ALBANY FUEL OIL PUMP PACKAGES

OPERATIONS & MAINTENANCE MANUAL

420 HARRY WALKER PARKWAY, NEWMARKET, ONTARIO.

L3Y 8P5

Telephone 888-334-3348 Fax 888-335-3391

www.albanypump.

www.albanypump.com
INTRODUCTION
Albany Fuel Oil Pump & Strainer Sets are packaged as a pre-engineered, integrated system of pumps,
pump motors, controls and accessories, pre-plumbed and pre-wired.
The Albany FO Series 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, jet fuel. The systems are suitable for wall or pad mounting. All devices, wiring and
plumbing are contained within the containment basin, which includes a leak detection switch. Inlet &
Outlet ports are provided for connection to field plumbing.
Assembly are built in Simplex, Duplex, Triplex, and custom arrangements. All assemblies are
fabricated in house at our manufacturing facility and custom design layouts and footprints are
available on request.
ALL PUMPS
1) All Pump sets are supplied with Albany Helical Gear Pumps. As positive
displacement pumps they will displace a definite amount of liquid with
each revolution and produce a discharge pressure equivalent to the
conditions of the particular installation.

2) Albany Gear pumps are self priming and capable of operating up to 25

ft. suction lift based on fuel oil at 70 F. If the static lift plus pipe friction
losses combine to exceed this figure, pump operation will be erratic or no
pumping at all will be realized.

3) It is particularly important that the suction line be air tight. Use a good
pipe joint compound or tape at all joints. If the suction line is not tight
and air is allowed to enter the pump capacity will be noticeably reduced
or it may not pump at all.
PRIMARY INSPECTION
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 Pump Set and
Control 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 all electrical terminals and connections for tightness.

If any problems are observed during Primary Inspection call the Albany Pump
Co. Ltd. 888-334-3348
INSTALLATION
- Connect the Suction and Discharge lines to the pump set (see drawing).

Duplex Suction: Simplex Suction:

INSTALLATION
- Connect the Suction and Discharge lines to the pump set (see drawing).

Thermal Relief Valve Discharge: No TRV Discharge:

INSTALLATION
- Connect suitably sized piping to the relief valve outlet and run to the main storage tank or
the main return line
INSTALLATION
- Confirm that motors are properly WIRED to their CORRECT VOLTAGE and ROTATION.
CHECKING ROTATION & PRIMING THE PUMPS
Checking Rotation:
Open all hand valves. Briefly jog Pump #1 and then Pump #2 to confirm that the ROTATION corresponds to the
directional ARROWS on the pumps. If required, change the wiring for correct rotation. (See wiring diagram on
the motor).

Priming the Pumps:

CLOSE the hand valves on both sides of Pump #2 and CLOSE all gauge cocks.
Start Pump #1 and operate until the system is completely primed and all air has been purged from the pump
and suction piping. NOTE: to assist in priming loosen the plug in the tee located at the base of the relief valve.
When the pump is fully primed the oil escaping from the plug will be clear in color (not milky). Tighten the
plug. Repeat for pump #2.
NOTE: A priming tee is included in some system to assist with priming.
SETTING THE RELIEF VALVES
The Relief Valves supplied on the unit must be SET at time of installation.
To set, remove the acorn nut covering the adjusting screw, loosen the lock nut
and back the screw off
(For Simplex). With Pump running tighten the screw until the gauge pressure
no longer rises. The gauge pressure showing will then be the required “system
working pressure”. Next loosen the adjusting screw until the gauge pressure
falls slightly below the “system working pressure”. Carefully close the discharge
valve for Pump. Further adjust the relief valve screw until the “shut off”
pressure is approximately 20 percent higher than the “system working
pressure”. Replace the lock nut and acorn nut with gasket. Stop Pump and close
all corresponding suction and discharge valves.

