Simplex SPS Series User manual

SPS/SKS SKID PUMP SET
PACKAGED PUMP SET

Last Revision Date: June 8, 2021
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 DescriptionandSpecification ................................4
Primary Inspection 5
Installation 5
4 Priming the System............................................6
Priming Overview 6
Priming Procedure 6
Single Pump Operation 7
Duplex Pump Operation 7
Alternate 8
Both Run 8
Fuel Line Leak 8
Loss of Flow 8
5 Maintenance ....................................................9
6 Troubleshooting.............................................. 10
No Fuel Delivered 10
Insufficient Fuel Delivered 10
Rapid Pump Wear 10
Pump Delivers for Short Period and Quits 10
Pump Requires too Much Power 10
Noisy Operation 10
Pump Requires Frequent Re-Priming 11
Motor Does Not Turn or Turns Intermittently 11
Pump Leaks Fuel 11
7 Drawings and Parts List..................................... 12
Abbreviation Index 13
Technical Data 14

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
3

3 DESCRIPTION AND SPECIFICATION
Packaged as a pre-engineered, integrated system of pumps,
pump motors, controls and accessories, pre-plumbed and
pre-wired, Simplex Packaged Pump Sets and Skid Pump
Sets provide the user with the reliability of job engineered,
system matched components, and factory assembled
systems. These pump sets are intended for use with fuel
oil, lube oil (class II or class III combustible liquids having a
fl ash point of 100°F or higher).
Simplex Packaged Pump Sets are totally enclosed units
suitable for wall or pad mounting. All devices, wiring and
plumbing are contained within the weatherproof
enclosure. Isolated compartments are provided for
mechanical and electrical devices. External ports are
provided for connection of field plumbing. The pump sets
include a catch basin with a leak detector.
Due to design layout, Simplex Skid Pump Sets offer the
customer a greater variety and quantity of options but because
of its open catch basin they are suitable for indoor installation
only.
Description
4

Preventative visual inspection of the shipping crate, Remote Pump
Unit, and accessories must be performed before installation.
Physical or electrical problems due to handling and vibration may
occur during shipment.
1. If the packing crate shows signs of damage inspect the
SPS cabinet for damage. Check the entire outside of the
cabinet for damage which could cause internal
mechanical or electrical problems.
2. Check main disconnect switch, door and hinge
operation.
3. Check pump/motor hardware for tightness. Rotate
motor shaft by hand and check for smooth operation.
Check pump/motor coupler for proper alignment and
spacing. The coupler should have approximately 1/8"
clearance between coupler halves. If this clearance is
reduced or the pump and motor are not properly aligned
excessive noise and pump/motor wear will occur.
4. Check all electrical terminals and connections for
tightness.
1.Properly mount and attach all components as shown in
the dimensional drawings using the mounting feet/holes
and plumbing provided. The pressure relief manifold
should be plumbed back to the main fuel tank.
2.Connect all components to earth ground at ground
studs provided as shown on the electrical drawings.
Unit must be grounded for operator safety.
3. If equipped, install level and alarm indication
accessories as shown on dimensional drawing and
connect them to the Pump Unit as shown on the
electrical drawings.
4. If equipped, connect dry alarm contacts for customer
use per specifications on the electrical drawings.
5. Connect pump motor/control power to the Remote
Pump Unit per specifications on the electrical drawings.
Primary
Inspection
Installation
5

