OilSafe Advanced Bulk System User manual

Advanced Bulk System
Owner’s Manual
Document #OSOM-ABS Rev1
Advanced Bulk
System
IMPORTANT
• Please read this Owner’s Manual carefully and thoroughly before
installing and operating your Advanced Bulk System.
• Please retain this Owner’s Manual for future reference after reading it
thoroughly.

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Table of Contents
Explanation of Symbols Used 3
Warnings and Cautions 4
OilSafe Limited Warranty 5
Introduction 6
Parts andPre-Installation Check List 9
Static Discharge Grounding Reel 10
Tools, Materials, and Personnel Requirements: 11
Installation 12
Power Installation 19
Initial Operation 21
Maintenance 28
Moving Your System 31
Troubleshooting 32
Repair and Replacement Procedures 35
Replacement Parts 36
Tank or Motor Replacement 38
DataTables 39
Plumbing Schematic 40
FOR YOUR RECORDS
Write the model and serial numbers
here: (You can find them on the Serial/Model
No. Plate mounted atthe 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 System.
INTELLECTUAL PROPERTY
OilSafe® is a Registered Trademark of Whitmore
Manufacturing, LLC All Rights Reserved.
Patents Pending.
©2022 Whitmore Manufacturing, LLC

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Explanation of Symbols Used
This manual contains some common symbols and indications to alert you to specific areas of
importance.
WARNING!
A situation that, if not avoided, could result in severe property damage, equipment
damage, severe injury,or even death. FAILURE TO FOLLOW this warning will void your
product warranty.
CAUTION!
A situation that, if not avoided, could result in property damage, equipment damage, or
injury. 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 that is helpful in the installation, operation, and maintenance of
your system.
NOTE:
This text will be used to highlight text that is important to read in order to fully understand the terms
and procedures usedin this manual.

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Warnings and Cautions
The OilSafe®Advanced Bulk System is designed for the storage of machinery lubricating oils and other NON-VOLATILE
fluids. STORAGE OF FLUIDSWITH A FLASHPOINT BELOW 150°F (65.5°C) IS STRICTLY PROHIBITED.
Components within this system consist of materials that may not be compatible with your fluid. ALWAYS consult
your supplier and refer to thefluid manufacturer’s Material Safety Data Sheet (“MSDS”) before introducing a fluid to
this system.
WARNING!
When replacing tanks, a Whitmore employee must be present to participate in, or supervise
theremoval of tanks on frames.
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 or change filter
elements or undertake any service work when this system is running or energized. SEVERE
INJURY OR DEATH MAY OCCUR.
CAUTION!
System Operating Pressure should NEVER exceed 300 PSI. Operating pressures can be
regulated by adjusting pump bypass relief valves located on pump heads to suit specific
lubricant viscosities and temperatures.
IMPORTANT:
ALWAYS REFER TO THIS MANUAL OR CONSULT YOUR SUPPLIER FOR MORE INFORMATION.
• ALWAYS ensure that you wear appropriate Personal Protective Equipment (“PPE”) when operating this system.
• ALWAYS ensure that all system hoses, filters, and fittings are securely fastened and in good working condition.
• THE FIRE SAFETY VALVES (LOCATED ON THE UNDERSIDE OF EACH TANK) MUST BE IN THE OPEN
POSITION WHEN OPERATING THE SYSTEM AND IN THE CLOSED POSITION WHEN SERVICING THE
SYSTEM.
• ALWAYS ensure that the System Pressure Return Hoses (discharging to the upper port on the rear face of each tank)
are never restricted or damaged.
• THE BULK TANKS MUST ALWAYS BE VENTED TO ATMOSPHERE (preferably utilizing a Desiccant Air Breather).
• When filling Bulk Tanks from drums or barrels 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 utilizing the grounding jacks provided at the rear
base of the system, together with relevant grounding equipment as specified and installed by your authorized
electrical personnel in accordance with your local and federal regulations and safety procedures.
• Ambient room temperature where the system is installed should be in the range of 60°F (15°C) TO 80°F (26°C) with
optimum room temperature being 70°F (21°C). For ambient temperatures below 60°F (15°C) consult the manufacturer
or your supplier for the supply of electric blanket heaters for oil barrels, pails, and bulk tanks to ensure stability of
lubricant viscosity, condition, and system performance. Temperatures less than (<60°F / 15°C) can result in lubricant
viscosity increasing above the rated ISO Code you specified at the time of order. Such adverse viscosity changes can
cause higher system operating pressures than those set at the factory. System operating pressure should never
exceed 300 PSI. Contact the manufacturer for more information prior to commissioning the system if the ambient
room temperature will ever fall below 60°F (15°C).
WARNING!
FAILURE TO FOLLOW System installation, safety and operating instructions may result in SEVERE
INJURYOR DEATH, damage to plant and equipment and void warranties.

