Fueltec BIO-VAC 270 User manual

Intrinsically safe for gasoline, jet & diesel fuel,
and ethanol blends
Purifi es fuel by removing sludge and microbial
contamination down to one micron
Removes fuel/water contamination to meet
engine manufacturer’s fuel cleanliness
requirements
Cleans your tank and purifi es fuel with little to
no loss of product!
BIO-VAC™270
PRODUCT MANUAL
Mobile Fuel Polishing & Tank Cleaning System

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BIO-VAC™270 Product Manual
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Bio-Vac 270 Overview, Operation & Maintenance
GENERAL OVERVIEW
Intended Use & Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Features & Benefi ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Markets & Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IDENTIFYING BAD FUEL
Contaminated Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to Take a Fuel Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WARNINGS & SAFETY
Preliminary Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warnings & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Precautions for Marine Applications . . . . . . . . . . . . . . . . . . . . . . . . . 15
Static Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SYSTEM OPERATION
Get to Know Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Startup & Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . 20
Servicing Diesel Fuel Storage Tanks . . . . . . . . . . . . . . . . . . . . . . . . . 21
Servicing Phase-Separated E-10 Fuel Storage Tanks . . . . . . . . . . . . . . . . 22
Fluid Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel Polishing & Tank Cleaning for Generator Base Tanks . . . . . . . . . . . . 24
Fuel Polishing & Tank Cleaning for Sub-Base Tanks . . . . . . . . . . . . . . . . 25
Draining System of Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SYSTEM MAINTENANCE
Primary Bag Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coalescer and Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . 28
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TABLE OF CONTENTS

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INTENDED USE & OPERATING PRINCIPLE
This System is designed to be used with diesel fuel, gasoline, jet fuel, heating oil,
kerosene, and ethanol blended fuels for removing water and other contaminants
from fuel tanks.
The System has two (2) modes of operation:
IT IS IMPORTANT THAT YOU READ THE ENTIRE MANUAL TO BECOME
FAMILIAR WITH THIS PRODUCT BEFORE YOU BEGIN USING IT.
This machine is designed for certain applications only. FuelTec Systems cannot
be responsible for issues arising from modifi cation. We strongly recommend this
machine is not modifi ed and/or used for any application other than that for which it
was designed.
If you have any questions relative to a particular application, DO NOT use the
machine until you have fi rst contacted FuelTec Systems to determine if it can or
should be performed on the product.
Please refer to page 21 in this manual for general instructions for each mode
of operation. Further instructions can found on pages 22–26.
REMOVE BULK WATER MODE
Used to remove bulk water and fast
fi lter when one or more inches of
water can be measured on the tank
bottom. This water can be pumped
directly into a waste container.
MAXIMUM WATER SEPARATING &
FILTERING MODE
Used to separate the remaining
water and fi lter the fuel after the
bulk water has been removed.
1
2

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This pneumatic system is designed to safely purify fl uids including gasoline, diesel,
hydraulic, motor oils, and jet fuel to meet or exceed the latest engine manufacturer’s
cleanliness specifi cations. Free and emulsifi ed water can be removed to less than
50 PPM. Particulate matter is removed to one micron.
• Chassis Construction: Powder Coated Steel
• Filter Housings: Stainless Steel
• Maximum Lift: 22 feet
• Pump Rated Flow Rate: Range 0 –1620 GPH (gallons per hour)*
• Water Trap: Two (2) gallons US
• Compressed Air Required: 60 psi at 0-12 CFM = 17 GPM
• 70 psi at 0-25 CFM = 27 GPM
• Width: 32” | Depth: 44” | Overall Height: 54” | Weight: 195 lbs.
• Pump 1” Air Operated Diaphragm
• Pickup Tube Hose: 25’ x 1-1/2” | Ball Valves with Cam-Locks
• Return Hose: 25’ x 1” | Ball Valves with Cam-Locks
• Drain Hose: 10′ x 1/2” | Ball Valves with Cam-Locks
• Vacuum Gauge: 2” Liquid Filled
• 24” Fueltec Primary Bag Filter
• Water Coalescer/Separator Micro-glass
• Water Separator Stainless Steel/Tefl on
• Air Regulator 3/8”
* Flow rates may vary with compressed air supply, fi lter type
and condition, length and size of hoses, and size and shape of
fl uid pickup and return tubes.
Model BIO-VAC 270 Mobile 1620 GPH Fuel Polishing & Tank Cleaning System
TECHNICAL SPECIFICATIONS
PLEASE NOTE:
Air compressor not included.
This system requires a
60 psi at 12 CFM air
compressor for 17 GPM or
a 70 psi at 25 CFM air
compressor for 27 GPM.