Open the suction and discharge valves for Pump #2 and START PUMP. Prime
Pump #2 as per the instructions above.
Adjust relief valve for Pump #2 as per instructions for valve #1. Upon
completion open all hand valves.
SETTING THE PRESSURE SWITCHES
SWITCH 1 ADJUSTMENT SCREW SWITCH 2ADJUSTMENT
(PS1) SCREW (PS2)

Your Albany Duplex Fuel Oil Pump Set is equipped with a two-stage pressure switch to
properly protect the system. The pressure switch can be used to monitor Low Pressure
along with High Pressure or Riser Pressure Loss. The switches must be wired to the
appropriate terminals in the electrical control panel (see control panel drawing). These
switches become operative in hand and automatic mode. Any alarm generated via the
pressure switch will remain on the control panel until acknowledged and reset.
SETTING THE PRESSURE SWITCHES
LOW PRESSURE SWITCH
A low pressure switch is used to detect a drop in pressure to something less than the established normal operating pressure. The
low pressure switch contacts are wired in the normally closed position. Starting with the setting indicator below the desired
actuation point, adjust the pressure upwards until the switch contacts open at a pressure approximately 5 psi below the established
system working pressure. If the system operating pressure falls below the low pressure setting, the switch contacts will close and
activate a timer in the control panel. If the system operating pressure stays below the low pressure set point for the full timer
length, the pump(s) stop. A fault light on the panel will serve to alert the operator.
HIGH PRESSURE SWITCH
The high pressure switch is intended to alarm in the event of a rise in pressure above the established relief valve pressure. This
switch is wired in the normally open position. Using the instructions supplied with the switch as a guide, set the activation point 5
to 10 psi above the relief valve pressure. If a condition occurs in the system causing the pressure to rise, the switch contacts will
close and send an alarm signal to the control panel. A fault light on the panel will serve to alert the operator.
RISER PRESSURE LOSS
The riser pressure loss switch is intended to alarm in the event of a drop in the static pressure on the discharge piping when the
pump is not in operation. The riser pressure loss switch contacts are wired in the normally closed position. Starting with the setting
indicator below the desired actuation point, adjust the pressure upwards until the switch contacts open at a pressure approximately
5 psi below the established system static pressure. If the static pressure falls below the riser pressure loss setting, the switch
contacts will close and activate a timer in the control panel. If the static pressure stays below the riser pressure loss set point for the
full timer length, the pumps will not operate. A fault light on the panel will serve to alert the operator.
STRAINERS
Duplex Pump Sets:

This valve is designed so that the strainer screen can be removed from one side (or the other) while the pump set is
in operation. When the pump set is operating, the handle must be positioned to one side or the other.
STRAINERS
Simplex Basket Strainer:

The strainer is installed downstream of pump suction isolating valve. To service strainer, close isolating valve before
opening strainer basket. .
OIL PUMP CONTROL PANELS
The FO Series Pump Set includes our SICON and DUCON Microprocessor Based Fuel Oil Management and Pump
Controller, which can be configured to monitor and control transfer pumps, return pumps, tank level gauges, and
tank leak detectors. It provides pump operation and monitoring with motor starters and HOA switches. Automatic
level control is managed by our control panels through signals received by float switches located in the day tank. The
Controller can network with other system controllers using Ethernet, and directly to Building Management Systems
with an option of BACnet, Modbus, Metasys N2, or Lon protocol.

All Fuel Pump Control Panels come standard with the following alarm light features:
- Low Level Day Tank/Lead Pump Failure (Duplex system only)
- High Level Day Tank
- Critical High Level Day Tank
- Low Level Main Tank
- High Level Main Tank
- Overload Pump 1
- Overload Pump 2 (Duplex system only)
- Low Pressure
- High Pressure
FLOAT SWITCHES
Principle of Operation:
The switching action is achieved through the use of an internal magnet within the float and its interaction with
the switch mechanism. As the liquid level changes inside the tank, the float moves. Its magnetic field opens or
closes each reed switch inside the stem to complete an electrical circuit.