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OilSafe Limited Warranty
OilSafe (“OS”) warrants to the original product purchaser (hereinafter the “Customer”) that the OS product
for which theCustomer received this warranty was designed, developed, and manufactured using all due reasonable
commercial care and good manufacturing practices.OS’ products shall be free from defects in material and workmanship
for 365 days from the original date of purchase by Customer. OS’ sole obligation under this warranty is to repair or replace
the product, at OS’ option. OS must be notified by Customer in writing of any claim under this warranty within 30-days of
any claimed lack of conformity of the product. THIS WARRANTY IS INTENDED TO BE IN LIEU OF ALL OTHER
WARRANTIES, WHETHER EXPRESSOR IMPLIED. OS SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Warranty Limitations:
In no event shall OS be liable for any loss, inconvenience, or damage, whether direct, incidental, consequential or
otherwise, resulting from breach of anyexpress or implied warranty or condition, of merchantability, fitness for a particular
purpose or otherwise with respect to this product, except as set forth herein. Some states or countries do not allow
limitation on how long an implied warranty lasts so the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights, and you may also have other rights, which may vary, from location to location. This
warranty will be interpreted pursuant to the laws of the United States and the State of Illinois. The original English language
version (meaning) of this warranty controls overall translations; OS is not responsible for any errors in translation of this
warranty and/or any product instructions. This warranty is not intended to confer any additional legal, jurisdictional or
warranty rights to you other than those set forth herein or required by law. If any portion of this warranty is held to be
invalid or unenforceable for any reason, such finding will not 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 theproduct 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
question by model and serial number, applicable purchase order number and/or the original of date of your written
notification.
You may contact OS as follows:
930 Whitmore Drive
Rockwall, TX 75087
www.oilsafe.com
972)771-1000
[email protected]
Any insurance and/or shipping costs incurred in returning your OS product for service pursuant hereto are your
responsibility. OS will not be responsiblefor any products lost or damaged in shipment.
Warranty Exclusions:
Representatives and brokers of OS products are not authorized to modify this warranty in any way. It is the Customer’s respon sibility to
regularly examinethe product to determine the need for normal service or replacement. This warranty does not cover the following:
•Products that have been modified, neglected, or poorly maintained, misused, abused, or involved in accidents or natural disasters.
•Damage occurring during shipment of the product (such claims must be presented directly to the freight forwarder or shipping
company).
•Damage to the product resulting from improper maintenance or repair, the use or installation of parts and/or accessories that are not
compatible withthe original intended use of the product, or the failure to follow the product warnings and usage instructions.
•Damage or deterioration to the surface finish, aesthetics, or appearance of the product.
•The labor costs required to remove and/or refit and readjust the product covered by this warranty.
•Normal wear and tear to the product, filter elements, air breather, level gauges and other consumable items.
•Service Trips to Customer’s location to teach Customer how to use the product.
•Defects that result from improper installation or damage not caused by OS.

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Introduction
Thank you for purchasing an OilSafe®Advanced Bulk System. This System was designed to store and dispense bulk
lubricants in the workplace.The system was designed with quality in mind and is fully modular. The interchangeable series
of tanks, frames, pumps, filters, and storage modules have been customized for your application. The installation,
operation, and maintenance instructions in this document will provide you with all the information you will need for the
lifetime of your system.
The system was specially configured per your specification. It features up to four standard tank sizes mixed and matched
to your specifications, 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 specifiedat 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 “TankPod” (or “Pod-1” in the event you have purchased more than one Pod).
Each Tank Pod can contain many different varieties of tanks including:
• One - 240-gallon tank
• Two - 120-gallon tanks
• Four - 65-gallon tanks (shown in this manual)
• Four – 30-gallon tanks
Combinations of these tanks can be configured for
your system as desired, and number of Pods can be
purchased to accommodate number of tanks
required to meet your applications.
Each Dispensing Pod can contain up to four (4) Dispensing Faucets. The number of Dispensing Reels will
depend on the number of available positions not used by tanks. The maximum number of hose reels for each pod
can be determined by starting with the number 4 and subtracting the number of tanks on the system. i.e. if a
systems has 2 tanks, then 2 dispensing reels will fit on the frame (4-2=2). If more dispensing reels are
required, a Hose Reel Rack can be used to house additional dispensing reels.
See Figure 1 and Figure 2 on pages 7 and 8.
Please make sure operating valves are in “Recirculation” positions before start-up and at
shutdown of units. This provides the lowest amp draw and system pressure, ensuring the
safest conditions for operators during start-up and shutdown of the unit.