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(1) Quick-Disconnect Right Angle Fluid Pickup
Tube 40” w/ BIO-VAC Nozzle (#100191)
(6) 1-Micron Particulate Filters (#241004)
(1) 4 OZ Fuel Sampler (#100013)
(1) 5-Micron Water Separating Coalescer/Filter
(#241024)
(1) Stainless Steel/Tefl on Separator Cartridge
(#241035)
(1) 12′ x 1-1/2” Pickup Tube Hose (#121043)
(1) 12′ x 1” Return Hose (#100503)
(1) 10′ x 1/2” Drain Hose [not shown] (#121039)
Fueltec’s BIO-VAC 270 Fuel Polishing System comes with:
SYSTEM COMPONENTS

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FEATURES & BENEFITS
FUELTEC’S BIO-VAC 270 27 GPM / 1,620 GPH SYSTEM FOR GASOLINE, JET, DIESEL &
ETHANOL, BLENDS
• In operation, the System pulls fl uid from the fuel tank bottom by a vacuum
created by the fuel pump.
• A bag-type fi lter is fi rst to remove rust, sludge, and solid contaminates from the
tank bottom fl uid which may also contain water.
• The fuel/water mix leaves the fuel pump under pressure and is forced through
a fi lter/ coalescer where the tiny water droplets are made larger and separate
from the fuel. This type of water separator is commonly used on aircraft jet fuel.
• The Tefl on separator prevents the water droplets from traveling with the fuel.
Separated water will drop into the water trap where it can be drained under
pressure.
• A clear sight tube allows you to see the level of the water that has been separated.
• With the system running; you can open a valve and send the water to a
waste container and the clean, dry fuel back to the fuel storage tank.
• The water level in the sight tube stops rising when all of the water has been
vacuumed and separated from the fuel storage tank.
• Separate and remove one ounce or 1,000 gallons without stopping the system.
• Tank cleaning is done with no loss of product.
FUELTEC’S QUALITY FIRST:
• Stainless steel fi lter housings to resist the acids found in today’s diesel and
ethanol blended gasoline.
• Filtration down to one micron, water removal to less than 100 parts per million.
• Meets engine manufacturers clean fuel requirements.
• Air operated diaphragm fuel pump intrinsically safe for all fuels.
• Static grounding reel for safety in class one areas.
• Variable speed control to avoid phase separation or emulsifi cation.

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MARKETS & APPLICATIONS
A variety of fuels are stored worldwide, and are constantly in need of testing and
routine maintenance. Here are some of the opportunities for your business to
provide fuel polishing services.
RETAIL FUELING
Gas stations and C-stores rely
on clean fuel. You can provide
the solution for remediating
phase separation in ethanol
blended gasoline or removing
contaminates from diesel fuel.
GOVERNMENT
Government agencies and
military units rely on all fuels:
diesel, gasoline, and jet fuel.
Fueltec’s systems for all fuels
are in use worldwide.
MISSION CRITICAL
When the lights go out,
diesel engines have to
operate—sometimes in a life
or death situation. You can
off er systems tailored to any
application.
MARINE
Water and contamination must
be removed from both gasoline
and diesel marine tanks for
safe operation. Fueltec marine
fuel polishing systems are
designed specifi cally for boats.
TRANSPORTATION
Trucks and locomotives rely
on clean diesel. Your Fueltec
system will have the answer to
keep their fl eets running 24-7.
POWER GENERATION
Diesel engines in industry have
to operate without hesitation.
Automated fuel polishing
systems ensure fuel is clean
and working to its best quality.

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CONTAMINATED DIESEL FUEL
• The fuel found above the tank bottom
water is usually clean and water free.
• Water being heavier than fuel will be
found at fuel tank bottoms.
• In fuel tanks, bacteria and fungus are
commonly found at the fuel/ water
interface.
• These microbes need water to live,
without water they will die.
• They feed on components of the fuel
while they fl oat on the water.
• The dead microbes are heavier than
fuel or water and sink to the tank
bottom
• When the fuel is added to a tank
where microbes are living, the
microbes get mixed with both the fuel
and water and can easily clog fi lters.
Bacteria living at the fuel-water interface feeds on
fuel but lives in water. Remove the water and the
bacteria and fungus will die!
O-Road Diesel Dyed Red
Bacteria & Fungus
Water
Dead Bacteria & Fungus
Sludge

