Axi STS 6000-P35 Parts list manual

STS 6000-P35 INSTRUCTION,
OPERATING, &MAINTENANCE MANUA L
Enclosed Programmable Automated
Fuel Polishing System
1.239.690.9859
AXI.International AXInternational AXIFuel AXIFuel
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INSTALLATION, OPERATING AND MAINTENANCE MANUAL
TABLE OF CONTENTS
OVERVIEW – BASIC SYSTEM COMPONENTS..................................................................................................................4
GENERAL SPECIFICATIONS ..................................................................................................................................................7
SYSTEM COMPONENTS.........................................................................................................................................................7
PRIMARY INSPECTION ...........................................................................................................................................................8
INSTALLATION.......................................................................................................................................................................... 8
Mounting................................................................................................................................................................................................................................................................8
Electrical...................................................................................................................................................................................................................................................................9
Plumbing ................................................................................................................................................................................................................................................................9
Typical plumbing / Above ground tank installation (schematically).............................................................................................................................10
IMPORTANT INSTALLATION PRECAUTIONS ................................................................................................................10
SMART FILTRATION CONTROLLER - ALARM FEATURES ..........................................................................................11
INITIAL START-UP / COMMISSIONING CHECKLIST ....................................................................................................11
Gauge venting / accuracy......................................................................................................................................................................................................................... 11
OPERATION .............................................................................................................................................................................11
Emergency Stop..............................................................................................................................................................................................................................................11
System Operation...........................................................................................................................................................................................................................................12
Programming the Timer.............................................................................................................................................................................................................................12
Fuel Line Leak....................................................................................................................................................................................................................................................13
Stabilizing and Optimizing Fuel Quality...........................................................................................................................................................................................13
MAINTENANCE.......................................................................................................................................................................14
Preventative Maintenance........................................................................................................................................................................................................................14
Servicing primary filter.................................................................................................................................................................................................................................15
Servicing secondary filters ........................................................................................................................................................................................................................16
TROUBLESHOOTING ............................................................................................................................................................17
AUTOMATIC 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

STS 6000-P35
Programmable Automated Fuel Maintenance System
STS 6000-P35 Programmable Automated Fuel Filtration System is a self-contained, stand-alone system that removes and
prevents the buildup of water, sludge and contaminants in tanks. It stabilizes diesel and bio-fuels, eliminates microbial
contamination to optimize and maintain fuel quality. STS systems guarantee Optimal Fuel Quality for Reliable Power at All
Times.
For safe operation, the STS 6000-SX-F is equipped with an
automatic pump shut-down and indicators when filter
elements require service. Also included are indicators for
high pump vacuum, high filter pressure, and leaks.
Preventive Maintenance Plans for mission-critical power are
essential. However, most service agreements do not cover
fuel-related engine failures. Fuel has a limited shelf-life and
even “fresh fuel” could contain water, sediment, microbes
and bio-fuel components upon delivery.
Periodic generator tests-runs are too short to determine if
fuel quality is adequate for the demands of continuous,
full-load operation. In fact, generator test runs significantly
accelerate the fuel polymerization and degradation proc-ess
by returning fuel that has been compromised by heat and
pressure back to the tank.
Potential liabilities can easily be avoided by implementing an
AXI Fuel Quality Maintenance Program as part
of every disaster recovery plan. An STS 6000-P35
automatically maintains fuel quality and guarantees reliable
emergency power whenever it is needed.
STS 6000-P35 SPECIFICATIONS
STS 6000-P35 SERIES FEATURE:
Multi-stage water removal and particulate filtration
NEMA 12, 13, 4 Powder Coated or Stainless
UL508A SMART Filtration Controller
Unique Alarm Functions and Remote Monitoring
Integrates with Building Management Systems
Carbon Steel Plumbing
Stand-Alone, Reliable & Turn-Key
1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
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Flow Rate 35 GPM
Primary Filter/
Secondary
1, 5, 10, or 25µ Particulate or Water Block
Dual 1, 3, 10 or 25µ
Pump Utilizes Existing Tank Pump
Smart Filtration
Controller
SMART PLC Controller
Ports 1 1/2” NPT In
1 1/2” NPT Out
Construction NEMA rated enclosure
Power 120VAC / 60hz / 20A
Plumbing Carbon Steel
Dimensions 42” x 68 x 14” (H x W x D)
(107 x 176 x 36 cm)
Weight ≈ 404 lbs (183.3 kgs)
(37.8°C).
REV0201P35011217

