Axi Sts 6030 Operation and maintenance manual

STS 6030 INSTRUCTION, OPERATION,

AND MAINTENANCE MANUAL

Enclosed Programmable Automated

Fuel Maintenance Systems

1.239.690.9859

AXI.International AXInternational AXIFuel AXIFuel

1.877.425.4239 Toll Free

www.AXI-International.com REV03016030010218

STS 6030

Enclosed Automated Fuel Maintenance Systems

The STS 6030 Programmable Automated Fuel Maintenance System is designed to optimize and maintain diesel fuel

indefinitely. Adding an STS 6030 system will remove particulate, separate water, and condition stored fuel. This innovative

process stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures clean reliable fuel at all times.

Generators and pumps operating in remote locations are ideal applications for STS 6030 systems.

STS 6030 SPECIFICATIONS

1.239.690.9589

AXI.International AXInternational AXIFuel AXIFuel

1.877.425.4239 Toll Free

www.AXI-International.com

ALL STS SYSTEMS FEATURE:

SMART FILTRATION CONTROLLERS:

Maintenance Alert Log File

Runtime Totalizer

Alarm History

On-Screen Help

Multi-stage Water Removal and Particulate Filtration

NEMA 12,13, 4, 4X Powder Coated or Stainless Enclosure

UL508A Smart Filtration Controller

STS 6000 SERIES SAFETY FEATURES:

Automatic Alerts

Pump Shut Down When Filters Need Service

Leak Detection

Water Detection

High Filter Vacuum

High Pump Pressure

Low Fuel Flow Alert

Emergency Stop

Flow Rate (@60Hz) 30 GPM/1800 GPH (113.6 LPM/6814 LPH)

Y-Strainer 20 Mesh

Primary Filter 1, 5, 10 or 25μ Racor FBO Particulate

or 1, 5, 10 or 25μ Racor FBO Water Block

Fuel Conditioner LG-X 4000 Inline Conditioner

System Controller

Programmable, Fully Automated UL 508A

SMART Filtration Controller with BMS/BAS

Interface and Digital Text Readout

Pump 2 HP Gear Pump

Power 208-230V/1Ph/60Hz/20A or

230V/1Ph/50Hz/15A or

480V/1Ph/60Hz/15A

Plumbing Carbon Steel

Ports 2” NPT In 1-1/2” NPT Out

Enclosure Cabinet NEMA 12 (IP55), 13 (IP65), 4 (IP66), and

4X (IP66) Powder Coat or Stainless Steel

Dimensions 56” x 72” x 17” (H x W x D)

(142 x 183 x 43 cm)

Weight ≈ 760 lbs (344.7 kg)

Not for use with fluids that have a flash point below 100°F (37.8°C).

Secondary Filter 10μ Racor FBO Coalescer

or 1, 5, 10 or 25μ Racor FBO Water Block

REV02016030011217

AFC 705/710 Fuel Catalyst

Stainless Steel Enclosure

Automatic Water Drain

Cabinet Color Options

Stand

Stainless Steal Plumbing

STS 6030 OPTIONS:

REPLACEMENT FILTER OPTIONS:

STS SYSTEM INTEGRATION:

Smart Filtration Controller

AXI Inline LG-X 4000 Conditioner

Primary Final Filter

Enclosure Heater (Optional)

Secondary Final Filter

Fuel Outlet (Discharge)

Outlet Ball Valve

Flow Switch with Sight Glass

Drain Valves

Leak Detector

Pressure Switch

Gear Pump

Wye-Strainer

Fuel Inlet (From Tank)

Vacuum Switch

10.

11.

12.

13.

14.

15.

Pre Filter

1µ Micro Filter Element

5µ Micro Filter Element

10µ Micro Filter Element

FBO-60339

FBO-60340

FBO-60357

25µ Micro Filter Element FBO-60341

Part No.

Fine Filter

1µ Coalescing Filter Element

5µ Coalescing Filter Element

10µ Coalescing Filter Element

FBO-60336

FBO-60337

FBO-60356

25µ Coalescing Filter Element FBO-60338

Part No.