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MICROBES FOUND IN DIESEL FUEL
Virtually all diesel fuel contains
some moisture. Additional
water accumulates in tanks as
atmospheric moisture condenses.
Moisture accumulates in diesel
tanks as condensate droplets
on exposed tank surfaces, as
dissolved water in the fuel and as
water bottoms beneath the fuel
microbes depend on this water
for growth.
Additionally, microbes depend on the organic and inorganic molecules in diesel
fuel for nutrition. Consequently, some species attack the fuel directly, growing
at the expense of hydrocarbons and non-hydrocarbon fuel components. The
biodegradation of fuel, in support of microbial growth, is a direct impact of
contamination.
Color, heat of combustion, pour point, cloud point, detergent and anti-corrosive
properties change as microbes selectively attack fuel components. Sulfur-
containing molecules are metabolized by a series of species, leading ultimately to
the production of high concentrations of hydrogen sulfi de.
In addition to creating new cells, many microbes produce metabolites which
promote further attack. Surfactants facilitate the emulsifi cation of fuel, leading to
the formation of a cloudy, invert-emulsion layer above the fuel/water interface.
Polysaccharide slimes create microenvironments wherein mixed populations
(consortia) of bacteria and fungi carry out biodegradation reactions that would
be impossible for a single species outside the microenvironment. The slime also
serves as a barrier, protecting the microbes from preservatives.
A variety of organic acids (primarily 2 - 4 carbon atoms) are also produced as by-
products of bacterial and fungal growth.

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HOW TO TAKE A FUEL SAMPLE
USE FUELTEC’S 4OZ. FUEL SAMPLER:
• Take samples by lowering the sampler to the tank bottom.
• Sample valve will open and sampler will fi ll with fl uid after 5-10
seconds.
• Lift the sampler above tank bottom and the valve will close. Fluid
will be trapped in sampler.
• After lifting sampler out of the tank; lower it into a sample jar.
• When the bottom valve contacts the jar bottom it will open;
draining the fl uid into the jar.
• Check sample fl uid for contaminates. Look for clarity and
uniform color, particles of rust and debris, sludge, or layers of
color may indicate bottom water or phase separation.
For complete instructions on how to take fuel samples, visit our website:
https://fueltecsystems.com/bad-fuel/how-to-take-fuel-samples/
Download full sampling instructions:
https://fueltecsystems.com/wp-content/uploads/2021/01/Fuel-Sampler-Kit-8-OZ.pdf
Fuel samples taken before and after tank cleaning with a
Fueltec Mobile tank cleaning system.
4oz. Fuel
Sampler
(#100017)

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PRELIMINARY PRECAUTIONS
WARNING:
• This product operates in the highly combustible atmosphere of a diesel or
gasoline storage tank.
• This fuel polishing system should NEVER BE OPERATED inside a truck cargo
body, enclosed trailer, or within fi fty (50) feet of an operating or hot engine,
motor or fuel dispenser.
• All work must comply with the latest issue of the National Electrical Code (NFPA
70), the Code for Motor Fuel Dispensing Facilities and Repair Garages (NFPA
30A), and any European, national, state, and local code requirements that apply.
• When servicing unit, use non-sparking tools and use caution when removing or
installing equipment to avoid generating a spark.
• To protect yourself and others from serious injury, death, or substantial
property damage, carefully read and follow all warnings and instructions
in this manual.
CAUTION!
Do not operate this system unless you have read and understand all safety
warnings. This product operates in the highly combustible atmosphere of a
diesel or gasoline storage tank.
FAILURE TO COMPLY WITH THE WARNINGS AND SAFETY PRECAUTIONS
COULD CAUSE DAMAGE TO PROPERTY OR ENVIRONMENT, RESULTING IN
SERIOUS INJURY OR DEATH.

