Claims
Thoroughly examine all components an units as soon as they are receive . If amage ,
write a complete an etaile escription of the amage on the face of the freight bill.
The carriers agent must verify the inspection an sign the escription. Imme iately notify
the elivering carrier of amage or loss. This notification may be given either in person or
by telephone. Written confirmation must be maile within 48 hours. Risk of loss, or amage
to merchan ise belongs with the buyer. It is the buyers responsibility to file a claim with the
carrier involve . Imme iately a vise Earthsafe of the problem so that we may assist you.
Safety Information
UL Liste . The Earthsafe Control Mo ule is UL liste .
Inten e Use. The Earthsafe Control Mo ule is inten e for use with iesel fuel systems for
emergency power generators. The control mo ule an any connecte sensors or evices are
inten e for operation only within or inary electrical areas. Use of the mo ule an
connecte sensors or evices within hazar ous electrical areas is prohibite .
Intellectual Property
The equipment an software escribe herein are the property of Earthsafe Systems, Inc.
an are protecte by various tra emarks an patents.
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Fuel Systems for Critical Power
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Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Fuel Systems for Critical Power
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Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General Description . . . . . . . . . . . . . . . . . . . . . . . . .6
Planning the Installation . . . . . . . . . . . . . . . . . . . . . . .8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Warranty an Service . . . . . . . . . . . . . . . . . . . . . . . .16
Appen ix: Viking Pump Manual . . . . . . . . . . . . . . .16
Table of Contents
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Fuel Systems for Critical Power
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EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE
Safety notices – General Safety Rules – Symbols (dan er-warnin -caution)
SAFETY INFORMATION AND INSTRUCTIONS
Dan er — Failure to follow the in icate instruction may result in serious injury or eath.
Warnin — In a ition to possible serious injury or eath, failure to follow the in icate
instruction may cause amage to pump an /or other equipment.
IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE
SERIOUS INJURY OR DEATH AND/OR RESULT IN DAMAGE TO PUMP 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 PUMP AND MUST BE KEPT WITH PUMP. PUMP 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.
Symb l Legend:
Dan er — Failure to follow the in icate instruction may result in serious injury or eath
Warnin — In a ition to possible serious injury or eath, failure to follow the in icate
instruction may cause amage to pump an /or other equipment.
BEFORE opening any liqui chamber (pumping chamber, reservoir, relief valve a justing cap
fitting, etc.) be sure that:
• Any pressure in the chamber has been completely vente through the suction or ischarge
lines or other appropriate openings or connections.
• The pump rive system means (motor, turbine, engine, etc.) has been “locke out” or
otherwise been ma e non-operational so that it cannot be starte while work is being one
on the pump.
• You know what material the pump has been han ling, have obtaine a material safety ata
sheet (MSDS) for the material, an un erstan an follow all precautions appropriate for the
safe han ling of the material.
DO NOT operate pump if the suction or ischarge piping is not connecte .
DO NOT place fingers into the pumping chamber or its connection ports or into any part of the
rive train if there is any possibility of the pump shafts being rotate .
Continued

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Fuel Systems for Critical Power
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EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE
Safety notices – General Safety Rules – Symbols (dan er-warnin -caution)
DO NOT excee the pumps rate pressure, spee , an temperature, or change the system/ uty
parameters from those the pump was originally supplie , without confirming its suitability for the
new service.
BEFORE operating the pump, be sure that:
• It is clean an free from ebris
• All valves in the suction an ischarge pipelines are fully opene .
• All piping connecte to the pump is fully supporte an correctly aligne with the pump.
• Pump rotation is correct for the esire irection of flow.
INSTALL pressure gauges/sensors next to the pump suction an ischarge connections to
monitor pressures.
USE extreme caution when lifting the pump. Suitable lifting evices shoul be use
when appropriate.
DO NOT attempt to ismantle a pressure relief valve that has not ha the spring pressure
relieve or is mounte on a pump that is operating.
AVOID contact with hot areas of the pump an /or rive. Certain operating con itions,
temperature control evices, improper installation, improper operation, an improper
maintenance can all cause high temperatures on the pump an /or rive.
THE PUMP must be provi e with pressure protection. This may be provi e through a
relief valve mounte irectly on the pump. Relief valve a justing screw caps must always
point towar s suction si e of the pump.
THE PUMP must be installe in a matter that allows safe access for routine maintenance an
for inspection uring operation to check for leakage an monitor pump operation.