STS 6030

Enclosed Automated Fuel Maintenance Systems

1.239.690.9589

AXI.International AXInternational AXIFuel AXIFuel

1.877.425.4239 Toll Free

www.AXI-International.com

2 3 54

101112

DIRTY FUEL

CLEAN FUEL

UNUSED HOT FUEL

ENGINE

PUMP SET

CLEAN FUEL

REV02016030011217

STS 6030

Enclosed Automated Fuel Maintenance Systems

The STS 6030 Programmable Automated Fuel Maintenance System is designed to optimize and maintain diesel fuel

indefinitely. Adding an STS 6030 system will remove particulate, separate water, and condition stored fuel. This innovative

process stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures clean reliable fuel at all times.

Generators and pumps operating in remote locations are ideal applications for STS 6030 systems.

STS 6030 SPECIFICATIONS

1.239.690.9589

AXI.International AXInternational AXIFuel AXIFuel

1.877.425.4239 Toll Free

www.AXI-International.com

ALL STS SYSTEMS FEATURE:

SMART FILTRATION CONTROLLERS:

Maintenance Alert Log File

Runtime Totalizer

Alarm History

On-Screen Help

Multi-stage Water Removal and Particulate Filtration

NEMA 12,13, 4, 4X Powder Coated or Stainless Enclosure

UL508A Smart Filtration Controller

STS 6000 SERIES SAFETY FEATURES:

Automatic Alerts

Pump Shut Down When Filters Need Service

Leak Detection

Water Detection

High Filter Vacuum

High Pump Pressure

Low Fuel Flow Alert

Emergency Stop

Flow Rate (@60Hz) 30 GPM/1800 GPH (113.6 LPM/6814 LPH)

Y-Strainer 20 Mesh

Primary Filter 1, 5, 10 or 25μ Racor FBO Particulate

or 1, 5, 10 or 25μ Racor FBO Water Block

Fuel Conditioner LG-X 4000 Inline Conditioner

System Controller

Programmable, Fully Automated UL 508A

SMART Filtration Controller with BMS/BAS

Interface and Digital Text Readout

Pump 2 HP Gear Pump

Power 208-230V/1Ph/60Hz/20A or

230V/1Ph/50Hz/15A or

480V/1Ph/60Hz/15A

Plumbing Carbon Steel

Ports 2” NPT In 1-1/2” NPT Out

Enclosure Cabinet NEMA 12 (IP55), 13 (IP65), 4 (IP66), and

4X (IP66) Powder Coat or Stainless Steel

Dimensions 56” x 72” x 17” (H x W x D)

(142 x 183 x 43 cm)

Weight ≈ 760 lbs (344.7 kg)

Not for use with fluids that have a flash point below 100°F (37.8°C).

Secondary Filter 10μ Racor FBO Coalescer

or 1, 5, 10 or 25μ Racor FBO Water Block

REV02016030011217

AFC 705/710 Fuel Catalyst

Stainless Steel Enclosure

Automatic Water Drain

Cabinet Color Options

Stand

Stainless Steal Plumbing

STS 6030 OPTIONS:

REPLACEMENT FILTER OPTIONS:

STS SYSTEM INTEGRATION:

Smart Filtration Controller

AXI Inline LG-X 4000 Conditioner

Primary Final Filter

Enclosure Heater (Optional)

Secondary Final Filter

Fuel Outlet (Discharge)

Outlet Ball Valve

Flow Switch with Sight Glass

Drain Valves

Leak Detector

Pressure Switch

Gear Pump

Wye-Strainer

Fuel Inlet (From Tank)

Vacuum Switch

10.

11.

12.

13.

14.

15.

Pre Filter

1µ Micro Filter Element

5µ Micro Filter Element

10µ Micro Filter Element

FBO-60339

FBO-60340

FBO-60357

25µ Micro Filter Element FBO-60341

Part No.

Fine Filter

1µ Coalescing Filter Element

5µ Coalescing Filter Element

10µ Coalescing Filter Element

FBO-60336

FBO-60337

FBO-60356

25µ Coalescing Filter Element FBO-60338

Part No.

STS 6030

Enclosed Automated Fuel Maintenance Systems

1.239.690.9589

AXI.International AXInternational AXIFuel AXIFuel

1.877.425.4239 Toll Free

www.AXI-International.com

2 3 54

101112

DIRTY FUEL

CLEAN FUEL

UNUSED HOT FUEL

ENGINE

PUMP SET

CLEAN FUEL

REV02016030011217

Table of Contents

General Overview ...............................................................................................................................................................

System Components .........................................................................................................................................................

