Axi STS 6004 Installation and operation manual

5400 Division Dr. | Fort Myers, FL 33905
239 690-9589 | Toll Free 877-425-4239 | FAX [phone]
www.AXI-International.com
STS
STS 6004 | 7004 Instruction,
Operating, & Maintenance
Manual
ENCLOSED FUEL MAINTENANCE SYSTEM
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Table of Contents
Table of Contents ................................................................................................................................................................ 2!
General Overview ................................................................................................................................................................ 4!
STS 6004 | 7004 Specifications ......................................................................................................................................... 4!
System Components ........................................................................................................................................................... 5!
Control and Safety Devices................................................................................................................................................ 5!
Pump/Motor........................................................................................................................................................................ 5!
Primary Filter/Water Separator .......................................................................................................................................... 5!
Fuel Conditioner................................................................................................................................................................. 5!
Fine Filter ........................................................................................................................................................................... 5!
Plumbing ............................................................................................................................................................................ 5!
Multi-Tank Assembly (2 Tank) – If Applicable.................................................................................................................... 5!
Auto Water Drain (AWD) Assembly – If Applicable............................................................................................................ 6!
Manual Additive Injection – If Applicable............................................................................................................................ 6!
Auto Additive Injection Assembly – If Applicable ............................................................................................................... 6!
System Operation ................................................................................................................................................................ 7!
Pump Operation ................................................................................................................................................................. 7!
Alarms ................................................................................................................................................................................ 7!
Multi-Tank – If Applicable................................................................................................................................................... 8!
Auto Water Drain (AWD) – If Applicable ............................................................................................................................ 8!
Manual Additive Injection – If Applicable............................................................................................................................ 8!
Auto Additive Injection – If Applicable ................................................................................................................................ 9!
Primary Inspection ............................................................................................................................................................ 10!
Checklist........................................................................................................................................................................... 10!
Installation.......................................................................................................................................................................... 11!
Mounting .......................................................................................................................................................................... 11!
Electrical........................................................................................................................................................................... 11!
Field Connections – If Applicable..................................................................................................................................... 11!
Plumbing .......................................................................................................................................................................... 11!
Typical Plumbing Installation (Schematically) .................................................................................................................. 12!
Important Installation Precautions.................................................................................................................................... 12!
Multi-Tank Installation – If Applicable............................................................................................................................... 12!
Controller............................................................................................................................................................................ 14!
Setting the Current Date and Time (6000 Series Controller) ........................................................................................... 14!
Programming the Timer (6000 Series Controller) ............................................................................................................ 14!
Setting the Current Date and Time (7000 Series Controller) ........................................................................................... 14!
Programming the Timer (7000 Series Controller) ............................................................................................................ 14!
Touchscreen Menu Structure (7000 Series Controller).................................................................................................... 15!
Modbus TCP/IP Communication (7000 Series Controller)............................................................................................... 15!
Priming the System ........................................................................................................................................................... 16!
Priming Procedure ........................................................................................................................................................... 16!
Commissioning/Initial Start-Up ........................................................................................................................................ 17!
Gauge Venting ................................................................................................................................................................. 17!
Switch Adjustments .......................................................................................................................................................... 17!
Internal Pressure Relief Adjustment................................................................................................................................. 17!
Initial Test Procedures ..................................................................................................................................................... 18!
Maintenance ....................................................................................................................................................................... 19!
Preventative Maintenance................................................................................................................................................ 19!
Servicing the Primary Filter/Water Separator................................................................................................................... 19!
Servicing the Fine Filter ................................................................................................................................................... 20!
Replacement Filter Chart ................................................................................................................................................. 20!
Auto Water Drain (AWD) – If Applicable .......................................................................................................................... 20!

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Troubleshooting ................................................................................................................................................................ 22!
Symptom Troubleshooting Guide..................................................................................................................................... 22!
AXI International Limited Warranty.................................................................................................................................. 23!
Warranty Claim Procedure ............................................................................................................................................... 24!
Technical Assistance and Ordering................................................................................................................................. 25!
Accessories and Additional Configuration Parameters .................................................................................................... 25!
Replacement Filter Elements ........................................................................................................................................... 25!
System Identification ........................................................................................................................................................ 25!

