Simplex STS DAY TANK User manual

STS DAY TANK
PACKAGED DAY TANK SYSTEMS

Last Revision Date: September 20, 2018
For the most up-to-date information for this product and others, please
contact Simplex, Inc. at [phone] or visit us on the web at
http://www.simplexdirect.com.

Table of Contents
1 Warnings and Cautions ........................................1
Safety information symbols 1
Cautions 1
2 Nameplates and Placards .....................................3
3 Installation ......................................................5
Overview of use 5
Installation Operations 6
Vent Openings 9
Day Tank Pump Priming Procedure 10
4 Day Tank Operation ...........................................11
Automatic Operation 12
High Level Fill Disabled 14
Fill Test Pushbutton 14
Low Level Alarm 15
Manual Operations 15
Lamp Test 15
Automatic Duplex Pump Controller, Option 345 16
Overflow-Return Tank, Option 383 17
Overflow-Return Pump/Controller Added to Day Tank, Option 390 18
5 Maintenance ....................................................19
Each Year 19
After the First Three Years 19
6 Troubleshooting.............................................. 20
No Fuel Delivered 20
Insufficient Fuel Delivered 20
Rapid Pump Wear 20
Pump Delivers for Short Period and Quits 20
Pump Requires too Much Power 20
Noisy Operation 20
Pump Requires Frequent Re-Priming 21
Motor Does Not Turn or Turns Intermittently 21
Pump Leaks Fuel 21
7 Drawings and Parts List..................................... 22
Abbreviation Index 22
Technical Data 23
Appendix A Product Warranty ................................. 25

1 WARNINGS AND CAUTIONS
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 poten-
tial explosion hazards.
This Fire warning symbol points out potential fire
hazards.
This Electrical warning symbol points out potential
electrical shock hazards.
•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 elec-
trical 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 equip-
ment. 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 discon-
nect the ground wire.
•Wire gauge sizes of electrical wiring, cables, and cord sets
must be adequate to handle the maximum electrical current
Safety
information
SymbolS
!
!
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 haz-
ardous 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 noncon-
ducting 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. Jewel-
ry 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 insula-
tion. Keep the extinguisher properly charged and be familiar
with its use. If there are any questions pertaining to fire extin-
guishers, please consult the local fire department.
•The illustrations in this manual are examples only and may
differ from your unit.
!
2

2 NAMEPLATES AND PLACARDS
Nameplates and Placards —3
3

4 —Nameplates and Placards
4

3 INSTALLATION
O verview of
Use
Location of the Day Tank is of prime importance and
should be done by trained personnel. It is one of the
most critical factors involved in reliable and safe
operation. The Day Tank must be positioned and
installed according to the main fuel storage tank and
engine location. In general, locate the Day Tank as close
to the engine as possible consistent with applicable local
and national plumbing and electrical codes. Always
position the Day Tank so that the highest fuel level in the
tank is lower than the engine injectors. The Day Tank
must be located not farther than 200' from the main fuel
tank. The Day Tank must not be more than 18' higher
than the lowest fuel level in the main fuel tank. Never
locate the Day Tank in a confined space without
consideration for accidental fuel spillage and use a
rupture basin when necessary. Never locate the Day
Tank near a surface or object which may be adversely
affected by fuel oil. Never locate a Day Tank system
above a residential living space.
See dimensional drawing for port sizes. All plumbing to
and from the Day Tank should be black iron pipe or copper
tubing. All plumbing connections at the tank should be
made with pipe unions to facilitate installation and service.
Special attention must be given to pump suction pipe
connections to avoid possible air leaks and subsequent loss
of pump prime. Never allow the Day Tank pump to run
“dry” as immediate pump damage will occur. Before
applying power to the pump/motor be sure all fuel
connections have been made and tightened and all holes are
plugged. Option 010 or 015, auxiliary hand pump, is
recommended for installation on all Day Tanks with motor-
pumps. The hand pump is used for initial priming of the
fuel line from the main tank and as a back up to the motor
pump.
If you have any questions regarding Day Tank
installation, call Simplex service at [phone]
(24 hrs.).
5