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FIGURE 1: Electric Tank Pod (Pod-1)

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FIGURE 2: Pneumatic Tank Pod (Pod-1)

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Parts and Pre-Installation Check List
IMPORTANT:
CHECK packaging list to ensure you have all applicable parts before continuing. CONTACT YOUR
SUPPLIER if it appears thatany parts are missing or damaged. Refer to the specification sheet for
your customized system for detailed system information including electrical requirements, and total
weight of system.
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. Follow written instructions to assemble and install, prior to operating.
NOTE: For this manual, the Tank Pod/s will each be shown with four 65-gallon Bulk Tanks.
POD 1 – TANK POD POD-2 – TANK POD
Sample 4x65
4Bulk Tanks 65-gallon size,
color-coded per order specifications, pre-installed)
4Motor/Pump (pre-installed)
4Dispensing Faucet (standard style comes with color-
codedball knob, fire upgrade comes as a brass valve)
4Spin-on Filters
4Fluid Level Gauge
4Desiccant Air Breather Air Filter
4Suction Hose Assembly
4System Pressure Gauge
4Isolation Valve (located on underside of tank)
Optional Equipment
4Fluid Level Gauge Overfill Alarm Spill Pan Connector Kit (see Page 14)

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Static Discharge Grounding Reel
Static Discharge Grounding Reels are used to ground static charges on service equipment during the transfer of
combustible fuel and other flammable liquids. The Static Discharge Grounding Reels supplied with your OilSafe®System
are spring operated automatic retrieve reels containing standard steel aircraft cable.
The reel is compact in design, for convenient mounting to your OilSafe®tank frame and provides a light, constant spring
tension on the grounding cable, keeping the cable from becoming tangled.
The reels are constructed of steel and are equipped with 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, always keeping tension on the cable.
The cable stop assembly may be adjusted to any position. The mechanical locking device works positively and in all
positions, regard- less of the cable retraction speed. The lock engages at the desired position by pulling the cable
approximately ½". The lock release knob completely disengages the lock to constant tension. Care should be taken to
mount the reel on the front face of the OilSafe®tank frame where threaded holes have been provided.
For instructions on use, see page 23.
FIGURE 3: Static Discharge Grounding Reel

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Tools, Materials, and Personnel Requirements:
• A minimum of two people is recommended to complete installation and setup.
• Electrical hook-ups and installation should be completed by your authorized electrical personnel in accordance with
all local and federal laws andregulations.
• A hand pallet truck is required to move each Pod into position.
• 1 - 1/2” wrench for connecting spill pallets.
• 3/4" wrench for system leveling/jacking bolts.
• 2 - 3/8" wrench to tighten Fluid Level Gauge.
• Personal Protective Equipment (“PPE”) should be worn when installing and operating this system.
Determine Placement:
1. The system should be installed indoors on a flat, level surface with sufficient load-bearing capacity to support the total
system weight. See Table 5on page 38.
2. Each mains supply electrical enclosure, and each motor requires a separate power outlet. See your specification
sheet (or system supply quotation) for electrical requirement details. Give consideration, to whether more than one
pump could be running at the same time, in which case it is recommended that each power outlet be wired with
independent circuits. CONSULT WITH AN AUTHORIZED AND TRAINED ELECTRICIAN.
3. BEFORE beginning installation, determine where your system will be installed and ensure sufficient power outlets
have been installed at the rear ofthe system, positioned behind where the motors will be located. Each power outlet
should be equally spaced along the wall and be placed approximately 12" up from floor level.
4. Pneumatically operated systems (in lieu of electrical) should be prepared with the same considerations, sizing
pneumatic lines and circuitry following OSHA safety guidelines.
IMPORTANT:
• It is important to note the effect of the ambient temperature in which the system is placed for
operation. System roomtemperature should be in the range of 60°F (15°C) TO 80°F (26°C) with
optimum room temperature being 70°F (21°C). For ambient temperatures below 60°F (15°C)
consult the manufacturer or your supplier for the supply of electric blanket heaters for oil barrels,
pails, and bulk tanks to ensure stability of lubricant viscosity, condition, and system performance.
• Temperatures less than (<60°F / 15°C) can result in lubricant viscosity increasing above the rated
ISO Code you specified at the time of order. Such adverse viscosity changes can cause higher
system operating pressures than those setat the factory.
• System operating pressure should never exceed 300 PSI. Normal system operating pressure
should be less than 240 PSI. Operating pressures above 240 PSI will necessitate adjustment of
the pump pressure relief bypass valve located on the pump head.
• Contact the manufacturer for more information prior to commissioning the system if the ambient
room temperature willever fall below 60°F (15°C).

