Reverso AFP-150 User manual
Table of Contents
System Overview............................................................................... 1
Control Panel Overview..................................................................... 2
Technical Specications .................................................................... 3
Primary Inspection, Installation, & Electrical Installation ................... 4
Piping Installation .............................................................................. 5
Initial Setup........................................................................................ 6
Digital Timer Instructions: Set Date and Time ................................... 7
Digital Timer Instructions: Set Schedule Timer.................................. 8
Digital Timer Instructions: Set Manual Timer..................................... 9
Digital Timer: Alarms........................................................................ 10
Backushing Instructions................................................................. 11
Filter Element Replacement ............................................................ 12
Troubleshooting............................................................................... 13
1
System Overview
1. Serial number plate
2. Vacuum gauge
3. Fuel/water separator
4. Inlet
5. Water sensors
6. Drain valve - Push in and turn counter-clockwise
to open
7. Control panel
8. Hinged cover - covers pump and outlet
9. Outlet
10. 2 micron lter
11. Spill sensor
12. Drip pan
13. Pump
1
2
3
4
6
5
7
8
9
10
11
12
13
Wall Mount Version
2
Control Panel Overview
1. Power button
2. Digital timer
3. Manual timer mode button
4. Circuit breaker
5. Start button
6. Alarm reset button
7. Power on light - indicates when
system is on
8. Service system light - indicates
an alarm has been triggered and
user must service the system
9. Pump active light - indicates fuel
polishing system is running
10. Manual timer mode active light
- indicates system is operating
in manual timer mode (not
schedule timer mode)
11. Left key
12. Up key
13. Right key
14. Down key
15. OK key
16. Escape key
Control PanelDigital Timer
15
6
7
8
9
10
2
3
4
Control Panel
Digital Timer
ESC OK
M - W - F - -
MTWTFSS
11:00
15:00
ON
OFF
16 15 14
11 12 13
3
Technical Specications
Flow Rate Approximately 150 GPH (568 LPH)
Dimensions (H x W x L) Wall Mount 22.25” x 22.25” x 8.25” (565 mm x 565 mm x 210 mm)
Circuit Breaker 10A@12V, 5A@24V
Service Space 4” on top and bottom, to facilitate changing filter elements and
draining water and particulate from the bowl
Pump Brass Gear stainless shaft- double lip seal
Max. Lift 5 ft. (1.52 m) vertical lift (lines>1/2”)
Timer Digital PLC
Inlet 1/2” male JIC flare fitting
Outlet 1/2” male JIC flare fitting
Filter Torque Values Bowl Retainer Ring 8 Nm (105 in-lbs)
Lid 8 Nm (105 in-lbs)
Bleed Screw 6 Nm (50 in-lbs)
Additional Options Enclosure
Stand for enclosure
• The system has been developed to be used with diesel fuel only, DO NOT USE WITH GASOLINE.
• The system is designed to meet environmental standards for safe operation (NOT for use with uids that have a
ash point below 100°F (38°C), e. g.: Gasoline, alcohol,...)
Warning
4
Primary Inspection, Installation, & Electrical Installation
• Upon delivery inspect the AFP (Automated Fuel Polishing) for any
damage that may have occurred during shipment.
• Inspect the interior of the unit for mechanical or electrical damage.
• If the unit is damaged upon delivery, contact the shipping
company immediately.
Primary Inspection
• The AFP should be wall mounted on a hard, level surface.
• This unit is designed for well-ventilated indoor use and should be located as close to the tank as possible.
• Unit should not be mounted more than 5’ above the tank or farther than 10’. Mounting farther than this will
require back ow protection.
Mounting
Electrical Installation
• Installation of unit should only be performed by qualied installation personnel who have thoroughly read
and understands the installation instructions covered in this manual.
• To avoid the risk of electric shock, make sure that the power supply is disconnected. Ensure that the power
supply is at zero volts with a multimeter before making any electrical connections.
