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OilSafe Lubrication Work Center Owner's Manual

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Lubrication Work Center
Lubrication Work Center
Owners Manual
IMPORTANT
• Please read this Owners Manual carefully and thoroughly before installing and
operating your Lubrication Work Center.
• Please retain this owners manual for future reference after reading it thoroughly.

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Summary of Contents for OilSafe Lubrication Work Center

  • Page 1 Lubrication Work Center Lubrication Work Center Owners Manual IMPORTANT • Please read this Owners Manual carefully and thoroughly before installing and operating your Lubrication Work Center. • Please retain this owners manual for future reference after reading it thoroughly.

  • Page 3: Table Of Contents

    Date Purchased: 1. Introduction READ THIS MANUAL 2. Parts and Pre-Installation Checklist Inside you will find important information on how 3. Static Discharge Grounding Reel to use and maintain your OilSafe Lubrication ® Work Station. 4. Installation and Setup 5. Installation 6.

  • Page 4: Explanation Of Symbols Used

    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.

  • Page 5: Warnings And Cautions

    Lubrication Work Center WARNINGS AND CAUTIONS The OILSAFE Lubrication Work Center is designed for the storage of machinery lubricating oils and other NON-VOLATILE fluids. STORAGE OF FLUIDS ® WITH 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 the fluid manufacturer’s Material Safety Data Sheet (“MSDS”) before introducing a fluid to this system.

  • Page 6: Oilsafe Limited Warranty

    OILSAFE LIMITED WARRANTY OilSafe (“OS”) warrants to the original product purchaser (hereinafter the “Customer”) that the OS product for which the Customer received this warranty was designed, developed and manufactured using all due reasonable commercial care and good manufacturing practices.

  • Page 7: Introduction

    1. INTRODUCTION Thank you for purchasing an OilSafe Lubrication Work Center. 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.
  • Page 8 FIGURE 1: Tank Pod (Pod-1) FIGURE 2: Dispensing Pod (Pod-2)

  • Page 9: Parts And Pre-Installation Checklist

    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. OilSafe has completed the assembly for each individual Pod. The only installation and assembly required after delivery is the placing of the Pods, and connecting the Pods together.
  • Page 10 Additional Features Cabinet Handles Your system includes additional features for the security and storage of your bulk fluids and other items. The cabinets are secured using a twist and pull type of handle which works as shown in Figure 4. The cabinet handles may or may not include a locking mechanism depending on your specific customization.

  • Page 11: Static Discharge Grounding Reel

    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 ®...

  • Page 12: Installation And Setup

    4. INSTALLATION AND SETUP Tools, Materials, and Personnel Requirements: • A minimum of two people are recommended to complete this install. • Electrical hook-ups and installation should be completed by your authorized electrical personnel in accordance with all local and federal laws and regulations.

  • Page 13: Installation

    Lubrication Work Center 5. 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.
  • Page 14 5. INSTALLATION 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.
  • Page 15 Lubrication Work Center 5. INSTALLATION Optional Equipment - New Product! Spill Containment Connector Kit OilSafe Bulk Systems are now configured to allow the containment pans to be connected at the back of each frame simply by ordering an optional ®...
  • Page 16 5. INSTALLATION Hoses STEP 8. Proceed to the rear of the Dispensing Pod and locate the hydraulic hoses that are connected to the system pressure gauges. There is one hose for each gauge. NOTE: Each hose will be labeled at the open end to correspond to its related Bulk Tank. STEP 9.
  • Page 17 Lubrication Work Center 5. INSTALLATION STEP 11. Tighten the hose connection fitting securely. TIP: Start with the hose closest to the adjoining Tank Pod, and thread the hose through the shortest available path. Follow this process with all pressure gauge hoses.
  • Page 18 5. INSTALLATION STEP 18. Installing the Fluid Level Gauges See Figure 14 and Figure 15 for details. Unscrew and remove the red locking nut. Remove the calibration. Gently pull up the red indicator. Carefully insert the float assembly into the tank. Screw the aluminum bushing into the tank port until tight and ensure the arrow on the flat side of the hex bushing is pointing toward the rear of the tank.
  • Page 19 Lubrication Work Center 5. INSTALLATION NOTE: For systems that have overfill alarms, follow STEPS 11 - 14 to install your overfill alarm. If you purchase an overfill alarm at a later date, these instructions will allow you to install the overfill alarm at that time.
  • Page 20 5. INSTALLATION Installing the Desiccant Air Breather ( See Figure 16 for details) STEP 27. Install the Desiccant Air Breather air filter to each tank by screwing it (clockwise) into the threaded opening on the top right of the Bulk Tank. Remove the elastic white band on the top of the Desiccant Air Breather to activate the breather.
  • Page 21 Lubrication Work Center 5. INSTALLATION IMPORTANT: • Per the manufacturer’s recommendation, write the installation date of the Spin-on Filter on the provided sticker located on the filter. 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 29.