4 PRIMING THE SYSTEM
The pumps supplied with Simplex Pump Set are not self-
priming. If a pump is allowed to run without fuel, pump
damage will occur. Pump Sets are shipped from the factory
filled with #30 oil to facilitate system priming. On
systems that contain a hand pump the hand pump may
be utilized to lift the fuel into the pump set cabinet.
This will not eliminate the need to prime the system at
the pump.
The Pump Set may be primed by installing a priming
tee on the inlet side of the pump. An alternative is to
disconnect the inlet line at the pump and fill the line
with fuel. If the system contains a fuel strainer the
strainer must be disassembled, filled with fuel, and
reassembled.
1. Ensure the Pump is filled with #30 priming oil.
2. Ensure that all ball valves are in the open position.
3. Use hand pump to lift fuel to fuel manifold level.
4. Open the pump inlet line or priming tee, fi ll the line with fuel,
close the line (it is recommended that a foot valve be installed at the
main fuel tank to hold the fuel column.)
5. If the system contains a fuel strainer, fi ll the strainer with fuel.
6. Energize the pump and observe fuel fl ow. If it is a duplex
system, operate both pumps simultaneously.
If the system contains a vacuum gauge on the input side of the
pump, the gauge should read 15" vacuum maximum under normal
conditions (15" vacuum = 20' vertical lift). Vacuum gauge readings
greater than 15" vacuum indicate excessive vertical lift demands or
line restrictions.
If the system contains a pressure gauge on the output side of the
pump the gauge should read 5 PSI minimum pressure 65psi
maximum pressure under normal conditions (.433psi = 1' vertical
head pressure). Pressure gauge readings greater than 65 PSI
pressure indicate excessive line restrictions and/or friction. Pump
Set flow switches have a 5 PSI minimum set point and system
pressure lower than 5 PSI will initiate a loss of fl ow failure.
Pressure relief valves have a 65 PSI set point. System pressure
greater than 65 PSI will cause the pressure relief valve to open and
vent fuel back to the main storage tank.
Priming
Overview
Priming
Procedure
6

Apply control power to unit. If equipped, place the Main
Disconnect Switch in the “On” position.
AUTOMATIC
Place the Pump Selector Switch in the Auto position. When the call
for fuel contacts close, the pump will start and run until the call for
fuel contacts are opened.
MANUAL
Place the Pump Selector Switch in the Manual Mode. The pump
motor will run until the switch is returned to the “Off” or “Auto”
mode positions or when the Overload Relay trips
Duplex pump units are used to increase the reliability of a pumping
system through the addition of a second, backup 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 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. To begin operation, apply
control power to unit and place the Main Disconnect Switch in the
“On” position.
Single
Pump
Operation
Duplex
Pump
Operation
7

Place the Duplex Pump Mode Switch in the Alternate position.
When the call to transfer fuel contacts close, Pump #1 will start
and run until the call to transfer fuel contacts are opened.
When the call to transfer fuel contacts close again Pump #2
will start and run until the call to transfer fuel contacts are
opened. Repeated operation will continue to alternate the
pumps.
Place the Duplex Pump Selector Switch in the Both position.
When the call to transfer fuel contacts close both pumps will
start and run until the call to transfer fuel contacts are opened.
No lead/lag alternation occurs in the both mode.
If fuel is detected in the catch basin, the floatswitch will close,
activating the fuel line leak alarm illuminating the leak
indicator.
Note: A fuel line leak disables the fill pumps in the Auto mode.
An adjustable time delay relay is wired in parallel with the motor
starter circuit through a normally closed fl ow switch. The time delay
relay, set to 30 seconds by Simplex, allows the pump time to
establish positive flow and prevent false alarms. If the pump does
not develop sufficient fl ow before the time delay relay picks up, or if
flow is lost during operation, the lag pump will be signaled to start
in duplex systems, the failed pump will be stopped and the pump
fail indicator will light. Alarm contacts rated 10A @ 125/250VAC,
10A @ 30VDC.
Alternate
Both Run
Fuel Line
Leak
Loss of
Flow
8

