ALGAE-X STS 6000-4GPM Installation guide

STS 6000-4GPM
Automated Fuel Filtration System
Installation, Operating and Maintenance Manual
Optimal Fuel Quality Provides Peak Engine Performance
Improves Engine Reliability
Removes Water & Sludge
Prevents Tank Sediments
Optimizes Fuel Quality
Stabilizes Fuel

STS 6000-4GPM ALGAE-X2007-Rev. B
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INSTALLATION, OPERATING AND MAINTENANCE MANUAL
CONTENT
OVERVIEW –BASIC SYSTEM COMPONENTS ...................................................................... 5
GENERAL SPECIFICATIONS................................................................................................... 6
SYSTEM COMPONENTS......................................................................................................... 6
PRIMARY INSPECTION ........................................................................................................... 7
INSTALLATION......................................................................................................................... 8
Mounting................................................................................................................................ 8
Electrical ................................................................................................................................ 8
Plumbing................................................................................................................................ 8
Typical plumbing / Above ground tank installation (schematically) ........................................ 9
IMPORTANT INSTALLATION PRECAUTIONS........................................................................ 9
PRIMING THE SYSTEM ......................................................................................................... 10
INITIAL START-UP / COMMISSIONING CHECKLIST............................................................ 11
Flow switch setting / adjustment (“No Flow Alarm”) ............................................................. 11
Initial test procedure............................................................................................................. 11
OPERATION ........................................................................................................................... 12
Emergency Stop .................................................................................................................. 12
Pump Operation................................................................................................................... 12
Programming the Timer ....................................................................................................... 12
Fuel Line Leak ..................................................................................................................... 13
Stabilizing and Optimizing Fuel Quality................................................................................ 13
MAINTENANCE ...................................................................................................................... 14
Preventative Maintenance.................................................................................................... 14
Servicing primary filter / strainer........................................................................................... 15
Servicing secondary filter..................................................................................................... 15
TROUBLESHOOTING............................................................................................................. 16
AUTOMATED FUEL FILTRATION SYSTEMS WARRANTY................................................... 18
TECHNICAL ASSISTANCE AND ORDERING........................................................................ 19
Replacement filter elements................................................................................................. 19
STS 6000 SYSTEM IDENTIFICATION.................................................................................... 20
APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL................................................... 21
APPENDIX B –DRAWINGS ................................................................................................... 21

STS 6000-4GPM ALGAE-X2007-Rev. B
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Automated Fuel Filtration System
STS 6000-4GPM
Three stage water removal and particulate filtration
down to 3 micron
Patented Fuel Conditioner reverses fuel deterioration
& polymerization to submicron levels
Algae-X “Smart Filtration Controller” –UL508A listed
Fully automated programmable control
Automatic shut-down for high vacuum, filter
pressure, leak and flow interruption detection
Integrated industrial display and control panel
Easy installation independent of genset
(“kidney loop”)
Stand alone, safe, reliable, turn key Solution
Ensures Safe & Reliable Emergency
Generator Operation.
The STS-6000 removes water, sludge and prevents
tank sediments in stored fuel.
Fuel is inherently unstable. It naturally forms sediments, solids and tank sludge. Clogged filters, smoke and
damage to injection systems are often symptoms of less than optimal fuel quality causing engines to be unreliable,
smoke, lose power and ultimately fail. Water naturally accumulates in storage tanks due to condensation or leaks in
fills and vents. Water and temperature changes create an environment for microbial growth and natural oxidation,
accelerating formation of sludge, acids and tank corrosion.
Series
STS 6000
Flow rates
4GPM
Tank Size
200 - 5,000 gal
Port Size
3/4” NPT
Power
110V / 60Hz
230V / 50Hz
Weight
~200 lbs
Dim. (HxWxD)
36” x 36” x 12”
LG-X Model
1500
Strainer /
Primary Filter
80 Mesh (178 micron)
10 or 15 micron
Second. Filter
(Water Block)
3 or 10 micron
* Not for use with fluids that have a flash point below 100F
(e.g. Gasoline, Alcohol, …)
The STS 6000 Fuel Filtration Systems are self contained, stand-alone and fully automated. They recondition and
stabilize fuel, eliminate & prevent microbial contamination and remove water, sludge and contaminants from tanks;
preserving the integrity of stored fuel, providing reliable power whenever it is needed.
Implementing STS Fuel Maintenance Systems assures Optimal Fuel Quality & Reliable Engine Performance at
all times. It prevents costly downtime, periodic tank cleaning, replacing out of spec fuel and injection system repairs.