General Description
The Duplex Pump Set is esigne for reliable fuel transfer in emergency power systems at
critical facilities. Its innovative compact esign has a minimal footprint while elivering 5 to 30
GPM of fuel to serve emergency generators an boilers.
The mechanical esign is base on Viking positive isplacement pumps an is complete with
strainers, check valves, ball, valves, pressure / vacuum gauges, relief valves. The unit is
mounte on an integral containment with leak etection monitoring.
The Duplex Pump Set inclu es a motor starter panel, or optional VFD rive, with isconnect
switch. The motor starter / rive inclu es current sensors for performance fee back to the
uplex pump controller.
The Controller provi es uplex pump operation an monitoring with HOA switches an an
emergency stop. The OmniPlex screen provi es a summary of operating parameters an
allows selection of special operating mo es. The Controller networks with other system
controllers using Ethernet, an irectly to Buil ing Management Systems with an option of
BACnet, Mo bus, Metasys N2, or Lon protocols.
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Fuel Systems for Critical Power
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EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Physical Description
1. Containment Base: Rigi support for pump set
with liqui tight containment of leaks.
2. Control panel support: Support for OmniPlex
Controller an pump motor starter panels.
3. Pump support bracket: Support pump an
motor for vertical mounting
4. Pump : Viking positive isplacement pump.
5. Pump internal relief valve: A justable pressure
relief on pump form ischarge to suction si e.
Protects ownstream piping from over-pressure,
an limits pump operation to within its power
range.
6. Motor: TEFC motor. 120-240 VAC single phase
or 240-480 VAC three phase.
7. Inlet strainer / screen: Locate on pump inlet to
protect pump from inlet piping ebris.
Threa e rain / cleanout port is provi e .
8. Outlet check valve: Locate on pump ischarge
to maintain pressure in pipeline, an allow
alternate pump operation without backflow.
Check valve is an in-line wafer style with 3 PSI
cracking pressure to prevent chatter.
9. Inlet an outlet ball valves: carbon steel ball
valves with Teflon seats, to allow isolation of
pumps for maintenance.
10. Inlet an outlet pipe assembly: Wel e steel
pipe with 1” MNPT connection for fiel piping.
Connect at either en of pump set.
11. Pressure an vacuum gauges: To confirm pump
operation an assist troubleshooting. Stan ar
Liqui fille , ¼” NPT bottom port, 2.5” iameter
gauges. Vacuum 0 to -30 IN-Hg. Pressure
0-100 PSI.
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Plannin the Installation
Location
1. Location — always locate the pump as close as possible to the supply of liqui to be
pumpe . Locate it below the liqui supply if at all practical. Viking pumps are self priming
but the better the suction con itions the better the performance.
2. Accessibility — the pump shoul be locate where it is accessible for inspection,
maintenance, an repair.
Pressure Relief
Pressure Protection — Viking pumps are positive isplacement. This means that when the
pump is rotate , liqui will be elivere to the ischarge si e of the pump. If there is no place
for this liqui to go — ischarge line is blocke or close — pressure can buil up until the
motor stalls, the rive equipment fails, a pump part breaks or ruptures, or the piping bursts.
Because of this, an integral pressure relief valve is mounte irectly on the pump hea .
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Pipin
The cause of many pumping problems can be traced to suction piping. It should always be as
large and short as practical. Before starting layout and installation of your piping system,
consider the following points:
1. Never use piping smaller than the pump port connections.
2. Be sure the insi e of the pipe is clean before hooking it up.
3. Foot valve — When pumping a light liqui with a suction lift, a foot valve at the en of the
suction piping or a check valve in the first horizontal run will hol the liqui in the line an
make it easier for the pump to prime. Be sure the foot or check valve is big enough so that it
oesn’t cause excessive line loss.
4. When approaching an obstacle in the suction or ischarge line, go aroun the obstacle
instea of over it. This minimizes air pockets air pockets which make it har for the pump to
prime.
5. For a suction line with a long horizontal run keep the horizontal portion below the liqui
level if possible. This keeps the pipe full so the pump oes not have to remove so much air
when starting.
6. Be sure allowance is ma e for expansion an contraction of the piping. Loops, expansion
joints, or unsecure (this oes not mean unsupporte ) runs shoul be use so the pump
casing is not stresse by the piping..