I
nstallation
Operations
1. Remove the Day Tank top. Check all visible hardware for
tightness. Attach the Vent Pipe. This is an NPT internal
connection. The vent pipe allows equalization of internal
Day Tank pressure. DO NOT INSTALL A VALVE IN
THE VENT LINE! Venting provides pressure relief in case
of overfill, rapid expansion, or gasification of contents in
the event of fire. The Day Tank may become
permanently distorted at pressures above 5PSI (10 and 25
gallon) and 3PSI (50–400 gallon) and may rupture at
pressures above the maximum withstand pressure of 25PSI
(10 and 25 gallon) and 15PSI (50–400 gallon). Day Tank
operation without a vent pipe is strictly not recommended.
The vent pipe should be at least 5 feet higher than any
other pipe and should terminate outdoors. The vent pipe
must be installed per local building codes and per NFPA
30 including but not limited to Section 19.5.3. There should
be no low portions or sags in the vent pipe which can trap
liquid. The end of the pipe should be fitted with a 180°
weather protected vent cap to shed water and should be
screened to keep out pests, leaves, etc.
2. Attach the Overflow Pipe. This is an NPT internal
connection. Simplex recommends the configuration shown
in the illustration below. The overflow pipe runs from the
Day Tank back to the main storage tank and allows for
draining of the tank should it become overfilled. This pipe
should be sized at least twice the diameter of the pump fill
pipe (minimum 1"I.D. for 10 and 25 gallons; minimum 2"
I.D. for 50-500 gallon). If the tank becomes overfilled and
the overflow line is not connected or is obstructed the tank
6

I
nstallation
Operations
Contd .
will distort and possibly rupture. In installations where the
main fuel tank is above ground the overflow pipe should
be connected to an Overflow Tank (Option #390
Recommended). DO NOT INSTALL A VALVE IN THE
OVERFLOW LINE!
3. Attach the Day Tank Intake Line (fill pipe) from the main
fuel tank to the pump inlet. This is an NPT internal
connection. Use black pipe with a union and size per the
installation drawing in this manual. Optional fuel strainer
(Option 060) with #60 mesh is recommended.
4. Attach the Engine Supply Line. This is an NPT external
connection. Use black pipe with a union and size per the
dimensional drawing in this manual. Attach the Engine
Return Line. This is an NPT internal connection. Use black
pipe with a union and size per the installation drawing in
this manual.
5. Attach the Engine Return Line. This is a NPT internal
connection. Use black pipe with a union and size per the
installation drawing in this manual.
6. WARNING! Verify the Day Tank mode selector switch is
in the “Off” position. Supply a 115-1-60, 15A, circuit
breaker protected circuit from a reliable power bus to the
control power terminal board (TB”PS”) at terminals 1 and
2. GROUND THE DAY TANK! Secure the conduit end to
the left side of the cover at the holes provided. Replace the
cover.
7. The pump has been pre-lubricated with heavy oil prior to
shipment. Prime the system by using the hand pump
(Option 010 or 015) to transfer fuel from the main tank to
7

the Day Tank. If the Day Tank is not equipped with a hand pump,
remove the tank inlet priming tee plug and fill the entire inlet line
with fuel. Replace the tee plug. Energize the Day Tank
pump/motor by placing the Day Tank mode selector switch in
the automatic position. Ensure that fuel is exiting the pump
by watching the clear pump outlet tubing. If not, repeat this
procedure and prime the pump also at the pump priming tee.
Make sure all unused Day Tank holes are plugged, all pipe
connections are secure and no leaks are present. The Day
Tank is now ready for unattended automatic operation. If
the Day Tank has been stored for extended periods of time
pre-lube the pump with oil at the pump priming tee.
8