Control and Safety Devices ..........................................................................................................................................

Pump/Motor .................................................................................................................................................................

Pre-Filter/Water Separator ..........................................................................................................................................

Final Filter(s) ..................................................................................................................................................................

Fuel Conditioner ............................................................................................................................................................

Filter Drain .....................................................................................................................................................................

System Enclosure .........................................................................................................................................................

Plumbing ........................................................................................................................................................................

System Operation ..............................................................................................................................................................

Pump Operation ............................................................................................................................................................

Emergency Stop ............................................................................................................................................................

Alarms.............................................................................................................................................................................

Primary Inspection .............................................................................................................................................................

Checklist .........................................................................................................................................................................

Installation ...........................................................................................................................................................................

Mounting ........................................................................................................................................................................

Electrical .........................................................................................................................................................................

Plumbing ........................................................................................................................................................................

Typical System Installation Conguration Schematic .................................................................................................

Installation Precautions .................................................................................................................................................

Controller .............................................................................................................................................................................

Setting Date and Time ...................................................................................................................................................

Programming the Timer .................................................................................................................................................

Menu Structure ..............................................................................................................................................................

Priming the System ............................................................................................................................................................

Priming Procedure .........................................................................................................................................................

Commissioning/Initial Startup ........................................................................................................................................

Flow Switch Setting & Adjustment ................................................................................................................................

Gauge Venting & Accuracy ...........................................................................................................................................

Initial Test Procedures ...................................................................................................................................................

Maintenance ........................................................................................................................................................................

Preventative Maintenance ............................................................................................................................................

Servicing Pre-Filter/Water Separator ..........................................................................................................................

Servicing Final Filter(s) ..................................................................................................................................................

Troubleshooting .............................................................................................................................................................

Filter Chart ......................................................................................................................................................................

Warranty ...............................................................................................................................................................................

Parts/Service ......................................................................................................................................................................

REV03016030010218

OVERVIEWSYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

General Overview

STS 6030 Specications

Note: The system is designed to meet environmental standards for safe operation. (Not for use with uids that have a

ash point below 100°F (37.8°C), e.g. gasoline, alcohol, etc.)

Flow Rate ................................................................................

Outline Dimensions (Enclosure) ............................................

System Weight .......................................................................

Operating Temperature ..........................................................

Electrical .................................................................................

Pump .......................................................................................

Suction Capability (Primed) ...................................................

Motor .......................................................................................

Timer .......................................................................................

Inlet ..........................................................................................

Outlet .......................................................................................

Maximum Fluid Viscosity ........................................................

30 GPM/1800 GPH (113.6 LPM/6814 LPH)

14,400 gallons (54,510 liters) per 8 hour shift

43,200 gallons (163,530 liters) per 24 hours

56” x 72” x 17” (142 x 183 x 43 cm) (H x W x D)

≈ 760 lbs (344.7 kg)

41 - 104°F (5 - 40°C)

208-230V//1Ph60Hz/20A, 120V/1Ph/60Hz/15A,

or 230V/1Ph/50Hz/15A

Gear pump

15 ft (4.57 m) suction (vertical lift) or 100’ (30.48 m) horizontal

run (lines > 1-1/2”, primed)

2 HP single phase, continuous duty, thermally protected

Programmable digital timer

2” NPT male port

1-1/2” NPT male port

5 cSt

OVERVIEW

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

System Components

Control and Safety Devices

• AXI International “Smart Filtration Controller” in electrical sub enclosure is a modular – 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 shutdown feature

• Inlet and outlet shut off ball valves

• Emergency stop button (outside enclosure)

• Leak sensor and alarm indicator (system shutdown)

• High vacuum alarm indicator and system shutdown (vacuum sensor)

• Secondary lter high pressure alarm indicator and system shutdown (pressure sensor)

• High water alarm indicator and system shutdown (water sensor)

• Pump motor starter with single-pole circuit breaker and contact

Pump/Motor

• Positive displacement gear pump

• Motor – UL listed with thermal overload protection

• Service Factor (1.00)

Strainer

• Wye-Strainer with drain valve

Final Filter(s)

• Dual, parallel RACOR FBO ne lters, down to 1µ nominal, 5µ nominal, and 5µ coalescing lter cartridges (other

cartridges available)