STS 6000-4GPM ALGAE-X2007-Rev. B
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Customer quotes:
“I had no idea how much sludge accumulated in
my tank, putting my emergency power at risk.”
“We had to learn the hard way that a clogged
filter will shut down the genset –Algae-X
provided us with the perfect “Fuel Solution” so
this will never happen again.”
The principal components are a continuous duty
motor with coupled gear pump, strainer/primary
filter with vacuum sensor & gauge, Algae-X Fuel
Conditioner, and a secondary filter with pressure
gauge & sensor. The system is automatically
operated by the programmable, UL 508A listed
Algae-X Smart Filtration Controller. All
components and control devices are contained
within a fully enclosed, lockable, weatherproof
NEMA 3R cabinet.
The strainer/primary filter protects the pump and
removes water and particulate. The secondary filter
is a quick change spin-on filter designed to remove
emulsified water and contaminants down to 3
Micron.
For safe operation the STS 6000 is equipped with a
drip tray monitored by a leak detector. Additional
safety elements include automatic system shut-
down and indicators when filter elements require
service, high pump vacuum exists or a flow
interruption is detected.
STS 6000 Accessories: AFC-705 Fuel Catalyst,
Wide range of filter elements, Rotor Sight Glass,
Foot Valve, Separ Primary Filter, Two tank control,
Digital flow meter
Fuel Maintenance is an important part of
periodic generator maintenance programs –
just like changing the oil and ensuring the
batteries are charged.
Do you have a “Fuel Maintenance
Program” in place?
Can you afford a clogged filter shutting
down your generator?
When did you last test your fuel or check
the tank for water & sediments?
Call us to engineer & design your “Fuel
Maintenance System”
Typical installation of the STS
Automatic Filtration System

STS 6000-4GPM ALGAE-X2007-Rev. B
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OVERVIEW –BASIC SYSTEM COMPONENTS
1) Fuel Inlet (From Tank)
11) Motor
2) Inlet Ball Valve
12) ALGAE-X®Magnetic Fuel Conditioner
3) Primary Filter / Strainer
13) Secondary Filter
4) Vacuum Gauge
14) Pressure Switch
5) Drain Valve
15) Pressure Gauge
6) Man. Air Vent / Bleed Screw (located back)
16) Outlet Ball Valve
7) Vacuum Switch
17) Fuel Outlet (To Tank)
8) ALGAE-X®Smart Filtration Controller
18) Mechanical Flow Meter with Flow Switch
9) Pressure Relief Valve
19) Leak Detector (Float Switch) in Spill Tray
10) Gear Pump

STS 6000-4GPM ALGAE-X2007-Rev. B
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GENERAL SPECIFICATIONS
STS 6000-4GPM
Flow Rate ............................................................ 4 gpm / 240 gph
1,920 Gallons per 8 hour shift
5,760 Gallons per 24 hours
Outline Dimensions (Enclosure) ......................... 36” x 36” x 12” (H x W x D)
System Weight .................................................... approx. 200 lbs
Operating Temperature ...................................... 32 - 104° F; 0 - 40° C
Electrical ............................................................. 115 V / 60 Hz / single phase (standard)
............................................................................. 230 V / 50 Hz also available
Pump .................................................................. Gear Pump
Suction capability (primed) .................................. 15 ft vertical or 100 ft. horizontal lift (lines >3/4”, primed)
Motor ................................................................... 1/2 hp single phase, continuous duty, thermally protected
Timer ................................................................... Programmable Digital Timer
Inlet ..................................................................... 3/4” NPT male port
Outlet .................................................................. 3/4”NPT male port
Max. Fluid Viscosity............................................. 29 cSt
Note: The STS 6000 is designed to meet environmental standards for safe operation.
(NOT for use with fluids that have a flash point below 100F (38C), e.g.: gasoline, alcohol, …)
SYSTEM COMPONENTS
Control and Safety Devices
Algae-X “Smart Filtration Controller” in electrical sub enclosure –UL 508A listed Industrial Control Panel
Programmable Digital Timer –Memory backup to retain program memory during power outages
Pump control switch (Auto-Off-Manual), weatherproof, key operated
Alarm Reset - weatherproof push button
Power available indicator
Pump running indicator
External remote shut-down feature
Inlet and outlet shut off ball valves
Emergency stop button
Pressure relieve valve
Leak sensor and alarm indicator (system shutdown)
Primary filter / strainer high vacuum alarm indicator and system shutdown (vacuum sensor)
Secondary filter high pressure alarm indicator and system shutdown (pressure sensor)
Flow meter with “no flow” alarm indicator and system shutdown (flow switch)
Pump motor starter with single-pole circuit breaker and contactor
Pump / Motor:
Positive displacement gear pump
Relief valve
Motor –UL listed
TEFC (Totally enclosed fan cooled)
Thermal overload protection