Vent Openings
The SmartFilter should be installed on a concrete pad at the
desired location, then wired to the power source and any other
sensors or system integration connections.
i nStalling
wiring
The SmartFilter must
be completely wired
prior to applying pow-
er. Failure to follow
the wiring information
and guide may result
in product damage and
loss of warranty cover-
age. If requested, startup
services can be provided
by Simplex Onsite, Inc.
orSimplex, Inc. to check
field wiring beforeap-
Conduit
Entry Area
PUMP
OUTLET
i nStalling
Control power
i nStalling ball
valveS
plying power as well as assuring proper operation.
To bring cabling into the SmartFilter, pull a hole into the
cabinetin the Conduit Entry Area (see ) and install a
3R-rated conduit connector for access.
To install control power, connect a primary 120VAC, 60Hz,
30-amp power source to the SmartFilter’s TB-PS-1-2. Ensure
power source and SmartFilter are properly grounded.
Ensure that the Manual Override Switches on each ball valve
are set to “(A) Auto.” (See
.)
8 —Installation
Connect the two cables provided with Motorized Ball Valve
1 to the SmartFilter controller as follows (see
for wire assignments:)
1. Neutral to TB-MBV-1
2. Open Valve toTB-MBV-10
3. Close Valve to TB-MBV-11
4. Actuator Ground to TB-MBV-4
5. Ground to TB-MBV-5
6. Valve Opened to TB-MBV-12
7. Valve Closed to TB-MBV-13
8. Status Common t
9

Day Tank
Pump Priming
Procedure
The Day Tank pump is shipped from the factory pre-primed
with SAE 30 oil. On initial start-up the pump must be
manually pre-primed. Do not prime the system by running
the pump motor ! Normally it is not necessary to fill the
supply line with fuel to prime the pump.
1. Remove the steel plug from the pump
priming tee, insert a short piece of pipe in the
pump priming tee and attach a reducing
coupler or funnel.
2. Fill the line from the check valve to the
pump with fuel oil or lube oil. Energize the
pump/motor and observe fuel flowing through
the clear flex hose. Allow the pipe to drain
about halfway, then hold your hand on the top
of the pipe to temporarily seal the open tee.
The oil drawn into the pump will act to seal
the pump and allow a large vacuum to be
generated. Repeat as required until line is
primed. After pump is primed remove
pipe/funnel and replace plug in pump priming
tee.
10

The control nameplate consists
of a durable, fuel oil resistant,
Lexan membrane which
contains the Day Tank control
pushbutton, switch and status
indicators. The control panel
contains a Fill Test pushbutton
(hold to test L.E.D. lamps), a
three position Day Tank Auto-
Off-Manual switch, and the
following L.E.D. lamps: Power
Available, Tank Filling, Tank
Leak, Not In Auto (blinking), High Level Alarm, Tank
Full, Normal Operating Range, Fill Start, and Low Level
Alarm. Day Tank operation is represented by the diagram
in the lower center of the nameplate.
The Day Tank control circuitry contains the following
serviceable components: motor starting contactor, and
control fuses. Control fuses are 2A, 250VAC, ABC type,
and the standard motor starting contactor is a double
pole, 24VDC coil, rated at 20A. The prime controller in
the Day Tank is the printed circuit board. The Day Tank
printed circuit board is powered by a fused internal
24VDC, 2A, power supply. The printed circuit board
utilizes 24VDC components to analyze the fuel level data
it receives from the four Day Tank fuel level sensors. The
four fuel level sensors
together with the sensor
mounting plate comprise
the fuel level sensor
assembly. When 120VAC,
single phase, 60Hz control
power is supplied to the
Day Tank control system
the Power Available L.E.D.
is illuminated. See Parts
Legend Drawing for
specific components used.
11