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WARNINGS & SAFETY
This section introduces the hazards and safety precautions associated with operating,
maintaining or servicing this product. Before performing any task on this product, read
this safety information and the applicable sections in this manual, where additional
hazards and safety precautions for your task will be found. Fire, explosion, or pressure
release could occur and cause damage to property, environment, resulting in serious
injury or death, if these safe service procedures are not followed.
You are working in a potentially dangerous environment of fl ammable
fuels, vapors, and fl uid pressures. Only trained or authorized individuals
knowledgeable in the related procedures should operate, inspect, maintain
or service this equipment.
READ THE MANUAL
Read, understand and follow this manual and any other labels or related materials
supplied with this equipment. If you do not understand a procedure, call 1-828-212-
1141 to locate a qualifi ed technician. It is imperative to your safety and the safety
of others to understand the procedures before beginning work. Make sure your
employees and any service contractors read and follow the instructions.
FOLLOW THE REGULATIONS
Applicable information is available in National Fire Protection Association (NFPA)
30A; Code for Motor Field Dispensing Facilities and Repair Garages, NFPA 70;
National Electrical Code (NEC), Occupational Safety and Hazard Association
(OSHA) regulations and federal, state, and local codes. All these regulations must
be followed. Failure to operate, inspect, maintain or service this equipment in
accordance with these codes, regulations and standards may lead to legal citations
with penalties or aff ect the safe use and operation of the equipment. OSHA fall
protection rules apply when working on above ground fuel storage tanks.
PREVENT EXPLOSIONS AND FIRES
Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels and
used fi lters cause vapors. All used fi lters should be promptly placed in an approved
safety container until disposed of.
Even fi lling air compressor fuel tanks will cause potentially dangerous vapors in the
vicinity of the work area.

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WARNINGS & SAFETY
WORKING ALONE
It is highly recommended that someone who is capable of rendering fi rst aid be
present during operation. Familiarize yourself with Cardiopulmonary Resuscitation
(CPR) methods, while working around fuel vapors. This information is available
from the American Red Cross. Always advise other personnel about where you will
be working, and caution them not to activate power tools or engines while you are
working with fuel fi ltration equipment. Use the OSHA Lockout/Tagout procedures. If
you are not familiar with this requirement, refer to OSHA documentation.
HAZARDOUS MATERIALS
Some materials may present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any equipment in the
mouth.
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS
COULD RESULT IN PROPERTY DAMAGE, INJURY OR DEATH.
FIRE HAZARD!
Do NOT use power tools (Class I Division I and Class I Division II) during the
operation or maintenance of equipment. Sparking could ignite fuel or vapors,
resulting in fi re.
CHEMICAL EXPOSURE HAZARD!
Wear appropriate safety equipment during operation or maintenance of
equipment. Avoid exposure to fuel and vapors. Prolonged exposure to fuel may
cause severe skin irritations and possible burns.
REQUIREMENTS FOR USE
• Fueltec fuel polishing and tank cleaning systems are designed for use only by
trained personal. Free training is available at Fueltec’s factory located in Granite
Falls, NC USA. Call 1-828-212-1141
• The operation of Fueltec’s systems must be consistent with NFPA Code 30A,
OSHA regulations, and federal, state and local fi re codes, and other applicable
local regulations.

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WARNINGS & SAFETY
OPERATING PRECAUTIONS
• NO SMOKING. Extinguish all open fl ames and pilot lights, such as on RV
appliances.
• TURN OFF cell phones and other electronic devices to prevent sparks which
could cause an explosion or fi re.
PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when operating
or maintaining the system. Do not operate or maintain the system while you
are tired or under the infl uence of drugs, alcohol or medication. A moment of
inattention while operating or maintaining the system may result in serious
personal injury or death.
Dress properly while operating this system. Do not expose bare skin or eyes
to fuels. Prolonged contact with fuel can damage the skin. Use safety apparel
and equipment. Use safety goggles or safety glasses. Also use non-skid safety
shoes, hardhat, gloves, and fall protection when appropriate.
CAUTION: BEFORE YOU START FUEL POLISHING!
DO NOT use Fueltec
fuel polishing systems
inside an enclosed
truck or trailer!
MOVE the fuel
polishing system to
a SAFE OUTDOOR
WORK AREA.
Keep air compressors,
generators, vehicles,
and other ignition
sources AT LEAST
25 FEET AWAY FROM
WORK AREA.

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PRECAUTIONS FOR MARINE APPLICATIONS
SPECIAL PRECAUTIONS SHALL BE FOLLOWED WHEN SERVICING MARINE FUEL TANKS:
• Have everyone leave the boat while servicing the fuel system.
• Shut off all engines, electric motors, and galley stoves and turn off the battery at
the main switch.
• Close all compartments, ports, windows, and hatches. The idea is to keep fumes
(vapors) out of all spaces while servicing fuel tanks.
• Don’t smoke and turn off cell phones.
• Attach a static grounding cable from fuel polisher to fuel tank to prevent static
sparks. (Refer to instructions for static grounding on the following page.)
• After fuel tank service, make sure all tank fi ttings are replaced, wipe up or wash
off any spilled fuel, open all hatches and ports, and let the boat air out.
• Operate the bilge blower for at least 30 minutes after service is completed.
• Sniff the bilge and engine compartment areas before starting the engine.
• Keep in mind that a bilge blower can’t remove vapors from spilled liquid gas, so
use your nose before turning the key.
• If there is a strong odor of gas, get everyone off the boat, notify the attendant,
and call 911.