5 MAINTENANCE
Simplex Pump Sets should be visually inspected for maintenance
purposes every six months during light duty cycles. Pumps sets used
daily for long hours should be inspected every month.
• Prior to performing the maintenance procedure ensure that the
optional main disconnect switch illustrated above is operating
properly, the user supplied circuit breaker is in the OFF position,
and that all sources of power are isolated from the Pump Set.
Proceed only after this is verified.
•Check main disconnect switch, door and hinge operation.
•Check cabinet mounting hardware at feet and wall mounting
flange. Tighten as necessary.
•Test pumps in duplex pump sets. Ensure both pumps are
operating normally, test each pump individually, test simultaneous
operation, test alternating operation.
•Check pump/motor hardware for tightness. Pump/motor
hardware for tightness. Pump/motor hardware will loosen after
normal operation due to vibration. This hardware is double nutted,
check all bolts for double nuts.
•Rotate shaft by hand and check for smooth operation. Check
pump/motor coupler shown at left for proper alignment and
spacing. The Lovejoy coupler should have approximately 1/8"
clearance between coupler halves. If this clearance is reduced or the
pump and motor are not properly aligned excessive noise and
pump/motor wear will occur. Loosen pump motor mounting
hardware to realign motor/coupler. Loosen one end of pump
coupler to adjust for necessary coupler clearance.
•Check all electrical terminals and connections for
tightness.
•All motors are permanently lubricated and do not
require any lubrication
•All pumps are self-lubricating and do not require
any maintenance.
• Check all plumbing joints for leaks. Tighten fittings
and joints as necessary. Drain accumulated fuel in
catch basin as necessary by removing catch basin plug.
•Inspect all fuel strainers. Disassemble strainer and clean strainer
element, replace as necessary. Re-assemble unit and check for leaks.
•Test hand pump operation, check for fuel leaks, tighten as
necessary
9

6 TROUBLESHOOTING
1. Pump not primed.
2. Lift is too high.
3. Rotation direction incorrect.
4. Check valve installed backwards.
1. Air leak at inlet.
2. Defective solenoid valve or check valve.
3. Lift too high.
4. Pump worn.
5. Inoperative foot valve.
6. Piping improperly installed.
7. Fuel strainer plugged.
1. Dirt or grit in fuel.
2. Pipe strain on pump causing bind.
3. Worn pump/motor coupler.
4. Pump has been run dry or with insufficient fuel.
1. Leak at inlet.
2. End of inlet not deep enough.
3. Air or gas in fuel.
4. Supply exhausted.
5. Vaporization of fuel at inlet.
6. Air or gas in inlet line.
7. Sand or abrasives in fuel.
1. Air in plumbing lines.
2. Liquid heavy or too viscous.
3. Bent pump shaft, binding rotating element.
4. Misalignment of pump/motor coupler.
1. Insufficient fuel supply.
2. Air leaks in the inlet pipe.
3. Air or gas at inlet connection.
4. Pump and motor out of alignment.
5. Worn out spider coupling.
6. Pump coupler out of balance.
No Fuel
Delivered
Rapid Pump
Wear
Insufficient
Fuel
Delivered
Pump
Delivers For
Short Period
And Quits
Pump
Requires Too
Much Power
Noisy
Operation
10

1. Inoperative foot valve.
2. Inoperative check valve.
3. Inoperative solenoid valve.
4. Pump cavitation.
5. Plumbing air leaks.
6. Lift too high.
7. Pump seal leaking.
1. Control power not available.
2. Motor thermal overload condition.
3. Pump failed and seized.
4. Motor failure.
1. Loose pump plumbing fittings.
2. Worn pump shaft seal.
3. Pump pressure relief valve failure.
4. Fuel leak elsewhere running towards pump area.
5. Excessive head from overhead storage tank.
6. Worn pump O-rings.
Pump
Requires
Frequent Re-
Priming
Motor Does
Not Turn Or
Turns
Intermittently
Pump Leaks
Fuel
11

7 DRAWINGS AND PARTS LIST
The drawings included in this manual are the most accurate source of
part numbers for your Pump Set. When ordering replacement parts for
Simplex Pump Sets, always consult the Parts Legend Drawing. When
contacting the Simplex Service Department always have your work
order and drawing number ready for reference. The Work Order
Number and the Drawing Numbers are also located on each drawing
legend. A typical drawing legend and parts list is illustrated below.
12

Abbreviation
Index
13

Technical
Data
14

15

Simplex, Inc.
5300 Rising Moon Road
Springfield, IL 62711-6228
[phone]
www.simplexdirect.com