7. Strainer — The pump inlet strainer will keep foreign objects from going into the pump. The
strainer is particularly important at start up to help clean the system of wel bea s, pipe
scale, an other foreign objects.
8. The pump shoul not be use to support the piping. The weight of the pipe shoul be
carrie by hangers, supports, stan s, etc.
9. When fastening the piping to the pump it shoul not be necessary to impose any strain on
the pump casing. “Springing” or “ rawing” the piping up to the pump will cause istortion,
possible misalignment, an probable rapi wear of the pump. Do not use the pump to
correct errors in piping layout or assembly.
10. All joints of the piping system shoul be tight; pipe sealer will help assure leak-free threa e
joints. Leaks in the suction line re uction in capacity.
11. Provi e a pressure relief evice in any part of a pump an piping system that can be valve
off an , thus, completely isolate . The rise in temperature causes the liqui to expan ; if
there is no provision for pressure relief in the close off section, there is a chance that the
pump or piping will rupture.
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Installation
1. Remove packaging an inspect for shipping amage. Note any shipping amage on the
shipping ticket an notify Earthsafe within 24 hours of receipt.
2. Set unit at installation location. Use proper han ling proce ures to avoi amage to
the unit.
3. Install anchor bolts at 4 corners. Use ½” iameter expansion anchors with 3” embe ment
or as require for local co e compliance.
4. Connect power to motor starters an controller. Reference specific installation
instructions an wiring iagrams for the controller an motor starter panels.
5. Check tightness of all bolts, which may have loose uring shipment. Tighten 4 bolt
flanges by gra ually tightening across the bolt pattern.
6. Pressure test the pump set to 50 PSI or in accor ance with project esign requirements.
Correct any loose bolts or threa e joints if require .
7. Connect piping to inlet an outlet (inlet piping consi erations). Confirm that fiel piping
is in epen ently supporte to avoi stress on the pump set piping.
8. Check pump rotation. Energize the pump momentarily to observe irection of motor fan
rotation. The pump inlet an outlet are offset from the centerline of the pump hea , so
that there is a long arc or short arc from the inlet to the outlet. The pump rotation shoul
be that it progresses along the long arc from the inlet to the outlet.
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Startup
1. Prime the suction line. Remove the threa e plug on the pump inlet piping an place
iesel fuel into the piping until full. Reinstall the threa e plug. Operate the pump for
60 secon s maximum. Observe the inlet an outlet gauges to confirm pump rotation an
progress of eliminating any remaining air from the suction piping. A fully prime suction
pipe will be emonstrate by a stea y vacuum gauge rea ing on the pump inlet.
2. Open all inlet an outlet valves an confirm that there is a clear flow path from the fuel
source to the estination.
3. Manually start pump to confirm pump prime. Operate the pump for 60 secon s
maximum. Observe the inlet an outlet gauges to confirm pump rotation an progress of
eliminating any remaining air from the suction piping. A fully prime suction pipe will be
emonstrate by a stea y vacuum gauge rea ing on the pump inlet.
4. If the pump still oes not eliver, the cause may be one or more of the following:
a. Suction line air leaks
b. Suction line obstructions
c. Suction tube or foot valve in tank is not installe .
. Suction lift is too great or the suction piping is too small.
e. Anti-siphon or check valve setting in suction line is excessive.
5. A just pressure relief valve to require setting. A just the pump pressure relief valve to the
maximum esign pressure of the system. This is one by removing the cap from the valve
an a justing the spring bolt. The valve a justment shoul result in the pump being able to
operate against close ischarge valves, without overloa trip to the motor.
6. Check pressure an vacuum operating ranges. Confirm that the vacuum an pressure
gauge rea ings are in conformance with the esign requirements.
7. Check for leaks an correct any loose flanges or threa e fittings.
8. Check motor starter overloa settings. Confirm that the motor starter overloa settings
match the full loa amps in icate on the pump motor.
9. Clean inlet strainer. Close the inlet valve to isolate the strainer. Remove the threa e plug.
Clean any ebris from the strainer screen.
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

Perform testing in accordance with the procedure described in the checklist.