• Drain valve on the bottom

• Differential pressure gauges

Fuel Conditioner

• Inline Magnetic Fuel Conditioner eliminates and prevents the formation of sediments that naturally occur in diesel fuel

and bio-blends

Carbon Steel Plumbing

SYSTEM COMPONENTS

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

System Enclosure

• 14-gauge steel construction with continuously welded seams

• Concealed hinges

• Finished in polyester powder coat inside and out over phosphatized surfaces

• Spill basin with leak detection

• Louvered side panels

• Brackets for wall mounting

• Literature pocket

Remote Monitoring Module (Option)

• System status and alarm monitored from remote location

Enclosure Heater (Option)

• Ensures electronics stay within operational temperature range

• Prevents internal holding tanks from freezing or gelling

• Built-in thermostat, eld adjustable to required temperature

SYSTEM COMPONENTS

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

System Operation

OPERATION

!WARNING! This system is not meant for use with gasoline or any other ammable liquids having a ash

point less than 100°F (37.8° C). Use with gasoline or any ammable liquids at a temperature exceeding their

ash point presents an immediate explosion and re hazard.

Pump Operation

Apply control power to unit. Place breakers for the Smart Filtration Controller in the “ON” position.

Automatic:

Place the key switch in the “AUTO” position. When the timer contacts close, the pump will start and run until the timer setting

has expired. See the Controller section for setting run times.

Manual (Override):

Place the key switch in the “MANUAL” position. The pump motor will run until the switch is returned to the “OFF” or “AUTO”

mode positions, or until an alarm or overload has been tripped.

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OPERATION OVERVIEW

Alarms

The system 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 box on the electronic controller.

Alarms featured on the system include:

• Leak Detection

• Low fuel ow alarm indicator

• High vacuum alarm indicator and system shutdown (vacuum sensor)

• Secondary lter high pressure alarm indicator and system shutdown (pressure sensor)

• High water alarm indicator and system shutdown (water sensor)

• Secondary lters alarm indicator and system shutdown (differential pressure transmitters)

Once triggered alarms are addressed, each alarm can be reset by pressing the weatherproof “ALARM RESET” push button

located on the outside of the enclosure door.

Emergency Stop

Note: In case of an emergency, the pump can be turned off and disabled by pressing the red “EMERGENCY STOP” button

on the outside of the enclosure door.

To release “EMERGENCY STOP” button, turn the red knob in the direction indicated by the arrows on the mushroom button

and push the “ALARM RESET” button to reset.

Enclosure Heater (Option)

The Enclosure Heater is an option used to maintain a certain temperature within the system enclosure and ensure that

components in contact with water do not freeze. It also ensures that electronics stay within their operating range. The

Enclosure Heater comes with a built-in thermostat, and can run continuously in cold environments.

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

Primary Inspection

PRIMARY INSPECTION

Upon arrival, the 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 enclosure for damage.

❑Check the entire outside of the enclosure 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.

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

Installation

OVERVIEW

!IMPORTANT! It is recommended that only qualied, 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 unit 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

specied temperature range, and should be located as close to the tank as possible. Please allow about 1’ (30.5 cm) of

space between the side louvers of the enclosure and nearby objects. This space is necessary to ensure sufcient 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 system’s power requirements and rated voltage/frequency match the electrical system (see wiring

diagram). The system 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 specication 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 Shutdown Feature:

If required, connect the “external pump shut down input terminal” (see wiring diagram) per specication on electric 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 Smart Filtration Controller.

Remote Monitoring - Dry Contacts:

The Smart Filtration Controller provides two Normally Open (N.O.) dry contacts for remote alarm monitoring. Please see

wiring diagram for contact rating, connection, and location.

1. “Summary Alarm” – dry alarm contact for high vacuum, high pressure, no ow, or water detection (as well as emergency

stop and overload relay triggered)

2. “Leak Detection” – dry alarm contact for leak detection

INSTALLATION

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

INSTALLATION

Plumbing

Use proper quality approved fuel line materials with at least 2” (5.1 cm) inner diameter on the suction side from the tank and

at least 1-1/2” (3.8 cm) inner diameter on the return/discharge side back to the tank. For long suction side plumbing runs, it

is recommended to install oversized pipe, or 2” in diameter.

Note: Do not put any stress on plumbing of the system, and use a backing wrench when connecting the external plumbing.