REPLACEMENT FILTER OPTIONS
Primary Filter
10µ Filter Element
30µ Filter Element
60µ Strainer
01010
01030
01060SS
Part No. Secondary Filter
3µ Water Block Filter
1µ Fine Filter FF-1
3µ Fine Filter FFZ-3
10µ Fine Filter FF-10
10µ Water Block Filter
WB-3
WB-10
Part No.
A unique and powerful broad spectrum concentrate for use
in diesel, gasoline, bio-fuel, kerosene, and HFO. Benefits
include:
Multiple tank functions
AFC-705 Fuel Catalyst
Foot Valve
Digital Flow Meter
STS 6000-P35 OPTIONS AFC 705/710 FUEL ADDITIVE
Tier 4 Compliant (710 only)
Stablized Fuel up to 12 mo.
Added Lubricity
Improved Combustion
Lower Emissions
Improved Fuel Economy
Extended Engine Life
Extended Filter Life
Removes / Prevents
Carbon Build Up
Prevents Corrosion
Cleans Injection System
STS 6000-P35
Programmable Automated Fuel Maintenance System
1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.877.425.4239 Toll Free
www.AXI-International.com
Fuel Inlet (From Tank)
Solenoid
FBO Primary Filter / Coalescer
Watect 550 Water Sensor
Fuel Conditioner
Secondary Filters
SMART Filtration Controller
Fuel Outlet (To Tank)
Flow Switch
Pressure Transmitters
Float Switch
Pressure Gauges
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
65
7
431
11
9
2
10
8
12
REV0201P35011217

GENERAL SPECIFICATIONS
STS 6000-P35
Flow Rate ................................................................................................ 35 gpm / 2100 gph
16,800 Gallons per 8 hour shift
50,400 Gallons per 24 hours
Outline Dimensions (Enclosure) .............................................. 37” x 60” x 12” (H x W x D)
System Weight .................................................................................... approx. 400 lbs
Operating Temperature ................................................................ 41 to 104° F; 5 to 40° C
Electrical .................................................................................................. 115 V / 60 Hz / single phase (standard)
Solenoid .................................................................................................. 115 V / 60 Hz, NC, Direct Acting
Timer ......................................................................................................... Programmable Digital Timer
Inlet ............................................................................................................ 1-1/2” NPT male port
Outlet ........................................................................................................ 1-1/2” NPT male port
Max. Fluid Viscosity ........................................................................... 5 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
•AXI International “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
•System/ Solenoid control switch (Auto-Off-Manual), weatherproof, key operated
•Alarm Reset - weatherproof push button
•Power available indicator
•System/Pump running indicator
•External remote shut-down feature
•Inlet and outlet shut off ball valves
•Emergency stop button
•Leak sensor and alarm indicator (system shutdown)
•Primary filter high differential pressure alarm indicator and system shutdown (pressure
transmitter)
•Primary filter / coalescer high water alarm indicator and system shutdown (water sensor)
•Secondary filter high differential pressure alarm indicator and system shutdown (pressure
transmitter)
•System high discharge pressure alarm indicator and system shutdown (pressure transmitter)
•Paddle type flow switch with “no flow” alarm indicator and system shutdown (flow switch)
PRIMARY FILTER / WATER SEPARATOR
•RACOR FBO fuel filter / coalescer with water sensor probe
•Drain valve on the bottom
•Analog pressure gauge
•Differential pressure indicator

8
•10-micron coalescing filter cartridge (other filter elements available)
FUEL CONDITIONER
•Inline Algae-X Fuel Conditioner eliminates and prevents microbial contamination and the
formation of sediments that naturally occur in diesel fuel.
SECONDARY FILTER
•Two 3 Micron water blocking spin on filter (other filter elements available)
•Pressure gauge (stainless steel, liquid filled)
WEATHERPROOF DOUBLE DOOR WALL-MOUNTED ENCLOSURE WITH
LOCKABLE HANDLES / LATCHES
•14-gauge steel construction with continuously welded seams
•Concealed hinges
•Finished in polyester powder coat inside and out over phosphatized surfaces
•Spill tray with leak detection
•Louvered side panels
•Brackets for wall mounting
•Literature pocket
CARBON STEEL PLUMBING
PRIMARY INSPECTION
Upon arrival, the STS 6000-P35 Automatic 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:
oIf 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.
oCheck locking handles, door and hinge operation.
oCheck pump/motor hardware and all plumbing connections for tightness.
oCheck all electrical terminals and connections for tightness.
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 copper wiring according to specification in wiring diagram and connect
system to a separate UL listed 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” (see wiring diagram) and follow the
specifications provided in the electrical wiring diagram to disable pump (e.g.: remote shut down, remote
pump control, …). Please note that the contact needs to be supplied with +24V DC from the power
supply of the STS 6000 AXI International Smart Filtration Controller.
Remote Monitoring - Dry Contacts:
The STS provides two NO (normally open) dry contacts for remote alarm monitoring. Please see wiring
diagram for contact rating, connection and location.
“Summary Alarm” – dry alarm contact for high pressure, no flow or water detection (as well as Emergency
stop and overload relay triggered)
“Leak Detection” – dry alarm contact for leak detection
Pump/System Running Remote Monitoring Feature:
Two NO dry contacts are provided for remote “Pump Running” monitoring. Please see wiring diagram for
contact rating, connection and location.
PLUMBING
Use proper quality approved fuel line materials with at least 1-1/2” inner diameter on the supply side
from the tank and at least 1-1/2” inner diameter on the return / discharge side back to the tank.
Note: Do not put any stress on plumbing of STS 6000 and use a backing wrench when
connecting the external plumbing.
The return line(s) should be plumbed to the “PUMP OUTLET – RETURN TO TANK” port (on the left 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.
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.
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).