STS 6000-4GPM ALGAE-X2007-Rev. B
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Primary Filter / Fuel Strainer
Fuel filter / strainer with clear bowl
Drain valve on the bottom
Vacuum gauge (stainless steel, liquid filled)
80 Mesh (178 Micron) cleanable stainless steel cartridge standard - other filter elements available
Fuel Conditioner
Inline Fuel Conditioner breaks down naturally forming sediments and solids found in diesel fuel to
submicron levels
Secondary Filter
3 Micron water blocking spin on filter (other filter elements available)
Pressure gauge (stainless steel, liquid filled)
Weatherproof NEMA 3R single door wall-mounted enclosure with lockable handles / latches
14-gauge steel construction with continuously welded seams
Concealed hinges
Finished in gray polyester powder coat inside and out over phosphatized surfaces
Spill tray with leak detection
Louvered side panels
Brackets for wall mounting
Literature pocket
Stainless steel plumbing
PRIMARY INSPECTION
Upon arrival, the STS 6000-4GPM Automated Fuel Filtration System and accessories must be visually inspected
before installation. Improper handling during shipping may cause physical or electrical problems. Immediately
report or note any damages (also concealed ones) to the shipper.
Checklist:
If the packing crate shows signs of damage inspect the STS-6000 cabinet for damage. Check the entire
outside of the cabinet for damage that could indicate internal mechanical or electrical problems.
Check locking handles, door and hinge operation.
Check pump/motor hardware and all plumbing connections for tightness.
Check all electrical terminals and connections for tightness.

STS 6000-4GPM ALGAE-X2007-Rev. B
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INSTALLATION
! IMPORTANT ! It is recommended that only qualified, experienced personnel, familiar with this
type of equipment, who have read and understood all the instructions in this manual should
install, operate and maintain the system.
MOUNTING
The STS-6000 is a totally enclosed system and should be permanently wall mounted on a hard, level surface.
Use provided mounting feet for proper fastening. This weatherproof unit is designed for well-ventilated indoor
or outdoor use within specified temperature range and should be located as close to the tank as possible.
Please allow about 1 ft of space between the side louvers of the enclosure and nearby objects. This space is
necessary to ensure sufficient ventilation of cooling air for the system and motor.
ELECTRICAL
! WARNING ! To avoid the risk of electric shock make sure that the power supply to the system is
disconnected and ensure that the system is at zero volts, before working on any of the system‟s
electrical parts.
Make sure that the systems power requirements and rated voltage / frequency match your electrical system (See
wiring diagram). The STS 6000 may only be connected to properly grounded power sources for operator safety.
Connect all components to the ground studs provided as shown on the electrical drawings.
! WARNING ! The whole system (Enclosure, doors, plumbing, motor, electric sub panel) must be
properly grounded for operator safety.
Depending on length of run, use #12 AWG or larger copper wiring and connect system to a separate UL listed
20A breaker (not included) appropriate for branch circuit protection.
Note: Wiring and electrical installation must be in accordance with all applicable Federal, State and
Local rules, laws, standards and regulations.
Remote Pump Shut-Down Feature:
If required, connect the “external pump shut down input terminal”(Terminal 15 on Terminal Block “TB2” –see
wiring diagram) for customers use per specification on electric diagram to disable pump (e.g.: remote shut down,
external emergency stop button). Please note that the contact needs to be supplied with +24V DC from the power
supply of the STS 6000 Algae-X Smart Filtration Controller.
PLUMBING
Use proper quality approved fuel line materials with at least 3/4” inner diameter on the suction side from
the tank and at least 1/2” inner diameter on the return / discharge side back to the tank.
The pick-up tube/line(s) should originate from the lowest point of the tank (to remove all water), should be
connected directly to the system’s “PUMP INLET –SUPPLY FROM TANK” port located on the left hand side of
the enclosure and kept as short as possible. It is recommended to install an oversized, low restriction foot
valve to keep the system primed, especially if the “PUMP INLET –SUPPLY FROM TANK” port of the system is
located above the lowest possible fuel level in the tank. A priming tee should be installed on the highest point
of the suction line to be able to easily prime the lines and system.
The return line(s) should be plumbed to the “PUMP OUTLET –RETURN TO TANK” port (on the right side of the
system) and enter the tank as far as possible from the pick up tube close to the tank bottom. A (swing) check
valve may be required on the return line(s) on some installations to prevent back flow pressure.
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STS 6000-4GPM ALGAE-X2007-Rev. B
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Multiple suction and/or return lines may be connected to a manifold outside the STS-6000 (see options list).
Anti-Siphon or other external plumbing devices may be required –please check local regulations / code.
The system capabilities are 15 ft suction (vertical) or 100 ft horizontal lift, when connected to piping of 3/4” ID or
more with no additional flow restrictions such as valves, 90-degree connectors or other plumbing accessories. For
continuous optimal performance, make sure suction and discharge lines are free and that nothing is blocking the
flow of fuel and that the suction line always stays primed.
Note: Plumbing and Installation must be in accordance with all applicable Federal, State and Local
rules, laws, standards and regulations.
TYPICAL PLUMBING / ABOVE GROUND TANK INSTALLATION (SCHEMATICALLY)
IMPORTANT INSTALLATION PRECAUTIONS
The suction line of the system should be independent and separate from the suction line of the engine. If
that is not possible, appropriate valves must be installed to completely separate the STS-6000 from the engine
fuel system to prevent any possible interference with safe engine operation.
It is highly recommended to plumb the discharge line independent and separate of the engine’s fuel return line
back to the tank. If the return line from the engine and the discharge of the STS 6000 have to be combined in any
way, adequate valves should be installed to prevent any possible interference with safe engine operation.
Note: If any of the STS 6000 system‟s fuel lines are used in combination with the engine‟s fuel system,
the STS 6000 should be disabled during engine operation (use the provided “remote pump shut
down” feature as shown in the electrical drawing and described above).