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Duplex Pump Startup and Test Checklist
Item Description Check Date Comments
1 Power to control panel
2 Power to Pump 1
3 Power to Pump 2
4 Initial isplay is accurate
5 Pump 1 Manual mo e start an isplay
6 Pump 2 Manual mo e start an isplay
7 Pump 1 current sensor or flow input
8 Pump 2 current sensor or flow input
9 Pump 1 suction PSI at static run
10 Pump 1 ischarge PSI at static run
11 Pump 2 suction PSI at static run
12 Pump 2 ischarge PSI at static run
13 Setup Auto mo e fuel request input
14 Pump 1 Auto mo e start an isplay
15 Pump 2 Auto mo e start an isplay
16 Pump 1 Auto mo e isable on leak
17 Pump 2 Auto mo e isable on leak
18 Pump 1 Auto mo e isable on estop
19 Pump 2 Auto mo e isable on estop
20 Select Pump 1 as lea
21 Confirm Pump 1 Auto start
22 Disable Pump 1 by change to Off Mo e
23 Confirm Pump 2 Auto start
24 Pump 1 trouble by no CS, no Flow, or DT Low
25 Confirm Pump 2 Auto start
26 Select Pump 2 as lea
27 Confirm Pump 2 Auto start
28 Disable Pump 2 by change to Off Mo e
29 Confirm Pump 1 Auto start
30 Pump 2 trouble by no CS, no Flow, or DT Low
31 Confirm Pump 1 Auto start
32 Confirm Output relay an horn on Alarm
33 Alarm mo es: Leak, Pump 1 Fail, Pump 2 Fail
Testin
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Operation
1. Pump controller operation.
Refer to Controller manual for etails of uplex pump set operations.
2. Pump motor starter operation.
Refer to Motor Starter manual for etails of motor starter operation.
Maintenance
1. Inspect for leaks at regular intervals, weekly as a minimum.
2. Operate pump manually to confirm prime at regular intervals, monthly as a minimum.
3. Check strainers after initial use an clean if require . Check strainers if an increase in
vacuum gauge rea ings is observe .
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Fuel Systems for Critical Power
Troubleshootin — General
1. Pump does not start:
Check power to motor starters an controllers,
check emergency stop,
check motor overloa s.
2. Overload trips:
Check relief valve settings.
Check for ebris in pump hea .
3. Excessive noise / vibration:
Cavitation ue to inlet con itions.
4. Excessive inlet suction:
Check an clean strainer.
Check foot valve at tank.
Check suction pipe size an vertical lift.
5. Insufficient inlet suction:
Check for prime in suction piping.
Test inlet piping for leaks.
6. Flutterin Suction readin :
Check for prime in suction piping.
Test inlet piping for leaks.
Confirm inlet con itions to avoi pump cavitation.
7. Excessive Dischar e pressure:
Check for close valve or other blockage.
Check pipe relief valve settings.
Check for thermal expansion relief in ischarge piping.
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Spare Parts:
1. Inlet / Outlet Gau es
Commercially available 2.5” iameter, liqui fille gauge, ¼” MNPT bottom connection
2. Pump Parts
Viking pump parts are reference in the appen ix.
3. Motors
Bal or motors are available from local istributers worl wi e.
4. Controllers / Motor Starters
See Eartthsafe Controller manuals for specific information.
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE

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Technical Support
Contact Earthsafe at
[phone]
www.earthsafe.com
Warranty Statement
Earthsafe Systems, Inc. warrants product to be the kin an quality escribe in specification
provi e herein an to be free from efects in material or workmanship un er normal service for a
perio of 1 year after shipment. Earthsafe obligations un er this warranty shall be limite to repair
or replacement, at the option of Earthsafe, of parts eeme to be efective upon inspection by
Earthsafe. User is responsible for transportation of parts or assemblies to Earthsafe or its authorize
repair location where the repairs are to be performe .
The provisions of the warranty shall not apply to any equipment, part, or accessory which
(a) has been improperly specifie by buyer, (b) has been improperly store or han le prior to
placing in service, (c) has been amage or loosene uring shipment, ( ) has been improperly
mounte or connecte , (e) has not been operate within the equipment specifications, or (f) has
been improperly maintaine .
Earthsafe reserves the right to reject warranty claims of any kin for equipment for which it has not
receive full payment.
This warranty is in lieu of all other warranties, express or implie , an all other obligations or
liabilities on the part of Earthsafe. Earthsafe assumes no responsibility or liability for any special,
inci ental, or consequential amage.
Appendix
1. Viking Pump Manual
Technical Support / Warranty Service
EMERGENCY POWER FUEL SYSTEMS
Model M20
Duplex Fuel Pump
INSTALLATION, OPERATION, AND MAINTENANCE