A four level float is used in a standard set up. A redundant, single point float switch is required by TSSA to
provide a Critical High Level shut off point in the case of the failure of the four level float.
LEVCON INSTALLATION
CAUTION: Refer to instructions before operating or servicing switch.
Construction: 316 Stainless Steel stem, 2” 316 ss float, 2“ NPT bushing.
Switch set-point distances are measured from the underside of the 2“ NPT bushing to the
centre of the float at the level where the switch is activated. Switch set-point distances are
field adjustable from 2” - 24” by adjusting the compression fitting to meet your needs. They
are factory-set as specified on the purchase order. The contact arrangement may be
changed from normally open (NO) to normally closed (NC) and vice versa. Turn over the
float and return the stop collars to their original positions. If the contact arrangement is
altered, use an ohmmeter to test that the switch operates correctly. Screw the float switch
into the 2“ NPT open ing on the top of the tank. The conductors are colour coded to
identify each switch. The switch must be connected in series with a load.
DO NOT CONNECT THE SWITCH DIRECTLY ACROSS THE POWER SUPPLY.
The voltage / current product must not exceed the power rating.
PUMP REPAIR – H SERIES
Disassembling Pump:
Repair kits are available for all Albany Gear pump models. Each
repair kit includes replacement gaskets, seal, gears, shafts and 10. Remove snap ring from shaft behind bearing.
bearings.
1. Remove rear cover.
2. Using fingers or hook tool, remove rear bearings.
3. Slide out idler gear assembly.
4. Grasp drive gear, slide off drive shaft and carefully remove
key from shaft.
5. Remove 3 screws from bearing retainer and pull shaft
assembly from pump
6. Remove screws from front cover.
7. Remove cover by light tapping; to ease off dowl pins, while
pulling from body. Front bearings can now be removed.
8. Loosen 2 set screws in outboard bearing and slide retainer
off shaft.
9. For 03 Models only: Remove snap ring from shaft in front
of outboard bearing and push shaft through retainer,
pushing out wearface and seal seat at same time.
11. To remove rotating seal head from shaft it is necessary to
protect the rubber bellows from grooves and keyway. This
can be accomplished by covering them with scotch tape.
Lubricate shaft and slide seal head off shaft.
12. To remove wearface and seal seat, remove snap ring from
outboard bearing. Pull out bearing and then push out
wearface and seal seat.
13. Replace any parts where wear is evident be re-assembling
pump.
PUMP REPAIR – H SERIES
Re-assembling Pump: slide rotating seal head on shaft using caution not to cut
rubber bellows or scratch seal wearfaces until spring washer is
Carefully clean all parts and lubricate lightly. Make sure pump against snap ring. Press wearfaces until spring washer is
body faces are clean and free of nicks or scratches. If new against snap ring. Press wearface and seal seat in bearing
bearings are used, try in body and on shafts before re- retainer taking care not to nick the seal seat, and make sure
assembling pump. the wearface is seated squarely on its back face. Slide bearing
Insert front bearings. Replace gasket, install front cover using retainer on shaft and place middle snap ring on shaft. Push
dowel pins for alignment. Tighten eight screws finger tight. ball bearing on shaft and press into retainer until snap ring can
Slide rotating seal head on shaft using caution not to cut be inserted to hold bearing in retainer. NOW place outer snap
rubber bellows or scratch seal wearfaces until spring washer is ring on shaft to complete retainer, seal and shaft assembly.
against snap ring. Press wearface and seal seat in bearing Insert retainer, seal and shaft assembly in front cover making
retainer; taking care not to nick the seal seat, and make sure sure drain hole is pointing down and replace screws.
wearface is seated squarely on back face. Press sealed ball Insert key in drive shaft and slide drive gear against front
bearing in retainer and insert snap ring. Slide this assembly bearing. Insert idler gear assembly and insert rear bearings.
over shaft after cleaning and lubricating seal faces. Remove Replace gasket and rear cover. Tighten all screws while
one set screw from ball bearing, push retainer until screw hole rotating drive shaft by hand.
lines up with locking groove on shaft and tighten other set
screw. Insert other screw and tighten both set screws until
allen wrench flexes approximately 15o.
For 03 models only: After installing front cover as previously,
PUMP REPAIR – G SERIES
Disassembling Pump:

Repair kits are available for all Albany Gear pump models. Each repair kit includes replacement gaskets, seal, gears, shafts and
bearings. Remove rear cover. Using fingers or hook tool, remove rear bearings. Slide out idler gear assembly.
Remove screws from seal retainer and remove seal retainer from pump.