  • Page 22: Electrical Installation

    6. ELECTRICAL INSTALLATION 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 the frame uprights. At the rear of the system, locate the female power supply cord(s) coming from the electrical - enclosure. See Figure 17. NOTE Each cord will be labeled at the female end to correspond to its related motor.
  • Page 23 Lubrication Work Center 6. ELECTRICAL INSTALLATION STEP 2. Feed the power cord from the electrical enclosure to the corresponding motor. See Figure 18. STEP 3. Connect the power cord to the threaded power inlet of the corresponding motor. Line up the power cord connector to fit into the power inlet of the motor.

  • Page 24: Initial Operation

    7. INITIAL OPERATION IMPORTANT: • Follow these steps the very first time you use your system. WARNING! The Tank Isolation 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. CAUTION! Personal Protective Equipment (“PPE”) should be worn when installing and operating this system.
  • Page 25 Lubrication Work Center 7. INITIAL OPERATION Filling the Tank(s) ( See Figure 20 and Figure 21 for details) IMPORTANT: • If you have not installed your Spin-on Filter, make sure you do so before proceeding. STEP 1. Locate the Suction Hose Assembly. Each tank will have its own individual Suction Hose Assembly. See Figure 20.
  • Page 26 7. INITIAL OPERATION Filling the Tank(s) ( See Figure 22 for details) STEP 3. Attach the Static Discharge Cable to the drum. See Figure 22. FIGURE 22: Attach Static Discharge Cable CAUTION! When filling Bulk Tanks from drums or barrels always ensure the Static Discharge Clip is connected to the drum or barrel before starting the pump.
  • Page 27 Lubrication Work Center 7. INITIAL OPERATION Filling the Tank(s) ( See Figure 23 and Figure 24 for details) STEP 4. Remove the fill port inlet end cap of the appropriate tank by lifting the tabs and pulling the end cap off. Clean the inlet of any debris before continuing.
  • Page 28 7. INITIAL OPERATION NOTE: OilSafe recommends an initial Re-Circulation (“Kidney-Loop”) of the fluid at the first fill. Refer to Re-Circulation (“Kidney-Loop”) Cycle Time Guide in the Data Tables section (page 43) for approximate run times to complete single pass filtration of each tank.
  • Page 29 Lubrication Work Center 7. INITIAL OPERATION Dispenser Faucets (continued) NOTE: Due to the air that has been trapped in the hoses during assembly, air will come out of the faucet initially. Keep the faucet in the open position until fluid is flowing at a steady pace.
  • Page 30 Using the Dispensing Reels NOTE: The Dispensing Reels are optional equipment. If you have ordered Dispensing Reels with your system, they will be located within the cabinet directly under the Dispensing Faucets. See Figure 26. STEP 1. Press START to start the pump. STEP 2.

  • Page 31: Maintenance

    Lubrication Work Center 8. MAINTENANCE PERIODIC MAINTENANCE SHOULD BE SCHEDULED AND PERFORMED ON YOUR SYSTEM EVERY THREE MONTHS AFTER YOUR INITIAL INSTALLATION. Requirements Prior to Maintenance: WARNING! ALWAYS ensure the main power supply is first locked out and the system depressurized before any service is performed on this system.
  • Page 32 If your system contains a fire safe valve (see your specification sheet for details), the valve can be closed by releasing the fusible link lead clip on the top of the valve. In the event of a fire, the lead clip will melt, forcing the valve to automatically close and secure your fluid. See Figure 29. FIGURE 29: Fire Safe Isolation Valve in the Open Position Maintenance Checklist: EVERY 3 MONTHS:...
  • Page 33 Lubrication Work Center 8. Maintenance Checklist EVERY 6 MONTHS: Flush out the spill transport pallet (bottom of the pods) with hot water and cleaner/degreasing fluid. Use a clean and damp rag and wipe down the motor and all painted surface areas.

  • Page 34: Moving Your System

    Continue to follow the normal installation steps for the system.. WARNING! OilSafe DOES NOT recommend changing the type of fluid dispensed by a pump. Each system is custom- built to customer specifications including the type of fluid stored. Contact your supplier if your fluid storage needs change to remove the possibility of cross-contamination and incompatibility of system materials or components with a new fluid.