AUTOMATIC
OPERATION
Automatic
Operation
During automatic operation, the printed circuit board energizes and
de-energizes control relays, the motor starter contactor, and the
pump/motor to automatically refill the Day Tank as fuel is consumed
by the prime mover. Dry contacts for Low Fuel Level, High
Fuel Level, Leak Alarm, and Not In Auto relays are wired to terminals
1-12 of terminal block TB‘A’ for customer use. The customer may
utilize these contacts to annunciate low fuel level and high fuel level.
Contacts are rated at the following specifications: 5A@30VDC,
5A@125VAC.
The Day Tank operator selects the Day Tank operating mode via the
three position Day Tank mode selector toggle switch. The operator
may choose Automatic, Manual, or Off. To alert the Day Tank
operator, the red Not In Auto lamp flashes continuously
when the Day Tank mode selector switch is not in the Auto
position. This is the only flashing lamp on the control
panel. Normally the mode selector switch is left in the
automatic position. After initial Day Tank installation,
priming, and fill, the controller printed circuit board will
energize and de-energize the Day Tank pump/motor as
determined by the opening and clos-ing of the fuel level sensors (25%-
FS1, 50%-FS2, 90%-FS3, 95%-FS4). As the Day Tank continues to fill
and the fuel level reaches 50% capacity the Normal Operating Range
L.E.D. will be illuminated. The Day Tank pump/motor will de-
energize when the fuel level reaches 90% (the Normal Operating
Range L.E.D. is extinguished and the Normal Maximum L.E.D. is
illuminated). During normal operation fuel is consumed by the prime
mover and the Day Tank cycles between 50 and 90% capacity,
energizing and de-energizing the motor/pump as necessary. If the
pump/motor continues to run past the 90% capacity level, normally
open fuel level sensor FS4 will close when 95% capacity is reached. At
this point the High Level Alarm L.E.D. will be illuminated and the
pump will de-energize. The fuel level sensors are shown on the
following page.
12

13

High Level
Fill Disabled
Fill Test
Pushbutton
A High Level alarm causes the Day Tank to enter a new mode
of operation dependent on the position of the mode selector
switch .Regardless of the operation mode, High Level
indicates that fuel level has reached or exceeded 95% capacity.
The pump/motor is de-energized and will re-main locked-out
until the Day Tank fuel level is decreased to 90% capacity or
less. The High Level L.E.D. will remain illuminated until reset
by the operator regardless of Day Tank fuel level. If a High
Level Alarm condition occurs and the Day Tank fuel level is
reduced to normal levels the High Level L.E.D. will remain
illuminated until it is reset by the operator. The operator must
place the Day Tank mode selector switch in the Off position
and then return it to the Manual or Automatic position to reset
the High Level failure. When High Level is initiated while in
Automatic Mode the Day Tank will continue to operate
normally and cycle from 50 to 90% but the High Level L.E.D.
will remain illuminated until it is reset. When the High Level
mode is initiated while in Manual Mode the Day Tank
pump/motor will cycle between the 90% and 95% levels as
determined by fuel level sensors FS3 and FS4. After the
condition is corrected and the control circuitry is returned to
Auto the pump/motor will resume normal operation and cycle
between 50% and 90%. Fuel level sensors FS1-FS3 (Low Fuel
Level Alarm, Fill Start, and Tank Full, respectively) have
normally closed contacts. FS4 (High Level Alarm) is the only
fuel level sensor with normally open contacts .
The Fill Test pushbutton
is a momentary type. It
may be used to provide
a quick verification of
overall pump/motor/fuel
level sensor operation
when the system is in
the Auto mode. When
the mode selector switch
is placed in the Off
position, the Fill Test
pushbutton is disabled.
When the mode selector
switch is in the
Automatic position, the
Fill Test pushbutton is
enabled.
14