• To ensure operator safety the AFP must be connected to properly grounded power sources.
Warning
• Make sure that your unit and power supply are congured for the same voltage rating.
• Dry contacts are for external use.
• External control voltage must be supplied by customer.
5
Diesel Fuel
Pick-Up Tube Return to Tank
Tank Vent
Moist
Air
Lowest Point
Of Tank
Accumulated
Water Sludge
Flow In
Flow Out
Piping Installation
Use quality approved fuel line materials with at least 1/2” inner diameter line. Smaller plumbing
will place excessive load on the motor and shorten its life. A full port ball valve should be installed
on the inlet and outlet ports of the AFP (Automated Fuel Polishing).
Note: It is recommended to install a foot valve to keep the system primed, especially if the system
is located above the lowest possible fuel level in the tank.
If the AFP is mounted below tank top level, a priming tee should be installed on the highest point of the suction line
to be able to easily prime the systems delivery line. The return line(s) (discharge) should be connected to the outlet
of the pump “OUT” port and enter the tank as far as possible from the pick up tube. For optimal performance, ensure
that the outlet, discharge or return, line(s) are free and nothing is restricting their ow.
The pickup tube/line(s) (suction)
should originate from the lowest point
of the tank and should be connected
directly to the IN port. For optimal
performance, ensure that the inlet
(suction) line(s) is free and nothing is
restricting ow.
The suction line of the AFP must be independent and separate from the suction line of the engine. Do not integrate
into engine fuel system.
1/2” ID
Installation Precaution
6
Initial Setup
Open the fuel supply valve.
Prime fuel system and
check for leaks.
in.Hg psi
Set gauge pressure indicator
(red needle) slightly to the
left of the black needle prior
to operation.
The gauge will indicate
maximum vacuum pressure
during system operation.
Press start button.
Power on indicator will be lit.
If in manual timer mode, pump will immediately
begin running.
If in schedule timer mode, pump will only begin
running if within programmed date/time to run.
Verify the pump is operating by checking vacuum
gauge located on the lter. Gauge will be reading
0-5 in-Hg of vacuum.
• Must press manual timer mode button to
activate / deactivate.
• Manual timer mode light will be ON.
• Pump will start upon pressing the start button.
• Pump will automatically shut off after the
preset run time.
Operate in this mode if system will run one set time.
Choose timer mode:
Operate in this mode if system will start/stop
automatically on the programmed days of the
week and times.
• Must press manual timer mode button to
activate / deactivate.
• Manual timer mode light will be OFF.
• Pump will automatically start and stop
according to the preset date and time.
in.Hg psi
-10
-20
-30 15
-10
5
0
0
-50 50
-100 100
KPa
-
-5
-5
When the indicator reaches
15 in-Hg, it is time to drain or
change the lter element.
The same procedure is
necessary if the water level
reaches 30% of the clear bowl.
The emergency stop button is located on the
right side of the enclosure, if equipped.
Turn clockwise and press down to shut down
the operation.
Press the reset button. Then press the start
button to resume operation.
Emergency Stop Button
1 2
3
4 5
Manual Timer Mode Schedule Timer Mode
7
Digital Timer Instructions: Set Date and Time
ESC OK
Th 19:35
2012-01-26
The current date and time is displayed. Time is shown
as 24 hr clock. Date is shown YYYY-MM-DD.
Press ESC key.
Select Set Clock option and press OK key to continue.
Use the DOWN arrow to move the cursor to Set.. option.
Press OK key to continue.
Starting at the program screen, press DOWN key to
view current time screen.
Flashing black box indicates your selection. Use
LEFT/RIGHT key to move selection. Use UP/DOWN
key to change date and time. Press OK key when
nished and to return to previous menu.
Select Clock.. option. Press OK key to continue.
1 2
3 4
5 6
Press ESC key. Press ESC key again to return to
current time screen.