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STATIC GROUND
ALWAYS ATTACH A STATIC DISCHARGE CABLE FROM THE FUELTEC SYSTEM TO A
LOW IMPEDANCE TRUE EARTH GROUND, AS DEFINED BY THE NATIONAL ELECTRICAL
CODE (NEC).
The fl owing movement of fl ammable liquids like gasoline inside a pipe can build
up static electricity. Non-polar liquids such as gasoline, diesel, kerosene and light
crude oils exhibit signifi cant ability for charge accumulation and charge retention
during high velocity fl ow. Static electricity can discharge into a fuel vapor. When
the electrostatic discharge energy is high enough, it can ignite a fuel vapor and air
mixture. Diff erent fuels have diff erent fl ammable limits and require diff erent levels
of electrostatic discharge energy to ignite.
Electrostatic discharge while fueling with gasoline is a present danger at gas stations.
Fires have also been started at airports while refueling aircraft with kerosene. The
use of a static discharge cable can help to prevent or safely dissipate the build up
of static electricity.
Connect static ground cable to earth ground.
Ground rod driven
into the earth.

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WORK AREA INSTRUCTIONS
25 FT.
• Mark work area with orange colored safety cones placed in a radius of
at least twenty-fi ve feet (25’) from fuel tank cleaning equipment, fuel
containers, and fuel tank openings.
• Place Flammable Liquid Warning Signs within work area.
• Keep work area clean, free of clutter and well lit. Cluttered and dark work
areas can cause accidents.
• Keep children and bystanders away while operating this system. Distractions
can cause you to lose control, so visitors should re-main at a safe distance of at
least forty feet (40’) from the work area.
• Be aware of all power lines, electrical circuits, water pipes and other
mechanical hazards in your work area, particularly those hazards below the
work surface hidden from the operator’s view that may be unintentionally
contacted and may cause personal harm or property damage.
• Be alert of your surroundings. Using your system in confi ned work areas may
put you dangerously close to unsafe conditions.
• Keep one or more Fire Extinguishers U.L. rated 10A-80B:C in the work area.
• Keep Air Compressor at least twenty-fi ve feet (25’) feet from fuel tank cleaning
equipment, fuel containers, and fuel tank openings.

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Return to Tank Valve 2
Return to Tank Port 2
(for fi ltered, dry fuel)
Water Separator Housing
Separated Water
Sight Tube
Fuel Pump Air Supply Valve
Separator Drain Valve
(not seen in picture)
3-Way Valve
Air Pressure
Air Bleed Valve
Primary Filter Inlet Valve 1
Primary Filter Inlet Port 1
Primary Filter Housing
Direct Pump Port 3
(for fi lter only or bulk
water removal)
GET TO KNOW YOUR SYSTEM
3/8” Air Inlet
Vacuum Gauge
Inlet Port 1

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Swing Bolt Eye Nut (hand tighten)
Filter Inlet Port 1
Fuel Pump Air Supply Valve
Primary Filter Cover
Vacuum Gauge
When gauge reads
15Hg, replace the
bag fi lter.
GET TO KNOW YOUR SYSTEM
Air Bleed Valve
Primary Filter
Inlet Valve 1
WARNING:
Set air pressure regulator not
to exceed 70 psi at any time.

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SYSTEM STARTUP & OPERATION MODES
THE SYSTEM HAS TWO (2) MODES OF OPERATION:
REMOVE BULK WATER MODE
Used to remove bulk water and fast
fi lter when one or more inches of water
can be measured on the tank bottom.
This water can be pumped directly into
a waste container.
• Connect Pickup Tube Hose
to Primary Filter Port 1.
• Connect Return to Tank Hose
to Direct Pump Port 3.
• Open 3-Way Valve.
MAXIMUM WATER SEPARATING &
FILTERING MODE
Used to separate the remaining water
and fi lter the fuel after the bulk water
has been removed.
• Connect Return to Tank Hose
to Return to Tank Port 2.
• Connect Pickup Tube Hose to
Filter Port 1. Open Valves 1 and 2.
• Set 3-Way Valve to pump from
Primary Filter Housing to Water
Separator Housing.
1
2