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Installation
CAUTION!
Personal Protective Equipment (“PPE”) should be worn when installing and operating this
system.
System Operating Pressure should NEVER exceed 300 PSI. System operating
pressures can be regulated by adjusting pump bypass relief valves located on pump
heads to suit specific lubricant viscosities and temperatures.
System SHOULD NOT be operated in a location with an ambient room temperature less
than 60°F/15°C Contact the manufacturer for more information relating to service in cold
environments.
STEP 1. The system is delivered pre-assembled, packaged, and serialized. Each frame is assigned a dash number, after
the serial number. Serial numbers are all located on backside of each frame. These serial numbers also indicate
the respective pod/frame position from left to right, when viewed from the front side of the frames.
STEP 2. Locate Pod-1 and remove and appropriately dispose of the freight packaging.
STEP 3. Using a suitable hand pallet truck, position Pod-1 into its service position, ensuring that there is at least 36" of free
clear space at the rear and18"on side of the system. This will enable personnel to access the system for service
work. See Figure 4.
FIGURE 4: Recommended Clearance

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STEP 4. 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.
Check to ensure it is square to any adjacent rear or side walls.
STEP 5. If the order contains multiple pods, Locate Pod-2 and remove and appropriately dispose of the freight packaging.
STEP 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
FIGURE 5: Pod-2 Placement FIGURE 6: Final Pod Positioning
CAUTION!
ALWAYS keep hands and feet clear of mating and moving parts when moving the Pods into position.

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Optional Equipment - Spill Containment Connector Kit
OilSafe Bulk Systems are configured to allow the containment pans to be joined together at the back of each frame simply
by ordering an optional Spill Containment Connector Kit. The kit can be installed in a few minutes and is easily
disconnected if it becomes necessary to move frames. See Figure 7.
FIGURE 7: Spill Containment Connector Kit
SPILL CONTAINMENT CONNECTOR KIT
PART # ’S
2 - Pod Connector Kit
821352
3 - Pod Connector Kit
821353
4 - Pod Connector Kit
821354
5 - Pod Connector Kit
821355
6 - Pod Connector Kit
821356

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STEP 8. Installing the Fluid Level Gauges See Figure 8a and Figure 8b for details.
a. Unscrew and remove the red plastic locking nut from level gauge.
b. Remove the clear calibration tube.
c. Gently pull up the red indicator disc.
d. Carefully insert the float assembly into the tank.
e. Screw the aluminum bushing into the tank port until tight and ensure the arrows on the flat side
of the hex bushing are pointing toward the back wall of the tank.
f. Gently raise & lower red indicator disc to ensure the float mechanism is free andclear inside the
tank.
g. Reinstall the clear calibration tube.
h. Fasten the red locking nut (as illustrated).
FIGURE 8a: Install Fluid Level Gauges
FIGURE 8b: Level gauge alignment arrows