The pick up tube/line(s) should originate from the lowest point of the tank to ensure all water is removed, 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) for some installations to prevent back ow pressure.

Multiple suction and/or return lines may be connected to a manifold outside the system.

Note: Anti-Siphon or other external plumbing devices may be required – please check local regulations/code.

The system capabilities are 15’ (4.57 m) suction (vertical) or 100’ (30.48 m) horizontal, when connected to piping of 1-1/2”

ID, or more, with no additional ow 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 ow of fuel,

and that the suction line always stays primed.

Note: Plumbing installation must be in accordance with all applicable federal, state, and local rules, laws, standards, and

regulations.

Typical Plumbing/Above Ground Tank Installation (Schematically)

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

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 system 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 system must be combined in any way, adequate valves

should be installed to prevent any possible interference with safe engine operation.

Note: If any of the system’s fuel lines are used in combination with the engine’s fuel system, the system should be disabled

during engine operation (use the provided “Remote Pump Shut Down” feature as shown in the electrical drawing and

described above).

INSTALLATION OVERVIEW

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

Controller (SFC-50 or SFC-55)

Programming the Timer

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 rst 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 (use up

and down arrow key) to change value, or (use left and right arrow keys) to change between week, day, time, and date

11. When nished entering press “OK” to conrm

12. Press “ESC” until you reach the base menu

13. Select ‘Start’ and press “OK” – correct time and date should be displayed (if asked, select “YES” to proceed)

14. We are now ready to program the run timer (military time format must be used):

15. Hit the “ESC” button

16. Select ‘Program’ and press “OK”

17. Select ‘Set Param’ (use arrow keys) and press “OK”

18. Use arrow key to select ‘Timer’ or ‘Timer 1’

19. Press “OK”

20. Use arrow keys to select the desired eld and press “OK” to edit

21. 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

22. Use arrow keys in same manner to program the ‘On’ time – when the system will switch on (on the selected day/days)

23. Use arrow keys in same manner to program the ‘Off’ time – when the system will switch off (on the selected day/days)

24. Press “OK” to conrm entry when nished setting all desired parameters

25. If required you can set up to 3 Timers by using the up and down arrow key

26. Press “ESC” until you return back to the time and date display

CONTROLLER

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

Priming the System

PRIMING OVERVIEW

The pump supplied with the system 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 system is shipped from the factory lled with #2 Diesel to facilitate initial lubrication. This will not

eliminate the necessity to prime the complete system. The system is primed by using the externally installed priming tee (not

provided) on the suction side of the system. Also, the pre-lter, as well as the suction line, has to be completely lled with

fuel prior to the initial system start-up.

Priming Procedure

1. Ensure the pump is lled 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 on top of the pre-lter/water separator

4. Open the externally installed priming tee (located at the highest point of the suction plumbing), ll the line with fuel until

fuel escapes from bleed screw (manual air vent), located on the pre-lter

5. Close the manual air vent, continue lling until all air is bled from the plumbing lines and system, close the priming tee.

For tanks situated on a lower elevation than the system, it is recommended that a foot valve is installed, on the bottom

of the suction line, at the fuel tank to hold the fuel column

6. Make sure to completely ll the suction line to its highest point with fuel (no trapped air). This is particularly important in

cases where the system is located at a lower elevation than the suction line exiting the tank

7. Open the outlet ball valve and ensure the inlet ball valve is also in open position

8. Switch on the pump

The system is equipped with a vacuum gauge on the suction side of the pump. The gauge should read 0 to 11” HG vacuum

maximum under normal conditions. Vacuum gauge readings reaching 12” HG vacuum indicate excessive debris in the

pre-lter/water separator, ow restriction, or too high of a suction height (and therefore pressure drop in the suction line),

activating the “HIGH VACUUM ALARM” and pump shutdown.

Note: 12” HG vacuum = clogged primary lter or suction line ow restriction/excessive lift.

The system’s pressure gauge on the secondary lter should show 22 PSI maximum pressure under normal conditions (.433

PSI = 1’ vertical head pressure). Pressure gauge readings in excess of 22 PSI pressure indicate excessive lter clogging,

or fuel line restrictions and/or friction.

Differential pressure over 22 PSI indicates lter clogging (“HIGH PRESSURE ALARM” indicator) and will automatically shut

down the pump.