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General Overview
STS 6004 | 7004 Specifications
Nominal Flow Rate……………………………………………..
4 GPM/240 GPH (15 LPM/984.2 LPH)
1,920 gallons (7,268 liters) per 8-hour shift
5,760 gallons (21,804 liters) per 24-hour shift
Primary Filter……………………………………………………
10 or 30μParticulate or 60μStainless Steel
Screen with Centrifugal Water Separator
Secondary Filter………………………………………………..
1, 3, 10, or 25μFine Filter or 3, 10μWater Block
Fuel Conditioner………………………………………………..
LG-X 1500 Inline Magnetic Conditioner
Plumbing………………………………………………………...
Black Iron
Inlet Port…………………………………………………………
3/4” NPT
Outlet Port…….…………………………………………………
3/4” NPT
System Enclosure……………………………………………..
NEMA 4 Rated Powder Coated or NEMA 4X Rated Stainless
Steel
Operating Temperature (6000 Series)……………………….
41 - 104°F (5 - 40°C)
Operating Temperature (7000 Series)……………………….
41 - 122°F (5 - 50°C)
Electrical………………………………………………………..
120V/60Hz/15A/1Ph or 230V/50Hz/15A/1Ph*
Pump……………………………………………………………
1/3 HP Spur Gear Pump
Suction Capability (Primed)…………………………………..
15ft. vertical lift or 100ft. horizontal run (lines >1”, primed)
Timer…………………………………………………………....
Incorporated PLC-based timer
Maximum Fluid Viscosity……………………………………..
5 cSt
Outline Dimensions………………………………..…………..
≈36” x 36” x 12” (91 x 91 x 31 cm) (H x W x D)
System Weight…………………………………………………
≈290 lbs (131.5 kg)
*Note: It is the user’s responsibility to ensure safe operating conditions for the system to be ran.
*At 50 Hz., nominal flow rate decreases from 4 GPM/240 GPH to 3.2 GPM/192 GPH.
!WARNING! This system is not meant for use with gasoline or any other flammable liquids having a flash point
less than 100°F (37.8° C). Use with gasoline or any flammable liquids at a temperature exceeding their flash point
presents an immediate explosion and fire hazard.

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System Components
Control and Safety Devices
• System Controller
o Incorporated PLC-based Timer
o Memory retention during power outages
o Alarm Indicator Light(s)
o Control Circuit Breakers (CB1, CB2)
o Pump Control Selector Switch {Hand (Manual) / Off / Auto}
o Alarm Reset Push Button
o Pump Running Indicator Light
o System Power Indicator Light
o Emergency Stop (E-Stop) Push Button
o 6000 Series Controller:
§ Smart Filtration PLC with LCD Display
o 7000 Series Controller:
§ HMI Touchscreen Control
• Water Detection Alarm Module
• Vacuum & Pressure Switches
• Flow Switch
• Leak Detection Float Switch
• Inlet and Outlet Isolation Ball Valves
Pump/Motor
• 1/3 HP Gear Pump
Primary Filter/Water Separator
• Fuel Filter
o Standard-issue back-flushable 30-micron hydrophobic filter cartridge (other filter elements available)
• Water Separator
• One Pair of Water Detection Sensor Probes
• Drain Valve
Fuel Conditioner
• Inline Magnetic Fuel Conditioner
Fine Filter
• Standard-issue 3μwater block cartridge (other filter elements available)
Plumbing
• Black Iron
Multi-Tank Assembly (2 Tank) – If Applicable
• External Bidirectional L-Port Ball Valves
o Enables system to service up to 2 tanks
• Tank Fuel Level Float Switches (Customer provided)

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Auto Water Drain (AWD) Assembly – If Applicable
• Accessory Pump
• Additional Water Detection Alarm Module
• Additional Pair of Water Detection Sensor Probes
• Solenoid Drain Valve
• Basket Strainer
• Water Collection Drum
o High Water Level Float Switch
Manual Additive Injection – If Applicable
• System Ball Valve
• Additive Injection Port
• Injection Port Ball Valve
Auto Additive Injection Assembly – If Applicable
• Accessory Pump
• Flexible Suction/Return Lines
• Additive Injection Flow Sensor
• Solenoid Valve
• Additive Container
• Float Switch/Container Port Assembly

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System Operation
Apply control power to unit. Place control breakers (CB1, CB2) for the System Controller in the “ON” position.
Pump Operation
Automatic Mode:
Switch the system to “Auto” mode via the Selector Switch on the system enclosure. During the time intervals set up by the
user, the pump will start and run until the scheduled runtime has ended. See the Controller section for setting scheduled
run times.
Manual Mode:
Switch the system to “Manual” mode via the Selector Switch on the system enclosure. The pump motor will run until the
system is switched off, into “Auto” mode, or an alarm has been tripped.
Alarms
Alarms featured on the system include:
• Leak Detection (system shutdown, alarm indication)
o Activated when the Float Switch in the system’s drip tray detects a raised liquid level. The system will go
into an alarm state and the pump will not be allowed to run until the alarm is addressed and cleared.
Note: Disposal of fuel and associated waste should be done in accordance with Federal, State and Local regulations.
• Low/No Flow (system shutdown, alarm indication)
o Activated when the Flow Switch on the pressure side of the pump detects a flow rate not adequate for the
pump. Once the alarm debounce timer is expired, the system will go into an alarm state and the pump will
not be allowed to run until the alarm is addressed and cleared.
• High Vacuum (system shutdown, alarm indication)
o Activated when the Vacuum Switch, placed on the suction side of the pump set, detects a reading above
the factory set point. The system will go into an alarm state and the pump will not be allowed to run until
the alarm is addressed and reset.
• High Pressure (system shutdown, alarm indication)
o Activated when a Pressure Switch, placed on the pressure side of the pump set, detects a reading above
the factory set point. The system will go into an alarm state and the pump will not be allowed to run until
the alarm is addressed and reset.
• High Water (system shutdown, alarm indication)
o Activated when water level trips the Water Detection Alarm Module via the Water Detection Sensor
Probes located on the mechanical water separator.
• Pump Overload (system shutdown, alarm indication) – If Applicable
o Activated when the amperage draw from the pump-motor assembly exceeds the factory set point
(determined by the pump’s FLA) on the pump overload relay module.
• Auto Water Drain Float Switch (halts auto water drain functionality, alarm indication) – If Applicable
o Activated when the float switch on the Auto Water Drain’s Water Collection Drum is triggered due to a
high water level.
• Tank Overflow (system shutdown, alarm indication) – If Applicable
o Activated when one of the customer provided tank fuel level float switches is triggered due to a high fuel
level in one of the connected tanks of a multi-tank configuration.
Note: If the Pump Overload Alarm triggers, please contact AXI International.
Once triggered alarms are addressed, each alarm can be reset via the Alarm Reset button on the enclosure door panel.