IMPORTANT
Do not remove screws fastening front cover to body – keep pump body and front cover assembly together as a unit in
order to preserve relative positions and alignment. In the event body and front cover are separated, it will be necessary to
tap body and cover lightly at pump re-assembly while tightening screws in order to insure alignment and free turning.

1. Remove drive shaft and gear assembly from cover and body assembly by pushing on drive shaft end while supporting on
body flange.
2. For pumps equipped with mechanical seals and lip seals, it is necessary to protect the rubber lip or bellows from shaft
grooves and keyway. This can be accomplished by covering them with scotch tape. Lubricate shaft before pushing drive
shaft and gear assembly from cover.
3. To remove wearface and seal seat, push out wearface and seal seat from seal retainer.
4. Replace any parts where wear is evident be re-assembling pump
PUMP REPAIR – H SERIES
Re-assembling Pump:

1. Carefully clean all parts and lubricate lightly. Make sure pump body faces are clean and free of nicks or scratches. If new
bearings are used, try in body and on shafts before re- assembling pump.

2. Place internal pump parts into front cover and body unit. Suggested sequence includes front bearings, drive and idle gear
assemblies, and rear bearings.
MAINTENANCE INSTRUCTIONS
Your Albany Fuel Oil Pump Set requires periodic cleaning of the Inlet Suction Strainers. Service as follows:

a) Select the pump to be serviced first and set the control panel selector switch for that pump to the “OFF” position.
b) Close the valve on the discharge of the pump to be serviced. Position either the 3 way suction valve handle or the
Duplex Strainer handle so that the flow to the pump/ basket being serviced is closed.
c) Remove the strainer basket and clean in a suitable solvent.
d) Re-install the strainer basket. (Ensure that any and all o-rings are suitably in place).
e) Repeat process for second pump / basket when required.

All other forms of service can be arranged through our office on a semi-annual or annual basis.
TROUBLESHOOTING MATRIX
Fuel Oil Transfer Pumps and Controller Installation Checklist
Site:
Client:
Completion Date:

ACTION YES NO N/A

PRIMARY INSPECTION
COMPLETE

SUPPLY PIPING FROM

MAIN TANK COMPLETE

DISCHARGE PIPING TO
DAY TANK COMPLETE

RELIEF VALVE PIPING

TO MAIN TANK
COMPLETE

PUMP MOTORS WIRED

FOR PROPER
ROTATION (CW & CCW)

ALL CONTROL PANEL

WIRING COMPLETE

PUMP Model Capacity (USGPM) Operating Pressure Relief Valve Set Low Pressure High Pressure Riser Pressure Loss Suction Pressure
(PSI) Pressure Switch Set Point Switch Set Point Set Point (“HG)
P1
P2
Fuel Oil Transfer Pumps and Controller Pre-Start Up Checklist
Site:
Client:
Start Up Date Requested:
ACTION YES NO N/A

MAIN TANK FILLED

WITH FUEL
ALL FUEL LINE
CONNECTIONS
COMPLETE
ALL FUEL LINE
PRESSURE TESTING
COMPLETE
POWER SUPPLIED TO
ALBANY PUMP
CONTROL PANEL
ALL EXTERNAL
DEVICES WIRED TO
ALBANY PUMP
CONTROL PANEL
FLOAT SENSING
DEVICES DRY TESTED
FOR FUNCTIONALITY
PROPER MOTOR
ROTATION
CONFIRMED
SITE CONTACT NAME AND PHONE NUMBER:
SPECIAL PARKING INSTRUCTIONS (IF ANY):
Failure to meet these conditions could result in additional commissioning charges