Low Level
Alarm
Manual
Operation
Lamp Test
The operator may energize the pump/motor with the Test Fill
pushbutton to test and cycle the Day Tank through the specified
capacity range. When the pump is operated by continuously
holding the Fill Test pushbutton the pump/motor will continue to
run past the normal stop level until 95% capacity is reached, at
which point the pump/motor is de-energized and locked out by
fuel level sensor FS4. The High Level L.E.D. will be illuminated
and the High Level alarm relay will be energized. Contact rated
5A @ 30 VDC, 5A @ 125VAC maximum.
During normal operation, the pump/motor is energized and the
Fill Start L.E.D. is illuminated when the Day Tank fuel level
reaches 50% capacity. If the pump/motor does not energize a low
fuel level alarm will be initiated when Day Tank fuel capacity
reaches the 25% level. The low fuel alarm relay LFR energizes, the
Low Level Alarm L.E.D. is illuminated, and LFR dry contacts
close. The Day Tank user may utilize these contacts to sound an
alarm horn or provide an input to a remote annunciator. Contacts
are 5A @ 30VDC, 5A @ 125VAC maximum.
For manual (continuous run) operation, the Day Tank operator
must place the Day Tank mode selector toggle switch in the
Manual position. Manual operation allows the Day Tank operator
to energize and run continuously the pump/motor independent of
fuel level sensors FS1-FS3. During manual operation the control
panel L.E.D. lamps will continue to annunciate fuel level to the
Day Tank operator. The Day Tank will continue to fill until 95%
capacity is reached at which time the High Level mode will be
initiated. The Day Tank pump/motor will be de-energized and
locked out until Day Tank fuel level is reduced to 90% capacity
and fuel level sensor FS3 changes state. Until the alarm condition
is corrected and the control circuitry is reset to Auto the Day Tank
pump/motor will continue to cycle between the 90% and 95%
levels. Upon return to Auto, the control circuitry is reset and the
pump/motor will resume normal operation and cycle between 50%
and 90%.
The momentary Fill Test pushbutton is also used to test L.E.D.
lamps on the control board. To use this feature, press and hold the
Fill Test pushbutton to illuminate the L.E.D. lamps. If desired, the
lamps may be tested without filling the tank further by placing the
mode switch in the “Off” position before pressing the Fill Test
pushbutton.
15

Automatic
Duplex Pump
Controller,
Option 345
Duplex pump options are used to in-crease the reliability of a day
tank system through the addition of a second, back-up pump and
level control. In a duplex system, one pump is designated the
“lead” pump and the other is the “lag” pump. The lead pump
automatically refills the day tank over the tank’s normal operating
range of 50% to full. Normally, once the tank has been initially
filled, the fuel level should never drop below 50%. Less than 50%
is indicative of either a failure of the lead pump or consumption in
excess of pump capacity. The lag pump and its separate level
controller, acting as a backup senses a drop in fuel level below 50%
and starts the lag pump, which then continues to run, along with
the lead pump, until the tank is full. Multi-function duplex pump
controller system providing selectable operating modes, including:
• Automatic lead pump alternating with automatic lag pump
back-up
•Automatic twin pump operation (both pumps run
simultaneously) automatic level control back-up
•Manual operation
Basic System includes the following:
•All controller features
•Manual off Auto Switch (1 per pump)
•Pump running indicators for each pump
•Two pumps, each with check valves
Operation: With the Duplex switch in the Alternate position,
Pump 1 will start at 50% and shut off at the 90% level. For
utilization of both Pump 1 and Pump 2 simultaneously, switch to
Both positions. In this position Pump 1 and Pump 2 will start at
the 50% level and shut off at the 90% level.
16

Overflow-
Return Tank,
Option 383
When the Mode Selector switch is in the Manual position all
floatswitches, except the high fuel level floatswitch are over-
ridden, and either position (Alternate or Both) may be selected.
The pumps will continue to run until Switch #1 is returned to the
Off or Auto position or if a high fuel condition occurs.
For standard duplex operation, the Du-plex switch should be in
the Alternate position and Mode Selector switch should be in the
Auto position. Pump #1 will then start at 50% level and stop at the
90% level. The next time fuel drops back to the 50% level Pump #2
will start and then stop at the 90% level. Continuing operation
alternates between Pump #1 and Pump #2.
When the fuel drops to the 25% level, both pumps will run
simultaneously until the fuel level returns to the 90% fuel level.
Operation: The control switch
should normally be in the Auto
position and the Power
Available L.E.D. should be
illuminated. The level controller
is set to pump the tank to
virtually empty. There-fore, normally the tank is empty and the
Tank Empty L.E.D. is illuminated. If the adjacent Day Tank should
overfill and overflow, oil will flow from the overflow line of the
Day Tank to the inlet port of the overflow-return tank. Above
empty level, float switch FS3 will close. At 20% level in the
overflow-return tank, float switch FS2 will close, activating the
overflow-return pump which is installed on the tank. The Pump
Start L.E.D. will illuminate and the tank will be pumped-down to
empty. At empty level, float switch FS3 will open and stop the
pump. If the level in the overflow-return tank should continue to
rise above the pump start level, float switch FS1 will close at the
30% level activating the “high fuel level” alarm indicator and
remote signal contacts.
17