Now shown is the current time screen. Press UP
key to return to program screen.
7 8
ESC OK
MTWTFSS
MTWTFSS
11:00
15:00
ON
OFF
ESC OK
Th 19:35
2012-01-26
ESC OK
Stop
Set Param
Set..
Prg Name
ESC OK
Clock..
Contrast
Start Screen
ESC OK
Set Clock
S/W Time..
Sync
ESC OK
Set Clock
S/W Time..
Sync
ESC OK
Set Clock
Th 19:35
YYYY-MM-DD
2 0 1 2- 0 1 - 2 6
ESC OK
Stop
Set Param
Set..
Prg Name
ESC OK
MTWTFSS
MTWTFSS
11:00
15:00
ON
OFF
8
Digital Timer Instructions: Set Schedule Timer
ESC OK
MTWTFSS
MTWTFSS
11:00
15:00
ON
OFF
1 2
3 4
5
7
6
8
A. Ensure the breaker is ON.
B. Move the red power switch to the ON position and
power indicator light is on.
C. Ensure timer mode is switched to Schedule Timer.
Change the run days
With the ashing underline in the days row, press the
OK key until ashing box appears. Use the LEFT/
RIGHT key to move between days. Use the UP/
DOWN key to program run days. A dash(-) indicates
the system will not run on that day. Press OK key when
nished and the cursor will return to ashing underline.
Press ESC to save. Flashing underline will disappear.
Every 5 seconds, screen will request user to push
Start button to activate pogram.
Hold the ESC key until ashing underline appears
under the rst day of the week. This ashing
underline indicates your selection. Use the LEFT/
RIGHT keys to move between the dates, start time,
and stop time.
When using this method, follow sequence
exactly or damage to program can occur (non-
warrantable situation).
Change the run time
With the ashing underline in the days row, use the
LEFT/RIGHT key to move to start time (ON).Press OK
key until ashing box appears. Use UP/DOWN key
to change time. Press OK key when nished and the
cursor will return to ashing underline. Repeat with
stop time (OFF).
Setting the schedule timer is nished. In this example,
system will run on Monday, Wednesday and Friday.
System will start at 8:00 am and stop at 2:00 pm.
Afterwards, every 5 seconds screen will indicate the
schedule timer is active.
Stop Time
Start Time
Run Days
ESC OK
MTWTFSS
MTWTFSS
11:00
15:00
ON
OFF
ESC OK
M- W - F - -
MTWTFSS
11:00
15:00
ON
OFF
ESC OK
M - W - F - -
MTWTFSS
08:00
14:00
ON
OFF
ESC OK
M - W - F - -
MTWTFSS
08:00
14:00
ON
OFF
ESC OK
M - W - F - -
MTWTFSS
08:00
14:00
ON
OFF
ESC OK
Automatic
Timer
Active
ESC OK
To Activate
Push the
Start
Button
9
Digital Timer Instructions: Set Manual Timer
Program time
Current time
ESC OK
Manual
00:00
10:00
CURR
SET m
ESC OK
Manual
00:00
10:00
CURR
SET m
Use RIGHT arrow key to move underline to
program time (SET).
Flashing box will return to ashing underline. Press
ESC to save. Flashing underline will disappear.
Press and hold ESC key until ashing underline
appears. This indicates your selection.
Press OK key and ashing box appears.
Use UP/DOWN key to change time. The “m” indicates
minutes and can be changed to “h” for hours.
When nished, press OK key.
In the screen shown below, the system is set to run for
20 minutes and will stop once the time has expired.
Top row indicates current time.
Bottom row indicates program time.
1 2
3
5
4
6
ESC OK
Manual
00:00
10:00
CURR
SET m
ESC OK
Manual
00:00
20:00
CURR
SET m
ESC OK
Manual
00:00
20:00
CURR
SET m
ESC OK
Manual
00:00
10:00
CURR
SET m
Manual
00:00
10:00
CURR
SET m
10
Digital Timer: Alarms
Backushing procedure can be executed up to 5 times
before replacing the lter element.