STS 6000-4GPM ALGAE-X2007-Rev. B
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PRIMING THE SYSTEM
The pump supplied with the STS 6000 is NOT automatically self-priming and must not be run dry.
! WARNING ! If the pump is allowed to run without fuel, pump damage will occur.
The pump head of the STS 6000 unit is shipped from the factory filled with Diesel #2 to facilitate initial lubrication.
This will not eliminate the necessity to prime the complete system. The STS 6000 is primed by using the
externally installed priming tee (not provided) on the suction side of the system. Also the strainer / primary filter as
well as the suction line has to be completely filled with fuel prior to the initial system start-up.
Priming procedure:
1. Ensure the pump is filled with #2 Diesel fuel.
2. Ensure that the inlet ball valve is in the open and the outlet ball valve is in the closed position.
3. Slightly open the manual air vent valve (bleed screw) located inside the STS 6000 (position #6 –page 5).
4. Open the externally installed priming tee (located at the highest point of the suction plumbing), fill the line
with fuel until fuel escapes from bleed screw (manual air vent), close the manual air vent, continue filling until
all air is bled from the plumbing lines and system, close the priming tee. (for tanks situated on a lower level
than the STS 6000, it is recommended that a foot valve is installed at the fuel tank to hold the fuel column).
5. Make sure to completely fill suction line to its highest point with fuel (no trapped air), in particular when the
suction line exits the tank top and the STS 6000 is located below that level.
6. Open the outlet ball valve and ensure the inlet ball valve is also in open position.
7. Switch on the pump and observe fuel flow.
The system is equipped with a vacuum gauge on the input side of the pump. The gauge should read 0 to 9" HG
vacuum maximum under normal conditions. Vacuum gauge readings reaching 10" HG vacuum indicate excessive
debris in the primary filter/ strainer (or a flow restriction or too high suction height and therefore pressure drop in
the suction line) and will result in pump shutdown and activate the alarm “HIGH VACUUM ALARM”.
Note: 10" HG vacuum = clogged primary filter / strainer or suction line flow restriction / excessive lift.
The system’s pressure gauge on the secondary filter should show 25 PSI maximum pressure under normal
conditions (.433 PSI = 1' vertical head pressure). Pressure gauge readings in excess of 25 PSI pressure indicate
excessive filter, or fuel line restrictions and/or friction.
System pressure over 25 PSI indicates a high-pressure failure (“HIGH PRESSURE ALARM” indicator) and will
automatically shut down the pump.
The pressure relief valve has a 35-40 PSI set point. System pressure in excess of 35-40 PSI will cause the
pressure relief valve to open and vent fuel back to the fuel transfer pump inlet side.
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