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Note: For information on factory set points or timer delays please refer to the “Accessories and Additional Configuration
Parameters” subsection in the “Technical Assistance and Ordering” section.
Multi-Tank – If Applicable
1. From the Main Menu screen select “CONFIG”
2. Enter password (9999)
3. Enter the correct number of connected tanks in the box under “Number of Tanks”.
4. To see actual valve positions, select “VALVES”
a. Press the “Open” and “Close” buttons to manually test the valves. If the “Open” or “Closed” rectangular
box is GREEN, that status is active. The opposite is true if said background is RED.
5. Return to Main Menu screen
6. To control Pump in Manual Mode, turn the selector switch on the enclosure door to the “MANUAL” position
7. Select “MANUAL CONTROL” from the Main Menu screen
8. Select the desired tank for manual operation
9. Pump will run when valves have reached correct positions
10. To stop pump operation, select “Cancel Manual” or turn the selector switch on the enclosure door to the “OFF”
position
11. For automatic fuel cleaning, turn the selector switch on the enclosure door to the “AUTO” position
12. Select “AUTO TIMER CONFIG” from the Main Menu screen
13. Program the timer start and stop times for each tank.
a. Use the “Next” and “Prev” buttons in the bottom corners of the screen to navigate between timer screens
for the tanks
Note: Please ensure the start and stop times for any of the tanks do not overlap or an error message will be displayed.
!WARNING! Do not start-up or operate system without high fuel level alarms from both tanks tied into the control
panel. Frequently test overflow alarms for proper functionality and pump shutdown.
Auto Water Drain (AWD) – If Applicable
1. When the Water Separator’s High-Water Sensor is triggered, the system will shutdown
2. The system will remain shut down for 60 seconds, allowing water to be completely separated from the fuel
3. After 60 seconds, the Auto Water Drain Solenoid Drain Valve opens and the Auto Water Drain Accessory Pump
turns on, draining the Water Separator bowl
4. Once the water level has dropped below the Water Separator’s Low-Water Sensor, the system automatically
turns back on and resumes normal operation
Manual Additive Injection – If Applicable
Note: Manual Additive Injection operation may vary depending on the vertical and horizontal distance between the
additive holding container and fuel polishing system.
1. With the system running, place flexible hose between the Additive Injection Port and Additive Container
2. Ensure sufficient additive is present in the container and that the flexible hose reaches the bottom
3. Open the Injection Port Ball Valve to begin injecting additive
4. To start or increase flow of additive into the system, slowly close the System Ball Valve to create a higher vacuum
as indicated on the vacuum gauge
5. Monitor the system’s vacuum gauge to avoid creating a vacuum higher than the system’s set point
Note: If a high vacuum alarm is triggered, return the System’s Ball Valve to the fully open position and reset the alarm by
pushing the Alarm Reset button on the enclosure door panel
6. Monitor the additive level in the holding container to gauge proper dosing

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7. After injecting the desired amount of additive, close the Injection Port Ball Valve and return the System Ball Valve
to the fully open position
Auto Additive Injection – If Applicable
1. To start Auto Additive Injection, navigate from the Main Menu to the Additive Injection screen on the HMI.
2. On the screen there are two fields to input information, Gallons to Treat and Treatment Ratio.
3. There are two other non-editable fields that show the last treatment date and also the amount of additive that was
added from the last treatment.
4. Enter the gallons of fuel to treat.
5. Then enter the treatment ratio (For example: 5 Gallon Jug of AFC treats 25,000 gallons of fuel, so enter 1:5000)
6. Once this information is entered, press the START button to begin the injection process.
7. There is a progress bar that will display the total amount of additive to be added (full red bar), and as the additive
is injected the red bar will decrease.
8. Once the bar is depleted, the process will stop.
9. If at any point the process needs to be manually stopped, press STOP on the screen.
10. After the injection is completed, the data is stored in the log, which can be accessed by pressing LOG on the
Additive Injection screen.
11. When the additive level reaches low, a “LOW ADDITIVE WARNING” will be displayed.
12. In order to run the process again, the additive must be refilled and the alarm reset by clearing all alarms.