  • Page 35: Troubleshooting

    Lubrication Work Center 10. TROUBLESHOOTING WARNING! 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, change filter elements, or undertake any service work when this system is running or energized. SEVERE injury or death may occur.
  • Page 36 10. TROUBLESHOOTING Issue Steps to Resolve The tank is not dispensing liquid correctly. 1. Check to ensure the valves on the front of the unit are in the correct position. 2. Check all fittings for cracks or leaks. 3. Check all hydraulic hoses for cracks or leaks. 4.
  • Page 37 Lubrication Work Center 10. TROUBLESHOOTING Issue Steps to Resolve The pump system pressure is above 240 PSI. 1. Locate the pump bypass pressure relief valve on the side of the pump head. 2. Using a wrench, loosen the lock nut on the valve spindle by turning it counter clock wise.

  • Page 38: Repair And Replacement Procedures

    The major components of the system were designed to be line replaceable. Before attempting any repairs or replacement, contact OilSafe in the event your part is covered by warranty.

  • Page 39: Replacement Parts

    Lubrication Work Center 12. REPLACEMENT PARTS FIGURE 32: Replaceable Parts...
  • Page 40 12. REPLACEMENT PARTS Tank Desiccant Air Breather (Part # 46Z134) This is the air filter on the top of the tanks. When the colored beads on the inside of the breather turn from orange to dark green, it is time to replace the filter.
  • Page 41 Lubrication Work Center 12. REPLACEMENT PARTS Colored Ball Knob for Standard Steel Shut Off Valve (Available in 10 colors – See Table 1 on page 41 for Part #’s) The ball knob on the end of the Dispensing Faucet Handle is color-coded to match the fluid tank it corresponds with. If the ball knob is damaged or requires replacing for any reason, it can be removed by unscrewing it from the handle and replacing it with a new knob.
  • Page 42 12. REPLACEMENT PARTS Spin-on Filter (3, 6, 12, or 25 um – micro glass) This is the filter for the tank. The micron rating required will depend on your stated specification. Contact your supplier for additional information. Cabinet Handle, Chrome (T-style) – available with and without key lock The cabinet handle on the front of each cabinet door can be removed and replaced if needed.
  • Page 43 Lubrication Work Center TABLE 1: Spare and Replacement Parts List Item Description Type Part # Direct Mount Overfill Alarm (Audible Only) - fits to Tank Level Gauge Alarm 921100 Direct Mount Overfill Alarm (Flashing Light Only) - fits to Tank Level Gauge...

  • Page 44: Tank Or Motor Replacement

    13. TANK OR MOTOR REPLACEMENT For repair or replacement of a tank or motor, contact your supplier for ordering information. Prior to servicing, the tank should be pumped empty and then isolated using the Tank Isolation Valves on the underside of the tank, power should be disconnected from the system, and all hoses and cords removed from the tank assembly.

  • Page 45: Data Tables

    Lubrication Work Center 14. DATA TABLES TABLE 3: Tank Re-Circulation (“Kidney-Loop”) Cycle Time Guide ISO Viscosity Pump Flow Rate (GPM) Rated Tank Size APPROXIMATE CIRCULATION TIME (Gallons) (Minutes) Single Pass Filtration Factor Reservoir Size x 7 / Pump Flow Rate = Time *Times will be a function of initial oil cleanliness, oil grades, oil temperature and other factors.
  • Page 46 OilSafe Lubrication Work Center Plumbing Schematic - Rev2 Hose Reel Illustrates 2 hose connections made during installation 1) Desiccant breather #Z134 2) Level Indicator 3) Reservoir with integral baffle 4) Return check valve 5) Fire protection valve with fusible link 6) 3/4"...

  • Page 47: Customer Service And Warranty Issues

    CUSTOMER SERVICE AND WARRANTY ISSUES For any customer service, ordering requests, or warranty issues, please contact your authorized supplier or OilSafe. You may contact OS as follows: Telephone: (972) 771-1000 930 Whitmore Drive Fax: (972) 722-3252 Rockwall, TX 75087 USA Email: sales@oilsafe.com...
  • Page 48 Lubrication Work Center NOTES:...
  • Page 49 NOTES:...
  • Page 51 Telephone: (972) 771-1000 930 Whitmore Drive Fax: (972) 722-3252 Rockwall, TX USA Email: sales@oilsafe.com www.oilsafe.com © 2016 Whitmore 100245.1BSLWC...

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