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NOTE: For tanks with overfill alarms, follow STEPS 10 - 16 to install your overfill alarm.
STEP 9. If this is an initial installation, and you ordered your bulk system with an overfill alarm, proceed to STEP 17.
STEP 10. To install the alarm on an existing gauge, first install the magnet (provided) on your gauge.
See Figure 9 for Alarm details.
FIGURE 9: Overfill Alarm
STEP 11. Remove the red locking nut that holds the top of the gauge in place. After you remove the nut, you will be able
to remove the calibration (the plastic tube that shows your tank level) and you should have access to the red
indicator. Pull the indicator off by pulling gently upward.
STEP 12. Make a mark on the indicator rod ½" from the top. Take the small metal clip (provided) and push it onto the rod
down to the mark. Then pushthe magnet onto the same rod until it is sitting flush on top of the small metal clip
(you may have to file off any burrs on the end of the rod to fit the magnet onto 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 level where you wish the alarm to activate and tighten the set screw to hold the alarm in place.
STEP 16. The switch located on the alarm can be used to silence the audible alarm (where fitted) after it goes off. It will
automatically reset to re-alarm when the magnet moves back out of the alarm area. The switch can also be used
to test the battery.Toggle it once to activate it and once moreto reset it.
IMPORTANT:
•The Switch is a toggle switch. It is meant to be moved left and right. DO NOT push down on the toggle switch.

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Installing the Desiccant Air Breather (See Figure 10 for details)
STEP 17.Remove desiccant air breather from sealed plastic packaging bag. Remove white elastic band from top
of desiccant air breather. Remove red plastic cap plug from bottom side of desiccant air breather. Screw
(clockwise) desiccant air breather onto ½” male pipe fitting atop oil tank.
FIGURE 10: Install Desiccant Breathers
STEP 18. Ensure spin-on filters are proper selection for each tank/oil viscosity and ensure each is properly tightened before
use.

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IMPORTANT:
• Write the installation date on each spin-on filter element. The first filter should be replaced after the
first 50 hours of system service. Subsequent filters should be replaced per the instructions in the
Maintenance Section of this manual, on page 28.
STEP 19. Install the Static Discharge Grounding Reel securely to the front face of the Tank Pod (Pod-1) frame using the
threaded holes provided in theframe and the mounting bolts supplied with the reel.
STEP 20. Pull the grounding cable out to determine if the tension is sufficient for the intended use.
a. If additional tension is needed, apply a wrench to flats on the mainspring shaft, rotating counter-
clockwise until the desired tensionis reached.
b. If mainspring tension is too high, it may be decreased by depressing the tension lock spring on the opposite
side of reel. DO NOT removemore tension than desired. If too much tension is removed, increase tension as
described above.
STEP 21. Install the dispensing faucets supplied with your system into the threaded ports provided on the front face of the
control panel.
Use of appropriate thread sealant is recommended on threaded joints.
STEP 22. Remove the drip pan from the packaging. Place the flange of the drip pan over the bottom horizontal support
beam at the front of the system. The drip pan rests on the beam and does not need to be fastened to the frame.
FIGURE 11a: Installing Drip Pan FIGURE 11b: Final Drip Pan Position

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Power 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 following instructions should be carried out by trained and authorized electrician or
electrical personnel in accordance with your local and federal regulations and safety
procedures. Always ensure the system is appropriately grounded to earth utilizing the
grounding lugs provided at the rear base of thesystem, together with relevant grounding
equipment as specified and installed by your authorized electricalpersonnel.
ELECTRICAL INSTALLATION (For Pneumatic systems, proceed to page 20)
STEP 1. THE SYSTEM SHOULD BE GROUNDED BEFORE USE. Grounding Lugs are provided at the rear base of the
system on the inner face of theframe uprights. At the rear of the system, locate the female power supply cord(s) coming
from the electrical – enclosure See Figure 12.
STEP 2. Plug the power cords into the individual wall outlets as designated in the specification sheet.
NOTE: There will be one (1) power supply cord for each motor and each will be labeled to
correspond to its relatedmotor/tank. ALL POWER CORDS MUST BE PLUGGED IN FOR
THE SYSTEM TO WORK PROPERLY
FIGURE 12: Electrical Enclosure (Rear View of System)

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PNEUMATIC SYSTEMS
WARNING!
Always ensure compressed air is properly locked-out, according to OSHA regulations before proceeding.
STEP 1. At the front of the system, unscrew the plastic plug from the ½” female NPT port on the inlet air valve.
See Figure 13.
STEP 2. Fasten the desired coupler into the front ½” female NPT port on the inlet air valve at the front of the system.
FIGURE 13: 1/2” Female NPT port for incoming air. (Front View of System)