The pressure relief valve has a 40-45 PSI set point. Pump discharge pressure in excess of 40-45 PSI will cause the

pressure relief valve to open and vent fuel back to the fuel transfer pump inlet side.

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

OVERVIEW

Commissioning/Initial Start-Up

COMMISSIONING

Flow Switch Setting & Adjustment

Note: Flow switch needs to be adjusted to actual ow rate for proper system operation.

Please make sure system is properly primed and check when pump running for a steady stream of fuel without air bubbles

in the mechanical ow meter (indicator) inside the systems enclosure. If the “NO FLOW ALARM” alarm light is blinking (and

after 10 seconds illuminate continuously as the pump is turned off) the ow switch located on the side of the mechanical

ow meter needs to be adjusted to the actual ow rate.

This can be easily done by sliding the black switch (with the wires attached) located on the side of the sight glass carefully up

or down (while pump is running) and lining up the ow switch with the indicator ring inside the sight tube of the ow meter

showing the actual ow rate. For further information please see enclosed instruction sheet. You can reset the alarm by

pushing the “ALARM RESET” button located on the control panel.

Gauge Venting & Accuracy

After shipment, the pointer on the gauges may not rest at zero, due to internal case pressure buildup caused by temperature

variations. This may cause the accuracy to be signicantly reduced. To restore the gauge to operating condition, move the

yellow lever of the ll plug to the ”open” position, or remove the small plug from top of gauge and leave open.

Initial Test Procedures

With breakers and power turned on, and pump running, check all alarms for proper operation:

• Leak Detection - Manually raise the oat switch located at the bottom of the enclosure. Pump should immediately turn

off, and “LEAK DETECTION” should illuminate. Reset the alarm by pushing the “ALARM RESET” button on the control

panel.

• High Vacuum Alarm - Slowly, partially close inlet ball valve. At 16” HG, the pump should turn off and “HIGH VACUUM

ALARM” should illuminate. Open inlet ball valve again. Reset the alarm by pushing the “ALARM RESET” button.

• No Flow Alarm - Slide the ow switch located on the side of the mechanical ow meter slightly upwards away from the

ow indicator inside the sight tube (mark original position before doing so). The “NO FLOW ALARM” indicator should

start blinking for 10 seconds and then illuminate constantly as the pump is turned off. Slide ow switch back into original

position and reset alarm by pushing the “RESET ALARM” button.

• Water Sensor - Jump the WATECT water sensor probes by placing a piece of conductive metal across the two

horizontal contacts. The pump should turn off and the “HIGH WATER ALARM” should illuminate. Remove the metal,

and reset the alarm by pushing the “ALARM RESET” button on the control panel.

• Emergency Stop - Press the “EMERGENCY STOP” button, located on the enclosure control panel. The pump should

turn off. Disengage the “EMERGENCY STOP” button by turning clockwise until the button pops out. Reset the alarm

by pushing the “ALARM RESET” button on the control panel.

Note: If any of the above described alarm test procedures fail or if any alarm trip value deviates, immediately contact AXI

International.

SYSTEM COMPONENTSPRIMARY INSPECTIONINSTALLATION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE

REV03016030010218

MAINTENANCE

Maintenance

OVERVIEW

The system should be visually inspected and tested a minimum of every six (6) months according to the procedure below

during light duty cycles. Monthly inspections are recommended for systems that are being used in excess of an average of

eight (8) hours day and ve (5) days a week.

Preventative Maintenance

Prior to performing the maintenance procedure ensure that:

1. The electrical sub-panel mounted main disconnect switch is operating properly

2. The user supplied remote circuit breaker is in the “OFF” position

3. All sources of power are isolated from the unit

Note: Proceed only after this has been veried and properly tagged.

• Check enclosure and all parts for corrosion and rust

• Check locking latches, door, and hinge operation

• Check cabinet mounting hardware - tighten as necessary

• Check pump/motor hardware for tightness, as pump/motor hardware will loosen after normal operation due to vibration

• The hardware uses lock nuts - check all bolts for secure nuts

• Check all electrical terminals and connections for tightness

• All motors are permanently lubricated and do not require any lubrication

• All pumps are self-lubricating and do not require any maintenance

• Check all plumbing joints for leaks, tighten ttings and joints as necessary, and remove accumulated fuel in drip tray as

necessary

• Inspect all lters and separators

Note: All lter elements should be replaced at least every six (6) months.