There are three different alarms installed in the unit.
If one of the alarms should sound: De-energize system when servicing unit.
1. Follow the directions displayed on the screen.
2. Press RESET/STOP button
3. Wait at least 2 minutes, then press START to restart the unit.
If you have successfully cleared the alarms, the unit should restart.
ESC OK
HI-WATER
DRAIN BOWL
ESC OK
HI-PRESS
Check
Discharge
ESC OK
HI-VAC
BACK FLUSH
FILTER
High Water Alarm
High Vacuum Alarm
Hi Pressure Alarm
11
Backushing Instructions
1
2 3
4
4
5
6 7
Prior to servicing the lters, ensure that the engine is OFF.
Backushing is for particulate removal only and will not remove sludge once embedded in the lter media.
Turn the system off and shut off the fuel
supply valve.
Open the bleed screw located at top of lter
lid by slightly unscrewing it.
This will break the vacuum in the lter
allowing water and small particulates to be
released from the lter element.
Allow water and dirt to settle
into bowl.
Large droplets of water and
dirt will fall to the bottom of
the bowl.
Drain out the water and dirt
that has accumulated in the
bottom of the bowl.
Close drain valve by pushing and turning
clockwise.
Allow dirt and water to settle again.
As the fuel is drained out of the
separator in step 4, more dirt and water
will be ushed from the lter and will
collect in the bottom of the bowl.
If necessary, repeat step 4 and 5.
Open fuel supply valve.
PUSH in and turn
counter-clockwise to
open drain valve.
closed open
Prime the lter and close
the bleed screw (refer to
Technical Specications for
torque values).
Bleed Screw
12
Filter Element Replacement
Step 1
Shut off the fuel supply valve
and isolate unit before servicing
the lter.
Step 2
Loosen the lid
screws evenly.
Step 3
Remove the lid.
Step 4
Take out the spring
cassette.
Step 5
Lift out lter element by the
handle. Replace with new
lter element and re-t the
spring cassette.
Step 6
Inspect lid gasket.
Replace if necessary.
Step 7
Fit lid checking for correct
positioning. Evenly tighten in
the sequence shown (refer to
Technical Specications for
torque values).
Step 8
Open the fuel
supply valve, prime fuel system
and check for leaks.
Prior to servicing the lters, ensure that the unit is OFF.
23
1
4
23
1
4
Replacement Filter Element
Element # Description
01010
01030
01060S
10 Micron
30 Micron (Standard)
60 Micron (Stainless Steel)
13
Troubleshooting
Version 8/27/13
• Pump does not run
• Pump and lter are not primed
• Fuel supply or discharge line blocked. Check the alarm
• Lift is too high
• Air leak in fuel supply to pump
• Inlet or outlet valve closed. Check the solenoid valve
• Foot (check) valve installed backwards
• Air leak at inlet
• Lift too high
• Pump worn
• Inoperative foot valve
• Piping improperly installed or dimensioned
• Filter/water separator plugged
• Pump has been run dry or insufcient fuel
• Plumbing on inlet side not appropriately
dimensioned. Pump requires too much power
• Air in plumbing lines
• Liquid too viscous
• Insufcient fuel supply
• Air leaks in the inlet pipe
• Air or gas on the suction side
• Control power not available
• Tripped circuit breaker on control board
• Pump failed and seized
• Motor failure
• Check service switch is in the ON position ( - )
• Loose pump plumbing ttings
• Worn pump shaft seal
• Excessive heat from over head storage tank
• Worn pump 0-rings or seals
No fuel delivery
Insufficient fuel delivered
Rapid pump wear
Noisy operation
Motor does not turn or turns intermittently
Pump leaks fuel
Problem Possible Causes
Table of contents
Other Reverso Tank Equipment manuals