SMART FILTRATION CONTROLLER - ALARM FEATURES
The STS 6000 is equipped with an AXI International Smart Filtration Controller. System and alarm status
are displayed on the industrial control panel (on the door) via indicator lights and on the text display
directly on the controller.
If all red indicator alarm lights are illuminated please see the text display for further info. One of the two
situations will be present:
Emergency stop button depressed (Unlock E-Stop button by turning and push “ALARM RESET” button to
return to normal operation.
Overload relay (OLR) tripped. Remove front panel of Smart Filtration Controller and push reset button on
OLR relay, close panel again and push “ALARM RESET” button on door panel to return to resume
operation.
Note: All red indicator lights on the control panel illuminated at the same time indicates that
either the Emergency stop button has been pressed or that the overload relay has been
tripped.
INITIAL START-UP /COMMISSIONING CHECKLIST
GAUGE VENTING / ACCURACY
After shipment, pointer of gauges may not rest at zero due to internal case pressure buildup caused
by temperature variations. Accuracy may be significantly reduced. To restore gauge to
operating condition, move yellow lever of fill plug to the ”open” position or remove small plug
from top of gauge and leave open.
OPERATION
! WARNING ! Do not use with gasoline. This System is not meant for use with gasoline
nor with other flammable liquids having a flash point less than 100°F. Use with gasoline
or use with any flammable liquids at a temperature exceeding their flash point,
presents an immediate explosion and fire hazard.
! WARNING ! Never use the STS 6000 at a temperature exceeding the flash point of its
contents.
EMERGENCY STOP
Note: In case of an emergency the Solenoid can be closed and system disabled by depressing
the red “EMERGENCY STOP” button on the control panel.
To release the “EMERGENCY STOP” button located on the control panel turn the red knob in the direction
indicated by the arrows on the mushroom button and push the “ALARM RESET” button to acknowledge.
`

SYSTEM OPERATION
Apply control power to unit. Place breakers in the AXI International Smart Filtration Controller in the “ON”
position.
Automatic:
Place the key switch in the “AUTO” position. When the timer contacts close, the solenoid will open until
the timer setting has expired.
Manual (Override):
Place the key switch in the “RUN” position. The solenoid will open until the switch is returned to the “OFF”
or “AUTO” mode positions or till an alarm or overload has been tripped.
PROGRAMMING THE TIMER
The programmable timer is part of the Micro PLC settings of the AXI International Smart Filtration
Controller located inside the STS 6000 system.
Note: The PLC uses military time – all times programmed must be in that format.
1. Please make sure the Emergency Stop button is not engaged, the key switch set to “OFF” and
push the “ALARM RESET” button on the control panel.
2. When power is first applied to the system the display of the PLC will show (blinking) date and time.
3. We will now set current date and time (must be in military format):
4. Hit the “ESC” button
5. Select ‘Stop’ and press “OK”
6. Select ‘Yes’ (use down arrow key) and press “OK”
7. Select ‘Setup’ (use down arrow key)and press “OK”
8. Select ‘Clock’ and press “OK”
9. Select ‘Set Clock’ and press “OK”
10. Using the arrow keys set current day of the week, time and date as indicated in the display and
press “OK”
( or to change value, or to change between week day, time and date).
11. When finished entering press “OK” to confirm
12. Press “ESC”
13. Select ‘Start’ and press “OK” – correct time and date should be displayed
14. We are now ready to program the timer (military time format must be used):
15. Hit the “ESC” button
16. Select ‘Set Param’ (use down arrow key) and press “OK”
17. Push down arrow key till ‘Timer 1’ is displayed
18. Press “OK”
19. Use left and right arrow keys to select the day/days of the week the system should
automatically turn on and the up or down arrow key to activate the selected day.
20. Use arrow keys in same manner to program the ‘On’ time – when the system will switch on (on
the selected day/days)
21. Use arrow keys in same manner to program the ‘Off’ time – when the system will switch off (on
the selected day/days)
22. Press “OK” to confirm entry when finished
23. If required you can set up to 3 Timers by using the up and down arrow key